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GUDEL ZP 3-5 V4 Operating Manual

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OPERATING MANUAL
ZP 3-5 V4
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
B1M.10xxxxxxx-xxxx
10xxxxxxx
99xxxxxxx
2018
72057594174110
BETRIEBSANLE

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Summary of Contents for GUDEL ZP 3-5 V4

  • Page 1 OPERATING MANUAL BETRIEBSANLE 72057594174110 ZP 3-5 V4 Project / Order: B1M.10xxxxxxx-xxxx Bill of materials: 10xxxxxxx Serial number: 99xxxxxxx Year of manufacture: 2018...
  • 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 10-11 Malfunctions / Troubleshooting

    OPERATING MANUAL ZP 3-5 V4 Revision history Revision history Version Date Description 02.05.2018 Valid as of product version ZP-3 V4.11; ZP-4 V4.21; ZP-5 V4.01 • Maintenance tasks after downtimes <4 weeks Ü Chapter 9.3.4, 2 156 • Maintenance tasks after downtimes >4 weeks Ü Chapter 9.3.5, 2 156 Modified: • Maintenance schedules Ü Chapter 9.4, 2 224...

  • Page 4: Table -1 Revision History

    Revision history OPERATING MANUAL ZP 3-5 V4 Version Date Description 29.11.2016 Updated: • New signatures on declaration of incor- poration Ü Chapter 1, 2 17 • Entire manual updated 21.04.2016 Basic version Table -1 Revision history...
  • Page 5 OPERATING MANUAL ZP 3-5 V4 Table of contents Table of contents Declaration of incorporation General  19 Further applicable documentation  ....... . .
  • Page 6 Table of contents OPERATING MANUAL ZP 3-5 V4 Fundamentals of safety ..........
  • Page 7 OPERATING MANUAL ZP 3-5 V4 Table of contents Commissioning  47 Introduction  ............
  • Page 8 Table of contents OPERATING MANUAL ZP 3-5 V4 7.4.6 Anchoring the product  ..........
  • Page 9 OPERATING MANUAL ZP 3-5 V4 Table of contents Connection  ............
  • Page 10 Table of contents OPERATING MANUAL ZP 3-5 V4 9.2.2 Lubricants  ............
  • Page 11 OPERATING MANUAL ZP 3-5 V4 Table of contents 9.3.11.3 Replacing the slide bars  ..........

  • Page 12: Intervention Report

    Table of contents OPERATING MANUAL ZP 3-5 V4 9.3.12.4 Check the tooth flank backlash  ........

  • Page 13: Table Of Contents

    OPERATING MANUAL ZP 3-5 V4 Table of contents 10.2.6 Setting the gear backlash ..........
  • Page 14 Table of contents OPERATING MANUAL ZP 3-5 V4 12.3 Waste management compliant assemblies  ..... . . 283 12.3.1 Disassembly  ............
  • Page 15 OPERATING MANUAL ZP 3-5 V4 Table of contents Appendix Hazard analysis, Risk analysis   Addition to declaration of incorporation   Technical data   Layout   Spare parts lists   Options   Third-party documentation  ...
  • Page 16 Table of contents OPERATING MANUAL ZP 3-5 V4...
  • Page 17 OPERATING MANUAL ZP 3-5 V4 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: ZP 3-5 V4 Product, type 99xxxxxxx Serial number 10xxxxxxx Parts list...
  • Page 18 Declaration of conformity, declaration of incorporation OPERATING MANUAL ZP 3-5 V4...
  • Page 19 OPERATING MANUAL ZP 3-5 V4 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 ZP 3-5 V4 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 OPERATING MANUAL ZP 3-5 V4 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 Safety OPERATING MANUAL ZP 3-5 V4 3.1.2 Personnel qualifications WARNING Lack of safety training Incorrect behavior of untrained or insufficiently trained technicians can result in severe or fatal injuries! Before technicians work on safety-related aspects of the product: • Ensure that the technicians are trained with regard to safety •...
  • Page 23 OPERATING MANUAL ZP 3-5 V4 Safety 3.1.2.1 Operating companies The operating company is responsible for ensuring that: • the product is used as intended • the product is sufficiently lubricated at all times • all safety aspects are complied with •...
  • Page 24 Safety OPERATING MANUAL ZP 3-5 V4 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 25 OPERATING MANUAL ZP 3-5 V4 Safety 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 26 Safety OPERATING MANUAL ZP 3-5 V4 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 27 OPERATING MANUAL ZP 3-5 V4 Safety 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 28 Safety OPERATING MANUAL ZP 3-5 V4 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 29: Fig. 3 -1 Danger Label "Danger Sign

    OPERATING MANUAL ZP 3-5 V4 Safety 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 30: Fig. 3 -2 Danger Label "Transport Information

    Safety OPERATING MANUAL ZP 3-5 V4 3.3.2 Danger label "Transport information" Fig. 3-2 Danger label "Transport information" The danger label "Transport information" • provides information on correctly attaching slings Fundamentals of safety 3.4.1 Separating protective equipment, monitoring equipment WARNING Missing separating protective equipment and monitoring equip-...
  • Page 31 OPERATING MANUAL ZP 3-5 V4 Safety 3.4.2 Product-specific hazards DANGER Hazardous voltage The product contains components that are energized with hazardous volt- ages. Touching these components will cause an electric shock. Electric shocks can be fatal! Before working in the danger area: •...
  • Page 32 Safety OPERATING MANUAL ZP 3-5 V4 WARNING Hot oil squirting out Overpressure in the gearbox is created by overload or incorrect perfor- mance parameters. Hot oil can squirt out. This can lead to severe burns or eye injuries! • Operate the gearbox within the performance parameters as defined in the catalog •...
  • Page 33 OPERATING MANUAL ZP 3-5 V4 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 34: Fig. 4 -1 Type Plate

    Product description OPERATING MANUAL ZP 3-5 V4 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 35: Fig. 4 -2 Position Of The Type Plate

    OPERATING MANUAL ZP 3-5 V4 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 36: Table 4-1 Temperature Ranges

    Product description OPERATING MANUAL ZP 3-5 V4 The following ambient temperatures and air humidities apply: Temperature 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 37: Fig. 5 -1 Design

    OPERATING MANUAL ZP 3-5 V4 Design, function Design, function Design The product consists of the following assemblies: Fig. 5-1 Design Manual lifting and safety unit (option) Rotary axis (option) Safety brake system (option) Y-carriage Energy chain Y-drive Automatic lubrication system (option)

  • Page 38: Fig. 5 -2 Axis Names

    Design, function OPERATING MANUAL ZP 3-5 V4 Function The product can move along the following axes: Fig. 5-2 Axis names Rotary axis (option)
  • Page 39 OPERATING MANUAL ZP 3-5 V4 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 40: Fig. 6 -1 Attaching Slings

    Transport OPERATING MANUAL ZP 3-5 V4 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...

  • Page 41: Fig. 6 -2 Packaging Symbols

    OPERATING MANUAL ZP 3-5 V4 Transport Depending on the contents, the packaging units are marked with the symbols shown below. Observe these at all times. HANDLE WITH CARE FRAGILE CRAINT L'HUMIDITE Fig. 6-2 Packaging symbols Fragile Keep dry This side up...

  • Page 42: Fig. 6 -3 Attaching The Slings: Güdel Uprights

    Transport OPERATING MANUAL ZP 3-5 V4 6.3.1 Attaching the slings: Güdel uprights WARNING Ripping of lifting belts The sharp edges cut the lifting belts. This can lead to severe or fatal injuries! • Always protect the lifting belts with an edge guard Fig. 6-3...
  • Page 43 OPERATING MANUAL ZP 3-5 V4 Transport Attach the slings as follows: Prepare the floor leveling screws according to the illustration If no bottom plate is available: Remove the floor leveling screw Remove the locknut Install the floor leveling screw Mount the locknut in place of the bottom plate on the floor level-...

  • Page 44: Fig. 6 -4 Attaching The Slings: Beam

    Transport OPERATING MANUAL ZP 3-5 V4 6.3.2 Attaching the slings: Beam Fig. 6-4 Attaching the slings: Beam Transport yoke Transport aid Hook Screw Lifting belts Attach the slings as follows: Fasten the transport aids by means of screws (Symmetric arrangement according to the figure)

  • Page 45: Fig. 6 -5 Attaching The Slings: Z-Axis, Sizes 2-5

    OPERATING MANUAL ZP 3-5 V4 Transport 6.3.3 Attaching the slings: Z-axis, sizes 2-5 Fig. 6-5 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 6-1...
  • Page 46 Transport OPERATING MANUAL ZP 3-5 V4...
  • Page 47 OPERATING MANUAL ZP 3-5 V4 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 48 Commissioning OPERATING MANUAL ZP 3-5 V4 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 49 OPERATING MANUAL ZP 3-5 V4 Commissioning Downtimes In some cases, the commissioning of the product may take a significant period of time. If the machine downtime is longer than two weeks, carry out the following jobs: • Check the lubricating film on guideways and racks ü...
  • Page 50 Commissioning OPERATING MANUAL ZP 3-5 V4 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 51 OPERATING MANUAL ZP 3-5 V4 Commissioning 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 52: Fig. 7 -1 Attaching The Slings: Beam

    Commissioning OPERATING MANUAL ZP 3-5 V4 7.4.4 Attaching the slings: Beam Fig. 7-1 Attaching the slings: Beam Transport yoke Transport aid Hook Screw Lifting belts Attach the slings as follows: Fasten the transport aids by means of screws (Symmetric arrangement according to the figure)

  • Page 53: Table 7-14 Special Tools, Testing And Measuring Instruments

    OPERATING MANUAL ZP 3-5 V4 Commissioning 7.4.5 Setup process This chapter describes the set-up procedure. Carefully read the procedure in- structions. Then carry out the individual steps according to the detailed de- scription. Position the product as follows: Position the base plates if necessary Ü 2 56 Anchor the base plates if necessary Ü 2 58...
  • Page 54 Commissioning OPERATING MANUAL ZP 3-5 V4 Tool Item number Leveling instrument Leveling the axis with tripod LEICA Op- tical Level N720 Chalk line Positioning the product Screw clamps Installing the racks HILTI special tools Anchoring the product Fastening device Blocking the drive pin-...

  • Page 55: Table 7-1 Special Tools, Testing And Measuring Instruments

    OPERATING MANUAL ZP 3-5 V4 Commissioning Tool Item number Mounting aid Installing the guideway/ 902280 rack: Module 1.5, heli- Corrosion protection Installing the coupling 0502037 agent MOTOREX In- Applying corrosion tact XD 20 protection to the product Table 7-1 Special tools, testing and measuring instruments...
  • Page 56 Commissioning OPERATING MANUAL ZP 3-5 V4 7.4.5.2 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 78...

  • Page 57: Fig. 7 -2 Positioning The Base Plates: Position Points

    OPERATING MANUAL ZP 3-5 V4 Commissioning Fig. 7-2 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...

  • Page 58: Fig. 7 -3 Clean The Bore Hole: Hit-Z / Hit-Hy-200A

    Commissioning OPERATING MANUAL ZP 3-5 V4 7.4.5.3 Anchoring the base plates For further information refer to the layout and drawings for anchoring in the appendix. WARNING Eye injuries / skin injuries When setting anchors, flying parts or chemical binding agents can present a hazard.
  • Page 59 OPERATING MANUAL ZP 3-5 V4 Commissioning 7.4.5.4 Setting up an upright For the product, the following fastening methods are possible: • Güdel uprights • Other uprights • Directly onto a machine • Directly onto a steel beam construction If you are not using Güdel uprights, contact the respective manufacturer.

  • Page 60: Fig. 7 -4 Setting Up An Upright

    Commissioning OPERATING MANUAL ZP 3-5 V4 Fig. 7-4 Setting up an upright Spirit level Floor leveling screw Lifting belts Upright footing Beam leveling kit (option) Squared timber Beam leveling screw Upright Locknut...
  • Page 61 OPERATING MANUAL ZP 3-5 V4 Commissioning Set up the upright as follows: Set beam leveling screws to the specified dimensions if necessary Set the front floor leveling screws to the specified mass Position the rear floor leveling screws flush with the upright footing...

  • Page 62: Fig. 7 -5 Measuring Height Of Upright

    Commissioning OPERATING MANUAL ZP 3-5 V4 7.4.5.5 Leveling uprights Measuring height of upright Fig. 7-5 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 63: Fig. 7 -6 Marking Floor Leveling Screw

    OPERATING MANUAL ZP 3-5 V4 Commissioning Determining average upright height Determine the average upright height as follows: Add smallest and largest upright heights Divide result by two Round up result to nearest millimeter The average upright height has been determined.
  • Page 64 Commissioning OPERATING MANUAL ZP 3-5 V4 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 65: Fig. 7 -7 Installing A Beam: Standard

    OPERATING MANUAL ZP 3-5 V4 Commissioning ü û Fig. 7-7 Installing a beam: Standard Covering Guideway Upright Wall mounting (e.g. TMO-W; ZP; EP) Beam Ceiling mounting (e.g. TMO-C) Screw Elevated mounting (e.g. TMO-E; CP; AP) Mount the beam as follows: Attach the slings to the beam...

  • Page 66: Fig. 7 -8 Installing A Beam: Beam Leveling Kit

    Commissioning OPERATING MANUAL ZP 3-5 V4 7.4.5.8 Installing a beam: Beam leveling kit Fig. 7-8 Installing a beam: Beam leveling kit Beam Screw Beam leveling screw and locknut Upright Washer Mount the beam as follows: Attach the slings to the beam...

  • Page 67: Fig. 7 -9 Connecting The Beams

    OPERATING MANUAL ZP 3-5 V4 Commissioning 7.4.5.9 Connecting the beams Fig. 7-9 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 68: Fig. 7 -10 Straightening Beams

    Commissioning OPERATING MANUAL ZP 3-5 V4 7.4.5.10 Straightening beams For aligning, use the guideways as a reference. Fig. 7-10 Straightening beams Upright Plate s = 10 mm Guideway Screw clamp Alignment wire Scale...
  • Page 69 OPERATING MANUAL ZP 3-5 V4 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 70: Fig. 7 -11 Aligning Upright And Beam

    Commissioning OPERATING MANUAL ZP 3-5 V4 Aligning upright and beam WARNING Hazard due to tipping Using excessive levering force can lead to the upright falling over. This can lead to severe or fatal injuries! • Carefully align the upright and beams Use suitable protective material to avoid damage to the paint.

  • Page 71: Fig. 7 -12 Aligning The Beam Horizontally

    OPERATING MANUAL ZP 3-5 V4 Commissioning Aligning the beam horizontally Fig. 7-12 Aligning the beam horizontally Beam Beam leveling screw Locknut Screw Align the beams as follows: Slightly loosen the screws Loosen locknuts Align the beam by means of the beam leveling screws...
  • Page 72 Commissioning OPERATING MANUAL ZP 3-5 V4 7.4.5.11 Assembling the bumper unit Some bumper units cannot be shipped in a properly assembled state for as- sembly and packaging reasons. In such cases, the entire bumper unit is shipped unassembled. The assembly site is designated with a danger label. Find the correct assembly site on the layout.

  • Page 73: Fig. 7 -13 Danger Label "Provisionally Assembled Bumper Unit

    OPERATING MANUAL ZP 3-5 V4 Commissioning Fig. 7-13 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 74: Fig. 7 -14 Bumper Unit With Shearing Sleeves

    Commissioning OPERATING MANUAL ZP 3-5 V4 Bumper unit with shearing sleeves Fig. 7-14 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 75 OPERATING MANUAL ZP 3-5 V4 Commissioning 7.4.6 Anchoring the product The base mounting is available either with an adhesive anchor or with a welded joint. You can find the appropriate anchor type in the layout. NOTE Expansion joints Expansion joints absorb expansion in the foundations. If products are posi- tioned over expansion joints, this expansion is transmitted to the product.

  • Page 76: Fig. 7 -15 Base Mounting With Adhesive Anchor: Has / Hvu

    Commissioning OPERATING MANUAL ZP 3-5 V4 The product is anchored with the anchor rod HAS and the HVU adhesive car- HAS / HVU tridge from HILTI. Fig. 7-15 Base mounting with adhesive anchor: HAS / HVU Floor leveling screw Anchor Upright/frame...
  • Page 77 OPERATING MANUAL ZP 3-5 V4 Commissioning Anchor the upright as follows: Make a bore hole according to the preceding table Clean the bore hole Insert the adhesive cartridge Screw in the anchor rod with the hammer drill Wait until the hardening period specified by the manufacturer has passed...
  • Page 78 Commissioning OPERATING MANUAL ZP 3-5 V4 7.4.6.2 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 79: Fig. 7 -16 Welded Base Mounting: Hst3

    OPERATING MANUAL ZP 3-5 V4 Commissioning HST3 The base plate is anchored with the HST3 anchoring bolt from HILTI. Fig. 7-16 Welded base mounting: HST3 Screw Bottom plate Floor leveling screw Anchor Upright/frame Base plate m (floor leveling screw) M24x2 M36x2...

  • Page 80: Fig. 7 -17 Welded Base Mounting: Has-Tz / Hvu-Tz

    Commissioning OPERATING MANUAL ZP 3-5 V4 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 81: Table 7-5 Welded Base Mounting: Has-Tz / Hvu-Tz

    OPERATING MANUAL ZP 3-5 V4 Commissioning 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 82: Fig. 7 -18 Welded Base Mounting: Hit-Z / Hit-Hy-200-A

    Commissioning OPERATING MANUAL ZP 3-5 V4 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. 7-18 Welded base mounting: HIT-Z / HIT-HY-200-A Screw Bottom plate Floor leveling screw...
  • Page 83 OPERATING MANUAL ZP 3-5 V4 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 84: Fig. 7 -19 Mounting Aid For Rack Installation

    Commissioning OPERATING MANUAL ZP 3-5 V4 Installing 7.5.1 Using the mounting aid: Installing the rack The start and end of the rack each form half of a tooth gap. For precise and quiet transition, we recommend using a mounting aid toothed in the opposite direction.

  • Page 85: Fig. 7 -20 Installing The Guideway

    OPERATING MANUAL ZP 3-5 V4 Commissioning 7.5.2 Installing the guideway If you check the rack transition and cannot comply with the required values, the gap dimension takes priority. Fig. 7-20 Installing the guideway Reference surface Screw clamp Guideway Torque wrench Cleaning agents mild universal cleaner free from aromatic compounds (e.g.
  • Page 86 Commissioning OPERATING MANUAL ZP 3-5 V4 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 87: Fig. 7 -21 Check Rack Transition

    OPERATING MANUAL ZP 3-5 V4 Commissioning 7.5.3 Check rack transition Rack quality and module Ü 2 220 Fig. 7-21 Check rack transition Rack transition Measurement bolt (diameter D = 2 × m ; accuracy: tolerance class 1 acc. to DIN 2269)

  • Page 88: Table 7-8 Permissible Deviation, Rack Transition

    Commissioning OPERATING MANUAL ZP 3-5 V4 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 89: Fig. 7 -22 Attaching The Slings: Z-Axis, Sizes 2-5

    OPERATING MANUAL ZP 3-5 V4 Commissioning 7.5.4 Installing the Z-axis In some cases, the Z-axis is not yet mounted on delivery. Depending on the available space, the Z-axis can be inserted into the carriage from the top or the bottom.
  • Page 90 Commissioning OPERATING MANUAL ZP 3-5 V4 7.5.4.2 Preparations Prepare the insertion of the Z-axis as follows: Remove the upper or lower bumper unit on the Z-axis Remove the wiper on the Z-carriage Remove rotary axis if necessary Remove the motor if necessary...
  • Page 91 OPERATING MANUAL ZP 3-5 V4 Commissioning 7.5.4.4 Assembling the bumper unit Some bumper units cannot be shipped in a properly assembled state for as- sembly and packaging reasons. In such cases, the entire bumper unit is shipped unassembled. The assembly site is designated with a danger label. Find the correct assembly site on the layout.

  • Page 92: Fig. 7 -23 Danger Label "Provisionally Assembled Bumper Unit

    Commissioning OPERATING MANUAL ZP 3-5 V4 Fig. 7-23 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 -24 Bumper Unit With Mechanical Limit Stops

    OPERATING MANUAL ZP 3-5 V4 Commissioning Bumper unit with limit stops Fig. 7-24 Bumper unit with mechanical limit stops Loctite Blue Threadlocker 7414 Bumper block / bumper bracket Screw Mating part Bumper Assemble the bumper unit as follows: Assemble the bumper on the bumper block / bumper bracket...
  • Page 94 Commissioning OPERATING MANUAL ZP 3-5 V4 7.5.5 Installing the motor 7.5.5.1 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 -25 Aligning The Gearbox Flange

    OPERATING MANUAL ZP 3-5 V4 Commissioning 7.5.5.3 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. 7-25 Aligning the gearbox flange...
  • Page 96 Commissioning OPERATING MANUAL ZP 3-5 V4 Align the gearbox flange as follows: Prerequisite:The gearbox unit is installed on the adjacent construction Ü 2 184 Switch off the system and secure it with a padlock against being switched on again Remove the plug...

  • Page 97: Fig. 7 -26 Aligning The Input Shaft To The Gearbox Flange

    OPERATING MANUAL ZP 3-5 V4 Commissioning 7.5.5.4 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. 7-26...
  • Page 98 Commissioning OPERATING MANUAL ZP 3-5 V4 Align the input shaft to the gearbox flange as follows: Prerequisite:The gearbox unit is installed on the adjacent construction Ü 2 184 Prerequisite:The gearbox flange has been aligned correctly Ü 2 95 Prerequisite:The wedge has been installed on the gearbox side...

  • Page 99: Fig. 7 -27 Positioning The Coupling On The Motor Shaft: Elastomer Coupling

    OPERATING MANUAL ZP 3-5 V4 Commissioning 7.5.5.5 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 Commissioning OPERATING MANUAL ZP 3-5 V4 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 5103-19- +0.5 15.5 +0.5 5103-14- +0.5 +0.5 5103-24- +0.5...

  • Page 101: Fig. 7 -29 Position The Coupling On The Motor Shaft: Make Use Of X Dimension Tolerance

    OPERATING MANUAL ZP 3-5 V4 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 5103-42- +0.5 +1.2 5103-38- +0.5 Table 7-11 Weight and tolerances for the elastomer coupling ü...
  • Page 102 Commissioning OPERATING MANUAL ZP 3-5 V4 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 -30 Installing The Motor And Coupling

    OPERATING MANUAL ZP 3-5 V4 Commissioning The tightening torque TA and the type of couping are engraved on the motor and gearbox sides in the couping. D1=20F7 02/17 Gearbox side HPG060 Fig. 7-30 Installing the motor and coupling Coupling screw Motor...
  • Page 104 Commissioning OPERATING MANUAL ZP 3-5 V4 Tool Item number Corrosion protection Installing the coupling 0502037 agent MOTOREX In- Applying corrosion tact XD 20 protection to the product Table 7-14 Special tools, testing and measuring instruments Install the motor and coupling as follows: Prerequisite:The gearbox unit is installed on the adjacent construction Ü 2 184...

  • Page 105: Fig. 7 -31 Checking Leveling Of The Guide Chute

    OPERATING MANUAL ZP 3-5 V4 Commissioning 7.5.6 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. 7-31 Checking leveling of the guide chute...

  • Page 106: Fig. 7 -32 Connecting The Side Panels

    Commissioning OPERATING MANUAL ZP 3-5 V4 7.5.7 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 channel.
  • Page 107 OPERATING MANUAL ZP 3-5 V4 Commissioning 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 242 to hexagonal nuts...
  • Page 108 Commissioning OPERATING MANUAL ZP 3-5 V4 Assembling the energy chain 7.6.1 Laying the cables and lines NOTE Cable damage Incorrectly laid cables and lines wear prematurely and will be destroyed. This results in operational failure. • Only use highly flexible lines suitable for use with energy chains •...

  • Page 109: Fig. 7 -33 Laying Cables And Lines (Image Source: Igus)

    OPERATING MANUAL ZP 3-5 V4 Commissioning ü û û ü û ü Fig. 7-33 Laying cables and lines (image source: IGUS) Screwdriver Opening bar Energy chain Vertical divider...
  • Page 110 Commissioning OPERATING MANUAL ZP 3-5 V4 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 111: Fig. 7 -34 Installing The Energy Chains

    OPERATING MANUAL ZP 3-5 V4 Commissioning 7.6.2 Installing the energy chain NOTE Connection elements installed at an angle If the connection elements are installed at an angle, the energy chain rolls away at an angle. The energy chain grinds on the guide channel. This results in increased wear.

  • Page 112: Fig. 7 -35 Installing The Slide Bars (Image Source: Igus)

    Commissioning OPERATING MANUAL ZP 3-5 V4 Install the energy chain as follows: Prerequisite:You have read and understood the IGUS assembly instruc- tions Install the mounting angle on the fixed side connection element using fas- tening screws and nuts Place the energy chain in the guide chute...
  • Page 113 OPERATING MANUAL ZP 3-5 V4 Commissioning 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 114 Commissioning OPERATING MANUAL ZP 3-5 V4 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 -36 Relieving The Strain On Cables And Lines (Image Source: Igus)

    OPERATING MANUAL ZP 3-5 V4 Commissioning ü û ü û ü û Fig. 7-36 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 Commissioning OPERATING MANUAL ZP 3-5 V4 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 OPERATING MANUAL ZP 3-5 V4 Commissioning Connection 7.7.1 Attaching optional components If equipped, attach the following optional components as per the separate documentation: • Automatic lubrication system • Z-axis impact protection • Manual lifting and safety unit • Safety brake system •...
  • Page 118 Commissioning OPERATING MANUAL ZP 3-5 V4 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 -37 Removing Transport Securing Device: Align Y-Rack

    OPERATING MANUAL ZP 3-5 V4 Commissioning Fig. 7-37 Removing transport securing device: Align Y-rack Transport securing device Screw Remove the transport securing device at the Y-rack as follows: Secure the carriage Loosen the screws Removing the transport securing device Transport securing device has been removed.
  • Page 120 Commissioning OPERATING MANUAL ZP 3-5 V4 7.8.1 Removing the transport securing device Remove the latch using a screwdriver...

  • Page 121: Fig. 7 -39 Removing Transport Securing Device: Güdel Gearbox Unit

    OPERATING MANUAL ZP 3-5 V4 Commissioning Fig. 7-39 Removing transport securing device: Güdel gearbox unit Plug Coupling Transport securing device Latch Coupling screw Remove the transport securing device as follows: Secure carriage or axis Remove the plug Release the coupling screws...
  • Page 122 Commissioning OPERATING MANUAL ZP 3-5 V4 7.8.2 Installing transport securing device WARNING Falling axes, workpieces Incorrect installation of the transport securing device can cause axes and workpieces to fall. This can lead to severe or fatal injuries! • Ensure that the sunk key of the input shaft is correctly installed •...

  • Page 123: Fig. 7 -40 Installing Transport Securing Device: Güdel Gearbox Unit

    OPERATING MANUAL ZP 3-5 V4 Commissioning Fig. 7-40 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 124 Commissioning OPERATING MANUAL ZP 3-5 V4 Install the transport securing device as follows: Installing transport securing device Prerequisite:The input shaft has been correctly aligned to the gearbox flange Ü 2 97 Prerequisite:The coupling has been removed Switch off the plant and secure it with a padlock against being switched...

  • Page 125: Fig. 7 -41 Checking The Transport Securing Device

    OPERATING MANUAL ZP 3-5 V4 Commissioning Checking the ü transport securing device û Fig. 7-41 Checking the transport securing device Fastening screw Latch Transport securing device Coupling Check the transport securing device as follows: Check whether the transport securing device is correctly positioned with...
  • Page 126 Commissioning OPERATING MANUAL ZP 3-5 V4 Tighten the coupling screws as follows: Tighten the cou- pling screws 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 127 OPERATING MANUAL ZP 3-5 V4 Commissioning Fine adjustment of the Z-axis The fine adjustment of the Z-axis determines your application process. • Vertically align the Z-axis as precisely as required WARNING Moving the axis The work requires moving the axis. This can lead to severe or fatal injuries! •...

  • Page 128: Fig. 7 -42 Aligning The Z-Axis Vertically In The X-Direction: Standard

    Commissioning OPERATING MANUAL ZP 3-5 V4 Fig. 7-42 Aligning the Z-axis vertically in the X-direction: Standard Z-axis Guideway Floor leveling screw Machine square frame level Locknut Upright...
  • Page 129 OPERATING MANUAL ZP 3-5 V4 Commissioning Align the Z-axis precisely as follows: Move to first pickup and deposit position Attach the machine square frame level to the Z-axis guideway as shown in the illustration Check vertical alignment In the event of deviations in the Z-axis, vertically align it precisely with...

  • Page 130: Fig. 7-43 Aligning The Z-Axis Vertically In The X-Direction: Beam Leveling Kit

    Commissioning OPERATING MANUAL ZP 3-5 V4 Fig. 7-43 Aligning the Z-axis vertically in the X-direction: Beam leveling kit Locknut Z-axis Beam leveling screw Guideway Screw Machine square frame level...
  • Page 131 OPERATING MANUAL ZP 3-5 V4 Commissioning Align the Z-axis precisely as follows: Move to first pickup and deposit position Attach the machine square frame level to the Z-axis guideway as shown in the illustration Check vertical alignment In the event of deviations in the Z-axis, vertically align it precisely with...

  • Page 132: Fig. 7 -44 Align The Z-Axis Vertically In The Y-Direction

    Commissioning OPERATING MANUAL ZP 3-5 V4 7.9.3 Y-direction: Standard For aligning, use the guideways as a reference. During the correct set-up process, the vertical position of the Z-axis is speci- fied by the production tolerances. • Only carry out fine adjustments •...
  • Page 133 OPERATING MANUAL ZP 3-5 V4 Commissioning Align the Z-axis precisely as follows: Prerequisite:You are aware of the different roller positions Ü 2 197 Move to first pickup and deposit position Position the Z-axis right at the bottom Attach the machine square frame level to the Z-axis guideway as shown...

  • Page 134: Fig. 7 -45 Align The Z-Axis Vertically In The Y-Direction: Safety Brake System

    Commissioning OPERATING MANUAL ZP 3-5 V4 During the correct set-up process, the vertical position of the Z-axis is speci- fied by the production tolerances. • Only carry out fine adjustments • If the Z-axis is very misaligned, please contact our service departments Average out the different measurements from various pickup and deposit po- sitions when the Y-axis has been correctly aligned horizontally.
  • Page 135 OPERATING MANUAL ZP 3-5 V4 Commissioning Align the Z-axis precisely as follows: Prerequisite:You are aware of the different roller positions Ü 2 197 Move to first pickup and deposit position Position the Z-axis right at the bottom Attach the machine square frame level to the Z-axis guideway as shown...

  • Page 136: Fig. 7 -46 Clean Guideways And Racks

    Commissioning OPERATING MANUAL ZP 3-5 V4 7.10 Initial lubrication Lubricate the guideway, rack and pinion before commissioning the product for the first time. 7.10.1 Clean guideways and racks WARNING Moving the axis The work requires moving the axis. This can lead to severe or fatal injuries! •...

  • Page 137: Fig. 7 -47 Pre-Lubricate Guideways And Racks

    OPERATING MANUAL ZP 3-5 V4 Commissioning 7.10.2 Pre-lubricate guideways and racks ü û Fig. 7-47 Pre-lubricate guideways and racks Lubrication ex Specification Lubrication quantity works Ü Chapter 9.2.2.1, Ü Chapter 9.2.2.1, 2 146 2 146 Table 7-17 Lubricants: Guideways, racks, and pinions Pre-lubricate the racks and guideways as follows:...

  • Page 138: Fig. 7 -48 Carrying Out A Lubrication Check

    Commissioning OPERATING MANUAL ZP 3-5 V4 7.10.3 Carrying out a lubrication check Perform a lubrication check as described in the separate documentation on the automatic lubrication system. ü û Fig. 7-48 Carrying out a lubrication check Lubrication ex Specification Lubrication quantity works Ü Chapter 9.2.2.1,...
  • Page 139 OPERATING MANUAL ZP 3-5 V4 Commissioning 7.11 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 140 Commissioning OPERATING MANUAL ZP 3-5 V4...
  • Page 141 OPERATING MANUAL ZP 3-5 V4 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 142 Operation OPERATING MANUAL ZP 3-5 V4...
  • Page 143 OPERATING MANUAL ZP 3-5 V4 Maintenance Maintenance Introduction The listed tasks have to be carried out at the prescribed time intervals. If they Maintenance 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 144 Maintenance OPERATING MANUAL ZP 3-5 V4 WARNING Automatic startup During work on the product, there is danger of the machine starting up auto- matically. This can lead to severe or fatal injuries! Before working in the danger area: • Secure vertical axes (if equipped) against falling.

  • Page 145: Table 9-1 Table Of Cleaning Agents

    OPERATING MANUAL ZP 3-5 V4 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 146 Maintenance OPERATING MANUAL ZP 3-5 V4 9.2.2 Lubricants NOTE Unsuitable lubricants Using unsuitable lubricants can cause damage to the machine! • Only use the lubricants listed • If uncertain, please contact our service departments For more information on the lubricants, refer to the tables below. For further information, refer to the chapter "Maintenance tasks"...

  • Page 147: Fig. 9 -1 Lubricating Manually With Grease

    OPERATING MANUAL ZP 3-5 V4 Maintenance Manual lubrication The following lubrication systems and lubricants are intended for the manual lubrication of the product: Fig. 9-1 Lubricating manually with grease Lubrication Specifica- Lubrica- Location of appli- Cate- ex works tion tion cation...

  • Page 148: Fig. 9 -3 Lubricating Manually With Oil

    Maintenance OPERATING MANUAL ZP 3-5 V4 Fig. 9-3 Lubricating manually with oil Lubrication Specifica- Lubrica- Location of appli- Cate- ex works tion tion cation gory quantity Elkalub FLC Cannot be Pre-lubricate guide- 8 H1 determined ways and racks Table 9-4 Lubricants: Pre-lubricate guideways and racks The markings apply to manual lubrication of the following Güdel components:...

  • Page 149: Fig. 9 -5 Automatic Lubrication System Flexxpump

    OPERATING MANUAL ZP 3-5 V4 Maintenance Automatic lubrication system The following lubrication systems and lubricants are provided for the auto- matic lubrication of the product: Fig. 9-5 Automatic lubrication system FlexxPump Lubrication Specifica- Lubrica- Location of appli- Cate- ex works tion...

  • Page 150: Fig. 9 -7 Automatic Lubrication System Memolub

    Maintenance OPERATING MANUAL ZP 3-5 V4 Fig. 9-7 Automatic lubrication system Memolub Lubrication Specifica- Lubrica- Location of appli- Cate- ex works tion tion cation gory quantity Castrol 2KP2K-30 in Automatic lubrica- grease Longtime PD accordance tion system with DIN Memolub 51502 Table 9-7...
  • Page 151 OPERATING MANUAL ZP 3-5 V4 Maintenance 9.2.2.2 Lubricant table Lubrication Specifica- Lubrica- Location of appli- Cate- ex works tion tion cation gory quantity 2KP2K-30 in Automatic lubrica- Castrol accordance tion system grease Longtime PD with DIN Memolub 51502 Automatic lubrica-...

  • Page 152: Table 9-10 Lubricant Table

    Maintenance OPERATING MANUAL ZP 3-5 V4 Lubrication Specifica- Lubrica- Location of appli- Cate- ex works tion tion cation gory quantity Güdel gearbox unit: Cannot be Vaseline elastomer gear rim Grease determined of the coupling This table does not purport to be exhaustive.

  • Page 153: Table 9-11 Maintenance Intervals In Shift Operation (5 Days A Week)

    OPERATING MANUAL ZP 3-5 V4 Maintenance 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 6'750 every 3 years every 1.5 years yearly...
  • Page 154 Maintenance OPERATING MANUAL ZP 3-5 V4 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 Extractor Replacing rollers...

  • Page 155: Table 9-13 Special Tools, Testing And Measuring Instruments

    OPERATING MANUAL ZP 3-5 V4 Maintenance Tool Item number Mounting aid Installing the guideway/ 902283 rack: Module 3, helical Lubricating spray Pre-lubricating guide- 10406825 ways and racks Corrosion protection Installing the coupling 0502037 agent MOTOREX In- Applying corrosion tact XD 20...
  • Page 156 Maintenance OPERATING MANUAL ZP 3-5 V4 9.3.4 Maintenance tasks after downtimes <4 weeks If the machine downtime is longer than two weeks, carry out the following jobs: • Check the lubricating film on guideways and racks ü û • Check hydraulic lines for air pockets and kinks ü...
  • Page 157 OPERATING MANUAL ZP 3-5 V4 Maintenance 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 158: Fig. 9 -10 Carrying Out A Lubrication Check

    Maintenance OPERATING MANUAL ZP 3-5 V4 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. 9-10 Carrying out a lubrication check Lubrication ex Specification Lubrication quantity works Ü Chapter 9.2.2.1,...

  • Page 159: Fig. 9 -11 Lubricating Components On The Grease Nipple

    OPERATING MANUAL ZP 3-5 V4 Maintenance 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 160: Table 9-15 Lubricants: Guideways, Racks, And Pinions

    Maintenance OPERATING MANUAL ZP 3-5 V4 Lubrication ex Specification Lubrication quantity works Ü Chapter 9.2.2.1, Ü Chapter 9.2.2.1, Roller size 10-20: 4.5 2 146 2 146 cm³ Roller size 25-52: 7.5 cm³ Roller size 72-215: 12 cm³ Table 9-15 Lubricants: Guideways, racks, and pinions Lubricate the guideways, racks, and pinions as follows:...
  • Page 161 OPERATING MANUAL ZP 3-5 V4 Maintenance 9.3.8 Maintenance tasks after 2,250 hours 9.3.8.1 General inspection For the general inspection, perform a rough check of the entire product. Performing a gen- eral inspection Perform the general inspection as follows: Switch off the system and padlock it to secure it against being switched...
  • Page 162 Maintenance OPERATING MANUAL ZP 3-5 V4 Inspection Description Measures point Damage Check the system for Immediately remedy all dis- damage: covered damage • Paint damage • Bent components • General damage • Cracks in the cast components • Cracks at welding...
  • Page 163 OPERATING MANUAL ZP 3-5 V4 Maintenance Inspection Description Measures point Components Check the condition of Replace worn and defective the components: components • Carrier • Rollers • Guideways • Racks • Cog belt • Pinion • Bumper unit • Switches, sensors •...

  • Page 164: Table 9-16 Inspection Table

    Maintenance OPERATING MANUAL ZP 3-5 V4 Inspection Description Measures point Guide chute Check the guide chute: Rectify defects immediately: Ü 2 106 • Side panel transitions Ü 2 177 • Slide bar transitions Ü 2 105 • Leveling Axes Position the axes on Calibrate the axes...

  • Page 165: Fig. 9 -12 Carrying Out A Lubrication Check

    OPERATING MANUAL ZP 3-5 V4 Maintenance 9.3.8.4 Carrying out a lubrication check Perform a lubrication check as described in the separate documentation on the automatic lubrication system. ü û Fig. 9-12 Carrying out a lubrication check Lubrication ex Specification Lubrication quantity works Ü Chapter 9.2.2.1,...

  • Page 166: Fig. 9 -13 Replacing The Lubricating Pinion

    Maintenance OPERATING MANUAL ZP 3-5 V4 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 167 OPERATING MANUAL ZP 3-5 V4 Maintenance Replace the lubricating pinion. Replacing the lu- bricating pinion Install the lubricat- Install the lubricating pinion as follows: ing pinion Install lubricating pinion using the fastening screw Install the covering Install the screws Tighten the screws and fastening screw...

  • Page 168: Fig. 9 -14 Replacing The Wiper And Lubrication Unit

    Maintenance OPERATING MANUAL ZP 3-5 V4 9.3.9.2 Replacing the wiper and lubrication unit The wiper and lubrication unit is supplied as piece parts. NOTE Destroyed cover Covers are designed for one-off installation. Snap off the latching elements when removing the cover. The cover must be replaced.
  • Page 169 OPERATING MANUAL ZP 3-5 V4 Maintenance 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 170: Table 9-20 Inspection Table

    Maintenance OPERATING MANUAL ZP 3-5 V4 9.3.10 Maintenance tasks after 11,250 hours 9.3.10.1 Checking automatic lubrication system Check the automatic lubrication system in accordance with the following ta- ble. Inspection Description Measures point Contamination Check the components Immediately clean away any...
  • Page 171 OPERATING MANUAL ZP 3-5 V4 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 172 Maintenance OPERATING MANUAL ZP 3-5 V4 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 173: Fig. 9 -15 Laying Cables And Lines (Image Source: Igus)

    OPERATING MANUAL ZP 3-5 V4 Maintenance ü û û ü û ü Fig. 9-15 Laying cables and lines (image source: IGUS) Screwdriver Opening bar Energy chain Vertical divider...
  • Page 174 Maintenance OPERATING MANUAL ZP 3-5 V4 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 175: Fig. 9 -16 Installing The Energy Chains

    OPERATING MANUAL ZP 3-5 V4 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. 9-16 Installing the energy chains Orange flag...
  • Page 176 Maintenance OPERATING MANUAL ZP 3-5 V4 Final tasks Perform the following final tasks: Connect the cables and lines in accordance with the electrical diagram. Relive the cables and lines of strain Ü 2 114 The final tasks have been performed. 9.3.11.3 Replacing the slide bars...

  • Page 177: Fig. 9 -17 Installing The Slide Bars (Image Source: Igus)

    OPERATING MANUAL ZP 3-5 V4 Maintenance 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 178 Maintenance OPERATING MANUAL ZP 3-5 V4 9.3.11.4 Replacing the gearbox unit This chapter describes the steps for replacing the Güdel gearbox unit. Replace the gearbox as follows: Attaching the slings: Motor...

  • Page 179: Fig. 9 -18 Attaching The Slings: Motor (Image Source: Bosch Rexroth)

    OPERATING MANUAL ZP 3-5 V4 Maintenance 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 • Never enter the area below a suspended load Fig. 9-18...

  • Page 180: Fig. 9 -19 Attaching The Slings: Güdel Gearbox Unit

    Maintenance OPERATING MANUAL ZP 3-5 V4 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 181 OPERATING MANUAL ZP 3-5 V4 Maintenance 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 182: Fig. 9 -20 Remove Motor And Coupling

    Maintenance OPERATING MANUAL ZP 3-5 V4 Fig. 9-20 Remove motor and coupling Plug Coupling screw Drill hole Motor Coupling Motor screw Remove the motor and coupling as follows: Switch off the plant and secure it with a padlock against being switched...

  • Page 183: Fig. 9 -21 Removing The Gearbox Unit

    OPERATING MANUAL ZP 3-5 V4 Maintenance Removing the gearbox unit Fig. 9-21 Removing the gearbox unit Adjacent construction Gearbox unit Gearbox screws Remove the gearbox unit as follows: Attach slings to the gearbox unit Ü 2 180 Remove the gearbox screws Remove the gearbox unit Remove the transport securing device or slings The gearbox unit has now been removed.

  • Page 184: Fig. 9 -22 Installing The Gearbox Unit

    Maintenance OPERATING MANUAL ZP 3-5 V4 Installing the gearbox unit NOTE Breakage of cast casing Excessively high tightening torques destroy the cast casing! • Observe the tightening torques Fig. 9-22 Installing the gearbox unit Adjacent construction Gearbox unit Gearbox screws Size...
  • Page 185 OPERATING MANUAL ZP 3-5 V4 Maintenance 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 186: Fig. 9 -23 Aligning The Gearbox Flange

    Maintenance OPERATING MANUAL ZP 3-5 V4 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. 9-23 Aligning the gearbox flange...
  • Page 187 OPERATING MANUAL ZP 3-5 V4 Maintenance Align the gearbox flange as follows: Prerequisite:The gearbox unit is installed on the adjacent construction Ü 2 184 Switch off the system and secure it with a padlock against being switched on again Remove the plug...

  • Page 188: Fig. 9 -24 Aligning The Input Shaft To The Gearbox Flange

    Maintenance OPERATING MANUAL ZP 3-5 V4 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. 9-24...
  • Page 189 OPERATING MANUAL ZP 3-5 V4 Maintenance Align the input shaft to the gearbox flange as follows: Prerequisite:The gearbox unit is installed on the adjacent construction Ü 2 184 Prerequisite:The gearbox flange has been aligned correctly Ü 2 186 Prerequisite:The wedge has been installed on the gearbox side...

  • Page 190: Fig. 9 -25 Positioning The Coupling On The Motor Shaft: Elastomer Coupling

    Maintenance OPERATING MANUAL ZP 3-5 V4 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 191: Fig. 9 -26 X Dimension Calculation Formula

    OPERATING MANUAL ZP 3-5 V4 Maintenance X = Z – Y Fig. 9-26 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 192: Fig. 9 -27 Position The Coupling On The Motor Shaft: Make Use Of X Dimension Tolerance

    Maintenance OPERATING MANUAL ZP 3-5 V4 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 5103-42- +0.5 +1.2 5103-38- +0.5 Table 9-24 Weight and tolerances for the elastomer coupling ü...
  • Page 193 OPERATING MANUAL ZP 3-5 V4 Maintenance 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 194: Fig. 9 -28 Installing The Motor And Coupling

    Maintenance OPERATING MANUAL ZP 3-5 V4 The tightening torque TA and the type of couping are engraved on the motor and gearbox sides in the couping. D1=20F7 02/17 Gearbox side HPG060 Fig. 9-28 Installing the motor and coupling Coupling screw Motor...

  • Page 195: Table 9-26 Cleaning Agents: Güdel Gearbox Unit: Coupling, Input Shaft And Wedge

    OPERATING MANUAL ZP 3-5 V4 Maintenance Cleaning agents mild universal cleaner free from aromatic compounds (e.g. Motorex OPAL 5000) Table 9-26 Cleaning agents: Güdel gearbox unit: coupling, input shaft and wedge Tool Item number Corrosion protection Installing the coupling 0502037 agent MOTOREX In-...
  • Page 196 Maintenance OPERATING MANUAL ZP 3-5 V4 Install the motor and coupling as follows: Prerequisite:The gearbox unit is installed on the adjacent construction Ü 2 184 Prerequisite:The gearbox flange has been aligned correctly Ü 2 186 Prerequisite:The input shaft has been aligned correctly to the gearbox flange Ü 2 188...

  • Page 197: Fig. 9 -29 Roller Positions

    OPERATING MANUAL ZP 3-5 V4 Maintenance 9.3.11.5 Replacing the roller The components are designed for continuous use. Their wear depends on the duration of operation of the product and the ambient conditions. Güdel rec- ommends preventatively replacing components as soon as their service life has been reached.

  • Page 198: Fig. 9 -30 Using The Mounting Aid: Relieving The Roller

    Maintenance OPERATING MANUAL ZP 3-5 V4 Using the mounting aid: Relieving the roller Use the support screws to relieve the strain on the rollers. The rollers can be removed more easily. The mounting aid serves as fall protection during replacement of the roller.
  • Page 199 OPERATING MANUAL ZP 3-5 V4 Maintenance Use the mounting aid as follows: Switch off the plant and padlock it to secure it against being switched on again Install the mounting aid on the carriage using the screw Install set screw and lock nut as illustrated...

  • Page 200: Fig. 9 -31 Replacing The Roller

    Maintenance OPERATING MANUAL ZP 3-5 V4 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. 9-31...
  • Page 201 OPERATING MANUAL ZP 3-5 V4 Maintenance 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 202: Fig. 9 -32 Removing The Ledge

    Maintenance OPERATING MANUAL ZP 3-5 V4 Removing the ledge Fig. 9-32 Removing the ledge Screw Rocker Ledge Guideway Remove the ledge as follows: Prerequisite:The rollers have been relieved Prerequisite:All components covering the ledges or rockers have been removed Switch off the plant and padlock it to secure it against being switched on...

  • Page 203: Fig. 9 -33 Releasing The Rocker

    OPERATING MANUAL ZP 3-5 V4 Maintenance Releasing the rocker Fig. 9-33 Releasing the rocker Wiper and lubrication unit Fastening screw Screw B Roller Release the rocker as follows: Remove screws B and wiper and lubrication unit Loosen fastening screw Tap the fastening screw with a plastic hammer until the rocker protrudes a few millimeters The rocker has been released.

  • Page 204: Fig. 9 -34 Replacing The Rollers

    Maintenance OPERATING MANUAL ZP 3-5 V4 Replacing the rollers Fig. 9-34 Replacing the rollers Fastening screw Guideway Roller Rocker Replace the rollers as follows: Remove the fastening screws Remove the rocker Replace the rollers Install the rocker and rollers Install and tighten the fastening screws The rollers have been replaced.

  • Page 205: Fig. 9 -35 Setting The Rollers: Prism Guideway, Centering And Eccentric Rollers

    OPERATING MANUAL ZP 3-5 V4 Maintenance Y-axis Setting the rollers ü û Fig. 9-35 Setting the rollers: Prism guideway, centering and eccentric rollers Axis Screw Supporting roller (concentric) Pin-type face wrench Carriage Guideway roller (eccentric) Hexagonal socket wrench Guideway...
  • Page 206 Maintenance OPERATING MANUAL ZP 3-5 V4 Adjust the rollers as follows: Prerequisite:The wiper and lubrication units have been removed Prerequisite:The maximum backlash has been set Ü 2 216 Prerequisite:Guideway rollers are set to position -1 Ü 2 197 Switch off the plant and padlock it to secure it against being switched on...

  • Page 207: Fig. 9 -36 Setting The Double Rollers: Prism Guideway, Eccentric Rollers

    OPERATING MANUAL ZP 3-5 V4 Maintenance Setting the double rollers The eccentric rollers of the double roller must be identically positioned. ü û ü û Fig. 9-36 Setting the double rollers: Prism guideway, eccentric rollers Axis Pin-type face wrench Carriage Roller (eccentric)
  • Page 208 Maintenance OPERATING MANUAL ZP 3-5 V4 Adjust the rollers as follows: Prerequisite:The wiper and lubrication units have been removed Prerequisite:The maximum tooth flank backlash has been set Ü 2 216 Prerequisite:All rollers have been set to their maximum distance from the guideway Ü 2 197...

  • Page 209: Fig. 9 -37 Setting The Rollers: Prism Guideway, Eccentric Rollers

    OPERATING MANUAL ZP 3-5 V4 Maintenance Z-axis Setting the rollers ü û Fig. 9-37 Setting the rollers: Prism guideway, eccentric rollers Guideway Screw Carriage Hexagonal socket wrench Pin-type face wrench Axis Roller (eccentric)
  • Page 210 Maintenance OPERATING MANUAL ZP 3-5 V4 Adjust the rollers as follows: Prerequisite:The wiper and lubrication units have been removed Prerequisite:The maximum backlash has been set Ü 2 216 Prerequisite:Right rollers are set to position +1 Ü 2 197 Prerequisite:Left rollers are set to position -1 Ü 2 197...

  • Page 211: Fig. 9 -38 Mounting Aid For Rack Installation

    OPERATING MANUAL ZP 3-5 V4 Maintenance 9.3.11.6 Replacing the guideway Disassembling the guideway Disassemble the guideway as follows: Switch off the system and padlock it to secure it against being switched on again Attach the slings to the carriage or axis...

  • Page 212: Fig. 9 -39 Installing The Guideway

    Maintenance OPERATING MANUAL ZP 3-5 V4 Installing the guideway If you check the rack transition and cannot comply with the required values, the gap dimension takes priority. Fig. 9-39 Installing the guideway Reference surface Screw clamp Guideway Torque wrench Cleaning agents mild universal cleaner free from aromatic compounds (e.g.
  • Page 213 OPERATING MANUAL ZP 3-5 V4 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 214: Fig. 9 -40 Check Rack Transition

    Maintenance OPERATING MANUAL ZP 3-5 V4 Check rack transition Rack quality and module Ü 2 220 Fig. 9-40 Check rack transition Rack transition Measurement bolt (diameter D = 2 × m ; accuracy: tolerance class 1 acc. to DIN 2269)

  • Page 215: Table 9-30 Permissible Deviation, Rack Transition

    OPERATING MANUAL ZP 3-5 V4 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 216 Maintenance OPERATING MANUAL ZP 3-5 V4 9.3.11.7 Replacing switches, sensors Replace the switches and sensors in accordance with the third-party docu- mentation. The components are designed for continuous use. Their wear depends on the duration of operation of the product and the ambient conditions. Güdel rec- ommends preventatively replacing components as soon as their service life has been reached.

  • Page 217: Fig. 9 -41 Eccentric Marking: Countersink Separate

    OPERATING MANUAL ZP 3-5 V4 Maintenance 9.3.12.1 Eccentric marking The eccentric ring has a marking of the eccentric maximum position: Fig. 9-41 Eccentric marking: Countersink separate Countersink Eccentric ring 9.3.12.2 Blocking, unblocking the eccentric ring The eccentric ring is blocked as follows: Fig. 9-42...

  • Page 218: Fig. 9 -43 Setting The Tooth Flank Backlash: Eccentric

    Maintenance OPERATING MANUAL ZP 3-5 V4 9.3.12.3 Eccentric Fig. 9-43 Setting the tooth flank backlash: Eccentric Gearbox screw Eccentric ring Eccentric marking (if present) Pinion Rack Set the tooth flank backlash as follows: Switch off the system and padlock it to secure it against being switched on again Check the tooth flank backlash Ü 2 219...

  • Page 219: Fig. 9 -44 Blocking The Drive Pinions: Güdel Gearbox Unit

    OPERATING MANUAL ZP 3-5 V4 Maintenance 9.3.12.4 Check the tooth flank backlash If the axis is not driven with Güdel gearbox type, then use the procedure de- scribed in the operating manual of the relevant gearbox. Blocking the drive pinions Block the drive pinion to check the tooth flank backlash.

  • Page 220: Table 9-31 Rack Quality And Module

    Maintenance OPERATING MANUAL ZP 3-5 V4 Rack quality and module The quality and module are found in the following table: Axis Rack quality Module Helix an- gle β [°] Hardened Soft rack rack 6h23 7h25 1.5 (ZP-3) 19.5283 2.5 (ZP-4)

  • Page 221: Fig. 9 -45 Checking The Tooth Flank Backlash: Dial Gauge (Exact Method)

    OPERATING MANUAL ZP 3-5 V4 Maintenance Fig. 9-45 Checking the tooth flank backlash: Dial gauge (exact method) Rack Gearbox Guideway Drive pinion Axle Dial gauge Carriage Check the tooth flank backlash as follows: Prerequisite:The drive pinion is blocked. Ü 2 219 Switch off the system and padlock it to secure it against being switched...

  • Page 222: Table 9-33 Tooth Flank Backlash: Paper Strip (Inexact Method)

    Maintenance OPERATING MANUAL ZP 3-5 V4 Inexact measuring method 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 Rack quality and module Ü 2 220...

  • Page 223: Fig. 9 -46 Checking The Tooth Flank Backlash: Paper Strip (Inexact Method)

    OPERATING MANUAL ZP 3-5 V4 Maintenance Fig. 9-46 Checking the tooth flank backlash: Paper strip (inexact method) Drive pinion Paper strip Rack Check the tooth flank backlash as follows: Switch off the system and padlock it to secure it against being switched on again Insert paper strip of 0.08 mm thickness and width b between drive pinion...
  • Page 224 Maintenance OPERATING MANUAL ZP 3-5 V4 Maintenance schedules...

  • Page 225: Fig. 9 -47 Maintenance Schedule For Zp

    OPERATING MANUAL ZP 3-5 V4 Maintenance 9.4.1 Maintenance schedule ZP 22'500 22'500 6'750 6'750 2'250 2'250 ü û ü 2'250 2'250 22'500 22'500 Fig. 9-47 Maintenance schedule for ZP Maintain in accordance with separate instructions Replacing Replacing lubricant Automatic lubrication Visual inspection...
  • Page 226 Maintenance OPERATING MANUAL ZP 3-5 V4...

  • Page 227: Fig. 9 -48 Maintenance Schedule For Güdel Gearbox Unit

    OPERATING MANUAL ZP 3-5 V4 Maintenance 9.4.2 Güdel gearbox unit maintenance schedule 22'500 22'500 2'250 2'250 Fig. 9-48 Maintenance schedule for Güdel gearbox unit Grease Replacing Replacing lubricant Clean Visual inspection...
  • Page 228 Maintenance OPERATING MANUAL ZP 3-5 V4...

  • Page 229: Fig. 9 -49 Maintenance Schedule For Automatic Lubrication System

    OPERATING MANUAL ZP 3-5 V4 Maintenance 9.4.3 Maintenance schedule for automatic lubrication system 22'500 22'500 11'250 11'250 2'250 2'250 ü û ü >30s ≤30s FlexxPump 402B Fig. 9-49 Maintenance schedule for automatic lubrication system Grease Replacing Replacing lubricant Clean Visual inspection...
  • Page 230 Maintenance OPERATING MANUAL ZP 3-5 V4...

  • Page 231: Table 9-34 Maintenance Table

    OPERATING MANUAL ZP 3-5 V4 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, 2 159 racks and pinions Güdel H1 NSF no.146621...
  • Page 232 Maintenance OPERATING MANUAL ZP 3-5 V4 Maintenance work Maintenance cycle [h] Duration [min] Target readership Lubricants Further information Cleaning agents Service technicians Replacing the gearbox unit The manufacturer's technicians  Ü Chapter 9.3.11.4, 2 178 Maintenance technicians The manufacturer's technicians Replacing the automatic lu-  Ü Chapter 9.3.11.1, 2 171...
  • 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 ZP 3-5 V4...
  • 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 ZP 3-5 V4...
  • Page 237 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 238 Maintenance OPERATING MANUAL ZP 3-5 V4...
  • Page 239 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 240 Maintenance OPERATING MANUAL ZP 3-5 V4...
  • Page 241 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 242 Maintenance OPERATING MANUAL ZP 3-5 V4...

  • Page 243: Fig. 9 -50 Identification Number Of The Instructions

    OPERATING MANUAL ZP 3-5 V4 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 244 Repairs OPERATING MANUAL ZP 3-5 V4 Repairs 10.1 Introduction Perform the work sequences in the order described. Perform the described Work sequences tasks at the specified times. This ensures a long service life for your product. Only use original spare parts. Ü 2 285...
  • Page 245 OPERATING MANUAL ZP 3-5 V4 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 246: Fig. 10 -1 Attaching The Slings: Motor (Image Source: Bosch Rexroth)

    Repairs OPERATING MANUAL ZP 3-5 V4 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 247: Fig. 10 -2 Attaching The Slings: Güdel Gearbox Unit

    OPERATING MANUAL ZP 3-5 V4 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 248 Repairs OPERATING MANUAL ZP 3-5 V4 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 249: Fig. 10 -3 Removing The Motor: Güdel Gearbox Unit

    OPERATING MANUAL ZP 3-5 V4 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 250: Fig. 10 -4 Removing The Gearbox Unit

    Repairs OPERATING MANUAL ZP 3-5 V4 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 2 247 Remove the gearbox screws Remove the gearbox unit Remove the transport securing device or slings The gearbox unit has now been removed.
  • Page 251 OPERATING MANUAL ZP 3-5 V4 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 252: Fig. 10 -5 Replacing Lubricant: Güdel Gearbox Unit

    Repairs OPERATING MANUAL ZP 3-5 V4 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 253 OPERATING MANUAL ZP 3-5 V4 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 254: Fig. 10 -6 Installing The Gearbox Unit

    Repairs OPERATING MANUAL ZP 3-5 V4 10.2.2.6 Installing the gearbox unit NOTE Breakage of cast casing Excessively high tightening torques destroy the cast casing! • Observe the tightening torques Fig. 10-6 Installing the gearbox unit Adjacent construction Gearbox unit Gearbox screws...

  • Page 255: Fig. 10 -7 Installing The Motor: Güdel Gearbox Unit

    OPERATING MANUAL ZP 3-5 V4 Repairs 10.2.2.7 Installing the motor Fig. 10-7 Installing the motor: Güdel gearbox unit Motor Gearbox unit Motor screw Forcing screw Elastomer gear rim Lubrication ex Specification Lubrication quantity works Vaseline Cannot be determined Table 10-4 Lubricants: Güdel gearbox unit: elastomer gear rim of the coupling...
  • Page 256 Repairs OPERATING MANUAL ZP 3-5 V4 Install the motor as follows: Switch off the system and secure it with a padlock against being switched on again Remove the forcing screws if necessary Lubricate the elastomer gear rim Attach slings to the motor Ü 2 246...
  • Page 257 OPERATING MANUAL ZP 3-5 V4 Repairs 10.2.3 Replacing the motor CAUTION Hot parts/surfaces Hot surfaces present a burn hazard during work on this product! • Protect yourself by wearing heat-resistant gloves • Allow the parts to cool down first Mark the position of the coupling on the motor shaft. The marking makes it easier for you to re-install the coupling.

  • Page 258: Fig. 10 -8 Replacing The Motor: Positioning The Coupling Half On The Motor Shaft

    Repairs OPERATING MANUAL ZP 3-5 V4 D2=24H7 02/17 Fig. 10-8 Replacing the motor: Positioning the coupling half on the motor shaft Elastomer gear rim Motor shaft Coupling half Motor Coupling screw Tool Item number Corrosion protection Installing the coupling 0502037 agent MOTOREX In-...
  • Page 259 OPERATING MANUAL ZP 3-5 V4 Repairs Replace the motor as follows: Switch off the plant and padlock it to prevent it from being switched on again Remove the cables and lines Remove motor Ü Chapter 10.2.2.3, 2 248 Remove the elastomer gear rim if necessary...
  • Page 260 Repairs OPERATING MANUAL ZP 3-5 V4 10.2.4 Replacing the motor flange and gearbox flange Mark the position of the drill holes of the gearbox flange. Install the new gearbox flange identically Do not change the position of the input shaft...

  • Page 261: Fig. 10 -9 Replacing The Motor Flange And Gearbox Flange

    OPERATING MANUAL ZP 3-5 V4 Repairs Fig. 10-9 Replacing the motor flange and gearbox flange Drill hole Motor flange Gearbox flange Screw Fastening screw 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 2 181...

  • Page 262: Table 10-6 Distinguishing Characteristics Of Wear: Pinion

    Repairs OPERATING MANUAL ZP 3-5 V4 10.2.5 Replacing pinion, bearing, and clamping set The components are designed for continuous use. Their wear depends on the duration of operation of the product and the ambient conditions. Güdel rec- ommends preventatively replacing components as soon as their service life has been reached.
  • Page 263 OPERATING MANUAL ZP 3-5 V4 Repairs The O-ring will be destroyed if you remove the centering flange. Always re- place the O-ring when you have removed the centering flange.

  • Page 264: Fig. 10 -10 Replacing Pinion, Bearing, And Clamping Set: Güdel Gearbox Unit

    Repairs OPERATING MANUAL ZP 3-5 V4 Fig. 10-10 Replacing pinion, bearing, and clamping set: Güdel gearbox unit Pinion O-ring Bearing Clamping set Centering flange Spacing strip Headless set screw Replace the pinion, bearing, and clamping set as follows: Switch off the system and padlock it to secure it against being switched...

  • Page 265: Fig. 10 -11 Setting The Gear Backlash: Güdel Gearbox Unit

    OPERATING MANUAL ZP 3-5 V4 Repairs 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 266 Repairs OPERATING MANUAL ZP 3-5 V4 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 267: Fig. 10 -12 Elastomer Gear Rim

    OPERATING MANUAL ZP 3-5 V4 Repairs 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 268 Repairs OPERATING MANUAL ZP 3-5 V4 10.3 Tasks to perform after a crash Güdel strongly recommends that the work be performed by Güdel techni- cians. Damage to the product can often only be found by experience. For this reason, the following tasks should not be regarded as conclusive.

  • Page 269: Fig. 10 -13 Bumper Unit With Shearing Sleeves

    OPERATING MANUAL ZP 3-5 V4 Repairs 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 270: Fig. 10 -14 Bumper Unit With Pins

    Repairs OPERATING MANUAL ZP 3-5 V4 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 271: Fig. 10 -15 Bumper Unit With Mechanical Limit Stops

    OPERATING MANUAL ZP 3-5 V4 Repairs 10.3.1.3 Bumper unit with limit stops Fig. 10-15 Bumper unit with mechanical limit stops Loctite Blue Threadlocker 7414 Bumper block / bumper bracket Screw Mating part Bumper Assemble the bumper unit as follows: Assemble the bumper on the bumper block / bumper bracket...
  • Page 272 Repairs OPERATING MANUAL ZP 3-5 V4 10.4 Malfunctions / Troubleshooting Malfunction Cause Measure Process inaccuracies Gear backlash too Setting the gear backlash Ü 2 265 large: Güdel gearbox unit Replace the pinion Ü 2 262 Process inaccuracies Pinion worn: Güdel gearbox unit Process inaccuracies...
  • Page 273 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 274 Repairs OPERATING MANUAL ZP 3-5 V4...

  • Page 275: Service Departments

    OPERATING MANUAL ZP 3-5 V4 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 2 287...

  • Page 276: Decommissioning, Storage

    Decommissioning, storage OPERATING MANUAL ZP 3-5 V4 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 277: Decommissioning

    OPERATING MANUAL ZP 3-5 V4 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 278: Identification

    Decommissioning, storage OPERATING MANUAL ZP 3-5 V4 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 279 OPERATING MANUAL ZP 3-5 V4 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 • Perform a lubrication check as described in the separate documentation on automatic lubrication.
  • Page 280 Decommissioning, storage OPERATING MANUAL ZP 3-5 V4...

  • Page 281: Disposal

    OPERATING MANUAL ZP 3-5 V4 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 282: Personnel Qualifications

    Disposal OPERATING MANUAL ZP 3-5 V4 WARNING Heavy components Components can be very heavy. Improper handling can cause severe or fatal injuries! • Use appropriate lifting units • Use suitable means to secure the components against tipping over • Only remove the safety devices after the product has been completely as- sembled 12.1.2...

  • Page 283: Waste Management Compliant

    OPERATING MANUAL ZP 3-5 V4 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 284: Material Groups

    Disposal OPERATING MANUAL ZP 3-5 V4 Disassemble the product as follows: Prerequisite:Prior to disassembly, shut down the product Ü 2 277 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 285: Spare Parts Supply

    OPERATING MANUAL ZP 3-5 V4 Spare parts supply Spare parts supply...
  • Page 286 Spare parts supply OPERATING MANUAL ZP 3-5 V4...

  • Page 287: Service Departments

    OPERATING MANUAL ZP 3-5 V4 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 288: Table 13-1 Service Departments Americas

    Spare parts supply OPERATING MANUAL ZP 3-5 V4 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 289: Table 13-2 Service Departments In Asia

    OPERATING MANUAL ZP 3-5 V4 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 290 Spare parts supply OPERATING MANUAL ZP 3-5 V4 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 291: Table 13-3 Service Departments In Europe

    OPERATING MANUAL ZP 3-5 V4 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 292 Spare parts supply OPERATING MANUAL ZP 3-5 V4...

  • Page 293: Explanations Regarding The Spare Parts List

    OPERATING MANUAL ZP 3-5 V4 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 294: Torque Tables

    Torque tables OPERATING MANUAL ZP 3-5 V4 Torque tables 14.1 Tightening torques for screws NOTE Vibrations Screws without screw lock become loose. • Secure screw connections on moving parts Loctite medium strength 242. • Apply the adhesive on the nut thread, not on the screw!

  • Page 295: Zinc Plated Screws

    OPERATING MANUAL ZP 3-5 V4 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 242: Thread size Tightening torque [Nm] 10.9 12.9...

  • Page 296: Black Screws

    Torque tables OPERATING MANUAL ZP 3-5 V4 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 242: Thread size Tightening torque [Nm] 10.9 12.9 10.1 14.9 17.4 24.6...

  • Page 297: Stainless Steel Screws

    OPERATING MANUAL ZP 3-5 V4 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 242: Thread size Tightening torque [Nm] 0.37 0.86 1.85...

  • Page 298: Tightening Torques For Hv Sets

    Torque tables OPERATING MANUAL ZP 3-5 V4 14.2 Tightening torques for HV sets The following tightening torques apply to DIN6914/15/16-10.9 HV sets: Thread size Tightening torques [Nm] Lubricated with Slightly oiled moly grease 1100 1250 1650 1650 2200 2800 3800 Table 14-4...

  • Page 299: Tightening Torques For Clamping Sets

    OPERATING MANUAL ZP 3-5 V4 Torque tables 14.3 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 300: Thread Rolling Screws

    Torque tables OPERATING MANUAL ZP 3-5 V4 14.4 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. 14-3...

  • Page 301: Illustrations

    OPERATING MANUAL ZP 3-5 V4 Illustrations Illustrations Fig. 3 -1 Danger label "danger sign" ............29 Fig. 3 -2 Danger label "Transport information" ........30 Fig. 4 -1 Type plate ..................34 Fig. 4 -2 Position of the type plate ............. 35 Fig.
  • Page 302 Illustrations OPERATING MANUAL ZP 3-5 V4 Fig. 7 -22 Attaching the slings: Z-axis, sizes 2-5 ........89 Fig. 7 -23 Danger label "Provisionally assembled bumper unit" ..... 92 Fig. 7 -24 Bumper unit with mechanical limit stops ........93 Fig. 7 -25 Aligning the gearbox flange ............
  • Page 303 OPERATING MANUAL ZP 3-5 V4 Illustrations Fig. 9 -5 Automatic lubrication system FlexxPump ........ 149 Fig. 9 -6 Automatic lubrication system FlexxPump ........ 149 Fig. 9 -7 Automatic lubrication system Memolub ........150 Fig. 9 -8 Automatic lubrication system Memolub ........150 Fig.
  • Page 304 Illustrations OPERATING MANUAL ZP 3-5 V4 Fig. 9 -36 Setting the double rollers: Prism guideway, eccentric rollers ....................207 Fig. 9 -37 Setting the rollers: Prism guideway, eccentric rollers .... 209 Fig. 9 -38 Mounting aid for rack installation ..........211 Fig.
  • Page 305 OPERATING MANUAL ZP 3-5 V4 Illustrations Fig. 13 -1 Explanation of symbols ..............293 Fig. 14 -1 Tightening the clamping set ............299 Fig. 14 -2 Releasing the clamping set ............299 Fig. 14 -3 Use of thread rolling screws ............300...
  • Page 306 Illustrations OPERATING MANUAL ZP 3-5 V4...
  • Page 307 OPERATING MANUAL ZP 3-5 V4 List of tables List of tables Table -1 Revision history................Table 2-1 Explanation of symbols/abbreviations ......... 20 Table 4-1 Temperature ranges................ 36 Table 6-1 Z-axis slings: Sizes................45 Table 7-1 Special tools, testing and measuring instruments..... 53...
  • Page 308 List of tables OPERATING MANUAL ZP 3-5 V4 Table 9-7 Lubricants: Automatic lubrication system Memolub....150 Table 9-8 Lubricants: Automatic lubrication system Memolub....150 Table 9-9 Lubricants: SKF-Vogel automatic lubrication system ....150 Table 9-10 Lubricant table.................. 151 Table 9-11 Maintenance intervals in shift operation (5 days a week) ..
  • Page 309 OPERATING MANUAL ZP 3-5 V4 List of tables Table 10-5 Special tools, testing and measuring instruments..... 258 Table 10-6 Distinguishing characteristics of wear: Pinion ......262 Table 10-7 Distinguishing characteristics of wear: Bearing......262 Table 10-8 Distinguishing characteristics of wear: Clamping set ....262 Table 10-9 Tightening torques of screws of casing cover......
  • Page 310 List of tables OPERATING MANUAL ZP 3-5 V4...
  • Page 311 OPERATING MANUAL ZP 3-5 V4 Index Index Adhesive anchor ......75 Base ..........50 Air humidity ......36, 276 Base mounting ........ 75 Align Y-rack Base plates Removing the transport securing anchoring ........58 device ........118 Positioning ........56...
  • Page 312 Index OPERATING MANUAL ZP 3-5 V4 Customer feedback ....243 Cable Relieving strain ......114 Decommissioning ......276 Cartridge Disassembling ........ 283 Replacing ........164 Guideway ........211 C-axis ..........117 Disposal .......... 281 Check Disposal facilities ......284 Automatic lubrication system ..
  • Page 313 OPERATING MANUAL ZP 3-5 V4 Index Identification ........278 Gear backlash Setting: Güdel gearbox unit .. 265 Identification of lubrication points ............148 Gearbox Replacing: Güdel gearbox unit ..Initial assembly ...... 94, 185 178, 183 Initial lubrication ......136...
  • Page 314 Index OPERATING MANUAL ZP 3-5 V4 Ledge Maintenance jobs Removing ........202 After 100 hours ...... 157 Leveling Maintenance tasks ......143 Upright ........62 After 11,250 hours ....170 After 150 hours ...... 159 Leveling of the guide chute After 2,250 hours ....
  • Page 315 OPERATING MANUAL ZP 3-5 V4 Index Occupational safety ...... 26 Rack Cleaning ........136 Replacing ........246 Lubricating ........ 159 Pre-lubrication ......137 Operation ......21, 141 Rack quality ........220 Options ..........36 Connecting ......117 Rack transition Checking ......87, 214 Original spare part ....
  • Page 316 Index OPERATING MANUAL ZP 3-5 V4 O-ring ........262 Pinion ........262 Safety brake system ....117 Roller ........197 Safety data sheet ......32 Sensor ........216 Slide bars ........176 Sensor Storage: Güdel gearbox unit 183 Replacing ........216 Switch ........
  • Page 317 OPERATING MANUAL ZP 3-5 V4 Index Strain relief Attaching ........114 Unpacking ........51 Switch Upright Replacing ........216 Aligning ........70 Correcting height ...... 63 Symbol ..........28 Leveling ........62 Measuring height ...... 62 Securing ........64 Technical data ........ 35 setting up ........
  • Page 318 Index OPERATING MANUAL ZP 3-5 V4...
  • Page 319 OPERATING MANUAL ZP 3-5 V4 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 320 Appendix OPERATING MANUAL ZP 3-5 V4...
  • Page 321 OPERATING MANUAL ZP 3-5 V4 Appendix Hazard analysis, Risk analysis...
  • Page 322 Appendix OPERATING MANUAL ZP 3-5 V4...
  • Page 323 Customer: Risk assessment / safety goals / protective measures / residual risks Machine type: all modules 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...
  • Page 324 Customer: Risk assessment / safety goals / protective measures / residual risks Machine type: all modules 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...
  • Page 325 Customer: Risk assessment / safety goals / protective measures / residual risks Machine type: all modules 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...
  • Page 326 OPERATING MANUAL ZP 3-5 V4 Appendix Addition to declaration of incorporation...
  • Page 327 Appendix OPERATING MANUAL ZP 3-5 V4...
  • Page 328 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 329 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 330 OPERATING MANUAL ZP 3-5 V4 Appendix Technical data...
  • Page 331 Appendix OPERATING MANUAL ZP 3-5 V4...
  • Page 332 OPERATING MANUAL ZP 3-5 V4 Appendix Layout...
  • Page 333 Appendix OPERATING MANUAL ZP 3-5 V4...
  • Page 334 OPERATING MANUAL ZP 3-5 V4 Appendix Spare parts lists...
  • Page 335 Appendix OPERATING MANUAL ZP 3-5 V4...
  • Page 336 OPERATING MANUAL ZP 3-5 V4 Appendix Options...
  • Page 337 Appendix OPERATING MANUAL ZP 3-5 V4...
  • Page 338 OPERATING MANUAL ZP 3-5 V4 Appendix Third-party documentation...
  • Page 339 Appendix OPERATING MANUAL ZP 3-5 V4...
  • Page 341 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 342 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 343 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 344 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 345 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 346 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 347 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 348 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 349 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 350 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 351 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 352 ...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 353 OPERATING MANUAL ZP 3-5 V4 Version larmin Author Date 02.05.2018 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 354 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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