GUDEL MLB 1-3 V2, Operating Manual

Page 1: ...OPERATING MANUAL MLB 1 3 V2 Project Order Bill of materials Serial number Year of manufacture BETRIEBSANLE 881017611_V1 0_ B1M 10xxxxxx xxxx 10xxxxxx 9910xxxxxx 2018 ...

Page 2: ...hat 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 ...

Page 3: ...ory 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 history OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 3 ...

Page 4: ...Revision history OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 4 ...

Page 5: ... 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 Explana...

Page 6: ...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 Table of contents OPERATING M...

Page 7: ...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 ...

Page 8: ...crews 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 ...

Page 9: ...eways 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...

Page 10: ...l 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 pull...

Page 11: ...isites 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 ...

Page 12: ...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 Disasse...

Page 13: ...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 Table of contents OPERATING MANUAL MLB 1 3 V2 8810176...

Page 14: ...Table of contents OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 14 ...

Page 15: ...as 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 41 0 62 916 92 31 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 ...

Page 16: ...Declaration of conformity declaration of incorporation OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 16 ...

Page 17: ...scribes 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 n...

Page 18: ... 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 881017611_v1 0_EN US 18 ...

Page 19: ...anger 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 al...

Page 20: ...horized 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 responsi...

Page 21: ...the technician at the operation site of the product at all times the technicians are kept up to date regarding best practice the technicians are informed about technical progress modifications and the like the contracted cleaning staff only work under the supervision of a mainte nance technician 3 1 2 2 Transport specialists The transport specialist is able to transport loads safely is able to use...

Page 22: ...system 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 on site at the premises of the manufacturer or representative has very good mechanical and or electrical knowledge has good software knowledge has maintenance service and repair experience has exp...

Page 23: ... in 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 knowledge has software knowledge has service and repair experience is flexible The service technician is responsible for the following tasks performing mechanical and electrical service work in accorda...

Page 24: ...rotective 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 guidelines and standards Before commissioning the system the operating company must check whether all the protective measures have been implemented These must cover all hazards This is the only way to en su...

Page 25: ...igh 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 hazards with a slight risk of moderate physical injury NOTE NOTE NOTE refers to hazards that can lead to property damage Safety OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 25 ...

Page 26: ...o general causes Hazards due to overpressure Hazards resulting from automatic startup Hazards due to falling axles Hazards due to heat Hazards due to heavy components Hazards due to environmental pollution Hazards due to suspended loads Hazards due to tipping over Hazards due to dangerous electrical voltage Safety OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 26 ...

Page 27: ...lowing warning labels are attached to the product 3 3 1 Danger label Hot surfaces Fig 3 1 Danger label Hot surfaces The danger label Hot surfaces warns against touching hot components Safety OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 27 ...

Page 28: ...protec 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 Hazardous voltage The product contains components that are energized with hazardous volt ages Touching these components will cause an electric shock Electric shocks can be fatal Before working in th...

Page 29: ... out if there is a crash This can lead to severe or fatal injuries Work spaces and operating devices in the direction of travel of the axis should be avoided Check the attachments regularly for condition and fit Clamp the workpieces properly WARNING Hot oil squirting out Overpressure in the gearbox is created by overload or incorrect perfor mance parameters Hot oil can squirt out This can lead to ...

Page 30: ...ws Suppliers 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 Safety infor mation about the material will be displayed Read the safety data sheets carefully Follow all the instructions We recom mend that you store the safety data sheets for future reference The s...

Page 31: ...l risks 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 for operation outside of the performance data specified by Güdel Any use other than the specified intended use will be considered improper use and is prohibited Do not make any modifications to the...

Page 32: ...ollowing 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 Serial number Product description OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 32 ...

Page 33: ...ype Gearbox ratios Motors Emission sound pressure level The emission sound pressure level depends on the machine 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 measurement is performed according to the ISO 11202 standard The measured value is time averaged over a...

Page 34: ...midity Transport 10 to 60 C Operation 5 to 40 C Up to and at 85 con densation formation is not permissible Storage 10 to 40 C Up to 75 Table 4 1 Temperature ranges 4 4 Options If available the following option comes with separate documentation Automatic lubrication system Information on any available options can be found in the spare parts lists and the layout in the appendix Where applicable any ...

Page 35: ...5 6 A B C D E F K J I H G Fig 5 1 Structure A Automatic lubrication system option G Guide chute B Y carriage H Y drive C Initiator for position monitoring option I Y axis D Bellows option J Cog belt E Energy chain K Deflection pulley F Bumper unit Design function OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 35 ...

Page 36: ...5 2 Function The product can move along the following axes D001459 Y Fig 5 2 Axis names Design function OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 36 ...

Page 37: ...fting 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 Use appropriate lifting units Wear appropriate protective clothing Always keep sufficient distance from suspended loads Never enter the area below a suspended load NOTE Improper transport Improper...

Page 38: ...ansport pallets crates cases observe the following symbols CENTEROF GRAVITY D003601 SLING HERE SLING HERE D003600 A B Fig 6 1 Attaching slings A Center of gravity B Fastening point Transport OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 38 ...

Page 39: ...nsport the pallet crate or case to the intended installation location Use appropriate transport devices 6 2 Industrial trucks Industrial trucks have to be capable of handling the size 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 the slings to st...

Page 40: ...e slings MLB horizontal A Hook B Lifting belts C MLB Attach the slings as follows 1 Mount the lifting belts on the MLB as illustrated 2 Hang the lifting belts into the hook The slings are in place Transport OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 40 ...

Page 41: ...y Ü 2 19 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 guard WARNING Suspended loads Improper handling of suspended loads can lead to severe injuries or death Use appropriate lifting units Wear appropriate protective clothing Always keep sufficient dista...

Page 42: ...screws 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 authorized technicians are allowed to commis sion the product 7 2 Intermediate storage Observe the storage conditions if the product needs to be stored for a cer tain amount of time before assembly ...

Page 43: ...Check the lubricating film on guideways and racks ü û Check hydraulic lines for air pockets and kinks ü û If the machine downtime is longer than four weeks carry out the following jobs Prelubricate guideways and racks Perform a lubrication check as described in the separate documentation on automatic lubrication Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 43 ...

Page 44: ...equisites 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 the complete system The assessment of the load capacity of the floor concrete reinforcement payload etc must be carried out by a structural engineer or architect Güdel is not responsible for th...

Page 45: ...ve packaging carefully The anti rust oil protects the components We recommend not removing the oil Dispose of the packaging in accordance with the local waste regulations Checking the deliv ery Check the content of the delivery by comparing it with the accompanying documents Check the product for damage Report transport damage promptly Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US...

Page 46: ...in place 7 4 5 Setup process This chapter describes the set up procedure Carefully read the procedure in structions Then carry out the individual steps according to the detailed de scription Set up the product as follows 1 Set up uprights if necessary Ü Chapter 7 4 5 2 2 47 2 Attach slings Ü 2 46 3 Install the product 4 Install the bumper unit Ü 2 48 The product has been set up Commissioning OPERA...

Page 47: ...HPG AE045 0917453 Fastening device Blocking the drive pin ions HPG AE060 0917454 Pin type face wrench Setting the rollers Sizes 10 15 20 999756 Table 7 1 Special tools testing and measuring instruments 7 4 5 2 Setting up an upright For the product the following fastening methods are possible Güdel uprights Other uprights Directly onto a machine Directly onto a steel beam construction If you are no...

Page 48: ...e layout WARNING Incorrectly installed safety component The bumper unit is a safety component Incorrectly installed bumper units may lead to severe injury or death Drill the pinhole into the mating part of the bumper unit if necessary Install all associated components Tighten all screws with a torque wrench to the specified tightening torques Check if the shearing sleeves and or pins are fully and...

Page 49: ... B 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 assembly of the bumper unit Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 49 ...

Page 50: ...ng 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 Check if the shearing sleeves have been fully and correctly installed 5 Assemble the pre assembled bumper unit 6 Seal all screws with Loctite Blue Threadlocker 7414 The bumper unit with shearing sleeves ha...

Page 51: ...imply disassembled and remounted with one half of the elastomer coupling 7 5 1 2 Prerequisites Three conditions must be fulfilled simultaneously to allow you to install the motor on the gearbox unit The gearbox flange is aligned to allow the coupling screws to be tightened through the drill holes of the gearbox flange with a torque wrench The input shaft with installed wedge must be positioned wit...

Page 52: ...ft lb s 3 2 N m D1 20F7 Gearbox side HPG060 02 17 ü û A B C D E F G H I J L K Fig 7 4 Aligning the gearbox flange A Articulated socket G Coupling B Torque wrench H Screw C Gearbox I Motor flange D Plug J Gearbox flange E Drill hole K Fastening screw F Coupling screw L Adjacent construction Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 52 ...

Page 53: ... through 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 Install and tighten the fastening screws 4 5 Install the motor flange 4 6 Install and tighten the screws 4 7 Place the coupling on the input shaft 5 Install the plug The gearbox flange has now been alig...

Page 54: ...ead 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 5 Aligning the input shaft to the gearbox flange A Drill hole E Coupling screw B Wedge F Coupling C Input shaft G Gearbox flange D Plug Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 54 ...

Page 55: ...erequisite 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 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 flange Commiss...

Page 56: ...nd the 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 N m 10401305 A B C D E F G H Fig 7 6 Positioning the coupling on the motor shaft Elastomer coupling A Gearbox E Installation surface B Motor flange F Coupling screw C Measuring instrument G Moto...

Page 57: ...30 GWE 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 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 Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 57 ...

Page 58: ...e coupling 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 3 Cleaning agents Gearbox unit Güdel Coupling and motor shaft Tool Use Item number Corrosion protection agent MOTOREX In tact XD 20 Installing the coupling Applying corrosion protection to the product 0502037 Table 7 4 Special tools testi...

Page 59: ... 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 tightening torque TA 7 2 Tighten alternately with 100 of the tightening torque TA The coupling is positioned 7 5 1 6 Installing the motor and coupling WARNING Heavy components Components can be very heavy...

Page 60: ...02 17 A B C D E F G Fig 7 9 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 compounds e g Motorex OPAL 5000 Table 7 5 Cleaning agents Gearbox unit Güdel coupling input shaft and wedge Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 60 ...

Page 61: ...g switched on again 2 Attach slings to the motor if necessary Ü 2 118 3 Clean the coupling input shaft and wedge to remove any grease 4 Install the wedge on the input shaft 5 Apply corrosion protection agent to the wedge and input shaft with a brush 6 Push the motor with installed coupling onto the gearbox unit 7 Install and tighten the motor screws 8 If the motor screws cannot be fitted 8 1 Vent ...

Page 62: ...A B Fig 7 10 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 If there are deviations 2 1 Correctly level the guide chute 2 2 Repeat the procedure The guide chute is leveled Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 62 ...

Page 63: ...gy 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 plates Secure screw connections with Loctite 243 û ü D003985 A B C D E F Fig 7 11 Connecting the side panels A Side panel D Lock washer B Screw clamp E Hexagon nut C Pan head screw F Connecting plate Com...

Page 64: ...e inner side of the guide chute 4 Apply Loctite 243 to hexagon nuts 5 Install lock washers and hexagon nuts 6 Tighten all screw connections 7 Check alignment of transitions 8 If there are deviations 8 1 Remove screw connections 8 2 Repeat the procedure The side panels are connected Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 64 ...

Page 65: ...evenly Never take the cables off in loops Lay out cables without twisting for at least 24 hours before putting them into energy chains Use the cable description to assist you The wires of the cable are thus aligned without twisting and can have a positive influence on the ser vice life of the cable Observe the following points Cables are separated by vertical dividers cables are not permitted to b...

Page 66: ...û û û ü ü ü A B C D Fig 7 12 Laying cables and lines image source IGUS A Screwdriver C Opening bar B Energy chain D Vertical divider Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 66 ...

Page 67: ... lines in accordance with the IGUS internal division document 3 Close the opening bars without force in reverse order 4 Check that the position of the cables and lines is correct 5 If there are deviations 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...

Page 68: ... Stepping on energy chains leads to material damage Do not step on energy chains The orange flag denotes the driver side The manufacturer turns the first three chain links on the driver side This makes the energy chain slide better D004003 û ü A B C D E B H G F Fig 7 13 Installing the energy chains A Nut E Orange flag B Fastening screw F Driver s side connection element C Mounting angle G Fixed si...

Page 69: ...relief on cables and lines in energy chains leads to damage Cables and lines will be destroyed This results in operational failure Relieve the strain on every cable and every line individually Never bunch together several cables and lines into one strain relief Exception IGUS Chainfix multi clamps For traverse paths of the energy chain that are less than 50 m Relieve the strain on the cables and l...

Page 70: ...ection element NOTE Damage to the sheaths of the cables Cable fittings which are too tight damage the sheaths of the cables Do not tighten the cable fittings too firmly NOTE Excessively high tightening torques Special cables such as FOC fiber optic cables or similar can be destroyed by the torque of 1 Nm at ChainFix strain reliefs It is essential to comply with the cable specifications Consult wit...

Page 71: ...ixed side connection 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 7 Strain relief Cable fitting ChainFix version Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 71 ...

Page 72: ...erse paths of the energy chain longer than 50 m 3 1 Relieve cable strain at the driver distance between the end of the bending movement and strain re lief 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 Correct the strain relief 5 Check the metal slee...

Page 73: ...follows 1 Attach the load gripper robot etc 2 Setting the roller and tooth flank backlash The load has been attached 7 7 3 Integrating the product Integrate the product into the complete system Connect the product with the supply lines for energy and consumables For information on the proce dure refer to the documentation on the complete system Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v...

Page 74: ...g devices 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 fatal injuries If necessary secure the vertical axes and the carriages before removing transport securing devices brakes or motors Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 74...

Page 75: ...Remove the latch using a screwdriver A B C D E Fig 7 15 Removing transport securing device Güdel gearbox unit A Plug D Coupling B Transport securing device E Latch C Coupling screw Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 75 ...

Page 76: ...ad to 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 fastening screws The transport securing de vice must never be able to rotate Tighten the coupling screws to the required torque NOTE Defective coupling The coupling is destroyed if the coupling sc...

Page 77: ...sport securing device Güdel 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 MANUAL MLB 1 3 V2 881017611_v1 0_EN US 77 ...

Page 78: ...ere are 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 Marking bore is visible on the input side 7 Use the latch to install the transport securing device in the direction of the arrow 8 Installing the coupling 8 1 Press the coupling in the direction o...

Page 79: ...curing 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 securing device and coupling 2 2 Correct install the transport securing device The transport securing device has been checked Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 79 ...

Page 80: ...n alternately to 50 of the tightening torque TA 1 2 Tighten alternately with 100 of the tightening torque TA The coupling screws are tightened 7 8 2 3 Final tasks Perform the following final tasks 1 Install the plug The final tasks have been performed Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 80 ...

Page 81: ...the danger area while the axis is moving Fig 7 18 Clean guideways and racks Cleaning agents mild universal cleaner free from aromatic compounds e g Motorex OPAL 5000 Table 7 8 Cleaning agents guideways racks Clean the racks and guideways as follows 1 Switch off the system and padlock it to secure it against being switched on again 2 Clean guideways and racks thoroughly The guideways and racks have...

Page 82: ...ricants Guideways racks and 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 Pre lubricate guideways and racks as shown in the illustration The guideways and racks have been pre lubricated Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US...

Page 83: ...ation on the automatic lubrication system ü û Fig 7 20 Carrying out a lubrication check Lubrication ex works Specification Lubrication quantity Ü Chapter 9 2 2 1 2 90 Ü Chapter 9 2 2 1 2 90 Table 7 10 Lubricants Guideways racks and pinions Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 83 ...

Page 84: ...tightly Prior to the functional check ensure that The installation regulations were observed The product is securely anchored The safety equipment has been 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 Commissioning OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 84 ...

Page 85: ...jury 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 qualifications of operating personnel before approving them Keep the operating personnel up to date in regard to best practices Also inform them about technical progress modifications etc ð If the...

Page 86: ...Operation OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 86 ...

Page 87: ...ified times This ensures a long service life for your product Original spare parts Only use original spare parts Ü 2 217 Options For information on the available options read the corresponding documenta tion in the appendix Third party prod ucts For information on third party products read the appropriate documents in the appendix Tightening torques Unless otherwise indicated adhere to the tighten...

Page 88: ...serious or fatal injuries Set down any workpieces before working in the danger area Never enter the area below suspended axes and workpieces Secure suspended axes using the stipulated equipment Check the belts of the telescope axes for signs of breakage and tears WARNING Heavy components Components can be very heavy Improper handling can cause severe or fatal injuries Use appropriate lifting units...

Page 89: ...ersal cleaner free from aro matic compounds e g Motorex OPAL 5000 Automatic lubrication system Pump lines other components Gearbox unit Güdel Coupling and motor shaft Gearbox unit Güdel coupling input shaft and wedge Guideway rack guideways racks MLB Drive shaft and clamping set This table does not purport to be exhaustive Table 9 1 Table of cleaning agents Maintenance OPERATING MANUAL MLB 1 3 V2 ...

Page 90: ... the lubricants Please inform your manufacturer accordingly They will then suggest an alternative from their product range Low tempera tures food grade Observe the application range limits of lubricants according to the safety data sheet 9 2 2 1 Lubrication Manual auto matic lubrication system The guideways racks and pinions of the product are lubricated either manu ally or automatically Lubricati...

Page 91: ... KP2K 30 in accordance with DIN 51502 As per instruc tions Guideways racks and pinions grease Table 9 2 Lubricants Guideways racks and pinions Fig 9 2 Lubricating manually with oil Lubrication ex works Specifica tion Lubrica tion quantity Location of appli cation Cate gory Güdel H1 NSF no 146621 cannot be found As per instruc tions Guideways racks and pinions oil Table 9 3 Lubricants Guideways rac...

Page 92: ... Pre lubricate guideways and racks Markings at the lubrication points The markings apply to manual lubrication of the following Güdel components Roller support Lubricating pinion unit Wiper and lubrication unit D000314 A B Fig 9 4 Markings at the lubrication points A Identification disc B Grease nipple Yellow identification disc Grease Red identification disc Oil Maintenance OPERATING MANUAL MLB 1...

Page 93: ...n accordance with DIN 51502 Automatic lubrica tion system Memolub grease Table 9 5 Lubricants Automatic lubrication system Memolub Fig 9 6 Automatic lubrication system Memolub Lubrication ex works Specifica tion Lubrica tion quantity Location of appli cation Cate gory Mobil Gly goyle 460 NSF no 136467 CLP PG 460 in accor dance with DIN 51502 Automatic lubrica tion system Memolub oil Table 9 6 Lubr...

Page 94: ...ons Guideways racks and pinions oil Mobil Gly goyle 460 NSF no 136467 CLP PG 460 in accor dance with DIN 51502 Automatic lubrica tion system Memolub oil CLP PG 460 in accor dance with DIN 51502 Gearbox unit Güdel oil Mobil Mo bilux EP 2 KP2K 30 in accordance with DIN 51502 As per instruc tions Guideways racks and pinions grease Vaseline Cannot be determined Gearbox unit Güdel elastomer gear rim of...

Page 95: ...ntimes of your system can result Güdel specifies the service life and maintenance intervals of the product so as to ensure safe and continuous operation The maintenance intervals relate to the effective operating hours of the product at a power on time POT of 100 Normal operating condi tions are assumed These correspond with the parameters used by Güdel when designing the product If the conditions...

Page 96: ...nance 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 9 months every 4 5 months every 3 months 6 750 every 2 5 years every 15 months every 10 months 11 250 every 4 years every 2 years every 16 months 13 500 every 4 5 years every 3 years every 1 5 years 22 500 every 7 75 years...

Page 97: ...to the product 0502037 Lubricating spray Pre lubricating guide ways and racks 10406825 Screw clamps Installing the racks Fastening device Blocking the drive pin ions HPG AE030 0917452 Fastening device Blocking the drive pin ions HPG AE045 0917453 Fastening device Blocking the drive pin ions HPG AE060 0917454 Pin type face wrench Setting the rollers Sizes 10 15 20 999756 Belt tension measuring inst...

Page 98: ... ü û Check hydraulic lines for air pockets and kinks ü û 9 3 5 Maintenance tasks after downtimes 4 weeks If the machine downtime is longer than four weeks carry out the following jobs Prelubricate guideways and racks Perform a lubrication check as described in the separate documentation on automatic lubrication Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 98 ...

Page 99: ...he product at all times Consider the envi ronmental conditions Adjust the maintenance intervals to your operating conditions if necessary Güdel is not liable for damage to the entire system caused by incorrect com missioning or incorrect integration by third parties Güdel is also not liable for damage to the entire system caused by improper operation improper care or non periodic maintenance Perfo...

Page 100: ...ntation on the automatic lubrication system ü û Fig 9 7 Carrying out a lubrication check Lubrication ex works Specification Lubrication quantity Ü Chapter 9 2 2 1 2 90 Ü Chapter 9 2 2 1 2 90 Table 9 11 Lubricants Guideways racks and pinions Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 100 ...

Page 101: ...using another type of lubricant replace the following components ð Wiper and lubrication unit ð Lubricating elements of the roller support ð Lubricating pinion Rinse the lines with fresh lubricant A type plate is attached to roller supports You will find the size of the roller on the type plate In all other cases the size of the roller can be found in the spare parts list D000314 Part No 904230 Ty...

Page 102: ...llows Prerequisite There is no automatic lubrication 1 Switch off the system and padlock it to secure it against being switched on again 2 Press in the lubricant into the grease nipple using a grease gun 2 1 for all available wiper 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...

Page 103: ...s or UV radia tion This can lead to leaks in the gearbox The lubricant leaks out The bear ings heat up and fail The gear teeth in the gear unit wear out and fail The gearbox fails Regularly check visible gaskets Replace defective gaskets immediately In the event of leaks check the gaskets Replace defective gaskets immedi ately Modify or replace the gearbox Repair any leaks promptly Inspection poin...

Page 104: ...Clamping sets Immediately tighten loose screws to the required torque Align and fasten loose at tachments Loss of oil Check the system and its surroundings for signs of the following Puddles of oil and oil spills 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...

Page 105: ...he rollers Energy chain and cable Check the energy chain Movability Wear Damage Position of the ca bles and lines Condition of the ca bles and lines Strain relief present Tightening torques 1 Nm for 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 Gu...

Page 106: ... out a lubrication check Perform a lubrication check as described in the separate documentation on the automatic lubrication system ü û Fig 9 9 Carrying out a lubrication check Lubrication ex works Specification Lubrication quantity Ü Chapter 9 2 2 1 2 90 Ü Chapter 9 2 2 1 2 90 Table 9 14 Lubricants Guideways racks and pinions Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 106 ...

Page 107: ...e frequency on the layout or the drawings Correctly tension belts that are tensioned incorrectly Distinguishing characteristics of wear Figure Fabric at the tooth head and tooth root is worn Cracks visible on tooth foot when tooth pressed It is not considered wear if the fabric loosens from the tooth base without cracks on the tooth foot Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US...

Page 108: ...og belt has swollen and draw heads become visible on the side of back The base material has become brit tle due to natural aging or high tem peratures Teeth are damaged or are missing Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 108 ...

Page 109: ...worn Replace the cog belt The cog belt has been checked 9 3 8 4 Check bellows Distinguishing characteristics of wear Plastic brittle Holes in the bellows Burned in swarf in the bellows Table 9 16 Distinguishing characteristics of wear Bellows Check the bellows as follows 1 Switch off the plant and padlock it to secure it against being switched on again 2 Check bellows 3 Replace bellows if necessar...

Page 110: ...llation Snap off the latching elements when removing the cover The cover must be replaced Replace the wiper and lubrication unit in accordance with the instructions Do not remove the cover D000109 A B C D E F Fig 9 10 Replacing the wiper and lubrication unit A Cover D Lubricating element B Grease nipple E Casing C Identification disc F Wiper Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_E...

Page 111: ... lubrication if necessary 3 Pre assemble the wiper and lubrication unit as shown in figure 4 Replace the wiper and lubrication unit 5 Only for manual lubrication 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 wiper See separate manual on automatic lubr...

Page 112: ...er components Immediately clean away any contamination Loss of lubricant Check system and its surroundings for traces Puddles of oil and oil spills on the floor or in the drip sheets Leaks torn or pinched lines Remove puddles of oil and oil spills on the floor or in the drip sheets Replace defective and pinched lines Function Check function Replace defective compo nents immediately Table 9 18 Insp...

Page 113: ...les 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 chains Only use lines whose minimum bending radius is smaller than the smallest radius of the energy chain Güdel shall only be liable for internal divisions which are found in spare parts lists in th...

Page 114: ...ertical 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 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 cable divider At its minimum it should be 10 of the cable diameter ...

Page 115: ...û û û ü ü ü A B C D Fig 9 11 Laying cables and lines image source IGUS A Screwdriver C Opening bar B Energy chain D Vertical divider Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 115 ...

Page 116: ...deviations 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 installed in an offset manner in the roll off direction of the energy chain The cables and lines are laid Installing the energy chain NOTE Connection elements installed at an angle If the conne...

Page 117: ...ide connection 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 side connection element using fas tening screws and nuts 2 Place the energy chain in the guide chute 3 Install fixed side on the guide chute 4 Install the driver side using fastening screws 5 Remo...

Page 118: ...hapter describes the steps for replacing the Güdel gearbox unit Replace the gearbox as follows Attaching the slings Motor WARNING Suspended loads Improper handling of suspended loads can lead to severe injuries or death Use appropriate lifting units Wear appropriate protective clothing Always keep sufficient distance from suspended loads Never enter the area below a suspended load Maintenance OPER...

Page 119: ...om motor if necessary 2 Mount lifting screw if necessary 3 Attach the slings as shown in the illustration 4 Carefully lift the load 5 Check horizontal alignment of the load 6 If the load tilts Repeat process from step 3 The slings are in place Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 119 ...

Page 120: ...opriate 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 14 Attaching the slings Güdel gearbox unit A Belt harness B Lifting screw C Thread hole Size Size of lifting screw 090 M10 120 M12 180 M16 Table 9 19 Size of lifting screw Maintenance OPERATING MANUAL MLB 1 3 V2 8...

Page 121: ...er area 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 vere or fatal injuries If necessary secure the vertical axes and the carriages before removing transport securing devices brakes or motors CAUTION Hot parts surfaces Hot surfaces present a burn haz...

Page 122: ...e are 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 motor Ü 2 118 7 Undoing the coupling screws on the gearbox unit side 8 Remove the motor screws 9 Remove motor and coupling 10 Undoing the coupling screws on the motor side 11 Remove the coupling from...

Page 123: ...ith clamping set as follows 1 Release and remove the clamping set 2 Remove gearbox screws 3 Pull the gearbox unit off the shaft The gearbox unit with clamping set is removed Replacing the gearbox unit Replace the gearbox unit as follows 1 Replace the complete gearbox unit and coupling The gearbox unit has been replaced Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 123 ...

Page 124: ... torques A B C D Fig 9 17 Installing the motor and gearbox unit A Shaft C Gearbox screw B Güdel gearbox unit D Clamping set Size 030 045 060 090 120 180 Thread size M6 M8 M10 M12 M16 M20 Tightening torque Nm 9 22 42 50 120 240 Table 9 20 Tightening torques for gearbox screws Güdel gearbox unit Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 124 ...

Page 125: ...y once during the entire service life of the gear box unit For maintenance tasks and repair the motor is simply disassembled 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 aligned to allow the coupling screws to be tightened through the drill holes of t...

Page 126: ...lb s 3 2 N m D1 20F7 Gearbox side HPG060 02 17 ü û A B C D E F G H I J L K Fig 9 18 Aligning the gearbox flange A Articulated socket G Coupling B Torque wrench H Screw C Gearbox I Motor flange D Plug J Gearbox flange E Drill hole K Fastening screw F Coupling screw L Adjacent construction Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 126 ...

Page 127: ...d through 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 Install and tighten the fastening screws 4 5 Install the motor flange 4 6 Install and tighten the screws 4 7 Place the coupling on the input shaft 5 Install the plug The gearbox flange has now been ali...

Page 128: ... 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 9 19 Aligning the input shaft to the gearbox flange A Drill hole E Coupling screw B Wedge F Coupling C Input shaft G Gearbox flange D Plug Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 128 ...

Page 129: ...rerequisite 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 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 flange Mainte...

Page 130: ...he 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 N m 10401305 A B C D E F G H Fig 9 20 Positioning the coupling on the motor shaft Elastomer coupling A Gearbox E Installation surface B Motor flange F Coupling screw C Measuring instrument G Motor s...

Page 131: ...030 GWE 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 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 Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 131 ...

Page 132: ...he coupling 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 9 22 Cleaning agents Gearbox unit Güdel Coupling and motor shaft Tool Use Item number Corrosion protection agent MOTOREX In tact XD 20 Installing the coupling Applying corrosion protection to the product 0502037 Table 9 23 Special tools te...

Page 133: ...tion 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 tightening torque TA 7 2 Tighten alternately with 100 of the tightening torque TA The coupling is positioned Installing the mo tor and coupling WARNING Heavy components Components can be very heavy Im...

Page 134: ...02 17 A B C D E F G Fig 9 23 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 compounds e g Motorex OPAL 5000 Table 9 24 Cleaning agents Gearbox unit Güdel coupling input shaft and wedge Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 134 ...

Page 135: ...ng switched on again 2 Attach slings to the motor if necessary Ü 2 118 3 Clean the coupling input shaft and wedge to remove any grease 4 Install the wedge on the input shaft 5 Apply corrosion protection agent to the wedge and input shaft with a brush 6 Push the motor with installed coupling onto the gearbox unit 7 Install and tighten the motor screws 8 If the motor screws cannot be fitted 8 1 Vent...

Page 136: ...tatively 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 immediately WARNING Unexpected movement of carriage and axis Simultaneous replacement of several rollers may lead to unexpected move ment of carriage or axis This can lead to severe or fatal injuries Replace the rollers individually Rol...

Page 137: ...iage 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 25 Replacing the roller A Wiper and lubrication unit G Carriage B Screw B H Flange C Roller I Screw I D Serrated lock washer J Extractor E Fastening screw K Screw K F Guideway Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 137 ...

Page 138: ...om the 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 Remove and replace roller 7 Replace serrated lock washer 8 Install the flange on the carriage using screws I 9 Install roller in flange using fastening screw and serrated lock washer 10 Tighten s...

Page 139: ... B C H G F E D Fig 9 26 Setting the rollers Prism guideway centering and eccentric rollers A Axis E Screw B Supporting roller concentric F Face spanner C Carriage G Guideway roller eccentric D Hexagonal socket wrench H Guideway Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 139 ...

Page 140: ...s by means of a face spanner 5 Check setting The roller touches the guideway The roller can still be turned by hand when a lot of force is applied 6 If there are deviations Repeat the procedure from step 2 7 Install the wiper and lubrication unit The rollers have been set Final tasks Perform the following final tasks 1 Calibrate the reference plane of the motor this procedure is described in the d...

Page 141: ...mble the guideway as follows 1 Switch off the system and padlock it to secure it against being switched on again 2 Attach the slings to the carriage or axis 3 Expose guideway 3 1 Move the carriage off the guideway or axis 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 Maintenance OPERATING MANUAL...

Page 142: ...akes priority D000108 A B D C B Fig 9 27 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 Motorex OPAL 5000 Table 9 27 Cleaning agents Guideway rack Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 142 ...

Page 143: ...eways 7 2 Repeat the procedure The guideway has been installed Final tasks Perform these final tasks as follows 1 Move the carriage along the axis if necessary 2 Retract the vertical axis if necessary 3 Remove the slings 4 Setting the rollers The final tasks have been performed 9 3 11 6 Replacing switches sensors Replace the switches and sensors in accordance with the third party docu mentation Th...

Page 144: ...nd tooth root is worn Cracks visible on tooth foot when tooth pressed It is not considered wear if the fabric loosens from the tooth base without cracks on the tooth foot Cog belt has swollen and draw heads become visible on the side of back Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 144 ...

Page 145: ...e The base material has become brit tle due to natural aging or high tem peratures Teeth are damaged or are missing Cog belt is torn Table 9 28 Wear characteristics of the cog belt Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 145 ...

Page 146: ...carriages before removing transport securing devices brakes or motors CAUTION Hot parts surfaces Hot surfaces present a burn hazard during work on this product Protect yourself by wearing heat resistant gloves Allow the parts to cool down first If the elastomer gear rim remains stuck on the gearbox side remove it manu ally This is necessary only if you wish to replace the elastomer gear rim Mainte...

Page 147: ...ainst being switched on again 2 Secure the carriage or axis with the transport securing device or lifting equipment 3 Attach slings to the motor Ü 2 118 4 Remove the motor screws 5 Force the motor off the gearbox unit with the forcing screws 6 Remove the motor together with the elastomer gear rim from the gear box unit The motor has now been removed Maintenance OPERATING MANUAL MLB 1 3 V2 88101761...

Page 148: ...removed Prerequisite The motor has been removed 1 Remove fastening screws and if necessary pins 2 Move carriage from the belt anchorage 3 Mark the position of the belt anchorage on the cog belt The carriage has been disassembled Loosening the cog belt 1 2 3 A B C Fig 9 30 Loosening the cog belt A Screw B Locking plate C Straining screw Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 1...

Page 149: ...elt anchorage C Cog belt Remove the cog belt as follows 1 Remove the set screws 2 Remove the belt anchorage 3 Remove the cog belt The cog belt is removed Replacing the cog belt Replace the cog belt as follows 1 Replace the cog belt 2 Transfer the markings of the old cog belt to the new cog belt if necessary The cog belt has been replaced Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US...

Page 150: ...Block E Deflection pulley C Fastening screw Remove the deflection pulley as follows 1 Loosen the screws 2 Remove the block 3 Loosen fastening screws 4 Remove the deflection pulley 5 Remove the covering The deflection pulley has been removed Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 150 ...

Page 151: ...olt C Deflection pulley Replace the ball bearings of the deflection pulley as follows 1 Remove the headless set screws 2 Remove the bolts 3 Remove the adjusting washers 4 Replace the ball bearings 5 Install the components in the reverse order The ball bearings of the deflection pulley have been replaced Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 151 ...

Page 152: ...29 Cleaning agents MLB Drive shaft and clamping set Replace the ball bearings belt pulley and clamping set as follows 1 Remove the clamping set 2 Remove the cover 3 Remove the bushings 4 Remove the retaining rings 5 Remove the ball bearings 6 Remove the belt pulley and flanged coupling pulleys 7 Remove the flanged coupling pulleys 8 Replace the ball bearings belt pulley and clamping set 9 Install ...

Page 153: ... under the drive wheel on gearbox side 2 Pull cog belt through the profile 3 Lay cog belt around deflection pulley and drive wheel 4 Mount deflection pulley 5 Insert ends of the cog belt in the belt anchorage 6 Position the belt anchorage on the marking of the cog belt and screw it on tightly The cog belt is installed Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 153 ...

Page 154: ...in Perform the following final tasks 1 Move carriage onto the belt anchorage 2 Mount pins and tighten screws 3 Install the covering 4 Mount the block 5 Install the motor 6 Tension the cog belt The final tasks have been performed Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 154 ...

Page 155: ... Gearbox unit B Motor screw E Forcing screw C Elastomer gear rim Lubrication ex works Specification Lubrication quantity Vaseline Cannot be determined Table 9 30 Lubricants Gearbox unit Güdel elastomer gear rim of the coupling Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 155 ...

Page 156: ... the elastomer gear rim on the gearbox unit 6 Install and tighten the motor screws The motor has now been installed Tensioning the cog belt WARNING Moving the axis The work requires moving the axis This can lead to severe or fatal injuries Ensure that no persons are in the danger area while the axis is moving LI A B C Fig 9 38 Free frequency length A Free frequency length B Carriage C Cog belt Mai...

Page 157: ...MLB 2 820 300 112 500 66 MLB 3 1950 300 138 500 84 Table 9 31 Cog belt natural frequency 1 2 3 4 5 Hz Hz Hz A B E D C Fig 9 39 Tensioning the cog belt A Cog belt D Locking plate B Belt tension measuring instrument E Screw C Straining screw Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 157 ...

Page 158: ...lt tension measuring instrument at a distance of 1 20 mm to the cog belt in the middle of the frequency length L 2 Strike the cog belt to set it in vibration 3 Interpret the measurement result according to the preceding table If there are deviations 3 1 Remove the locking plate and screw 3 2 Set the belt tension using straining screw 3 3 Repeat process from step 1 4 Carry out a control measurement...

Page 159: ...9 4 Maintenance schedules Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 159 ...

Page 160: ...Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 160 ...

Page 161: ... h 6 750 h 2 250 h 150 h 150 h 2 250 h 6 750 h 22 500 û ü D003983 ü Fig 9 40 Maintenance schedule Grease Replacing Automatic lubrication system Memolub Oil Clean Visual inspection Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 161 ...

Page 162: ...Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 162 ...

Page 163: ...stem h 2 250 h 2 250 h 22 500 h 11 250 h 22 500 h 11 250 ü û ü û Fig 9 41 Maintenance schedule for automatic lubrication system Grease Replacing Replacing lubricant Oil Clean Visual inspection Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 163 ...

Page 164: ...Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 164 ...

Page 165: ...enance schedule h 22 500 h 22 500 2 250 h 2 250 h Fig 9 42 Maintenance schedule for Güdel gearbox unit Grease Replacing Replacing lubricant Oil Clean Visual inspection Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 165 ...

Page 166: ...Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 166 ...

Page 167: ...n unit 6 750 50 Service technicians Maintenance technicians The manufacturer s technicians Mobil Mobilux EP 2 Güdel H1 NSF no 146621 Ü Chapter 9 3 9 1 2 110 Checking automatic lubrica tion system 11 250 The manufacturer s technicians Maintenance technicians mild universal cleaner free from aro matic compounds e g Motorex OPAL 5000 Ü Chapter 9 3 10 1 2 112 Replacing the energy chain 22 500 30 Maint...

Page 168: ...facturer s technicians Ü Chapter 9 3 11 7 2 144 Replacing ball bearings of deflection pulley Service technicians Maintenance technicians The manufacturer s technicians Ü 2 151 Replacing ball bearings belt pulley and clamping set The manufacturer s technicians Maintenance technicians Service technicians mild universal cleaner free from aro matic compounds e g Motorex OPAL 5000 Ü 2 152 This table do...

Page 169: ...rator details 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 working electronically Send it to service ch gudel com after every intervention Effective operating hours1 Service hours h of the entire system according to service hour counter in the control ...

Page 170: ...Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 170 ...

Page 171: ...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 Comments3 Date Check bellows 2 250 Carrying out a lubrication check General inspection Check cog belt Effective operating hours1 Service hours h of the entire system according to service hour counter in the contr...

Page 172: ...Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 172 ...

Page 173: ...report 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 Comments3 Date Replacing the wiper and lu brication unit 6 750 Effective operating hours1 Service hours h of the entire system according to service hour counter in the control panel Service hou...

Page 174: ...Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 174 ...

Page 175: ... report 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 Comments3 Date Checking automatic lubrica tion system 11 250 Effective operating hours1 Service hours h of the entire system according to service hour counter in the control panel Service hour...

Page 176: ...Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 176 ...

Page 177: ...e ch gudel com after every intervention Maintenance work Maintenance cycle h Effective operating hours1 Name2 Comments3 Date Replacing the energy chain 22 500 Replacing the gearbox unit Replacing the automatic lu brication pump Replacing the roller Replacing the guideway Replacing switches sensors Replacing the cog belt Replacing ball bearings of deflection pulley Effective operating hours1 Servic...

Page 178: ...Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 178 ...

Page 179: ...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 Comments3 Date Replacing ball bearings belt pulley and clamping set 22 500 This table does not purport to be exhaustive Effective operating hours1 Service hours h of the entire system according to service hour counter in ...

Page 180: ...Maintenance OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 180 ...

Page 181: ...ating 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 D Covering Lubrication ex works Specification Lubrication quantity Ü Chapter 9 2 2 1 2 116 Ü Chapter 9 2 2 1 2 116 Table 9 12 Lubricants Guideways racks and pinions Removing the lu bricating pinion ...

Page 182: ...re to the tightening torques of Güdel Ü Chapter 14 2 226 10 1 1 Safety Only perform the tasks described in this chapter after you have read and un derstood the chapter Safety Ü 2 19 It concerns your personal safety WARNING Automatic startup During work on the product there is danger of the machine starting up auto matically This can lead to severe or fatal injuries Before working in the danger are...

Page 183: ...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 10 1 2 Personnel qualifications Only appropriately trained and authorized technicians are allowed to work on the product 10 2 Repairs 10 2 1 General prerequisites Prior to performing repair and maintenance tasks do the following If verti...

Page 184: ...spended loads Never enter the area below a suspended load Fig 10 1 Attaching the slings Motor image source Bosch Rexroth Attach the slings as follows 1 Remove fan from motor if necessary 2 Mount lifting screw if necessary 3 Attach the slings as shown in the illustration 4 Carefully lift the load 5 Check horizontal alignment of the load 6 If the load tilts Repeat process from step 3 The slings are ...

Page 185: ...se appropriate 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 Attaching the slings Güdel gearbox unit A Belt harness B Lifting screw C Thread hole Size Size of lifting screw 090 M10 120 M12 180 M16 Table 10 1 Size of lifting screw Repairs OPERATING MANUAL MLB 1 3 V...

Page 186: ...y run 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 surfaces Hot surfaces present a burn hazard during work on this product Protect yourself by wearing heat resistant gloves Allow the parts to cool down first If the elastomer gear rim remains stuck on t...

Page 187: ...against being switched on again 2 Secure the carriage or axis with the transport securing device or lifting equipment 3 Attach slings to the motor Ü 2 184 4 Remove the motor screws 5 Force the motor off the gearbox unit with the forcing screws 6 Remove the motor together with the elastomer gear rim from the gear box unit The motor has now been removed Repairs OPERATING MANUAL MLB 1 3 V2 881017611_...

Page 188: ... A Shaft C Gearbox screw B Gearbox unit D Clamping set Remove the gearbox unit with clamping set as follows 1 Release and remove the clamping set 2 Remove gearbox screws 3 Pull the gearbox unit off the shaft The gearbox unit with clamping set is removed Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 188 ...

Page 189: ... work 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 data sheets Oils and greases must be disposed of as hazardous waste even if the total quantity is small Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 189 ...

Page 190: ...s Specification 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 HPG180 as per type plate Table 10 2 Lubricants Gearbox unit Güdel Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 190 ...

Page 191: ...ow the drain screw 3 Remove the bleed filler and drain screws 4 Drain the lubricant 5 Rinse the gearbox with fresh lubricant 6 Allow 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 Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 191 ...

Page 192: ...tening torques A B C D Fig 10 6 Installing the motor and gearbox unit A Shaft C Gearbox screw B Güdel gearbox unit D Clamping set Size 030 045 060 090 120 180 Thread size M6 M8 M10 M12 M16 M20 Tightening torque Nm 9 22 42 50 120 240 Table 10 3 Tightening torques for gearbox screws Güdel gearbox unit Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 192 ...

Page 193: ...set has been installed 10 2 2 7 Installing the motor A B C E D Fig 10 7 Installing the motor Güdel gearbox unit A Motor D Gearbox unit B Motor screw E Forcing screw C Elastomer gear rim Lubrication ex works Specification Lubrication quantity Vaseline Cannot be determined Table 10 4 Lubricants Gearbox unit Güdel elastomer gear rim of the coupling Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_E...

Page 194: ...the reference plane of the motor this procedure is described in the documentation for the complete system or the motor The final tasks have been performed 10 2 3 Replacing the motor CAUTION Hot parts surfaces Hot surfaces present a burn hazard during work on this product Protect yourself by wearing heat resistant gloves Allow the parts to cool down first Mark the position of the coupling on the mo...

Page 195: ...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 20 Installing the coupling Applying corrosion protection to the product 0502037 Table 10 5 Special tools testing and measuring instruments Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 195 ...

Page 196: ...h a brush 10 Push the coupling half onto the motor shaft 11 Set the Y distance 12 Tighten the coupling screws 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 Ü 2 193 14 Connect the cables and lines in accordance with the electrical schematics 15 Calibrate the reference plane of the motor t...

Page 197: ... position of the drill holes of the gearbox flange Install the new gearbox flange identically Do not change the position of the input shaft Do not change the position of the coupling on the motor shaft Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 197 ...

Page 198: ... secure it with a padlock against being switched on again 2 Remove the motor and coupling Ü 2 121 3 Remove the fastening screws screws and motor flange 4 Remove the gearbox flange 5 Replacing the motor flange and gearbox flange 6 Install the components in the reverse order 7 Install the motor Ü 2 51 The motor flange and gearbox flange have now been replaced Repairs OPERATING MANUAL MLB 1 3 V2 8810...

Page 199: ...es incorrectly 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 10 Setting the gear backlash Güdel gearbox unit A Worm shaft B Casing cover C Screw Size 030 045 060 090 120 180 Tightening torque Nm 6 7 8 19 36 36 Table 10 6 Tightening torques of screws of casing cover Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0...

Page 200: ...h Rotate 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 resists rotation Replace gearbox unit immediately 7 Insert all screws on both sides and tighten crosswise 8 Checking the gear backlash Rotate the worm shaft 360 by hand The shaft resists rotation ...

Page 201: ... the product and the ambient conditions However components may fail before expiry of the service life Replace worn components immediately Fig 10 11 Elastomer gear rim Distinguishing characteristics of wear Teeth broken out Teeth frayed Material brittle Table 10 7 Distinguishing characteristics of wear Elastomer gear rim Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 201 ...

Page 202: ...ks have been performed 10 3 1 Replacing the bumper unit The bumper unit is a safety component Replace the entire bumper unit after a crash has occurred WARNING Weakened safety component After a crash it is not immediately apparent whether bumper unit compo nents have been weakened or are defective A further crash can lead to se vere or fatal injuries Replace the entire bumper unit after a crash ha...

Page 203: ... 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 Check if the shearing sleeves have been fully and correctly installed 5 Assemble the pre assembled bumper unit 6 Seal all screws with Loctite Blue Threadlocker 7414 The bumper unit with shearing sleeves has been assembled 10 3 2 Referencing the axes R...

Page 204: ...ints are supplied too lit tle or not at all Lubrication line leaks Check lubrication lines Check connection points Remove leakage Lubrication points are supplied too lit tle or not at all Air in the automatic lubrication system Venting the automatic lubri cation system Lubrication points are supplied too lit tle or not at all Lubrication line too long Shorten the lubrication line Mounting aid Inst...

Page 205: ...can it in 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 out during the unplanned maintenance Component2 Affected component assembly Effective operating hours3 Service hours h of the entire system according to service hour counter in the control pa...

Page 206: ...Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 206 ...

Page 207: ...tion 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 Ü 2 219 Repairs OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 207 ...

Page 208: ...vented 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 is small Room Store the product in a dry location For information on the required space and the floor capacity refer to the layout Use a covering to protect the product against dust and dirt Tempe...

Page 209: ... proceed 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 the lubricant dispenser and remove the batteries The product has been shut down 11 3 2 Cleaning rust proofing Clean away any dirt and dust from the product Clean the product thor oughly Dispose of ...

Page 210: ...the steps described for commissioning Prior to recommissioning perform the general inspection Ü 2 103 Perform the required maintenance tasks and repairs If the machine downtime is longer than two weeks carry out the following jobs Check the lubricating film on guideways and racks ü û Check hydraulic lines for air pockets and kinks Decommissioning storage OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_...

Page 211: ...arate 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 fresh lubricant Replace the lubricating elements and lubricating pinion Check the gaskets and replace if necessary Decommissioning storage OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 211 ...

Page 212: ...Decommissioning storage OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 212 ...

Page 213: ... or fatal 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 for the complete system Before switching on the system again make sure that no one is in the dan ger area WARNING Falling axes workpieces Falling axes or workpieces can cause physical damage seriou...

Page 214: ...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 auxiliary agents oil paper Wood Plastic film Consumables Lubricants oils greases Batteries Base unit Metals steel aluminum Plastics thermoplasts duroplasts Contaminated materials auxiliary agents felt cle...

Page 215: ...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 guard 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 data sheets Oils and greases must be di...

Page 216: ...ps in accordance with the following table Material Disposal method Contaminated materials auxiliary agents Hazardous waste Wood Municipal waste Plastic Collecting point or municipal waste Lubricants Collecting point disposal in accor dance with the safety data sheets Ü 2 30 Batteries Battery collection Metals Scrap metal collection Electrical material Electrical waste Table 12 1 Disposal material ...

Page 217: ...13 Spare parts supply Spare parts supply OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 217 ...

Page 218: ...Spare parts supply OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 218 ...

Page 219: ...le service 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 specified in the contract Americas Country Relevant service department Phone E mail Brazil Güdel Lineartec Comércio de Automção Ltda Rua Américo Brasiliense n 2170 cj 506 Chácara Santo Antonio CE...

Page 220: ...ess automation Güdel Jier Automation Ltd A Zone 16th Floor JIER Building 21th Xinxi Road 250022 Jinan China 86 531 81 61 6465 service gudeljier com India Güdel India Pvt Ltd Gat No 458 459 Mauje Kasar Amboli Pirangut Tal Mulshi 412 111 Pune India 91 20 679 10200 service in gudel com Korea Güdel Lineartec Inc 11 22 Songdo dong Yeonsu Ku Post no 406 840 Incheon City South Korea 82 32 858 05 41 gkr s...

Page 221: ...del 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 Güdel GmbH Schöneringer Strasse 48 4073 Wilhering Austria 43 7226 20690 0 service at gudel com Croatia Austria Romania Serbia Slovenia Hungary Slovakia Güdel a s Holandská 4 63900 Brno Czech Republic 420 602 309 593 info cz ...

Page 222: ...any intralogistics Güdel Intralogistics GmbH Gewerbegebiet Salzhub 11 83737 Irschenberg Germany 49 8062 7075 0 service intralogistics de gudel com Italy Güdel S r l Via per Cernusco 7 20060 Bussero Mi Italy 39 02 92 17 021 info it gudel com Belgium Güdel Benelux Eertmansweg 30 7595 PA Weerselo The Netherlands 31 541 66 22 50 info nl gudel com Luxembourg The Netherlands Estonia Gudel Sp z o o ul Le...

Page 223: ...Güdel 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 have service inquiries outside of business hours please contact the following service departments Europe Güdel AG Gaswerkstrasse 26 Industrie Nord 4900 Langenthal Switzerland 41 62 916 91 70 serv...

Page 224: ...Spare parts supply OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 224 ...

Page 225: ...r a 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 ø130 110 8030 018a 2 Stk E 1000 0910499 Mechanical multi limit switch accessories 750 Y 8523 024 2 Stk 1100 230803 Felt pinion for lubrication ø40 6x20 Modul m 2 387 pitch P 7 5 Z 15 8102 039d 1 Stk V Güdel AG Insustrie Nord CH 4900 Langnethal phone 41 62 916 91 91 fax 41 62 916 95...

Page 226: ... NOTE 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 OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 226 ...

Page 227: ... Nm 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 1041 M27 915 1304 1526 M30 1246 1775 2077 M36 2164 3082 3607 Table 14 1 Torque table for zinc plated screws lubricated with Molykote MoS2 grease Torque tables OPERATING MANUAL MLB 1 3 V2 881017611_v1...

Page 228: ... torque 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 1050 1496 1750 M30 1420 2033 2380 M36 2482 3535 4136 Table 14 2 Torque table for black oiled and non lubricated screws Torque tables OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 228 ...

Page 229: ...size 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 M24 198 426 568 M27 292 M30 397 M36 690 Table 14 3 Torque table for stainless steel screws lubricated with Molykote MoS2 grease Torque tables OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 229 ...

Page 230: ... gearbox units Gearbox unit size Tightening torque TA Nm 030 5 045 060 6 5 090 120 12 180 59 Table 14 4 Torque table for clamping sets Properly tighten and loosen clamp ing sets Properly tighten clamping sets Do not remove any screws D003842 2x TA 1x TA I II III IV V VI VII VIII IX X I II III IV V VI Fig 14 1 Tightening the clamping set D003843 I II III IV V VI VII VIII IX X Fig 14 2 Releasing the...

Page 231: ...mula 57 Fig 7 8 Position the coupling on the motor shaft Make use of X dimension tolerance 58 Fig 7 9 Installing the motor and coupling 60 Fig 7 10 Checking leveling of the guide chute 62 Fig 7 11 Connecting the side panels 63 Fig 7 12 Laying cables and lines image source IGUS 66 Fig 7 13 Installing the energy chains 68 Fig 7 14 Relieving the strain on cables and lines image source IGUS 71 Fig 7 1...

Page 232: ...the gearbox unit with clamping set 123 Fig 9 17 Installing the motor and gearbox unit 124 Fig 9 18 Aligning the gearbox flange 126 Fig 9 19 Aligning the input shaft to the gearbox flange 128 Fig 9 20 Positioning the coupling on the motor shaft Elastomer coupling 130 Fig 9 21 X dimension calculation formula 131 Fig 9 22 Position the coupling on the motor shaft Make use of X dimension tolerance 132 ...

Page 233: ...4 Fig 10 2 Attaching the slings Güdel gearbox unit 185 Fig 10 3 Removing the motor Güdel gearbox unit 187 Fig 10 4 Removing the gearbox unit with clamping set 188 Fig 10 5 Replacing lubricant Güdel gearbox unit 190 Fig 10 6 Installing the motor and gearbox unit 192 Fig 10 7 Installing the motor Güdel gearbox unit 193 Fig 10 8 Replacing the motor Positioning the coupling half on the motor shaft 195...

Page 234: ...List of illustrations OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 234 ...

Page 235: ...ing agents 89 Table 9 2 Lubricants Guideways racks and pinions 91 Table 9 3 Lubricants Guideways racks and pinions 91 Table 9 4 Lubricants Pre lubricate guideways and racks 92 Table 9 5 Lubricants Automatic lubrication system Memolub 93 Table 9 6 Lubricants Automatic lubrication system Memolub 93 Table 9 7 Lubricant table 94 Table 9 8 Maintenance intervals in shift operation 5 days a week 96 Table...

Page 236: ...ency 157 Table 9 32 Special tools testing and measuring instruments 158 Table 9 33 Maintenance table 167 Table 10 1 Size of lifting screw 185 Table 10 2 Lubricants Gearbox unit Güdel 189 Table 10 3 Tightening torques for gearbox screws Güdel gearbox unit 192 Table 10 4 Lubricants Gearbox unit Güdel elastomer gear rim of the coupling 193 Table 10 5 Special tools testing and measuring instruments 19...

Page 237: ...ed and non lubricated screws 228 Table 14 3 Torque table for stainless steel screws lubricated with Molykote MoS2 grease 229 Table 14 4 Torque table for clamping sets 230 List of tables OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 237 ...

Page 238: ...List of tables OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 238 ...

Page 239: ...0 203 Attaching Slings 120 185 Automatic lubrication system Checking 112 Replacing the pump 113 B Ball bearing Replacing 151 152 Base 44 Bearing Replacing Güdel gearbox unit 123 Bellows Checking 109 Belt pulley Replacing 152 Bumper unit Installing 50 203 Replacing 202 Index OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 239 ...

Page 240: ...ehavior afterward 202 Further procedure 202 Connecting Options 73 Side panels 63 Coupling Installing 59 133 Mounting 56 130 Removing 121 Replacing 121 Replacing Güdel gearbox unit 123 Coupling screw Tighten 80 Crash Behavior afterward 202 Customer feedback 181 D Decommissioning 208 Deflection pulley Removing 150 Replacing ball bearings 151 Disassembling 215 Carriage 148 Guideway 141 Product 216 Di...

Page 241: ...ing the transport securing device 75 Setting the gear backlash 199 Guideway Cleaning 81 Disassembling 141 Installing 142 Lubricating 101 Replacing 141 H Hazard symbol 27 Hazard warnings 25 I Identification 210 Identification of lubrication points 92 Initial assembly 51 125 Initial lubrication 81 Input shaft Aligning 54 128 Inserting Energy chain 65 113 Installation instructions 24 Installing Coupl...

Page 242: ... tasks 87 After 11 250 hours 112 After 150 hours 101 After 2 250 hours 103 After 22 500 hours 113 After 6 750 hours 110 Malfunctions 204 Measuring instruments 47 97 Monitoring equipment 28 Motor Attaching the slings 118 184 Calibrating the reference plane 136 140 194 Installing 51 59 125 133 155 193 Mounting 56 130 Removing 121 146 186 Replacing 194 Motor flange Replacing 197 Mounting Clamping set...

Page 243: ...g 136 140 194 Relieving Cog belt 148 Removing Clamping set 123 188 Cog belt 149 Coupling 121 Deflection pulley 150 Energy chain 113 Gearbox unit 123 188 Motor 121 146 186 Replacing Automatic lubrication pump 113 Ball bearing 151 152 Belt pulley 152 Bumper unit 202 Clamping set 152 Clamping set Güdel gearbox unit 123 Cog belt 107 149 Coupling 121 Coupling Güdel gearbox unit 123 Elastomer gear rim 2...

Page 244: ...tup Product 46 Upright 47 Setup process 46 Shutdown 209 Product 209 Side panels Connecting 63 Mounting 63 Slings Attaching Güdel gearbox unit 120 185 Attaching MLB horizontal 40 46 Attaching Motor 118 184 Spare part 87 182 Spare parts list 225 Special tools 47 97 State of the art 19 Storage 208 Storage conditions 208 Strain relief Attaching 69 Switch Replacing 143 Symbol 26 Index OPERATING MANUAL ...

Page 245: ... 230 Screws 227 Torques 226 Training of operating personnel 85 Transport 37 Transport securing device Checking 79 Installing Güdel gearbox unit 76 Removing Güdel gearbox unit 75 Tribocorrosion 90 Troubleshooting 204 Type plate 32 33 U Unpacking 45 Upright Setup 47 Use 31 W Warning label 27 Warning symbols 26 Warranty 24 Wiper and lubrication unit Replacing 110 Index OPERATING MANUAL MLB 1 3 V2 881...

Page 246: ...Index OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US 246 ...

Page 247: ...manual 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 MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 248: ...Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 249: ...Hazard analysis Risk analysis Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 250: ...Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 251: ...p of the plant without the enable button being pressed or available must be prevented With the permission device pressed moving plant parts can be moved in a controlled manner even if the plant is unsecured When the enable button is pressed it must not be possible for the operator to be endangered by an automatic movement triggered by a third party The lockable main plant switch breaks all main an...

Page 252: ...ries Maintenance instructions must be observed None x Y 1 20 x x x x x x x x x x x Oil running out due to leaks All Failure of the gasket Environmental damage slipping hazard as well as consequential damage due to the insufficient oil see 1 18 x x 10 3 d The occurrence of consequential damage with injuries and environmental damage Maintenance intervals must be maintained Application specific prote...

Page 253: ...ply Operator Maintenance personnel Power failure lightning interrupted compressed air supply Someone is surprised by the unexpected movement and injured as a result x x 10 3 d The effects of a power failure endanger the operator or third parties The movement of the drives is mechanically limited in case the supply voltage fails mechanical limit stops and holding brakes The movement of the drives i...

Page 254: ...Addition to declaration of incorporation Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 255: ...Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 256: ...x 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 due to modifying the use conditions x 1 3 7 Risks due to moving parts x x 1 3 8 Selection of the protective equipment against risks due to moving parts x 1 3 8 1 Moving parts of the transmission of fo...

Page 257: ... 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 integrator depending on the use of the machine 3 Additional basic work safety and health protection requirements for eliminating hazards due to machine movements x To be checked by the system integrato...

Page 258: ...Technical data Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 259: ...Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 260: ...Layout Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 261: ...Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 262: ...Spare parts lists Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 263: ...Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 264: ...Options Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 265: ...Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 266: ...Third party documentation Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 267: ...Appendix OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 268: ...Montagehandbuch für gleitende Anwendungen Installation guide for gliding applications Notice d installation pour applications glissantes Guía de Instalación para aplicaciones deslizantes ...

Page 269: ...Führungsrinne Guide trough Goulotte de guidage Guía Carrilera Fixpunkt Fixed end Point fixe Punto fijo Unterkonstruktion Support structure Structure d appui Estructura del soporte Mitnehmer Moving end Point mobile Punto móvil Führungsrinne Guide trough Goulotte de guidage Guía Carrilera e kette e chain Chaîne porte câbles Cadena Portacables Mitnehmer Moving end Point mobile Punto móvil Fixpunkt Fi...

Page 270: ...position I End position I Position finale I Posición final 1 Mitnehmer Moving end Point mobile Punto móvil Führungsrinne mit Gleitleiste Guide trough with glide bar Goulotte avec bande de glissement Guía carrilera con barra deslizante Führungsrinne ohne Gleitleiste Guide trough without glide bar Goulotte sans bande de glissement Guía carrilera sin barra deslizante Fixpunkt Fixed end Point fixe Pun...

Page 271: ...fahrwegs länge frei verfahren können Es dürfen keine störenden Gegenstände im Fahrbereich der e kette sein e chain has to be free moving along the entire travel length There must be no obstacles or crane structure in this area La chaîne doit pouvoir se déplacer sans entraves sur toute la longueur de la course Il ne doit pas y avoir d objets gênants dans ce périmètre La Cadena portacables debe move...

Page 272: ...are made before next installation step Vérifiez la structure d appui avant d installer la goulotte Veillez à ce que les corrections soient faites avant de passer à l étape suivante Chequear la estructura de soporte Perfil C antes de la instalación de la guía carrilera Chequear que las correcciones están hechas antes del próximo paso de lainstalación Führungsschiene und Tragwerk müssen aufeinander ...

Page 273: ...e élevée de la chaîne 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 écartement Barra del espaciador Große Lücke Abrieb an Kettengliedern und Öffnungsstegen Large gap wear on chain links and cross bars The e chain will glide on its crossbars instead of the gliding surfaces Trop de place ...

Page 274: ...efore assembly For example E4 56 Series Vérifiez la référence sur la chaîne avant de la monter Par exemple série E4 56 Chequear el número de piezas en la Cadena Portacables antes del montaje Teil 3 part 3 3ème partie pieza 3 Teil 2 part 2 2ème partie pieza 2 Teil 1 part 1 1ère partie pieza 1 Festpunkt Ende Fixed end Point fixe Terminal fijo Mitnehmer Ende Moving end Point mobile Punto móvil Orange...

Page 275: ...tive to the travel stroke Lay the pre assembled e chain into the guide trough Vérifiez si la position du point fixe par rapport à la course est identique à celle des plans igus Placez la chaîne pré assemblée dans la goulotte Chequear que la posición del punto fijo está de acuerdo con los diseños de igus respecto al recorrido total Dejar la Cadena portacables pre montada en la guía carrilera Überpr...

Page 276: ...in All separators aligned and straight Vérifiez la division interne de la chaîne porte câbles Séparateurs tous bien droits et fixes Chequear la separación interna de la Cadena Portacables Todos los separadores están alineados y rectos Alle Öffnungsstege eingerastet Gebrochene Teile All crossbars correctly fitted Any broken parts Entretoises toutes bien en place Pièces cassées Todas los travesaño e...

Page 277: ...z vous que les inserts de l élément de fixation aient été retirées sur le côté glissant de la chaîne Chequear que los bujes hayan sido retirados del lado deslizante del terminal Incorrect Falsch Incorrect Incorreto h Leitungsreserve min Minimum reserve length Longueur minimum Largo reserva mínimo 0 5 m Montage des Mitnehmers gemäß der igus Systemzeichnungen Ein Unterstützungsblech muss in Waage se...

Page 278: ...a de la linea central Incorrect Falsch Incorrect Incorreto Korrigieren Sie die Leitungen Correct cable adjustment Corrigez la position des câbles Ajuste correcto de los cables Bewege den Kettenradius zum Mitnehmerarm und befestige es mit innensechskant Schrauben DIN 912 EN ISO 7462 Flip chain radius move it to the towing arm and fix it with hex screws DIN 912 EN ISO 7462 Retournez le rayon de la c...

Page 279: ...en el punto móvil y fijo Überprüfen Sie die Höhe Check height Vérifiez la hauteur Verificar altura Incorrect Falsch Incorrect Incorreto Bewegen Sie die e kette langsam und vorsichtig in beide Endpositionen und überprüfen Sie die Lage der Leitungen Überprüfen Sie dies nochmals nach einigen Testläufen Move the e chain slowly and carefully to both end positions and check cable tension Double check sy...

Page 280: ...bH Spicher Straße 1a 51147 Köln igus SARL 49 avenue des Pépinières Parc Médicis F 94260 Fresnes igus GmbH Spicher Str 1a 51147 Cologne igus S L Ctra Llobatona 6 Poligono Noi del Sucre 08840 Viladecans Barcelona de eu fr es ...

Page 281: ...or Date GÜDEL 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 clasch 1 0 19 11 2018 OPERATING MANUAL MLB 1 3 V2 881017611_v1 0_EN US ...

Page 282: ...GÜDEL AG Industrie Nord CH 4900 Langenthal Switzerland Phone 41 62 916 91 91 info ch gudel com www gudel com ...