GUDEL CP 3-5 V2, Operating Manual

Page 1: ...OPERATING MANUAL CP 3 5 V2 Project Order Bill of materials Serial number Year of manufacture BETRIEBSANLE 90072022528153 B1M 10xxxxxxx xxxx 10xxxxxxx 99xxxxxxx 2019...

Page 2: ...ay 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 req...

Page 3: ...Revision history Version Date Description 1 0 17 06 2019 Basic version Table 1 Revision history Revision history OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 3...

Page 4: ...Revision history OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 4...

Page 5: ...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 Disre...

Page 6: ...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...

Page 7: ...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...

Page 8: ...gning 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 Changin...

Page 9: ...ays 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 P...

Page 10: ...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 lubr...

Page 11: ...acing the guideway 195 X Y axis 196 Z axis 197 Final tasks 200 9 3 11 7 Replacing the rack 201 X Y axis 201 9 3 11 8 Replacing switches sensors 205 9 3 11 9 Replace the bronze wipers 206 9 3 12 Settin...

Page 12: ...Attaching the slings G del gearbox unit 241 10 2 2 3 Remove the motor 242 10 2 2 4 Removing the gearbox unit 244 10 2 2 5 Replacing lubricant 245 10 2 2 6 Installing the gearbox unit 247 10 2 2 7 Ins...

Page 13: ...conditions 268 11 3 Decommissioning 269 11 3 1 Shutdown 269 11 3 2 Cleaning rust proofing 269 11 3 3 Transport securing devices 269 11 3 4 Identification 270 11 4 Recommissioning 270 12 Disposal 273...

Page 14: ...14 1 2 Black screws 288 14 1 3 Stainless steel screws 289 14 2 Tightening torques for roller holders 290 14 3 Thread rolling screws 291 14 4 HV sets 292 14 5 Tightening torques for clamping sets 296 L...

Page 15: ...Options Third party documentation Table of contents OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 15...

Page 16: ...Table of contents OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 16...

Page 17: ...ion as per Appendix VII Part B has been compiled This is submitted in electronic form depending on the respective regulations of the national bodies Authorized representative responsible for compiling...

Page 18: ...Declaration of conformity declaration of incorporation OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 18...

Page 19: ...bes all the product life phases of the product Transport Commissioning Operation Maintenance Repairs Disposal The manual contains the information required for using the product as in tended It is an e...

Page 20: ...mbol Abbrevia tion Use Explanation For cross reference See 2 Possibly for cross ref erence Page Fig Designation of graphics Figure Table Designation of tables Table In the tip Information or tip Table...

Page 21: ...re that the system is always in perfect working order 3 1 2 Personnel qualifications WARNING Lack of safety training Incorrect behavior of untrained or insufficiently trained technicians can result in...

Page 22: ...ly trained the technician is provided with personal protective equipment the operating manual is available to the technician at the operation site of the product at all times the technicians are kept...

Page 23: ...em of the product on and off creating production readiness monitoring the production process localizing minor malfunctions 3 1 2 6 Manufacturer s technicians The manufacturer s technician is employed...

Page 24: ...the safety zone during the cleaning process 3 1 2 8 Service technicians The service technician was trained by the operating company or the manufacturer has very good mechanical and or electrical knowl...

Page 25: ...ective mea sures The operating company is responsible for ensuring safe conditions in the vicin ity of the product In particular he must ensure compliance with the general safety regulations guideline...

Page 26: ...risk of severe physical injury or im mediate fatality WARNING WARNING WARNING refers to hazards with a moderate risk of severe physical injury or potential fatality CAUTION CAUTION CAUTION refers to h...

Page 27: ...l causes Hazards due to loose connecting elements Hazards due to overpressure Hazards resulting from automatic startup Hazards due to falling axles Hazards due to heat Hazards due to heavy components...

Page 28: ...GEFAHR Vor dem Bewegen der Achse n s mtliche Transportsicherungen entfernen WARNUNG WARNING Remove all transport securing devices before attempting to move any axis axes DANGER Secure gravity loaded...

Page 29: ...g 3 2 Danger label Tearing due to rack Danger label Tearing due to rack warns against tearing apart lifting belts due to the sharp edges of the rack provides information on correctly attaching slings...

Page 30: ...ec tive equipment and monitoring equipment For more information on separating safety and monitoring equipment refer to the documentation on the complete system 3 4 2 Product specific hazards DANGER Ha...

Page 31: ...seri ous or fatal injuries Always reduce the torque of the motor in all operating modes according to the technical data in the appendix Make sure that the protective equipment is attached to the produ...

Page 32: ...is prohibited without G del s approval WARNING Parts flung out Improperly clamped workpieces or attachments can be flung out if there is a crash This can lead to severe or fatal injuries Work spaces...

Page 33: ...uppliers of chemicals usually supply their substances together with safety data sheets Safety data sheets are available on the Internet Enter msds and the name of the material in a search engine Safet...

Page 34: ...Safety OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 34...

Page 35: ...sks are carried solely by the user 4 1 2 Non intended use The product is not intended for the movement of toxic goods for the movement of explosive goods for operation in potentially explosive areas f...

Page 36: ...wing information D004026 A B C G F E D Fig 4 1 Type plate A Project number order number E Special labeling B Sales order item number F Product type C Year of manufacture G Material number parts list D...

Page 37: ...achine properties and the operating conditions Generally the emissions sound pressure level LpA is 80dB A measured at a distance of 1 m from the safety fence and 1 6 m above ground level The measureme...

Page 38: ...ble the following options come with separate documentation Automatic lubrication system Manual lifting and safety unit Safety brake system Rotary axis Telescope axis Pneumatic load balance Z axis impa...

Page 39: ...t B Z axis K X axis C Drive for Y axis L X carriage D Z axis drive M Z carriage E Y axis N Mechanical multi limit switch optional F Automatic lubrication system optional O Rotary axis optional G Energ...

Page 40: ...5 2 Function The product can move along the following axes C Z Y X A Fig 5 2 Axis designations A Rotary axis optional Design function OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 40...

Page 41: ...g axes or workpieces can cause serious injury or death Make sure all emergency guideways are correctly installed before operating the product The product does not have the following protective equipme...

Page 42: ...Design function OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 42...

Page 43: ...belts This can lead to severe or fatal injuries Always protect the lifting belts with an edge guard WARNING Suspended loads Improper handling of suspended loads can lead to severe injuries or death U...

Page 44: ...pending on the contents the packaging units are marked with the symbols shown below Observe these at all times FRAGILE D000098 D000099 CRAINT L HUMIDITE D000100 HANDLE WITH CARE D000101 A B C D Fig 6...

Page 45: ...and weight of the crate The driver of the industrial truck must be authorized to drive the vehi cle 6 3 Slings Slings chains ropes or belts must be suitable for the load of weight of the crate Fasten...

Page 46: ...severe or fa tal injuries Always protect the lifting belts with the guard plate D003791 2X X X A B C D E F G H Fig 6 3 Attaching the slings Beam A Screw E Danger label Tearing due to rack B Transport...

Page 47: ...material numbers Attach the slings as follows 1 Fasten the transport aids by means of screws 2 Push guard plates onto rack 3 Position the lifting belts as shown in the illustration 4 Hang the ends of...

Page 48: ...n lead to severe or fa tal injuries Always protect the lifting belts with the guard plate 2 X X X A B C D E F G Fig 6 4 Attaching the slings Beam A Forklift E Lifting belts B Screws F Guard plate C Tr...

Page 49: ...Guard plates material numbers Attach the slings as follows 1 Fasten the transport aids by means of screws 2 Push guard plates onto rack 3 Position the lifting belts as illustrated 4 Affix the ends of...

Page 50: ...Fig 6 5 Attaching the slings carriage A Carriage B Limit stop peg Attach the slings as follows 1 Install the limit stop peg as shown in the illustration 2 Attach the belt harness as shown in the illu...

Page 51: ...Z axis Product size Shackle bolt diame ter mm Shackle payload kg 2 3 10 400 4 5 16 1000 Table 6 3 Z axis slings Sizes Attach the slings as follows 1 Mount the shackle and lifting belts as illustrated...

Page 52: ...Transport OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 52...

Page 53: ...21 It concerns your personal safety 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 guar...

Page 54: ...ews with a torque wrench to the specified tightening torques Check if the shearing sleeves and or pins are fully and correctly assembled 7 1 2 Personnel qualifications Only appropriately trained and a...

Page 55: ...may take a significant period of time After cleaning work on the product or a downtime of one to four weeks carry out the following jobs Check the lubricating film on guideways and racks Commissionin...

Page 56: ...owntime is longer than four weeks carry out the following jobs Prelubricate guideways and racks Check the lubrication system as described in the separate documentation on automatic lubrication Commiss...

Page 57: ...tes Base The base must comply with the requirements of the intended application For information on the load per unit area and the surface properties please refer to the layout or the documentation for...

Page 58: ...anying documents Check the product for damage Report transport damage promptly 7 4 4 Setup process This chapter describes the set up procedure Carefully read the procedure in structions Then carry out...

Page 59: ...lly Size 5 7 10360146 Adjusting tool Setting the rollers Size 52 72 10392234 Adjusting tool Setting the rollers Size 62 72 90 0915289 Pry bar L 1500 mm Aligning upright and beam Corrosion protection a...

Page 60: ...cks 10406825 Screw clamps Installing the racks HILTI special tools Anchoring the product Fastening device Blocking the drive pin ions HPG AE045 0917453 Fastening device Blocking the drive pin ions HPG...

Page 61: ...transmitted to the product This could lead to material damage or to imprecision in the process If the edge clearances of the anchorage facing the expansion joint are less than the specified values th...

Page 62: ...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 haz...

Page 63: ...rout hnom tfix 2 2 Fig 7 2 Clean the bore hole HIT Z HIT HY 200A Anchor the base plate as follows 1 Anchor the base plates according to the HILTI instructions The base plates are anchored 7 4 4 4 Set...

Page 64: ...g screws flush with the upright footing 3 Attach the slings as shown in the illustration 4 Place the squared timber on the floor 5 Set up the upright 6 Set the rear floor leveling screws to the specif...

Page 65: ...right as follows 1 Set up leveling instrument with visual contact to the holes of the uprights 2 Upright 1 2 1 Hook tape measure into hole of the upright 2 2 Measure and write down height of upright 3...

Page 66: ...height has been determined Correcting the upright height Also mark the socket when you are working with a socket A B C D Fig 7 5 Marking floor leveling screw A Floor leveling screw C Upright B Markin...

Page 67: ...ining uprights The height of the uprights has been corrected 7 4 4 6 Securing uprights against falling over Secure the uprights as follows 1 Use suitable means to secure the upright against falling ov...

Page 68: ...follows 1 Remove coverings 2 Attach the slings to the beam 3 Lift beam to upright height 4 Mount the beam to the upright by means of screws and washers 5 Tighten the screws 6 Install the coverings Th...

Page 69: ...eams as follows 1 Lift the loose beam to the height of the fixed beam the beams must be flush 2 Adjust the spacer sheet if necessary 3 Insert sleeves centering bolts and washers 4 Connect the beam wit...

Page 70: ...igning use the guideways as a reference 1 2 A B C D E C F Fig 7 8 Straightening beams A Upright D Plate s 10 mm B Guideway E Screw clamp C Alignment wire F Scale Commissioning OPERATING MANUAL CP 3 5...

Page 71: ...m step 2 for the remaining uprights 4 Check distance between guideway and alignment wire for all uprights 5 If there are deviations Repeat process from step 2 The beams are aligned Aligning upright an...

Page 72: ...There are no adjustment mechanisms present in the direc tion of movement 1 Place pry bar in desired position as shown in the illustration 2 Carefully move the upright in the direction of the arrow in...

Page 73: ...sting tools every time the product is used Position the bolt of the KM0 in the storage position before moving the axis You can only move the beam to a limited extent Sizes 3 4 and 5 10 mm 5 mm in each...

Page 74: ...sion joints Expansion joints absorb expansion in the foundations If products are posi tioned over expansion joints this expansion is transmitted to the product This could lead to material damage or to...

Page 75: ...xclusively to standard G del components For information on deviations refer to the lay out and the drawings for anchoring in the Appendix HAS HVU2 The product is anchored with the anchor rod HAS and t...

Page 76: ...base mounting HAS HVU2 Anchor the upright as follows 1 Make a bore hole according to the preceding table 2 Clean the bore hole 3 Insert the adhesive cartridge 4 Screw in the anchor rod with the hamme...

Page 77: ...rmation on deviations refer to the layout and the drawings in the appendix WARNING Hazard due to tipping Products that are incorrectly anchored can tip over This can lead to severe or fatal injuries T...

Page 78: ...ate B Floor leveling screw E Anchor C Upright frame F Base plate m floor leveling screw M24x2 M36x2 Anchor size M10 M16 hmin concrete thickness mm 120 160 cmin edge clearance mm 90 130 k fillet weld d...

Page 79: ...the safety devices 5 Attach suitable corrosion protection to the base plate and bottom plate The welded joint has been created HAS TZ HVU TZ The base plate is anchored with the HAS TZ anchor rod and...

Page 80: ...lows Prerequisite The base plate is anchored to the floor 1 Connect the floor leveling screw and bottom plate by means of the screw 2 Weld the bottom plate to the base plate Select weld seam type acco...

Page 81: ...A A Screw D Bottom plate B Floor leveling screw E Anchor C Upright frame F Base plate m floor leveling screw M48x3 M56x3 Anchor size M16x175 M20x215 hmin concrete thickness mm 210 210 cmin edge cleara...

Page 82: ...5 Attach suitable corrosion protection to the base plate and bottom plate The welded joint has been created 7 5 Installing 7 5 1 Using the mounting aid Installing the rack The start and end of the ra...

Page 83: ...rack A Screw clamp D Reference surface B Mounting aid E Wood block C Rack Cleaning agents mild universal cleaner free from aromatic compounds e g Motorex OPAL 5000 Table 7 7 Cleaning agents Rack Comm...

Page 84: ...crew clamp at the level of the screw to be tight ened 3 Tighten all screws 4 Inspect rack transition 2 85 5 If there are deviations 5 1 Remove screws and racks 5 2 Repeat the procedure The rack has be...

Page 85: ...lity and module 2 211 X X Y Y X Y A B Fig 7 17 Check rack transition A Rack transition B Measurement bolt diameter D 2 m accuracy tolerance class 1 acc to DIN 2269 Commissioning OPERATING MANUAL CP 3...

Page 86: ...016 0 016 Table 7 8 Permissible deviation rack transition Check the rack transition as follows 1 Position the measurement bolt as shown in the illustration 2 Check dimension X and Y permissible devia...

Page 87: ...s Prerequisite For axes over 20 meters the assembly of the guideways must be performed from the middle 1 Clean the reference surfaces and guideways thoroughly and rub a sharp ening stone across them 2...

Page 88: ...lifting units Wear appropriate protective clothing Always keep sufficient distance from suspended loads Never enter the area below a suspended load A B C D E F Fig 7 19 Inserting the Y axis A Y axis D...

Page 89: ...cating pinion unit 5 Assemble the bumper unit 2 91 The Y axis has been inserted 7 5 6 Installing the Z axis In some cases the Z axis is not yet mounted on delivery Depending on the available space the...

Page 90: ...the Z carriage 3 Remove the rotary axis if necessary 4 Remove the motor if necessary 5 Vent the safety brake system if necessary Power connection according to the type place of the safety brake The re...

Page 91: ...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 WARNING Incorrectly installed safety compon...

Page 92: ...Danger label Provisionally assembled bumper unit The danger label Provisionally assembled bumper unit warns against Provisionally assembled or non assembled bumper units Moving the axes before proper...

Page 93: ...Install the bumper on the bumper block bracket 2 Remove the warning sticker from the installation site if necessary 3 Clean the contact surface of the mating part meticulously 4 Position the pre asse...

Page 94: ...sembled and remounted with one half of the elastomer coupling 7 5 7 2 Prerequisites Three conditions must be fulfilled simultaneously to allow you to install the motor on the gearbox unit The gearbox...

Page 95: ...lb s 3 2 N m D1 20F7 Gearbox side HPG060 02 17 A B C D E F G H I J L K Fig 7 23 Aligning the gearbox flange A Articulated socket G Coupling B Torque wrench H Screw C Gearbox I Motor flange D Plug J G...

Page 96: ...ough the drill hole and tightened with a torque wrench 4 If there are deviations 4 1 Remove the coupling 4 2 Remove the fastening screws screws and motor flange 4 3 Align the gearbox flange 4 4 Instal...

Page 97: ...to severe or fatal injuries Ensure that no persons are in the danger area while the axis is moving A G F E D C B Fig 7 24 Aligning the input shaft to the gearbox flange A Drill hole E Coupling screw B...

Page 98: ...uisite The coupling has been placed correctly on the input shaft 1 Check whether the coupling screws can be reached through the drill holes 2 If there are deviations Traverse the axis until the coupli...

Page 99: ...e type of coupling are engraved on the mo tor and gearbox sides in the coupling G W E 5103 28 SP TA 24ft lb s 3 2 N m D1 20F7 Gearbox side HPG060 02 17 D2 24H7 02 17 G W E 5103 28 SP TA 24ft l b s 3 2...

Page 100: ...WE 5103 19 SP 50 L 1 0 5 8 5 X 0 5 1 GWE 5103 14 SP 32 L 1 0 5 15 5 X 0 5 0 045 GWE 5103 24 SP 54 L 1 0 5 11 X 0 5 0 GWE 5103 19 SP 50 L 1 0 5 10 X 0 5 0 060 GWE 5103 28 SP 62 L 1 0 5 16 5 X 1 3 GWE 5...

Page 101: ...ling on the motor shaft Make use of X dimension tolerance Cleaning agents mild universal cleaner free from aromatic compounds e g Motorex OPAL 5000 Table 7 12 Cleaning agents Gearbox unit G del Coupli...

Page 102: ...pling according to the cal culated dimension 6 2 Coupling rest a little on the motor shaft Make use of X dimension tolerance 7 Tighten the coupling screws 7 1 Tighten alternately to 50 of the tighteni...

Page 103: ...A B C D E F G Fig 7 28 Installing the motor and coupling A Coupling screw E Motor B Drill hole F Coupling C Plug G Motor screw D Motor flange Cleaning agents mild universal cleaner free from aromatic...

Page 104: ...witched on again 2 Attach slings to the motor if necessary 2 166 3 Clean the coupling input shaft and wedge to remove any grease 4 Install the wedge on the input shaft 5 Apply corrosion protection age...

Page 105: ...n A Lubricant channel D Roller support B Lubricating position of wiper E Grease nipple lubrication connection C Screw stopper Change the lubricating position as follows 1 Remove grease nipple or lubri...

Page 106: ...7 30 Checking leveling of the guide chute A Spirit level B Guide chute Check the leveling of the guide chute as follows 1 Check the leveling of the guide chute using a level as per the illustration 2...

Page 107: ...chain becomes hooked in if the side panel transitions do not align The energy chain can break or become prematurely worn Install the side panels without any offset Install all of the connecting plate...

Page 108: ...ly flexible lines suitable for use with energy chains Only use lines whose minimum bending radius is smaller than the smallest radius of the energy chain G del shall only be liable for internal divisi...

Page 109: ...ed to be sep arated from each other risk of sticking The vertical dividers are not allowed to be positioned in an offset manner in the roll off direction The cable must have play on all sides of the c...

Page 110: ...A B C D Fig 7 32 Laying cables and lines image source IGUS A Screwdriver C Opening bar B Energy chain D Vertical divider Commissioning OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 110...

Page 111: ...ns repeat process as of step 1 6 Check opening bars correctly latched and intact 7 If there are deviations repeat process as of step 1 8 Check vertical dividers exactly positioned vertically and not i...

Page 112: ...nection element D Energy chain H Guide chute Install the energy chain as follows Prerequisite You have read and understood the IGUS assembly instruc tions 1 Install the mounting angle on the fixed sid...

Page 113: ...Installing the slide bars image source IGUS A Sliding energy chain B Fixed side C Slide bar Install the slide bars as follows 1 Screw the pre assembled slide bars tightly 2 Check the alignment of all...

Page 114: ...se paths of the energy chain longer than 50 m Relieve the strain on the cables and lines on the driver side NOTE Protruding strain relief The energy chain becomes hooked in if metal sleeves and protru...

Page 115: ...onnection element B Metal sleeve Versions Explanation Figure Cable fittings Two cable fittings 4 5 mm wide on the appropriate holders ChainFix Tightening torque 1 Nm Table 7 16 Strain relief Cable fit...

Page 116: ...ef of 10 30 times the diameter of the cable 3 2 Ensure cable runs straight for at least 50 cm after the strain relief 4 Check the height of the strain relief on the fixed side If there are deviations...

Page 117: ...sical damage and seri ous or fatal injuries Always reduce the torque of the motor in all operating modes according to the technical data in the appendix Make sure that the protective equipment is atta...

Page 118: ...vices for future work WARNING Falling axes After removing the transport securing device brakes or motors the vertical axes fall downwards Carriages may run off to the side This can lead to se vere or...

Page 119: ...ve the latch using a screwdriver A B C D E Fig 7 36 Removing transport securing device G del gearbox unit A Plug D Coupling B Transport securing device E Latch C Coupling screw Commissioning OPERATING...

Page 120: ...severe or fatal injuries Ensure that the sunk key of the input shaft is correctly installed Make sure that the transport securing device is correctly positioned with a positive connection using the f...

Page 121: ...securing device G del gearbox unit A Plug F Input shaft with sunk key B Output axis G Latch C Fastening screw H Transport securing device D Marking bore I Coupling E Groove Commissioning OPERATING MA...

Page 122: ...re deviations Correctly install the sunk key 5 Bend the latch as shown in the illustration 6 Positioning the transport securing device on the latch 6 1 Groove is perpendicular to the output axis 6 2 M...

Page 123: ...device as follows 1 Check whether the transport securing device is correctly positioned with a positive connection using the fastening screws 2 If there are deviations 2 1 Remove the latch transport s...

Page 124: ...formed 7 9 Initial lubrication Lubricate the guideway rack and pinion before commissioning the product for the first time 7 9 1 Clean guideways and racks WARNING Moving the axis The work requires movi...

Page 125: ...agents guideways racks Clean the racks and guideways as follows 1 Switch off the system and secure it with a padlock against being switched on again 2 Clean the guideways and racks thoroughly The gui...

Page 126: ...d pinions Pre lubricate the racks and guideways as follows Prerequisite The guideways and racks have been cleaned 1 Switch off the system and padlock it to secure it against being switched on again 2...

Page 127: ...tion on the automatic lubrication system Fig 7 41 Carrying out a lubrication check Lubrication ex works Specification Lubrication quantity Chapter 9 2 2 1 2 134 Chapter 9 2 2 1 2 134 Table 7 19 Lubric...

Page 128: ...attached and is closed No persons are present in the danger area The procedure for the functional check is described in the documentation for the complete system WARNING Falling axes workpieces If eme...

Page 129: ...or damage to property Before the operating personnel begin working with the product Train and instruct the operating personnel Point out dangers in the work area to the operating personnel Check the...

Page 130: ...Operation OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 130...

Page 131: ...hird party prod ucts For information on third party products read the appropriate documents in the appendix Tightening torques Unless otherwise indicated adhere to the tightening torques of G del Chap...

Page 132: ...or signs of breakage and tears WARNING Heavy components Components can be very heavy Improper handling can cause severe or fatal injuries Use appropriate lifting equipment Use suitable means to secure...

Page 133: ...his table does not purport to be exhaustive Table 9 1 Table of cleaning agents 9 2 2 Lubricants NOTE Unsuitable lubricants Using unsuitable lubricants can cause damage to the machine Only use the lubr...

Page 134: ...first With automatic lubrication it may not be possible to set this lubrication cycle exactly I In this case select the nearest lubrication cycle Perform lubri cation work at soon as the first signs...

Page 135: ...cks and pinions oil Table 9 3 Lubricants Guideways racks and pinions Fig 9 3 Lubricating manually with oil Lubrication ex works Specifica tion Lubrica tion quantity Location of appli cation Cate gory...

Page 136: ...ntification disc Oil 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 Flexx...

Page 137: ...ubricants Automatic lubrication system FlexxPump Prelubricate guideways and racks Fig 9 7 SKF Vogel automatic lubrication system Lubrication ex works Specifica tion Lubrica tion quantity Location of a...

Page 138: ...o 146621 cannot be found Automatic lubrication system FlexxPump oil cannot be found Guideways racks and pinions oil Mobil Gly goyle 460 NSF no 136467 CLP PG 460 in accor dance with DIN 51502 Gearbox u...

Page 139: ...of the product to ensure safe uninterrupted operation The maintenance intervals apply to the effective operating hours of the prod uct at a duty cycle ED of 100 Normal operating conditions are assume...

Page 140: ...ears Table 9 10 Maintenance intervals in shift operation 5 days a week Operating hours 1 shift opera tion 2 shift opera tion 3 shift opera tion 150 every 18 days every 9 days every 6 days 2 250 every...

Page 141: ...t XD 20 Installing the coupling Applying corrosion protection to the product 0502037 Machine frame spirit level 0 1 mm m Leveling the axis Dial gauge Setting the tooth flank backlash Checking the circ...

Page 142: ...ve pin ions HPG AE045 0917453 Fastening device Blocking the drive pin ions HPG AE060 0917454 Fastening device Blocking the drive pin ions HPG AE090 0917447 Pin type face wrench Setting the rollers Siz...

Page 143: ...ating film on guideways and racks Check hydraulic lines for air pockets and kinks 9 3 5 Maintenance tasks after downtimes 4 weeks If the machine downtime is longer than four weeks carry out the follow...

Page 144: ...roduct at all times Consider the envi ronmental conditions Adjust the maintenance intervals to your operating conditions if necessary G del is not liable for damage to the entire system caused by inco...

Page 145: ...tation on the automatic lubrication system Fig 9 8 Carrying out a lubrication check Lubrication ex works Specification Lubrication quantity Chapter 9 2 2 1 2 134 Chapter 9 2 2 1 2 134 Table 9 13 Lubri...

Page 146: ...sing another type of lubricant replace the following components Wiper and lubrication unit Lubricating elements of the roller support Lubricating pinion Rinse the lines with fresh lubricant A type pla...

Page 147: ...and lubrication units or roller supports Lu brication quantity 2 2 for all available lubricating pinions Double lubrication quantity The guideways racks and pinions are lubricated 9 3 8 Maintenance ta...

Page 148: ...s immedi ately Modify or replace the gearbox Repair any leaks promptly Inspection point Description Measures Contamination Check all the compo nents for contamina tion Rollers Guideways Racks Switches...

Page 149: ...ls on the floor or in the drip sheets Leaks torn or pinched lines Leakage at the gear boxes Replace any defective or pinched lines Repair or replace the gearbox Remove puddles of oil and oil spills on...

Page 150: ...IGUS Chainfix Look for cause Replace defective or worn energy chains Correct faulty positions of cables and lines Replace worn or defec tive cables Relieve cable strain Correct the tightening torque...

Page 151: ...Lubrication ex works Specification Lubrication quantity Aral Arcanol LOAD 150 KP2N 20 in accordance with DIN 51825 high quality lithium complex soap grease 40 1 1g 52 2 4g 72 7 3g 90 7 3g 110 7 3g 180...

Page 152: ...e separate documentation 9 3 8 5 Carrying out a lubrication check Perform a lubrication check as described in the separate documentation on the automatic lubrication system Fig 9 11 Carrying out a lub...

Page 153: ...ion to ensure uniform lubrication D003232 A B C D E Fig 9 12 Replacing the lubricating pinion A Lubrication point D Lubricating pinion B Holder of the axis to the lubricating pin ion E Gasket C Axis t...

Page 154: ...ew lubricant flows out at the lubricating pinion 8 Only for automatic lubrication 8 1 Connect lubrication line 8 2 Start lubrication procedure until the new lubricant flows out at the lubricating pini...

Page 155: ...ing element B Grease nipple E Casing C Identification disc F Wiper Lubrication ex works Specification Lubrication quantity Chapter 9 2 2 1 2 134 Chapter 9 2 2 1 2 134 Table 9 19 Lubricants Guideways r...

Page 156: ...on Lubricate the guideways until the new lubricant flows out at the wiper 6 Only for automatic lubrication 6 1 Connect lines 6 2 Start lubrication procedure until the new lubricant flows out at the wi...

Page 157: ...placing the lubricating element 6 Submerge the new lubricating element in the lubricant for several min utes 7 To install the wiper and lubricating element reverse the removal steps 8 Only for manual...

Page 158: ...Inspection point Description Measures Contamination Check the components for contamination Pump Lines other components Immediately clean away any contamination Loss of lubricant Check system and its...

Page 159: ...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 cha...

Page 160: ...cal dividers cables are not permitted to be laid next to each other Cables laid over each other with different jacket materials need to be sep arated from each other risk of sticking The vertical divi...

Page 161: ...A B C D Fig 9 16 Laying cables and lines image source IGUS A Screwdriver C Opening bar B Energy chain D Vertical divider Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 161...

Page 162: ...ations repeat process as of step 1 6 Check opening bars correctly latched and intact 7 If there are deviations repeat process as of step 1 8 Check vertical dividers exactly positioned vertically and n...

Page 163: ...ve read and understood the IGUS assembly instruc tions 1 Install the mounting angle on the fixed side connection element using fas tening screws and nuts 2 Place the energy chain in the guide chute 3...

Page 164: ...ide 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 sl...

Page 165: ...there are deviations 3 1 Loosen the screws on the slide bars 3 2 Align the slide bars 3 3 Tighten the screws on the slide bars 3 4 Repeat process from step 2 The slide bars have been installed and ali...

Page 166: ...ds Never enter the area below a suspended load Fig 9 19 Attaching the slings Motor Attach the slings as follows 1 Remove fan from motor if necessary 2 Mount lifting screw if necessary 3 Attach the sli...

Page 167: ...ate 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 D003628 A B C Fig 9 20 Attaching the...

Page 168: ...rea while the axis is moving WARNING Falling axes After removing the transport securing device brakes or motors the vertical axes fall downwards Carriages may run off to the side This can lead to se v...

Page 169: ...re deviations Adjust axis until the coupling screws can be reached through the drill hole 5 Switch off the system and secure it with a padlock against being switched on again 6 Attach slings to the mo...

Page 170: ...e gearbox unit 2 167 2 Remove the gearbox screws 3 Remove the gearbox unit 4 Remove the transport securing device or slings The gearbox unit has now been removed Replacing the gearbox unit Replace the...

Page 171: ...0 090 120 180 Thread size M6 M8 M10 M12 M16 M20 Tightening torque Nm 9 22 42 50 120 240 Table 9 24 Tightening torques for gearbox screws G del gearbox unit Install the gearbox unit as follows 1 Attach...

Page 172: ...mbled and remounted with one half of the elastomer coupling Prerequisites Three conditions must be fulfilled simultaneously to allow you to install the motor on the gearbox unit The gearbox flange is...

Page 173: ...s 3 2 N m D1 20F7 Gearbox side HPG060 02 17 A B C D E F G H I J L K Fig 9 24 Aligning the gearbox flange A Articulated socket G Coupling B Torque wrench H Screw C Gearbox I Motor flange D Plug J Gear...

Page 174: ...rough the drill hole and tightened with a torque wrench 4 If there are deviations 4 1 Remove the coupling 4 2 Remove the fastening screws screws and motor flange 4 3 Align the gearbox flange 4 4 Insta...

Page 175: ...severe or fatal injuries Ensure that no persons are in the danger area while the axis is moving A G F E D C B Fig 9 25 Aligning the input shaft to the gearbox flange A Drill hole E Coupling screw B We...

Page 176: ...until the coupling screws can be reached through the drill holes 3 Switch off the system and secure it with a padlock against being switched on again The input shaft has been aligned to the gearbox f...

Page 177: ...nstallation surface B Motor flange F Coupling screw C Measuring instrument G Motor shaft D Coupling H Motor X Z Y Fig 9 27 X dimension calculation formula G del HPG gearbox unit size Coupling type L d...

Page 178: ...0 L 1 0 5 10 X 0 5 0 060 GWE 5103 28 SP 62 L 1 0 5 16 5 X 1 3 GWE 5103 24 SP 54 L 1 0 5 18 5 X 1 2 090 GWE 5103 38 SP 76 L 1 2 0 5 25 X 1 2 GWE 5103 28 SP 62 L 1 0 5 29 X 1 2 120 GWE 5103 42 SP 102 L...

Page 179: ...torex OPAL 5000 Table 9 26 Cleaning agents Gearbox unit G del Coupling and motor shaft Tool Use Item number Corrosion protection agent MOTOREX In tact XD 20 Installing the coupling Applying corrosion...

Page 180: ...coupling according to the cal culated dimension 6 2 Coupling rest a little on the motor shaft Make use of X dimension tolerance 7 Tighten the coupling screws 7 1 Tighten alternately to 50 of the tigh...

Page 181: ...7 A B C D E F G Fig 9 29 Installing the motor and coupling A Coupling screw E Motor B Drill hole F Coupling C Plug G Motor screw D Motor flange Cleaning agents mild universal cleaner free from aromati...

Page 182: ...switched on again 2 Attach slings to the motor if necessary 2 166 3 Clean the coupling input shaft and wedge to remove any grease 4 Install the wedge on the input shaft 5 Apply corrosion protection ag...

Page 183: ...e duration of operation of the product and the ambient conditions G del rec ommends preventatively replacing components as soon as their service life has been reached Components may fail before expiry...

Page 184: ...r holder installation types A Installation type E1 Eccentric zero po sition fixed with positioning screw B Installation type E2 Eccentric infinitely adjustable fixed with flange C Installation type E3...

Page 185: ...arrangement loaded and unloaded rollers A Vertical axis B Cantilever arm axis C Horizontal axis Roller holder ar rangement lateral rollers The roller holders are arranged according to the following f...

Page 186: ...ions perceptible Running surface worn Notches on guide running surface Table 9 30 Distinguishing characteristics of wear Roller D000753 A B C D E F G H Fig 9 33 Replacing the roller A Screw E Covering...

Page 187: ...roller holder 7 1 Remove screw and peg 7 2 Replacing the roller 7 3 Install screw and peg The roller has been replaced Setting the roller NOTE Wear of components Incorrectly set rollers and tooth flan...

Page 188: ...alling the flange 4 3 Only lightly tighten fastening screws 5 If necessary remove the securing element support or sling 6 E2 roller holder 6 1 Tighten roller holder towards the guideway Tightening tor...

Page 189: ...rceptible Running surface worn Notches on guide running surface Table 9 31 Distinguishing characteristics of wear Roller Roller positions The eccentric rollers have three home positions D000275 A B C...

Page 190: ...is Product size Shackle bolt diame ter mm Shackle payload kg 2 3 10 400 4 5 16 1000 Table 9 32 Z axis slings Sizes Attach the slings as follows 1 Mount the shackle and lifting belts as illustrated 2 H...

Page 191: ...or axis This can lead to severe or fatal injuries Replace the rollers individually A B C D E K J I H G F Fig 9 37 Replacing the roller A Wiper and lubrication unit G Carriage B Screw B H Flange C Rol...

Page 192: ...he carriage using the extractor 5 1 Screw in screw K into thread of the flange through hole of extrac tor 5 2 Screw in screw K and remove flange from carriage 5 3 Remove screw K extractor and flange 6...

Page 193: ...G Fig 9 38 Setting the rollers Prism guideway eccentric rollers A Guideway E Screw B Carriage F Hexagonal socket wrench C Pin type face wrench G Axis D Roller eccentric Maintenance OPERATING MANUAL CP...

Page 194: ...uches the guideway The roller can still be turned by hand when a lot of force is applied 7 If there are deviations Repeat process from step 2 8 Install the wiper and lubrication unit The rollers have...

Page 195: ...ll screwed reinforcing ribs for correct assembly 1 1 If there are deviations Correctly mount screwed reinforcing ribs 2 Check all protective equipment for correct installation 2 1 If there are deviati...

Page 196: ...to be replaced if neces sary 3 2 Move out the vertical axis if necessary 4 Remove all screws 5 Remove the guideway The guideway has been disassembled Installing the guideway D003620 A C B Fig 9 39 Ins...

Page 197: ...ws 1 Move the carriage along the axis if necessary 2 Retract the vertical axis if necessary 3 Remove the slings 4 Set the rollers and the tooth flank backlash 2 207 The final tasks have been performed...

Page 198: ...priority D000108 A B D C B Fig 9 40 Installing the guideway A Reference surface C Screw clamp B Guideway D Torque wrench Cleaning agents mild universal cleaner free from aromatic compounds e g Motore...

Page 199: ...he entire length The drive pinion with correctly set tooth flank backlash should not jam at the transitions of the guideway 7 If deviations of the transition or parallelism occur 7 1 Remove the screws...

Page 200: ...ages or axles in an emergency Axes and workpieces can fall down Falling axes or workpieces can cause serious injury or death Make sure all emergency guideways are correctly installed before operating...

Page 201: ...aced if necessary 3 2 Move out the vertical axis if necessary 4 Remove all screws 5 Remove the rack The rack has been disassembled Using the mount ing aid Installing the rack The start and end of the...

Page 202: ...ck A Screw clamp D Reference surface B Mounting aid E Wood block C Rack Cleaning agents mild universal cleaner free from aromatic compounds e g Motorex OPAL 5000 Table 9 36 Cleaning agents Rack Mainte...

Page 203: ...crew clamp at the level of the screw to be tight ened 3 Tighten all screws 4 Inspect rack transition 2 203 5 If there are deviations 5 1 Remove screws and racks 5 2 Repeat the procedure The rack has b...

Page 204: ...ty and module 2 211 X X Y Y X Y A B Fig 9 43 Check rack transition A Rack transition B Measurement bolt diameter D 2 m accuracy tolerance class 1 acc to DIN 2269 Maintenance OPERATING MANUAL CP 3 5 V2...

Page 205: ...the carriage along the axis if necessary 2 Retract the vertical axis if necessary 3 Remove the slings 4 Set the rollers 5 Set the tooth flank backlash The final tasks have been performed 9 3 11 8 Repl...

Page 206: ...e E Guideway C Bronze wiper Replace the bronze wipers as follows 1 Switch off the system and padlock it to secure it against being switched on again 2 Remove the screw 3 Remove the bronze wipers 4 Rep...

Page 207: ...load attached and at operating temperature Reset the rollers and the tooth flank backlash after each replacement of the following components Roller Guideway Rack Pinion Gearbox 9 3 12 1 Eccentric mar...

Page 208: ...tric ring 9 3 12 2 Blocking unblocking the eccentric ring The eccentric ring is blocked as follows A B Fig 9 47 Blocking the eccentric ring Hexagonal screw A Eccentric ring B Hexagonal screw Maintenan...

Page 209: ...on again 2 Check the tooth flank backlash 2 210 3 If there are deviations 3 1 Unblocking the eccentric ring 3 2 Slightly loosen fastening screws 3 3 Backlash too large Turn the eccentric ring away fro...

Page 210: ...back onto the gearbox unit D002894 A B C D E Fig 9 49 Blocking the drive pinions G del gearbox unit A Motor D Fastening device B Carriage E Plug C Gearbox unit Block the drive pinion as follows 1 Swi...

Page 211: ...Axis Rack quality Module Helix angle Hardened rack Soft rack X 9h27 Size 3 3 Size 4 3 Size 5 4 19 5283 Y 9h27 Size 3 2 Size 4 3 Size 5 4 Z 6h23 Size 3 1 5 Size 4 2 5 Size 5 3 Table 9 38 Rack quality a...

Page 212: ...3 Module 3 m 8 Module 8 m 12 Q4 h21 0 010 0 012 0 016 Q5 h22 0 016 0 019 0 025 Q6 h23 0 025 0 03 0 04 Q7 h25 0 059 0 079 0 099 Q8 h27 0 158 0 198 0 247 Q9 h27 0 158 0 198 0 247 Table 9 39 Tooth flank...

Page 213: ...th a padlock against being switched on again 2 Mount the dial gauge to the guideway 3 Mount dial gauge in the direction of travel aligned with the center of the drive pinion 4 Zero the dial gauge 5 Mo...

Page 214: ...every kind Use it only when the exact method is not possible Rack quality Tooth flank backlash mm Module m 3 Module 3 m 8 Module 8 m 12 Q4 h21 0 010 0 012 0 016 Q5 h22 0 016 0 019 0 025 Q6 h23 0 025 0...

Page 215: ...he carriage or axis paper strip is turned through 4 Interpret the result 4 1 Paper strip worn Tooth flank backlash 0 05 mm 4 2 Paper strip cut partially disconnected pieces Tooth flank backlash 0 05 m...

Page 216: ...Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 216...

Page 217: ...9 4 Maintenance schedules Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 217...

Page 218: ...Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 218...

Page 219: ...h 6 750 h 2 250 h 150 h 2 250 h 22 500 h 22 500 D003692 D000753 D000349 Fig 9 52 Maintenance schedule CP Grease Replacing Oil Visual inspection Automatic lubrication Maintain in accordance with separa...

Page 220: ...Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 220...

Page 221: ...ce schedule h 22 500 h 2 250 h 22 500 h 2 250 Fig 9 53 Maintenance schedule for G del gearbox unit Grease Replacing Replacing lubricant Oil Clean Visual inspection Maintenance OPERATING MANUAL CP 3 5...

Page 222: ...Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 222...

Page 223: ...h 22 500 h 11 250 h 2 250 h 22 500 h 11 250 h 2 250 FlexxPump 402B Fig 9 54 Maintenance schedule for automatic lubrication system Grease Replacing Replacing lubricant Oil Clean Visual inspection Main...

Page 224: ...Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 224...

Page 225: ...on check The manufacturer s technicians Service technicians Maintenance technicians Mobil Mobilux EP 2 G del H1 NSF no 146621 Chapter 9 3 6 1 2 145 General inspection Maintenance technicians The manuf...

Page 226: ...2 165 Replacing the automatic lu brication pump The manufacturer s technicians Maintenance technicians Chapter 9 3 11 1 2 159 Replacing the roller Service technicians The manufacturer s technicians Ma...

Page 227: ...ails 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 wo...

Page 228: ...Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 228...

Page 229: ...ou are not working electronically Send it to service ch gudel com after every intervention Maintenance work Maintenance cycle h Effective operating hours1 Name2 Comments3 Date Replacing the cartridge...

Page 230: ...Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 230...

Page 231: ...u are not working electronically Send it to service ch gudel com after every intervention Maintenance work Maintenance cycle h Effective operating hours1 Name2 Comments3 Date Replacing the lubricating...

Page 232: ...Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 232...

Page 233: ...and scan it in after completing it if you are not working electronically Send it to service ch gudel com after every intervention Maintenance work Maintenance cycle h Effective operating hours1 Name2...

Page 234: ...Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 234...

Page 235: ...vention Maintenance work Maintenance cycle h Effective operating hours1 Name2 Comments3 Date Replacing the slide bars 22 500 Replacing the energy chain Replacing the gearbox unit Replacing the automat...

Page 236: ...Maintenance OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 236...

Page 237: ...ting pinion to ensure uniform lubrication A B C D E F G Fig 9 7 Replacing the lubricating pinion A Lubrication point E Fastening screw B Screw F Lubricating pinion C Hexagonal socket wrench G Carriage...

Page 238: ...to the tightening torques of G del Chapter 14 2 286 10 1 1 Safety Only perform the tasks described in this chapter after you have read and un derstood the chapter Safety 2 21 It concerns your personal...

Page 239: ...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 10 1 2 Personnel qualifications Only app...

Page 240: ...e from suspended loads Never enter the area below a suspended load Fig 10 1 Attaching the slings Motor Attach the slings as follows 1 Remove fan from motor if necessary 2 Mount lifting screw if necess...

Page 241: ...ppropriate 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 D003628 A B C Fig 10 2 Attachi...

Page 242: ...n off to the side This can lead to se vere or fatal injuries If necessary secure the vertical axes and the carriages before removing transport securing devices brakes or motors CAUTION Hot parts surfa...

Page 243: ...inst being switched on again 2 Secure the carriage or axis with the transport securing device or lifting equipment 3 Attach slings to the motor 2 240 4 Remove the motor screws 5 Force the motor off th...

Page 244: ...x unit C Gearbox screws Remove the gearbox unit as follows 1 Attach slings to the gearbox unit 2 241 2 Remove the gearbox screws 3 Remove the gearbox unit 4 Remove the transport securing device or sli...

Page 245: ...k CAUTION Oil greases Oils and greases are harmful to the environment The oils and greases must not get into the drinking water supply Take ap propriate measures Observe the country specific safety da...

Page 246: ...ecification Lubrication quantity Mobil Glygoyle 460 NSF no 136467 CLP PG 460 in accor dance with DIN 51502 AE HPG030 40cm3 AE HPG045 100cm3 AE HPG060 250cm3 AE HPG090 700cm3 AE HPG120 1400cm3 AE HPG18...

Page 247: ...the gearbox to drain 7 Screw in the drain screw 8 Fill up the gearbox through the filler screw 9 Screw in the bleed and filler screws The lubricant is replaced 10 2 2 6 Installing the gearbox unit NO...

Page 248: ...ings to the gearbox unit 2 241 2 Install the gearbox unit 3 Install and tighten the gearbox screws 4 Remove the transport securing device or slings The gearbox unit has now been installed 10 2 2 7 Ins...

Page 249: ...ten the motor screws The motor has now been installed 10 2 2 8 Final tasks Perform the following final tasks 1 Set the tooth flank backlash 2 207 2 Calibrate the reference plane of the motor procedure...

Page 250: ...e motor Positioning the coupling half on the motor shaft A Elastomer gear rim D Motor shaft B Coupling half E Motor C Coupling screw Tool Use Item number Corrosion protection agent MOTOREX In tact XD...

Page 251: ...crews 12 1 Tighten alternately to 50 of the tightening torque TA 12 2 Tighten alternately with 100 of the tightening torque TA 13 Installing the motor and coupling Chapter 10 2 2 7 2 248 14 Connect th...

Page 252: ...e coupling on the motor shaft A B C D E Fig 10 9 Replacing the motor flange and gearbox flange A Drill hole D Motor flange B Gearbox flange E Screw C Fastening screw Repairs OPERATING MANUAL CP 3 5 V2...

Page 253: ...conditions G del rec ommends preventatively replacing components as soon as their service life has been reached Components may fail before expiry of the service life how ever Replace worn components i...

Page 254: ...s Check the tightening torques regularly 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 A B C D E F G H Fig 10 10...

Page 255: ...axis direction 6 Loosen the clamping set screws 7 Replace pinion bearing O ring and clamping set 8 Install the pinion bearing O ring and clamping set in reverse order 8 1 Tightening torque of clampin...

Page 256: ...ncorrectly with the worm gear Do not remove the casing cover Align both casing covers in the identical position 2 3 4 1 D000317 A B C Fig 10 11 Setting the gear backlash G del gearbox unit A Worm shaf...

Page 257: ...tate the worm shaft 360 by hand 6 1 The shaft does not resist rotation Repeat from step 3 6 2 The shaft resists rotation Remove the screws set both gearbox covers one level lower 6 3 The shaft always...

Page 258: ...product and the ambient conditions However components may fail before expiry of the service life Replace worn components immediately Fig 10 12 Elastomer gear rim Distinguishing characteristics of wear...

Page 259: ...neral detailed inspection and release the product for operation again Further operation is prohibited without G del s approval 10 3 1 Replacing the bumper unit The bumper unit is a safety component Re...

Page 260: ...earing sleeves as follows 1 Assemble the bumper on the bumper block bumper bracket 2 Remove the danger label from the assembly site if necessary 3 Install the shearing sleeves at the assembly site 4 C...

Page 261: ...s as follows 1 Assemble the bumper on the bumper block bumper bracket 2 Remove the danger label from the assembly site if necessary 3 Install pre assembled bumper unit along with the mating part using...

Page 262: ...t 2 Remove the warning sticker from the installation site if necessary 3 Clean the contact surface of the mating part meticulously 4 Position the pre assembled bumper unit on the mating part 5 Tighten...

Page 263: ...it Replace the pinion 2 253 Process inaccuracies Tooth flank backlash too large Set the tooth flank backlash 2 207 Process inaccuracies Clamping set loose G del gearbox unit Tighten the clamping set 2...

Page 264: ...Repairs OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 264...

Page 265: ...n after completing it if you are not working electronically Send it to service ch gudel com after every intervention Work1 Component2 Effective operating hours3 Name4 Comments5 Date Work1 Work carried...

Page 266: ...Repairs OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 266...

Page 267: ...n 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 2 279 Repairs OPERATING MANUAL CP...

Page 268: ...d from entering the drinking water supply Take appropriate measures Observe the country specific safety data sheets Oils and greases must be disposed of as hazardous waste even if the total quantity i...

Page 269: ...oceed as follows 1 Lock the axes in place 2 Switch off the system main switch of complete system 3 Disconnect the supply lines for energy and consumables 4 Automatic lubrication system option Unscrew...

Page 270: ...oning follow the steps described for commissioning Prior to recommissioning perform the general inspection 2 147 Perform the required maintenance tasks and repairs After cleaning work on the product o...

Page 271: ...escribed in the separate documentation on automatic lubrication If the machine downtime is longer than one year carry out the following tasks Replace the gear oil Rinse the lubrication lines with fres...

Page 272: ...Decommissioning storage OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 272...

Page 273: ...atal injuries Before working in the danger area Secure vertical axes if equipped against falling Switch off the superordinate main power supply Secure it against being switched on again main switch fo...

Page 274: ...el qualifications Only appropriately trained and authorized technicians are allowed to work on the product 12 2 Disposal Your product consists of the following units Packaging Contaminated materials a...

Page 275: ...ING 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 CAUTION Oil greases Oils and greases ar...

Page 276: ...n accordance with the following table Material Disposal method Contaminated materials auxiliary agents Hazardous waste Wood Municipal waste Plastic Collecting point or municipal waste Lubricants Colle...

Page 277: ...13 Spare parts supply Spare parts supply OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 277...

Page 278: ...Spare parts supply OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 278...

Page 279: ...ervice department For all other countries not included in the following list please contact the service department in Switzerland Customer with special agreements should contact the service department...

Page 280: ...automation G del Jier Automation Ltd A Zone 16th Floor JIER Building 21th Xinxi Road 250022 Jinan China 86 531 81 61 6465 service gudeljier com India G del India Pvt Ltd Gat No 458 459 Mauje Kasar Amb...

Page 281: ...AG Gaswerkstrasse 26 Industrie Nord 4900 Langenthal Switzerland 41 62 916 91 70 service ch gudel com Finland Greece Norway Sweden Switzerland Turkey Bosnia and Herzegovina G del GmbH Sch neringer Str...

Page 282: ...intralogistics G del Intralogistics GmbH Gewerbegebiet Salzhub 11 83737 Irschenberg Germany 49 8062 7075 0 service intralogistics de gudel com Italy G del S r l Via per Cernusco 7 20060 Bussero Mi Ita...

Page 283: ...l AG Gaswerkstrasse 26 Industrie Nord 4900 Langenthal Switzerland 41 62 916 91 70 service ch gudel com Table 13 4 Service departments for all other countries Inquiries outside of business hours If you...

Page 284: ...Spare parts supply OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 284...

Page 285: ...C 900 406015 10 00 Worm gear unit AE060 L left Ratio i 10 00 AE060 2 Stk E 910 406089 Motor flange 060 18x116x116 130 110 8030 018a 2 Stk E 1000 0910499 Mechanical multi limit switch accessories 750...

Page 286: ...E Vibrations Screws without screw lock can come loose Secure screw connections on moving parts with Loctite medium strength 243 Apply the adhesive on the nut thread not on the screw Torque tables OPER...

Page 287: ...8 8 10 9 12 9 M3 1 1 1 58 1 9 M4 2 6 3 9 4 5 M5 5 2 7 6 8 9 M6 9 13 2 15 4 M8 21 6 31 8 37 2 M10 43 63 73 M12 73 108 126 M14 117 172 201 M16 180 264 309 M20 363 517 605 M22 495 704 824 M24 625 890 104...

Page 288: ...que Nm 8 8 10 9 12 9 M4 3 4 6 5 1 M5 5 9 8 6 10 M6 10 1 14 9 17 4 M8 24 6 36 1 42 2 M10 48 71 83 M12 84 123 144 M14 133 195 229 M16 206 302 354 M20 415 592 692 M22 567 804 945 M24 714 1017 1190 M27 10...

Page 289: ...Tightening torque Nm 50 70 80 M3 0 37 0 8 1 1 M4 0 86 1 85 2 4 M5 1 6 3 6 4 8 M6 2 9 6 3 8 4 M8 7 1 15 2 20 3 M10 14 30 39 M12 24 51 68 M14 38 82 109 M16 58 126 168 M20 115 247 330 M22 157 337 450 M2...

Page 290: ...1 D Screw B Adjusting tool E Tighten screw with hexagonal socket wrench tightening torque A2 C Roller holder The following tightening torques apply for roller holders Size Tightening torque Nm A1 A2 4...

Page 291: ...are supplied by G del with a Torx drive can be screwed directly into the core hole It is not necessary to cut the thread in advance After the first use of a thread cutting screw a metric screw can als...

Page 292: ...washers with identical surface treat ment Use only HV screws and HV nuts that comply with the EN 14399 4 stan dard Use only HV washers that comply with the EN 14399 6 standard Do not lubricate HV set...

Page 293: ...D B C PEINER PEINER P A Fig 14 3 HV set A Stamp C HV washer B HV nut D HV screw Torque tables OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 293...

Page 294: ...torque Nm M12 75 100 M16 190 250 M20 340 450 M22 490 650 M24 600 800 M27 940 1250 M30 1250 1650 M36 2100 2800 Table 14 6 HV set Initial torques and tightening torques Torque tables OPERATING MANUAL C...

Page 295: ...mfer 4 Install HV screw 5 Mount HV washer on HV screw observe correct position of chamfer 6 Install HV nut stamp visible from outside 7 Thread projection check 1x thread 8 If there are deviations 8 1...

Page 296: ...rbox units Gearbox unit size Tightening torque TA Nm 030 5 045 060 6 5 090 120 12 180 59 Table 14 7 Torque table for clamping sets Properly tighten and loosen clamp ing sets Properly tighten clamping...

Page 297: ...T HY 200A 63 Fig 7 3 Setting up an upright 64 Fig 7 4 Measuring height of upright 65 Fig 7 5 Marking floor leveling screw 66 Fig 7 6 Installing the beams 68 Fig 7 7 Connecting the beams 69 Fig 7 8 Str...

Page 298: ...slide bars image source IGUS 113 Fig 7 35 Relieving the strain on cables and lines image source IGUS 115 Fig 7 36 Removing transport securing device G del gearbox unit 119 Fig 7 37 Installing transpor...

Page 299: ...oning the coupling on the motor shaft Elastomer coupling 177 Fig 9 27 X dimension calculation formula 177 Fig 9 28 Position the coupling on the motor shaft Make use of X dimension tolerance 179 Fig 9...

Page 300: ...s G del gearbox unit 241 Fig 10 3 Removing the motor G del gearbox unit 243 Fig 10 4 Removing the gearbox unit 244 Fig 10 5 Replacing lubricant G del gearbox unit 246 Fig 10 6 Installing the gearbox u...

Page 301: ...Fig 14 4 Tightening the clamping set 296 Fig 14 5 Releasing the clamping set 296 List of illustrations OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 301...

Page 302: ...List of illustrations OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 302...

Page 303: ...Guideway 87 Table 7 10 Z axis slings Sizes 90 Table 7 11 Cleaning agents Gearbox unit G del Coupling and motor shaft 99 Table 7 12 Weight and tolerances for the elastomer coupling 100 Table 7 13 Spec...

Page 304: ...uideways racks and pinions 154 Table 9 20 Lubricants Guideways racks and pinions 156 Table 9 21 Cleaning agents Automatic lubrication system Pump lines other components 158 Table 9 22 Inspection table...

Page 305: ...orques of screws of casing cover 256 Table 10 10 Distinguishing characteristics of wear Elastomer gear rim 258 Table 10 11 Malfunctions Troubleshooting 263 Table 12 1 Disposal material groups 276 Tabl...

Page 306: ...List of tables OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US 306...

Page 307: ...cation system 116 Checking 158 Replace battery 152 Replace the cartridge 152 Replacing the pump 159 B Base 57 Base mounting 74 Base plates anchoring 62 Positioning 61 Battery Replacing 152 Beam Aligni...

Page 308: ...s 133 Collision Behavior afterward 259 Further procedure 259 Connecting Beam 69 Side panels 107 Connector Options 116 Coupling Installing 102 180 Mounting 99 176 Removing 168 Replacing 168 Replacing G...

Page 309: ...99 200 205 249 G Gear backlash Setting G del gearbox unit 256 Gearbox Replacing G del gearbox unit 165 170 Gearbox flange Aligning 95 173 Replacing 251 General inspection 147 Greasing Roller 151 G del...

Page 310: ...bar 113 164 Integrating Product 117 L Leveling Upright 65 Leveling of the guide chute Checking 106 Liability 25 Lifting units 57 Lines 57 Relieving strain 114 Load Attaching 117 Load balance Pneumati...

Page 311: ...ling 99 176 Motor 99 176 Rack 83 202 Side panels 107 Mounting aid Using Installing the rack 82 201 MSDS 33 O Occupational safety 25 Oil Replacing 240 Operation 21 129 Options 38 Connecting 116 Origina...

Page 312: ...70 Elastomer gear rim 258 Energy chain 159 Gearbox flange 251 G del gearbox unit 165 170 Guideway 195 Lubricants 240 245 Lubricating element 156 Lubricating pinion 153 Motor 249 Motor flange 251 O rin...

Page 313: ...duct 269 Side panels Connecting 107 Mounting 107 Slide bar Installing 113 164 Slide bars Premount 164 Replacing 164 Slings Attaching Beam 46 48 Attaching Carriage 50 Attaching G del gearbox unit 167 2...

Page 314: ...of operating personnel 129 Transport 43 Beam 48 Transport securing device Checking 123 Installing G del gearbox unit 120 Removing G del gearbox unit 119 Tribocorrosion 134 Troubleshooting 263 Type pla...

Page 315: ...al contains the following documents Hazard analysis Risk analysis Addition to declaration of incorporation Technical data Layout Spare parts lists Options Third party documentation Appendix OPERATING...

Page 316: ...Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 317: ...Hazard analysis Risk analysis Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 318: ...Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 319: ...p load balancing general problems in the drive train Someone is surprised by parts flying away and being injured as a result x x 10 3 d Parts are flung out The axes can only be moved with reduced spee...

Page 320: ...lations are not observed Environmental hazard x x 10 3 d The device and its consumables are not disposed of properly at the end of their service life National regulations regarding disposal of the sys...

Page 321: ...for all hazards to ensure CE compliant use of the G del devices According to the CE Machinery Directive 2006 42 EC these suitable protective measures including all modifications must comply with the...

Page 322: ...Addition to declaration of incorporation Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 323: ...Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 324: ...1 3 2 Breaking risk during operation x x 1 3 3 Risks due to falling or flung out objects x 1 3 4 Risks from surfaces edges and corners x 1 3 5 Risks dues to multiple combined machines x 1 3 6 Risks d...

Page 325: ...x 1 7 4 2 Content of the operating manual x x 1 7 4 3 Sales brochures x 2 Additional basic work safety and health protection requirements for certain types of machines x To be checked by the system in...

Page 326: ...Technical data Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 327: ...Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 328: ...Layout Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 329: ...Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 330: ...Spare parts lists Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 331: ...Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 332: ...Options Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 333: ...Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 334: ...Third party documentation Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 335: ...Appendix OPERATING MANUAL CP 3 5 V2 9007202252815371_v1 0_EN US...

Page 336: ...Montagehandbuch f r gleitende Anwendungen Installation guide for gliding applications Notice d installation pour applications glissantes Gu a de Instalaci n para aplicaciones deslizantes...

Page 337: ...hrungsrinne Guide trough Goulotte de guidage Gu a Carrilera Fixpunkt Fixed end Point fixe Punto fijo Unterkonstruktion Support structure Structure d appui Estructura del soporte Mitnehmer Moving end...

Page 338: ...osition I End position I Position finale I Posici n final 1 Mitnehmer Moving end Point mobile Punto m vil F hrungsrinne mit Gleitleiste Guide trough with glide bar Goulotte avec bande de glissement Gu...

Page 339: ...ahrwegs l nge frei verfahren k nnen Es d rfen keine st renden Gegenst nde im Fahrbereich der e kette sein e chain has to be free moving along the entire travel length There must be no obstacles or cra...

Page 340: ...e made before next installation step V rifiez la structure d appui avant d installer la goulotte Veillez ce que les corrections soient faites avant de passer l tape suivante Chequear la estructura de...

Page 341: ...lev e de la cha ne ou blocage de celle ci Sin juego gran desgaste en los laterales de la cadena portacables o la cadena portacables se obstruye Abstandhalter Spacer bar Etrier d cartement Barra del e...

Page 342: ...ore assembly For example E4 56 Series V rifiez la r f rence sur la cha ne avant de la monter Par exemple s rie E4 56 Chequear el n mero de piezas en la Cadena Portacables antes del montaje Teil 3 part...

Page 343: ...elative to the travel stroke Lay the pre assembled e chain into the guide trough V rifiez si la position du point fixe par rapport la course est identique celle des plans igus Placez la cha ne pr asse...

Page 344: ...All separators aligned and straight V rifiez la division interne de la cha ne porte c bles S parateurs tous bien droits et fixes Chequear la separaci n interna de la Cadena Portacables Todos los sepa...

Page 345: ...ez vous que les inserts de l l ment de fixation aient t retir es sur le c t glissant de la cha ne Chequear que los bujes hayan sido retirados del lado deslizante del terminal Incorrect Falsch Incorrec...

Page 346: ...de la linea central Incorrect Falsch Incorrect Incorreto Korrigieren Sie die Leitungen Correct cable adjustment Corrigez la position des c bles Ajuste correcto de los cables Bewege den Kettenradius z...

Page 347: ...en el punto m vil y fijo berpr fen Sie die H he Check height V rifiez la hauteur Verificar altura Incorrect Falsch Incorrect Incorreto Bewegen Sie die e kette langsam und vorsichtig in beide Endpositi...

Page 348: ...H Spicher Stra e 1a 51147 K ln igus SARL 49 avenue des P pini res Parc M dicis F 94260 Fresnes igus GmbH Spicher Str 1a 51147 Cologne igus S L Ctra Llobatona 6 Poligono Noi del Sucre 08840 Viladecans...

Page 349: ...ate G DEL AG Industrie Nord CH 4900 Langenthal Switzerland Phone 41 62 916 91 91 Fax 41 62 916 91 50 E mail info ch gudel com www gudel com chrgal 1 0 17 06 2019 OPERATING MANUAL CP 3 5 V2 90072022528...

Page 350: ...G DEL AG Industrie Nord CH 4900 Langenthal Switzerland Phone 41 62 916 91 91 info ch gudel com www gudel com...