GUDEL MLB 1-3 V2 User manual

OPERATING MANUAL
MLB 1-3 V2
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG MLB 1-3 V2881017611_V1.0_EN-US
B1M.10xxxxxx-xxxx
10xxxxxx
9910xxxxxx
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.
881017611_v1.0_EN-US

Revision history
Version Date Description
1.0 19.11.2018 Basic version, valid as of product version
MLB-1V2.20; MLB-2V2.11; MLB-3V2.20
Table-1 Revision history
Revision historyOPERATING MANUAL MLB 1-3 V2
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3

Revision history OPERATING MANUAL MLB 1-3 V2
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4

Table of contents
1 Declaration of incorporation 15
2 General 17
2.1 Further applicable documentation................ .................17
2.2 Purpose of the document..................... ......................17
2.3 Explanation of symbols/abbreviations.............................. 18
3 Safety 19
3.1 General ...............................................................19
3.1.1 Product safety .........................................................19
3.1.2 Personnel qualifications..................................................20
3.1.2.1 Operating companies....................................................21
3.1.2.2 Transport specialists....................................................21
3.1.2.3 Fitters ................................ .................................21
3.1.2.4 Commissioning technicians ...................... .......................22
3.1.2.5 Operators .............................. ...............................22
3.1.2.6 Manufacturer's technicians.............................................. 22
3.1.2.7 Maintenance technicians.................................................23
3.1.2.8 Service technicians .......................... ...........................23
3.1.2.9 Disposal specialists.......................... ...........................23
3.1.3 Disregarding safety regulations.......................................... 24
3.1.4 Installation instructions..................................................24
3.2 Hazard symbols in the manual .....................................25
3.2.1 Hazard warnings .......................................................25
3.2.2 Explanation of warning symbol.......................................... 26
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3.3 Hazard symbols on the product.................................... 27
3.3.1 Danger label "Hot surfaces"..............................................27
3.4 Fundamentals of safety..............................................28
3.4.1 Separating protective equipment, monitoring equipment........ .........28
3.4.2 Product-specific hazards.................................................28
3.4.3 Material safety data sheets (MSDS)...................................... 30
4 Product description 31
4.1 Use ................................. ..................................31
4.1.1 Intended use............................. ..............................31
4.1.2 Non-intended use.......................................................31
4.2 Product designation........................ .........................32
4.2.1 Type plate .............................. ...............................32
4.2.2 Position of the type plate................................................33
4.3 Technical data........................... ............................33
4.4 Options .............................. ................................34
5 Design, function 35
5.1 Design................................................................ 35
5.2 Function .............................................................36
6 Transport 37
6.1 Packaging symbols....................................................38
6.2 Industrial trucks .......................... ...........................39
6.3 Slings................................ .................................39
6.3.1 Attaching the slings: MLB....................... ........................40
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7 Commissioning 41
7.1 Introduction .........................................................41
7.1.1 Safety.................................................................. 41
7.1.2 Personnel qualifications..................................................42
7.2 Intermediate storage................................................42
7.3 Downtimes ............................ ..............................43
7.4 Setup, fastening .....................................................44
7.4.1 General................................................................ 44
7.4.2 Prerequisites............................................................44
7.4.3 Unpacking .............................................................45
7.4.4 Attaching the slings: MLB....................... ........................46
7.4.5 Setup process.......................................................... 46
7.4.5.1 Special tools, testing and measuring instruments..........................47
7.4.5.2 Setting up an upright ...................................................47
7.4.5.3 Assembling the bumper unit.............................................48
Bumper unit with shearing sleeves.................................... 50
7.5 Installing .............................................................51
7.5.1 Installing the motor .....................................................51
7.5.1.1 Information on initial assembly.......................................... 51
7.5.1.2 Prerequisites............................................................51
7.5.1.3 Aligning the gearbox flange .............................................52
7.5.1.4 Aligning the input shaft to the gearbox flange............................ 54
7.5.1.5 Positioning the coupling on the motor shaft.............. ...............56
7.5.1.6 Installing the motor and coupling........................................ 59
7.5.2 Check leveling of the guide chute................... ....................62
7.5.3 Connecting the side panels ...................... .......................63
7.6 Assembling the energy chain ................... ....................65
7.6.1 Laying the cables and lines...............................................65
7.6.2 Installing the energy chain................................................68
7.6.3 Relieving the cables and lines of strain....................................69
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7.7 Connection ...........................................................73
7.7.1 Attaching optional components..........................................73
7.7.2 Attaching the load ..................................................... 73
7.7.3 Integrating the product..................................................73
7.8 Transport securing devices .................... .....................74
7.8.1 Removing the transport securing device..................................75
7.8.2 Installing transport securing device...................................... 76
7.8.2.1 Checking the transport securing device .................................79
7.8.2.2 Tighten the coupling screws .............................................80
7.8.2.3 Final tasks ............................................................. 80
7.9 Initial lubrication .....................................................81
7.9.1 Clean guideways and racks.............................................. 81
7.9.2 Pre-lubricate guideways and racks........................................82
7.9.3 Carrying out a lubrication check.........................................83
7.10 Functional check......................................................84
8 Operation 85
8.1 General ...............................................................85
8.2 Personnel ............................................................ 85
9 Maintenance 87
9.1 Introduction .........................................................87
9.1.1 Safety.................................................................. 87
9.1.2 Personnel qualifications..................................................88
9.2 Consumables and auxiliary agents..................................89
9.2.1 Cleaning agents .........................................................89
9.2.1.1 Table of cleaning agents .................................................89
9.2.2 Lubricants ............................................................. 90
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9.2.2.1 Lubrication .............................................................90
Manual lubrication...................................................91
Automatic lubrication system........................................ 93
9.2.2.2 Lubricant table............................ .............................94
9.3 Maintenance tasks......................... ..........................95
9.3.1 General prerequisites....................................................95
9.3.2 Maintenance intervals....................................................95
9.3.3 Special tools, testing and measuring instruments..........................97
9.3.4 Maintenance tasks after downtimes <4 weeks............. ..............98
9.3.5 Maintenance tasks after downtimes >4 weeks............. ..............98
9.3.6 Maintenance tasks 100 hours after commissioning........... ............99
9.3.6.1 Carrying out a lubrication check.......................................100
9.3.7 Maintenance tasks after 150 hours.................. ...................101
9.3.7.1 Lubricating guideways, racks and pinions ...............................101
9.3.8 Maintenance tasks after 2,250 hours ...................................103
9.3.8.1 General inspection.....................................................103
9.3.8.2 Carrying out a lubrication check.......................................106
9.3.8.3 Check cog belt........................................................ 107
9.3.8.4 Check bellows .........................................................109
9.3.9 Maintenance tasks after 6,750 hours ...................................110
9.3.9.1 Replacing the wiper and lubrication unit................................ 110
9.3.10 Maintenance tasks after 11,250 hours...................................112
9.3.10.1 Checking automatic lubrication system................ .................112
9.3.11 Maintenance tasks after 22,500 hours...................................113
9.3.11.1 Replacing the automatic lubrication pump.............................. 113
9.3.11.2 Replacing the energy chain..............................................113
Removing the energy chain .........................................113
Laying the cables and lines..........................................113
Installing the energy chain...........................................116
Final tasks..........................................................118
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9.3.11.3 Replacing the gearbox unit..............................................118
Attaching the slings: Motor .........................................118
Attaching the slings: Güdel gearbox unit.............................120
Removing the motor and coupling...................................121
Removing the gearbox unit with clamping set........................123
Replacing the gearbox unit..........................................123
Installing the gearbox unit with clamping set.........................124
Installing the motor ................................................125
Final tasks..........................................................136
9.3.11.4 Replacing the roller....................................................136
Roller positions ....................................................136
Replacing the roller ................................................137
Setting the rollers..................................................139
Final tasks..........................................................140
9.3.11.5 Replacing the guideway................................................ 141
Disassembling the guideway.........................................141
Installing the guideway..............................................142
Final tasks..........................................................143
9.3.11.6 Replacing switches, sensors............................................ 143
9.3.11.7 Replacing the cog belt........................ .........................144
Remove the motor.................................................146
Disassembling the carriage..........................................148
Loosening the cog belt..............................................148
Removing cog belt .................................................149
Replacing the cog belt ..............................................149
Removing deflection pulley..........................................150
Replacing ball bearings of deflection pulley...........................151
Replacing ball bearings, belt pulley, and clamping set..................152
Assembling the cog belt.............................................153
Final tasks..........................................................154
Installing the motor ................................................155
Tensioning the cog belt.............................................156
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9.4 Maintenance schedules...................... ...................... 159
9.4.1 Maintenance schedule .................................................161
9.4.2 Maintenance schedule for automatic lubrication system........ .........163
9.4.3 Güdel gearbox unit maintenance schedule.............................. 165
9.5 Maintenance table..................................................167
9.6 Intervention protocol: Maintenance............... ............... 169
9.7 Feedback on the instructions......................................181
10 Repairs 182
10.1 Introduction ........................... ............................ 182
10.1.1 Safety................................ .................................182
10.1.2 Personnel qualifications................................................ 183
10.2 Repairs .............................................................. 183
10.2.1 General prerequisites..................................................183
10.2.2 Replacing lubricant .....................................................184
10.2.2.1 Attaching the slings: Motor.............................................184
10.2.2.2 Attaching the slings: Güdel gearbox unit................................185
10.2.2.3 Remove the motor.................................................... 186
10.2.2.4 Removing the gearbox unit with clamping set............................188
10.2.2.5 Replacing lubricant .....................................................189
10.2.2.6 Installing the gearbox unit with clamping set............................ 192
10.2.2.7 Installing the motor ...................................................193
10.2.2.8 Final tasks .............................................................194
10.2.3 Replacing the motor....................................................194
10.2.4 Replacing the motor flange and gearbox flange..........................197
10.2.5 Setting the gear backlash................................................199
10.2.6 Replacing the elastomer gear rim .......................................201
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10.3 Tasks to perform after a crash ................. .................. 202
10.3.1 Replacing the bumper unit...................... .......................202
10.3.1.1 Bumper unit with shearing sleeves .....................................203
10.3.2 Referencing the axes ...................................................203
10.4 Malfunctions / Troubleshooting....................................204
10.5 Intervention report: Repairs................... ....................205
10.6 Other documentation..............................................207
10.7 Service departments....................... ........................207
11 Decommissioning, storage 208
11.1 Introduction ........................... ............................ 208
11.1.1 Personnel qualifications................................................ 208
11.2 Storage conditions .................................................208
11.3 Decommissioning......................... ......................... 209
11.3.1 Shutdown.............................. ...............................209
11.3.2 Cleaning, rust-proofing.................................................209
11.3.3 Transport securing devices .............................................209
11.3.4 Identification.......................................................... 210
11.4 Recommissioning......................... ..........................210
12 Disposal 213
12.1 Introduction ........................... ............................ 213
12.1.1 Safety................................ .................................213
12.1.2 Personnel qualifications................................................ 214
12.2 Disposal .............................................................214
12.3 Waste management compliant assemblies........... ............215
12.3.1 Disassembly ...........................................................215
12.3.2 Material groups .......................................................216
12.4 Disposal facilities, authorities......................................216
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13 Spare parts supply 217
13.1 Service departments....................... ........................219
13.2 Explanations regarding the spare parts list.......................225
13.2.1 Parts list...............................................................225
13.2.2 Position drawings .....................................................225
14 Torque tables 226
14.1 Tightening torques for screws................... ................... 226
14.1.1 Zinc plated screws ......................................................227
14.1.2 Black screws ............................................................228
14.1.3 Stainless steel screws ...................................................229
14.2 Tightening torques for clamping sets .............................. 230
List of illustrations 231
List of tables 235
Index 239
Appendix
Hazard analysis, Risk analysis
Addition to declaration of incorporation
Technical data
Layout
Spare parts lists
Options
Third-party documentation
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1 Declaration of incorporation
The manufacturer: GÜDEL AG
Industrie Nord
CH-4900 Langenthal
hereby declares that the partly completed machine:
Product, type
Serial number
Parts list
Year of manufacture
corresponds to the fundamental requirements of the Machinery Directive
(2006/42/EC), Appendix 1.
The partly completed machine may only be commissioned after it has been
determined that the machine into which the partly completed machine is to
be incorporated complies with the stipulations of Machinery Directive
(2006/42/EC).
The special technical documentation 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 the technical documenta-
tion:
Alain Knuchel Tel. [phone]
The partly completed machine complies with the following additional EC di-
rectives:
• Low Voltage Directive2014/35/EU
• EMC Directive2014/30/EU
The following harmonized standards have basically been applied:
EN ISO 12100:2010; EN ISO 13850:2015; EN 60204-1:2006; EN ISO
14119:2013; EN ISO 4413:2010; EN ISO 4414:2010; EN ISO 13849-1:2015
Langenthal,
Markus Ruprecht
CEO
Alain Knuchel
General Manager
Robotics
Declaration of conformity, declaration of incorporationOPERATING MANUAL MLB 1-3 V2
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MLB 1-3 V2
9910xxxxxx
10xxxxxx
2018
xx.xx.20xx

Declaration of conformity, declaration of incorporation OPERATING MANUAL MLB 1-3 V2
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2 General
Read the entire manual before working with the product. The manual con-
tains important information for your personal safety. The manual must be
read and understood by all persons who work on the product in any of the
product life phases.
2.1 Further applicable documentation
All documents delivered with this manual are further applicable documenta-
tion. They must be observed in addition to this operating manual for the safe
handling of the product.
2.2 Purpose of the document
This manual describes 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 essential component of the product.
The manual must be available at the product site throughout the entire ser-
vice life of the product. If the product is sold, the manual must be transferred
to the new owner.
Assembly instruc-
tions for partly
completed ma-
chinery
This document serves as the "Assembly instructions for partly completed ma-
chines" in accordance with the Machinery Directive 2006/42/EC, and is in this
respect an "Operating Manual".
GeneralOPERATING MANUAL MLB 1-3 V2
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2.3 Explanation of symbols/abbreviations
The following symbols and abbreviations are used in this manual:
Symbol/Abbrevia-
tion
Use Explanation
Ü
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2-1 Explanation of symbols/abbreviations
General OPERATING MANUAL MLB 1-3 V2
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3 Safety
3.1 General
Read the entire manual before working with the product. The manual con-
tains important information for your personal safety. The manual must be
read and understood by all persons who work on the product in any of the
product life phases.
3.1.1 Product safety
Residual danger The product is built using state-of-the-art technology. It was designed and
constructed in accordance with the accepted safety regulations. However,
some residual danger remains during its operation.
There is danger to the personal safety of the operator as well as for the prod-
uct and other property.
Operation When operating the product, always observe this manual and ensure that the
system is always in perfect working order.
SafetyOPERATING MANUAL MLB 1-3 V2
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3.1.2 Personnel qualifications
WARNING
Lack of safety training
Incorrect behavior of untrained or insufficiently trained technicians can result
in severe or fatal injuries!
Before technicians work on safety-related aspects of the product:
• Ensure that the technicians are trained with regard to safety
• Train and instruct the technicians specifically for their area of responsibility
Only appropriately trained and authorized technicians are allowed to work on
the product.
Persons are authorized if:
• they are familiar with the relevant safety regulations for their area of re-
sponsibility
• they have read and understood this manual
• they meet the requirements for an area of responsibility
• they were assigned an area of responsibility by the operator
The technician is responsible to third parties in his area of responsibility.
During a training session or instruction, the technician may only work on the
product under the supervision of an experienced manufacturer's technician.
Safety OPERATING MANUAL MLB 1-3 V2
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