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GUDEL FlexxPump 402 Operating Manual

Automatic lubrication system
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OPERATING MANUAL
Automatic lubrication system
FlexxPump 402 / 402B
402
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
B1X.xxxxxxxxx-xxxx
09xxxxxx
2019
90071992656444
BETRIEBSANLE
402 B
_
+

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Do you have a question about the FlexxPump 402 and is the answer not in the manual?

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Dindah
April 12, 2025

Flexxpump 402 dls automatic lubricant

0
1 comments:
Mr. Anderson
April 12, 2025

The function of the GUDEL FlexxPump 402 automatic lubricant is to feed lubricant from a cartridge into lubrication lines. The lubricant is then distributed to lubrication areas through splitters, Y-segments, or directly. It lubricates rack and pinions using lubricating pinions and guideways using lubricating elements. The pump also sends signals in case of overpressure, an empty cartridge, or each piston stroke.

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Summary of Contents for GUDEL FlexxPump 402

  • Page 1 OPERATING MANUAL BETRIEBSANLE 90071992656444 Automatic lubrication system FlexxPump 402 / 402B 402 B Project / Order: B1X.xxxxxxxxx-xxxx Bill of materials: 09xxxxxx 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 OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Revision history Revision history Version Date Description 10/28/2019 New: • Packaging symbols Ü Chapter 5.2.1, 2 44 • Repairing damaged packaging Ü Chapter 5.2.2, 2 45 • Declaration of conformity for TriboServ Ü Chapter , 2 151 Entire manual updated. 02/27/2019 Updated: • Checking the lubrication system Ü 2 57...

  • Page 4: Table -1 Revision History

    OPERATING MANUAL Automatic lubrication system Revision history FlexxPump 402 / 402B Version Date Description 06/05/2018 Updated: • Error message E3 Ü 2 108 • Lubrication recommendation Ü 2 65 New: • Splitter Ü 2 34 Ü Chapter 4.2.3.1, 2 41 Removed: • Transport information for lithium battery (new different battery type)

  • Page 5: Table Of Contents

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Table of contents Table of contents General  13 Further applicable documentation  ....... . .
  • Page 6 OPERATING MANUAL Automatic lubrication system Table of contents FlexxPump 402 / 402B Product description  27 Use  ..............

  • Page 7: Fig. 5 -6 Connecting 402

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Table of contents Function  .............
  • Page 8 OPERATING MANUAL Automatic lubrication system Table of contents FlexxPump 402 / 402B Initial commissioning  ..........
  • Page 9 OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Table of contents Consumables and auxiliary agents ........

  • Page 10: Table 8-1 Empty E1

    OPERATING MANUAL Automatic lubrication system Table of contents FlexxPump 402 / 402B Malfunctions / Troubleshooting ........
  • Page 11 OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Table of contents Accessories  121 11.1 PLC connecting cable  ..........
  • Page 12 OPERATING MANUAL Automatic lubrication system Table of contents FlexxPump 402 / 402B...

  • Page 13: General

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 14: Further Applicable Documentation

    OPERATING MANUAL Automatic lubrication system General FlexxPump 402 / 402B 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.
  • Page 15 OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 16: Table 1-2 Explanation Of Symbols/Abbreviations

    OPERATING MANUAL Automatic lubrication system General FlexxPump 402 / 402B 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...

  • Page 17: Safety

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 18: Personnel Qualifications

    OPERATING MANUAL Automatic lubrication system Safety FlexxPump 402 / 402B 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 19: Operating Companies

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 20: Technicians

    OPERATING MANUAL Automatic lubrication system Safety FlexxPump 402 / 402B 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 21: Maintenance Technicians

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 22: Disregarding Safety Regulations

    OPERATING MANUAL Automatic lubrication system Safety FlexxPump 402 / 402B 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 23: Manual

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 24: Explanation Of Warning Symbol

    OPERATING MANUAL Automatic lubrication system Safety FlexxPump 402 / 402B 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 25: Product-Specific Hazards

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Safety Fundamentals of safety 2.3.1 Product-specific hazards CAUTION Leaking batteries Battery fluids and their fumes are hazardous to the environment, corrosive and poisonous! They cause injury to persons and damage to property! Observe the following points: •...

  • Page 26: Material Safety Data Sheets

    OPERATING MANUAL Automatic lubrication system Safety FlexxPump 402 / 402B 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 27 OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 48 Any other or additional use is not considered to be use in the intended man- ner.

  • Page 28: Fig. 3 -1 Type Plate

    OPERATING MANUAL Automatic lubrication system Product description FlexxPump 402 / 402B 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...

  • Page 29: Fig. 3 -2 Position Of The Type Plate

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 30 OPERATING MANUAL Automatic lubrication system Product description FlexxPump 402 / 402B Technical data For specific information on the product, refer to the respective drawings as well as the documentation on the complete system. Emission sound The emission sound pressure level depends on the machine properties and pressure level the operating conditions.

  • Page 31: Fig. 3 -3 Dimensions And Connections 402

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Product description 3.3.1 FlexxPump 3.3.1.1 Dimensions and connections 402 The FlexxPump 402 weighs approx. 1500 g and has the following dimensions: Fig. 3-3 Dimensions and connections 402 Hydraulic outputs Connection plug M12x1 Connections Hydraulic: •...

  • Page 32: Fig. 3 -4 Dimensions And Connections 402B

    OPERATING MANUAL Automatic lubrication system Product description FlexxPump 402 / 402B 3.3.1.2 Dimensions and connections 402B The FlexxPump 402B weighs approx. 1500 g and has the following dimensions: Fig. 3-4 Dimensions and connections 402B Hydraulic outputs Connections Hydraulic: • Two connections for hydraulic tubes with a diameter of 6/3 mm Operating voltage The operating voltage is 3 VDC.

  • Page 33: Table 3-2 Temperature Ranges: Flexxpump

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Product description 3.3.1.3 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 34: Table 3-3 Temperature Ranges: Splitter

    OPERATING MANUAL Automatic lubrication system Product description FlexxPump 402 / 402B 3.3.2 Splitter 3.3.2.1 Temperature ranges The following temperature ranges and humidity apply: Product life phase Temperature range Air humidity Transport -10 to +60 °C Operation +10 to +80°C Up to and at 85 %,...

  • Page 35: Fig. 4 -1 Design Of Flexxpump Lubrication System

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 48 Fig. 4-1...

  • Page 36: Fig. 4 -2 Detailed Design Of Flexxpump 402

    OPERATING MANUAL Automatic lubrication system Design, function FlexxPump 402 / 402B 4.1.1 Detailed design of FlexxPump 402 The FlexxPump 402 consists of the following elements: Fig. 4-2 Detailed design of FlexxPump 402 Vent locking mechanism, including mag- Connection plug for supply and commu-...

  • Page 37: Fig. 4 -3 Detailed Design Of Flexxpump 402B

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Design, function 4.1.2 Detailed design of FlexxPump 402B The FlexxPump 402B consists of the following elements: Fig. 4-3 Detailed design of FlexxPump 402B Vent locking mechanism, including mag- Battery netic peg Covering...

  • Page 38: Function

    OPERATING MANUAL Automatic lubrication system Design, function FlexxPump 402 / 402B 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 39: Display Elements

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Design, function 4.2.2.3 Display elements The LCD displays indicates malfunctions and operating states of the pump types 402/402B. The flashing interval of the green LEDs lets you distinguish between the pump types 402/402B during operation: •...

  • Page 40: Control Elements

    OPERATING MANUAL Automatic lubrication system Design, function FlexxPump 402 / 402B Digit display The digit display serves for communication. The LED indicates the function: • The green and red LEDs glow for 5 seconds after activation to check their own status •...

  • Page 41: Splitter

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Design, function 4.2.3 Splitter 4.2.3.1 Function The quantity of lubricant at the input is distributed evenly between the out- puts. The splitter only works in the direction of the arrow. ½ lubrication quantity Lubrication quantity ½...
  • Page 42 OPERATING MANUAL Automatic lubrication system Design, function FlexxPump 402 / 402B...

  • Page 43: Commissioning

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 17 It concerns your personal safety! WARNING Automatic startup During work on the product, there is danger of the machine starting up auto- matically.

  • Page 44: Transport

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 402 / 402B Transport Avoid strong impacts and shocks while transporting the automatic lubrication system. 5.2.1 Packaging symbols A lithium battery is also included with the product. The packaging unit is marked by one of the following or similar transport information labels. Ob- serve these at all times.

  • Page 45: Repairing Damaged Packaging

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Commissioning 5.2.2 Repairing damaged packaging Repair damaged packaging units as follows: Remove packaging unit Check batteries In case of damaged batteries: Contact manufacturer by phone number on the transport informa- tion...

  • Page 46: Installing

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 402 / 402B Installing 5.3.1 Prerequisites Dispose of the packaging in accordance with the local waste regulations. Ü 2 117 Checking the deliv- Check the scope of delivers based on the shipping papers. Check the product for damage.

  • Page 47: Installing The Flexxpump

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Commissioning 5.3.2 Installing the FlexxPump The installation position of the FlexxPump is not important. Fig. 5-2 Installing the FlexxPump Assembly site FlexxPump Screw Assemble the FlexxPump as follows: Mount FlexxPump with two screws M6 L = 40 mm...

  • Page 48: Connect Hydraulics

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 402 / 402B 5.3.3 Connect hydraulics 5.3.3.1 402/402B 3-fold System with 3 lubrication points Fig. 5-3 Design 402/402B 3-fold Lubricating pinion (not included in the 2x Splitters scope of delivery) Lubricating element for guideway rails Hydraulic hose diameter 6/3 mm...

  • Page 49: 402/402B 6-Fold

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Commissioning 5.3.3.2 402/402B 6-fold System with 6 lubrication points Fig. 5-4 Design 402/402B 6-fold Lubricating pinion (not included in the 2rd axle (not included in the scope of scope of delivery) delivery) Lubricating element for guideway rails Hydraulic hose diameter 6/3 mm...

  • Page 50: 402/402B 10-Fold

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 402 / 402B 5.3.3.3 402/402B 10-fold System with 10 lubrication points Fig. 5-5 Design 402/402B 10-fold Lubricating pinion (not included in the 2rd axle (not included in the scope of scope of delivery) delivery)

  • Page 51: Equipment

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 52 OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 402 / 402B 5.3.4.1 Connecting 402 Fig. 5-6 Connecting 402 FlexxPump 402 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 48...

  • Page 53: Connecting 402

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Commissioning 5.3.4.2 Connecting 402B Fig. 5-7 Connecting 402B FlexxPump 402B Hydraulic outputs Connect the product as follows: Connect the hydraulic hoses Ü 2 48 Insert battery Ü 2 81 The product is connected.

  • Page 54: Actuate

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 402 / 402B 5.3.5 Actuate 5.3.5.1 FlexxPump 402 The output signal on PIN 4 is High (20...30V) during normal operation. Malfunctions are signaled on PIN 4 as follows: Malfunction Signal Cause Measure Ü 2 106...

  • Page 55: Initial Commissioning

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Commissioning Initial commissioning...
  • Page 56 OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 402 / 402B...

  • Page 57: Checking The Lubrication

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Commissioning 5.4.1 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...
  • Page 58 Commissioning FlexxPump 402 / 402B • 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 59 OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Commissioning VIII 404 DLS 402 B ü ü û û...

  • Page 60: Table 5-3 Lubricants, Cleaning Agents: Prelubricate Guideways And Racks

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 402 / 402B 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 61: Switching On The Flexxpump

    Software release Lubrication quantity P2 Number of hydraulic outputs FlexxPump switched on Switch on the FlexxPump 402/402B as follows: Touch the active surface with the magnetic peg Wait for LED to flash 3x Remove magnetic peg The FlexxPump is switched on.

  • Page 62: Lubrication Cycle

    OPERATING MANUAL Automatic lubrication system Commissioning FlexxPump 402 / 402B 5.4.2.1 Lubrication cycle 1 MAX 2 MAX Fig. 5-9 Lubrication cycle LED green Pressure of Hydraulic Output 1.1 in bar Pressure of Hydraulic Output 1.2 in bar The green LED glows during the lubrication cycle. The displayed pressure cor- responds to the pressure from the hydraulic output to the lubrication point.

  • Page 63: Operation

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Operation 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...

  • Page 64: Safety

    OPERATING MANUAL Automatic lubrication system Operation FlexxPump 402 / 402B Safety Only perform the tasks described in this chapter after you have read and un- derstood the chapter "Safety". Ü 2 17 It concerns your personal safety! WARNING Automatic startup During work on the product, there is danger of the machine starting up auto- matically.

  • Page 65: Setting The Lubrication

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Operation Setting the lubrication cycle 6.4.1 Lubrication recommendation 6.4.1.1 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.

  • Page 66: Basics

    OPERATING MANUAL Automatic lubrication system Operation FlexxPump 402 / 402B 6.4.1.2 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...

  • Page 67: Calculation Formulas

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Operation 6.4.1.3 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 68: Lubrication Quantity

    OPERATING MANUAL Automatic lubrication system Operation FlexxPump 402 / 402B 6.4.2 Lubrication quantity The effective lubrication quantity dispensed in a defined period depends on two settings: • Emptying time P1 of the cartridge • Lubrication quantity P2 The lubrication quantity P2 defines the lubrication quantity per cycle and out- let.

  • Page 69: Fig. 6 -2 Example: Lubrication Quantity

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Operation The following example will help you understand the relationship between the settings: Fig. 6-2 Example: lubrication quantity With a cartridge emptying time of 12 months and a lubrication quantity P2 = 1, 2666 lubrication cycles are carried out with 0.15 cm...

  • Page 70: Setting The Lubrication

    OPERATING MANUAL Automatic lubrication system Operation FlexxPump 402 / 402B 6.4.4 Setting the lubrication cycle The lubrication cycle is set as follows by default: Setting Value Emptying time of the cartridge P1 12 months Table 6-4 Lubrication cycle: Factory settings for P1...

  • Page 71: Malfunctions

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Operation Fig. 6-3 Set lubrication cycle LCD display Display emptying time P1 of cartridge in months (minimum and maximum) Display lubrication quantity P2 (mini- mum and maximum) You can adjust the lubrication cycle as follows:...

  • Page 72: Switching Off Flexxpump

    OPERATING MANUAL Automatic lubrication system Operation FlexxPump 402 / 402B Switching off FlexxPump 402/402B Switch off the FlexxPump 402/402B as follows: Switch off FlexxPump Touch the active surface with the magnetic peg Wait for LED to flash 3x Remove magnetic peg (display switches to "OFF")

  • Page 73: Maintenance

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance Maintenance Introduction Maintenance The listed tasks have to be carried out at the prescribed time intervals. If they tasks are not carried out at the specified intervals or improperly, all warranty is voided.

  • Page 74: Personnel Qualifications

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B 7.1.2 Personnel qualifications Only appropriately trained and authorized technicians are allowed to work on the product.

  • Page 75: Consumables And Auxiliary Agents

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance 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...

  • Page 76: Lubrication

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B 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 77: Lubricant Table

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance 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...
  • Page 78 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B Maintenance tasks...

  • Page 79: Replacing The Cartridge

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance 7.3.1 Replacing the cartridge Replace the cartridge if the malfunction message "Empty" appears. For pump type 402B, replace the battery at the same time. CAUTION Danger from spring tension The covering contains a spring with tension. The covering jumps up when opened.

  • Page 80: Fig. 7 -3 Replacing The Cartridge

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B Fig. 7-3 Replacing the 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 76 2 76 Table 7-5 Lubricants: Automatic lubrication system FlexxPump...

  • Page 81: Replacing The Battery 402B

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance 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...

  • Page 82: Fig. 7 -4 Replacing The Battery 402B

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B NOTE Empty battery A battery charge lasts for one cartridge only and for a maximum of 3 years (P1 ≤ 36 months). An empty battery causes material damage to the entire plant due to inadequate lubrication.
  • Page 83 OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance Replace the battery as follows: Prerequisite:The cartridge is removed Ü 2 79 Remove battery Loosen plug Wait for 30 seconds Attach plug to new battery Insert new battery Install cartridge Switch on the FlexxPump Ü 2 101 Carry out a special dispensing Ü 2 62...
  • Page 84 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B...

  • Page 85: Checking The Lubrication

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance 7.3.3 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...
  • Page 86 Maintenance FlexxPump 402 / 402B • 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 87 OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance VIII 404 DLS 402 B ü ü û û...

  • Page 88: Table 7-6 Lubricants, Cleaning Agents: Prelubricate Guideways And Racks

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B 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 89: Checking Automatic Lubrication

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance 7.3.4 Checking automatic lubrication system Fig. 7-5 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 90: Replacing The Flexxpump

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B 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 91: Installing The

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance 7.3.5.2 Installing the FlexxPump The installation position of the FlexxPump is not important. Fig. 7-6 Installing the FlexxPump Assembly site FlexxPump Screw Assemble the FlexxPump as follows: Mount FlexxPump with two screws M6 L = 40 mm...

  • Page 92: Connect Hydraulics

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B 7.3.5.3 Connect hydraulics 402/402B 3-fold System with 3 lubrication points Fig. 7-7 Design 402/402B 3-fold Lubricating pinion (not included in the 2x Splitters scope of delivery) Lubricating element for guideway rails Hydraulic hose diameter 6/3 mm...

  • Page 93: 402/402B 6-Fold

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance 402/402B 6-fold System with 6 lubrication points Fig. 7-8 Design 402/402B 6-fold Lubricating pinion (not included in the 2rd axle (not included in the scope of scope of delivery) delivery) Lubricating element for guideway rails Hydraulic hose diameter 6/3 mm...

  • Page 94: 402/402B 10-Fold

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B 402/402B 10-fold System with 10 lubrication points Fig. 7-9 Design 402/402B 10-fold Lubricating pinion (not included in the 2rd axle (not included in the scope of scope of delivery) delivery) Lubricating element for guideway rails...

  • Page 95: Equipment

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance 7.3.5.4 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 96 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B...

  • Page 97: Checking The Lubrication

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance 7.3.5.5 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...
  • Page 98 Maintenance FlexxPump 402 / 402B • 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 99 OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Maintenance VIII 404 DLS 402 B ü ü û û...

  • Page 100: Table 7-9 Lubricants, Cleaning Agents: Prelubricate Guideways And Racks

    OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B 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 101: 402/402B

    Software release Lubrication quantity P2 Number of hydraulic outputs FlexxPump switched on Switch on the FlexxPump 402/402B as follows: Touch the active surface with the magnetic peg Wait for LED to flash 3x Remove magnetic peg The FlexxPump is switched on.
  • Page 102 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B...

  • Page 103: System

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 79 Güdel H1 NSF no.146621 Maintenance technicians Maintenance technicians Replacing the battery 402B  Ü Chapter 7.3.2, 2 81...
  • Page 104 OPERATING MANUAL Automatic lubrication system Maintenance FlexxPump 402 / 402B...

  • Page 105: Repairs

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 2 123...

  • Page 106: Repairs

    OPERATING MANUAL Automatic lubrication system Repairs FlexxPump 402 / 402B Repairs Always replace the complete FlexxPump, splitter, Y-segments, or hoses with new ones in case of defects. Send the defective FlexxPump back to Güdel for repairs. Malfunctions / Troubleshooting 8.3.1 Display element and malfunctions Fig. 8-1...

  • Page 107: Empty E1

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Repairs 8.3.2 Empty E1 The red LED flashes every 5 seconds. The FlexxPump stops operating. Malfunction Cause Measure Empty E1 • Cartridge is missing • Insert or replace car- or empty tridge, perform functional •...

  • Page 108: Operating Voltage Too Low E3

    OPERATING MANUAL Automatic lubrication system Repairs FlexxPump 402 / 402B 8.3.4 Operating voltage too low E3 The red LED flashes every 5 seconds. Operating voltage too low. FlexxPump stops operating. Malfunction Cause Measure Operating voltage • No voltage or volt- •...

  • Page 109: Internal Mechanical Error E5

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Repairs 8.3.6 Internal mechanical error E5 The red LED flashes every 5 seconds. The FlexxPump stops operating. Malfunction Cause Measure Internal mechani- Mechanical error Carry out a special dispens- ing Ü 2 62...
  • Page 110 Repairs FlexxPump 402 / 402B 8.3.8 Functional check The switched on FlexxPump 402/402B can release lubricant for test purposes. Perform the functional check as follows: Touch the active surface with the magnetic peg Wait for LED to flash 2x Remove magnetic peg Evaluate success Ü 2 62...

  • Page 111: Decommissioning, Storage

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 17 It concerns your personal safety! 9.1.1 Personnel qualifications Only appropriately trained and authorized technicians are allowed to work on the product.

  • Page 112: Storage Conditions

    OPERATING MANUAL Automatic lubrication system Decommissioning, storage FlexxPump 402 / 402B Storage conditions CAUTION Leaking batteries Battery fluids and their fumes are hazardous to the environment, corrosive and poisonous! They cause injury to persons and damage to property! Observe the following points: •...

  • Page 113: Decommissioning

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Decommissioning, storage 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 •...

  • Page 114: Recommissioning

    OPERATING MANUAL Automatic lubrication system Decommissioning, storage FlexxPump 402 / 402B 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 115 OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Decommissioning, storage • 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 •...
  • Page 116 OPERATING MANUAL Automatic lubrication system Decommissioning, storage FlexxPump 402 / 402B...

  • Page 117: Disposal

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 118 OPERATING MANUAL Automatic lubrication system Disposal FlexxPump 402 / 402B 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 •...

  • Page 119: Waste Management Compliant

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Disposal 10.3 Waste management compliant assemblies 10.3.1 Disassembly 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 •...

  • Page 120: Material Groups

    OPERATING MANUAL Automatic lubrication system Disposal FlexxPump 402 / 402B 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 121: Accessories

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 122 OPERATING MANUAL Automatic lubrication system Accessories FlexxPump 402 / 402B...

  • Page 123: Spare Parts Supply

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Spare parts supply Spare parts supply...
  • Page 124 OPERATING MANUAL Automatic lubrication system Spare parts supply FlexxPump 402 / 402B...

  • Page 125: Service Departments

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 126: Table 12-1 Service Departments Americas

    OPERATING MANUAL Automatic lubrication system Spare parts supply FlexxPump 402 / 402B 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...

  • Page 127: Table 12-2 Service Departments In Asia

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 128 OPERATING MANUAL Automatic lubrication system Spare parts supply FlexxPump 402 / 402B Country Relevant service department Phone E-mail Portugal Güdel Spain +34 644 347 058 info@es.gudel.com Avinguda de Catalunya 49B Spain 1º 3ª 08290 Cerdanyola del Vallés Spain France Güdel SAS +33 1 6989 80 16...

  • Page 129: Table 12-3 Service Departments In Europe

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 130 OPERATING MANUAL Automatic lubrication system Spare parts supply FlexxPump 402 / 402B...

  • Page 131: Parts List

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 132: Torque Tables

    OPERATING MANUAL Automatic lubrication system Torque tables FlexxPump 402 / 402B 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 133: Zinc Plated Screws

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 134: Black Screws

    OPERATING MANUAL Automatic lubrication system Torque tables FlexxPump 402 / 402B 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...

  • Page 135: Stainless Steel Screws

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B 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 136 OPERATING MANUAL Automatic lubrication system Torque tables FlexxPump 402 / 402B...

  • Page 137: Illustrations

    Dimensions and connections 402B ..........32 Fig. 4 -1 Design of FlexxPump lubrication system ........35 Fig. 4 -2 Detailed design of FlexxPump 402 ..........36 Fig. 4 -3 Detailed design of FlexxPump 402B ........... 37 Fig. 4 -4 Display element and malfunctions ..........39 Fig.
  • Page 138 OPERATING MANUAL Automatic lubrication system Illustrations FlexxPump 402 / 402B Fig. 8 -1 Display element and malfunctions ..........106 Fig. 11 -1 PLC connecting cable ..............121 Fig. 12 -1 Explanation of symbols ..............131...

  • Page 139: List Of Tables

    Temperature ranges: FlexxPump ..........33 Table 3-3 Temperature ranges: Splitter ............34 Table 5-1 Interfaces ................... 46 Table 5-2 Malfunction FlexxPump 402 ............54 Table 5-3 Lubricants, Cleaning agents: Prelubricate guideways and racks....................57 Table 6-1 Average lubricant requirement per lubrication point (U)..66 Table 6-2 Recommended lubrication quantity (Pt) ........
  • Page 140 OPERATING MANUAL Automatic lubrication system List of tables FlexxPump 402 / 402B Table 8-5 Internal mechanical error E5............109 Table 10-1 Disposal: material groups............... 120 Table 11-1 PLC connecting cable..............121 Table 11-2 PLC connecting cable: Meaning of the LED color ....121 Table 12-1 Service departments Americas .............

  • Page 141: Index

    Assembly site ........46 Checking Automatic lubrication system Automatic lubrication system 89 Checking ........89 Delivery ........46 Function: : FlexxPump 402/402B ............62 Lubrication system ..57, 85, 97 Battery Cleaning ........ 113, 114 Lithium ........44, 45 Replacing ........
  • Page 142 FlexxPump 402B Replace the battery ....81 Display ..........39 Function ..........41 Display elements ......39 check: FlexxPump 402/402B .. 62 Disposal .......... 117 Functional check 402/402B ..110 Disposal facilities ......120 Functional description ....38 Downtime ......114, 115 Güdel H1...
  • Page 143 Connecting cable ....121 Lubrication system Power Off Checking ......57, 85, 97 FlexxPump 402/402B ....72 Power On FlexxPump 402/402B ..61, 101 Magnetic peg ........40 Pressure Maintenance tasks ......73 maximum ........33 Malfunctions Operation ........33 Display element ......
  • Page 144 OPERATING MANUAL Automatic lubrication system Index FlexxPump 402 / 402B Repairs ..........106 Technical data ........ 30 Replacing Temperature ........ 112 Battery ........81 Temperature range ....33, 34 Cartridge ........79 Tension ..........32 FlexxPump ........ 106 Hoses ........106 Tightening torque ....

  • Page 145: Appendix

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Appendix Appendix The appendix of this operating manual contains the following documents: • Layout • Spare parts lists • Declaration of conformity for TriboServ...
  • Page 146 OPERATING MANUAL Automatic lubrication system Appendix FlexxPump 402 / 402B...

  • Page 147: Layout

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Appendix Layout...
  • Page 148 OPERATING MANUAL Automatic lubrication system Appendix FlexxPump 402 / 402B...

  • Page 149: Spare Parts Lists

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Appendix Spare parts lists...
  • Page 150 OPERATING MANUAL Automatic lubrication system Appendix FlexxPump 402 / 402B...

  • Page 151: Declaration Of Conformity For Triboserv

    OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Appendix Declaration of conformity for TriboServ See also 2 Declaration of conformity for TriboServ [} 153] 2 Declaration of conformity for TriboServ [} 154]...
  • Page 152 OPERATING MANUAL Automatic lubrication system Appendix FlexxPump 402 / 402B...
  • Page 153 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, 402 and FlexxPump 401 M, 402 M as well as FlexxPump 501, 502 and FlexxPump 501 M, 502 M delivered by us, concerning design and construction as well as the model put into circulation,...
  • Page 154 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 B / 402 B and FlexxPump 401 BM / 402 BM as well as FlexxPump 501 B / 502 B and FlexxPump 501 BM / 502 BM delivered by us, concerning design and construction as well as the model put into circulation,...
  • Page 155 OPERATING MANUAL Automatic lubrication system FlexxPump 402 / 402B Version clasch Author Date 28.10.2019 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 156 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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