INIRA®

Assembly instructions

2022-D050733

Revision: 02

INIRA®

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

Utility film

https://alpha.wittenstein.de/rack-assembly/
Customer Service department

Deutschland

WITTENSTEIN alpha GmbHservice@wittenstein-alpha.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.

info@wittenstein.it+39 02 241357-1

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

North America

WITTENSTEIN holding Corp.

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

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

Türkiye

WITTENSTEIN Güç Aktarma
Sistemleri Tic. Ltd. Şti.

info@wittenstein.com.tr+90 216 709 21 23© WITTENSTEIN alpha GmbH 2018
Subject to technical and content changes without notice.

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Table of Contents
1

About this manual ................................................................................................2
1.1 Information symbols and cross references ..........................................................2
1.2 Scope of delivery .................................................................................................2
2 Safety.....................................................................................................................2
2.1 EC/EU Directive ...................................................................................................3
2.1.1 Machinery Directive.........................................................................................3
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..........................................................................3
2.6.1 Safety symbols ................................................................................................4
2.6.2 Signal words....................................................................................................4
3 Description of racks.............................................................................................5
3.1 Ordering code / Name plate .................................................................................5
4 Transport and storage .........................................................................................5
4.1 Packaging ............................................................................................................5
4.2 Transport..............................................................................................................5
4.3 Storage ................................................................................................................5
5 Assembly ..............................................................................................................6
5.1 Requirements in respect of installation location and mounting base ...................6
5.2 Required tools and assembly material .................................................................7
5.3 Preparations.........................................................................................................85.3.1 After the cleaning ............................................................................................9
5.4 Mounting the racks.............................................................................................10
5.4.1 Assemble first rack with INIRA clamping.......................................................10
5.4.2 Assembling subsequent racks.......................................................................11
5.4.3 Checking the transition between the racks....................................................125.4.4 Correct the transition between the racks with INIRA adjusting .....................13
5.4.5 Mounting additional racks..............................................................................14
5.5 Checking the parallelism of all racks..................................................................14
5.6 Pinning the racks ...............................................................................................145.6.1 Pinning the racks (conventional) ...................................................................14
5.6.2 Pinning the racks with INIRA pinning ............................................................14
6 Startup and operation ........................................................................................16
7 Maintenance and disposal.................................................................................17
7.1 Disassembly / replacement ................................................................................17
7.2 Disposal .............................................................................................................17
8 Malfunctions .......................................................................................................17
9 Appendix .............................................................................................................18
9.1 Weight of racks ..................................................................................................18
9.2 Information for mounting the racks ....................................................................18
9.2.1 Overview of the required fastening screws ...................................................18
9.2.2 Overview of the mounting kit MKP (mounting pin) ........................................18
9.2.3 Overview of tool sizes ...................................................................................199.2.4 Tightening torques for assembly bushings ....................................................19
9.3 Specifications for mounting onto a mounting base ............................................19
9.4 Maximum height of the stop surface on the machine bed .................................19
9.5 Permissible parallelism deviation of the assembly surface ................................20
9.6 Permissible roll size fluctuation at the rack transition ........................................20
9.7 Permissible roll size fluctuation within an axis ...................................................20
9.8 Overview of the assembly accessory kit ............................................................21
9.9 Tightening torques for common thread sizes in generalmechanical engineering .....................................................................................21
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About this manual
1

About this manualThis operating manual contains necessary information to safely and correctly install the racks.
The operator must ensure that this operating manual is read by all persons assigned to install,
operate, or maintain the drive system, and that they fully comprehend its content.
In addition, the basic instructions for the "alpha rack and pinion system" (doc. no 2022-D001333),
which contain additional important safety information, must also be read.
Store this manual within reach of the drive system.
Inform colleagues who work in the area around the machine about the safety and warning notices
to avoid injuries.
The original instructions were prepared in German; all other language versions are translations ofthese instructions.

1.1

Information symbols and cross references
The following information symbols are used: Indicates an action to be performed
 Indicates the results of an action
 Provides additional information about the action
A cross reference refers to the chapter number and the header of the target section (e. g. 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.
 Missing parts or damage must be notified immediately in writing to the carrier, theinsurance company, or WITTENSTEIN alpha GmbH.

2

SafetyThese instructions, especially the safety and warning notices as well as 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.
 Apply the racks exclusively in accordance with their intended use.
 Carry out maintenance and repair work appropriately and professionally in conformity with thespecified intervals.
 Always mount, dismantle, and operate the racks properly(e.g. also test run only with lubrication).
 Operate the racks only with lubrication (type and amount).
 Prevent soiling of the racks.
 Only carry out modifications or reconstructions when these are approved in writing by the
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 and otherwise
applicable rules and regulations, particularly for accident prevention (e.g. personal safety
equipment) and environmental protection.

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Safety2.1

EC/EU Directive

2.1.1

Machinery Directive
The racks are considered a "machine component" and are therefore not subject to the EC
Machinery Directive 2006/42/EC.
Startup is prohibited within the area of validity of the EC directive until it has been determined thatthe machine in which these racks are 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 theracks. Based on their training and experience, technicians must be able to evaluate the tasks
assigned to them in order to recognize and avoid risks.

2.3

Intended use
Racks are used to convert rotational motion to linear motion or vice versa and are intended to beinstalled in a machine.
 To avoid danger to the operator or damage to the machine, employ the racks only for theirintended use and in a technically flawless and safe state.
 If you notice any altered operating behavior, check the racks in accordance with Chapter 8"Malfunctions".
 Read the general safety instructions before beginning to work (see Chapter 2.5 "Generalsafety instructions").

2.4

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

2.5

General safety instructions
The general safety instructions are contained in the basic operating
manual "alpha rack and pinion system" (doc. no. 2022-D001333).
Ignoring the safety instructions can lead to severe injuries or todamage to the racks and/or the machine in which these are fitted.

2.6Structure of warning instructions

B

A

C

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DWarning instructions are situation-specific. They
will be precisely where tasks are described inwhich dangers can arise.
The warning instructions in this manual aredesigned according to the following pattern:
A = Safety symbol(see Chapter 2.6.1 "Safety symbols")
B = Signal word (see Chapter 2.6.2 "Signal words")
C = Type and consequence of the danger
D = Avoiding the danger

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Safety2.6.1 Safety symbols
The following safety symbols are used to indicate possible hazards, prohibitions, and important
information:

General hazard

Environmental
protection

Information

2.6.2 Signal words
The following signal words are used to indicate possible hazards, prohibitions, and important
information:

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

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

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

This signal word indicates a potential hazard that could lead tomaterial damage.
A note without a signal word indicates application hints or especially
important application hint for handling the rack.

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3

Description of racks

Description of racks
Depending on the application, a range of different rack variants are available.
For the assembly described in this operating manual, additional tools/materials are required.
 Additionally, WITTENSTEIN alpha GmbH offers a tool kit INIRA. Further information and thematerial number of the tool kit INIRA can be found in the "alpha Linear Systems" catalog.

3.1

Ordering code / Name plate
The ordering code (A) for the racks is located on
the racks (e.g.: ZST 200-334-1000-R1C-35).
The name plate for the gearbox is located on thegear housing.
 More information is available in our catalog or atwww.wittenstein-alpha.de.

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.
 Dispose of the packaging materials at the recycling sites intended for this purpose. Observe
the applicable national regulations concerning disposal.

4.2

Transport

If the rack falls, it could lead to severe injuries or to damage to therack.
 Suitable hoisting equipment should be used when transporting heavy
racks.
 When using hoisting equipment, do not stand below the suspended load.
 Wear protective gloves and safety shoes.
Details on the weight of the racks can be found in Chapter 9.1 "Weight of racks".
4.3

Storage
Store the racks at a temperature of 0 °C to +40 °C in the original packaging. Store the racks for no
more than 2 years. Consult our Customer Service department if conditions are different.
For storage logistics, we recommend the "first in - first out" method.

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Assembly5

Assembly
Read the general safety instructions before beginning to work (see Chapter 2.5 "Generalsafety instructions").
 If you have questions about correct mounting, consult our Customer Service department.


5.1

Requirements in respect of installation location and mounting baseRequirements in respect of installation 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 the mounting
base depend on the application. For applications with high requirments regarding positioning
accuracy and smooth running, the aim should be to achieve low deviations. For applications
with low requirements, greater deviation may be allowed.

.
ax

R

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0,04

Requirements in respect of mounting base:- The rack is designed with a chamfer at thetransition point between the screw-on and stopsurface. This allows the mounting base to be
designed without recesses. The mounting baseon the machine must be designed in such a waythat the milling edge does not collide with therack chamfer.
- The stop surfaces should not fall below aminimum height of 5 mm.
 Information on the maximum permissibleheight of the stop surfaces can be found in
Chapter 9.4 "Maximum height of the stopsurface on the machine bed".
- The threaded holes for the fastening screws
have to feature a sufficient screw-in depth
depending on the material of the mountingbase.
 The necessary length of the fastening screws
can be found in Chapter 9.2.1 "Overview of
the required fastening screws".

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5.2

Assembly

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

F
A

C

B

E

D

H
G

V

K

L

M

Y
Pos.

Tool / Material

Task / Purpose

Additional information

A

Fastening screws(WITTENSTEIN alphacylinder head screws)

To bold the racks to thescrew-on surface

Included in the scope of delivery of
the racks
Required size, see Chapter 9.2.1"Overview of the required fastening
screws"B

Mounting pins (part of For efficient pinning of thethe mounting kit MKP) racks to the mounting base(for INIRA pinning)

Included in the scope of delivery of
the racks
Required size, see Chapter 9.2.2"Overview of the mounting kit MKP(mounting pin)"C

Open-end wrench

To tension the assemblybushings (J)Required width across flats, see
Chapter 9.2.3 "Overview of tool sizes"

D

Torque wrench withhex key insert

To tighten the fastening
screws (A)Hex key size, see Chapter 9.2.3"Overview of tool sizes"

ESoft-head hammer

To tap in the racks
afterwards / drive inmounting pins (B) andassembly bushings (V)–F

Dial gauge holder with To check the parallelism of
dial gauge
the assembly surfaces andthe assembled racks

G

Cleaning agent

H

Dressing stoneI

MagnetRevision: 02

Resolution: 0.01 mm

To clean the assembly
surfaces–

To magnetize the needle
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Assembly
Pos.

Tool / Material

Task / Purpose

Additional information

J

Assembly bushings

To press the racks onto
the stop surface

K

Assembly jig

To align the transition point
between two racks

Included in the tool kit INIRA
Further information and the material
number can be found in the "alphaLinear Systems" catalog.

L

Adjustment tool

For fine adjustment of thetransition point between
two racks

M

Needle roller

To check the rolldimensions using a dial
gauge

V

Assembly bushings(part of the mounting
kit MKP)

For efficient pinning of theracks to the mounting base(for INIRA pinning)–

Y

Hexagon socket
screwdriver

To hold the fastening
screws (A) / alignmounting pins (B) andassembly bushings (V)–Tbl-1: List of necessary tools/materials

5.3

Preparations

If the rack falls, it could lead to severe injuries or to damage to therack.
 Suitable hoisting equipment should be used when transporting heavy
racks.
 When using hoisting equipment, do not stand below the suspended load.
 Wear protective gloves and safety shoes.


Observe the safety and processing instructions of the cleaning agent 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 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.


The pin bores (O1) of the mounting base (O) for
installing the rack in the machine can already be
drilled to final dimension during the manufacturing
O
process. Thus there is no need for machining during
installation of the rack.
 For the bore diameter and minimum depth of pin
bores, see Chapter 9.3 "Specifications for
mounting onto a mounting base".
 The position of the pin bores (O1) can be found in
the "alpha Linear Systems" catalog or thedimensional drawing of the respective product.
 You can find the dimensional drawing of your rack on our website at www.wittenstein-alpha.deor contact our Customer Service.

O1

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Assembly
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 the screw-on
surface (O) with a dressing stone (H), a suitablecleaning agent (G), and a lint-free cloth.


P
G

H

O
N



P

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

F
O
N
5.3.1

After the cleaning
Uneven temperatures between the rack andmounting base can have a considerable impact on
the smooth running and positioning accuracy of thedrive system.
 Place the unpacked racks on the mounting basein adequate time before assembly in order toallow the temperatures to equalize.

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Assembly
5.4

Mounting the racks

5.4.1 Assemble first rack with INIRA clamping
Position the first rack in the middle of themachine bed.
 The through-holes (Q) of the rack have to becentered above the corresponding threadedholes (R) of the screw-on surface.
 Insert the fastening screws (A).
 To secure the screws, we recommend usinga threadlocker (e.g. Loctite 243).
 Position the fastening screws free of backlash(with no tightening torque).
 Place the assembly bushings (J) in the following
positions on the heads of the fastening screws,
with the flat side (S) facing in the direction of thestop surface (N).
 Place the assembly bushings on the first andlast fastening screws.
 Also on every second fastening screw or atleast every 125 mm (depending on the holepattern).
 Tighten all assembly bushings
counterclockwise with an open-end wrench one
after the other.
 For the necessary tightening torque: see
Chapter 9.2.4 "Tightening torques for
assembly bushings".
 Proceed uniformly from one end of the rack to
the other.
 While doing so, hold the cylinder headscrews in place with the hex key (D), toprevent them from loosening.


S
N

J
A
Q

R
E
D

Tap the tooth crests with a soft-head hammer (E) along the entire rack to ensure evenpositioning of the rack.
 Tighten all fastening screws that do not have an assembly bushing one after the other, using
the required tightening torque (see Chapter 9.9 "Tightening torques for common thread sizes
in general mechanical engineering").
 Tighten all fastening screws that have assembly bushings one after the other, using therequired tightening torque.
 Use an open-end wrench to keep the assembled assembly bushings in place while doing
so to prevent them coming loose.
 Loosen and remove the corresponding assembly bushing with an open-end wrench aftertightening each fastening screw.
 While doing so, keep the fastening screw in place with the torque wrench/hex key so that it
does not come loose.
 Check the tightening torque of all fastening screws again after loosening all assemblybushings and, if necessary, retighten the screws.


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5.4.2

Assembly

Assembling subsequent racks
Position the rack (T) to be assembled beside thepreviously assembled rack.
 Make sure the through-holes of the rack arecentrically above the corresponding
threaded holes of the screw-on surface.
 Insert a fastening screw into the first two
through-holes (Q) beside the joint.
TQ
Insert the assembly jig (K) into both racks at thejoint as shown in the diagram, in order to adjust
the transition between the two racks.
 Position the fastening screws without backlash(with no tightening torque).
 Place the assembly bushings (J) on the twoscrew heads and tension the assembly bushing
as described for the first rack.


K
J

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Assembly
5.4.3 Checking the transition between the racks

Magnetize the needle rollers (M) with a 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 the needle
rollers at position 1 and position 3 using the dialgauge (F) and calculate the midpoint of the twopoints.
 The midpoint is the target value for the highest
point of the needle roller at position 2.
 Maximum permissible deviation in height fromposition 1 to position 3: see Chapter 9.6"Permissible roll size fluctuation at the racktransition"
 Measure the highest point of the needle roller at
position 2 with the dial gauge.
 If the value falls within the range of tolerance,
assemble the remaining screws in the rack as
described for the first rack.
 Make sure that an assembly bushing is
tensioned at the first and last fastening screw
as well as at least at every second fastening
screw or every 125 mm in between.
 If the value falls outside of the range of tolerance,correct the transition between the two racks as
described in the following section.


P

M
1 2

3

F

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5.4.4

Assembly

Correct the transition between the racks with INIRA adjusting Carry out the following steps in case the transfer between the racks exceeds the tolerance
range.
Position the adjustment tool (L) on the two
racks, as shown in the adjacent diagram picture.
 Do not make any changes to the dial gauge
holder and dial gauge (F), so as not to lose
the previously-set zero position.
 Place the centering pin (T) of the adjustment
tool (L) and the eccentric bolt (U) into the fitting
bores of the two racks to be aligned to eachother.
 Move towards the highest point of the needle
roller in position 2.
 Set the target value for the roll size on theneedle roller in position 2 by turning theeccentric bolt (U) on the adjustment tool.
 Tighten the screws below the two assemblybushings with the required tightening torque(keep a hold of the eccentric bushing).
 Remove the adjustment tool (L).
 Remove the two assembly bushings on the rackwith the open-end wrench.
 Assemble the remaining screws in the rack as
described for the first rack.
 Make sure that an eccentric bushing ismounted at the first and last fastening screw
and at least at every 125 mm in between.


T

U

L

M
1 2

3

F

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Assembly
5.4.5 Mounting additional racks
 Mount all additional racks in the same manner as described in the sections above.
5.5

Checking the parallelism of all racks
V M

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 atthe outer end of the axle into a tooth gap.
 Move the dial gauge (F) towards the highest pointof this needle roller and set the dial gauge to "0".
 Mark the measurement value at the measuring
point (V) (reference point) with a pin on the rack.
 Insert at least 5 further needle rollers into toothgaps at regular intervals per 1000 mm of axle
length.
F

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 roll size 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.
Further information can be found in the basic operating manual "alpha rack and pinion
system" (doc. no. 2022-D001333).


5.6

Pinning the racks

5.6.1 Pinning the racks (conventional)
No conventional pinning is intended for this type of rack.
5.6.2 Pinning the racks with INIRA pinningObserve the safety and processing instructions for the threadlocker to be
used.
Clean/Degrease and dry the following
components using a clean and lint-free cloth, anda grease-dissolving, non-aggressive cleaning
agent:- Mounting pins (B)- Assembly bushings (V)- Pin bores (Z1) of the racks
 The mounting pins (B) and assembly bushings (V)are included in the scope of delivery.



V
B

Z1

Z1

Z

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Assembly Only use the mounting pins included in thescope of delivery for pinning the racks.
 Apply threadlocker all around the upper part ofthe pin bore (Z1) and the mounting pin (B) (e.g.
Loctite® 243).

B

Z1

Z

Push the mounting pin (B) through the pin bore
(Z1) and insert it into the pin hole of themounting base (O).
 Tap in the mounting pin (B) with a soft-headed
hammer (E).


E
B
Z1

O

Z

 The mounting pin (B) has to be flush with theupper edge of the rack.

B

V2
V1

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V Only use the assembly bushing (V) included in
the scope of delivery for pinning the racks. The
assembly bushing has two identification grooves(V1, V2) on the top side.
 Place the assembly bushing, with theidentification grooves facing upward, between
the pin bore and the mounting pin.

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Startup and operation

Push a hex key (Y) through the assemblybushing (V) and insert it into the hex socket ofthe mounting pin.
 Size hex socket mounting pin, see
Chapter 9.2.2 "Overview of the mounting kit
MKP (mounting pin)".
 Turn the assembly bushing and mounting pin in
opposite directions with slight axial pressure
until the assembly bushing slides between the
joint surfaces of the mounting pin and the pinbore of the rack.


Y
V
V1

Press in the assembly bushing by hand until the
lower identification groove (V1) has reached theupper edge of the pin bore.
 Tap in the assembly bushing (V) with the softheaded hammer (E).
 The assembly bushing has to be flush withthe top edge of the rack.
 Repeat the steps above for all other pin bores.


V

V1

6

E

Startup and operation
Read the general safety instructions before beginning to work (see Chapter 2.5 "Generalsafety instructions").
 Ensure that the racks are always well lubricated during startup and operation.
 Further information can be found in the basic operating manual "alpha rack and pinion
system" (doc. no. 2022-D001333).


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7

Maintenance and disposal

7.1

Maintenance and disposal

Read the general safety instructions before beginning to work (see Chapter 2.5 "Generalsafety instructions").

Disassembly / replacement
 To allow easy disassembly, the mounting pins
have an interior thread.
 Remove the mounting pins (B) with anappropriate pulling device.
 Size interior thread, mounting pin, see
Chapter 9.2.2 "Overview of the mounting kit
MKP (mounting pin)", Table "Tbl-4".
 Mounting pins that are undamaged may be
used again.

B

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.
 For information on the assembly of the new rack: see Chapter 5 "Assembly".


7.2

DisposalSolvents and lubricants are flammable, can cause skin irritation, andcan pollute soil and water.
 Use protective gloves to avoid direct skin contact with solvents andlubricants.
 Use and dispose of the cleaning solvents and lubricants properly.
Remove all deposits of lubricant from the individual racks.
 Dispose of the lubricant deposits and the racks at the appropriate disposal sites.
 Observe the applicable national regulations concerning disposal.
8

Malfunctions

Changed operational behavior can be an indication of existing damage
to the drive train or can cause damage to the drive train.
 Take action immediately if lubricant loss, increased operating noise,increased operating temperatures, frictional corrosion on tooth flanks,
broken teeth, or position deviations become noticeable within the travelpath.
 Do not put the drive train back into operation until the cause of themalfunction has been rectified.
Rectifying of malfunctions may only be done by specially trained
technicians.

 Further information can be found in the basic operating manual "alpha rack and pinion system"(doc. no. 2022-D001333).
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Appendix
9

Appendix

9.1

Weight of racks
Weight of racks [kg]Length [mm] Module 2 mm Module 3 mm Module 4 mm Module 5 mm Module 6 mm
167

0.7

-

-

-

-

250

-

1.5

-

-

-

333

1.4

-

-

-

-

480

1.9

2.7

4.7

-

-

500

2.1

3

-

6.5

9.9

506

-

-

5.4

-

-

960

-

-

-

-

-

1000

4.1

5.9

10.7

13.1

19.9

1500

6.2

8.9

-

19.5

27.1

2000

8.2

11

21.4

26

36.2

Tbl-2: Weight

9.2

Information for mounting the racks

9.2.1 Overview of the required fastening screws
The special fastening screws with optimized screw heads are included in the scope of delivery of
the racks. Make sure that the correct screw length is selected when ordering.
The required screw lengths depend on the shearing strength τB of the internal thread material.
Screws of the property class 12.9 are used.
Rack
module[mm]

τB > 200 N/mm2

τB > 300 N/mm2

Fastening screw

Material
numberFastening screw

Material
number2

M6x35

20059051

M6x30

20058979

3

M8x45

20059052

M8x35

20058980

4

M10x55

20059053

M10x45

20058981

5

M12x65

20059054

M12x6020058982

6

M16x8020059055

M16x7020058983

τB= Shearing strength of the internal thread material
Tbl-3: Overview of the required fastening screws

9.2.2 Overview of the mounting kit MKP (mounting pin)
Rack module[mm]

Mounting kit

Material number

Hex socket[mm]Internal thread[mm]

2

MKP ZST 200

20064392

Size 5M4

3MKP ZST 300

20064393

Size 6M5

4MKP ZST 400

20064394

Size 8M6

5MKP ZST 500

20064395

Size 10M86MKP ZST 600

20064396

Size 10

M8

Tbl-4: Mounting kit

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9.2.3

Appendix

Overview of tool sizes
Tool

Rack module [mm]Fastening screw width across flats (Hex socket)
Assembly bushing width across flats (Hex head)

2

3

4

5

6

5

6

8

10

14

SW10 SW13 SW17 SW19 SW24

Tbl-5: Overview of tool sizes

9.2.4

Tightening torques for assembly bushings
The specified tightening torques must be complied with when tensioning the assembled rack
through the assembly bushings (see Chapter 5.4 "Mounting the racks"):
Assembly bushing

Tightening torque

MZST M6

3 ± 0.5

MZST M8

4.5 ± 0.5

MZST M10

7±1

MZST M12

8±1

MZST M16

11 ± 1

Tbl-6: Tightening torques for assembly bushings

9.3

Specifications for mounting onto a mounting base
Rack module [mm]Pin bore Ø (O1) x depth[mm] x [mm]2

6 H7 x 123

8 H7 x 144

10 H7 x 185

12 H7 x 236

16 H7 x 23

O1
O

Tbl-7: Specifications for mounting onto a mounting base

9.4

Maximum height of the stop surface on the machine bed
The maximum permissible height of the stop surfaces must not exceed the following values:
Rack module [mm]Max. stop surface height [mm]

2

16

3

19

4

26

5

33

6

39

Tbl-8: Maximum height of the stop surface on the machine bed

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Appendix
9.5

Permissible parallelism deviation of the assembly surface
Rack module [mm]Parallelism deviation [μm]Requirements in respect of positioning accuracy and smoothrunning2

High

moderate

Low

10

15

30

3
4
5
6
Tbl-9: Permissible parallelism deviation of the assembly surface

9.6

Permissible roll size fluctuation at the rack transition
Rack module [mm]Measurement over pins deviation [μm]Requirements in respect of positioning accuracy and smoothrunningHighmoderate

Low

2

10

15

25

3

15

20

40

4

15

20

45

5

20

25

45

6

20

25

50

Tbl-10: Recommended roll size deviation between two neighboring tooth gaps at the rack transition

9.7

Permissible roll size fluctuation within an axis
Rack module [mm]Roll size deviation [μm]Requirements in respect of positioning accuracy and smoothrunningHighmoderate

Low

2

30

45

85

3

35

50

100

4

40

55

110

5

40

60

120

6

40

60

120

Tbl-11: Recommended roll size deviation between two neighboring tooth gaps at the rack transition

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Appendix

9.8

Overview of the assembly accessory kit
The assembly accessory kit is needed for the rack assembly and is not included in the scope ofdelivery of the racks.
The assembly accessory kit includes:- Assembly jig- Adjustment tool
- Assembly bushings- Needle rollers / Cylinder rollers
Further information can be found in the "alpha Linear Systems" catalog or our website atwww.wittenstein-alpha.de

9.9

Tightening torques for common thread sizes in general mechanical engineering
The specified tightening torques for set 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 setting possibilities.
 Use the exact values in this table to set your tools.
Tightening torque [Nm] with thread
Propertyclass
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 73.5 118

10.9 / 10

1.68 3.88

7.6

13.2 32.0 62.5 108

12.9 / 12

1.97 4.55

9.0

15.4 37.5 73.5 126

180

258

362

495

625

173

264

368

520

700

890

202

310

430

605

820 1040

Tbl-12: Tightening torques for set screws and nuts

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Revision history
Revision

Date

Comment

Chapter01

31.03.14

New version

All

02

07.12.18

INIRA pinning

All

Revision: 02

2022-D050733

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-D050733Revision: 02