GUDEL FlexxPump4 B User manual

OPERATING MANUAL
FlexxPump4B lubrication system
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG FLEXXPUMP4B LUBRICATION SYSTEM3421295627_V1.0_EN-US
B1X.xxxxxxxxx-xxxx
10xxxxxx
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.
3421295627_v1.0_EN-US

Revision history
Version Date Description
1.0 02.03.2021 Basic version
Tab.-1 Revision history
Revision historyOPERATING MANUAL FlexxPump4B lubrication system
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Revision history OPERATING MANUAL FlexxPump4B lubrication system
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Table of contents
1 General 13
1.1 Further applicable documentation................ .................13
1.2 Purpose of the document..................... ......................14
1.3 Explanation of symbols/abbreviations.............................. 14
2 Safety 15
2.1 Hazard symbols in the manual .....................................15
2.1.1 Hazard warnings .......................................................15
2.1.2 Explanation of warning symbol.......................................... 16
2.2 Product safety ........................... ............................16
2.3 Danger areas ........................... .............................17
2.3.1 Safety and monitoring equipment ................... ....................17
2.4 Personnel ............................................................ 17
2.4.1 Personal safety equipment...............................................18
2.4.2 Personnel qualifications..................................................19
2.4.2.1 Operating companies....................................................20
2.4.2.2 Fitters ................................ .................................20
2.4.2.3 Commissioning technicians ...................... .......................20
2.4.2.4 Operators .............................. ...............................21
2.4.2.5 Manufacturer's technicians.............................................. 21
2.4.2.6 Maintenance technicians.................................................22
2.4.2.7 Service technicians .......................... ...........................22
2.4.2.8 Disposal specialists.......................... ...........................22
2.5 Product-specific hazards ............................................ 23
2.6 Material safety data sheets (MSDS)................................ 24
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3 Product description 25
3.1 Use ................................. ..................................25
3.1.1 Lifetime................................................................ 25
3.1.2 Intended use............................. ..............................25
3.1.3 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 FlexxPump4 B.............. ...............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 .................................................................30
3.3.2.1 Temperature ranges.................................................... 30
3.3.2.2 Accuracy of the lubricant distribution................. ..................30
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 FlexxPump4B.................... ....................32
4.2 Function .............................................................33
4.2.1 Functional description...................................................33
4.2.2 FlexxPump..............................................................33
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4.2.2.1 Display elements........................... ............................33
LED ................................................................34
Character display.................................................... 34
Sub-menu........................................................... 35
Malfunctions ........................................................36
4.2.2.2 Control elements .......................................................37
4.2.3 Splitter .................................................................38
4.2.4 Y-segment.............................. ...............................38
5 Commissioning 39
5.1 Introduction .........................................................39
5.1.1 Safety.................................................................. 39
5.1.2 Personnel qualifications..................................................40
5.2 Intermediate storage................................................40
5.3 Transport ............................................................ 41
5.3.1 Packaging symbols...................................................... 41
5.3.2 Repairing damaged packaging............................................42
5.4 Installing .............................................................42
5.4.1 Prerequisites............................................................42
5.4.2 Installing the lubricant pump.............................................43
5.4.3 Connect hydraulics......................................................44
5.4.3.1 FlexxPump4 N/B 3-fold..................................................44
5.4.3.2 FlexxPump4 N/B 6-fold..................................................45
5.4.3.3 FlexxPump4 N/B 9-fold..................................................46
5.4.3.4 FlexxPump4 N/B 10-fold................................................ 47
5.4.4 Connecting .............................................................48
5.5 Initial commissioning................................................ 49
5.5.1 Switch on the FlexxPump................................................49
5.5.2 Execute FIL menu.......................................................49
5.5.2.1 Cancel FIL menu ........................... ............................50
5.5.3 Checking the lubrication system .........................................51
5.5.4 Check settings ............................ .............................55
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6 Operation 56
6.1 General ...............................................................56
6.2 Personnel qualifications...................... .......................56
6.3 Operating mode.......................... ...........................56
6.4 Lubrication recommendation .......................................57
6.4.1 General information.................................................... 57
6.4.2 Basics.................................................................. 58
6.4.3 Minimum lubrication quantity..................... ......................58
6.4.4 Calculation formulas.................................................... 59
6.5 Menu ................................ .................................60
6.5.1 Explanation of symbols........................ .........................60
6.5.2 Menu navigation........................................................ 61
6.6 Sub-menu............................................................ 62
6.6.1 SET menu.............................................................. 62
6.6.2 PRO menu in emptying time mode...................................... 64
6.6.3 PRO menu in hour mode................................................66
6.6.4 INF menu in emptying time mode........................................68
6.6.5 INF menu in hour mode.................................................69
6.6.6 RUN menu .............................................................70
6.7 Switch off FlexxPump....................... ........................71
7 Maintenance 73
7.1 Introduction .........................................................73
7.1.1 Safety.................................................................. 74
7.1.2 Personnel qualifications..................................................74
7.2 Consumables and auxiliary agents..................................75
7.2.1 Cleaning agents .........................................................75
7.2.1.1 Table of cleaning agents .................................................75
7.2.2 Lubricants ............................................................. 75
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7.2.2.1 Lubrication .............................................................76
Standard............................................................ 76
Temperature range 0°C to +5°C..................................... 77
Temperature range -30°C to -20°C..................................77
7.2.2.2 Lubricant table............................ .............................78
7.3 Maintenance tasks......................... ..........................78
7.3.1 Maintenance intervals....................................................78
7.3.2 Maintenance tasks after 2,200 hours .....................................81
7.3.2.1 Replacing lubricant cartridge............................................ 81
7.3.2.2 Replace battery .........................................................83
7.3.2.3 Checking the lubrication system .........................................87
7.3.3 Maintenance tasks after 10,000 hours................. ..................91
7.3.3.1 Cleaning and checking lubrication system................................ 91
7.3.4 Maintenance tasks after 20,000 hours................. ..................93
7.3.4.1 Replacing the lubricant pump ..................... ......................93
Removing the lubricant pump........................................ 93
Replacing the lubricant pump ........................................93
Installing the lubricant pump......................................... 94
Connect hydraulics..................................................95
Connecting .........................................................99
Switch on the FlexxPump...........................................100
Checking the lubrication system.....................................101
7.4 Maintenance table..................................................105
7.5 Feedback on the instructions......................................107
8 Repairs 108
8.1 Introduction ........................... ............................ 108
8.1.1 Safety................................ .................................109
8.1.2 Personnel qualifications................................................ 109
8.2 Repairs .............................................................. 110
8.3 Malfunctions / Troubleshooting....................................111
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9 Decommissioning, storage 113
9.1 Introduction ........................... ............................ 113
9.1.1 Personnel qualifications................................................ 113
9.2 Storage conditions .................................................113
9.3 Decommissioning......................... ......................... 115
9.3.1 Shutdown.............................. ...............................115
9.3.2 Cleaning, rust-proofing.................................................115
9.3.3 Identification.......................................................... 115
9.4 Recommissioning......................... ..........................116
9.4.1.1 Cleaning the rails and racks............................................ 117
9.4.1.2 Pre-lubricating rails and racks.......................................... 118
10 Disposal 121
10.1 Introduction ........................... ............................ 121
10.1.1 Safety................................ .................................121
10.1.2 Personnel qualifications................................................ 122
10.2 Disposal .............................................................122
10.3 Waste management compliant assemblies........... ............123
10.3.1 Disassembly ...........................................................123
10.3.2 Material groups .......................................................124
10.4 Disposal facilities, authorities......................................124
11 Spare parts supply 125
11.1 Service departments....................... ........................127
11.2 Explanations regarding the spare parts list.......................133
11.2.1 Spare parts and wear items list..........................................133
11.2.2 Position drawings .....................................................133
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