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GUDEL CP 3-5 V2 Operating Manual

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OPERATING MANUAL
CP 3-5 V2
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
B1M.10xxxxxxx-xxxx
10xxxxxxx
99xxxxxxx
2019
90072022528153
BETRIEBSANLE

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Summary of Contents for GUDEL CP 3-5 V2

  • Page 1 OPERATING MANUAL BETRIEBSANLE 90072022528153 CP 3-5 V2 Project / Order: B1M.10xxxxxxx-xxxx Bill of materials: 10xxxxxxx Serial number: 99xxxxxxx Year of manufacture: 2019...
  • Page 2 © GÜDEL Translation of the original instructions This manual contains standard illustrations that may deviate from the original. In the case of special models, options, or technical changes, the scope of deliv- ery may differ from the descriptions here. Reprinting the instructions, in whole or in part, requires our permission.

  • Page 3: Table -1 Revision History

    OPERATING MANUAL CP 3-5 V2 Revision history Revision history Version Date Description 17.06.2019 Basic version Table -1 Revision history...
  • Page 4 Revision history OPERATING MANUAL CP 3-5 V2...

  • Page 5: Table Of Contents

    OPERATING MANUAL CP 3-5 V2 Table of contents Table of contents Declaration of incorporation General  19 Further applicable documentation  ....... . .
  • Page 6 Table of contents OPERATING MANUAL CP 3-5 V2 Fundamentals of safety ..........
  • Page 7 OPERATING MANUAL CP 3-5 V2 Table of contents Commissioning  53 Introduction  ............

  • Page 8: Bumper Unit With Limit

    Table of contents OPERATING MANUAL CP 3-5 V2 Installing  .............
  • Page 9 OPERATING MANUAL CP 3-5 V2 Table of contents Transport securing devices  ........
  • Page 10 Table of contents OPERATING MANUAL CP 3-5 V2 Maintenance tasks  ..........
  • Page 11 OPERATING MANUAL CP 3-5 V2 Table of contents 9.3.11.4 Replacing the gearbox unit ..........
  • Page 12 Table of contents OPERATING MANUAL CP 3-5 V2 Maintenance schedules ..........
  • Page 13 OPERATING MANUAL CP 3-5 V2 Table of contents 10.3.1.3 Bumper unit with limit stops  ..........
  • Page 14 Table of contents OPERATING MANUAL CP 3-5 V2 Spare parts supply  277 13.1 Service departments  ..........
  • Page 15 OPERATING MANUAL CP 3-5 V2 Table of contents Options   Third-party documentation  ...
  • Page 16 Table of contents OPERATING MANUAL CP 3-5 V2...

  • Page 17: Declaration Of Incorporation

    OPERATING MANUAL CP 3-5 V2 Declaration of conformity, declaration of incorporation Declaration of incorporation The manufacturer: GÜDEL AG Industrie Nord CH-4900 Langenthal hereby declares that the partly completed machine: CP 3-5 V2 Product, type 99xxxxxxx Serial number 10xxxxxxx Parts list...
  • Page 18 Declaration of conformity, declaration of incorporation OPERATING MANUAL CP 3-5 V2...

  • Page 19: General

    OPERATING MANUAL CP 3-5 V2 General General Read the entire manual before working with the product. The manual con- tains important information for your personal safety. The manual must be read and understood by all persons who work on the product in any of the product life phases.

  • Page 20: Table 2-1 Explanation Of Symbols/Abbreviations

    General OPERATING MANUAL CP 3-5 V2 Explanation of symbols/abbreviations The following symbols and abbreviations are used in this manual: Symbol/Abbrevia- Explanation tion Ü For cross-reference Possibly for cross-ref- Page erence Fig. Designation of graphics Figure Table Designation of tables Table...

  • Page 21: Safety

    OPERATING MANUAL CP 3-5 V2 Safety Safety General Read the entire manual before working with the product. The manual con- tains important information for your personal safety. The manual must be read and understood by all persons who work on the product in any of the product life phases.

  • Page 22: Operating Companies

    Safety OPERATING MANUAL CP 3-5 V2 The technician is responsible to third parties in his area of responsibility. During a training session or instruction, the technician may only work on the product under the supervision of an experienced manufacturer's technician.

  • Page 23: Commissioning

    OPERATING MANUAL CP 3-5 V2 Safety 3.1.2.4 Commissioning technicians The commissioning technician: • has good programming knowledge • has mechanical and/or electrical knowledge • is flexible The commissioning technician is responsible for the following tasks: • commissioning the product • testing the functions of the product 3.1.2.5...

  • Page 24: Maintenance Technicians

    Safety OPERATING MANUAL CP 3-5 V2 3.1.2.7 Maintenance technicians The maintenance technician: • was trained by the operating company or the manufacturer • has very good mechanical and/or electrical knowledge • has software knowledge • has maintenance experience • bears responsibility for the safety of the cleaning staff The maintenance technician is responsible for the following tasks: •...

  • Page 25: Disregarding Safety

    OPERATING MANUAL CP 3-5 V2 Safety 3.1.3 Disregarding safety regulations DANGER Disregarding safety regulations Disregarding safety regulations can result in damage to property, severe or fatal injuries. • Always comply with the safety regulations Liability Güdel shall not be held liable under any of the following circumstances: •...

  • Page 26: Hazard Symbols In The

    Safety OPERATING MANUAL CP 3-5 V2 Hazard symbols in the manual 3.2.1 Hazard warnings The hazard warnings are defined for the following four types of danger levels: DANGER DANGER DANGER refers to hazards with a high risk of severe physical injury or im- mediate fatality.

  • Page 27: Explanation Of Warning

    OPERATING MANUAL CP 3-5 V2 Safety 3.2.2 Explanation of warning symbol Hazard warnings for personal injuries contain the symbol of the correspond- ing hazard. Symbol Explanation of symbols Hazards due to general causes Hazards due to loose connecting elements Hazards due to overpressure...

  • Page 28: Fig. 3 -1 Danger Label "Danger Sign

    Safety OPERATING MANUAL CP 3-5 V2 Symbol Explanation of symbols Hazards due to tipping over Hazards due to dangerous electrical voltage Hazard symbols on the product The following warning labels are attached to the product: 3.3.1 Danger label "danger sign"...

  • Page 29: Fig. 3 -2 Danger Label "Tearing Due To Rack

    OPERATING MANUAL CP 3-5 V2 Safety 3.3.2 Danger label "Tearing due to rack" Fig. 3-2 Danger label "Tearing due to rack" Danger label "Tearing due to rack" • warns against tearing apart lifting belts due to the sharp edges of the rack...

  • Page 30: Fundamentals Of

    Safety OPERATING MANUAL CP 3-5 V2 Fundamentals of safety 3.4.1 Separating protective equipment, monitoring equipment WARNING Missing separating protective equipment and monitoring equip- ment Missing or modified separating protective equipment and monitoring equip- ment may result in damage to property or serious injuries! •...
  • Page 31 OPERATING MANUAL CP 3-5 V2 Safety WARNING Falling axes, workpieces Falling axes or workpieces can cause physical damage, serious or fatal injuries! • Set down any workpieces before working in the danger area • Never enter the area below suspended axes and workpieces •...
  • Page 32 Safety OPERATING MANUAL CP 3-5 V2 WARNING Falling axes/workpieces A crash leads to the breakage of components and mounting elements. After a crash, it is not immediately apparent whether components have been weak- ened or are defective. If the product continues to be used, axes or work- pieces may fall down.

  • Page 33: Material Safety Data Sheets

    OPERATING MANUAL CP 3-5 V2 Safety 3.4.3 Material safety data sheets (MSDS) Safety data sheets contain safety information about the materials. They are country-specific. Safety data sheets are issued, for example, for materials such as oils, greases, cleaning agents, etc. The operating company is responsible for obtaining safety data sheets for all materials used.
  • Page 34 Safety OPERATING MANUAL CP 3-5 V2...

  • Page 35: Product Description

    OPERATING MANUAL CP 3-5 V2 Product description Product description 4.1.1 Intended use The product is intended exclusively for moving and positioning workpieces and goods. Any other or additional use is not considered to be use in the intended man- ner. The manufacturer assumes no liability for any resulting damage. All risks are carried solely by the user! 4.1.2...

  • Page 36: Fig. 4 -1 Type Plate

    Product description OPERATING MANUAL CP 3-5 V2 Product designation 4.2.1 Type plate Each product has a type plate. It contains the following information: Fig. 4-1 Type plate Project number, order number Special labeling Sales order item number Product, type Year of manufacture...

  • Page 37: Fig. 4 -2 Position Of The Type Plate

    OPERATING MANUAL CP 3-5 V2 Product description 4.2.2 Position of the type plate The type plate is attached according to the following illustration: Fig. 4-2 Position of the type plate Type plate Technical data For the following data, refer to the layout(s) in the appendix.

  • Page 38: Table 4-1 Temperature Ranges

    Product description OPERATING MANUAL CP 3-5 V2 Temperature The following ambient temperatures and air humidities apply: ranges Product life phase Temperature range Air humidity Transport -10 to +60 °C Operation +5 to +40 °C Up to and at 85%, con-...

  • Page 39: Fig. 5 -1 Structure

    OPERATING MANUAL CP 3-5 V2 Design, function Design, function Design The product consists of the following assemblies and components: Fig. 5-1 Structure Bumper unit Lubricating pinion unit Z-axis X-axis Drive for Y-axis X-carriage Z-axis drive Z-carriage Y-axis Mechanical multi-limit switch (optional)

  • Page 40: Fig. 5 -2 Axis Designations

    Design, function OPERATING MANUAL CP 3-5 V2 Function The product can move along the following axes: Fig. 5-2 Axis designations Rotary axis (optional)

  • Page 41: Fig. 5 -3 Protective Equipment

    OPERATING MANUAL CP 3-5 V2 Design, function 5.2.1 Protective equipment WARNING Falling axes/workpieces If emergency guideways are removed, they will not hold carriages or axles in an emergency. Axes and workpieces can fall down. Falling axes or workpieces can cause serious injury or death! •...
  • Page 42 Design, function OPERATING MANUAL CP 3-5 V2...
  • Page 43 OPERATING MANUAL CP 3-5 V2 Transport Transport The product is transported by air, land, or water. The packaging depends on the mode of transport. Truck Shipped on a transport pallet Aircraft Shipped in a crate Ship Shipped in a case or container Only perform the tasks described in this chapter after you have read and un- derstood the chapter "Safety".

  • Page 44: Fig. 6 -1 Attaching Slings

    Transport OPERATING MANUAL CP 3-5 V2 Packaging symbols When moving the transport pallets / crates / cases, observe the following symbols: CENTER OF SLING SLING GRAVITY HERE HERE Fig. 6-1 Attaching slings Center of gravity Fastening point Depending on the contents, the packaging units are marked with the symbols shown below.
  • Page 45 OPERATING MANUAL CP 3-5 V2 Transport Transport the pallet, crate, or case to the intended installation location. Use appropriate transport devices. Industrial trucks Industrial trucks have to be capable of handling the size and weight of the crate. The driver of the industrial truck must be authorized to drive the vehi- cle.

  • Page 46: Fig. 6 -3 Attaching The Slings: Beam

    Transport OPERATING MANUAL CP 3-5 V2 6.3.1 Attaching the slings: Beam WARNING Ripping of lifting belts The sharp edges of the rack cut the lifting belts. This can lead to severe or fa- tal injuries! • Always protect the lifting belts with the guard plate Fig. 6-3...

  • Page 47: Table 6-1 Guard Plates Material Numbers

    OPERATING MANUAL CP 3-5 V2 Transport Product Guard plate material number TMO 3-4 / AP 5-6 / CP 5-6 / 0213768 ZP 6-7 / FP 6-7 / TMF 3-4 P TMO 1-2 / AP 3-4 / CP 3-4 / 10136821 TMF 1-2 P Table 6-1...

  • Page 48: Fig. 6 -4 Attaching The Slings: Beam

    Transport OPERATING MANUAL CP 3-5 V2 6.3.2 Attaching the slings: Beam WARNING Ripping of lifting belts The sharp edges of the rack cut the lifting belts. This can lead to severe or fa- tal injuries! • Always protect the lifting belts with the guard plate Fig. 6-4...

  • Page 49: Table 6-2 Guard Plates Material Numbers

    OPERATING MANUAL CP 3-5 V2 Transport Product Guard plate material number TMO 3-4 / AP 5-6 / CP 5-6 / 0213768 ZP 6-7 / FP 6-7 / TMF 3-4 P TMO 1-2 / AP 3-4 / CP 3-4 / 10136821 TMF 1-2 P Table 6-2...

  • Page 50: Fig. 6 -5 Attaching The Slings: Carriage

    Transport OPERATING MANUAL CP 3-5 V2 6.3.3 Attaching the slings: carriage Position the axes in their central cantilever arm positions. Fig. 6-5 Attaching the slings: carriage Carriage Limit stop peg Attach the slings as follows: Install the limit stop peg as shown in the illustration Attach the belt harness as shown in the illustration The slings have been attached.

  • Page 51: Fig. 6 -6 Attaching The Slings: Z-Axis, Sizes 2-5

    OPERATING MANUAL CP 3-5 V2 Transport 6.3.4 Attaching the slings: Z-axis, sizes 2-5 Fig. 6-6 Attaching the slings: Z-axis, sizes 2-5 Hook Shackle Lifting belts Z-axis Product size Shackle bolt diame- Shackle payload ter [mm] [kg] 2 + 3 4 + 5 1000 Table 6-3...
  • Page 52 Transport OPERATING MANUAL CP 3-5 V2...

  • Page 53: Introduction

    OPERATING MANUAL CP 3-5 V2 Commissioning Commissioning Introduction Various options are available for your product. This chapter provides informa- tion on several available options. It therefore describes components with which your product is not equipped. 7.1.1 Safety Only perform the tasks described in this chapter after you have read and un- derstood the chapter "Safety".

  • Page 54: Personnel Qualifications

    Commissioning OPERATING MANUAL CP 3-5 V2 WARNING Incorrectly installed safety component The bumper unit is a safety component. Incorrectly installed bumper units may lead to severe injury or death! • Drill the pinhole into the mating part of the bumper unit if necessary •...

  • Page 55: Downtimes

    OPERATING MANUAL CP 3-5 V2 Commissioning Downtimes In some cases, the commissioning of the product may take a significant period of time. After cleaning work on the product or a downtime of one to four weeks, carry out the following jobs: •...
  • Page 56 Commissioning OPERATING MANUAL CP 3-5 V2 • Check hydraulic lines for air pockets and kinks ü û If the machine downtime is longer than four weeks, carry out the following jobs: • Prelubricate guideways and racks • Check the lubrication system as described in the separate documentation...

  • Page 57: Setup, Fastening

    OPERATING MANUAL CP 3-5 V2 Commissioning Setup, fastening 7.4.1 General The following describes the steps for setting up and fastening the product. WARNING Heavy components Components can be very heavy. Improper handling can cause severe or fatal injuries! • Use appropriate lifting units •...

  • Page 58: Unpacking

    Commissioning OPERATING MANUAL CP 3-5 V2 7.4.3 Unpacking Accessories and small parts are packaged in a separate case or directly with the product itself. The components have been treated with anti-rust oil (spray) and wrapped in oiled paper. Remove packaging carefully.

  • Page 59: Special Tools, Testing And Measuring Instruments

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.4.4.1 Special tools, testing and measuring instruments Ensure that you have the following special tools, testing and measuring instru- ments at hand: Tool Item number Sharpening stone Rubbing reference sur- 0503016 faces Adjusting tool...

  • Page 60: Table 7-1 Special Tools, Testing And Measuring Instruments

    Commissioning OPERATING MANUAL CP 3-5 V2 Tool Item number Mounting aid Installing the guideway/ 902282 rack: Module 2.5, heli- Mounting aid Installing the guideway/ 902281 rack: Module 2, helical Mounting aid Installing the guideway/ 902283 rack: Module 3, helical Mounting aid...

  • Page 61: Positioning The Base Plates

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.4.4.2 Positioning the base plates WARNING Hazard due to tipping Products that are incorrectly anchored can tip over. This can lead to severe or fatal injuries! • Observe the minimum values for concrete quality, thickness and edge dis- tances Ü 2 74...

  • Page 62: Fig. 7 -1 Positioning The Base Plates: Position Points

    Commissioning OPERATING MANUAL CP 3-5 V2 Fig. 7-1 Positioning the base plates: Position points Position points (diagonal on plate corners) Reference axis Base plate Position the base plates as follows: Position the base plates according to the foundation plan or layout The base plates are positioned.

  • Page 63: Fig. 7 -2 Clean The Bore Hole: Hit-Z / Hit-Hy-200A

    OPERATING MANUAL CP 3-5 V2 Commissioning WARNING Hazard due to tipping Inadequate drill hole cleaning, drill hole filling and failure to adhere to times will result in poor holding strength or failure of the anchors. The product can overturn. This can lead to severe or fatal injuries.

  • Page 64: Fig. 7 -3 Setting Up An Upright

    Commissioning OPERATING MANUAL CP 3-5 V2 Fig. 7-3 Setting up an upright Spirit level Locknut Upright Upright footing Lifting belts Squared timber Floor leveling screw Set up the upright as follows: Set the front floor leveling screws to the specified mass...

  • Page 65: Fig. 7 -4 Measuring Height Of Upright

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.4.4.5 Leveling uprights Measuring height of upright Fig. 7-4 Measuring height of upright Upright Leveling instrument Tape measure Measure the height of the upright as follows: Set up leveling instrument with visual contact to the holes of the uprights...

  • Page 66: Fig. 7 -5 Marking Floor Leveling Screw

    Commissioning OPERATING MANUAL CP 3-5 V2 Determining average upright height Determine the average upright height as follows: Add the smallest to the largest upright height Divide the result by two Round up the result to the nearest millimeter The average upright height has been determined.

  • Page 67: Securing Uprights Against Falling Over

    OPERATING MANUAL CP 3-5 V2 Commissioning Correct the height of the upright as follows: Upright 1: Calculate difference between average upright height and height of upright 1 Mark floor leveling screws according to the illustration Loosen locknuts Determine the number of rotations according to the table above...

  • Page 68: Fig. 7 -6 Installing The Beams

    Commissioning OPERATING MANUAL CP 3-5 V2 Fig. 7-6 Installing the beams Beam Screw, washer Upright Covering Mount the beam as follows: Remove coverings Attach the slings to the beam Lift beam to upright height Mount the beam to the upright by means of screws and washers...

  • Page 69: Fig. 7 -7 Connecting The Beams

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.4.4.8 Connecting the beams Fig. 7-7 Connecting the beams Fixed beam Spacer sheet Loose beam Sleeve / Centering bolt Washer HV set Connect the beams as follows: Lift the loose beam to the height of the fixed beam (the beams must be...

  • Page 70: Fig. 7 -8 Straightening Beams

    Commissioning OPERATING MANUAL CP 3-5 V2 7.4.4.9 Straightening beams For aligning, use the guideways as a reference. Fig. 7-8 Straightening beams Upright Plate s = 10 mm Guideway Screw clamp Alignment wire Scale...

  • Page 71: Aligning Upright And Beam

    OPERATING MANUAL CP 3-5 V2 Commissioning Align the beams as follows: Attach two plates of equal thickness and alignment wire to guideway as shown in the illustration Upright 2: Check distance between guideway and alignment wire If there are deviations: Align upright in the corresponding direction Repeat process from step 2.1...

  • Page 72: Fig. 7 -9 Aligning Upright And Beam

    Commissioning OPERATING MANUAL CP 3-5 V2 Fig. 7-9 Aligning upright and beam Pry bar Upright Align the upright and beam as follows: Prerequisite:There are no adjustment mechanisms present in the direc- tion of movement Place pry bar in desired position as shown in the illustration Carefully move the upright in the direction of the arrow in small steps Upright and beam have been aligned.

  • Page 73: Fig. 7 -10 Aligning The Beam Horizontally

    OPERATING MANUAL CP 3-5 V2 Commissioning Aligning the beam horizontally NOTE Collision hazard When moving the axis, the product can be damaged by mounting aids, mounting devices, KM0, or adjusting tools that have been left behind. • Remove mounting aids, mounting devices, and adjusting tools every time the product is used.

  • Page 74: Anchoring The Product

    Commissioning OPERATING MANUAL CP 3-5 V2 Finely align the beam of the secondary side as follows: Prerequisite:Uprights and beam of the secondary side have already been roughly aligned Ü 2 71 Remove coverings Slightly loosen the screws Rotate set screws to the outermost position of the adjusting tool...

  • Page 75: Fig. 7 -11 Base Mounting With Adhesive Anchor: Has / Hvu2

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.4.5.1 Base mounting with adhesive anchor This fastening requires uncracked concrete with a quality of at least C20/25 (EN 206-1) with ideal stiffness. The minimum concrete thickness and edge clearance are stated in the table below. The information applies exclusively to standard Güdel components.

  • Page 76: Table 7-3 Anchored Base Mounting: Has / Hvu2

    Commissioning OPERATING MANUAL CP 3-5 V2 Floor leveling screw M24x2 M36x2 M48x3 M56x3 m (anchor size) (concrete thickness) [mm] (edge clearance) [mm] Z (drill diameter) [mm] ø14 ø22 ø30 ø35 Y (drilling depth) [mm] Tightening torque [Nm] Table 7-3 Anchored base mounting: HAS / HVU2...

  • Page 77: Fixing Base With Welded Joint

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.4.5.2 Fixing base with welded joint This anchoring requires cracked or uncracked concrete with a quality of at least C20/25 (EN 206-1) with ideal stiffness. The minimum concrete thickness and edge clearance are stated in the table below. The information applies ex- clusively to standard Güdel components.

  • Page 78: Fig. 7 -12 Welded Base Mounting: Hst3

    Commissioning OPERATING MANUAL CP 3-5 V2 HST3 The base plate is anchored with the HST3 anchoring bolt from HILTI. Fig. 7-12 Welded base mounting: HST3 Screw Bottom plate Floor leveling screw Anchor Upright/frame Base plate m (floor leveling screw) M24x2 M36x2...

  • Page 79: Fig. 7 -13 Welded Base Mounting: Has-Tz / Hvu-Tz

    OPERATING MANUAL CP 3-5 V2 Commissioning Weld the joint as follows: Prerequisite:The base plate is anchored to the floor Connect the floor leveling screw and bottom plate by means of the screw Weld the bottom plate to the base plate...

  • Page 80: Table 7-5 Welded Base Mounting: Has-Tz / Hvu-Tz

    Commissioning OPERATING MANUAL CP 3-5 V2 m (floor leveling screw) M48x3 M56x3 Anchor size (concrete thickness) [mm] (edge clearance) [mm] k (fillet weld dimension) [mm] n (joint length) [mm] Table 7-5 Welded base mounting: HAS-TZ / HVU-TZ Weld the joint as follows:...

  • Page 81: Fig. 7 -14 Welded Base Mounting: Hit-Z / Hit-Hy-200-A

    OPERATING MANUAL CP 3-5 V2 Commissioning HIT-Z / HIT-HY-200-A The base plate is anchored with the anchor rod HIT-Z and the injection mor- tar HIT-HY-200-A from HILTI. Fig. 7-14 Welded base mounting: HIT-Z / HIT-HY-200-A Screw Bottom plate Floor leveling screw...

  • Page 82: Fig. 7 -15 Mounting Aid For Rack Installation

    Commissioning OPERATING MANUAL CP 3-5 V2 Weld the joint as follows: Prerequisite:The base plate is anchored to the floor Connect the floor leveling screw and bottom plate by means of the screw Weld the bottom plate to the base plate...

  • Page 83: Fig. 7 -16 Installing The Rack

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.5.2 Installing the rack Fig. 7-16 Installing the rack Screw clamp Reference surface Mounting aid Wood block Rack Cleaning agents mild universal cleaner free from aromatic compounds (e.g. Motorex OPAL 5000) Table 7-7 Cleaning agents: Rack...
  • Page 84 Commissioning OPERATING MANUAL CP 3-5 V2 Install the rack as follows: Prerequisite:For combinations of three or more racks, always start at the middle Clean the reference surfaces and racks thoroughly and rub an sharpening stone across them Clamp rack to reference surfaces with screw clamps (Be sure to apply the screw clamp at the level of the screw to be tight- ened.)

  • Page 85: Fig. 7 -17 Check Rack Transition

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.5.3 Check rack transition Rack quality and module Ü 2 211 Fig. 7-17 Check rack transition Rack transition Measurement bolt (diameter D = 2 × m ; accuracy: tolerance class 1 acc. to DIN 2269)

  • Page 86: Table 7-8 Permissible Deviation, Rack Transition

    Commissioning OPERATING MANUAL CP 3-5 V2 Rack quality Permissible deviation [mm] Module Module m ≤ 3 3 < m ≤ 8 Q4 h21 0.006 0.010 Q5 h22 0.008 0.012 Q6 h23 0.012 0.012 Q7 h25 0.016 0.016 Q8 h27 0.016 0.016...

  • Page 87: Fig. 7 -18 Installing The Guideway

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.5.4 Installing the guideway Fig. 7-18 Installing the guideway Feeler gauge Guideway Reference surfaces Cleaning agents mild universal cleaner free from aromatic compounds (e.g. Motorex OPAL 5000) Table 7-9 Cleaning agents: Guideway Install the guideway as follows:...

  • Page 88: Fig. 7 -19 Inserting The Y-Axis

    Commissioning OPERATING MANUAL CP 3-5 V2 7.5.5 Inserting the Y-axis WARNING Suspended loads Improper handling of suspended loads can lead to severe injuries or death! • Use appropriate lifting units • Wear appropriate protective clothing • Always keep sufficient distance from suspended loads •...

  • Page 89: Fig. 7 -20 Attaching The Slings: Z-Axis, Sizes 2-5

    OPERATING MANUAL CP 3-5 V2 Commissioning Insert the Y-axis as follows: Prerequisite:Lubricating pinion unit and wiper have been dismantled Prerequisite:The maximum tooth flank backlash has been set Raise the Y-axis with a suitable lifting unit Insert the Y-axis into the X-carriage...

  • Page 90: Table 7-10 Z-Axis Slings: Sizes

    Commissioning OPERATING MANUAL CP 3-5 V2 Product size Shackle bolt diame- Shackle payload ter [mm] [kg] 2 + 3 4 + 5 1000 Table 7-10 Z-axis slings: Sizes Attach the slings as follows: Mount the shackle and lifting belts as illustrated Hang the lifting belts into the hooks The slings are in place.

  • Page 91: Assembling The Bumper Unit

    OPERATING MANUAL CP 3-5 V2 Commissioning Retract the Z-axis as follows: Attach the slings to the Z-axis Retract the Z-axis into the carriage Install the components: Wiper Rotary axis if present Motor if present De-energize the safety brake system if necessary Secure the Z-axis against falling The Z-axis has been retracted.

  • Page 92: Fig. 7 -21 Danger Label "Provisionally Assembled Bumper Unit

    Commissioning OPERATING MANUAL CP 3-5 V2 Fig. 7-21 Danger label "Provisionally assembled bumper unit" Assembly site of the bumper unit Danger label "Provisionally assembled bumper unit" The danger label "Provisionally assembled bumper unit" warns against • Provisionally assembled or non-assembled bumper units...

  • Page 93: Fig. 7 -22 Bumper Unit With Mechanical Limit Stops

    OPERATING MANUAL CP 3-5 V2 Commissioning Bumper unit with limit stops Fig. 7-22 Bumper unit with mechanical limit stops "Loctite 7414, blue" threadlocker Bumper block / bumper bracket Screw Mating part Bumpers Install the bumper unit as follows: Install the bumper on the bumper block / bracket...

  • Page 94: Installing The Motor

    Commissioning OPERATING MANUAL CP 3-5 V2 7.5.7 Installing the motor 7.5.7.1 Information on initial assembly The range of motors for the gearbox unit is very broad. The same applies to the dimensions of the motor shafts. A design solution was selected that al- lowed for the greatest variety of motor to be mounted on the gearbox unit.

  • Page 95: Fig. 7 -23 Aligning The Gearbox Flange

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.5.7.3 Aligning the gearbox flange You can align the gearbox flange. When correctly aligned, the motor and cou- pling can be installed. ü û D1=20F7 02/17 Gearbox side HPG060 Fig. 7-23 Aligning the gearbox flange...
  • Page 96 Commissioning OPERATING MANUAL CP 3-5 V2 Align the gearbox flange as follows: Prerequisite:The gearbox unit has been installed on the adjacent con- struction Switch off the system and secure it with a padlock against being switched on again Remove the plug...

  • Page 97: Fig. 7 -24 Aligning The Input Shaft To The Gearbox Flange

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.5.7.4 Aligning the input shaft to the gearbox flange WARNING Moving the axis The work requires moving the axis. This can lead to severe or fatal injuries! • Ensure that no persons are in the danger area while the axis is moving Fig. 7-24...
  • Page 98 Commissioning OPERATING MANUAL CP 3-5 V2 Align the input shaft to the gearbox flange as follows: Prerequisite:The gearbox unit has been installed on the adjacent con- struction Prerequisite:The gearbox flange has been aligned correctly Prerequisite:The wedge has been installed on the gearbox side...

  • Page 99: Fig. 7 -25 Positioning The Coupling On The Motor Shaft: Elastomer Coupling

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.5.7.5 Positioning the coupling on the motor shaft NOTE Defective coupling The coupling is destroyed if the coupling screws are tightened and the cou- pling is not installed on the shaft. • Tighten the coupling screws only when the coupling is installed on the shaft.

  • Page 100: Fig. 7 -26 X Dimension Calculation Formula

    Commissioning OPERATING MANUAL CP 3-5 V2 X = Z – Y Fig. 7-26 X dimension calculation formula Güdel Coupling L dimen- L dimen- Y dimen- X di- type sion sion tol- sion mension gearbox [mm] erance [mm] toler- unit size [mm]...

  • Page 101: Fig. 7 -27 Position The Coupling On The Motor Shaft: Make Use Of X Dimension Tolerance

    OPERATING MANUAL CP 3-5 V2 Commissioning Güdel Coupling L dimen- L dimen- Y dimen- X di- type sion sion tol- sion mension gearbox [mm] erance [mm] toler- unit size [mm] ance [mm] +1.2 +0.5 5103-42- +1.2 +0.5 5103-38- Table 7-12 Weight and tolerances for the elastomer coupling ü...

  • Page 102: Installing The Motor And Coupling

    Commissioning OPERATING MANUAL CP 3-5 V2 Position the coupling on the motor shaft as follows: Prerequisite:The transport securing device in effect at the gearbox is dis- assembled Clean the coupling and motor shaft to ensure that they are free of grease...

  • Page 103: Fig. 7 -28 Installing The Motor And Coupling

    OPERATING MANUAL CP 3-5 V2 Commissioning The tightening torque TA and the type of coupling are engraved on the mo- tor and gearbox sides in the coupling. D1=20F7 02/17 Gearbox side HPG060 Fig. 7-28 Installing the motor and coupling Coupling screw...

  • Page 104: Table 7-15 Special Tools, Testing And Measuring Instruments

    Commissioning OPERATING MANUAL CP 3-5 V2 Tool Item number Corrosion protection Installing the coupling 0502037 agent MOTOREX In- Applying corrosion tact XD 20 protection to the product Table 7-15 Special tools, testing and measuring instruments Install the motor and coupling as follows:...

  • Page 105: Fig. 7 -29 Changing The Lubricating Position

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.5.8 Changing the lubricating position Continuous lubrication of the guideways at operating temperatures below 0°C or with grease requires a modification to the lubricating position. The lubricant channel is inside and carries the lubricant past the lubricating el- ement to the guideway.

  • Page 106: Fig. 7 -30 Checking Leveling Of The Guide Chute

    Commissioning OPERATING MANUAL CP 3-5 V2 7.5.9 Check leveling of the guide chute NOTE Increased wear An incorrectly leveled guide chute leads to increased wear on the energy chain. • Correctly level the guide chute ü û Fig. 7-30 Checking leveling of the guide chute...

  • Page 107: Fig. 7 -31 Connecting The Side Panels

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.5.10 Connecting the side panels Energy chains are guided along laterally by the side panels. The side panels en- sure that the energy chain rolls cleanly along the traverse path. The side pan- els are part of the guide chute.

  • Page 108: Assembling The Energy Chain

    Commissioning OPERATING MANUAL CP 3-5 V2 Connect the side panels as follows: Install screw clamps as shown in the illustration Align connecting plates Install pan-head screws from the inner side of the guide chute Apply Loctite 243 to hexagon nuts...
  • Page 109 OPERATING MANUAL CP 3-5 V2 Commissioning Observe the following points: • Cables are separated by vertical dividers; cables are not permitted to be laid next to each other • Cables laid over each other with different jacket materials need to be sep- arated from each other (risk of sticking) •...

  • Page 110: Fig. 7 -32 Laying Cables And Lines (Image Source: Igus)

    Commissioning OPERATING MANUAL CP 3-5 V2 ü û û ü û ü Fig. 7-32 Laying cables and lines (image source: IGUS) Screwdriver Opening bar Energy chain Vertical divider...

  • Page 111: Installing The Energy Chain

    OPERATING MANUAL CP 3-5 V2 Commissioning Lay the cables and lines as follows: Prerequisite:You have read and understood the IGUS assembly instruc- tions Open the opening bar of the energy chain Place the screwdriver on the opening bar Tilt the screwdriver backwards until the opening bar is released...

  • Page 112: Fig. 7 -33 Installing The Energy Chains

    Commissioning OPERATING MANUAL CP 3-5 V2 The orange flag denotes the driver side. The manufacturer turns the first three chain links on the driver side. This makes the energy chain slide better. ü û Fig. 7-33 Installing the energy chains Orange flag...

  • Page 113: Fig. 7 -34 Installing The Slide Bars (Image Source: Igus)

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.6.3 Installing the slide bars Slide bars are installed on sliding energy chains. The slide bars support the en- ergy chain where is slides over the fixed side. NOTE Breaking the energy chain The energy chain becomes hooked in if the slide bar transitions do not align.

  • Page 114: Relieving The Cables And Lines Of Strain

    Commissioning OPERATING MANUAL CP 3-5 V2 7.6.4 Relieving the cables and lines of strain NOTE Incorrectly implemented strain relief Lack of strain relief or incorrectly implemented strain relief on cables and lines in energy chains leads to damage. Cables and lines will be destroyed.

  • Page 115: Fig. 7 -35 Relieving The Strain On Cables And Lines (Image Source: Igus)

    OPERATING MANUAL CP 3-5 V2 Commissioning ü û ü û ü û Fig. 7-35 Relieving the strain on cables and lines (image source: IGUS) Fixed side connection element Metal sleeve Versions Explanation Figure Cable fittings Two cable fittings 4.5 mm wide on the...

  • Page 116: Connection

    Commissioning OPERATING MANUAL CP 3-5 V2 Attach the strain relief as follows: Position cables and lines in the correct position in accordance with the il- lustration For traverse paths of the energy chain that are less than 50 m: Relieve cable strain at the driver and the fixed side.

  • Page 117: Attaching The Load

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.7.2 Attaching the load Attach the load as follows: Attach the load (gripper, robot, etc.) Setting the roller and tooth flank backlash The load has been attached. 7.7.3 Integrating the product Integrate the product into the complete system. Connect the product with the supply lines for energy and consumables.

  • Page 118: Transport Securing Devices

    Commissioning OPERATING MANUAL CP 3-5 V2 Transport securing devices At delivery, a transport securing device is in effect at the rack or the gearbox. Remove all transport securing devices before moving the axes. Store the transport securing devices for future work.

  • Page 119: Fig. 7 -36 Removing Transport Securing Device: Güdel Gearbox Unit

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.8.1 Removing the transport securing device Remove the latch using a screwdriver Fig. 7-36 Removing transport securing device: Güdel gearbox unit Plug Coupling Transport securing device Latch Coupling screw...

  • Page 120: Installing Transport Securing Device

    Commissioning OPERATING MANUAL CP 3-5 V2 Remove the transport securing device as follows: Secure carriage or axis Remove the plug Release the coupling screws If necessary, bend the latch so that it is straight, as shown in the illustra- tion...

  • Page 121: Fig. 7 -37 Installing Transport Securing Device: Güdel Gearbox Unit

    OPERATING MANUAL CP 3-5 V2 Commissioning Fig. 7-37 Installing transport securing device: Güdel gearbox unit Plug Input shaft with sunk key Output axis Latch Fastening screw Transport securing device Marking bore Coupling Groove...
  • Page 122 Commissioning OPERATING MANUAL CP 3-5 V2 Install the transport securing device as follows: Prerequisite:The input shaft has been correctly aligned to the gearbox flange Ü 2 97 Prerequisite:The coupling has been removed Switch off the system and secure it with a padlock against being switched...

  • Page 123: Fig. 7 -38 Checking The Transport Securing Device

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.8.2.1 Checking the transport securing device ü û Fig. 7-38 Checking the transport securing device Fastening screws Latch Transport securing device Coupling Check the transport securing device as follows: Check whether the transport securing device is correctly positioned with...

  • Page 124: Tighten The Coupling Screws

    Commissioning OPERATING MANUAL CP 3-5 V2 7.8.2.2 Tighten the coupling screws Tighten the coupling screws as follows: Tighten the coupling screws: Tighten alternately to 50% of the tightening torque TA Tighten alternately with 100% of the tightening torque TA The coupling screws are tightened.

  • Page 125: Fig. 7 -39 Cleaning The Guideways And Racks

    OPERATING MANUAL CP 3-5 V2 Commissioning Fig. 7-39 Cleaning the guideways and racks Cleaning agents mild universal cleaner free from aromatic compounds (e.g. Motorex OPAL 5000) Table 7-17 Cleaning agents: guideways, racks Clean the racks and guideways as follows: Switch off the system and secure it with a padlock against being switched...

  • Page 126: Fig. 7 -40 Pre-Lubricate Guideways And Racks

    Commissioning OPERATING MANUAL CP 3-5 V2 ü û Fig. 7-40 Pre-lubricate guideways and racks Lubrication ex Specification Lubrication quantity works Ü Chapter 9.2.2.1, Ü Chapter 9.2.2.1, 2 134 2 134 Table 7-18 Lubricants: Guideways, racks, and pinions Pre-lubricate the racks and guideways as follows: Prerequisite:The guideways and racks have been cleaned...

  • Page 127: Fig. 7 -41 Carrying Out A Lubrication Check

    OPERATING MANUAL CP 3-5 V2 Commissioning 7.9.3 Carrying out a lubrication check Perform a lubrication check as described in the separate documentation on the automatic lubrication system. ü û Fig. 7-41 Carrying out a lubrication check Lubrication ex Specification Lubrication quantity works Ü Chapter 9.2.2.1,...

  • Page 128: Functional Check

    Commissioning OPERATING MANUAL CP 3-5 V2 7.10 Functional check WARNING Hazard due to tipping Products that are incorrectly anchored can tip over. This can lead to severe or fatal injuries! • Ensure that the product is anchored tightly Prior to the functional check, ensure that: •...

  • Page 129: General

    OPERATING MANUAL CP 3-5 V2 Operation Operation General Only operate the product after observing the installation instructions. For information on operating the product, refer to the appropriate chapter of the documentation for the complete system. Personnel WARNING Training of operating personnel...
  • Page 130 Operation OPERATING MANUAL CP 3-5 V2...

  • Page 131: Introduction

    OPERATING MANUAL CP 3-5 V2 Maintenance Maintenance Introduction Maintenance The listed tasks have to be carried out at the prescribed time intervals. If they tasks are not carried out at the specified intervals or improperly, all warranty is voided. Observing these obligations is a significant condition so that the prod- uct performing without malfunction as well as its long service life.

  • Page 132: Personnel Qualifications

    Maintenance OPERATING MANUAL CP 3-5 V2 WARNING Falling axes, workpieces Falling axes or workpieces can cause physical damage, serious or fatal injuries! • Set down any workpieces before working in the danger area • Never enter the area below suspended axes and workpieces •...

  • Page 133: Table 9-1 Table Of Cleaning Agents

    OPERATING MANUAL CP 3-5 V2 Maintenance Consumables and auxiliary agents 9.2.1 Cleaning agents Use a soft rag or cloth for cleaning tasks. Only use permissible cleaning agents. 9.2.1.1 Table of cleaning agents Cleaning agents Location of application Automatic lubrication system: Pump, lines, other components Gearbox unit Güdel: Coupling and...

  • Page 134: Fig. 9 -1 Lubricating Manually With Grease

    Maintenance OPERATING MANUAL CP 3-5 V2 Alternative manu- The following tables show the specifications of the lubricants. Please inform facturers your manufacturer accordingly. They will then suggest an alternative from their product range. Low tempera- Observe the application range limits of lubricants according to the safety data tures / food grade sheet.

  • Page 135: Fig. 9 -2 Lubricating Manually With Oil

    OPERATING MANUAL CP 3-5 V2 Maintenance Fig. 9-2 Lubricating manually with oil Lubrication Specifica- Lubrica- Location of appli- Cate- ex works tion tion cation gory quantity Güdel H1 cannot be As per Guideways, racks, found instruc- and pinions no.146621 tions Table 9-3 Lubricants: Guideways, racks, and pinions Fig. 9-3...

  • Page 136: Fig. 9 -4 Markings At The Lubrication Points

    Maintenance OPERATING MANUAL CP 3-5 V2 Markings at the The markings apply to manual lubrication of the following Güdel components: lubrication points • Roller support • Lubricating pinion unit • Wiper and lubrication unit Fig. 9-4 Markings at the lubrication points...

  • Page 137: Fig. 9 -6 Automatic Lubrication System Flexxpump

    OPERATING MANUAL CP 3-5 V2 Maintenance Fig. 9-6 Automatic lubrication system FlexxPump Lubrication Specifica- Lubrica- Location of appli- Cate- ex works tion tion cation gory quantity Elkalub FLC Cannot be Automatic lubrica- 8 H1 determined tion system FlexxPump: Prelubri- cate guideways and racks Table 9-6...

  • Page 138: Table 9-8 Lubricant Table

    Maintenance OPERATING MANUAL CP 3-5 V2 9.2.2.2 Lubricant table Lubrication Specifica- Lubrica- Location of applica- Cat- ex works tion tion tion quantity gory KP2N-20 in 40: 1.1g accordance 52: 2.4g with DIN 72: 7.3g Aral Arcanol 51825 high- 90: 7.3g...

  • Page 139: Table 9-9 Conversion Table: Operating Hours At The Respective Duty Cycle

    OPERATING MANUAL CP 3-5 V2 Maintenance Maintenance tasks 9.3.1 General prerequisites Prior to performing repair and maintenance tasks, do the following: • If vertical axes are present, secure them against falling • Switch off the system and padlock it to secure it against being switched on again •...

  • Page 140: Table 9-10 Maintenance Intervals In Shift Operation (5 Days A Week)

    Maintenance OPERATING MANUAL CP 3-5 V2 The definition is based on 5/7 working days per week. Operating 1-shift opera- 2-shift opera- 3-shift opera- hours tion tion tion every 4 weeks every 2 weeks Weekly 2'250 yearly every 6 months every 4 months...

  • Page 141: Special Tools, Testing And Measuring Instruments

    OPERATING MANUAL CP 3-5 V2 Maintenance 9.3.3 Special tools, testing and measuring instruments Ensure that you have the following special tools, testing and measuring instru- ments at hand: Tool Item number Sharpening stone Rubbing reference sur- 0503016 faces Adjusting tool...

  • Page 142: Table 9-12 Special Tools, Testing And Measuring Instruments

    Maintenance OPERATING MANUAL CP 3-5 V2 Tool Item number Mounting aid Installing the rack: 902284 Module 4, helical Lubricating spray Pre-lubricating guide- 10406825 ways and racks Screw clamps Installing the racks Fastening device Blocking the drive pin- 0917453 ions: HPG/AE045...
  • Page 143 OPERATING MANUAL CP 3-5 V2 Maintenance 9.3.4 Maintenance tasks after cleaning or downtimes 1<4 weeks After cleaning work on the product or a downtime of one to four weeks, carry out the following jobs: • Check the lubricating film on guideways and racks ü...

  • Page 144: Maintenance Tasks 100 Hours After Commissioning

    Maintenance OPERATING MANUAL CP 3-5 V2 9.3.6 Maintenance tasks 100 hours after commissioning To ensure smooth operation, certain maintenance tasks have to be per- formed after commissioning. NOTE Material damage Product damage can be reduced with the general inspection 100 hours after commissioning of the entire system.

  • Page 145: Fig. 9 -8 Carrying Out A Lubrication Check

    OPERATING MANUAL CP 3-5 V2 Maintenance 9.3.6.1 Carrying out a lubrication check Perform a lubrication check as described in the separate documentation on the automatic lubrication system. ü û Fig. 9-8 Carrying out a lubrication check Lubrication ex Specification Lubrication quantity works Ü Chapter 9.2.2.1,...

  • Page 146: Fig. 9 -9 Lubricating Components On The Grease Nipple

    Maintenance OPERATING MANUAL CP 3-5 V2 9.3.7 Maintenance tasks after 150 hours 9.3.7.1 Lubricating guideways, racks and pinions Guideways are lubricated using the grease nipple of the wiper and lubrication unit or the roller supports. Lubricate the racks and pinion using the lubricating nipple of the lubricating pinion.

  • Page 147: Table 9-14 Lubricants: Guideways, Racks, And Pinions

    OPERATING MANUAL CP 3-5 V2 Maintenance Lubrication ex Specification Lubrication quantity works Ü Chapter 9.2.2.1, Ü Chapter 9.2.2.1, Roller size 10-20: 4.5 2 134 2 134 cm³ Roller size 25-52: 7.5 cm³ Roller size 72-215: 12 cm³ Table 9-14 Lubricants: Guideways, racks, and pinions Lubricate the guideways, racks, and pinions as follows:...
  • Page 148 Maintenance OPERATING MANUAL CP 3-5 V2 NOTE Leaks due to worn gaskets Gaskets become brittle due to natural ageing, high temperatures or UV radia- tion. This can lead to leaks in the gearbox. The lubricant leaks out. The bear- ings heat up and fail. The gear teeth in the gear unit wear out and fail. The gearbox fails.
  • Page 149 OPERATING MANUAL CP 3-5 V2 Maintenance Inspection Description Measures point Loose compo- Check the fit of the • Immediately tighten loose nents components: screws to the required torque • Screws • Align and fasten loose at- • Nuts tachments • Attachments •...

  • Page 150: Axes

    Maintenance OPERATING MANUAL CP 3-5 V2 Inspection Description Measures point Setting Check for correct set- • Set the tooth flank back- ting in the components: lash • Set the rollers • Pinions • Rollers Energy chain and Check the energy chain: •...

  • Page 151: Fig. 9 -10 Greasing The Roller

    OPERATING MANUAL CP 3-5 V2 Maintenance 9.3.8.2 Greasing the roller A type plate is attached to roller supports. You will find the size of the roller on the type plate. In all other cases, the size of the roller can be found in the spare parts list.

  • Page 152: Fig. 9 -11 Carrying Out A Lubrication Check

    Maintenance OPERATING MANUAL CP 3-5 V2 9.3.8.3 Replacing the cartridge Replace the cartridge according to the separate documentation on automatic lubrication. 9.3.8.4 Replacing the battery Replace the battery in battery-operated automatic lubrication systems accord- ing to the separate documentation. 9.3.8.5...

  • Page 153: Fig. 9 -12 Replacing The Lubricating Pinion

    OPERATING MANUAL CP 3-5 V2 Maintenance 9.3.9 Maintenance tasks after 6,750 hours 9.3.9.1 Replacing the lubricating pinion A pinion soaked in lubricant runs along next to the drive pinion. It ensures a continuous lubrication of the rack and the drive pinions.

  • Page 154: Replacing The Wiper And Lubrication Unit

    Maintenance OPERATING MANUAL CP 3-5 V2 Replace the lubricating pinion as follows: Switch off the system and padlock it to secure it against being switched on again Remove the line of the automatic lubrication if necessary Remove the entire lubricating pinion unit...

  • Page 155: Fig. 9 -13 Replacing The Wiper And Lubrication Unit

    OPERATING MANUAL CP 3-5 V2 Maintenance Fig. 9-13 Replacing the wiper and lubrication unit Cover Lubricating element Grease nipple Casing Identification disc Wiper Lubrication ex Specification Lubrication quantity works Ü Chapter 9.2.2.1, Ü Chapter 9.2.2.1, 2 134 2 134 Table 9-19 Lubricants: Guideways, racks, and pinions...

  • Page 156: Fig. 9 -14 Replacing The Wiper And Lubricating Element

    Maintenance OPERATING MANUAL CP 3-5 V2 Replace the wiper and lubrication unit as follows: Switch off the system and padlock it to secure it against being switched on again Remove the line of the automatic lubrication if necessary Pre-assemble the wiper and lubrication unit as shown in figure...

  • Page 157: Table 9-20 Lubricants: Guideways, Racks, And Pinions

    OPERATING MANUAL CP 3-5 V2 Maintenance Lubrication ex Specification Lubrication quantity works Ü Chapter 9.2.2.1, Ü Chapter 9.2.2.1, 2 134 2 134 Table 9-20 Lubricants: Guideways, racks, and pinions Replace the wiper and lubricating element as follows: Switch off the system and padlock it to secure it against being switched...

  • Page 158: Fig. 9 -15 Inspect Automatic Lubrication System

    Maintenance OPERATING MANUAL CP 3-5 V2 9.3.10 Maintenance tasks after 11,250 hours 9.3.10.1 Checking automatic lubrication system Fig. 9-15 Inspect automatic lubrication system Cleaning agents mild universal cleaner free from aromatic compounds (e.g. Motorex OPAL 5000) Table 9-21 Cleaning agents: Automatic lubrication system: Pump, lines, other components Check the automatic lubrication system in accordance with the following ta- ble.

  • Page 159: Maintenance Tasks After 22,500 Hours

    OPERATING MANUAL CP 3-5 V2 Maintenance 9.3.11 Maintenance tasks after 22,500 hours 9.3.11.1 Replacing the automatic lubrication pump Replace the pump of the automatic lubrication according to the separate doc- umentation. 9.3.11.2 Replacing the energy chain Removing the energy chain...
  • Page 160 Maintenance OPERATING MANUAL CP 3-5 V2 Lay out cables without twisting for at least 24 hours before putting them into energy chains. Use the cable description to assist you. The wires of the cable are thus aligned without twisting and can have a positive influence on the ser-...

  • Page 161: Fig. 9 -16 Laying Cables And Lines (Image Source: Igus)

    OPERATING MANUAL CP 3-5 V2 Maintenance ü û û ü û ü Fig. 9-16 Laying cables and lines (image source: IGUS) Screwdriver Opening bar Energy chain Vertical divider...

  • Page 162: Installing The Energy Chain

    Maintenance OPERATING MANUAL CP 3-5 V2 Lay the cables and lines as follows: Prerequisite:You have read and understood the IGUS assembly instruc- tions Open the opening bar of the energy chain Place the screwdriver on the opening bar Tilt the screwdriver backwards until the opening bar is released...

  • Page 163: Fig. 9 -17 Installing The Energy Chains

    OPERATING MANUAL CP 3-5 V2 Maintenance The orange flag denotes the driver side. The manufacturer turns the first three chain links on the driver side. This makes the energy chain slide better. ü û Fig. 9-17 Installing the energy chains Orange flag...

  • Page 164: Fig. 9 -18 Installing The Slide Bars (Image Source: Igus)

    Maintenance OPERATING MANUAL CP 3-5 V2 9.3.11.3 Replacing the slide bars Replacing and pre-assembling the slide bars Mount the slide bars as follows: Switch off the system and secure it with a padlock against being switched on again Remove all slide bars Pre-assemble new slide bars The slide bars are pre-assembled.

  • Page 165: Replacing The Gearbox Unit

    OPERATING MANUAL CP 3-5 V2 Maintenance Install the slide bars as follows: Screw the pre-assembled slide bars tightly Check the alignment of all slide bars (Slide bars and fixed side of the energy chain align in accordance with the illustration)

  • Page 166: Fig. 9 -19 Attaching The Slings: Motor

    Maintenance OPERATING MANUAL CP 3-5 V2 Attaching the slings: Motor WARNING Suspended loads Improper handling of suspended loads can lead to severe injuries or death! • Use appropriate lifting units • Wear appropriate protective clothing • Always keep sufficient distance from suspended loads •...

  • Page 167: Fig. 9 -20 Attaching The Slings: Güdel Gearbox Unit

    OPERATING MANUAL CP 3-5 V2 Maintenance Attaching the slings: Güdel gearbox unit Use lifting units to transport gearbox units from size 090 upwards. WARNING Heavy components Components can be very heavy. Improper handling can cause severe or fatal injuries! • Use appropriate lifting units •...

  • Page 168: Removing The Motor And Coupling

    Maintenance OPERATING MANUAL CP 3-5 V2 Attach the slings as follows: Insert lifting screws into threaded holes on desired side (Diagonal arrangement according to illustration) Attach the slings as shown in the illustration The slings are in place. Removing the motor and coupling...

  • Page 169: Fig. 9 -21 Remove Motor And Coupling

    OPERATING MANUAL CP 3-5 V2 Maintenance Fig. 9-21 Remove motor and coupling Plug Coupling screw Drill hole Motor Coupling Motor screw Remove the motor and coupling as follows: Switch off the system and secure it with a padlock against being switched...

  • Page 170: Fig. 9 -22 Removing The Gearbox Unit

    Maintenance OPERATING MANUAL CP 3-5 V2 Removing the gearbox unit Fig. 9-22 Removing the gearbox unit Adjacent construction Gearbox unit Gearbox screws Remove the gearbox unit as follows: Attach slings to the gearbox unit Ü 2 167 Remove the gearbox screws Remove the gearbox unit Remove the transport securing device or slings The gearbox unit has now been removed.

  • Page 171: Fig. 9 -23 Installing The Gearbox Unit

    OPERATING MANUAL CP 3-5 V2 Maintenance Installing the gearbox unit NOTE Breakage of cast casing Excessively high tightening torques destroy the cast casing! • Observe the tightening torques Fig. 9-23 Installing the gearbox unit Adjacent construction Gearbox unit Gearbox screws Size...

  • Page 172: Installing The Motor

    Maintenance OPERATING MANUAL CP 3-5 V2 Installing the motor Information on ini- The range of motors for the gearbox unit is very broad. The same applies to tial assembly the dimensions of the motor shafts. A design solution was selected that al- lowed for the greatest variety of motor to be mounted on the gearbox unit.

  • Page 173: Fig. 9 -24 Aligning The Gearbox Flange

    OPERATING MANUAL CP 3-5 V2 Maintenance Aligning the gear- You can align the gearbox flange. When correctly aligned, the motor and cou- box flange pling can be installed. ü û D1=20F7 02/17 Gearbox side HPG060 Fig. 9-24 Aligning the gearbox flange...
  • Page 174 Maintenance OPERATING MANUAL CP 3-5 V2 Align the gearbox flange as follows: Prerequisite:The gearbox unit has been installed on the adjacent con- struction Switch off the system and secure it with a padlock against being switched on again Remove the plug...

  • Page 175: Fig. 9 -25 Aligning The Input Shaft To The Gearbox Flange

    OPERATING MANUAL CP 3-5 V2 Maintenance Aligning the input shaft to the gear- box flange WARNING Moving the axis The work requires moving the axis. This can lead to severe or fatal injuries! • Ensure that no persons are in the danger area while the axis is moving Fig. 9-25...
  • Page 176 Maintenance OPERATING MANUAL CP 3-5 V2 Align the input shaft to the gearbox flange as follows: Prerequisite:The gearbox unit has been installed on the adjacent con- struction Prerequisite:The gearbox flange has been aligned correctly Prerequisite:The wedge has been installed on the gearbox side...

  • Page 177: Fig. 9 -26 Positioning The Coupling On The Motor Shaft: Elastomer Coupling

    OPERATING MANUAL CP 3-5 V2 Maintenance D2=24H7 02/17 D1=20F7 02/17 Gearbox side HPG060 Fig. 9-26 Positioning the coupling on the motor shaft: Elastomer coupling Gearbox Installation surface Motor flange Coupling screw Measuring instrument Motor shaft Coupling Motor X = Z – Y Fig. 9-27...
  • Page 178 Maintenance OPERATING MANUAL CP 3-5 V2 Güdel Coupling L dimen- L dimen- Y dimen- X di- type sion sion tol- sion mension gearbox [mm] erance [mm] toler- unit size [mm] ance [mm] +0.5 +0.5 5103-24- +0.5 +0.5 5103-19- 16.5 +0.5 5103-28- 18.5...

  • Page 179: Fig. 9 -28 Position The Coupling On The Motor Shaft: Make Use Of X Dimension Tolerance

    OPERATING MANUAL CP 3-5 V2 Maintenance ü û Fig. 9-28 Position the coupling on the motor shaft: Make use of X dimension tolerance Cleaning agents mild universal cleaner free from aromatic compounds (e.g. Motorex OPAL 5000) Table 9-26 Cleaning agents: Gearbox unit Güdel: Coupling and motor shaft...
  • Page 180 Maintenance OPERATING MANUAL CP 3-5 V2 Position the coupling on the motor shaft as follows: Prerequisite:The transport securing device in effect at the gearbox is dis- assembled Clean the coupling and motor shaft to ensure that they are free of grease...

  • Page 181: Fig. 9 -29 Installing The Motor And Coupling

    OPERATING MANUAL CP 3-5 V2 Maintenance The tightening torque TA and the type of coupling are engraved on the mo- tor and gearbox sides in the coupling. D1=20F7 02/17 Gearbox side HPG060 Fig. 9-29 Installing the motor and coupling Coupling screw...

  • Page 182: Table 9-29 Special Tools, Testing And Measuring Instruments

    Maintenance OPERATING MANUAL CP 3-5 V2 Tool Item number Corrosion protection Installing the coupling 0502037 agent MOTOREX In- Applying corrosion tact XD 20 protection to the product Table 9-29 Special tools, testing and measuring instruments Install the motor and coupling as follows:...

  • Page 183: Final Tasks

    OPERATING MANUAL CP 3-5 V2 Maintenance Final tasks Perform the following final tasks: Set the tooth flank backlash Ü 2 207 Calibrate the reference plane of the motor (procedure is described in the documentation for the complete system or the motor) The final tasks have been performed.

  • Page 184: Fig. 9 -30 Roller Holder Installation Types

    Maintenance OPERATING MANUAL CP 3-5 V2 X-, Y-axis Roller holder in- There are three types of installation for roller holders: stallation types Fig. 9-30 Roller holder installation types Installation type (E1): Eccentric zero po- sition, fixed with positioning screw Installation type (E2): Eccentric infinitely...

  • Page 185: Fig. 9 -31 Roller Holder Arrangement: Loaded And Unloaded Rollers

    OPERATING MANUAL CP 3-5 V2 Maintenance Roller holder ar- The roller holders are arranged according to the following figure: rangement: loaded and unloaded rollers Fig. 9-31 Roller holder arrangement: loaded and unloaded rollers Vertical axis Cantilever arm axis Horizontal axis Roller holder ar-...

  • Page 186: Fig. 9 -33 Replacing The Roller

    Maintenance OPERATING MANUAL CP 3-5 V2 Replacing the roller Distinguishing characteristics of wear • Excessive noise is audible • Discoloration due to heat present • Uneven running due to vibrations perceptible • Running surface worn • Notches on guide running surface Table 9-30...

  • Page 187: Fig. 9 -34 Zero Position Of Eccentric

    OPERATING MANUAL CP 3-5 V2 Maintenance Replace the roller as follows: Switch off the system and padlock it to secure it against being switched on again Secure the vertical axis, if necessary Attach slings or support the carriage Remove fastening screws and flange...

  • Page 188: Axis

    Maintenance OPERATING MANUAL CP 3-5 V2 Adjust the rollers as follows: Prerequisite:The maximum tooth flank backlash has been set Switch off the system and padlock it to secure it against being switched on again Remove coverings if necessary Install or check E1 and E3 roller holders:...

  • Page 189: Fig. 9 -35 Roller Positions

    OPERATING MANUAL CP 3-5 V2 Maintenance Distinguishing characteristics of wear • Excessive noise is audible • Discoloration due to heat present • Uneven running due to vibrations perceptible • Running surface worn • Notches on guide running surface Table 9-31 Distinguishing characteristics of wear: Roller...

  • Page 190: Fig. 9 -36 Attaching The Slings: Z-Axis, Sizes 2-5

    Maintenance OPERATING MANUAL CP 3-5 V2 Attaching the slings: Z-axis, sizes Fig. 9-36 Attaching the slings: Z-axis, sizes 2-5 Hook Shackle Lifting belts Z-axis Product size Shackle bolt diame- Shackle payload ter [mm] [kg] 2 + 3 4 + 5 1000 Table 9-32...

  • Page 191: Fig. 9 -37 Replacing The Roller

    OPERATING MANUAL CP 3-5 V2 Maintenance Replacing the roller WARNING Unexpected movement of carriage and axis Simultaneous replacement of several rollers may lead to unexpected move- ment of carriage or axis. This can lead to severe or fatal injuries! • Replace the rollers individually Fig. 9-37...
  • Page 192 Maintenance OPERATING MANUAL CP 3-5 V2 Replace the roller as follows: Prerequisite:The roller has been relieved Switch off the system and padlock it to secure it against being switched on again Remove screws B and wiper and lubrication unit Remove the fastening screw and serrated lock washer...

  • Page 193: Fig. 9 -38 Setting The Rollers: Prism Guideway, Eccentric Rollers

    OPERATING MANUAL CP 3-5 V2 Maintenance Setting the rollers ü û Fig. 9-38 Setting the rollers: Prism guideway, eccentric rollers Guideway Screw Carriage Hexagonal socket wrench Pin-type face wrench Axis Roller (eccentric)

  • Page 194: Final Tasks

    Maintenance OPERATING MANUAL CP 3-5 V2 Adjust the rollers as follows: Prerequisite:The wiper and lubrication units have been removed Prerequisite:The maximum backlash has been set Ü 2 207 Prerequisite:Right rollers are set to position +1 Ü 2 189 Prerequisite:Left rollers are set to position -1 Ü 2 189...

  • Page 195: Table 9-33 Distinguishing Characteristics Of Wear: Guideway

    OPERATING MANUAL CP 3-5 V2 Maintenance WARNING Falling axes/workpieces If emergency guideways are removed, they will not hold carriages or axles in an emergency. Axes and workpieces can fall down. Falling axes or workpieces can cause serious injury or death! •...

  • Page 196: Fig. 9 -39 Installing The Guideway

    Maintenance OPERATING MANUAL CP 3-5 V2 X-, Y-axis Disassembling the Disassemble the guideway as follows: guideway Switch off the system and padlock it to secure it against being switched on again Attach the slings to the carriage or axis Expose guideway:...

  • Page 197: Axis

    OPERATING MANUAL CP 3-5 V2 Maintenance Install the guideway as follows: Prerequisite:For axes over 20 meters, the assembly of the guideways must be performed from the middle Clean the reference surfaces and guideways thoroughly and rub a sharp- ening stone across them...

  • Page 198: Fig. 9 -40 Installing The Guideway

    Maintenance OPERATING MANUAL CP 3-5 V2 Installing the guideway If you check the rack transition and cannot comply with the required values, the gap dimension takes priority. Fig. 9-40 Installing the guideway Reference surface Screw clamp Guideway Torque wrench Cleaning agents mild universal cleaner free from aromatic compounds (e.g.
  • Page 199 OPERATING MANUAL CP 3-5 V2 Maintenance Install the guideway as follows: Clean the reference surfaces and guideways thoroughly and rub a sharp- ening stone across them Clamp guideways to reference surfaces with screw clamps Tighten all screws Checking the transition: Gap dimension < 0.02 mm...

  • Page 200: Final Tasks

    Maintenance OPERATING MANUAL CP 3-5 V2 Final tasks WARNING Falling axes/workpieces If screwed reinforcing ribs are not reassembled after disassembly, the carriage is not stable enough. This can lead to axes or workpieces falling. Falling axes or workpieces can cause serious injury or death! •...

  • Page 201: Fig. 9 -41 Mounting Aid For Rack Installation

    OPERATING MANUAL CP 3-5 V2 Maintenance 9.3.11.7 Replacing the rack X-, Y-axis Disassembling the Disassemble the rack as follows: rack Switch off the system and padlock it to secure it against being switched on again Attach the slings to the carriage or axis...

  • Page 202: Fig. 9 -42 Installing The Rack

    Maintenance OPERATING MANUAL CP 3-5 V2 Installing the rack Fig. 9-42 Installing the rack Screw clamp Reference surface Mounting aid Wood block Rack Cleaning agents mild universal cleaner free from aromatic compounds (e.g. Motorex OPAL 5000) Table 9-36 Cleaning agents: Rack...
  • Page 203 OPERATING MANUAL CP 3-5 V2 Maintenance Install the rack as follows: Prerequisite:For combinations of three or more racks, always start at the middle Clean the reference surfaces and racks thoroughly and rub an sharpening stone across them Clamp rack to reference surfaces with screw clamps (Be sure to apply the screw clamp at the level of the screw to be tight- ened.)

  • Page 204: Fig. 9 -43 Check Rack Transition

    Maintenance OPERATING MANUAL CP 3-5 V2 Rack quality and module Ü 2 211 Check rack transi- tion Fig. 9-43 Check rack transition Rack transition Measurement bolt (diameter D = 2 × m ; accuracy: tolerance class 1 acc. to DIN 2269)

  • Page 205: Table 9-37 Permissible Deviation, Rack Transition

    OPERATING MANUAL CP 3-5 V2 Maintenance Rack quality Permissible deviation [mm] Module Module m ≤ 3 3 < m ≤ 8 Q4 h21 0.006 0.010 Q5 h22 0.008 0.012 Q6 h23 0.012 0.012 Q7 h25 0.016 0.016 Q8 h27 0.016 0.016...

  • Page 206: Fig. 9 -44 Replace The Bronze Wipers

    Maintenance OPERATING MANUAL CP 3-5 V2 9.3.11.9 Replace the bronze wipers In welding applications, bronze scrapers are used. The bronze wiper is located on the carriage near the rollers. It needs to be replaced as soon as it no longer properly cleans the guideway.

  • Page 207: Fig. 9 -45 Eccentric Marking: Countersink Separate

    OPERATING MANUAL CP 3-5 V2 Maintenance 9.3.12 Setting the tooth flank backlash NOTE Wear of components Incorrectly set rollers and tooth flank backlash increase the wear on the guideway, roller, rack and pinion. • Always set the rollers and the tooth flank backlash with load attached and...

  • Page 208: Fig. 9 -46 Eccentric Marking: Drill Hole

    Maintenance OPERATING MANUAL CP 3-5 V2 Fig. 9-46 Eccentric marking: Drill hole Drill hole Eccentric ring 9.3.12.2 Blocking, unblocking the eccentric ring The eccentric ring is blocked as follows: Fig. 9-47 Blocking the eccentric ring: Hexagonal screw Eccentric ring Hexagonal screw...

  • Page 209: Fig. 9 -48 Setting The Tooth Flank Backlash: Eccentric

    OPERATING MANUAL CP 3-5 V2 Maintenance 9.3.12.3 Eccentric Fig. 9-48 Setting the tooth flank backlash: Eccentric Fastening screw Eccentric ring Eccentric marking (if present) Pinion Rack Set the tooth flank backlash as follows: Switch off the system and secure it with a padlock against being switched on again Check the tooth flank backlash Ü 2 210...

  • Page 210: Fig. 9 -49 Blocking The Drive Pinions: Güdel Gearbox Unit

    Maintenance OPERATING MANUAL CP 3-5 V2 9.3.12.4 Check the tooth flank backlash Blocking the drive pinions Block the drive pinion to check the tooth flank backlash. Remove the block once you have completed the check. For this purpose, remove the fastening device and place the plug back onto the gearbox unit.

  • Page 211: Table 9-38 Rack Quality And Module

    OPERATING MANUAL CP 3-5 V2 Maintenance Rack quality and module The quality and module are found in the following table: Axis Rack quality Module Helix angle β [°] Hardened Soft rack rack 9h27 • Size 3: 3 19.5283 • Size 4: 3 •...

  • Page 212: Table 9-39 Tooth Flank Backlash: Güdel Gearbox Unit

    Maintenance OPERATING MANUAL CP 3-5 V2 Exact measuring method Rack quality and module Ü 2 211 Rack quality Tooth flank backlash [mm] Module Module Module m ≤ 3 3 < m ≤ 8 8 < m ≤ 12 Q4 h21 0.010 0.012 0.016...

  • Page 213: Fig. 9 -50 Checking The Tooth Flank Backlash: Dial Gauge (Exact Method)

    OPERATING MANUAL CP 3-5 V2 Maintenance Fig. 9-50 Checking the tooth flank backlash: Dial gauge (exact method) Rack Gearbox Guideway Drive pinion Axis Dial gauge Carriage Check the tooth flank backlash as follows: Prerequisite:The drive pinion is blocked Ü 2 210 Switch off the system and secure it with a padlock against being switched...

  • Page 214: Table 9-40 Tooth Flank Backlash: Paper Strip (Inaccurate Method)

    Maintenance OPERATING MANUAL CP 3-5 V2 Inexact measuring method Rack quality and module Ü 2 211 NOTE Damage resulting from inexact measuring method The inexact measurement method described here can lead to incorrect inter- pretations and subsequent damage of every kind! • Use it only when the exact method is not possible...

  • Page 215: Fig. 9 -51 Checking The Tooth Flank Backlash: Paper Strip (Inaccurate Method)

    OPERATING MANUAL CP 3-5 V2 Maintenance Fig. 9-51 Checking the tooth flank backlash: paper strip (inaccurate method) Drive pinion Paper strip Rack Check the tooth flank backlash as follows: Switch off the system and secure it with a padlock against being switched on again Insert a paper strip of 0.08 mm thickness and width b between the drive...
  • Page 216 Maintenance OPERATING MANUAL CP 3-5 V2...

  • Page 217: Maintenance Schedules

    OPERATING MANUAL CP 3-5 V2 Maintenance Maintenance schedules...
  • Page 218 Maintenance OPERATING MANUAL CP 3-5 V2...

  • Page 219: Fig. 9 -52 Maintenance Schedule Cp

    OPERATING MANUAL CP 3-5 V2 Maintenance 9.4.1 Maintenance schedule CP 22'500 22'500 6'750 6'750 2'250 2'250 ü ü û 2'250 2'250 22'500 22'500 Fig. 9-52 Maintenance schedule CP Grease Replacing Visual inspection Automatic lubrication Maintain in accordance with separate instructions...
  • Page 220 Maintenance OPERATING MANUAL CP 3-5 V2...

  • Page 221: Fig. 9 -53 Maintenance Schedule For Güdel Gearbox Unit

    OPERATING MANUAL CP 3-5 V2 Maintenance 9.4.2 Güdel gearbox unit maintenance schedule 22'500 22'500 2'250 2'250 Fig. 9-53 Maintenance schedule for Güdel gearbox unit Grease Replacing Replacing lubricant Clean Visual inspection...
  • Page 222 Maintenance OPERATING MANUAL CP 3-5 V2...

  • Page 223: Fig. 9 -54 Maintenance Schedule For Automatic Lubrication System

    OPERATING MANUAL CP 3-5 V2 Maintenance 9.4.3 Maintenance schedule for automatic lubrication system 22'500 22'500 11'250 11'250 2'250 2'250 ü û >30s ≤30s ü FlexxPump 402B Fig. 9-54 Maintenance schedule for automatic lubrication system Grease Replacing Replacing lubricant Clean Visual inspection...
  • Page 224 Maintenance OPERATING MANUAL CP 3-5 V2...

  • Page 225: Table 9-41 Maintenance Table

    OPERATING MANUAL CP 3-5 V2 Maintenance Maintenance table Maintenance work Maintenance cycle [h] Duration [min] Target readership Lubricants Further information Cleaning agents Service technicians Lubricating guideways, Mobil Mobilux EP 2 Maintenance technicians  Ü Chapter 9.3.7.1, 2 146 racks and pinions Güdel H1 NSF no.146621...
  • Page 226 Maintenance OPERATING MANUAL CP 3-5 V2 Maintenance work Maintenance cycle [h] Duration [min] Target readership Lubricants Further information Cleaning agents The manufacturer's technicians mild universal cleaner free from aro- Checking automatic lubrica- 11,250 matic compounds (e.g. Motorex  Ü Chapter 9.3.10.1, 2 158 Maintenance technicians...

  • Page 227: Intervention Protocol: Maintenance

    Sending only works if you have completed the operator details in the intervention report as specified in the Maintenance chapter. Save the generated XML file as a backup. Copy the empty inter- vention report and scan it in after completing it if you are not working electronically. Send it to service@ch.gudel.com after every intervention.
  • Page 228 Maintenance OPERATING MANUAL CP 3-5 V2...
  • Page 229 Sending only works if you have completed the operator details in the intervention report as specified in the Maintenance chapter. Save the generated XML file as a backup. Copy the empty inter- vention report and scan it in after completing it if you are not working electronically. Send it to service@ch.gudel.com after every intervention.
  • Page 230 Maintenance OPERATING MANUAL CP 3-5 V2...
  • Page 231 Sending only works if you have completed the operator details in the intervention report as specified in the Maintenance chapter. Save the generated XML file as a backup. Copy the empty inter- vention report and scan it in after completing it if you are not working electronically. Send it to service@ch.gudel.com after every intervention.
  • Page 232 Maintenance OPERATING MANUAL CP 3-5 V2...
  • Page 233 Sending only works if you have completed the operator details in the intervention report as specified in the Maintenance chapter. Save the generated XML file as a backup. Copy the empty inter- vention report and scan it in after completing it if you are not working electronically. Send it to service@ch.gudel.com after every intervention.
  • Page 234 Maintenance OPERATING MANUAL CP 3-5 V2...
  • Page 235 Sending only works if you have completed the operator details in the intervention report as specified in the Maintenance chapter. Save the generated XML file as a backup. Copy the empty inter- vention report and scan it in after completing it if you are not working electronically. Send it to service@ch.gudel.com after every intervention.
  • Page 236 Maintenance OPERATING MANUAL CP 3-5 V2...

  • Page 237: Fig. 9 -55 Identification Number Of The Instructions

    OPERATING MANUAL CP 3-5 V2 Maintenance Feedback on the instructions Your feedback helps us to keep improving these instructions. Thank you! mailto: docufeedback@ch.gudel.com Please provide the following information with your feedback: • Identification number of the instructions • Product, type •...

  • Page 238: Repairs

    Repairs OPERATING MANUAL CP 3-5 V2 Repairs 10.1 Introduction Work sequences Perform the work sequences in the order described. Perform the described tasks at the specified times. This ensures a long service life for your product. Only use original spare parts. Ü 2 277...

  • Page 239: Personnel Qualifications

    OPERATING MANUAL CP 3-5 V2 Repairs WARNING Falling axes, workpieces Falling axes or workpieces can cause physical damage, serious or fatal injuries! • Set down any workpieces before working in the danger area • Never enter the area below suspended axes and workpieces •...

  • Page 240: Fig. 10 -1 Attaching The Slings: Motor

    Repairs OPERATING MANUAL CP 3-5 V2 10.2.2 Replacing lubricant 10.2.2.1 Attaching the slings: Motor WARNING Suspended loads Improper handling of suspended loads can lead to severe injuries or death! • Use appropriate lifting units • Wear appropriate protective clothing • Always keep sufficient distance from suspended loads •...

  • Page 241: Fig. 10 -2 Attaching The Slings: Güdel Gearbox Unit

    OPERATING MANUAL CP 3-5 V2 Repairs 10.2.2.2 Attaching the slings: Güdel gearbox unit Use lifting units to transport gearbox units from size 090 upwards. WARNING Heavy components Components can be very heavy. Improper handling can cause severe or fatal injuries! •...

  • Page 242: Remove The Motor

    Repairs OPERATING MANUAL CP 3-5 V2 Attach the slings as follows: Insert lifting screws into threaded holes on desired side (Diagonal arrangement according to illustration) Attach the slings as shown in the illustration The slings are in place. 10.2.2.3 Remove the motor...

  • Page 243: Fig. 10 -3 Removing The Motor: Güdel Gearbox Unit

    OPERATING MANUAL CP 3-5 V2 Repairs Fig. 10-3 Removing the motor: Güdel gearbox unit Motor Gearbox unit Motor screw Forcing screw Elastomer gear rim Remove the motor as follows: Switch off the system and secure it with a padlock against being switched...

  • Page 244: Fig. 10 -4 Removing The Gearbox Unit

    Repairs OPERATING MANUAL CP 3-5 V2 10.2.2.4 Removing the gearbox unit Fig. 10-4 Removing the gearbox unit Adjacent construction Gearbox unit Gearbox screws Remove the gearbox unit as follows: Attach slings to the gearbox unit Ü 2 241 Remove the gearbox screws Remove the gearbox unit Remove the transport securing device or slings The gearbox unit has now been removed.
  • Page 245 OPERATING MANUAL CP 3-5 V2 Repairs 10.2.2.5 Replacing lubricant WARNING Hot gearbox oil Working on the gearbox carries the risk of severe injury due to burns! • Let the gearbox cool before commencing any work CAUTION Oil, greases Oils and greases are harmful to the environment! •...

  • Page 246: Fig. 10 -5 Replacing Lubricant: Güdel Gearbox Unit

    Repairs OPERATING MANUAL CP 3-5 V2 Fig. 10-5 Replacing lubricant: Güdel gearbox unit Bleed screw Filler screw Drain screw Lubrication ex Specification Lubrication quantity works Mobil Glygoyle 460 NSF CLP PG 460 in accor- AE/HPG030: 40cm3 no.136467 dance with DIN 51502...

  • Page 247: Fig. 10 -6 Installing The Gearbox Unit

    OPERATING MANUAL CP 3-5 V2 Repairs Replace the lubricant as follows: Position the gearbox: Drain screw at the bottom Filler and bleed screw at the top Position a suitable container below the drain screw Remove the bleed, filler, and drain screws...

  • Page 248: Fig. 10 -7 Installing The Motor: Güdel Gearbox Unit

    Repairs OPERATING MANUAL CP 3-5 V2 Size Thread size Tightening torque [Nm] Table 10-3 Tightening torques for gearbox screws: Güdel gearbox unit Install the gearbox unit as follows: Attach slings to the gearbox unit Ü 2 241 Install the gearbox unit Install and tighten the gearbox screws Remove the transport securing device or slings The gearbox unit has now been installed.

  • Page 249: Table 10-4 Lubricants: Gearbox Unit Güdel: Elastomer Gear Rim Of The Coupling

    OPERATING MANUAL CP 3-5 V2 Repairs Lubrication ex Specification Lubrication quantity works Technical Vaseline Cannot be determined Table 10-4 Lubricants: Gearbox unit Güdel: elastomer gear rim of the coupling Install the motor as follows: Switch off the system and secure it with a padlock against being switched...

  • Page 250: Fig. 10 -8 Replacing The Motor: Positioning The Coupling Half On The Motor Shaft

    Repairs OPERATING MANUAL CP 3-5 V2 The tightening torque TA and the type of coupling are engraved on the mo- tor and gearbox sides in the coupling. D2=24H7 02/17 Fig. 10-8 Replacing the motor: Positioning the coupling half on the motor shaft...

  • Page 251: Replacing The Motor Flange And Gearbox Flange

    OPERATING MANUAL CP 3-5 V2 Repairs Replace the motor as follows: Switch off the system and padlock it to prevent it from being switched on again Remove the cables and lines Remove motor Ü Chapter 10.2.2.3, 2 242 Remove the elastomer gear rim if necessary...

  • Page 252: Fig. 10 -9 Replacing The Motor Flange And Gearbox Flange

    Repairs OPERATING MANUAL CP 3-5 V2 Do not change the position of the coupling on the motor shaft! Fig. 10-9 Replacing the motor flange and gearbox flange Drill hole Motor flange Gearbox flange Screw Fastening screw...

  • Page 253: Table 10-6 Distinguishing Characteristics Of Wear: Pinion

    OPERATING MANUAL CP 3-5 V2 Repairs Replace the motor flange and gearbox flange as follows: Switch off the system and secure it with a padlock against being switched on again Remove the motor and coupling Ü 2 168 Remove the fastening screws, screws and motor flange...

  • Page 254: Fig. 10 -10 Replacing Pinion, Bearing, And Clamping Set: Güdel Gearbox Unit

    Repairs OPERATING MANUAL CP 3-5 V2 WARNING Loose components Vibrations can loosen connecting elements. Persons are surprised by unex- pected situations and seriously injured as a result. Observe the following points: • Secure the connection elements by appropriate means • Check the tightening torques regularly The O-ring will be destroyed if you remove the centering flange.
  • Page 255 OPERATING MANUAL CP 3-5 V2 Repairs Replace the pinion, bearing, and clamping set as follows: Switch off the system and padlock it to secure it against being switched on again Remove the drive if necessary Remove the spacing strips Remove the headless set screws...

  • Page 256: Fig. 10 -11 Setting The Gear Backlash: Güdel Gearbox Unit

    Repairs OPERATING MANUAL CP 3-5 V2 10.2.6 Setting the gear backlash The gear backlash is set ex works. Reset the gear backlash to ensure reliable function. NOTE Incorrect assembly of the casing cover The gearbox oil runs out. The worm shaft engages incorrectly with the worm gear.
  • Page 257 OPERATING MANUAL CP 3-5 V2 Repairs Set the gear backlash as follows: Switch off the system and padlock it to secure it against being switched on again Disassemble the drive Remove all screws on both sides Rotate both covers toward the next higher, cast-in number Tighten four screws on each of the two sides Checking the gear backlash: Rotate the worm shaft 360°...

  • Page 258: Fig. 10 -12 Elastomer Gear Rim

    Repairs OPERATING MANUAL CP 3-5 V2 10.2.7 Replacing the elastomer gear rim The elastomer gear rim is designed for a service life of 3 years or 22,500 op- erating hours. The wear depends on the duration of operation of the product and the ambient conditions.

  • Page 259: Tasks To Perform After A Crash

    OPERATING MANUAL CP 3-5 V2 Repairs 10.3 Tasks to perform after a crash WARNING Falling axes/workpieces A crash leads to the breakage of components and mounting elements. After a crash, it is not immediately apparent whether components have been weak- ened or are defective.

  • Page 260: Fig. 10 -13 Bumper Unit With Shearing Sleeves

    Repairs OPERATING MANUAL CP 3-5 V2 10.3.1.1 Bumper unit with shearing sleeves Fig. 10-13 Bumper unit with shearing sleeves Bumper block / bumper bracket Bumper Screw Mating part Loctite Blue Threadlocker 7414 Shearing sleeve Assemble the bumper unit with shearing sleeves as follows:...

  • Page 261: Fig. 10 -14 Bumper Unit With Pins

    OPERATING MANUAL CP 3-5 V2 Repairs 10.3.1.2 Bumper unit with pins Fig. 10-14 Bumper unit with pins Loctite Blue Threadlocker 7414 Bumper Screw Bumper block / bumper bracket Mating part Assemble the bumper unit with pins as follows: Assemble the bumper on the bumper block / bumper bracket...

  • Page 262: Fig. 10 -15 Bumper Unit With Mechanical Limit Stops

    Repairs OPERATING MANUAL CP 3-5 V2 10.3.1.3 Bumper unit with limit stops Fig. 10-15 Bumper unit with mechanical limit stops "Loctite 7414, blue" threadlocker Bumper block / bumper bracket Screw Mating part Bumpers Install the bumper unit as follows: Install the bumper on the bumper block / bracket...

  • Page 263: Table 10-11 Malfunctions / Troubleshooting

    OPERATING MANUAL CP 3-5 V2 Repairs 10.4 Malfunctions / Troubleshooting Malfunction Cause Measure Noise • The tooth flank • Check tooth flank back- backlash may be lash and adjust if neces- sary Ü 2 210 incorrectly set • Insufficient lubri- • Ensure adequate lubrica-...
  • Page 264 Repairs OPERATING MANUAL CP 3-5 V2...

  • Page 265: Intervention Report: Repairs

    Sending only works if you have completed the operator details in the intervention report as specified in the Maintenance chapter. Save the generated XML file as a backup. Copy the empty inter- vention report and scan it in after completing it if you are not working electronically. Send it to service@ch.gudel.com after every intervention.
  • Page 266 Repairs OPERATING MANUAL CP 3-5 V2...

  • Page 267: Documentation

    OPERATING MANUAL CP 3-5 V2 Repairs 10.6 Other documentation For information on the available options, read the corresponding documenta- tion in the appendix. 10.7 Service departments If you have questions, please contact the service departments. Ü 2 279...

  • Page 268: Decommissioning, Storage

    Decommissioning, storage OPERATING MANUAL CP 3-5 V2 Decommissioning, storage 11.1 Introduction Only perform the tasks described in this chapter after you have read and un- derstood the chapter "Safety". Ü 2 21 It concerns your personal safety! 11.1.1 Personnel qualifications Only appropriately trained and authorized technicians are allowed to work on the product.

  • Page 269: Decommissioning

    OPERATING MANUAL CP 3-5 V2 Decommissioning, storage 11.3 Decommissioning 11.3.1 Shutdown WARNING Falling axes, workpieces Falling axes or workpieces can cause physical damage, serious or fatal injuries! • Set down any workpieces before working in the danger area • Never enter the area below suspended axes and workpieces •...

  • Page 270: Identification

    Decommissioning, storage OPERATING MANUAL CP 3-5 V2 11.3.4 Identification Label the product with the following data: • Date of decommissioning • Internal machine number/name • Additional data as per internal guidelines 11.4 Recommissioning For recommissioning, follow the steps described for commissioning.
  • Page 271 OPERATING MANUAL CP 3-5 V2 Decommissioning, storage • Check hydraulic lines for air pockets and kinks ü û If the machine downtime is longer than four weeks, carry out the following jobs: • Prelubricate guideways and racks • Check the lubrication system as described in the separate documentation...
  • Page 272 Decommissioning, storage OPERATING MANUAL CP 3-5 V2...

  • Page 273: Disposal

    OPERATING MANUAL CP 3-5 V2 Disposal Disposal 12.1 Introduction Observe the following during disposal: • Adhere to the country-specific regulations • Separate the material groups • Dispose of the materials in an environmentally friendly way • Recycle waste if possible 12.1.1...

  • Page 274: Personnel Qualifications

    Disposal OPERATING MANUAL CP 3-5 V2 WARNING Heavy components Components can be very heavy. Improper handling can cause severe or fatal injuries! • Use appropriate lifting equipment • Use suitable means to secure the parts against tipping over or falling down •...

  • Page 275: Waste Management Compliant

    OPERATING MANUAL CP 3-5 V2 Disposal 12.3 Waste management compliant assemblies 12.3.1 Disassembly WARNING Suspended loads Improper handling of suspended loads can lead to severe injuries or death! • Use appropriate lifting units • Wear appropriate protective clothing • Always keep sufficient distance from suspended loads •...

  • Page 276: Material Groups

    Disposal OPERATING MANUAL CP 3-5 V2 Disassemble the product as follows: Prerequisite:Prior to disassembly, shut down the product Ü 2 269 Remove connecting elements (cables / energy chains) Disassemble moving axes Remove the gearbox and drain the oil Disassemble the carriage Dismount fixed assemblies (axes / supports) Take the assemblies apart and separate the different materials The product has been disassembled.

  • Page 277: Spare Parts Supply

    OPERATING MANUAL CP 3-5 V2 Spare parts supply Spare parts supply...
  • Page 278 Spare parts supply OPERATING MANUAL CP 3-5 V2...

  • Page 279: Service Departments

    OPERATING MANUAL CP 3-5 V2 Spare parts supply 13.1 Service departments Have the following information available for service inquiries: • Product, type (as per type plate) • Project number, order number (as per type plate) • Serial number (as per type plate) •...

  • Page 280: Table 13-1 Service Departments Americas

    Spare parts supply OPERATING MANUAL CP 3-5 V2 Country Relevant service department Phone E-mail Canada Güdel Inc. +1 734 214 0000 service@us.gudel.com 4881 Runway Blvd. United States Ann Arbor, Michigan 48108 United States Table 13-1 Service departments Americas Asia Country Relevant service department Phone...

  • Page 281: Table 13-2 Service Departments In Asia

    OPERATING MANUAL CP 3-5 V2 Spare parts supply Country Relevant service department Phone E-mail Thailand Güdel Lineartec Co. Ltd. +66 2 374 0709 service@th.gudel.com 19/28 Private Ville Hua Mak Road Hua Mak Bang Kapi 10240 Bangkok Thailand Table 13-2 Service departments in Asia Europe...
  • Page 282 Spare parts supply OPERATING MANUAL CP 3-5 V2 Country Relevant service department Phone E-mail Portugal Güdel Spain +34 93 476 03 80 info@es.gudel.com C/Industria 60 Spain Local 7 08025 Barcelona Spain France Güdel SAS +33 1 6989 80 16 info@fr.gudel.com Tour de l'Europe 213 3 Bd de l'Europe...

  • Page 283: Table 13-3 Service Departments In Europe

    OPERATING MANUAL CP 3-5 V2 Spare parts supply Country Relevant service department Phone E-mail Russia Gudel Russia +7 848 273 5544 info@ru.gudel.com Yubileynaya 40 Belarus Office 1902 445057 Togliatti Russia Ireland Güdel Lineartec (U.K.) Ltd. +44 24 7669 5444 service@uk.gudel.com Unit 5 Wickmans Drive, Banner Lane...
  • Page 284 Spare parts supply OPERATING MANUAL CP 3-5 V2...

  • Page 285: Explanations Regarding The Spare Parts List

    OPERATING MANUAL CP 3-5 V2 Spare parts supply 13.2 Explanations regarding the spare parts list 13.2.1 Parts list The parts list contains all parts of your product. The spare parts and wear items are indicated as described in the explanation of symbols.

  • Page 286: Torque Tables

    Torque tables OPERATING MANUAL CP 3-5 V2 Torque tables 14.1 Tightening torques for screws NOTE Vibrations Screws without screw lock can come loose. • Secure screw connections on moving parts with Loctite medium strength 243. • Apply the adhesive on the nut thread, not on the screw!

  • Page 287: Zinc Plated Screws

    OPERATING MANUAL CP 3-5 V2 Torque tables 14.1.1 Zinc plated screws Unless otherwise specified, the following tightening torques apply for zinc- plated screws lubricated with Molykote (MoS2) grease or secured with Loc- tite 243: Thread size Tightening torque [Nm] 10.9 12.9...

  • Page 288: Black Screws

    Torque tables OPERATING MANUAL CP 3-5 V2 14.1.2 Black screws Unless otherwise specified, the following tightening torques apply for black oiled and non-lubricated screws, or screws secured with Loctite 243: Thread size Tightening torque [Nm] 10.9 12.9 10.1 14.9 17.4 24.6...

  • Page 289: Stainless Steel Screws

    OPERATING MANUAL CP 3-5 V2 Torque tables 14.1.3 Stainless steel screws Unless otherwise specified, the following tightening torques apply for stainless steel screws lubricated with Molykote (MoS2) grease or secured with Loctite 243: Thread size Tightening torque [Nm] 0.37 0.86 1.85...

  • Page 290: Tightening Torques For Roller Holders

    Torque tables OPERATING MANUAL CP 3-5 V2 14.2 Tightening torques for roller holders Fig. 14-1 Tightening torques for roller holders Move roller with hexagonal socket Screw wrench (tightening torque A1) Adjusting tool Tighten screw with hexagonal socket wrench (tightening torque A2)

  • Page 291: Thread Rolling Screws

    OPERATING MANUAL CP 3-5 V2 Torque tables 14.3 Thread rolling screws Thread rolling screws are mainly used for guideways, mounting plates, and ca- ble tray brackets. Nicht Gewindeschneiden No tapping A max 30Nm 60Nm 100Nm Gewindefurchende Schrauben Thread grooving screw Fig. 14-2...

  • Page 292: Hv Sets

    Torque tables OPERATING MANUAL CP 3-5 V2 14.4 HV sets HV sets are high-strength, pre-stressable screw sets. An HV set consists of: • HV screw 10.9 • HV nut 10 • HV washer 295-350 HV WARNING Falling axles, workpieces HV sets that are incorrect, incorrectly mounted or have been lubricated on- site by the customer can cause axles to drop.

  • Page 293: Fig. 14 -3 Hv Set

    OPERATING MANUAL CP 3-5 V2 Torque tables ü ü ü PEINER PEINER Fig. 14-3 HV set Stamp HV washer HV nut HV screw...

  • Page 294: Table 14-6 Hv Set: Initial Torques And Tightening Torques

    Torque tables OPERATING MANUAL CP 3-5 V2 Thread size Initial torque [Nm] Tightening torque [Nm] 1250 1250 1650 2100 2800 Table 14-6 HV set: Initial torques and tightening torques...
  • Page 295 OPERATING MANUAL CP 3-5 V2 Torque tables Tighten the HV sets professionally as follows: Prerequisite:The HV set is new Prerequisite:The HV set shows no corrosion or storage damages Prerequisite:The HV set has not been lubricated by the installer Check HV screw, HV nut and HV washer for identical manufacturer...

  • Page 296: Tightening Torques For Clamping Sets

    Torque tables OPERATING MANUAL CP 3-5 V2 14.5 Tightening torques for clamping sets Normally, the tightening torque will be stamped onto the clamping set by the manufacturer. If you have conflicting values, always use the manufacturer's in- formation. The following tightening torques are applicable for clamping sets on Güdel...

  • Page 297: List Of Illustrations

    OPERATING MANUAL CP 3-5 V2 List of illustrations List of illustrations Fig. 3 -1 Danger label "danger sign" ............28 Fig. 3 -2 Danger label "Tearing due to rack" ..........29 Fig. 4 -1 Type plate ..................36 Fig. 4 -2 Position of the type plate .............
  • Page 298 List of illustrations OPERATING MANUAL CP 3-5 V2 Fig. 7 -20 Attaching the slings: Z-axis, sizes 2-5 ........89 Fig. 7 -21 Danger label "Provisionally assembled bumper unit" ..... 92 Fig. 7 -22 Bumper unit with mechanical limit stops ........93 Fig.
  • Page 299 OPERATING MANUAL CP 3-5 V2 List of illustrations Fig. 9 -11 Carrying out a lubrication check ..........152 Fig. 9 -12 Replacing the lubricating pinion ..........153 Fig. 9 -13 Replacing the wiper and lubrication unit ........155 Fig. 9 -14 Replacing the wiper and lubricating element ......
  • Page 300 List of illustrations OPERATING MANUAL CP 3-5 V2 Fig. 9 -44 Replace the bronze wipers ............206 Fig. 9 -45 Eccentric marking: Countersink separate ......... 207 Fig. 9 -46 Eccentric marking: Drill hole ............208 Fig. 9 -47 Blocking the eccentric ring: Hexagonal screw ......208 Fig.
  • Page 301 OPERATING MANUAL CP 3-5 V2 List of illustrations Fig. 14 -4 Tightening the clamping set ............296 Fig. 14 -5 Releasing the clamping set ............296...
  • Page 302 List of illustrations OPERATING MANUAL CP 3-5 V2...
  • Page 303 OPERATING MANUAL CP 3-5 V2 List of tables List of tables Table -1 Revision history................Table 2-1 Explanation of symbols/abbreviations ......... 20 Table 4-1 Temperature ranges................ 38 Table 6-1 Guard plates material numbers ............ 47 Table 6-2 Guard plates material numbers ............ 49 Table 6-3 Z-axis slings: Sizes................
  • Page 304 List of tables OPERATING MANUAL CP 3-5 V2 Table 9-5 Lubricants: Automatic lubrication system FlexxPump .... 136 Table 9-6 Lubricants: Automatic lubrication system FlexxPump: Pre- lubricate guideways and racks............137 Table 9-7 Lubricants: SKF-Vogel automatic lubrication system ....137 Table 9-8 Lubricant table..................
  • Page 305 OPERATING MANUAL CP 3-5 V2 List of tables Table 9-36 Cleaning agents: Rack ..............201 Table 9-37 Permissible deviation, rack transition ......... 205 Table 9-38 Rack quality and module ..............211 Table 9-39 Tooth flank backlash: Güdel gearbox unit ......... 212 Table 9-40 Tooth flank backlash: paper strip (inaccurate method)..
  • Page 306 List of tables OPERATING MANUAL CP 3-5 V2...
  • Page 307 OPERATING MANUAL CP 3-5 V2 Index Index Adhesive anchor ......75 Base ..........57 Air humidity ......38, 268 Base mounting ........ 74 Aligning Base plates Beam ........70, 71 anchoring ........62 Beam: Horizontal ...... 73 Positioning ........61 Gearbox flange ....
  • Page 308 Index OPERATING MANUAL CP 3-5 V2 Replacing: Güdel gearbox unit ..Cable Coupling screw Relieving strain ......114 Tighten ........124 Cartridge Crash Replacing ........152 Behavior afterward ....259 C-axis ..........116 Customer feedback ....237 Changing Lubricating position ....105 Check Decommissioning ......
  • Page 309 OPERATING MANUAL CP 3-5 V2 Index Gear backlash Roller holder installation type ..Setting: Güdel gearbox unit .. 256 Gearbox Replacing: Güdel gearbox unit ..Roller holder installation type ..165, 170 Gearbox flange Aligning ......95, 173 Roller holder installation type ..
  • Page 310 Index OPERATING MANUAL CP 3-5 V2 Identification ........270 Leveling Identification of lubrication points ... Upright ........65 ............. 136 Leveling of the guide chute Initial assembly ...... 94, 172 Checking ........106 Initial lubrication ......124 Liability ..........25 Input shaft Lifting units ........
  • Page 311 OPERATING MANUAL CP 3-5 V2 Index Occupational safety ...... 25 Maintenance jobs After 100 hours ...... 144 Replacing ........240 Maintenance tasks ......131 After 11,250 hours ....158 Operation ......21, 129 After 150 hours ...... 146 Options ..........38 After 2,250 hours ....
  • Page 312 Index OPERATING MANUAL CP 3-5 V2 Sensor ........205 Slide bars ........164 Rack Storage: Güdel gearbox unit 170 Cleaning ........124 Switch ........205 disassembly ......201 Wiper ........156 Lubricating ........ 146 Wiper and lubrication unit .. 154 Mounting ......
  • Page 313 OPERATING MANUAL CP 3-5 V2 Index Spare parts list ......285 Safety brake system ....116 Special tools ......59, 141 Safety data sheet ......33 State of the art ........ 21 Sensor Storage ..........268 Replacing ........205 Storage conditions ...... 268 Service departments ....
  • Page 314 Index OPERATING MANUAL CP 3-5 V2 Technical data ........ 37 Unpacking ........58 Telescopic axis ......116 Upright Aligning ........71 Temperature ........ 268 Correcting height ...... 66 Temperature range ......38 Leveling ........65 Measuring height ...... 65 Testing instruments ....59, 141 Securing ........
  • Page 315 OPERATING MANUAL CP 3-5 V2 Appendix Appendix The appendix of this operating manual contains the following documents: • Hazard analysis, Risk analysis • Addition to declaration of incorporation • Technical data • Layout • Spare parts lists • Options • Third-party documentation...
  • Page 316 Appendix OPERATING MANUAL CP 3-5 V2...
  • Page 317 OPERATING MANUAL CP 3-5 V2 Appendix Hazard analysis, Risk analysis...
  • Page 318 Appendix OPERATING MANUAL CP 3-5 V2...
  • Page 319 Customer: Risk assessment / safety goals / protective measures / residual risks Machine type: CP with/without control system Hazard analysis / Risk analysis Project no.: Solution suggested to the customer (cursive, Times New Roman) Document no.: Güdel solution (Arial) Special operating modes Application area Event Safety goal...
  • Page 320 Customer: Risk assessment / safety goals / protective measures / residual risks Machine type: CP with/without control system Hazard analysis / Risk analysis Project no.: Solution suggested to the customer (cursive, Times New Roman) Document no.: Güdel solution (Arial) 1.14 x x x x x x x x Risk of injury (cutting,...
  • Page 321 Customer: Risk assessment / safety goals / protective measures / residual risks Machine type: CP with/without control system Hazard analysis / Risk analysis Project no.: Solution suggested to the customer (cursive, Times New Roman) Document no.: Güdel solution (Arial) Protective measures (comments): The suggested solutions printed in italics are binding suggestions for achieving CE conformity.
  • Page 322 OPERATING MANUAL CP 3-5 V2 Appendix Addition to declaration of incorporation...
  • Page 323 Appendix OPERATING MANUAL CP 3-5 V2...
  • Page 324 CH-4900 Langenthal phone + 41 62 916 91 91 + 41 62 916 91 50 service@ch.gudel.com www.gudel.com Appendix to the conformity assessment List for the Declaration of Incorporation of the observed basic requirements acc. to Appendix I, EC Machinery Directive 2006/42/EC...
  • Page 325 Güdel AG Industrie Nord CH-4900 Langenthal phone + 41 62 916 91 91 + 41 62 916 91 50 service@ch.gudel.com www.gudel.com 1.6. Service 1.6.1. Maintenance of the machine 1.6.2. Access to the operation stations and intervention points for service 1.6.3.
  • Page 326 OPERATING MANUAL CP 3-5 V2 Appendix Technical data...
  • Page 327 Appendix OPERATING MANUAL CP 3-5 V2...
  • Page 328 OPERATING MANUAL CP 3-5 V2 Appendix Layout...
  • Page 329 Appendix OPERATING MANUAL CP 3-5 V2...
  • Page 330 OPERATING MANUAL CP 3-5 V2 Appendix Spare parts lists...
  • Page 331 Appendix OPERATING MANUAL CP 3-5 V2...
  • Page 332 OPERATING MANUAL CP 3-5 V2 Appendix Options...
  • Page 333 Appendix OPERATING MANUAL CP 3-5 V2...
  • Page 334 OPERATING MANUAL CP 3-5 V2 Appendix Third-party documentation...
  • Page 335 Appendix OPERATING MANUAL CP 3-5 V2...
  • Page 337 igus ® e-kettensysteme ® – Montagehandbuch für gleitende Anwendungen igus ® e-chainsystems ® – installation guide for gliding applications Systèmes de chaînes porte-câbles igus ® – Notice d‘installation pour applications glissantes Sistema de cadenas portacables igus ® – guía de instalación para aplicaciones deslizantes e-kette e-chain...
  • Page 338 igus ® e-kettensysteme ® – Montagehandbuch für gleitende Anwendungen igus ® e-chainsystems ® – installation guide for gliding applications Systèmes de chaînes porte-câbles igus ® – Notice d‘installation pour applications glissantes Sistema de cadenas portacables igus ® – guía de instalación para aplicaciones deslizantes Fixpunkt Endposition II...
  • Page 339 Einbauraum prüfen igus ® Systemzeichungen nutzen Check installation space Use igus ® system drawings ® Vérifier l‘espace de montage Utiliser les plans igus ® Chequear el espacio de instalación Utilizar los diseños de sistema igus Einbauraum für e-kettensysteme Montage nach igus ®...
  • Page 340 Tragwerk für die Führungsrinne Support structure for guiding trough Structure d‘appui de la goulotte Estructura de soporte para guía carrilera Tragwerk muss ausgerichtet und im Lot sein ● C-Profil Support structure must be aligned and levelled ● C-profile La structure d‘appui doit être alignée et plane z = 2000 ±...
  • Page 341 Montage der Führungsrinne Guide trough installation Installation de la goulotte de guidage lación de la guía carrilera Bereiten Sie einen Abstandhalter vor, um die Innenbreite der Rinne anzupassen. ● Prepare a spacer bar, to adjust the inner trough width. ● Préparez un étrier d‘écartement pour régler la largeur de la goulotte de guidage.
  • Page 342 e-ketten ® Montage e-chain ® pre-assembly Pré-assemblage de la chaîne porte-câbles Pre-montaje de la Cadena Portacables Überprüfen Sie die Artikelnummer auf der E-Kette bevor Sie sie montieren. ● Mitnehmer-Ende Zum Beispiel: Serie E4.56 Moving end Check part no. on e-chain ®...
  • Page 343 e-ketten ® Montage e-chain ® pre-assembly Pré-assemblage de la chaîne porte-câbles Pre-montaje de la Cadena Portacables Überprüfen Sie, ob die Position des Festpunktes den igus Zeichnungen entspricht, ● ® relativ zum Verfahrweg Ensure the fixed end position is according to the igus drawings, relative to the travel ®...
  • Page 344 Einlegen der Leitungen Cable assembly Mise en place des câbles Montaje del cable Incorrect! Falsch! Incorrect ! Incorreto! Leitungsverteilung gemäß igus ® Innenaufteilungszeichnungen Mögliche Fehler: ● Cable arrangement should be to igus ® interior separation drawing u Leitungen mit Drall eingebaut ●...
  • Page 345 Befestigung der e-kette ® Mitnehmer ins Lot bringen Attach e-chain ® Level moving end Fixation de la chaîne porte-câbles Mise à niveau du point mobile Fijar la Cadena Portacables Nivel del terminal móvil Lassen Sie eine Leitungsreserve von min 0,5 m am Festpunkt und am Montage des Mitnehmers gemäß...
  • Page 346 Mitnehmer montieren Passen Sie die Leitungen an Attach moving end Adjust cables Fixation du point mobile Ajustement des câbles Fijar el punto móvil Ajustar los cables Bewege den Kettenradius zum Mitnehmerarm und befestige es mit innensechskant Korrigieren Sie die Leitungen ●...
  • Page 347 Montieren Sie die Zugentlastung Überprüfen Sie die Installation Install strain relief Check installation before first movement Installation des serre-câbles Vérifiez l‘installation avant le premier mouvement Instalar los aliviadores de tensión Chequear la instalación antes del primer movimiento Montieren Sie die Zugentlastungsklemmen am Mitnehmer und Festpunkt. Alle Schrauben angebracht und mit Höhe des Mitnehmers und die Fixierung ●...
  • Page 348 ...de igus GmbH ® Spicher Straße 1a ...eu 51147 Köln igus ® GmbH Spicher Str. 1a ...fr 51147 Cologne igus SARL ® 49, avenue des Pépinières Parc Médicis ...es F-94260 Fresnes igus S.L. ® Ctra. Llobatona, 6 Poligono Noi del Sucre 08840 Viladecans Barcelona...
  • Page 349 OPERATING MANUAL CP 3-5 V2 Version chrgal Author Date 17.06.2019 GÜDEL AG Industrie Nord CH-4900 Langenthal Switzerland Phone +41 62 916 91 91 +41 62 916 91 50 E-mail info@ch.gudel.com www.gudel.com...
  • Page 350 GÜDEL AG Industrie Nord CH-4900 Langenthal Switzerland Phone +41 62 916 91 91 info@ch.gudel.com www.gudel.com...

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