ZIMM Z Series User manual

2015-01
1.2
EN
Instruction manual
Installation –Operation –Maintenance –Inspection
ZIMM Screw Jacks
Z-5 to Z-1000
GSZ-2 to GSZ-100

Translation of the original instruction manual
Publisher
ZIMM Maschinenelemente GmbH + Co KG
Millennium Park 3
6890 Lustenau/Austria
Tel.: [phone]
Fax: [phone]
e-mail: [e-mail]
Internet: http://www.zimm.eu
Author
ZIMM Maschinenelemente GmbH + Co KG
Issue date
2015-01
Version
1.2
Copyright
© 2015 ZIMM Maschinenelemente GmbH + Co KG
We reserve the right to make changes to technical aspects and content
Legal notices
The contents of this instruction manual must be kept confidential. It is
intended only for use by company personnel.
Reproduction or distribution and release of this instruction manual to
third parties is prohibited. Offenders are liable to pay damages.
The ZIMM Maschinenelemente GmbH + Co KG accepts no liability for
damages arising from disregard of this instruction manual.

ZIMM Screw Jack 1About this document
2015-01 Version 1.2 3
Contents
1About this document .......................................................................................................................5
1.1 Use of this instruction manual.............................................................................................5
1.2 Symbols and identifying marks...........................................................................................5
2Safety.................................................................................................................................................6
2.1 Use for the intended purpose .............................................................................................6
2.2 Duties of the operating company........................................................................................6
3Scope of supply................................................................................................................................7
4Description of the product ..............................................................................................................7
4.1 Overview.............................................................................................................................7
4.2 Rating plate.........................................................................................................................8
4.3 Versions/variants ................................................................................................................9
4.4 Grease nipple....................................................................................................................10
5Transport and storage ...................................................................................................................11
5.1 Transport...........................................................................................................................11
5.2 Storage..............................................................................................................................13
6Installation.......................................................................................................................................14
6.1 Installing screw jacks and bevel gear drives.....................................................................15
6.2 Fitting the couplings and connecting shafts......................................................................16
6.3 Fitting the motor................................................................................................................18
6.4 Connecting the electrical components..............................................................................19
6.5 Trial running......................................................................................................................21
6.6 Correcting the alignment...................................................................................................22
6.7 Commissioning .................................................................................................................23
6.8 Running-in phase..............................................................................................................23
7Operation and maintenance..........................................................................................................24
7.1 Inspection..........................................................................................................................24
7.2 Lubrication ........................................................................................................................25
7.3 Troubleshooting ................................................................................................................31
8Decommissioning and recommissioning....................................................................................33
9Repair and replacement.................................................................................................................33
10 Disposal...........................................................................................................................................33
11 Declaration of incorporation.........................................................................................................34

1About this document ZIMM Screw Jack
4Version 1.2 2015-01
12 Appendix: Inspection certificate...................................................................................................35

ZIMM Screw Jack 1About this document
2015-01 Version 1.2 5
1 About this document
1.1 Use of this instruction manual
This instruction manual forms part of the ZIMM Screw Jack.
Before using the equipment read the instruction manual carefully.
Keep the instruction manual safe throughout the working life of the
equipment.
Keep the instruction manual available to operating and maintenance
personnel at all times.
Pass the instruction manual to any subsequent owner or user of the
equipment.
Keep the instruction manual updated with any supplements issued
by the manufacturer.
1.2 Symbols and identifying marks
Symbol
Meaning
DANGER
Hazards to personnel
Disregard will lead to death or serious injuries.
WARNING
Hazards to personnel
Disregard may lead to death or serious injuries.
CAUTION
Hazards to personnel
Disregard may lead to minor injuries.
CAUTION
Information for avoiding damage to property
NOTE
Notes for understanding or
optimising working procedures

Precondition to an operation

Single step operation requirement
1. …
2. …
Multi-step operation requirement
Comply with the sequence
Tab. 1: Symbols and identifying marks

2Safety ZIMM Screw Jack
6Version 1.2 2015-01
2 Safety
The ZIMM Screw Jack has been produced to modern standards and
recognised safety regulations. Nevertheless hazards to life and limb of
the users or third parties, or risks of damage to the ZIMM Screw Jack
and other property may arise during use.
The ZIMM Screw Jack may be used only when it is in technically
good condition and in compliance with the instruction manual.
Have any defects rectified without delay.
Do not perform any unauthorised modifications to the ZIMM Screw
Jack.
Fit only original spare parts from ZIMM Maschinenelemente
GmbH + Co KG.
2.1 Use for the intended purpose
The ZIMM Screw Jack is suitable only for lifting, lowering, tilting and
advancing movements within the specified lifting capacity ranges.
Responsibility to ensure correct use lies with the user.
Screw jacks may be used only in the context and within the limits
specified in our catalogues and brochures.
To ensure compliance with the statutory limits for electromagnetic
compatibility, the ZIMM Screw Jack may be used only within industrial
applications as defined in EN 50 081-2.
Use for any purpose other than these intended purposes constitutes
improper use.
If in doubt regarding the application of the ZIMM Screw Jack, consult
ZIMM Maschinenelemente GmbH + Co KG before proceeding.
2.2 Duties of the operating company
Ensure that the ZIMM Screw Jack is operated and maintained only
in compliance with this instruction manual and the rules and
regulations applicable in the country of use.
Ensure that the personnel
–responsible for operating the ZIMM Screw Jack are authorised,
–are trained and qualified for the respective work,
–have read and understood this instruction manual,
–know the applicable safety rules and
–wear personal safety equipment
(safety gloves, safety helmet and safety shoes).

ZIMM Screw Jack 3Scope of supply
2015-01 Version 1.2 7
3 Scope of supply
The ZIMM Screw Jack is delivered in sufficiently secure packaging to
prevent possible damage in transit.
The scope of supply of the ZIMM Screw Jack includes the following
parts:
•ZIMM Screw Jack
•This instruction manual
•Further parts as listed on the delivery note
4 Description of the product
4.1 Overview
Fig. 1: Overview ZIMM Screw Jack
A to F: Faces of the ZIMM Screw Jack. For the Z series this is also
displayed on the casing.

4Description of the product ZIMM Screw Jack
8Version 1.2 2015-01
4.2 Rating plate
Fig. 2: Example of a rating plate
1 ZIMM contact data
2 Type designation
3 Maximum static load gearbox
(spindle etc. not considered)
4 Gear ratio
5 Rated speed
6 max. speed
7 Serial number
8 Serial number as
Data Matrix Code

ZIMM Screw Jack 4Description of the product
2015-01 Version 1.2 9
4.3 Versions/variants
Variant
Static (S version)
Rotating (R version)
Z series,
Standard
(with trapezoidal screw drive TR)
1 Travelling nut
2 Trapezoidal screw
spindle TR
3 Housing, Z series
4 Drive shaft
5 Spindle lubrication
6 Limit switch
7 Protective tube
Z series,
with ball screw drive KGT
1 Ball screw spindle KGT
2 Spindle lubrication
3 Gearbox for ball screw
drive KGT

4Description of the product ZIMM Screw Jack
10 Version 1.2 2015-01
Variant
Static (S version)
Rotating (R version)
Z series,
with safety nut SIFA
1 Electrical or optical
monitoring
2 Gearbox with integral safety
nut SIFA
3 Safety nut SIFA
4 Electrical monitoring
GSZ series,
Standard
1 Housing, GSZ series
4.4 Grease nipple
S and R versions of the ZIMM Screw Jack are fitted with grease nipples,
which allow simple and clean greasing of the spindle (apart from the
flanged nut FM).
NOTE
For optimum greasing, use an automatic grease dispenser (such
as the Z-LUB).

ZIMM Screw Jack 5Transport and storage
2015-01 Version 1.2 11
5 Transport and storage
5.1 Transport
WARNING
Falling load!
Falling loads may lead to serious injuries.
Make sure that the lifting slings that are used are securely
attached and cannot slip.
Do not remain under a suspended load.
Wear personal safety equipment.
CAUTION
Heavy weight!
Injuries from parts weighing 25 kg and above.
Transport the heavy ZIMM Screw Jack correctly (max. 25 kg per
person).
CAUTION
Damage to the ZIMM Screw Jack!
On receipt, check the packaging for signs of damage.
Do not let the ZIMM Screw Jack drop, and do not subject it to
impacts.
Use appropriate lifting gear as necessary.
Risk of bending the spindle!
Take particular care when handling long and slender spindles, so
as to avoid bending them.

5Transport and storage ZIMM Screw Jack
12 Version 1.2 2015-01
Fig. 3: Examples for transporting the S version
When lifting with a crane, attach the slings to the lifting points
provided.
When lifting the ZIMM Screw Jack for transport, spread the weight
as evenly as possible across all the lifting points.
Fig. 4: Examples for transporting the R version
S version
R version

ZIMM Screw Jack 5Transport and storage
2015-01 Version 1.2 13
For secure attachment, insert ring bolts or ring nuts to the gearbox.
Fig. 5: Fit ring bolts (1) or ring nuts (not supplied)
5.2 Storage
CAUTION
Incorrect storage!
Damage due to corrosion.
Store only in enclosed and dry rooms.
Do not store for more than a brief period in areas that although
roofed still allow free circulation of air from outside.
Perform commissioning not later than 1 year after delivery (the
dispatch from ZIMM is the relevant date).
For other storage conditions and storage times:
Consult ZIMM Maschinenelemente GmbH + Co KG.
Securing for transport

6Installation ZIMM Screw Jack
14 Version 1.2 2015-01
6 Installation
CAUTION
Laceration, trapping and crushing hazards!
Switch off the entire system and secure it against switching on
again.
Allow only skilled and trained personnel to perform the work.
Do not remove the covers that are fitted.
Wear personal safety equipment.
Sharp edges!
Laceration hazard.
Wear safety gloves.
CAUTION
High forces are generated!
Material damage to the entire system and the screw jack.
Ensure that the following installation conditions are satisfied:
–Limit switches are not overrun.
–For parallelism and angularity tolerances: see section 6.1,
page 15.
–Directions of rotation and movement are correct for all
components.
–Safety clearance between moving and fixed parts is
maintained.
Lack of self-locking!
Material damage to the entire system and the screw jack due to lack of
self-locking for spindles with ball screw drive KGT.
Spring pressure brake FDB or brake motor provided.
For the S version run-off protection AS or torsional protection VS is
provided.
In particular for vertical installation, make sure that during
installation neither the spindle nor the nut unscrews.

ZIMM Screw Jack 6Installation
2015-01 Version 1.2 15
CAUTION
The system will run on!
Material damage to the entire system and the screw jack due to
running on.
•The run-on travel may increase after the running-in phase.
If necessary provide a spring pressure brake FDB or brake motor.
NOTE
Additional hazards may arise during installation and operation of the
overall system.
Comply with regional regulations and take necessary measures
(such as risk assessment).
Document all additional hazards in the documentation for the
overall system.
6.1 Installing screw jacks and bevel gear drives
Ensure that the spindle of the ZIMM Screw Jack or on the ZIMM
Screw Jack cannot be exposed to lateral loads.
Fig. 6: Side forces on the spindle are not permissible.
Fig. 7: Flatness, parallelism and angular accuracy

6Installation ZIMM Screw Jack
16 Version 1.2 2015-01
1. Install the ZIMM Screw Jack and ensure straight alignment for the
spindle attachments.
2. Install the ZIMM Screw Jack with bolts, tighten the installation bolts.
3. Install the spindle attachment with bolts, tighten the installation
bolts.
Fig. 8: Exceptions: Maximum inclination angle for self-aligning
nuts (PM) is 3°, install all other nuts at right angles.
The T version can be turned round to change the direction of rotation.
Fig. 9: T version (bevel gear drive)
Check the direction of rotation at installation.
6.2 Fitting the couplings and connecting shafts
The screw jacks to be connected must have been fully installed.
The bevel gear drives must be installed where appropriate.
CAUTION
Moving parts!
Injuries due to rotating parts.
Switch off the entire system and secure it against switching on
again.
1. Place the connecting shaft on the shaft extensions (ZIMM Screw
Jack or bevel gear drives). Check that the gearboxes are correctly
levelled.
Bevel gear drive

ZIMM Screw Jack 6Installation
2015-01 Version 1.2 17
2. Secure the coupling half shells with attachment bolts tightened to
the following torques:
Connecting shaft
Coupling
Torque
VWZ-30
KUZ-KK-16
4 Nm
VWZ-40
KUZ-KK-24
8 Nm
VWZ-60
KUZ-KK-32
15 Nm
VWZ-60V
KUZ-KK-35
35 Nm
VWZ-80
KUZ-KK-45
70 Nm
VWZ-100
KUZ-KK-60
120 Nm
Fig. 10:Installation of connecting shafts
CAUTION
Axial joining force!
Damage to the roller bearings, circlips etc.
Use a suitable fixture to draw the connecting parts together.
Do not apply blows or impacts to the shaft extensions.
Pull the couplings KUZ (couplings without half shells) on to the shaft
extensions. Tighten the set screw to the following torques:
Size KUZ-..
Set screw
Torque
09, (14)
M4
1.5 Nm
24, 28
M5
2.0 Nm
14, 19, 38
M6
4.8 Nm
45, 55, 60
M8
10 Nm
70, 75, 90
M10
17 Nm
For increased security the set screw can be secured using “medium
strength” thread locking agent.

6Installation ZIMM Screw Jack
18 Version 1.2 2015-01
6.3 Fitting the motor
The screw jack must be installed.
CAUTION
Moving parts!
Injuries due to rotating parts.
Switch off the entiresystem and secure it against switching on again.
Fig. 11:Installing the motor
1. Fit the motor flange (1) to the screw jack and bolt it into place.
2. Fit the coupling halves (2) to the gearbox shaft and bolt them into place.
3. Attach the coupling star (3).
4. Pull the motor-side coupling halves (4) on to the motor shaft.
5. Attach the motor (5) to the motor flange and bolt it into place.
6. Fit the motor-side coupling halves (6) as follows:
–Slide them on to the gearbox-side coupling halves, leaving
1 mm axial play.
–Tighten the securing bolt (7).
–If the coupling halves cannot be slid on to the motor shaft:
Adjust the position before step 5 and tighten them.

ZIMM Screw Jack 6Installation
2015-01 Version 1.2 19
6.4 Connecting the electrical components
WARNING
Electric shock!
Electric shock can lead to death or serious injuries.
Allow only skilled electricians to work on the electrics.
Comply with the basic rules:
–Deenergise the system.
–Secure it against switching on again.
–Ensure all phases are electrically dead.
–Earth and short-circuit the system.
–Cover any adjacent parts that are still live.
6.4.1 Motor
The motor (if supplied) must be installed.
1. Open the motor terminal box. The connection assignment is shown
within the motor terminal box.
2. Connect the motor in accordance with the circuit diagram.
6.4.2 Limit switch
Fig. 12:Fitting the plug connector on the limit switch
1. Remove the protection element (1) from the limit switch.
2. Remove the protection element (2) from the plug connector.
3. Insert the plug connector (3) into the limit switch.
4. Turn the screw (4) 90° clockwise.
Connecting the limit
switch

6Installation ZIMM Screw Jack
20 Version 1.2 2015-01
5. Connect the cable ends (5) in accordance with diagram (see
Fig. 13).
Fig. 13:Connection diagram for the limit switch
BN Brown
BK Black
BU Blue
BK-WHBlack-White
GN-YE Green-Yellow
If necessary the cable outlet can be turned through 180°.
Fig. 14:Turning the cable outlet of the limit switch
1. Loosen the screws (1) and unscrew them.
2. Pull the limit switch (3) out of its bracket (2) and turn it through 180°.
3. Insert the limit switch into the bracket (2) again.
4. Refit the screws (1) and tighten them.
Fig. 15:Adjustment of the limit switch
1. Move the screw jack away from the limit switch trigger point.
2. Loosen the screws (1).
3. Adjust the limit switch by sliding it in the direction shown.
4. Tighten the screws (1).
Turning the cable outlet
Adjusting the position of
the limit switch
±5mm