GUDEL CP 3-5 V2 User manual

OPERATING MANUAL
CP 3-5 V2
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG CP 3-5 V29007202252815371_V1.0_EN-US
B1M.10xxxxxxx-xxxx
10xxxxxxx
99xxxxxxx
2019

© 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. Subject to change due to technical im-
provements.
9007202252815371_v1.0_EN-US

Revision history
Version Date Description
1.0 17.06.2019 Basic version
Table-1 Revision history
Revision historyOPERATING MANUAL CP 3-5 V2
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Revision history OPERATING MANUAL CP 3-5 V2
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Table of contents
1 Declaration of incorporation 17
2 General 19
2.1 Further applicable documentation................ .................19
2.2 Purpose of the document..................... ......................19
2.3 Explanation of symbols/abbreviations.............................. 20
3 Safety 21
3.1 General ...............................................................21
3.1.1 Product safety .........................................................21
3.1.2 Personnel qualifications..................................................21
3.1.2.1 Operating companies....................................................22
3.1.2.2 Transport specialists....................................................22
3.1.2.3 Fitters ................................ .................................22
3.1.2.4 Commissioning technicians ...................... .......................23
3.1.2.5 Operators .............................. ...............................23
3.1.2.6 Manufacturer's technicians.............................................. 23
3.1.2.7 Maintenance technicians.................................................24
3.1.2.8 Service technicians .......................... ...........................24
3.1.2.9 Disposal specialists.......................... ...........................24
3.1.3 Disregarding safety regulations.......................................... 25
3.1.4 Installation instructions..................................................25
3.2 Hazard symbols in the manual .....................................26
3.2.1 Hazard warnings .......................................................26
3.2.2 Explanation of warning symbol.......................................... 27
3.3 Hazard symbols on the product.................................... 28
3.3.1 Danger label "danger sign"...............................................28
3.3.2 Danger label "Tearing due to rack"...................................... 29
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3.4 Fundamentals of safety..............................................30
3.4.1 Separating protective equipment, monitoring equipment........ .........30
3.4.2 Product-specific hazards.................................................30
3.4.3 Material safety data sheets (MSDS)...................................... 33
4 Product description 35
4.1 Use ................................. ..................................35
4.1.1 Intended use............................. ..............................35
4.1.2 Non-intended use.......................................................35
4.2 Product designation........................ .........................36
4.2.1 Type plate .............................. ...............................36
4.2.2 Position of the type plate................................................37
4.3 Technical data........................... ............................37
4.4 Options .............................. ................................38
5 Design, function 39
5.1 Design................................................................ 39
5.2 Function .............................................................40
5.2.1 Protective equipment....................................................41
6 Transport 43
6.1 Packaging symbols....................................................44
6.2 Industrial trucks .......................... ...........................45
6.3 Slings................................ .................................45
6.3.1 Attaching the slings: Beam...............................................46
6.3.2 Attaching the slings: Beam...............................................48
6.3.3 Attaching the slings: carriage............................................ 50
6.3.4 Attaching the slings: Z-axis, sizes 2-5.................................... 51
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7 Commissioning 53
7.1 Introduction .........................................................53
7.1.1 Safety.................................................................. 53
7.1.2 Personnel qualifications..................................................54
7.2 Intermediate storage................................................54
7.3 Downtimes ............................ ..............................55
7.4 Setup, fastening .....................................................57
7.4.1 General................................................................ 57
7.4.2 Prerequisites............................................................57
7.4.3 Unpacking .............................................................58
7.4.4 Setup process.......................................................... 58
7.4.4.1 Special tools, testing and measuring instruments..........................59
7.4.4.2 Positioning the base plates.............................................. 61
7.4.4.3 Anchoring the base plates ...............................................62
7.4.4.4 Set up an upright........................... ............................63
7.4.4.5 Leveling uprights ........................... ............................65
Measuring height of upright.......................................... 65
Determining average upright height ..................................66
Correcting the upright height........................................ 66
7.4.4.6 Securing uprights against falling over .....................................67
7.4.4.7 Installing the beams......................................................67
7.4.4.8 Connecting the beams.................................................. 69
7.4.4.9 Straightening beams.....................................................70
Aligning upright and beam............................................ 71
Aligning the beam horizontally....................................... 73
7.4.5 Anchoring the product ........................ .........................74
7.4.5.1 Base mounting with adhesive anchor.....................................75
7.4.5.2 Fixing base with welded joint ..................... ......................77
HST3............................................................... 78
HAS-TZ / HVU-TZ..................................................79
HIT-Z / HIT-HY-200-A..............................................81
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7.5 Installing .............................................................82
7.5.1 Using the mounting aid: Installing the rack................................82
7.5.2 Installing the rack .......................................................83
7.5.3 Check rack transition....................................................85
7.5.4 Installing the guideway.................................................. 87
7.5.5 Inserting the Y-axis......................................................88
7.5.6 Installing the Z-axis......................................................89
7.5.6.1 Attaching the slings: Z-axis, sizes 2-5.................................... 89
7.5.6.2 Preparations ............................. ..............................90
7.5.6.3 Inserting the Z-axis......................................................90
7.5.6.4 Assembling the bumper unit.............................................91
Bumper unit with limit stops......................................... 93
7.5.7 Installing the motor .....................................................94
7.5.7.1 Information on initial assembly.......................................... 94
7.5.7.2 Prerequisites............................................................94
7.5.7.3 Aligning the gearbox flange .............................................95
7.5.7.4 Aligning the input shaft to the gearbox flange............................ 97
7.5.7.5 Positioning the coupling on the motor shaft.............. ...............99
7.5.7.6 Installing the motor and coupling........................................102
7.5.8 Changing the lubricating position........................................105
7.5.9 Check leveling of the guide chute.......................................106
7.5.10 Connecting the side panels .............................................107
7.6 Assembling the energy chain ...................................... 108
7.6.1 Laying the cables and lines...................... .......................108
7.6.2 Installing the energy chain..............................................111
7.6.3 Installing the slide bars..................................................113
7.6.4 Relieving the cables and lines of strain.................................. 114
7.7 Connection .........................................................116
7.7.1 Attaching optional components........................................ 116
7.7.2 Attaching the load .....................................................117
7.7.3 Integrating the product................................................ 117
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7.8 Transport securing devices ................... .................... 118
7.8.1 Removing the transport securing device................................ 119
7.8.2 Installing transport securing device.................. ...................120
7.8.2.1 Checking the transport securing device .................................123
7.8.2.2 Tighten the coupling screws ...........................................124
7.8.2.3 Final tasks .............................................................124
7.9 Initial lubrication ...................................................124
7.9.1 Clean guideways and racks..............................................124
7.9.2 Pre-lubricate guideways and racks...................................... 125
7.9.3 Carrying out a lubrication check.......................................127
7.10 Functional check....................................................128
8 Operation 129
8.1 General .............................................................129
8.2 Personnel ...........................................................129
9 Maintenance 131
9.1 Introduction ........................... ............................ 131
9.1.1 Safety................................ .................................131
9.1.2 Personnel qualifications................................................ 132
9.2 Consumables and auxiliary agents................ ................ 133
9.2.1 Cleaning agents .......................................................133
9.2.1.1 Table of cleaning agents ...............................................133
9.2.2 Lubricants .............................................................133
9.2.2.1 Lubrication ...........................................................134
Manual lubrication..................................................134
Automatic lubrication system.......................................136
9.2.2.2 Lubricant table........................................................ 138
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9.3 Maintenance tasks..................................................139
9.3.1 General prerequisites..................................................139
9.3.2 Maintenance intervals..................................................139
9.3.3 Special tools, testing and measuring instruments........................ 141
9.3.4 Maintenance tasks after cleaning or downtimes 1<4 weeks.............. 143
9.3.5 Maintenance tasks after downtimes >4 weeks...........................143
9.3.6 Maintenance tasks 100 hours after commissioning.......................144
9.3.6.1 Carrying out a lubrication check.......................................145
9.3.7 Maintenance tasks after 150 hours.................. ...................146
9.3.7.1 Lubricating guideways, racks and pinions ...............................146
9.3.8 Maintenance tasks after 2,250 hours ...................................147
9.3.8.1 General inspection.....................................................147
9.3.8.2 Greasing the roller.....................................................151
9.3.8.3 Replacing the cartridge.................................................152
9.3.8.4 Replacing the battery.................................................. 152
9.3.8.5 Carrying out a lubrication check.......................................152
9.3.9 Maintenance tasks after 6,750 hours ...................................153
9.3.9.1 Replacing the lubricating pinion.........................................153
9.3.9.2 Replacing the wiper and lubrication unit................................ 154
9.3.9.3 Replacing the wiper and lubricating element............................ 156
9.3.10 Maintenance tasks after 11,250 hours...................................158
9.3.10.1 Checking automatic lubrication system................ .................158
9.3.11 Maintenance tasks after 22,500 hours...................................159
9.3.11.1 Replacing the automatic lubrication pump...............................159
9.3.11.2 Replacing the energy chain..............................................159
Removing the energy chain .........................................159
Laying the cables and lines..........................................159
Installing the energy chain...........................................162
Final tasks..........................................................163
9.3.11.3 Replacing the slide bars................................................ 164
Replacing and pre-assembling the slide bars..........................164
Installing the slide bars..............................................164
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