Monorail guidance systems must only be located using the specified screws.

It is vital to follow the information:

• in this catalogue
• in the technical proposal letter
• in the assembly drawing – if contained therein.

The screw specifications and tightening torques must be observed.

Any deviations will influence the performance of the screw connections as well as the function and operating life of the guidance systems.

Only screws of the specified grades must be used.

If there is a possibility of settling, the fixing screws should be secured against rotation.

It must be ensured that the adjacent construction has adequate strength.

The technical performance capability can only be achieved if:

• all the threaded fixing holes are used
• the specified screw grades are used
• the specified screw tightening torques are observed.

They can only achieve their optimum function and maximum operating life if they are correctly fitted and maintained. Examples of fitting methods are shown on link to link.

The specifications and regulations in the table must be observed.

Monorail guidance systems are supplied with a preservative or initial greasing, see table.

The preservative is compatible with oils and greases having a mineral oil base.

The sharp-edged counterbores of the holes in the guideways are covered by an adhesive strip, Figure 1.

Avoid damage to the seal lips on the wipers of the carriages.

The adhesive strip protects the seal lips on the wipers of the carriages. The adhesive strip should not be removed until immediately before the guidance system is fitted.

The counterbores may cause injury.

The locating face is always on the opposing side to the marked face. The locating face and marked face (of the guideway and carriage) must always be on opposing sides, Figure 2.

The locating heights and corner radii in the table must be observed, see the section for the specific series.

Note the mounting position of the carriages – unmarked locating face.

Carriages should only be removed from the guideway or slid onto the guideways if necessary.

Locate the dummy guideway  on one end face of the guideway  and slide the carriage  carefully onto the dummy guideway , Figure 3.

Do not remove the dummy guideway from the carriage. Protect the rolling element set against contamination and damage.

Locate the dummy guideway  with the carriage  on one end face of the guideway , Figure 3.

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

The tightening torques M_A in the dimension tables are valid for screws coated with preservative. If there is a possibility of settling, the fixing screws should be secured against rotation.

Observe the tightening torques M_A for the fixing screws.

If the carriages are not connected to a central lubrication system, grease the carriages using the initial grease quantity – for grease quantities see tables, link and link.

The guideways and carriages must be protected before and during fitting against solid and fluid contaminants.

Before the carriages are screw mounted to the adjacent construction, remove the adhesive strip covering the O rings.

Check the seating of the O rings.

The sharp-edged counterbores for the fixing screws may cause injury.

The tightening torques M_A in the dimension tables are valid for screws coated with preservative. For high accuracy requirements, the screws can be lubricated with grease containing MoS₂. Since the coefficient of friction may be up to 50% lower in this case, the tightening torques should be reduced accordingly.

• Tighten the screws consecutively; in the first step to 0,5×M_A, in the second step to 1×M_A, Figure 4.

The end faces of the guideways are abutted against each other and the carriages are moved over the joint – this has the effect of aligning the guideways.

Screw mount the guideways according to the tightening scheme, Figure 4. Leave the carriages located at the joint.

The individual guideway sections are marked with numbers and letters, Figure 5.

During fitting, the numbers and letters of the ends at each joint must match.

Before fitting, guideways must be located using the tightening torque M_A according to the dimension tables.

Do not move carriages over counterbores of the fixing holes that have not been closed off. Ensure that the seal lips of the wipers are protected if carriages are moved.

Depending on the environment and operating conditions, the counterbores are closed off using plastic or brass closing plugs. For fitting using a fitting device, see link.

Knock in the closing plugs, Figure 6:

• Insert the closing plugs  in the correct position in the counterbore.
• Place the press-in block  vertically on the closing plugs.
• Knock in the closing plugs by means of concentric impacts.
• Remove the ring-shaped burr from the closing plugs .

Finish fitting the closing plugs, Figure 7:

• Knock the closing plugs in flush with the surface of the guideway  by means of a second impact.
• Smooth off the top surface of brass closing plugs flat using an oilstone .
• Clean the guideway using a lint-free clean cloth and check that the closing plugs are fitted flush by means of a “finger tip test”.

Insert the closing plugs in the counterbore, Figure 8:

• Insert the closing plug  in the correct position in the counterbore.

Fit the fitting device, Figure 9:

• Locate the fitting device MVH  on the guideway.
• Connect the fitting device to the hydraulic source  and ensure that the bleed  is activated.

Press in the closing plugs, Figure 10:

• Position the fitting device  over the closing plug  until the pawl  contacts the next closing plug that has not yet been pressed in; for the last closing plug, carry out this alignment visually .
• Press in the closing plug using a maximum of 300 bar.

Smooth off the closing plugs flat, Figure 11:

• Smooth off the top surface of brass closing plugs flat using an oilstone .
• Then clean the guideway using a lint-free clean cloth.

Press in the closing plugs, Figure 12:

• Insert the plastic clinch rings  in the holes.
• Press the closing plugs  in flush using a press-in block .

Do not work the plastic closing plugs using an oil stone  or similar, Figure 13.

Do not use the covering strip ADB with RUDS.

Only fit the covering strip to guideways that have been fitted in place.

The surface for adhesive fitting – the slot in the guideway – must be clean, free of grease and dry.

Avoid damaging the seal lip on the carriage.

Place the covering strip in the slot, Figure 14:

• Unroll a portion of the covering strip  and place with the adhesive film side face down in the slot  – the covering strip should finish approx. 2 mm from the end of the guideway.

Stick down the covering strip, Figure 15:

• Peel off the protective film  approx. 30 mm and fold it out at an angle to one side.
• Align the covering strip in the slot and stick it down by applying pressure – for example by means of a pressure roller . The strength of the bond will depend on the pressure used.
• Remove the protective film  and finish fitting the covering strip.

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

The covering strip ADB-K is a precision product and must be handled with great care.

Before fitting the covering strip, check that the clamping lugs are undamaged and that there are no creases.

Place the covering strip in the slot, Figure 16:

• Clean the covering strip ADB-K and the slot in the guideway surface using a cleaning cloth.
• Place the side of the strip with the larger radius in the slot; note the direction of curvature in the figure – sabre shape and the direction of the arrow; the other side of the strip must remain on the guideway surface.

Locate the covering strip, Figure 17:

• The covering strip protrudes 10 mm to 20 mm above the guideway.
• Locate the covering strip over 2 mm to 5 mm in the slot using a rubber hammer .

Locate the fitting device so that the pressure roller  forces outwards, Figure 18. At the overhang of the covering strip, bend it slightly downwards as shown by the arrow.

Press the covering strip obliquely into the slot in front of the fitting device. Ensure that pressing is carried out in the correct direction.

Fit the covering strip using the fitting device, Figure 18:

• Press the covering strip  on the locating side obliquely into the slot with the fingers and slide on the fitting device . Ensure that pressing is carried out in the correct direction.
• Slide the fitting device 300 mm onto the guideway.

Press the covering strip obliquely into the slot in front of the fitting device. Ensure that pressing is carried out in the correct direction.

We recommend that the covering strip should not be fitted more than once.

Fit the covering strip using the fitting device, Figure 19:

• Remove the fitting device  from the guideway, turn it through 180° and slide it back onto the guideway. The pressure roller  should now face towards the guideway.
• Cut the protruding end to length using snips.
• Fit the retainer.
• Check that the covering strip is correctly seated. The guideway must have a smooth surface; if necessary, smooth off using an oilstone.

The clamping element RUKS should only be located once the guideways and carriages have been fitted.

The counterbores of the fixing holes must be closed off first.

Align the clamping element, Figure 20:

• Tighten the fixing screws  in the clamping element finger tight. Use all the threaded holes.
• Place one dial gauge  at each corner of one longitudinal side  of the clamping element.
• Press one longitudinal side of the clamping element against the guideway (in the direction of the arrows) and set the dial gauges to “0” .

Do not exceed the maximum oil pressure of 350 bar. Pay attention to pressure spikes.

Finish fitting the clamping element, Figure 21:

• Press the opposing longitudinal side of the clamping element against the guideway (in the direction of the arrow).
• Read off and record the measured values on both dial gauges .
• Calculate the mean value of the measured values .
• Set the RUKS to half the mean value.
• Tighten the fixing screws  in accordance with the table.
• Fit the hydraulic connector  to the clamping element.
• Apply oil pressure and increase slowly to the maximum operating pressure.
• Check the clamping element for seal integrity, reduce the oil pressure.

The damping carriage RUDS should only be located once the guideways and carriages have been fitted.

Before fitting, the counterbores of the fixing holes in the guideways must be closed off.

Keep the guideways free from oil.

Align the damping carriage, Figure 22:

• Insert the fixing screws  in the damping carriage  and tighten finger tight.
• Place one dial gauge at each corner of one longitudinal side of the damping carriage.
• Press one longitudinal side of the damping carriage against the guideway (in the direction of the arrow)  and set the dial gauges to “0” .

Finish fitting the damping carriage, Figure 23:

• Press the opposing longitudinal side of the damping carriage  against the guideway (in the direction of the arrow).
• Read off and record the measured values on both dial gauges .
• Calculate the mean value  of the measured values.
• Set the damping carriage to half the value.
• Tighten the fixing screws .
• Fit the lubricant connector and charge the system with oil.

As an example, a fitting variant from Figure , link , has been selected.

Screw mount the datum side, Figure 24:

• Press the guideway on the datum side  against the locating face (in the direction of the arrows) and screw mount; observe the tightening torque M_A in the dimension tables.

Screw mount the adjustment side, Figure 25:

• Screw mount the guideway on the adjustment side  finger tight.

Screw mount the table, Figure 26:

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

Screw mount the adjustment side, Figure 27:

• Align the guideway on the adjustment side  with the carriage  and screw mount; observe the tightening torque M_A in the dimension tables.

Fit the closing plugs, Figure 28:

• Fit the closing plugs flush with the guideway surface , ; see also link to link.
• Clean the surface .

Secure the position, Figure 29:

• If necessary, secure the position  of the guideways and carriages on the datum and adjustment sides.

Ensure that the guideways show a visible oil film.

Supply the guidance system with oil:

• In order to ensure cleanliness and prevent corrosion, flush and fill all lubrication point supply pipes and lubrication holes immediately after connection.
• When putting monorail guidance systems into operation, supply the minimum oil quantity Q_min, while moving the carriage four times its length; for oil quantities, see tables link to link.

The damping carriage RUDS should be connected to the lubricant supply system of the linear recirculating roller bearing and guideway assembly RUE..-E (-L-KT) or RUE25-D.

Ensure that the guideways show a visible grease film.

KUVE..-B and KUVE..-B-KT have an initial grease quantity.

Supply the guidance system with grease:

• Fill a clean grease gun or other lubrication device with fresh grease.
• Clean the lubrication nipple and its immediate environment.
• Lightly grease the cleaned guideways.
• While the carriage is being filled by hand with the initial grease quantity, move the carriage four times its length; for grease quantities, see tables link and link.
• If connected lubrication devices are being used, relubrication should be carried out until fresh grease emerges from the carriage – move the carriage over the guideway length several times without load.

At initial operation and relubrication, the coefficient of friction increases temporarily due to the fresh grease. After a short running‑in period, however, the coefficient of friction returns to its original lower value.

The friction behaviour is determined significantly by the characteristics of the grease used. The consistency and base oil viscosity serve as approximate guide values.