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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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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