GUDEL 404DLS User manual

404 DLS
OPERATING MANUAL
Automatic lubrication system
FlexxPump 404DLS
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG AUTOMATIC LUBRICATION SYSTEM FLEXXPUMP 404DLS99079191943154059_V10.0_EN-US
B1X.xxxxxxxxx-xxxx
09xxxxx
2019

© 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. Subject to change due to technical im-
provements.
99079191943154059_v10.0_EN-US

Revision history
Version Date Description
10.0 10/28/2019 New:
• Declaration of conformity for TriboServ
ÜChapter,2133
Entire manual updated.
9.0 02/27/2019 Updated:
• Type plate and location of type plate
Ü226
• Maintenance tasks Ü271
• Interim times for PIN4 output signal
Ü247 Ü249 Ü251 Ü253
• Recommended solution for software
programming Ü244
• Recommissioning Ü297
New:
• Overview of other applicable documen-
tation ÜChapter1.1,212
• Reference to lubrication requirements
ÜChapter5.4,243
• Reference to software modules
ÜChapter5.4,243
8.0 07/27/2018 Updated:
• Lubrication recommendation Ü255
• Checking the lubrication system
Ü259
• Checking the automatic lubrication sys-
tem Ü279
• Replacing the cartridge Ü272
• Maintenance table
New:
• Replacing the FlexxPump
ÜChapter7.3.4,280
Revision history
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
99079191943154059_v10.0_EN-US
3

Version Date Description
7.0 06/01/2018 Valid as of FlexxPump serial number
1601929
Updated:
• Actuate ÜChapter5.4,243
• Lubrication recommendation Ü255
New:
• Splitter Ü229
ÜChapter4.2.3.1,233
6.0 04/12/2018 Updated:
• Lubrication check Ü259
5.0 12/12/2017 Updated:
• Lubrication check Ü259
4.0 08/08/2017 Added:
• Lubrication check Ü259
3.0 02/27/2017 Corrected:
• Standards and guidelines of the Declara-
tion of conformityDeclaration of con-
formity, declaration of incorporation
2.0 11/29/2016 Updated:
• New signatures on Declaration of con-
formityDeclaration of conformity, decla-
ration of incorporation
• Entire manual updated
1.0 07/29/2016 Basic version
Table-1 Revision history
Revision history
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
99079191943154059_v10.0_EN-US
4

Table of contents
1 General 11
1.1 Further applicable documentation................ .................12
1.2 Purpose of the document..................... ......................13
1.3 Explanation of symbols/abbreviations.............................. 14
2 Safety 15
2.1 General ...............................................................15
2.1.1 Product safety .........................................................15
2.1.2 Personnel qualifications..................................................16
2.1.2.1 Operating companies....................................................17
2.1.2.2 Transport specialists....................................................17
2.1.2.3 Fitters ................................ .................................17
2.1.2.4 Commissioning technicians ...................... .......................18
2.1.2.5 Operators .............................. ...............................18
2.1.2.6 Manufacturer's technicians.............................................. 18
2.1.2.7 Maintenance technicians.................................................19
2.1.2.8 Service technicians .......................... ...........................19
2.1.2.9 Disposal specialists.......................... ...........................19
2.1.3 Disregarding safety regulations.......................................... 20
2.1.4 Installation instructions..................................................20
2.2 Hazard symbols in the manual .....................................21
2.2.1 Hazard warnings .......................................................21
2.2.2 Explanation of warning symbol.......................................... 22
2.3 Fundamentals of safety..............................................22
2.3.1 Product-specific hazards.................................................22
2.3.2 Material safety data sheets (MSDS)...................................... 23
Table of contents
OPERATING MANUAL Automatic lubrication system
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3 Product description 25
3.1 Use ................................. ..................................25
3.1.1 Intended use............................. ..............................25
3.1.2 Non-intended use.......................................................25
3.2 Product designation........................ .........................26
3.2.1 Type plate .............................. ...............................26
3.2.2 Position of the type plate................................................27
3.3 Technical data........................... ............................27
3.3.1 FlexxPump..............................................................28
3.3.1.1 Dimensions and connections 404DLS................. ..................28
3.3.1.2 Temperature ranges.................................................... 29
3.3.1.3 IP protection class ..................................................... 29
3.3.1.4 Operating pressure......................................................29
3.3.2 Splitter .................................................................29
3.3.2.1 Temperature ranges.................................................... 29
3.3.2.2 Accuracy of the lubricant distribution................. ..................29
3.3.2.3 Minimum lubrication quantity..................... ......................30
3.3.2.4 Maximum pressure.......................... ...........................30
3.3.3 Lubricant amount .......................................................30
3.3.4 Shelf life of Güdel H1 lubricant.......................................... 30
4 Design, function 31
4.1 Design................................................................ 31
4.1.1 Detailed design of FlexxPump 404DLS ...................................32
4.2 Function .............................................................33
4.2.1 Functional description...................................................33
4.2.2 FlexxPump..............................................................33
4.2.2.1 404DLS................................................................ 33
4.2.3 Splitter .................................................................33
4.2.3.1 Function............................... ................................33
Table of contents
OPERATING MANUAL Automatic lubrication system
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5 Commissioning 35
5.1 Introduction .........................................................35
5.1.1 Safety.................................................................. 35
5.1.2 Personnel qualifications..................................................35
5.2 Transport ............................................................ 35
5.3 Installing .............................................................36
5.3.1 Prerequisites............................................................36
5.3.2 Installing the FlexxPump.................................................37
5.3.3 Connect hydraulics......................................................38
5.3.3.1 404DLS 3-fold ......................................................... 38
5.3.3.2 404DLS 6-fold ......................................................... 39
5.3.3.3 404DLS 10-fold .........................................................40
5.3.4 Connecting electrical equipment.........................................41
5.3.4.1 Connecting the 404DLS.................................................42
5.4 Actuate ...............................................................43
5.4.1 Suggested solution: Programming software...............................44
5.4.2 Connecting FlexxPump to power supply .................................45
5.4.3 Lubrication .............................................................47
5.4.4 Filling hydraulic lines / venting the FlexxPump............................ 49
5.4.5 Error message: Empty...................................................51
5.4.6 Error message: General..................................................53
5.4.7 Lubrication recommendation ..................... ......................55
5.4.7.1 General information.................................................... 55
5.4.7.2 Basics.................................................................. 56
5.4.7.3 Minimum lubrication quantity..................... ......................56
5.4.7.4 Calculation formulas.................................................... 57
5.5 Initial commissioning................................................ 58
5.5.1 Checking the lubrication system .........................................59
Table of contents
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
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6 Operation 64
6.1 General ...............................................................64
6.2 Personnel ............................................................ 64
6.3 Safety .................................................................65
7 Maintenance 67
7.1 Introduction .........................................................67
7.1.1 Safety.................................................................. 67
7.1.2 Personnel qualifications..................................................67
7.2 Consumables and auxiliary agents..................................68
7.2.1 Cleaning agents .........................................................68
7.2.1.1 Table of cleaning agents .................................................68
7.2.2 Lubricants ............................................................. 68
7.2.2.1 Lubrication .............................................................69
Automatic lubrication system........................................ 69
7.2.2.2 Lubricant table............................ .............................70
7.3 Maintenance tasks......................... ..........................71
7.3.1 Replacing the cartridge........................ .........................72
7.3.2 Checking the lubrication system .........................................75
7.3.3 Checking automatic lubrication system.................................. 79
7.3.4 Replacing the FlexxPump....................... ........................80
7.3.4.1 Disassembling the FlexxPump............................................80
7.3.4.2 Installing the FlexxPump.................................................81
7.3.4.3 Connect hydraulics......................................................82
404DLS 3-fold ...................................................... 82
404DLS 6-fold ...................................................... 83
404DLS 10-fold ..................................................... 84
7.3.4.4 Connecting electrical equipment.........................................85
7.3.4.5 Checking the lubrication system .........................................87
7.4 Maintenance table......................... ..........................91
Table of contents
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
99079191943154059_v10.0_EN-US
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8 Repairs 93
8.1 Introduction .........................................................93
8.1.1 Safety.................................................................. 93
8.1.2 Personnel qualifications..................................................93
8.2 Repairs ............................... ................................93
8.3 Malfunctions / Troubleshooting.................. ...................94
8.4 Service departments................................................ 94
9 Decommissioning, storage 95
9.1 Introduction .........................................................95
9.1.1 Personnel qualifications..................................................95
9.2 Storage conditions ...................................................95
9.3 Decommissioning....................................................96
9.3.1 Shutdown.............................................................. 96
9.3.2 Cleaning, rust-proofing........................ .........................96
9.3.3 Identification............................................................96
9.4 Recommissioning.................................................... 97
10 Disposal 99
10.1 Introduction .........................................................99
10.1.1 Safety.................................................................. 99
10.1.2 Personnel qualifications..................................................99
10.2 Disposal .............................................................100
10.3 Waste management compliant assemblies........... ............100
10.3.1 Disassembly ...........................................................100
10.3.2 Material groups .......................................................101
10.4 Disposal facilities, authorities......................................101
Table of contents
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
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11 Accessories 103
11.1 PLC connecting cable .............................................. 103
12 Spare parts supply 105
12.1 Service departments....................... ........................107
12.2 Explanations regarding the spare parts list.......................113
12.2.1 Parts list...............................................................113
12.2.2 Position drawings .....................................................113
13 Torque tables 114
13.1 Tightening torques for screws................... ................... 114
13.1.1 Zinc plated screws ......................................................115
13.1.2 Black screws ............................................................116
13.1.3 Stainless steel screws ...................................................117
Illustrations 119
List of tables 121
Index 123
Appendix
Layout
Spare parts lists
Declaration of conformity for TriboServ
Table of contents
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
99079191943154059_v10.0_EN-US
10