Professional Documents
Culture Documents
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.
Version c3US
Author chrgal / thoanl
GÜDEL, Inc.
4881 Runway Blvd
Ann Arbor, MI, 48130
USA
Phone +1 734 214 0000
D003052c3US
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OPERATING MANUAL Automatic lubrication system
3
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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OPERATING MANUAL Automatic lubrication system Table of contents
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
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
12 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Connecting cable PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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OPERATING MANUAL Automatic lubrication system General
1 General
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
Symbol /
Abbrevia- Use Explanation
tion
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OPERATING MANUAL Automatic lubrication system General
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:
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
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!
Any use other than the specified intended use will be considered improper use
and is forbidden!
11
OPERATING MANUAL Automatic lubrication system Product description
A
D003061
GÜDEL B
C
Artikelnummer 0193906
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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OPERATING MANUAL Automatic lubrication system Product description
Emission noise level The A-weighted sound level is less than 70 dB(A).
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
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
Operating voltage/
current Operating Operating Peak power Idle Peak output
voltage power Imax power power
14
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.
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.
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.
D003052c3US
15
OPERATING MANUAL Automatic lubrication system Safety
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
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.
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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lowed.
16
OPERATING MANUAL Automatic lubrication system Safety
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."
Hazard location
Special symbols
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OPERATING MANUAL Automatic lubrication system Safety
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.
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!
19
OPERATING MANUAL Automatic lubrication system Safety
• 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
4.1 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
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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
D003139
22
OPERATING MANUAL Automatic lubrication system Design and function
404DLS A PLC (not included) feeds and controls the FlexxPump. All signals are trans-
mitted to the PLC.
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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.
24
OPERATING MANUAL Automatic lubrication system Commissioning
5.2 Transport
Avoid strong impacts and shocks while transporting the automatic lubrication
system.
25
OPERATING MANUAL Automatic lubrication system Commissioning
5.4.1 Prerequisites
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:
26
OPERATING MANUAL Automatic lubrication system Commissioning
5.4.2 Assembly
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
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C Screws
27
OPERATING MANUAL Automatic lubrication system Commissioning
404DLS 3x
F E D
28
OPERATING MANUAL Automatic lubrication system Commissioning
404DLS 6x
G F E
29
OPERATING MANUAL Automatic lubrication system Commissioning
404DLS 10x
.
A B C D E
D003081
I H G F
30
OPERATING MANUAL Automatic lubrication system Commissioning
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.
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31
OPERATING MANUAL Automatic lubrication system Commissioning
D003089
E D
A FlexxPump 404DLS
B Connection plug for connecting cable
C Socket of connecting cable
D Connector pin assignment
E Hydraulic outputs
32
OPERATING MANUAL Automatic lubrication system Commissioning
5.4.5 Actuate
33
OPERATING MANUAL Automatic lubrication system Commissioning
A B
Control system on
No No
Yes Yes
No
Malfunction
No
Yes
Start lubrication
control PIN2
Feedback from
8s 8s PIN4 is HIGH (24 V) ?
>30
>5 s
s
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
D C
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%!
35
OPERATING MANUAL Automatic lubrication system Commissioning
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.
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.
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36
OPERATING MANUAL Automatic lubrication system Commissioning
This section describes the initial commissioning of the automatic lubrication sys-
tem FlexxPump 404DLS.
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
37
OPERATING MANUAL Automatic lubrication system Operation
6 Operation
6.1 Introduction
Only operate the product after observing the installation instructions!
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.
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.
39
OPERATING MANUAL Automatic lubrication system Maintenance
NOTE
Unsuitable lubricants
Using unsuitable lubricants can lead to machine damage!
Only use the listed lubricants. If uncertain, please contact our service de-
partments!
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.
40
OPERATING MANUAL Automatic lubrication system Maintenance
Inspection table
Inspection cri- Specification /
Measures
terion Description
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
42
OPERATING MANUAL Automatic lubrication system Maintenance
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.
44
OPERATING MANUAL Automatic lubrication system Repairs
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.
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!
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
Temperature The ambient storage temperature must remain between -10 and +40°C. Make
sure that the product is not subjected to large temperature fluctuations.
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!
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.
9.3.2 Labeling
D003052c3US
47
OPERATING MANUAL Automatic lubrication system Decommissioning, storage
9.4 Recommissioning
For recommissioning, follow the steps described for commissioning.
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!
10.2 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
10.3.1 Disassembly
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.
50
OPERATING MANUAL Automatic lubrication system Disposal
51
OPERATING MANUAL Automatic lubrication system Spare part supply
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.
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
52
OPERATING MANUAL Automatic lubrication system Spare part supply
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
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
• Layout
• Accessories
• Spare parts list
D003052c3US
56
OPERATING MANUAL Automatic lubrication system Layout
Layout
D003052c3US
57
60 10 11 20 21 30 Cartouche
50
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
bei A3 BCH-Nr.
Autsch FlexxPump 404DLS 3-fach Artikel-Nr. 0927004
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
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
A LED white
D003052c3US
B LED green
C LED yellow
D FlexxPump
58
OPERATING MANUAL Automatic lubrication system Spare parts list
59
60 10 11 20 21 30 Cartouche
50
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
bei A3 BCH-Nr.
Autsch FlexxPump 404DLS 3-fach Artikel-Nr. 0927004
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