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GUDEL FlexxPump 404DLS Operating Manual

Automatic lubrication system
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OPERATING MANUAL
Automatic lubrication system
FlexxPump 404DLS
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
404 DLS
B1X.xxxxxxxxx-xxxx
09xxxxx
2019
99079191943154
BETRIEBSANLE

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Summary of Contents for GUDEL FlexxPump 404DLS

  • Page 1 OPERATING MANUAL BETRIEBSANLE 99079191943154 Automatic lubrication system FlexxPump 404DLS 404 DLS Project / Order: B1X.xxxxxxxxx-xxxx Bill of materials: 09xxxxx Serial number: Year of manufacture: 2019...
  • Page 2 © GÜDEL Translation of the original instructions This manual contains standard illustrations that may deviate from the original. In the case of special models, options, or technical changes, the scope of deliv- ery may differ from the descriptions here. Reprinting the instructions, in whole or in part, requires our permission.

  • Page 3: Table -1 Revision History

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Revision history Revision history Version Date Description 10.0 10/28/2019 New: • Declaration of conformity for TriboServ Ü Chapter , 2 133 Entire manual updated. 02/27/2019 Updated: • Type plate and location of type plate Ü 2 26 • Maintenance tasks Ü 2 71 •...
  • Page 4 OPERATING MANUAL Automatic lubrication system Revision history FlexxPump 404DLS Version Date Description 06/01/2018 Valid as of FlexxPump serial number 1601929 Updated: • Actuate Ü Chapter 5.4, 2 43 • Lubrication recommendation Ü 2 55 New: • Splitter Ü 2 29 Ü Chapter 4.2.3.1, 2 33 04/12/2018 Updated: • Lubrication check Ü 2 59 12/12/2017 Updated: •...

  • Page 5: Table Of Contents

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Table of contents Table of contents General  11 Further applicable documentation  ....... . .
  • Page 6 OPERATING MANUAL Automatic lubrication system Table of contents FlexxPump 404DLS Product description  25 Use  ..............
  • Page 7 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Table of contents Commissioning  35 Introduction  ............
  • Page 8 OPERATING MANUAL Automatic lubrication system Table of contents FlexxPump 404DLS Operation  64 General  ............. .
  • Page 9 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Table of contents Repairs  93 Introduction  ............
  • Page 10 OPERATING MANUAL Automatic lubrication system Table of contents FlexxPump 404DLS Accessories  103 11.1 PLC connecting cable  ..........

  • Page 11: General

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS General General Read the entire manual before working with the product. The manual con- tains important information for your personal safety. The manual must be read and understood by all persons who work on the product in any of the...

  • Page 12: Further Applicable Documentation

    OPERATING MANUAL Automatic lubrication system General FlexxPump 404DLS Further applicable documentation All documents delivered with this manual are further applicable documenta- tion. They must be observed in addition to this operating manual for the safe handling of the product. Document...

  • Page 13: Document

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS General Purpose of the document This manual describes all the product life phases of the product: • Transport • Commissioning • Operation • Maintenance • Repairs • Disposal The manual contains the information required for using the product as in- tended.

  • Page 14: Table 1-2 Explanation Of Symbols/Abbreviations

    OPERATING MANUAL Automatic lubrication system General FlexxPump 404DLS Explanation of symbols/abbreviations The following symbols and abbreviations are used in this manual: Symbol/Abbrevia- Explanation tion Ü For cross-reference Possibly for cross-ref- Page erence Fig. Designation of graphics Figure Table Designation of tables...

  • Page 15: Safety

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Safety Safety General Read the entire manual before working with the product. The manual con- tains important information for your personal safety. The manual must be read and understood by all persons who work on the product in any of the product life phases.

  • Page 16: Personnel Qualifications

    OPERATING MANUAL Automatic lubrication system Safety FlexxPump 404DLS 2.1.2 Personnel qualifications WARNING Lack of safety training Incorrect behavior of untrained or insufficiently trained technicians can result in severe or fatal injuries! Before technicians work on safety-related aspects of the product: •...

  • Page 17: Operating Companies

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Safety 2.1.2.1 Operating companies The operating company is responsible for ensuring that: • the product is used as intended • the product is sufficiently lubricated at all times • all safety aspects are complied with •...

  • Page 18: Technicians

    OPERATING MANUAL Automatic lubrication system Safety FlexxPump 404DLS 2.1.2.4 Commissioning technicians The commissioning technician: • has good programming knowledge • has mechanical and/or electrical knowledge • is flexible The commissioning technician is responsible for the following tasks: • commissioning the product •...

  • Page 19: Service Technicians

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Safety 2.1.2.7 Maintenance technicians The maintenance technician: • was trained by the operating company or the manufacturer • has very good mechanical and/or electrical knowledge • has software knowledge • has maintenance experience •...

  • Page 20: Regulations

    OPERATING MANUAL Automatic lubrication system Safety FlexxPump 404DLS 2.1.3 Disregarding safety regulations DANGER Disregarding safety regulations Disregarding safety regulations can result in damage to property, severe or fatal injuries. • Always comply with the safety regulations Liability Güdel shall not be held liable under any of the following circumstances: •...

  • Page 21: Manual

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Safety Hazard symbols in the manual 2.2.1 Hazard warnings The hazard warnings are defined for the following four types of danger levels: DANGER DANGER DANGER refers to hazards with a high risk of severe physical injury or im- mediate fatality.

  • Page 22: Symbol

    OPERATING MANUAL Automatic lubrication system Safety FlexxPump 404DLS 2.2.2 Explanation of warning symbol Hazard warnings for personal injuries contain the symbol of the correspond- ing hazard. Symbol Explanation of symbols Hazards due to general causes Hazards resulting from automatic startup...

  • Page 23: (Msds)

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Safety 2.3.2 Material safety data sheets (MSDS) Safety data sheets contain safety information about the materials. They are country-specific. Safety data sheets are issued, for example, for materials such as oils, greases, cleaning agents, etc. The operating company is responsible for obtaining safety data sheets for all materials used.
  • Page 24 OPERATING MANUAL Automatic lubrication system Safety FlexxPump 404DLS...
  • Page 25 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Product description Product description 3.1.1 Intended use The automatic lubrication system is designed exclusively for lubricating Güdel guideways and Güdel gear teeth. Be sure the hydraulic system is installed cor- rectly Ü 2 38 Any other or additional use is not considered to be use in the intended man- ner.

  • Page 26: Fig. 3 -1 Type Plate

    OPERATING MANUAL Automatic lubrication system Product description FlexxPump 404DLS Product designation 3.2.1 Type plate The product has a type plate. FlexxPump 40X Bill of materials: XXXXXXX Serial number: 18XXXXXX Güdel AG Industrie Nord CH-4900 Langenthal www.gudel.com Fig. 3-1 Type plate Serial number...

  • Page 27: Fig. 3 -2 Position Of The Type Plate

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Product description 3.2.2 Position of the type plate The type plate is attached to the right side of the casing. The hydraulic out- puts are indicated by engraved numbers. Fig. 3-2 Position of the type plate...

  • Page 28: Fig. 3 -3 Dimensions And Connections 404Dls

    OPERATING MANUAL Automatic lubrication system Product description FlexxPump 404DLS 3.3.1 FlexxPump 3.3.1.1 Dimensions and connections 404DLS The FlexxPump 404DLS weighs approx. 1500 g and has the following dimen- sions: Fig. 3-3 Dimensions and connections 404DLS Hydraulic outputs Connection plug M12x1 Connections Hydraulic: •...

  • Page 29: Table 3-2 Temperature Ranges: Flexxpump

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Product description 3.3.1.2 Temperature ranges The following temperature ranges and humidity apply: Product life phase Temperature range Air humidity Transport -10 to +60 °C Operation -20 to +70 °C Up to and at 85 %,...
  • Page 30 OPERATING MANUAL Automatic lubrication system Product description FlexxPump 404DLS 3.3.2.3 Minimum lubrication quantity Splitters only function correctly if > 0.5 cm of lubricant is produced at their input per lubrication cycle. 3.3.2.4 Maximum pressure The maximum pressure at the input of splitters is 110 bar.

  • Page 31: Fig. 4 -1 Design Of Flexxpump Lubrication System

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Design, function Design, function Design The product consists of the following components: • FlexxPump • Splitters or Y-segments • Hydraulic hoses • Connecting cable, if necessary More detailed information Ü 2 38 Fig. 4-1 Design of FlexxPump lubrication system...

  • Page 32: Fig. 4 -2 Detailed Design Of Flexxpump 404Dls

    OPERATING MANUAL Automatic lubrication system Design, function FlexxPump 404DLS 4.1.1 Detailed design of FlexxPump 404DLS The FlexxPump 404DLS consists of the following elements: Fig. 4-2 Detailed design of FlexxPump 404DLS Vent locking mechanism Casing Covering Connection plug for supply and control...

  • Page 33: Fig. 4 -3 Function: Splitter, 2-Fold

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Design, function Function 4.2.1 Functional description The automatic lubrication system is a lubrication system for Güdel compo- nents. The FlexxPump feeds the lubricant from the cartridge into the lines. Depending on the design, the lubricant is distributed through splitters, com- bined through Y-segments, or distributed directly to the lubrication area.
  • Page 34 OPERATING MANUAL Automatic lubrication system Design, function FlexxPump 404DLS...

  • Page 35: Commissioning

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning Commissioning Introduction 5.1.1 Safety Only perform the tasks described in this chapter after you have read and un- derstood the chapter "Safety". Ü 2 15 It concerns your personal safety! WARNING Automatic startup During work on the product, there is danger of the machine starting up auto- matically.

  • Page 36: Installing

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS Installing 5.3.1 Prerequisites Dispose of the packaging in accordance with the local waste regulations. Ü 2 99 Checking the deliv- Check the content of the delivery by comparing it with the accompanying documents. Check the product for damage. Report transport damage immedi- ately.

  • Page 37: Installing The Flexxpump

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning 5.3.2 Installing the FlexxPump The installation position of the FlexxPump is not important. Fig. 5-1 Installing the FlexxPump Assembly site FlexxPump Screw Assemble the FlexxPump as follows: Mount FlexxPump with two screws M6 L = 40 mm...

  • Page 38: Connect Hydraulics

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS 5.3.3 Connect hydraulics 5.3.3.1 404DLS 3-fold System with 3 lubrication points Fig. 5-2 Design 404DLS 3-fold Lubricating pinion (not included in the Y-segment scope of delivery) Lubricating element (not included in the Hydraulic hose diameter of 6/3 mm...

  • Page 39: 404Dls 6-Fold

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning 5.3.3.2 404DLS 6-fold System with 6 lubrication points Fig. 5-3 Design 404DLS 6-fold Lubricating pinion (not included in the 2nd axle (not included in the scope of scope of delivery) delivery) Lubricating element for guideway rails Hydraulic hose diameter of 6/3 mm...

  • Page 40: 404Dls 10-Fold

    2nd axle (not included in the scope of scope of delivery) delivery) Lubricating element for guideway rails 2nd FlexxPump 404DLS (not included in the scope of delivery) 1st axle (not included in the scope of de- Hydraulic hose diameter of 6/3 mm...

  • Page 41: Equipment

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning 5.3.4 Connecting electrical equipment WARNING Faulty cabling The available mains voltage (supply voltage) has to match the specifications on the rating plate. A faultily connected product can cause material damage, or serious or even fatal injuries.

  • Page 42: Connecting The

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS 5.3.4.1 Connecting the 404DLS Fig. 5-5 Connecting the 404DLS FlexxPump 404DLS Connector pin assignment Connection plug for connecting cable Hydraulic outputs Socket of connecting cable Connect the product as follows: Connect the hydraulic hoses Ü 2 38...

  • Page 43: Actuate

    404DLS" provides detailed, non-binding recommendations from Güdel for in- tegration into the overall system. The document can be found in the down- load area of our company website http://www.gudel.com. Güdel provides software modules for the standard control systems without obligation. The software modules can be found in the download area of our company website http://www.gudel.com...

  • Page 44: Suggested Solution: Programming

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS 5.4.1 Suggested solution: Programming software Start Pump fault? / Set warning message** Cartridge empty? Indicator reached? / Manual start? Indicator (distance; cycle number; Pump ready?* time) started? Start lubrication cycle Set flag for machine stop...

  • Page 45: Connecting Flexxpump To Power

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning 5.4.2 Connecting FlexxPump to power supply Input signal PIN 1 +24 V (High) + 0 V (Low) Output signal PIN 4 +24 V (High) + 0 V (Low) Hydraulic output Fig. 5-7 Switching time diagram: Connecting FlexxPump to power supply The FlexxPump is switched on as long as a constant voltage of 24 V DC is applied at PIN 1.
  • Page 46 OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS...

  • Page 47: Lubrication

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning 5.4.3 Lubrication The following signal to PIN 2 results of 0.15 cm of lubricant being dispensed to each of the four hydraulic outputs: Accuracy of the impulses (High) on PIN 2: +/- 0.2s or +/- 10%!
  • Page 48 OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS...

  • Page 49: Filling Hydraulic Lines / Venting The

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning 5.4.4 Filling hydraulic lines / venting the FlexxPump The following signal on PIN 2 causes 20 x 0.15 cm of lubricant to be dispensed at each of the four hydraulic outputs: Accuracy of the impulses (High) on PIN 2: +/- 0.2s or +/- 10%!
  • Page 50 OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS...

  • Page 51: Fig. 5 -10 Switching Time Diagram: Error Message: Empty

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning 5.4.5 Error message: Empty The FlexxPump issues the following signal on PIN 4 if the lubricant cartridge is empty: Input signal PIN 2 +24 V (High) + 0 V (Low) Output signal PIN 4 2.3 s …...
  • Page 52 OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS...

  • Page 53: General

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning 5.4.6 Error message: General The following causes may lead to a general error message (the list is not exhaustive): • counterpressure in the hydraulic lines is too high • destroyed electronic component on PIN 4 due to electrical overcurrent •...

  • Page 54: Table 5-3 Malfunctions / Troubleshooting

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS Malfunction Cause Measure Lubrication system does not lubricate The measured counterpressure was too high three times Remove cause of the counterpressure, switch off the power supply to the in a row. Hydraulic connections or hoses may be FlexxPump and switch it on again.

  • Page 55: Lubrication Recommendation

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning 5.4.7 Lubrication recommendation 5.4.7.1 General information NOTE Lubricating film missing A missing lubricating film on guideways and racks leads to damage to the product. This results in operational failure. • Ensure that there is always a lubricating film on guideways and racks during operation •...

  • Page 56: Basics

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS 5.4.7.2 Basics Average lubricant The following lubricant quantities should be dispensed at least per lubrication requirement at a point. These are empirical values from Güdel. These values can be met only lubrication point approximatively due to the number of outputs of the pumps and the installed splitters.

  • Page 57: Calculation Formulas

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning 5.4.7.4 Calculation formulas The emptying time of cartridge P1 needs to be determined. With multiple axles per FlexxPump, the axle most traveled needs to be taken into consider- ation for the calculation (on linear gantries, this is typically the Y-axis).

  • Page 58: Commissioning

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS Initial commissioning...
  • Page 59 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning 5.5.1 Checking the lubrication system Connect all hydraulic lines to the hydraulic outputs Start of the pump Start the pump's lubrication cycle Clean guideways and racks Start lubrication point check Lubricate guideways and racks with lubricating spray (material number 10406825) Hydraulic line filled;...
  • Page 60 OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS • In case of downtimes of 1 to 4 weeks before commissioning, as a minimum check the lubricating film on guideways and racks (II) and the hydraulic lines for air bubbles and kinks (VII). If necessary, carry out a check of the complete lubrication system.
  • Page 61 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning VIII 404 DLS 402 B ü ü û û...

  • Page 62: Table 5-7 Lubricants, Cleaning Agents: Prelubricate Guideways And Racks

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 404DLS 404 DLS 402 B ü ü û û Lubrication ex works Specification Lubrication quantity Elkalub FLC 8 H1 Cannot be determined Running surfaces of the roller and pinion need to be covered...
  • Page 63 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Commissioning Check the connections of the hydraulic system before starting up the prod- uct.
  • Page 64 OPERATING MANUAL Automatic lubrication system Operation FlexxPump 404DLS Operation General Only operate the product after observing the installation instructions. For information on operating the product, refer to the appropriate chapter of the documentation for the complete system. Personnel WARNING Training of operating personnel...
  • Page 65 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Operation Safety Only perform the tasks described in this chapter after you have read and un- derstood the chapter "Safety". Ü 2 15 It concerns your personal safety! WARNING Automatic startup During work on the product, there is danger of the machine starting up auto- matically.
  • Page 66 OPERATING MANUAL Automatic lubrication system Operation FlexxPump 404DLS...
  • Page 67 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance Maintenance Introduction Work sequences Perform the work sequences in the order described. Perform the described tasks at the specified times. This ensures a long service life for your product. Only use original spare parts. Ü 2 105...

  • Page 68: Table 7-1 Table Of Cleaning Agents

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS Consumables and auxiliary agents 7.2.1 Cleaning agents Use a soft rag or cloth for cleaning tasks. Only use permissible cleaning agents. 7.2.1.1 Table of cleaning agents Cleaning agents Location of application Automatic lubrication system: Pump,...

  • Page 69: Fig. 7 -1 Automatic Lubrication System Flexxpump

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance 7.2.2.1 Lubrication Automatic lubrication system The following lubrication systems and lubricants are provided for the auto- matic lubrication of the product: Fig. 7-1 Automatic lubrication system FlexxPump Lubrication Specifica- Lubrica- Location of appli-...

  • Page 70: Table 7-4 Lubricant Table

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS 7.2.2.2 Lubricant table Lubrication Specifica- Lubrica- Location of appli- Cate- ex works tion tion cation gory quantity Automatic lubrica- tion system Elkalub FLC Cannot be FlexxPump: Prelubri- 8 H1 determined cate guideways and racks Güdel H1...
  • Page 71 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance Maintenance tasks...
  • Page 72 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS 7.3.1 Replacing the cartridge Replace the cartridge if the malfunction message "Empty" appears. Switch on or off pump type 404DLS via PLC. CAUTION Residual amounts in empty cartridges Empty cartridges contain lubricant residues. Oils and greases are harmful to the environment! •...

  • Page 73: Fig. 7 -3 Replacing Cartridge

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance Fig. 7-3 Replacing cartridge Vent locking mechanism O-ring Covering Retaining cover Cartridge Lubrication ex Specification Lubrication quantity works Ü Chapter 7.2.2.1, Ü Chapter 7.2.2.1, 400 cm³ 2 69 2 69 Table 7-5 Lubricants: Automatic lubrication system FlexxPump...
  • Page 74 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS Replace the cartridge as follows: Remove the vent locking mechanism in the direction of the arrow Switch off FlexxPump Remove the covering by turning in the direction of the arrow Remove empty cartridge...
  • Page 75 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance 7.3.2 Checking the lubrication system Connect all hydraulic lines to the hydraulic outputs Start of the pump Start the pump's lubrication cycle Clean guideways and racks Start lubrication point check Lubricate guideways and racks with lubricating spray (material number 10406825) Hydraulic line filled;...
  • Page 76 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS • In case of downtimes of 1 to 4 weeks before commissioning, as a minimum check the lubricating film on guideways and racks (II) and the hydraulic lines for air bubbles and kinks (VII). If necessary, carry out a check of the complete lubrication system.
  • Page 77 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance VIII 404 DLS 402 B ü ü û û...

  • Page 78: Table 7-6 Lubricants, Cleaning Agents: Prelubricate Guideways And Racks

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS 404 DLS 402 B ü ü û û Lubrication ex works Specification Lubrication quantity Elkalub FLC 8 H1 Cannot be determined Running surfaces of the roller and pinion need to be covered...

  • Page 79: Fig. 7 -4 Inspect Automatic Lubrication System

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance 7.3.3 Checking automatic lubrication system Fig. 7-4 Inspect automatic lubrication system Cleaning agents mild universal cleaner free from aromatic compounds (e.g. Motorex OPAL 5000) Table 7-7 Cleaning agents: Automatic lubrication system: Pump, lines, other components Check the automatic lubrication system in accordance with the following ta- ble.
  • Page 80 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS NOTE Lubricating film missing A missing lubricating film on guideways and racks leads to damage to the product. This results in operational failure. • Ensure that there is always a lubricating film on guideways and racks during operation •...

  • Page 81: Fig. 7 -5 Installing The Flexxpump

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance 7.3.4.2 Installing the FlexxPump The installation position of the FlexxPump is not important. Fig. 7-5 Installing the FlexxPump Assembly site FlexxPump Screw Assemble the FlexxPump as follows: Mount FlexxPump with two screws M6 L = 40 mm...

  • Page 82: Fig. 7 -6 Design 404Dls 3-Fold

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS 7.3.4.3 Connect hydraulics 404DLS 3-fold System with 3 lubrication points Fig. 7-6 Design 404DLS 3-fold Lubricating pinion (not included in the Y-segment scope of delivery) Lubricating element (not included in the Hydraulic hose diameter of 6/3 mm...

  • Page 83: Fig. 7 -7 Design 404Dls 6-Fold

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance 404DLS 6-fold System with 6 lubrication points Fig. 7-7 Design 404DLS 6-fold Lubricating pinion (not included in the 2nd axle (not included in the scope of scope of delivery) delivery) Lubricating element for guideway rails Hydraulic hose diameter of 6/3 mm...

  • Page 84: Fig. 7 -8 Design 404Dls 10-Fold

    2nd axle (not included in the scope of scope of delivery) delivery) Lubricating element for guideway rails 2nd FlexxPump 404DLS (not included in the scope of delivery) 1st axle (not included in the scope of de- Hydraulic hose diameter of 6/3 mm...
  • Page 85 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance 7.3.4.4 Connecting electrical equipment WARNING Faulty cabling The available mains voltage (supply voltage) has to match the specifications on the rating plate. A faultily connected product can cause material damage, or serious or even fatal injuries.
  • Page 86 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS...
  • Page 87 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance 7.3.4.5 Checking the lubrication system Connect all hydraulic lines to the hydraulic outputs Start of the pump Start the pump's lubrication cycle Clean guideways and racks Start lubrication point check Lubricate guideways and racks with lubricating spray (material number 10406825) Hydraulic line filled;...
  • Page 88 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS • In case of downtimes of 1 to 4 weeks before commissioning, as a minimum check the lubricating film on guideways and racks (II) and the hydraulic lines for air bubbles and kinks (VII). If necessary, carry out a check of the complete lubrication system.
  • Page 89 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance VIII 404 DLS 402 B ü ü û û...

  • Page 90: Table 7-9 Lubricants, Cleaning Agents: Prelubricate Guideways And Racks

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS 404 DLS 402 B ü ü û û Lubrication ex works Specification Lubrication quantity Elkalub FLC 8 H1 Cannot be determined Running surfaces of the roller and pinion need to be covered...

  • Page 91: Checking The Lubrication System

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Maintenance Maintenance table Maintenance work Maintenance cycle [h] Duration [min] Target readership Lubricants Further information Cleaning agents The manufacturer's technicians Replacing the cartridge  Ü Chapter 7.3.1, 2 72 Güdel H1 NSF no.146621 Maintenance technicians Elkalub FLC 8 H1;...
  • Page 92 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 404DLS...
  • Page 93 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Repairs Repairs Introduction Work sequences Perform the work sequences in the order described. Perform the described tasks at the specified times. This ensures a long service life for your product. Only use original spare parts. Ü 2 105...

  • Page 94: Table 8-1 Malfunctions / Troubleshooting

    OPERATING MANUAL Automatic lubrication system Repairs FlexxPump 404DLS Malfunctions / Troubleshooting Malfunction Cause Measure Lubrication system Cartridge missing/ Insert new cartridge or vent does not lubricate empty or air in FlexxPump; the pump con- FlexxPump; pump tinues running without function stopped...
  • Page 95 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Decommissioning, storage Decommissioning, storage Introduction Only perform the tasks described in this chapter after you have read and un- derstood the chapter "Safety". Ü 2 15 It concerns your personal safety! 9.1.1 Personnel qualifications Only appropriately trained and authorized technicians are allowed to work on the product.
  • Page 96 OPERATING MANUAL Automatic lubrication system Decommissioning, storage FlexxPump 404DLS Decommissioning 9.3.1 Shutdown WARNING Falling axes, workpieces Falling axes or workpieces can cause physical damage, serious or fatal injuries! • Set down any workpieces before working in the danger area • Never enter the area below suspended axes and workpieces •...
  • Page 97 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Decommissioning, storage Recommissioning For recommissioning, follow the steps described for commissioning. After cleaning work on the product or a downtime of one to four weeks, carry out the following jobs: • Check the lubricating film on guideways and racks ü...
  • Page 98 OPERATING MANUAL Automatic lubrication system Decommissioning, storage FlexxPump 404DLS • 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 • Checking the lubrication system...
  • Page 99 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Disposal Disposal 10.1 Introduction Observe the following during disposal: • Adhere to the country-specific regulations • Separate the material groups • Dispose of the materials in an environmentally friendly way • Recycle waste if possible 10.1.1...
  • Page 100 OPERATING MANUAL Automatic lubrication system Disposal FlexxPump 404DLS 10.2 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 •...

  • Page 101: Table 10-1 Disposal: Material Groups

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Disposal 10.3.2 Material groups Dispose of the material groups in accordance with the following table: Material Disposal method Contaminated materials / auxiliary Hazardous waste agents Wood Municipal waste Plastic Collecting point or municipal waste...
  • Page 102 OPERATING MANUAL Automatic lubrication system Disposal FlexxPump 404DLS...

  • Page 103: Accessories

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Accessories Accessories 11.1 PLC connecting cable The following M12 cables are permitted for the product FlexxPump 402 / 404DLS: Material number Designation Round plug connector M12 4-pin prefitted LED 0200513 Length 1 m...
  • Page 104 OPERATING MANUAL Automatic lubrication system Accessories FlexxPump 404DLS...

  • Page 105: Spare Parts Supply

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Spare parts supply Spare parts supply...
  • Page 106 OPERATING MANUAL Automatic lubrication system Spare parts supply FlexxPump 404DLS...

  • Page 107: Service Departments

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Spare parts supply 12.1 Service departments Have the following information available for service inquiries: • Product, type (as per type plate) • Project number, order number (as per type plate) • Serial number (as per type plate) •...

  • Page 108: Table 12-1 Service Departments Americas

    OPERATING MANUAL Automatic lubrication system Spare parts supply FlexxPump 404DLS Country Relevant service department Phone E-mail Canada Güdel Inc. +1 734 214 0000 service@us.gudel.com 4881 Runway Blvd. United States Ann Arbor, Michigan 48108 United States Table 12-1 Service departments Americas Asia Country Relevant service department...

  • Page 109: Table 12-2 Service Departments In Asia

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Spare parts supply Country Relevant service department Phone E-mail Thailand Güdel Lineartec Co. Ltd. +66 2 374 0709 service@th.gudel.com 19/28 Private Ville Hua Mak Road Hua Mak Bang Kapi 10240 Bangkok Thailand Table 12-2 Service departments in Asia...
  • Page 110 Via per Cernusco, 7 20060 Bussero (Mi) Italy Belgium Güdel Benelux +31 541 66 22 50 info@nl.gudel.com Eertmansweg 30 Luxembourg 7595 PA Weerselo The Netherlands The Netherlands Estonia Gudel Sp. z o.o. +48 33 819 01 25 serwis@pl.gudel.com ul. Legionów 26/28 Latvia 43-300 Bielsko-Biała Poland Lithuania Poland Ukraine...

  • Page 111: Table 12-3 Service Departments In Europe

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Spare parts supply Country Relevant service department Phone E-mail Russia Gudel Russia +7 848 273 5544 info@ru.gudel.com Yubileynaya 40 Belarus Office 1902 445057 Togliatti Russia Ireland Güdel Lineartec (U.K.) Ltd. +44 24 7669 5444 service@uk.gudel.com Unit 5 Wickmans Drive, Banner Lane...
  • Page 112 OPERATING MANUAL Automatic lubrication system Spare parts supply FlexxPump 404DLS...

  • Page 113: Explanations Regarding The Spare Parts List

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Spare parts supply 12.2 Explanations regarding the spare parts list 12.2.1 Parts list The parts list contains all parts of your product. The spare parts and wear items are indicated as described in the explanation of symbols.

  • Page 114: Torque Tables

    OPERATING MANUAL Automatic lubrication system Torque tables FlexxPump 404DLS Torque tables 13.1 Tightening torques for screws 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!

  • Page 115: Zinc Plated Screws

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Torque tables 13.1.1 Zinc plated screws Unless otherwise specified, the following tightening torques apply for zinc- plated screws lubricated with Molykote (MoS2) grease or secured with Loc- tite 243: Thread size Tightening torque [Nm] 10.9...

  • Page 116: Black Screws

    OPERATING MANUAL Automatic lubrication system Torque tables FlexxPump 404DLS 13.1.2 Black screws Unless otherwise specified, the following tightening torques apply for black oiled and non-lubricated screws, or screws secured with Loctite 243: Thread size Tightening torque [Nm] 10.9 12.9 10.1 14.9...

  • Page 117: Stainless Steel Screws

    OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Torque tables 13.1.3 Stainless steel screws Unless otherwise specified, the following tightening torques apply for stainless steel screws lubricated with Molykote (MoS2) grease or secured with Loctite 243: Thread size Tightening torque [Nm] 0.37...
  • Page 118 OPERATING MANUAL Automatic lubrication system Torque tables FlexxPump 404DLS...

  • Page 119: Illustrations

    Dimensions and connections 404DLS ........28 Fig. 4 -1 Design of FlexxPump lubrication system ........31 Fig. 4 -2 Detailed design of FlexxPump 404DLS ........32 Fig. 4 -3 Function: Splitter, 2-fold ............... 33 Fig. 5 -1 Installing the FlexxPump ............... 37 Fig.
  • Page 120 OPERATING MANUAL Automatic lubrication system Illustrations FlexxPump 404DLS...
  • Page 121 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS List of tables List of tables Table -1 Revision history................Table 1-1 Other applicable documentation ..........12 Table 1-2 Explanation of symbols/abbreviations ......... 14 Table 3-1 Operating voltage ................28 Table 3-2 Temperature ranges: FlexxPump ..........29 Table 3-3 Temperature ranges: Splitter ............
  • Page 122 OPERATING MANUAL Automatic lubrication system List of tables FlexxPump 404DLS Table 12-2 Service departments in Asia ............108 Table 12-3 Service departments in Europe ............ 109 Table 12-4 Service departments for all other countries ......111 Table 12-5 Service departments outside of business hours ....... 111...
  • Page 123 Index Decommissioning ......95 Accuracy Splitter ........29 Design ..........31 Actuation Dimensions FlexxPump 404DLS ....47 FlexxPump 404DLS ....28 Air humidity ......29, 95 Disassembling ........ 100 FlexxPump ........80 Automatic lubrication system Product ........100 Checking ........79 Programming software ....
  • Page 124 Maximum storage period Güdel H1 ........30 Hazard warnings ......21 Minimum lubrication quantity Splitter ........30, 56 Hydraulic lines Filling: FlexxPump 404DLS ..49 Mounting FlexxPump ......37, 81 Prerequisites ......36 Identification ........96 MSDS ..........23 Initial commissioning ...... 58 Installation instructions ....
  • Page 125 Replacing Cartridge ........72 Original spare part ....67, 93 FlexxPump ........93 Overcurrent Hoses .......... 93 FlexxPump 404DLS ....53 Pump ..........80 Splitter ........93 Y-segments ........ 93 Personnel qualifications ....35 Residual danger ......15 Connecting cable ....103 Safety data sheet ......
  • Page 126 Temperature range ......29 Tightening torques Screws ........115 Torques .......... 114 Training of operating personnel .. 64 Transport ........35 Troubleshooting ......94 Type plate ........26 Non-intended ......25 Ventilate FlexxPump 404DLS ....49 Warning symbols ......22 Warranty .......... 20...
  • Page 127 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Appendix Appendix The appendix of this operating manual contains the following documents: • Layout • Spare parts lists • Declaration of conformity for TriboServ...
  • Page 128 OPERATING MANUAL Automatic lubrication system Appendix FlexxPump 404DLS...
  • Page 129 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Appendix Layout...
  • Page 130 OPERATING MANUAL Automatic lubrication system Appendix FlexxPump 404DLS...
  • Page 131 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Appendix Spare parts lists...
  • Page 132 OPERATING MANUAL Automatic lubrication system Appendix FlexxPump 404DLS...
  • Page 133 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Appendix Declaration of conformity for TriboServ See also 2 Declaration of conformity for TriboServ [} 135]...
  • Page 134 OPERATING MANUAL Automatic lubrication system Appendix FlexxPump 404DLS...
  • Page 135 Declaration of EG conformity according to the Machinery Directive 2006/42/EG of 2006, May 17th Herewith the manufacturer TriboServ GmbH & Co. KG, Gelthari-Ring 3, D-97505 Geldersheim, declare that the following lubricating systems FlexxPump 401 DLS, 402 DLS, 403 DLS, 404 DLS, 422 DLS as well as FlexxPump 401 DLSA, 402 DLSA, 403 DLSA, 404 DLSA, 422 DLSA delivered by us, concerning design and construction as well as the model put into circulation,...
  • Page 136 OPERATING MANUAL Automatic lubrication system FlexxPump 404DLS Version 10.0 clasch Author Date 24.10.2019 GÜDEL AG Industrie Nord CH-4900 Langenthal Switzerland Phone +41 62 916 91 91 +41 62 916 91 50 E-mail info@ch.gudel.com www.gudel.com...
  • Page 137 GÜDEL AG Industrie Nord CH-4900 Langenthal Switzerland Phone +41 62 916 91 91 info@ch.gudel.com www.gudel.com...

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