GUDEL ZP 3-5 V4 User manual

OPERATING MANUAL
ZP 3-5 V4
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG ZP 3-5 V472057594174110603_V5.0_EN-US
B1M.10xxxxxxx-xxxx
10xxxxxxx
99xxxxxxx
2018

© 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.
72057594174110603_v5.0_EN-US

Revision history
Version Date Description
5.0 02.05.2018 Valid as of product version ZP-3V4.11;
ZP-4V4.21; ZP-5V4.01
New
• 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
Updated:
• Position the base plates Ü256
• Anchor the base plates Ü258
• General inspection Ü2161
• Mount motor Ü294
4.0 15.02.2018 New:
• Feedback on instructions
ÜChapter9.7,2243
• Intervention report
• Malfunctions / Troubleshooting
ÜChapter10.4,2272
Modified:
• New gearbox unit with elastomer cou-
pling
Added:
• Double rollers Ü2197
Updated:
• Module of ZP-5 rack module Ü2220
• Setting the gear backlash Ü2265
3.0 16.02.2017 Updated:
• Entire manual updated
Revision historyOPERATING MANUAL ZP 3-5 V4
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3

Version Date Description
2.0 29.11.2016 Updated:
• New signatures on declaration of incor-
poration ÜChapter1,217
• Entire manual updated
1.0 21.04.2016 Basic version
Table-1 Revision history
Revision history OPERATING MANUAL ZP 3-5 V4
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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..................................................22
3.1.2.1 Operating companies....................................................23
3.1.2.2 Transport specialists....................................................23
3.1.2.3 Fitters ................................ .................................23
3.1.2.4 Commissioning technicians ...................... .......................24
3.1.2.5 Operators .............................. ...............................24
3.1.2.6 Manufacturer's technicians.............................................. 24
3.1.2.7 Maintenance technicians.................................................25
3.1.2.8 Service technicians .......................... ...........................25
3.1.2.9 Disposal specialists.......................... ...........................25
3.1.3 Disregarding safety regulations.......................................... 26
3.1.4 Installation instructions..................................................26
3.2 Hazard symbols in the manual .....................................27
3.2.1 Hazard warnings .......................................................27
3.2.2 Explanation of warning symbol.......................................... 28
3.3 Hazard symbols on the product.................................... 29
3.3.1 Danger label "danger sign"...............................................29
3.3.2 Danger label "Transport information"................. ..................30
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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.................................................31
3.4.3 Material safety data sheets (MSDS)...................................... 32
4 Product description 33
4.1 Use ................................. ..................................33
4.1.1 Intended use............................. ..............................33
4.1.2 Non-intended use.......................................................33
4.2 Product designation........................ .........................34
4.2.1 Type plate .............................. ...............................34
4.2.2 Position of the type plate................................................35
4.3 Technical data........................... ............................35
4.4 Options .............................. ................................36
5 Design, function 37
5.1 Design................................................................ 37
5.2 Function .............................................................38
6 Transport 39
6.1 Packaging symbols....................................................40
6.2 Industrial trucks .......................... ...........................41
6.3 Slings................................ .................................41
6.3.1 Attaching the slings: Güdel uprights.................. ...................42
6.3.2 Attaching the slings: Beam...............................................44
6.3.3 Attaching the slings: Z-axis, sizes 2-5.................................... 45
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7 Commissioning 47
7.1 Introduction .........................................................47
7.1.1 Safety.................................................................. 47
7.1.2 Personnel qualifications..................................................48
7.2 Intermediate storage................................................48
7.3 Downtimes ............................ ..............................49
7.4 Setup, fastening .....................................................50
7.4.1 General................................................................ 50
7.4.2 Prerequisites............................................................50
7.4.3 Unpacking .............................................................51
7.4.4 Attaching the slings: Beam...............................................52
7.4.5 Setup process.......................................................... 53
7.4.5.1 Special tools, testing and measuring instruments..........................53
7.4.5.2 Positioning the base plates.............................................. 56
7.4.5.3 Anchoring the base plates ...............................................58
7.4.5.4 Setting up an upright ...................................................59
7.4.5.5 Leveling uprights ........................... ............................62
Measuring height of upright.......................................... 62
Determining average upright height ..................................63
Correcting the upright height........................................ 63
7.4.5.6 Securing uprights against falling over .....................................64
7.4.5.7 Installing a beam: Standard.............................................. 64
7.4.5.8 Installing a beam: Beam leveling kit.......................................66
7.4.5.9 Connecting the beams.................................................. 67
7.4.5.10 Straightening beams.....................................................68
Aligning upright and beam............................................ 70
Aligning the beam horizontally....................................... 71
7.4.5.11 Assembling the bumper unit.............................................72
Bumper unit with shearing sleeves.................................... 74
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7.4.6 Anchoring the product ........................ .........................75
7.4.6.1 Base mounting with adhesive anchor.....................................75
7.4.6.2 Fixing base with welded joint ..................... ......................78
HST3............................................................... 79
HAS-TZ / HVU-TZ.................................................. 80
HIT-Z / HIT-HY-200-A.............................................. 82
7.5 Installing .............................................................84
7.5.1 Using the mounting aid: Installing the rack................................84
7.5.2 Installing the guideway.................................................. 85
7.5.3 Check rack transition....................................................87
7.5.4 Installing the Z-axis......................................................89
7.5.4.1 Attaching the slings: Z-axis, sizes 2-5.................................... 89
7.5.4.2 Preparations ............................. ..............................90
7.5.4.3 Inserting the Z-axis......................................................90
7.5.4.4 Assembling the bumper unit.............................................91
Bumper unit with limit stops......................................... 93
7.5.5 Installing the motor .....................................................94
7.5.5.1 Information on initial assembly.......................................... 94
7.5.5.2 Prerequisites............................................................94
7.5.5.3 Aligning the gearbox flange .............................................95
7.5.5.4 Aligning the input shaft to the gearbox flange............................ 97
7.5.5.5 Positioning the coupling on the motor shaft.............. ...............99
7.5.5.6 Installing the motor and coupling........................................102
7.5.6 Check leveling of the guide chute.......................................105
7.5.7 Connecting the side panels .............................................106
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..................................................112
7.6.4 Relieving the cables and lines of strain.................................. 114
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7.7 Connection .........................................................117
7.7.1 Attaching optional components........................................ 117
7.7.2 Attaching the load .....................................................117
7.7.3 Integrating the product................................................ 117
7.8 Transport securing devices ................... .................... 118
7.8.1 Removing the transport securing device................................ 120
7.8.2 Installing transport securing device.................. ...................122
7.9 Fine adjustment of the Z-axis......................................127
7.9.1 X-direction: Standard..................................................127
7.9.2 X-direction: Beam leveling kit.......................................... 129
7.9.3 Y-direction: Standard.................................................. 132
7.9.4 Y-direction: Safety brake system................... ....................133
7.10 Initial lubrication ...................................................136
7.10.1 Clean guideways and racks..............................................136
7.10.2 Pre-lubricate guideways and racks...................................... 137
7.10.3 Carrying out a lubrication check.......................................138
7.11 Functional check....................................................139
8 Operation 141
8.1 General .............................................................141
8.2 Personnel ...........................................................141
9 Maintenance 143
9.1 Introduction ........................... ............................ 143
9.1.1 Safety................................ .................................143
9.1.2 Personnel qualifications................................................ 144
9.2 Consumables and auxiliary agents................ ................ 145
9.2.1 Cleaning agents .......................................................145
9.2.1.1 Table of cleaning agents ...............................................145
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9.2.2 Lubricants .............................................................146
9.2.2.1 Lubrication ...........................................................146
Manual lubrication..................................................147
Automatic lubrication system.......................................149
9.2.2.2 Lubricant table........................................................ 151
9.3 Maintenance tasks..................................................152
9.3.1 General prerequisites..................................................152
9.3.2 Maintenance intervals..................................................152
9.3.3 Special tools, testing and measuring instruments........................ 154
9.3.4 Maintenance tasks after downtimes <4 weeks...........................156
9.3.5 Maintenance tasks after downtimes >4 weeks...........................156
9.3.6 Maintenance tasks 100 hours after commissioning.......................157
9.3.6.1 Carrying out a lubrication check.......................................158
9.3.7 Maintenance tasks after 150 hours.................. ...................159
9.3.7.1 Lubricating guideways, racks and pinions ...............................159
9.3.8 Maintenance tasks after 2,250 hours ...................................161
9.3.8.1 General inspection.....................................................161
9.3.8.2 Replacing the battery.................................................. 164
9.3.8.3 Replacing the cartridge.................................................164
9.3.8.4 Carrying out a lubrication check.......................................165
9.3.9 Maintenance tasks after 6,750 hours ...................................166
9.3.9.1 Replacing the lubricating pinion.........................................166
9.3.9.2 Replacing the wiper and lubrication unit................................ 168
9.3.10 Maintenance tasks after 11,250 hours...................................170
9.3.10.1 Checking automatic lubrication system................ .................170
9.3.11 Maintenance tasks after 22,500 hours...................................171
9.3.11.1 Replacing the automatic lubrication pump...............................171
9.3.11.2 Replacing the energy chain..............................................171
Removing the energy chain .........................................171
Laying the cables and lines..........................................171
Installing the energy chain...........................................174
Final tasks..........................................................176
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