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COMPONENTS MODULES ROBOTICS SYSTEMS

OPERATING MANUAL
Automatic lubrication system FlexxPump 404DLS

404 DLS

Project: 18-2745
Bill of materials: 0927004
Year of production: 2018
OPERATING MANUAL Automatic lubrication system

© by GÜDEL 2014

This operating manual contains standard illustrations that may deviate from the
original. In the case of special models, options, or technical changes, the scope
of delivery may differ from the descriptions here. Any reproduction of this
operating manual, in whole or in part, requires our express permission. Subject
to change in the course of technical improvements.

Original operating manual

Version c3US
Author chrgal / thoanl
GÜDEL, Inc.
4881 Runway Blvd
Ann Arbor, MI, 48130
USA
Phone +1 734 214 0000
D003052c3US

Fax +1 734 214 9000


E-mail info@us.gudel.com
www.gudel.com

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OPERATING MANUAL Automatic lubrication system

Version Date Description

a 3/20/2012 Basic version


b 2/15/2013 Adjustment of type description, integration of
types 402 and 402 B
cUS 4/15/2014 Chapter 6: Set lubrication cycle amended
c1US 3/9/2015 Chapter 5/6: Recommended lubrication cycle
updated
c2US 6/2/2015 Deleted references to 402-models
c3US 1/31/2017 Chapter 5: Pulse rhythm and flow chart cor-
rected

Tab. 0-1 Revision history


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OPERATING MANUAL Automatic lubrication system Table of contents

Table of contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Further applicable documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Purpose of the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Target readership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Explanation of symbols/abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Tightening torques for screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.2 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Product label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.1 Pump type 404DLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.2 Operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.3 Failure to comply with safety regulations . . . . . . . . . . . . . . . . . . . . . 16
3.1.4 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Hazard symbols and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hazard warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Special symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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3.3 Fundamentals of safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19


3.3.1 Product-specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Dangers from oils/greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Danger from batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.2 Safety data sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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OPERATING MANUAL Automatic lubrication system Table of contents

4 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21


4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.1 Detailed design of FlexxPump 404DLS . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1.2 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3 Intermediate storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4 Provisioning, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.3 Connect hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
404DLS 3x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
404DLS 6x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
404DLS 10x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.4 Connect electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.4.5 Actuate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.5 Initial commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.5.1 Switch on FlexxPump 404DLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1.2 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2 Malfunctions / troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.2 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.2 Consumables andauxiliary agents for . . . . . . . . . . . . . . . . . . . . . . . . . 40

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OPERATING MANUAL Automatic lubrication system Table of contents

7.2.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40


7.2.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.3 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.3.1 Replace cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.1.2 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.2 Malfunctions / troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.4 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9 Decommissioning, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.1.2 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.2 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.3 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.3.1 Cleaning / rust-proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.3.2 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.4 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.1.2 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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10.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.3 Waste management compliant assemblies. . . . . . . . . . . . . . . . . . . . . 50
10.3.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.3.2 Material groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.4 Disposal facilities, authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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OPERATING MANUAL Automatic lubrication system Table of contents

11 Spare part supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52


11.1 Explanations regarding the spare parts list . . . . . . . . . . . . . . . . . . . . 52
11.1.1 Positioning drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
11.1.2 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
11.2 Service departments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

12 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Connecting cable PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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OPERATING MANUAL Automatic lubrication system General

1 General

1.1 Further applicable documentation


All documents in the appendix of this operating manual are further applicable
documentation. They must be observed in addition to this operating manual for
the safe handling of the product.

1.2 Purpose of the document


This operating manual describes all product life phases of the Automatic lubri-
cation system product:
• Transport
• Repairs
• Commissioning
• Operation
• Maintenance
• Disposal

The operating manual contains the required information on how to operate the
product in the intended manner. It is an important component of the product
Automatic lubrication system.
The operating manual must be available at the product site throughout its entire
service life. If the product is sold, it has to be transferred to the new owner with
the machine.

NOTE
Read the entire operating manual before working with the prod-
uct! It contains important information for your personal safety.
The operating manual must be read and understood by all per-
sons who work on the product in any of the product life phases.
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OPERATING MANUAL Automatic lubrication system General

1.3 Target readership


This operating manual is aimed at the following target readership:
• Construction
• Specialists
• Technicians
• Forwarding agents
• Operating companies
• Operating personnel
• Service personnel

1.4 Explanation of symbols/abbreviations


The following symbols and abbreviations are used in this operating manual:

Symbol /
Abbrevia- Use Explanation
tion

 For cross-reference Page


Fig. Description of drawings Figure
Tab. Description of tables Table
HPG In the instructions High Performance Gearbox

Tab. 1-1 Explanation of symbols/abbreviations


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OPERATING MANUAL Automatic lubrication system General

1.5 Tightening torques for screws

NOTE
Screw connections on moving parts have to
be secured with Loctite medium strength 242. The adhesive has
to be applied onto the nut thread, not onto the screw!

If no other specifications have been made, the following tightening torques apply
for zinced plated screws lubricated with Molykote (MoS2) grease or secured
with Loctite 242:

Tightening torque [Nm]


Thread
size 8.8 10.9 12.9

M5 5.2 7.6 8.9


M6 9 13 15

Tab. 1-2 Torque table for zinced plated screws lubricated with Molykote (MoS2) grease
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OPERATING MANUAL Automatic lubrication system Product description

2 Product description

2.1 Purpose

2.1.1 Proper use

The product Automatic lubrication system is designed exclusively for lubricating


Güdel guideways and Güdel tooth systems. It must be connected as described
in the Chapter "Connect hydraulic system."

Other use or use that goes beyond the described purpose does not fall under
the intended use. The manufacturer assumes no liability for any resulting dam-
age. All risks are carried solely by the user!

2.1.2 Improper use

The product Automatic lubrication system is not intended for:

• Lubrication of runners, bearing or other elements


• Operation in potentially explosive areas
• Lubrication of elements in or on automobiles
• Operation outside of specified performance data
• Operation outside of permissible temperature range
• Using lubricants with properties others than the ones
specified

Any use other than the specified intended use will be considered improper use
and is forbidden!

Do not make any changes to the product.


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OPERATING MANUAL Automatic lubrication system Product description

2.2 Product label


The product has a type plate. It contains the following information:

A
D003061

GÜDEL B

C
Artikelnummer 0193906

www.gudel.com Made in Germany

Fig. 2-1 Type plate

A Product name
B Pump type
C Item number

The type plate is attached to the bottom of the casing. The hydraulic outputs
are indicated by engraved numbers.
D003063

B
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Fig. 2-2 Product labels

A Numbers of the hydraulic outputs


B Type plate

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OPERATING MANUAL Automatic lubrication system Product description

2.3 Technical data

Emission noise level The A-weighted sound level is less than 70 dB(A).

Ambient conditions The following temperature ranges apply:

Transport -10 to +60°C


Operation +10 to +70°C Up to and at 85 %, condensation formation
is not permissible
Storage -10 to +40°C

Protection class The product conforms to the protection class IP65.

Lubricants and The cartridge contains 400 cm3 of lubricant. The fill level is monitored by an
amount of lubricant integrated reed contact. Find information on the lubricant in the corresponding
chapter of the maintenance manual.

Operating pressure The operating pressure is 70 bar and is monitored electronically by counter-
pressure measuring. The maximum pressure is 150 bar.
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OPERATING MANUAL Automatic lubrication system Product description

2.3.1 Pump type 404DLS

The FlexxPump weighs approx. 1500 g and has the following dimensions:
D003135
196

A
35,3

96 94
107 110
112

B
Fig. 2-3 Dimensions and connections 404DLS

A Hydraulics connection
B Terminal plug M12x1

Connections Hydraulic:
Four connections for hydraulic tubes with diameter of 6/3 mm

Electrical:
the four-pole connection with a size of M12x1 transmits the control signals and
the operating voltage

Interfaces The product FlexxPump 404DLS features an integrated microprocessor. It is


controlled via a programmable logic controller (PLC).

Operating voltage/
current Operating Operating Peak power Idle Peak output
voltage power Imax power power

24 V DC 200 mA 350 mA <20 mA 300 mA


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OPERATING MANUAL Automatic lubrication system Safety

3 Safety

3.1 General

NOTE
Read this chapter prior to working with the product! It contains
important information for your personal safety. This chapter
must be read and understood by all persons who work on the
product in any of the product life phases.

3.1.1 Product safety

Residual danger The Automatic lubrication system product corresponds to the state of the art.
It was designed and constructed according to the recognized safety regulations.
However, some residual danger remains during its operation.

There is danger to the personal safety of the operator, as well as to the Auto-
matic lubrication system product and other property.

Operation Always adhere to the instructions in this manual when operating the Automatic
lubrication system product, and ensure that it is always in perfect working
order.

3.1.2 Operating personnel

Persons who work with the Automatic lubrication system product must be
technically qualified and trained. They must be familiar with all hazards associ-
ated with using the Automatic lubrication system product.
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OPERATING MANUAL Automatic lubrication system Safety

3.1.3 Failure to comply with safety regulations

DANGER
Disregarding safety regulations
Disregarding the safety regulations can be very hazardous for personnel and
the surroundings!
Always comply with the safety regulations!

Liability Güdel shall not be held liable under any of the following circumstances:
• The installation regulations were disregarded
• Included protective equipment was not installed
• Included protective equipment was modified

3.1.4 Installation instructions

Protective measures The operator is responsible for ensuring safe conditions in the vicinity of the
product Automatic lubrication system, in particular, for complying with all gen-
eral safety regulations, guidelines and standards . This includes implementing all
of the safety measures before commissioning the system. These must cover all
hazards. This is the only way to ensure that operation of the product conforms
with CE regulations.

As stipulated by the machinery directive, the protective measures must:


• Correspond to best practices
• Comply with the required safety category

Changes The product must never be modified or used in a manner contrary to its
intended use. Intended use and non-intended use is described in Chapter 2
’Product description’,  11.

General rules for The generally accepted occupational safety rules have to be observed and fol-
occupational safety
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OPERATING MANUAL Automatic lubrication system Safety

3.2 Hazard symbols and instructions

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.

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 a hazard that can lead to property damage.

NOTE
NOTE refers to helpful information and tips for users.
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OPERATING MANUAL Automatic lubrication system Safety

Warning symbols

The hazard warnings for the levels danger, warning and caution include the cor-
responding symbol for the hazard. Notifications about dangers which lead to
property damage always contain the symbol "Hazard location."

Symbol Explanation of symbols

Hazards resulting from automatic operation


of the system

Hazards from leaking


batteries

Hazards from environmental pollution

Hazard location

Tab. 3-1 Warning symbols

Special symbols

Symbol Explanation of symbols

Helpful information and other tips


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Tab. 3-2 Special symbols

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OPERATING MANUAL Automatic lubrication system Safety

3.3 Fundamentals of safety

3.3.1 Product-specific hazards

Dangers from oils/greases

CAUTION
Oils/greases
Oils and greases are harmful to the environment!
The oils and greases must not get into 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 to-
tal quantity is small.

Danger from batteries

CAUTION
Leaking batteries
Battery fluids and their vapors are environmentally dangerous, abrasive and
toxic! They harm people and property!
Prevent battery fluids from entering the public water system. Dispose of
batteries in an environmentally friendly manner! Please observe the follow-
ing issues when removing leakages:
• Wear protective goggles and gloves
• Only use dry cleaning cloths without cleaning agent
• In closed rooms, ensure good ventilation before removing leakages
Rescue:
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In case of skin contact, immediately wash the location with water. In case
of eye contact, immediately wash eyes with water. Immediately visit an eye
doctor!

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OPERATING MANUAL Automatic lubrication system Safety

3.3.2 Safety data sheets (MSDS)

Safety data sheets contain safety-relevant information on materials. The opera-


tor is responsible for obtaining safety data sheets for all materials used, such as
oils, greases, cleaning agents, etc.

Safety data sheets can be obtained as follows:

• Vendors of chemicals usually deliver their substances with safety data sheets
• Safety data sheets are available on the Internet
Example: Enter "msds" plus the description of the material to find safety in-
formation for the material
• You can download safety data sheets for the lubricant Güdel H1 on the web-
site of the company Güdel in the category "Safety data sheets"

Read the safety data sheets carefully and follow all instructions. We recommend
that you store the safety data sheets for future reference.
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OPERATING MANUAL Automatic lubrication system Design and function

4 Design and function

4.1 Design
The product Automatic lubrication systemFlexxPump consists of the following
components:
• FlexxPump
• Splitters or Y-segments
• Hydraulic tubes
• Connection cables, if necessary

Find more detailed information on the structure of the system in Chapter 5.4.3
’Connect hydraulic system’,  28.
D003515

E D
Fig. 4-1 Design of FlexxPump lubrication system
D003052c3US

A FlexxPump
B Connecting cable
C Hydraulic tubes
D Y-segment (combines lubricants)
E Splitter (separates lubricants)

21
OPERATING MANUAL Automatic lubrication system Design and function

4.1.1 Detailed design of FlexxPump 404DLS

The FlexxPump 404DLS consists of the following elements:

D003139

Fig. 4-2 Detailed design of FlexxPump 404DLS

A Vent locking mechanism


B Cover
C Cartridge
D Casing
E Connection plug for supply and control system
F Hydraulic outputs
D003052c3US

22
OPERATING MANUAL Automatic lubrication system Design and function

4.2 Functional description


The Automatic lubrication system is a lubrication system for Güdel compo-
nents. A FlexxPump pumps the lubricant in the cartridge to the port. Depending
on the design, the lubricant is distributed through splitters, combined through
Y-segments or distributed directly to the lubrication area. Lubricating pinions
lubricate the tooth system, the felt insert lubricates the guideway.
The FlexxPump emits a signal in case of overpressure, if the cartridge is empty
and for each piston stroke. This makes it possible to process such information
further.

404DLS A PLC (not included) feeds and controls the FlexxPump. All signals are trans-
mitted to the PLC.
D003052c3US

23
OPERATING MANUAL Automatic lubrication system Commissioning

5 Commissioning

5.1 Introduction

5.1.1 Safety

Only perform the tasks described in this chapter after you have read and under-
stood chapter 3 ’Safety’,  15. It concerns your personal safety!

WARNING
Automatic startup
When work is being performed on the product, there is danger of the ma-
chine starting up automatically. This can cause severe or fatal injuries!
Before working in the danger area:
• Switch off the main power supply and secure it against being switched on
again (main switch of complete plant)
• Before switching on the plant again, make sure that no one is in the dan-
ger area.

5.1.2 Personnel qualification

Only appropriately trained and authorized personnel are allowed to commis-


sion the Automatic lubrication system product.
D003052c3US

24
OPERATING MANUAL Automatic lubrication system Commissioning

5.2 Transport
Avoid strong impacts and shocks while transporting the automatic lubrication
system.

5.3 Intermediate storage


In case the product Automatic lubrication system needs to be stored for a cer-
tain time before assembly, the storage conditions according to chapter 9,  46
need to be observed.
D003052c3US

25
OPERATING MANUAL Automatic lubrication system Commissioning

5.4 Provisioning, assembly

5.4.1 Prerequisites

Dispose of the packaging in accordance with the local disposal regulations.


For more information on disposal, refer to chapter 10 ’Disposal’,  49.

Checking the Check the content of the delivery by comparing it with the accompanying
delivery papers.
Check the product for damage. Report transport damage immediately.

Interfaces Check whether the necessary interfaces exist and are functional. Order infor-
mation for the connection cable can be found in the Accessories chapter in the
appendix. The following interfaces are needed:

• Lubricating pinion for tooth system and felt insert for guideway rail
• Connecting cable M12x1, 4-pole with the corresponding length
• PLC

Assembly site The following prerequisites are made for the assembly site:

• Even surface that is at least 107 mm long and 45 mm wide


• Sufficiently rigid
• In order to minimize condensation, the casing should not be subjected to di-
rect sunlight and/or radiation heat
D003052c3US

26
OPERATING MANUAL Automatic lubrication system Commissioning

5.4.2 Assembly

This section describes the mechanical assembly of the FlexxPump.

NOTE
The installation position of the FlexxPump is not important.
D003085

A B C
Fig. 5-1 Mechanical assembly

A Assembly site
B FlexxPump piston pump
D003052c3US

C Screws

Assemble the FlexxPump as follows:

1 Mount piston pump with two screws M6 Lmin = 40 mm


(Tightening torque 5 Nm)

The FlexxPump is assembled.

27
OPERATING MANUAL Automatic lubrication system Commissioning

5.4.3 Connect hydraulic system

404DLS 3x

System with 3 lubrication points


.
A B C
D003078

F E D

Fig. 5-2 Design of 404DLS 3x

A Lubricating pinion (not included in the scope of delivery)


B Felt insert for guideway rail (not included in the scope of delivery)
C FlexxPump 404DLS
D Y-segment
E Hydraulic hose diameter 6/3 mm
F 1st axis (not included in scope of delivery)

Lubrication quantity Lubrication quantity


Axis
Guideway [cm3] Pinion [cm3]

1st axis 0.15 0.3

Tab. 5-1 Lubrication quantities 404DLS 3x


D003052c3US

28
OPERATING MANUAL Automatic lubrication system Commissioning

404DLS 6x

System with 6 lubrication points


.
D003080 A B C D

G F E

Fig. 5-3 Design of 404DLS 6x

A Lubricating pinion (not included in the scope of delivery)


B Felt insert for guideway rail (not included in the scope of delivery)
C FlexxPump 404DLS
D 2x splitter
E 2nd axis (not included in scope of delivery)
F Hydraulic hose diameter 6/3 mm
G 1st axis (not included in scope of delivery)

Lubrication quantity Lubrication quantity


Axis
Guideway [cm3] Pinion [cm3]

1st axis 0.075 0.15


2nd axis 0.075 0.15
D003052c3US

Tab. 5-2 Lubrication quantities 404DLS 6x

29
OPERATING MANUAL Automatic lubrication system Commissioning

404DLS 10x

System with 10 lubrication points

.
A B C D E
D003081

I H G F

Fig. 5-4 Design of 404DLS 10x

A Lubricating pinion (not included in the scope of delivery)


B Felt insert for guideway rail (not included in the scope of delivery)
C 1st axis (not included in scope of delivery)
D 1st FlexxPump 404DLS
E 2x splitter
F 2nd axis (not included in scope of delivery)
G 2nd FlexxPump 404DLS
H Hydraulic hose diameter 6/3 mm
I 3rd axis (not included in scope of delivery)

Lubrication quantity Lubrication quantity


Axis
Guideway [cm3] Pinion [cm3]
D003052c3US

1st axis 0.075 0.15


2nd axis 0.075 0.15
3rd axis 0.15 0.15

Tab. 5-3 Lubrication quantities 404DLS 10x

30
OPERATING MANUAL Automatic lubrication system Commissioning

5.4.4 Connect electrical equipment

NOTE
Do not close any hydraulic outputs!

WARNING
Incorrect polarity
Incorrect polarity can lead to short circuits or misinformation, causing fires,
explosions, and other material damages and, as a result, personal injuries.
Observe the following:
• Always keep the correct polarity in accordance with the connection di-
agram or connection scheme.
• Secure the lines with fuses
• Whenever possible, utilize non-twisting connections and plugs.

We recommend using a 1A delay-action fuse for protecting the supply and con-
trol cable.
D003052c3US

31
OPERATING MANUAL Automatic lubrication system Commissioning

D003089

E D

Fig. 5-5 Connect 404DLS

A FlexxPump 404DLS
B Connection plug for connecting cable
C Socket of connecting cable
D Connector pin assignment
E Hydraulic outputs

Connect the product as follows:

1 Connect hydraulic system hoses as described in chapter 5.4.3, 28


2 Screw the connecting cable to the connecting plug
3 Connect cable
3.1 PIN 1: Input voltage 24 V DC, color: brown
3.2 PIN 2: Actuate individual pump outputs (404DLS), color: white
D003052c3US

3.3 PIN 3: Output/Mass (GND), color: blue


3.4 PIN 4: Output signal, color: black

The product is connected.

32
OPERATING MANUAL Automatic lubrication system Commissioning

5.4.5 Actuate

The FlexxPump is active as long as a permanent voltage of 24 V DC is applied


at PIN 1. Saved information is not lost when the FlexxPump is off.

For regular lubricant dispensing, the FlexxPump 404DLS needs to be controlled


by a PLC. For that, a pulse rhythm needs to be sent by control signal for every
lubrication cycle. Güdel recommends the following program sequence:
D003052c3US

33
OPERATING MANUAL Automatic lubrication system Commissioning

A B

Control system on

No No

Feedback from PIN4


Lubrication
pulse frequency or
time/path reached ?
LOW (0 V)?

Yes Yes

No
Malfunction

Empty indicator or overcurrent

Feedback from Yes


PIN4 is HIGH (24 V) ?

No
Yes

Start lubrication
control PIN2
Feedback from
8s 8s PIN4 is HIGH (24 V) ?
>30
>5 s
s

Reset lubrication time/path


D003052c3US

Fig. 5-6 Program sequence scheme

A Lubrication cycle sequence


B Error evaluation sequence

34
OPERATING MANUAL Automatic lubrication system Commissioning

Pulse rhythm The following pulse rhythm is used on PIN 2 for controlling the outputs and PIN
4, return signal:

A B
D003096

8s
8s 8s High

>5s >30s Low

D C

Fig. 5-7 Pulse rhythm

A Hydraulic output 1.1 (Pump body PK1)


B Hydraulic output 1.2 (Pump body PK1)
C Hydraulic output 2.2 (Pump body PK2)
D Hydraulic output 2.1 (Pump body PK2)

The lubricant amount per pulse and output is 0.15 cm3. Begin dispensing = Out-
put 1.1 or 1.2, then Output 2.1 or 2.2; the outputs are actuated one by one.

NOTE
Keep the intermission between two pulses longer than
53 seconds.
Precision of the pulses (high): +/- 0.2s or +/- 10%!

Lubrication recom- Güdel recommends the following lubrication cycles:


mendation for pump
type 404DLS
3x (e.g., EP or TM) 1 lubrication cycle after 12 h or 10 km 1)
6x (e.g., ZP) 1 lubrication cycle after 8 h or 10 km 1)
D003052c3US

10x (e.g., FP) 1 lubrication cycle after 6 h or 10 km 1)


1)
= whichever occurs first, however, at the latest, if first signs of tribocorro-
sions (reddish discoloration of the guideway or tooth system) appear.

These recommendations are valid exclusively for systems according to


Chapter 5.4.3 ’Connect hydraulic system’, 28!

35
OPERATING MANUAL Automatic lubrication system Commissioning

Special functions There are two special functions available:

• Venting the FlexxPump


12 seconds of the high signal on PIN 2 effect a special dispensing on all hy-
draulic outputs. The pump is vented.
• Fill hoses
After venting, 12 seconds of high signal on PIN 2 effect a special dispensing
of 10x 0.15 cm3 of lubricant per output for filling the hoses

Messages and The output signal on PIN 4 is High (20...30 V) in normal operation. If the Flexx-
malfunctions Pump motor actually runs, the signal switches to Low (0 V). This usually takes
approx. 7 seconds. Afterwards, the signal switches back to High. This message
can be used for estimating the drainage.

Malfunctions are signaled on PIN 4 as follows:

Empty

• Signal: Change signal (rectangular pulse) between High and Low with a
frequency of 0.5 Hz
• Cause: Cartridge missing/empty or air in FlexxPump; pump function
stopped
• Solution: Insert new cartridge or vent FlexxPump; the pump continues
running without change

Overcurrent

• Signal: Low
• Cause: The measured counter-pressure was too high three times in a
row. Hydraulic connections or hoses may be blocked, hoses too long
and/or lubricant too stiff/thick. Pump function has been stopped.
• Solution: Remove cause of the counter-pressure, switch the device off
(OFF) and on again "ON". The error is set to zero. The pump starts up
again.

In case of system malfunctions, switch the device off and on again. This does not
delete the data memory.
D003052c3US

36
OPERATING MANUAL Automatic lubrication system Commissioning

5.5 Initial commissioning


Check the hydraulic system connections before commissioning the product
Automatic lubrication system.

5.5.1 Switch on FlexxPump 404DLS

This section describes the initial commissioning of the automatic lubrication sys-
tem FlexxPump 404DLS.

Perform the initial commissioning as follows:

1 Switch on FlexxPump
2 Emit lubricant using pulse rhythm
3 In case of malfunctions:
3.1 Fix malfunctions as in Section ’Messages and malfunctions’,  36
3.2 Adjust control if necessary
3.3 Repeat procedure from Step 1

Initial commissioning is complete.


D003052c3US

37
OPERATING MANUAL Automatic lubrication system Operation

6 Operation

6.1 Introduction
Only operate the product after observing the installation instructions!

For information on operating the automatic lubrication system FlexxPump


404DLS, refer to the appropriate chapter of the documentation of the com-
plete system.

6.1.1 Safety

Only perform the tasks described in this chapter after you have read and under-
stood chapter 3 ’Safety’,  15. It concerns your personal safety!

WARNING
Automatic startup
When work is being performed on the product, there is danger of the ma-
chine starting up automatically. This can cause severe or fatal injuries!
Before working in the danger area:
• Switch off the main power supply and secure it against being switched on
again (main switch of complete plant)
• Before switching on the plant again, make sure that no one is in the dan-
ger area.

6.1.2 Personnel qualification

Only appropriately trained and authorized personnel are allowed to commis-


D003052c3US

sion the Automatic lubrication system product.

6.2 Malfunctions / troubleshooting


Information on fixing malfunctions of pump type 404DLS is available in Chapter
5.4.5 ’Actuate’,  33.

38
OPERATING MANUAL Automatic lubrication system Maintenance

7 Maintenance

7.1 Introduction
Use only original spare parts. For information on spare parts and wear items,
refer to chapter 11 ’Spare part supply’,  52.

7.1.1 Safety

Only perform the tasks described in this chapter after you have read and under-
stood chapter 3 ’Safety’,  15. It concerns your personal safety!

WARNING
Automatic startup
When work is being performed on the product, there is danger of the ma-
chine starting up automatically. This can cause severe or fatal injuries!
Before working in the danger area:
• Switch off the main power supply and secure it against being switched on
again (main switch of complete plant)
• Before switching on the plant again, make sure that no one is in the dan-
ger area.

7.1.2 Personnel qualification

Only appropriately trained and authorized personnel are allowed to work on


the Automatic lubrication system product.
D003052c3US

39
OPERATING MANUAL Automatic lubrication system Maintenance

7.2 Consumables andauxiliary agents for

NOTE
Unsuitable lubricants
Using unsuitable lubricants can lead to machine damage!
Only use the listed lubricants. If uncertain, please contact our service de-
partments!

7.2.1 Cleaning agents

For cleaning tasks, have a grease-dissolving cleaning agent (e.g. acetone) at hand.

7.2.2 Lubricants

If special lubricants have been delivered ex works at the request of the cus-
tomer, you can find the relevant specifications in the spare parts list.

Use only Güdel cartridges with Güdel H1


as a lubricant!

7.3 Maintenance tasks


For the general inspection, perform a rough check of the entire product. Per-
form a general inspection every 500 hours.

Performing a general Perform the general inspection as follows:


inspection
1 Switch off the system and padlock it to secure it against being switched
on again
D003052c3US

2 Check the inspection points as described in the inspection table


3 Take measures as described in the inspection table

The general inspection has been performed.

40
OPERATING MANUAL Automatic lubrication system Maintenance

Inspection table
Inspection cri- Specification /
Measures
terion Description

Damage Check the system for Immediately remedy all dis-


damage: covered damage
• Tubes
• Splitters and Y-seg-
ments
• FlexxPump
Loss of lubricant Check system and its sur- • Replace defective and
roundings for traces: pinched lines
• Pools and traces of lu- • Remove Pools and trac-
bricant es of lubricant
• Leaks, torn or pinched
lines
Lubricants Check amount of lubri- Replace empty cartridges
cant

Tab. 7-1 Inspection table

7.3.1 Replace cartridge

Replace the cartridge if the malfunction message "Empty" appears.

Switch on or off pump type 404DLS via PLC.

CAUTION
Danger from spring tension
The cover contains a spring with tension. The cover jumps up when
opened. This can lead to minor injuries!
Make sure that no extremities are in the danger area. Carefully remove the
cover.
D003052c3US

NOTE
Empty cartridges contain lubricant residues.
Dispose of them in an environmentally friendly manner! For
more information on disposal, refer to chapter 10 ’Disposal’,
 49.

41
OPERATING MANUAL Automatic lubrication system Maintenance

NOTE
Use only original Güdel cartridges!
Never refill the cartridges

A B C
D003502

Fig. 7-1 Replace cartridge

A Vent locking mechanism


B Cover
C Cartridge
D O-ring
E Retaining cover
D003052c3US

42
OPERATING MANUAL Automatic lubrication system Maintenance

Replace the cartridge as follows:

1 Switch off FlexxPump


2 Remove the vent locking mechanism in the direction of the arrow
3 Remove the cover by turning in the direction of the arrow
4 Remove empty cartridge
5 Remove the retaining cover from the new cartridge
6 Lubricate the O-ring slightly
7 Insert new cartridge
8 Put on the cover and turn hand-tight in the direction of the arrow
9 Insert vent locking mechanism and secure
10 Switch on FlexxPump as in Chapter ’Check the hydraulic system connec-
tions before commissioning the product Automatic lubrication system.’,
 37

The cartridge is replaced.


D003052c3US

43
OPERATING MANUAL Automatic lubrication system Repairs

8 Repairs

8.1 Introduction
This chapter describes repair tasks.

Use only original spare parts. For information on spare parts and wear items,
refer to chapter 11 ’Spare part supply’,  52.

8.1.1 Safety

Only perform the tasks described in this chapter after you have read and under-
stood chapter 3 ’Safety’,  15. It concerns your personal safety!

WARNING
Automatic startup
When work is being performed on the product, there is danger of the ma-
chine starting up automatically. This can cause severe or fatal injuries!
Before working in the danger area:
• Switch off the main power supply and secure it against being switched on
again (main switch of complete plant)
• Before switching on the plant again, make sure that no one is in the dan-
ger area.

8.1.2 Personnel qualification

Only appropriately trained and authorized personnel are allowed to work on


the Automatic lubrication system product.
D003052c3US

44
OPERATING MANUAL Automatic lubrication system Repairs

8.2 Malfunctions / troubleshooting


Information on fixing malfunctions of pump type 404DLS is available in Chapter
5.4.5 ’Actuate’,  33.

8.3 Repairs
In case of defects, always replace the entire FlexxPump, splitter,
Y-segments or tubes with new ones. Send the defective FlexxPump back to
Güdel for repairs.

8.4 Service departments


If you have questions, please contact the service departments. For a list with
their contact information, see chapter 11.2 ’Service departments’,  53.
D003052c3US

45
OPERATING MANUAL Automatic lubrication system Decommissioning, storage

9 Decommissioning, storage

9.1 Introduction

9.1.1 Safety

Only perform the tasks described in this chapter after you have read and under-
stood chapter 3 ’Safety’,  15. It concerns your personal safety!

9.1.2 Personnel qualification

Only appropriately trained and authorized personnel are allowed to work on


the Automatic lubrication system product.

9.2 Storage conditions

CAUTION
Leaking fluids
During storage, substances that are hazardous to the environment could
leak!
Hazardous substances must not get into the drinking water supply:
• Take appropriate measures.
• Observe the country-specific safety data sheets.
• Fluids 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 machine layout or general layout.
D003052c3US

Use a covering to protect the product against dust and dirt.

Temperature The ambient storage temperature must remain between -10 and +40°C. Make
sure that the product is not subjected to large temperature fluctuations.

Air humidity The air humidity must be below 75%.

46
OPERATING MANUAL Automatic lubrication system Decommissioning, storage

9.3 Shutdown
This chapter describes how to shut down the product.

NOTE
Do not empty the lubrication lines and the gearbox when shut-
ting down the product!

To shut down the product, proceed as follows:

1 Switch off FlexxPump


2 Remove cartridge
3 Separate energy supply lines

The product is shut down.

9.3.1 Cleaning / rust-proofing

Prior to performing rust-proofing, clean away any dirt and dust from the prod-
uct. Clean the product thoroughly.

NOTE
Dispose of any cloths soaked in oils and/or greases in an environ-
mentally friendly manner! For more information on disposal, re-
fer to chapter 10 ’Disposal’,  49.

Apply corrosion protection to all parts.

9.3.2 Labeling
D003052c3US

Label the product with the following data:


• Date of decommissioning
• Internal machine number/name
• Further data as per internal guidelines

47
OPERATING MANUAL Automatic lubrication system Decommissioning, storage

9.4 Recommissioning
For recommissioning, follow the steps described for commissioning.

Prior to recommissioning, perform the general inspection as set out in chapter


7.3 ’Maintenance tasks’,  40. Perform the required maintenance tasks and
repairs.

If the machine has been standing still for more than one year, perform the fol-
lowing tasks:
• Insert new cartridge
• Rinse the lubrication lines with fresh lubricant
D003052c3US

48
OPERATING MANUAL Automatic lubrication system Disposal

10 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 Safety

Only perform the tasks described in this chapter after you have read and under-
stood chapter 3 ’Safety’,  15. It concerns your personal safety!

10.1.2 Personnel qualification

Only appropriately trained and authorized personnel are allowed to work on


the Automatic lubrication system product.

10.2 Disposal
Your product consists of the following units:
• Packaging
• Contaminated materials /auxiliary agents (oil paper)
• Wood
• Plastic (film)
• Consumables
• Lubricants (oils/greases)
D003052c3US

• Batteries
• Base unit
• Metals (steel/aluminum)
• Plastics (thermoplasts/duroplasts)
• Contaminated materials/auxiliary agents (felt/cleaning cloths)
• Electrical material (cables)

49
OPERATING MANUAL Automatic lubrication system Disposal

10.3 Waste management compliant assemblies

10.3.1 Disassembly

This chapter describes how to disassemble the product.

Shut down the product prior to disassembly as described in Chapter 9.3 ’Shut-
down’,  47.

CAUTION
Oils/greases
Oils and greases are harmful to the environment!
The oils and greases must not get into 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 to-
tal quantity is small.

Disassemble the product as follows:

1 Remove connecting elements


2 Take the assemblies apart and separate the different materials

The product is disassembled.


D003052c3US

50
OPERATING MANUAL Automatic lubrication system Disposal

10.3.2 Material groups

Dispose of the material groups in accordance with the following table.

Material Disposal route

Contaminated mate- Hazardous waste


rials/auxiliary agents
Wood Municipal waste
Plastic Collecting point or municipal waste
Lubricants Collecting point
Disposal in accordance with the safety data
sheets 3.3.2 ’Safety data sheets (MSDS)’,  20
Batteries Battery collection
Metals Scrap metal collection
Electrical material Electrical rubbish

Tab. 10-1 Disposal: material groups

10.4 Disposal facilities, authorities


The disposal facilities and authorities differ from country to country. Observe
the local laws and regulations on disposal.
D003052c3US

51
OPERATING MANUAL Automatic lubrication system Spare part supply

11 Spare part supply

11.1 Explanations regarding the spare parts list


The spare parts list can be found in chapter 13 ’Appendix’,  56. It contains
position drawings and the complete parts list of your product.

11.1.1 Positioning drawings

The positions of the spare parts can be seen on the drawings. These are stand-
ard drawings. Individual positions or images might differ from your product.

11.1.2 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.

Explanation of
D000094

symbols Güdel AG
Insustrie Nord
CH-4900 Langnethal
phone +41 62 916 91 91
fax +41 62 916 95 29
info@ch.gudel.com 14.07.2008 / Page 1 of 1

A
VS0035 2-Amod ZP-4 M MO mec 3.10 10947-001A

Position Item number Text Drawing Quantity Unit E


300 V000134 Y-Axis LP220/220-25 V L=9200 8523-032 1 Stk
302 0141004 Energy chain 390.17.200.0 IGUS 390.17.200.0 77 Stk E
400 0916667 Y-Carriage ZP-4 8523-030 2 Stk
900 406015-10.00 Worm gear unit AE060/L left AE060 2 Stk E
Ratio i=10.00
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 8102-039d 1 Stk V
ø40.6x20, Modul m=2.387 pitch P=7.5, Z=15
D003052c3US

Fig. 11-1 Explanation of symbols

A Spare part status

Spare part status (column E): E = Spare part


V = Wear item

52
OPERATING MANUAL Automatic lubrication system Spare part supply

11.2 Service departments


If you have questions on service, please use the service form at www.gudel.com
or contact the offices in the appropriate country:

USA: +1 734 214 0000


Germany: +49 6291 6446 41
Great Britain: +44 24 7669 5444
India: +91 20 5622 7165
Italy: +39 02 9217021
South Korea: +82 2168 98 00
Taiwan: +88 635 97 8808
All other countries and Switzerland: +41 62 916 91 91

For urgent service requests, our Helpdesk provides after-hour assistance


(24-hour support):

USA: +1 248 456 0440 service@us.gudel.com


Europe/Asia: +41 62 916 9170 service@ch.gudel.com

Please have the following information, as labeled on the type plate, at hand:
• Serial no.
• Part list no.
• Drawing number (if applicable)
D003052c3US

53
OPERATING MANUAL Automatic lubrication system Index

12 Index

A Functional description 23
Ambient conditions 13 Fundamentals of safety 19
Appendix 56
Assembly 26, 27
Assembly site 26
Authorities 51
G
Auxiliary agents 40 General rules for occupational safety 16

C I
Changes 16 Installation instructions 16
Checking Interfaces 14
Delivery 26 Intermediate storage 25
Cleaning 47
Cleaning agents 40
Commissioning 24 L
Connections 14
Labeling 47
Consumables 40
Liability 16
Lubricant and amount of lubrication 13
Lubricants 40
D
Declaration of conformity 17
Decommissioning 46 M
Delivery
Maintenance 39
Checking 26
Tasks 40
Design 21
Malfunctions 38, 45
Disposal 49
Material groups 51
Disposal facilities 51
Messages and malfunctions 36

E O
Explanation
Operating personnel 15
Abbreviations 9
Operating voltage and operating
Symbols 9
D003052c3US

pressure 14
Explanation of abbreviations 9
Operation 38
Explanation of symbols 9

F P
Parts list 52
Function 21

54
OPERATING MANUAL Automatic lubrication system Index

Personnel qualifications 24, 38, 39, 44, T


46, 49 Target readership 9
Position drawings 52 Technical data 13
Prerequisites 26 Ambient conditions 13
Positioning 26 Connections 14
Prerequisites at the assembly site 26 Interface 14
Product Lubricant and amount of lubrication
Description 11 13
Label 12 Operating voltage and operating
Safety 15 pressure 14
Product-specific hazards 19 protection class 13
Protection class 13 Transport 25
Protective measures 16 Type plate 12
Provisioning 26
Pulse rhythm 35
Pump types
FlexxPump 404DLS-24 V DC 22 U
Purpose of the document 8 Use
Improper 11
Proper 11
Purpose 11
R
Repairs 44, 45
Replace
Cartridge 41
Replace cartridge 41
Residual danger 15
Rust-proofing 47

S
Safety 15, 24, 38, 39, 44, 46, 49
safety regulations
disregarding 16
Screw locked 10
Service departments 53
Spare part supply 52
Spare parts list 52
Explanation of symbols 52
Explanations 52
Special functions 36
Special symbols 18
D003052c3US

Storage 46
Storage conditions 46
Symbols
Special symbols 18

55
OPERATING MANUAL Automatic lubrication system Appendix

13 Appendix

The appendix of this operating manual contains the following documents:

• Layout
• Accessories
• Spare parts list
D003052c3US

56
OPERATING MANUAL Automatic lubrication system Layout

Layout
D003052c3US

57
60 10 11 20 21 30 Cartouche

50

felt pinion lubrication unit


rollers support

40

50
- Position 50 in use with wiper and lubrication unit to assemble as Stever SAT 066 G (0193910)
Änderungen Letzte Änderung Material: Blätter Ersetzt durch: Gewicht ca.
Nr.: 2626 A/09.11.12/chrvet 1/1 Ersatz für: 22.6 kg

Modules Massstab Gezeichnet 09.02.12 rensch

Automatische Schmierung 1:10 Geprüft 09.02.12 rensch

bei A3 BCH-Nr.
Autsch FlexxPump 404DLS 3-fach Artikel-Nr. 0927004

Güdel AG, Switzerland


Ursprung:

Dieses Dokument ist Eigentum der Firma Güdel AG und darf ohne schriftliche Genehmigung weder vervielfältigt noch irgendwelchen Drittpersonen oder Drittfirmen zugänglich gemacht werden. Industrie Nord, 4900 Langenthal 8590-037 A
This document is property of Güdel AG and may not be reproduced nor distributed to any third party without prior written consent.
OPERATING MANUAL Automatic lubrication system Accessories

Accessories

Connecting cable PLC

Serial number Description

Round plug connection M12 4-pole. conf. LED


0200513 Length 1 m
0152900 Length 2 m
0200515 Length 5 m
0200516 Length 10 m
0200517 Length 20 m

Tab. 13-1 Connecting cable PLC

The PLC connecting cables are equipped with three colored LEDs: Green, yel-
low, white. If green glows, voltage on PIN 1 is available and everything is okay.
With yellow, there is a signal in PIN 4; with white, there is a signal on PIN 2.

A
D003115

D C B

Fig. 13-1 LED positions

A LED white
D003052c3US

B LED green
C LED yellow
D FlexxPump

58
OPERATING MANUAL Automatic lubrication system Spare parts list

Spare parts list


D003052c3US

59
60 10 11 20 21 30 Cartouche

50

felt pinion lubrication unit


rollers support

40

50
- Position 50 in use with wiper and lubrication unit to assemble as Stever SAT 066 G (0193910)
Änderungen Letzte Änderung Material: Blätter Ersetzt durch: Gewicht ca.
Nr.: 2626 A/09.11.12/chrvet 1/1 Ersatz für: 22.6 kg

Modules Massstab Gezeichnet 09.02.12 rensch

Automatische Schmierung 1:10 Geprüft 09.02.12 rensch

bei A3 BCH-Nr.
Autsch FlexxPump 404DLS 3-fach Artikel-Nr. 0927004

Güdel AG, Switzerland


Ursprung:

Dieses Dokument ist Eigentum der Firma Güdel AG und darf ohne schriftliche Genehmigung weder vervielfältigt noch irgendwelchen Drittpersonen oder Drittfirmen zugänglich gemacht werden. Industrie Nord, 4900 Langenthal 8590-037 A
This document is property of Güdel AG and may not be reproduced nor distributed to any third party without prior written consent.
11/25/2014 / Page 1 of 1

BUS033285 0927004 Automatic lubrication system FlexxPump 404DLS 3- 8590-037


fach
Position Item nr. Text Drawing Quantity Unit Spare/wear part
10 0199281 Angle 45x65x110 10-00008158-028 1 EA

11 0102613 Socket head cap screw In-6kt DIN912-M6x12-8.8 BN3-DIN912- 2 EA


zinced ISO4762
20 0193906 Pump FlexxPump 404DLS - 24VDC 700306 1 EA E
21 0113289 Socket head cap screw In-6kt DIN912-M6x35-8.8 BN3-DIN912- 2 EA
zinced ISO4762
30 0206399 Cartridge with Güdel H1 - Vol. 400ccm NSF-Nr.: 1 EA V
146621
40 0193909 Push-pull connector ø6 700434 1 EA
50 0193911 Push-pull connector 700082 2 EA
60 0193912 Hose ø6/3 -PA12 700559 3 M E

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