alpha rack and pinion system
Technical documents

2022-D001333

Revision: 13

Technical documents

Rack and pinion system

WITTENSTEIN alpha GmbH
Walter-Wittenstein-Straße 1D-97999 Igersheim
Germany

Customer Service

Deutschland

WITTENSTEIN alpha GmbHservice@wittenstein.de+49 7931 493-12900

Benelux

WITTENSTEIN BVBA

service@wittenstein.biz+32 9 326 73 80

BrasilWITTENSTEIN do Brasil

vendas@wittenstein.com.br+55 15 3411 6454

service@wittenstein.cn+86 571 8869 5856

Österreich

WITTENSTEIN GmbHoﬃce@wittenstein.at+43 2256 65632-0

Danmark

WITTENSTEIN AB

info@wittenstein.dk+45 4027 4151

FranceWITTENSTEIN sarlinfo@wittenstein.fr+33 134 17 90 95

Great Britain

WITTENSTEIN Ltd.

sales.uk@wittenstein.co.uk+44 1782 286 427

ItaliaWITTENSTEIN S.P.A.

customerservice@wittenstein.it+39 02 241357-1

sales@wittenstein.jp+81-3-6680-2835

technicalsupport@wittenstein-us.com+1 630-540-5300

North America

WITTENSTEIN holding Corp.

EspañaWITTENSTEIN S.L.U.

info@wittenstein.es+34 93 479 1305

Sverige

WITTENSTEIN AB

info@wittenstein.se+46 40-26 50 10

Schweiz

WITTENSTEIN AG Schweiz

sales@wittenstein.ch+41 81 300 10 30

info@wittenstein.tw+886 3 287 0191

info@wittenstein.com.tr+90 216 709 21 23

Template no.: D90097-D000464 Rev.: 01

Türkiye

WITTENSTEIN Güç Aktarma
Sistemleri Tic. Ltd. Şti.

Copyright© WITTENSTEIN alpha GmbH 2022
This documentation is protected by copyright.
WITTENSTEIN alpha GmbH reserves all rights to photo-mechanical reproduction, copying,
and the distribution by special processes (such as computers, file media, data networks),
in whole or in part.
Subject to technical and content changes without notice.

2022-D001333

Revision: 13

Rack and pinion system
Contents

Technical documents

1

About this manual2
1.1
Information symbols
2
1.2
Scope of delivery
2
2 Safety2
2.1
EC/EU Directives
3
2.1.1 Machinery Directive3
2.2
Personnel
3
2.3
Intended use
3
2.4
Reasonably foreseeable misuse
3
2.5
General safety instructions
3
2.6
Structure of warning instructions
4
2.7
Safety symbols
4
2.8
Signal words
5
3 Description of the drive system
6
3.1
Ordering code / Name plate6
3.2
Dimensions and performance data 6
3.3
Weight6
4 Transport and storage
7
4.1
Packaging7
4.2
Transport
7
4.3
Storage75 Assembly
8
5.1
Requirements in respect ofassembly location and mounting
base
8
5.2
Required tool and assemblymaterial
95.3
Preparations
10
5.3.1 After the cleaning
11
5.4
Mounting the racks
11
5.4.1 Assembling the first rack
12
5.4.2 Assembling subsequent racks 13
5.4.3 Checking the transition
between the racks
14
5.4.4 Correcting the transition
between the toothed racks (only ifnecessary)15
5.4.5 Assembling additional racks
15
5.5
Checking the parallelism of all
racks
15
5.6
Pinning the racks
16
5.6.1 Pinning the racks (conventional) 16
5.6.2 Pinning the racks with INIRA®
pinning17
5.7
Mounting the gearbox
17
5.7.1 Inserting the gearbox at thehighest point
18
5.8
Final inspection
19
5.8.1 Contact pattern inspection
19
5.8.2 Checking the runningcharacteristics after assembly 20
5.9
Mounting the lubrication system 20

Revision: 132022-D001333

5.9.1 Mounting the lubricating pinion
on the lubricating axis
20
5.9.2 Venting the lubricating axis andlubricating pinion
22
5.9.3 Mounting the lubrication system 23
5.9.4 Installing distribution systems(optional)
24
6 Startup and operation
25
7 Maintenance and disposal
26
7.1
Shutdown, preparation
26
7.2
Maintenance schedule
26
7.3
Maintenance work26
7.3.1 Visual inspection
26
7.3.2 Checking the lubrication system 27
7.4
Replacing the rack28
7.4.1 Disassembling the rack28
7.4.2 Assembling the rack28
7.4.3 Pinning the mounted andaligned rack28
7.5
Startup after maintenance work 29
7.6
Disassembly29
7.6.1 Preparation
29
7.6.2 Disassembling the rack29
7.7
Lubricants29
7.8
Disposal29
8 Malfunctions
30
9 Appendix
32
9.1
Weight of racks
32
9.2
Information for mounting theracks
32
9.2.1 Overview of the required
cylinder head screws
32
9.2.2 Overview of cylindrical pins
33
9.3
Specifications for mounting onto
a mounting base
(INIRA® pinning)
33
9.4
Maximum height of the stopedges on the machine base33
9.5
Permissible parallelism deviation of
the assembly surface
33
9.6
Permissible measurement over pin
fluctuation at the rack transition 33
9.7
Permissible measurement over pin
fluctuation within an axis
34
9.8
Overview of the assembly
accessories
34
9.9
Lubricants for pre-oiling / venting /pre-greasing
34
9.10 Tightening torques for common
thread sizes in generalmechanical engineering
35

en-1

Technical documents

Rack and pinion system

1 About this manualThis manual contains necessary information to safely use the rack and pinion system,hereinafter referred to as drive system.
If this manual is supplied with amendment sheets (e.g. for special applications), then theinformation in the amendment is valid. Contradictory specifications in this manual are therefore
void.
The user should contact WITTENSTEIN alpha GmbH with any questions about special
applications. The operator must ensure that this operating manual is read through by all persons
assigned to install, operate, or maintain the drive system, and that they fully comprehend its
content.
Store this manual within reach of the drive system.
Inform colleagues who work in the area around the machine about the safety instructions andwarnings so that no one sustains injuries.
The original was written in German, all other language versions are translations of the original
manual.

1.1 Information symbols
The following information symbols are used: Indicates an action to be performed
 Indicates the results of an action
 Provides additional handling information
A cross reference refers to the chapter number and the header of the target section(z. B. 2.3 "Intended use").
A cross reference on a table refers to the table number (e. g. Table "Tbl-15").

1.2 Scope of delivery
 Check the completeness of the delivery against the delivery note.
 Immediately notify the carrier, the insurance company, or WITTENSTEIN alpha GmbH in
writing of any missing parts or damage.

2 Safety
These instructions, especially the safety and warning notices and the rules and regulations valid
for the operating site, must be observed by all persons working with the racks.
The following, especially, must be strictly adhered to: Observe the instructions for transport and storage.
 Use the drive system exclusively in accordance with its intended use and in a technicallyflawless and safe condition.
 Carry out maintenance and repair work appropriately and professionally in conformity withthe specified intervals.
 Always mount, dismantle, and operate the drive system properly (e.g. even test run only withlubrication).
 Only operate the drive system with intact protective devices and equipment.
 Only operate the drive system with lubrication (type and quantity).
 Prevent pollution of the drive system.
 Only carry out modifications or reconstructions when these are approved in writing by
WITTENSTEIN alpha GmbH.
Personal injuries or material damage, or other claims arising from non-observance of theseminimum requirements, are the sole responsibility of the operator.
In addition to the safety-related information in this manual, also observe any legal andotherwise applicable rules and regulations, particularly for accident prevention(e.g. personal safety equipment) and environmental protection.

en-2

2022-D001333

Revision: 13

Rack and pinion system

Technical documents

2.1 EC/EU Directives
2.1.1

Machinery Directive
The rack and pinion system is considered a "machine component" and is therefore not subject tothe EC Machinery Directive 2006/42/EC.
Operation is prohibited within the scope of the EC directive until it has been determined that themachine in which this product is installed corresponds to the regulations within this directive.

2.2 Personnel
Only technicians who have read and understood this operating manual may perform work on thedrive system. Based on their training and experience, technicians must be able to evaluate thetasks assigned to them in order to recognize and avoid risks.

2.3 Intended use
The drive system is used to convert rotational motion to linear motion (e.g. for feed drives) or viceversa and is intended to be installed in a machine.
It is suitable for industrial applications.
The drive system may not be operated in potentially explosive atmospheres. In the foodprocessing/pharmaceutical/cosmetics industry, the drive system may only be used next to or
under the product area.
The drive system has been constructed according to current technological standards andaccepted safety regulations.
 To avoid any hazard to the operator or damage to the machine, use the drive system only inaccordance with its intended use and in a technically flawless and safe condition.
 If you notice any altered operating behavior, check the gearbox in accordance withchapter 8 "Malfunctions".
 Read the general safety instructions before beginning to work(see chapter 2.5 "General safety instructions").

2.4 Reasonably foreseeable misuse
All other applications other than the intended use specified above, are deemed to be improper
use and are therefore prohibited.

2.5 General safety instructions
The operation of the drive system involves residual risks even when adhering to theintended use.
Moving components can cause serious injuries: Before startup, remove objects, loose components, and tools from the drive system,in order to avoid danger from thrown parts.
 Keep a sufficient distance to moving machine components when the drive system is running.
 Secure the machine against restarting and unintentional movement during assembly andmaintenance work.
 Hot components (e.g. gearboxes) of the drive system can cause serious burns:
 Touch hot components only with protective gloves.
The noise emissions can cause hearing damage. The continuous noise pressure level may vary
according to product type and size: Information about your specific product is available in the catalog underwww.wittenstein-alpha.de or from our Customer Service / Sales department.
 For noise protection measures, observe the total noise pressure level of the machine.

Revision: 132022-D001333

en-3

Technical documents

Rack and pinion system

Loose or overloaded screw connections can cause damage to the drive system:
 Use a calibrated torque wrench to tighten and check all screw connections for whichtightening torques have been specified.
Solvents and lubricants are flammable, can cause skin irritation, and can pollute soil and water: In case of fire: Do not use a jet of water to extinguish.
 Suitable extinguishing agents are powder, foam, water mist and carbon dioxide. Observe thesafety instructions of the lubricant manufacturer (see chapter 7.3.2 "Checking the lubrication
system").
 Use protective gloves to avoid direct skin contact with solvents and lubricants.
 Use and dispose of solvents and lubricants properly.
A damaged drive system can cause accidents and injury:
 Immediately shut down a gearbox that has been overloaded due to misuse or a machinecrash (see chapter 2.4 "Reasonably foreseeable misuse").
 Replace the damaged drive system, even if no external damage is visible.

2.6 Structure of warning instructions
B
A

C

Warning instructions are situation-specific.
They will be precisely where tasks are describedin which dangers can arise.
The warning instructions in this manual aredesigned according to the following pattern:
A = Safety symbol(See chapter 2.7 "Safety symbols")
B = Signal word
(See chapter 2.8 "Signal words")
C = Type and consequence of the danger
D = Avoiding the danger

D
Figure 2.1

2.7 Safety symbols
The following safety symbols are used to indicate hazards, things that are forbidden andimportant information:

en-4

General danger

Entanglement

Environmental
protection

Information

Substances that
represent a fire risk2022-D001333

Suspended loads

Revision: 13

Rack and pinion system

Technical documents

2.8 Signal words
The following signal words are used to indicate hazards, things that are forbidden and important
information:

DANGER
This signal word indicates an imminent danger that will cause
serious injuries or even death.

WARNING
This signal word indicates a potential hazard that could cause
serious injuries and even death.

CAUTION
This signal word indicates a potential hazard that could cause
minor or serious injuries.

NOTE
This signal word indicates a potential hazard that could lead toproperty damage.
A note without a signal word indicates application tips or especially
important information for handling the drive system.

Revision: 132022-D001333

en-5

Technical documents

Rack and pinion system

3 Description of the drive system
The drive system consists of:racks,
the corresponding gearbox with one pinion at the output
and a lubrication system.
The drive system is available in different versions. Refer to our catalog or our website for thecorresponding installation dimensions: www.wittenstein-alpha.de.
For the assembly described in this manual, additional parts/tools are required which are available
as self-contained accessories (see chapter 9.8 "Overview of the assembly accessories").

3.1 Ordering code / Name plate
The ordering code (A) for the racks is located on
the racks (e.g.: ZST 200-XXX-1000-XXX-R11 or
ZST 200-XXX-1000-R11).

More information is available in our catalog
or at www.wittenstein-alpha.de.
Figure 3.1

The name plate forthe gearbox is located on the gearbox housing or drive flange.
the lubrication system is located on the lubricator.
 More information is available in our catalog at www.wittenstein-alpha.de or in the respective
instructions.

3.2 Dimensions and performance data
The dimensions, the maximum permissible speeds and torques, and information on the service
life can be foundin our catalog,
under www.wittenstein-alpha.dewith the respective customer-specific performance data (2093–D...).
For additional information, contact WITTENSTEIN alpha GmbH. Always provide the ordering
code / serial number.
 Consult our Customer Service department if the drive system is older than one year.
The user will then receive the valid performance data.

3.3 Weight
The total weight of the drive system is the combination of the weight of the gearbox with thepinion and the corresponding racks.
 The mass of the individual racks can be found in chapter 9.1 "Weight of racks".
 For the weight of the gearbox and the lubricator (components of the lubrication system),refer to the relevant operating manual.

en-6

2022-D001333

Revision: 13

Rack and pinion system

Technical documents

4 Transport and storage
4.1 Packaging
The racks are delivered individually wrapped in VCI paper / protective foil and packed in
cardboard boxes if necessary.
The gearbox has corrosion protection agent on the unpainted interfaces and on the mounted
output pinion and is packaged in foil and cardboard boxes.
 Dispose of the packaging materials at the recycling sites intended for this purpose.
Please observe the valid national regulations for waste disposal.

4.2 Transport

WARNING
Suspended loads can fall and can cause serious injuries and evendeath.
 Do not stand under suspended loads.
 Secure the drive system before transport with suitable fasteners(e.g. belts).

CAUTION
There is a risk of injury or damage due to sharp edges on the rack.
 Wear protective gloves and safety shoes.

NOTE
Hard knocks, for instance because of falling or hard dropping, candamage the drive train.
 Only use hoisting equipment and lifting accessories with sufficient
capacity.
 Never exceed the maximum permissible load for hoisting equipment.
 Lower the drive system slowly.
For information on the mass of the drive system, see chapter 3.3 "Weight".

4.3 Storage
Store the drive system in horizontal position and dry surroundings at a temperature of
0 °C to +40 °C in the original packaging. Store the drive system for a maximum of
2 years. Consult our Customer Service department if conditions are different.
For storage logistics, we recommend the "first in – first out" method.

Revision: 132022-D001333

en-7

Technical documents

Rack and pinion system

5 AssemblyRead the general safety instructions before beginning to work(see chapter 2.5 "General safety instructions").
Observe the instructions in the relevant manual for the gearbox and lubrication system.
If you have questions about correct assembly, consult our Customer Service department.

5.1 Requirements in respect of assembly location and mounting baseRequirements in respect of assembly location:
The racks must be installed in a clean and dry environment. Dust and liquids of any kind
impair its function.
The precision of installation and geometric tolerance of the assembly surfaces in themounting base depend on the application in question. For applications with highpositioning accuracy and smooth drive train running requirements, the aim should be toachieve low deviation. For applications with low requirements, greater deviation may beallowed.
 For specifications regarding the assembly surfaces, see chapter 9.5 "Permissible parallelism
deviation of the assembly surface".

R

m

.
ax

1,3

0,04
Figure 5.1

en-8

Mounting base requirements:
There is a chamfer on the rack at the transition
point between the mounting and rear surface.
Recesses can be omitted from the mounting
base as a result. The mounting base on themachine must be designed in such a way thatthe milling edge does not collide with the rack
chamfer.
The stop surface should be designed in sucha way that the rack can be clamped easily.
This is achieved when the height of the stopsurface is more than 50 % of the rack height andwhen a suitable opposing surface is available forclamping using a clamping device.
The threaded holes for the fastening screws
must allow a sufficient screw-in depth,
depending on the material used for themounting base.

Our Customer Service department is available toanswer any questions regarding calculation of
the screw-in depth.

2022-D001333

Revision: 13

Rack and pinion system

Technical documents

5.2 Required tool and assembly material
Below is an overview of the tools/materials needed for assembly.

C

D

E

F

H

G

I
M

A B

K

Figure 5.2

Pos.

Tool / MaterialA

Fastening screws

B

Cylindrical pins

Task / Purpose

Required size: see chapter 9.2.1"Overview of the required cylinder headscrews".
To affix the racks to
The length of the fastening screws must be
the screw-on
chosen depending on the material of thesurfacemounting base on the machine.
The number of fastening screws required
depends on the bores provided in the rack.
Required size: see chapter 9.2.2"Overview of cylindrical pins"
To pin the racks to The length of the cylindrical pins must be
chosen depending on the material of thethe screw-on
mounting base on the machine. The number
surfaceof cylindrical pins required depends on thebores provided in the rack.

C

Clamping devices
To clamp the racks(e.g. screw clamps withto the machine bed
protective caps)

D

Torque wrench with hex
key insert

Revision: 13

Additional information

To tighten thefastening screws

2022-D001333

Tightening torque: see chapter 9.2.1
Overview of the required cylinder headscrewsen-9

Technical documents
Pos.

Tool / MaterialESoft-head hammer

F

Dial gauge holder withdial gauge

G

Cleaning agent

H

Sharpening stoneI

MagnetK

Assembly jig

M

Needle roller

Rack and pinion system
Task / Purpose
To adjust thetransition point
between two racks
To check theassembly surfaces
and theassembled racks

Additional information-

Resolution: min. 0.01 mm

To clean theassembly surfaces
To magnetize theneedle rollers (M)To align thetransition point
between two racks
To check the rolldimensions using
a dial gauge

Size: See chapter 9.8 Overview of theassembly accessories
Size: See chapter 9.8 Overview of theassembly accessories
Table 1: List of necessary tools/materials

5.3 Preparations

CAUTION
There is a risk of injury or damage due to falling racks and sharpedges on the rack.
 Suitable hoisting equipment should be used when transporting
heavy racks.
 When using hoisting equipment, do not stand below thesuspended load.
 Wear protective gloves and safety shoes.


Observe the safety and processing instructions of the cleaning
agents to be used.

Unpack the racks to be assembled and remove the VCI paper or protective foil in which theracks are packed.
 Check the ordering codes (see chapter 3.1 "Ordering code / Name plate") of all toothed
racks. Use only racks with the same ordering code for the same application.
 Always enter the ordering code when ordering spare parts in order to receive precisely
coordinated racks and pinions.

en-10

2022-D001333

Revision: 13

Rack and pinion system

Technical documents


G
H

O

N

Remove all traces of the anti-corrosion agent
before mounting the racks. Use a clean,lint-free cloth and a grease-dissolving,
non-aggressive cleaning agent.
Clean the stop surface (N) and thescrew-on surface (O) with asharpening stone (H), a suitable cleaning
agent (G), and a lint-free cloth.



Figure 5.3

P

Check the parallelism between the stopsurface (N) / screw-on surface (O), and thelinear guide (P) with a dial gauge (F).
For permissible tolerances, see chapter 5.1"Requirements in respect of assembly
location and mounting base".



O

F

N
Figure 5.4

5.3.1

After the cleaning
Uneven temperatures between the rack andmounting base can have a considerable impact
on the smooth running and positioning accuracyof the drive train.
Place the unpacked racks on the mounting
base in good time before assembly in order
to allow the temperatures to equalize.

Figure 5.5

5.4 Mounting the racks

NOTE
The improper usage of clamping devices (e.g. such as screw
clamps) can damage the gear teeth of the racks.
 Only use clamping devices with protective caps or use immediate
layers of plastic or brass.


Observe the safety and processing instructions for the threadlocker
to be used.

 Optimum precision of installation can be achieved through prior alignment of the linear guideor guide rails with the racks' assembly surfaces.

Revision: 132022-D001333

en-11

Technical documents
5.4.1

Rack and pinion system

Assembling the first rack

Only cylinder head screws in property class 12.9. are approved forfastening the racks.
For Screw sizes and prescribed tightening torques,see chapter 9.2.1 "Overview of the required cylinder head screws".

R




Q



Figure 5.6

Position the first rack in the middle of themachine bed.
The through bore holes (Q) of the rack mustbe centered above the corresponding
threaded holes (R) of the screw-on surface.
It is recommended that the user commences
installation in the center of the axle,
particularly in the case of long axles.
If installation commences at the end of theaxle, pitch deviation in the racks and position
deviations in the bores can accumulate tosuch an extent that the through bore holes in
the racks and the threaded holes in themounting base no longer sit above one
another.

D
CA

Figure 5.7



Clamp the rack to the machine bed in the area of the fastening bores using clamping
devices (C).
 Insert the first cylinder head screw (A).
 To secure the cylinder head screws, we recommend using a thread locking glue
(e.g. Loctite® 243).
 Tighten the cylinder head screws with the required tightening torque, while the clamping
device (in the following simply called screw clamp) holds the position.
 For Screw sizes and prescribed tightening torques, see chapter 9.2.1 "Overview of therequired cylinder head screws".
 Repeat the previous steps for the remaining cylinder head screws.
 For Screw sizes and prescribed tightening torques, see chapter 9.2.1 "Overview of therequired cylinder head screws".
 Remove the screw clamps.
en-12

2022-D001333

Revision: 13

Rack and pinion system
5.4.2

Technical documents

Assembling subsequent racks

D
C

A

K

Figure 5.8

Due to too much pressing force of the assembly jig for the connection of two racks, the rack
gap can widen. The assembly jig should serve only as an insert between two racks.
 Position the rack to be assembled beside the previously assembled rack.
 Insert the assembly jig (K) into both racks at the transition point, in order to adjust thetransition between the two racks.
 Clamp the rack to the machine bed in the area of the through bore holes.
 Insert the first cylinder head screw (A) in assembly direction.
 To secure the cylinder head screws, we recommend using a thread locking glue
(e.g. Loctite® 243).
 Tighten the cylinder head screw in assembly direction with half of the predeterminedtightening torque.
 For Screw sizes and prescribed tightening torques, see chapter 9.2.1 "Overview of therequired cylinder head screws".
 Repeat the previous steps for the remaining cylinder head screws.
 Loosen all screw clamps (C) and the assembly jig.
 Check the levelness of the butt joint as described in chapter 5.4.3 "Checking the transition
between the racks" before you mount the next rack.


Revision: 132022-D001333

en-13

Technical documents
5.4.3

Rack and pinion system

Checking the transition between the racks

NOTE
A rack can be permanently magnetized by placing the dial gauge
holder on it.
 Fasten the dial gauge holder on the guiding carriage or the machineslide only.






E

P







1 2 3

M


F

Magnetize the needle rollers (M) witha suitable magnet.
Insert the magnetized needle rollers into
positions 1, 2 and 3, as shown in the
diagram.
Due to the magnetization, the needle rollers
remain attached to the positions.
Attach the dial gauge holder to the guiding
carriage (P) and insert the dial gauge.
Measure the highest point at each of theneedle rollers at position 1 and position 3
using the dial gauge (F) and calculate the
midpoint of the two points.
The midpoint is the target value for thehighest point of the needle roller at position 2.
For the maximum permissible deviation inheight from position 1 to position 3, seechapter 9.6 "Permissible measurement overpin fluctuation at the rack transition".
Measure the highest point of the needle roller
at position 2 with the dial gauge.
If the value is within the tolerance range,
clamp only the screw clamps and tighten thecylinder head screws with full tightening
torque (see chapter 9.2.1 "Overview of therequired cylinder head screws").
If the value falls outside of the range oftolerance, correct the transition between thetwo racks as described in the following
section.

Figure 5.9

en-14

2022-D001333

Revision: 13

Rack and pinion system

Technical documents

5.4.4

Correcting the transition between the toothed racks (only if necessary)
Carry out the following step in case the transition between the racks exceeds the tolerance range: Correct the transition between the two racks by hitting them in the corresponding direction
with a copper punch and/or a soft-headed hammer (E). To do this, place the copper punch
on one of the rack's fastening bores.

5.4.5

Assembling additional racks
 Assemble all additional racks in the same manner as described in the chapters above.

5.5 Checking the parallelism of all racks


V
M



F



Attach the dial gauge holder to the guiding
carriage and move this to the end of the axle.
Place a magnetized needle roller (M) if
possible at the outer end of the axle intoa tooth gap.
Move the dial gauge (F) towards the highest
point of this needle roller and set the dialgauge to "0".
Mark the measurement value at themeasuring point (V) (reference point) witha pin on the rack.

Figure 5.10

Insert needle rollers into tooth gaps at regular intervals (at least 5 needle rollers per1000 mm of axle length).
 Check the deviation from the reference point with the dial gauge.
 Mark the deviation from the reference point at each measuring point.
 For permissible deviations within an axis, see chapter 9.7 "Permissible measurement overpin fluctuation within an axis".
 Identify the highest point of measurement of the entire axle and mark this.
 This measuring point is necessary for the correct adjustment of the gearing backlash
between the pinion and the rack.

Revision: 132022-D001333

en-15

Technical documents

Rack and pinion system

5.6 Pinning the racks
5.6.1

Pinning the racks (conventional)

Figure 5.11

 Clamp the rack tightly at all pin holes using screw clamps.
 Drill the pin holes in the mounting base on the machine at the locations provided.
 The pin holes are pre-drilled in the racks by the manufacturer. The diameter of the pin holes
in condition of delivery is lower than the final dimension to be achieved.
 Grind the bores in the rack and the machine bed to the required fit size for the cylindrical pins(see chapter 9.2.2 "Overview of cylindrical pins").
 The tolerance range for the bores is H7. For specifications on the diameters of the cylindricalpins, see chapter 9.2.2 "Overview of cylindrical pins".
 Remove the accumulating chips with a vacuum cleaner.


B




To enable easier disassembly of the rack,cylindrical pins (B) with internal threads arerecommended.
Fasten the racks with cylindrical pins.
If it is not possible to pin the racks, contact ourCustomer Service department.

Figure 5.12



en-16

If the machine is not to be put into operation immediately,conserve the racks using a suitable corrosion protection agent.

2022-D001333

Revision: 13

Rack and pinion system
5.6.2

Technical documents

Pinning the racks with INIRA® pinning
For this type of rack, no pinning with INIRA® pinning is intended.
With INIRA ® pinning, we have already made the assembly process much faster, more accurate
and more ergonomic. There is no need to drill and grate. The time requirement for pinning is
reduced to about 1 min per rack.
 For more information about INIRA®, see the "INIRA®" installation instructions or
www.wittenstein-alpha.de/INIRA.

5.7 Mounting the gearbox
The gearbox is delivered with the mounted pinion. To ensure an easy assembly procedure,
we recommend not mounting the motor until the rack and pinion system has been adjusted andchecked.
The machine's gearbox interface should be constructed in such a way that assembly and aligning(e.g. with an adjusting tool) should be easy.
When employing a gearbox with integrated
slotted holes (Z) in the gearbox flange no
additional adjusting tool is necessary.
More information about assembly and themounting base on this gearbox can befound in the relevant operating manual.

Z

Figure 5.13

Revision: 132022-D001333

en-17

Technical documents
5.7.1

Rack and pinion system

Inserting the gearbox at the highest point

Observe the safety and processing instructions for the threadlocker tobe used.

The gearbox can be installed in any mounting position.
The highest point, i.e. the tooth with the greatest radial runout deviation, is marked on the
output pinion by the manufacturer.
Align the "highest points" of the pinion andrack with one another using the machine's
adjusting tool.
Slide the gearbox pinion unit into the rack byhand. The tooth flanks of the pinion and rackshould be free of backlash and without
preload at their "highest points".
Wet the screws with thread locking glue andfix the gearbox.

Figure 5.14

Feeding in the gearbox


Refer to our catalog or our
website for feed dimension "A":www.wittenstein-alpha.de.

Figure 5.15

en-18

2022-D001333

Revision: 13

Rack and pinion system

Technical documents

Figure 5.16

A flank play is possible in some segments of the travel path. Clamping of toothedparts is not permitted.

5.8 Final inspection
5.8.1

Contact pattern inspection











Observe the safety and processing instructions of the cleaning
agents to be used and the gear marking compound.

Degrease the tooth flanks of the rack (e.g. with acetone).
Coat the tooth flanks with gear marking compound or with a water-proof pen.
Shift or move the slide several times so that the pinion runs over the coated tooth flanks.
Check thereby that the gearing runs smoothly.
Check in which range the color is removed from the tooth flanks.
Evaluate the alignment of the gearbox based on the following illustrations.
If necessary, correct the alignment of the gearbox.
Oil or grease all blank parts with a cloth against corrosion.

Correct

Not right-angled

Revision: 13

Not parallel

2022-D001333

Wrong axis distanceen-19

Technical documents
5.8.2

Rack and pinion system

Checking the running characteristics after assembly
Shift or move the slide several times acrossthe entire movement range.
The exerted force and the running noise needto remain the same.
Use a hand wheel or crank connected to theclamping hub in the gearbox. Consult ourCustomer Service department to receive
further information.

Figure 5.17

5.9 Mounting the lubrication system
Read the general safety instructions in the lubricator's manual and inchapter 2.5 "General safety instructions".

The lubrication of the rack and pinion system is effected by a lubrication system.
Depending on the configuration, lubricant is transferred from a lubricator via
a plastic hose,a distribution system,
a lubricating pinion for lubricating the rack and pinion drive; oranother lubrication point, e.g. a guiding carriage.
 The lubricator is filled with grease that is optimized for the application and approved by
WITTENSTEIN at the factory.
 The operating manuals for our LUC+125 and LUC+400 lubricators can be found in thedownload area on our website www.wittenstein-alpha.de.
 The recommended, adjustable amount of lubricant depends on the application.
The recommended amount of lubricant can be found in the catalog in the download area on
our website www.wittenstein-alpha.de or you can contact our sales department.
5.9.1

Mounting the lubricating pinion on the lubricating axisObserve the safety and processing instructions for the threadlocker
to be used.

The lubricating pinion is made of PU foam and is delivered dry.
 We recommend that our standard lubricants WITTENSTEIN alpha G11, G12, and G13 beused for lubrication.
Pre-oiling the lubricating pinion
 Insert the lubricating pinion into a suitable oil for a maximum of 2 minutes. The lubricating
pinion must be immersed completely in the oil bath.
 WITTENSTEIN alpha GmbH offers suitable lubricants, see chapter 9.9 "Lubricants forpre-oiling / venting / pre-greasing".

en-20

2022-D001333

Revision: 13

Rack and pinion system

Technical documents

Mounting the lubricating pinion


X




W1



S
W2



Y



Figure 5.18




Slide the flat flanged wheel (W1) up to the stopon the lubricating axis (X).
Grease the lubricating axis slightly.
Slide the pre-oiled lubricating pinion (S) up to
the stop on the lubricating axis.
Check that there is enough grease between
the lubricating axis and the slide bearing on
the lubricating pinion.
Insert the flat head screw (Y) into the second
flanged wheel (W2).
Wet the flat head screw with a thread
locking glue (e.g. Loctite® 243).
Screw the flanged wheel onto the
lubricating axis using the flat head screw.
Align the flange wheel.
The permissible tightening torque is 6 Nm.

Installing the hose connector



Ä
X

Check that the O-ring is sitting correctly on thehose connector.
Screw the hose connector (Ä) into the
lubricating axis (X) with the specified tightening
torque (see table 2).
Hose connector

Tightening torque
[Nm]

M6x1

2

M10x1

15
Table 2: Hose connector tightening torques

Figure 5.19

The maximum length of the plastic hose line for grease lubrication
depends on the lubricant used and the temperature, see Table 3.

LubricantTemperature[°C]

Max. hose length(without distribution system*) [m]
LUC+400

LUC+125 (24V)

WITTENSTEIN alpha G11

20

10

5

WITTENSTEIN alpha G12

20

5

2

WITTENSTEIN alpha G13

20

8

3

* When using a distribution system, the permissible hose length must be reduced.
Please observe your design documentation or contact our Customer Service / Sales
department.
Table 3: max. hose length

Revision: 132022-D001333

en-21

Technical documents

Rack and pinion system

 Slide the pre-filled plastic hose, included in delivery, up to the stop on the hose connector.
 Install the plastic hose so that it cannot bend during operation (minimum bending radius
static 30 mm; dynamic 40 mm).
 Use a hose cutter to cut the plastic hose. This ensures a rectangular and clean cut without
damaging the hose.

NOTE
Faulty disassembly of the plastic hose can damage the hoseconnector and lead to leaks.
 To disassemble a plastic hose, press in the release ring on the hoseconnector until it stops and pull out the plastic hose.
5.9.2

Venting the lubricating axis and lubricating pinion
In order to ensure perfect operation from the start, the lubricating pinion and lubricating axis must
be vented.
Venting using the ventilation function of the lubricator Connect the pre-filled plastic hose, included in LUC+ delivery, to the mounting axis.
 Vent the lubricating pinion and lubricating axis using the lubricator vent function
LUC+125/400 impulse-controlled via the 12 s signal.
LUC+125 timed via the Fill function.
 The lubricating pinion must be rotated during the venting process.
 For further information, see the instructions of the respective lubricator.
Venting with a grease gun
Alternatively, it is possible to vent using a grease gun.
 Use a suitable intermediate piece or screw a lubricating nipple into the mounting axis insteadof a hose connector.
 Use the grease gun to pump the appropriate volume of grease into the mounting axis.
The corresponding amount of grease is shown in Table 4.
 The lubricating pinion must be rotated during the venting process.
Venting volume of the lubricating pinion and mounting axis
Module [mm]

1.5

2

3

4

5

6

8

Amount of grease for initial
greasing [cm³]

4

4

5

6

12

14

18

Number of strokes LUC+
(0.15 cm³ stroke)

27

27

33

40

80

94

120

Table 4: Venting volumeen-22

2022-D001333

Revision: 13

Rack and pinion system
5.9.3

Technical documents

Mounting the lubrication system
 Calculate the axis distance between the pinion and lubricating pinion approximately using thefollowing formula:
Axis distance=d lubricating pinion+
2dA pinion a)+h rackorAxis distance=d lubricating pinion
2a) d

A pinion = d pinion + 2 * x * md pinion = Reference circle diameter pinion [mm]x
= Profile correction factorm= Normal module [mm]



S



Mount the lubricating axis with the installed
lubricating pinion (S), without pretensioning on
the pinion or rack, onto the mounting base.
To secure the screws, we recommend usinga thread locking glue (e.g. Loctite® 243).

Figure 5.20

 Refer to our catalog or our website for specifications on the installation dimensions:www.wittenstein-alpha.de Close off plastic hoses that are not being used with the hose end caps provided.

NOTE
Too little or incorrect lubrication of the drive system damages thegearing.
 Always ensure sufficient lubrication with a suitable lubricant.
 Grease the racks and the pinion before startup.
 Further information on the lubricator can be found in the respective instructions of the
lubricator.
 Special operating conditions may require different lubricants and lubricant quantities.
In this case, consult our Customer Service department.

Revision: 132022-D001333

en-23

Technical documents
5.9.4

Rack and pinion system

Installing distribution systems (optional)
Splitter - LUS
Splitters evenly divide the lubricant volume
between 2, 3 or 4 outlets.
This function is realized by means of chokes leading
to a pressure difference of approx. 10 bar between
the inlet and outlet of the splitter. The outlets areequipped with integrated non-return valves toprevent backflow of lubricants.

Figure 5.21

Application conditions:Comparable lengths of the hoses at the outlet (+/-10 % difference).
Comparable back pressures at the lubrication point
Identical line cross sections at the outlet
Operating temperature +10 °C to +60 °C (please see technical data sheet of lubricant)Permitted lubricants: WITTENSTEIN alpha G11, G12, G13
 Splitters are vented with a food grade H1 grease. Before commissioning, flushing withseveral pulses of the lubricator is recommended.
 Splitters must not be set up in a cascaded arrangement.
Progressive distributor – LUP
 For instructions on installing the progressive distributor, see the separate instructions"Progressive distributor LUP" (doc. no. 1000080446).

en-24

2022-D001333

Revision: 13

Rack and pinion system

Technical documents

6 Startup and operation


Read the general safety instructions before beginning to work(see chapter 2.5 "General safety instructions").
Observe the instructions in the relevant manual for the gearbox and lubrication system.

NOTE
Insufficient lubrication upon startup of the drive system damages
the toothing.
 Always make sure that there is sufficient lubrication and exchange
the lubricant cartridge in the lubricator in time.
Improper use can cause damage to the drive system.
 Ensure thatthe ambient temperature does not drop below +10 °C or
exceed +40 °C andthe operating temperature does not exceed +90 °C.
 For other conditions of use, consult our Customer Service
department.
 Only use the gearbox up to its maximum limit values, see 3.2"Dimensions and performance data". For other conditions of use,
consult our Customer Service department.
 Use the drive system only in a clean, dust-free and dry environment.

Revision: 132022-D001333

en-25

Technical documents

Rack and pinion system

7 Maintenance and disposal

Read the general safety instructions before beginning to work(see chapter 2.5 "General safety instructions").
Observe the instructions in the relevant manual for the gearbox and lubrication system.

7.1 Shutdown, preparation

Shut down the machine that contains the drive system.
Disconnect the machine from the mains before starting maintenance work.

7.2 Maintenance schedule
Maintenance work

At startup

Visual inspection andcleaning

X

Checking the lubrication
systemX

After 500 operating Every 3 months
hours or 3 months
X
X
X

X
Table 5: Maintenance schedule

To ensure reliable lubrication in the long term, we recommend replacing the components after thefollowing period of use:
Exchange work
Components

After 3 years

Lubricating pinion

X*

Lubricant cartridge LUC+

X

Hoses

After 5 years

After 10 years

X

Lubricator LUC+

X

* in two-shift operation after 2 years
 Should you have any further questions about replacements, please contact ourCustomer Service department.
Table 6: Exchange work

7.3 Maintenance work
7.3.1

Visual inspection
 Check the entire drive system by carrying out a thorough visual inspection for exterior
damage and sufficient lubrication.
 Repair or replace defective parts immediately.
 For specific information on maintenance-related issues, contact our Customer Service
department.

en-26

2022-D001333

Revision: 13

Rack and pinion system
7.3.2

Technical documents

Checking the lubrication system

NOTE
Too little lubrication damages the gearing.
 Always make sure that there is sufficient lubrication and exchange
the lubricant cartridge in time.






Check the entire lubrication system bycarrying out a thorough visual inspection
for exterior damage such as loosened or
defective hoses and worn or soiled(plugged) lubricating pinions.
Replace damaged parts immediately toensure a continuous lubrication.
The service life of the lubricating pinion
depends on the ambient conditions.
Check the fill level in the lubricator.

Figure 7.1

 Further information on the lubricants in the gearbox and in the lubricator can be found in therelevant instructions.
 Despite the comparatively long service life of the polyurethane foam lubricating pinion,
we recommend the preventive replacement of the lubricating pinion after a running timeof 2-3 years. The replacement intervals depend on the duration of use. In case of visible
wear we recommend an immediate replacement.
 We also recommend that you consider replacing the lubricant cartridge, hoses and lubricatorin the maintenance schedule, see chapter 7.2 Maintenance schedule.

Revision: 132022-D001333

en-27

Technical documents

Rack and pinion system

7.4 Replacing the rack

CAUTION
There is a risk of injury or damage due to falling racks and sharpedges on the rack.
 Suitable hoisting equipment should be used when transporting
heavy racks.
 When using hoisting equipment, do not stand below the suspendedload.
 Wear protective gloves and safety shoes.

NOTE
Avoid heat transfer to the racks during assembly.
 Wear protective gloves during assembly.
Improper replacement of a rack can cause damage to the drive
system and the neighboring parts.
 Make sure that the rack is replaced only by trained technicians.

7.4.1

Disassembling the rack Remove the pins of the racks with a suitable tool.
 Loosen all fastening screws and remove the rack.
 Remove the rack with care, so as to safeguard the drive train and adjacent parts against
damage.

7.4.2

Assembling the rack
 Use only racks with the same ordering code for the same application.
 Carry out the assembly of the new rack as described in chapter 5.4.2
Assembling subsequent racks.
 During the assembly of the rack, check the transitions to the adjacent racks.

7.4.3

Pinning the mounted and aligned rack
 Clamp the rack tightly at all pin holes using screw clamps.
 Select the next larger cylinder pins than specified in chapter 9.2.1 Overview of the required
cylinder head screws.
 In chapter 9.2.1 Overview of the required cylinder head screws only the standard sizes
are given.
 Drill and ream the rack and machine bed to the required fit size.
 The tolerance range for the bores is H7.
 For an easier disassembly, we recommend the cylindrical pins with internal threads.
 Remove the accumulating chips with a vaccum cleaner.
 Fasten the racks with cylindrical pins.
 If a pinning of the racks is not possible, consult our Customer Service department.

en-28

2022-D001333

Revision: 13

Rack and pinion system

Technical documents

7.5 Startup after maintenance work

Clean and grease the racks and the pinion.
Attach all safety devices.
Do a test run before re-releasing the machine for operation.

7.6 Disassembly

CAUTION
Improperly executed work can lead to injury and damage.
 Ensure that the drive system is only installed, maintained,
and dismantled by trained technicians.
 The disassembly of the gearbox and lubricator is described in the relevant operating
manuals.
7.6.1

Preparation
 Shut down the machine that contains the drive system.
 Ensure that it is possible to dismantle the drive system without constituting a damage hazard
for the whole machine.
 Before starting work, disconnect the machine from the mains.

7.6.2

Disassembling the rack Carry out the disassembly of the toothed racks as described in chapter 7.4.1
Disassembling the rack.

7.7 LubricantsSolvents and lubricants are hazardous substances that cancontaminate soil and water.
 Use and dispose of cleaning solvents and lubricants properly.
 Do not mix polyglycol with mineral oils that are intended forrecycling.

 Remove all deposits of lubricant from the individual racks.
 Dispose of the lubricant deposits and the racks at the appropriate disposal sites.
 Please observe the valid national regulations for waste disposal.

7.8 Disposal
Consult our Customer Service department for supplementary information on disposal ofthe drive system.
 Dispose of the drive system at the appropriate disposal sites.
 Please observe the valid national regulations for waste disposal.

Revision: 132022-D001333

en-29

Technical documents

Rack and pinion system

8 Malfunctions

NOTE
Changed operational behavior can be an indication of existingdamage to the drive system or can cause damage to the drive
system.
 Take action immediately if lubricant loss, increased operating noise,increased operating temperatures, frictional corrosion on toothflanks, broken teeth, or position deviations become noticeable within
the travel path.
 Do not put the drive system back into operation until the cause of themalfunction has been rectified.
Malfunctions may only be rectified by specially trained technicians.

Fault
Increased
operatingtemperature

Possible cause

RemedyInput system overloaded

Check the technical specifications

Motor is heating the gearbox.

Check the controller's settings.

Ambient temperature too high.

Ensure adequate cooling.

Braced motor/gearbox unit
Increased
operatingnoisesDamaged bearings
Toothing damage

Consult our Customer Service department.

Distorted rack and pinion unit
Imprecise rack assembly

Loss oflubricantFormation of
bubbles in the
lubricantfeed line

en-30

Excessive amount of lubricant

Change the settings on the lubricator andwipe away excess lubricant.
Information for setting the automatedlubrication amount/duration can be foundin the manual for the lubricator.

Seals not tightConsult our Customer Service
department.

Lubricant quantity too low

Change the settings on the lubricator.
Information for setting the automatedlubrication amount/duration can be foundin the manual for the lubricator.
As an alternative, the use of a check valve
is possible. Contact our Customer Service
department for this.

2022 D001333

Revision: 13

Rack and pinion system
Fault

Technical documents
Possible cause

RemedyDefective lubrication

Install a lubricating pinion on the output
pinion or rack. Make sure on short travel
paths that the tooth contact on the output
pinion and racks are lubricated sufficiently.
Information for setting the automatedlubrication amount can be found in the
manual for the lubricator.

Ambient influences

The rack always has to be installed ina clean and dry environment and protect
the rack against outer influences(e.g. chips, cleaning agents)

Wrong lubricant

Use only lubricants that have been
approved by us.

Frictional
corrosion on
tooth flanks

Overload
Machine collision
Foreign medium

Check the output pinion / rack for possible
foreign medium (e.g. chips, forgotten
assembly tools)

Lubrication faults

Always ensure sufficient lubrication.
Information for setting the automatedlubrication duration can be found in the
manual for the lubricator.

Position of the output pinion
compared to the rack

Carry out a contact pattern inspection(see chapter 5.8.1 Contact patterninspection). Correct the alignment of the
gearbox if necessary.

Wrong alignment between output
pinion and rack

Correct the axis distance (highest point of
the output pinion to highest point of
the rack) and the alignment of the
gearbox/rack.

Tooth breakage

Position
deviation or
great flankbacklashwithin thetravel path

Check the dimensioning for normal andemergency stop conditions.

Table 7: Malfunctions

Revision: 132022-D001333

en-31

Technical documents

Rack and pinion system

9 Appendix
9.1 Weight of racks
Weight of helically toothed racks [kg]Length[mm]

Module
1.5 mmModule2 mmModule3 mmModule
4 mm

Module5 mmModule
6 mmModule
8 mm

167

-

0.7

-

-

-

-

-

250

-

-

1.5

-

-

-

-

333

-

1.4

-

-

-

-

-

480

-

1.9

2.7

4.7

-

-

21.0

500

1.3

2.1

3.0

-

6.5

9.9

-

506

-

-

-

5.4

-

-

960

-

-

-

-

-

-

42.0

1000

2.5

4.1

5.9

10.7

13.1

19.9

-

1500

3.8

6,2

8.9

-

19.5

27.1

-

2000

5.0

8.2

11.0

21.4

26.0

36.2

-

Module
6 mmModule8 mm

Weight of straight toothed racks [kg]Length[mm]

Module
1.5 mmModule2 mmModule3 mm

167 - 2000

Module
4 mm

Module5 mmupon request
Table 8: Weight

9.2 Information for mounting the racks
9.2.1

Overview of the required cylinder head screws
Cylinder head screw
EN ISO 4762, property class 12.9
Bore [mm]ThreadTightening torque [Nm]

Ø7

M6

15.4

Ø 10

M8

37.3

Ø 12

M10

73.4

Ø 14

M12

126

Ø 18

M16

310

Ø 22

M20

604
Table 9: Cylinder head screws

en-32

2022 D001333

Revision: 13

Rack and pinion system
9.2.2

Technical documents

Overview of cylindrical pins
Cylindrical pin with interior thread
Shape A acc. to DIN 7979 or EN ISO 8735
Bore [mm]Cylindrical pin size

Ø 5.7

6 m6

Ø 7.7

8 m6

Ø 9.7

10 m6

Ø 11.712 m6

Ø 15.716 m6

Ø 19.7

20 m6
Table 10: Cylindrical pins for standard rack mounting

9.3 Specifications for mounting onto a mounting base (INIRA® pinning)
For this type of rack, no pinning with INIRA® pinning is intended.

9.4 Maximum height of the stop edges on the machine base
For this type of rack, no maximum height of the stop edges is defined.

9.5 Permissible parallelism deviation of the assembly surface
Parallelism deviation [µm]Rack module [mm]1.5 – 8Requirements in respect of positioning accuracy andsmooth running
High
Normal
Low
10

15

30

Table 11: Parallelism deviation of the assembly surfaces

9.6 Permissible measurement over pin fluctuation at the rack transition
Measurment over pin deviation [µm]Rack module [mm]Requirements in respect of positioning accuracy andsmooth running
High
Normal
Low

1.5

10

15

25

2

10

15

30

3

15

20

40

4

15

20

45

5

20

25

45

6

20

25

50

8

20

30

55

Table 12: Recommended measurement over pin deviation between two neighboring tooth gaps at the rack transition

Revision: 132022-D001333

en-33

Technical documents

Rack and pinion system

9.7 Permissible measurement over pin fluctuation within an axis
Measurement over pin fluctuation [µm]Requirements in respect of positioning accuracy andsmooth running
High
NormalLow

Rack module [mm]

1.5

30

45

80

2

30

45

85

3

35

50

100

4

40

55

110

5

40

60

120

6

40

60

120

8

50

70

130

Table 13: Recommended roll size fluctuation within an axis

9.8 Overview of the assembly accessories
Rack
module[mm]

Size

Order number

Diameter [mm]Order number

1.5

ZMT 150

20064154

2.5 0/-0.002

20006839

2

ZMT 200

20020582

3.5 0/-0.002

20001001

3

ZMT 300

20021966

5.0 0/-0.002

20000049

4

ZMT 400

20037466

7.0 0/-0.002

20038001

5

ZMT 500

20037469

9.0 0/-0.002

20038002

6

ZMT 600

20037470

10.0 0/-0.002

20038003

8

ZMT 800

20052289

14.0 0/-0.002

20052298

Assembly jig

Needle roller

Table 14: Assembly accessories

9.9 Lubricants for pre-oiling / venting / pre-greasing
Use

Version

Quantity

LubricantDesignation

Order number

Venting /pre-greasing
Venting /pre-greasing
Venting /pre-greasing

Grease gun
cartridge
Grease gun
cartridge
Grease gun
cartridge

400 cm3

G11

LGC 400-05

20058111

400 cm3

G12

LGC 400-06

20058112

400 cm3

G13

LGC 400-07

20058113

Pre-oiling

Box

1l

G11 / G13

LUO 1000-11

20074218

Pre-oiling

Can

5l

G11 / G13

LUO 5000-11

20074219

Pre-oiling

Box

1l

G12

LUO 1000-12

20074353

Pre-oiling

Can

5l

G12

LUO 5000-12

20074354
Table 15: Lubricants

en-34

2022 D001333

Revision: 13

Rack and pinion system

Technical documents

9.10 Tightening torques for common thread sizes in general mechanical engineering
The specified tightening torques for headless screws and nuts are calculated values and are
based on the following conditions:
Calculation in accordance with VDI 2230 (February 2003 version)
Friction value for thread and contact surfaces µ =0.10
Utilization of the yield stress 90%
Torque tools type II classes A and D in accordance with ISO 6789
The settings are values rounded to usual commercial scale gradations or settings.
 Use the exact values in this table to set your tools.
Tightening torque [Nm] with thread
Property
class
Screw/nut

M3

M4

M5

M6

M8

M10 M12 M14 M16 M18 M20 M22 M24

8.8 / 81.15 2.64

5.2

9.0

21.5 42.5 73.5

10.9 / 10

1.68 3.88

7.6

13.2 32.0 62.5

12.9 / 12

1.97 4.55

9.0

15.4 37.5 73.5

118

180

258

362

495

625

108

173

264

368

520

700

890

126

202

310

430

605

820 1040

Table 16: Tightening torques

Revision: 132022-D001333

en-35

Technical documents
Revision history

en-36

Rack and pinion system

Revision

Date

Comment

Chapter

01

08/23/01

New version

All

02

10/18/05

Ordering code

4.5

03

11/10/06

RevisionAll04

12/14/06

Technical data

All

05

04/28/08

1106

04/22/09

07

12/16/10

Chapter on lubricator
added
Chapter on lubricator
removedTechnical data

08

07/20/11

RevisionAll

09

09/19/13

New safety instruction

3.3.1

10

10/21/16

All

11

02/28/17

Revision; new productline
Revision1204/15/2019

All

13

10/13/2022

Revision of INIRA
pinning
Lubrication system

2022 D001333

11
All

5.4.3

5.9, 9

Revision: 13

WITTENSTEIN alpha GmbH ꞏ Walter-Wittenstein-Straße 1 ꞏ 97999 Igersheim ꞏ Germany
Tel. +49 7931 493-0 ꞏ info@wittenstein.de

WITTENSTEIN ‒ one with the futurewww.wittenstein-alpha.de
AC: XXXXXXXX

2022-D062611Revision: 02