Index C200-sl Operating Instructions And Maintenance Instructions Download Page 18

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Example: Hydraulic unit C100, C200

Filler neck

Base plate of hydraulic unit

Level control

Drain plug

Accumulator drain valve

Check fill level at hydraulic fluid tank.

3. Check fill level at cooling lubricant tank.

Maintenance Summary - Care activities

Maintenance Instructions

G220

DIE017EN - 05.06.2019

Summary of Contents for C200-sl

Page 1: ...Maintenance Instructions G220 Control C200 sl OPERATING INSTRUCTIONS Maintenance Instructions DIE017EN 05 06 2019 05 06 2019 Sp Wartungsanleitung 20080649 ...

Page 2: ...advances A Word on Copyright This document is proprietary and was originally written in German Its reproduction and distribution in whole or in individual parts without permission of the copyright owner is prohibited and will be prosecuted under criminal or civil law All rights reserved including for translation Copyright by INDEX Werke GmbH Co KG Hahn Tessky ...

Page 3: ...090 Check electrical lines visual inspection 18 A095 Visual inspection of all fluid lines and electrical cables 19 A097 Clean cooling lubricant outlet on clamping cylinder 20 A110 Clean filter screens on chip conveyor 21 A120 Check cooling lubricant visual inspection 23 A124 Check the cooling unit and the coolant 25 A130 Check work area light visual inspection 27 A180 Clean the work area 28 A265 C...

Page 4: ...k backup data carrier 55 C525 Check control cabinet 56 C555 Replace hydraulic fluid filters 57 C570 Wassermann tool change system 60 Service Interval 4 000 Operating hours 61 Maintenance Summary 4 000 Operating hours 62 D015 Clean cover in the area of the work area door 63 D050 Check the lubrication system 65 D055 Check the pneumatic system 67 D105 Wassermann tool change system 70 D170 Check the s...

Page 5: ...intenance activities carried out The maintenance intervals are given based on the operating hours counter Hydraulic system On operating condition Do not clean the machine with compressed air Raised dirt particles may cause breathing difficulties or injuries especially of the sensory organs Furthermore raised dirt particles or chips may reach spots where they cause technical problems Do not use cot...

Page 6: ...ries These maintenance activities must be carried out with special care Prior to working on the machine it must be allowed to cool down as hot parts may be located under the covers All maintenance work on the machine must be carried out with utmost care Fasteners must be loosened carefully and parts must be secured against falling down When elastic items springs are removed replaced appropriate de...

Page 7: ...ormed Additionally the general safety precautions in the operating manual Safety instructions for CNC turning machines must be observed The safety precautions as a separate document are part of the INDEX TRAUB user documentation When carrying out maintenance work on fluid systems hydraulic lubrication and pneumatic systems make sure before starting the work that the respective system has been depr...

Page 8: ...Preface 4 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 9: ...Service Interval Care activities Service Interval Care activities 5 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 10: ...aulic system visual inspection A037 Check pneumatic system visual inspection A075 Checking fill levels of the fluid tanks A080 Clean and lubricate clamping device A090 Check electrical lines visual inspection A095 Visual inspection of all fluid lines and electrical cables A097 Clean cooling lubricant outlet on clamping cylinder A110 Clean filter screens on chip conveyor A120 Check cooling lubrican...

Page 11: ...is accelerated even further If the viewing glass is damaged it must be replaced This is necessary regardless of the extent of damage Even with minimal damage the impact resistance of the glass can no longer be guaranteed Heavily soiled or damaged wipers may cause damage to the inner pane Moreover it may be possible that the work area door can be moved only with considerable effort due to heavy sol...

Page 12: ...ved only with effort determine the cause Possible causes include depending on the work area door defective or improperly adjusted wipers Chips on the guide bar or between the door and wiper or in the guide rollers of the work area door Maintenance Summary Care activities 8 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 13: ...nger hydraulic unit HLP32 b2 Heat exchanger spindle unit HLP5 VG5 c Fill level indicator d Monitoring level and temperature e Accumulator drain valve f Monitoring system pressure g Shut off valve cooling water side h Return flow cooling water side i Inlet flow cooling water side j Oil drain plug X Hydraulic fluid filter hydraulic fluid HLPD32 VG32 Y Filter bowl Screws on the hydraulic system the c...

Page 14: ... the hydraulic fluid 3 Check pressure setting on pressure gauge and adjust if necessary The operating pressure is different depending on the machine type See the fluid charts for the correct pressure setting 4 Check supply and fluid lines damage and leakage Supply and fluid lines must be checked for damage Pre damage such as kinks or abrasions should be logged and replacement should be initiated M...

Page 15: ...ents are used on the system maintenance unit X and the extension for sealing air on the glass scales Y 1 Switch on valve manual 2 Pressure regulating valve for system pressure 6 8 bar 3 Pressure gauge for system pressure 4 Filter insert with retained particle size 40 µm with automatic condensate drain 5 Filter insert with retained particle size 5 µm with automatic condensate drain 6 System pressur...

Page 16: ...of 6 bar has been set at the factory 3 Check supply and fluid lines damage and leakage Supply and fluid lines must be checked for damage Pre damage such as kinks or abrasions should be logged and replacement should be initiated 4 Example Various silencer versions from FESTO Check silencers 5 Drain condensate not applicable to auto drain Maintenance Summary Care activities 12 Maintenance Instructio...

Page 17: ...he top mark when the machine is switched off During production the oil level may drop after several consumers have been connected The interval for this maintenance activity is strongly dependent on the operating profile of the machine If the machine is used in three shift operation this maintenance activity must be carried out much more frequently Requirement For all work in connection with operat...

Page 18: ...e plate of hydraulic unit c Level control d Drain plug e Accumulator drain valve Check fill level at hydraulic fluid tank 3 Check fill level at cooling lubricant tank Maintenance Summary Care activities 14 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 19: ...cycling system Knoll X Fill level indicator Check the fill level at the cooling lubricant reconditioning system option 5 Check fill level at coolant tank option Maintenance Summary Care activities 15 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 20: ... the materials to be machined e g brass cast iron and the number of shifts per day more frequent cleaning of the chuck is necessary For this the clamping device must be removed and completely cleaned Here also the labyrinth ring spindle cover and the space behind the ring must be cleaned Requirement Example Three jaw chuck from different manufacturers Do not use cotton waste for cleaning When clea...

Page 21: ...follow manufacturer s instructions 2 Lubricate clamping devices according to manufacturer s instructions 3 Clean labyrinth ring and space behind the labyrinth ring Maintenance Summary Care activities 17 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 22: ...cal lines Electric shock Switch off machine and accessory units and arrange for immediate replacement of damaged lines by an electrically trained technician Check electrical lines to chip conveyor 2 Check electrical lines to cooling lubricant system 3 Check electrical lines to workpiece feeder 4 Check electrical lines to workpiece discharge unit 5 Electrical leads for the pedal switches 6 Check el...

Page 23: ...ause leakage of fluids under high pressure Be sure to use personal protective equipment during visual inspection Requirement Should defective points be found on fluid lines or electrical cables during the visual inspection the machine must be switched off and the damaged lines or cables must be promptly replaced Replaced fluid lines must be tightened to the torque specified by the manufacturer Pro...

Page 24: ...regular intervals Procedure 1 Disassemble the machine enclosure in the area ofthe spindles 2 If necessary remove the acrylic glass cover on the cooling lubricant collection bin 3 Example Cooling lubricant outlet B400 Clean cooling lubricant collection bin Check that the cooling lubricant outlet X is free of chips or other debris 4 Reinstall the acrylic glass cover if applicable Maintenance Summary...

Page 25: ...erating Materials must be observed The chip conveyor must not be operated without the filters and filter plates provided by the manufacturer Follow the manufacturer s documentation Example Plug in strainers ABC Procedure 1 Caution Cooling lubricant splashing out of the chip conveyor Skin irritation and damage to the eyes Wear personal protective equipment e g safety gloves and safety goggles Remov...

Page 26: ...on the cooling lubricant pump Alternatively the following procedure can be used Extract cooling lubricant remove screen directly from the cooling lubricant pump and clean it Maintenance Summary Care activities 22 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 27: ...etermine the cause of the oil ingression Synthetic cooling lubricants or cooling lubricant based on esters are not admissible If the type of cooling lubricant or the manufacturer is changed make sure that the cooling lubricant meets the required specifications See the manufacturer s documentation for the fill quantities Regularly checking the cooling lubricant is necessary in particular if cooling...

Page 28: ...s Supply and fluid lines must be checked for damage Pre damage such as kinks or abrasions should be logged and replacement should be initiated Maintenance Summary Care activities 24 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 29: ...ording to the manufacturer s documentation These activities can be carried out by instructed individuals with appropriate expertise Due to different requirements and or specifications of the respective manufacturers be sure to review the respective manufacturer s documentation Schematic of cooling system G220 G420 1 External cooling unit or customer side cooling 2 Heat exchanger hydraulic unit 3 H...

Page 30: ...ntial pressure Pinlet and Preturn bar E Required cooling capacity kW F Pressure in the cooling system bar The information given in the Technical Data of the cooling water apply at an ambient temperature of max 40 C The values specified in the table must absolutely be observed Deviating from these values will not ensure sufficient cooling of the machine The maximum operating pressure must not excee...

Page 31: ...aced immediately Be sure to follow the manufacturer s documentation According to the manufacturer this lighting fixture is maintenance free Procedure 1 Example Work area light R200 R300 photo Herbert Waldmann GmbH Co KG Check all lamps visual inspection Check lamp protective glass for damage If cooling lubricant has already penetrated into the work area light the lamp must be repaired Maintenance ...

Page 32: ...is particularly important Requirement Only the agents described in the documentation may be used for the cleaning and after treatment of the machine Always use the proper tool to remove chips The following tools are required for cleaning chip hooks chip brushes spray bottles of cleaners or cooling lubricant a sufficient quantity of rags oil to apply to the telescopic plates and all other bare part...

Page 33: ...nt Be sure to interrupt the motion of the conveyor belt by opening the work area door or switching off the chip conveyor before commencing cleaning work around the discharge chute The conveyor belt can only move when the chip conveyor is switched on and the work area door is closed Procedure 1 Clean the chip conveyor Sweep accumulated chips from the tool carriers and chip deflectors onto the chip ...

Page 34: ...revents sludge deposits and chips from entering the suction area of the pump Then remove and clean the dirty screen and have it ready for the next maintenance interval 6 Remove and clean pre filters option on the cooling lubricant pump 7 If the supply of cooling lubricant is insufficient the filter basket on the cooling lubricant pump must be cleaned Remove cooling lubricant pump Remove and clean ...

Page 35: ...cular to remove and clean the labyrinth rings Procedure 1 Loosen and remove the screws on the labyrinth ring X of the spindle The number of screws that are necessary to fasten the labyrinth ring may differ depending on the type of machine 2 Example X Labyrinth ring on the main spindle G200 Remove the labyrinth ring 3 Clean the labyrinth ring Clean the free space behind the labyrinth ring by hand w...

Page 36: ... review the respective manufacturer s documentation The visual inspections described in the manufacturer s documentation must be carried out as part of maintenance activities Procedure 1 Perform visual inspections according to manufacturer s instructions Maintenance Summary Care activities 32 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 37: ...Service Interval 2 000 Operating hours Service Interval 2 000 Operating hours 33 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 38: ...cking and potentially replacing the cooling lubricant adapter HSK tool mountings C065 Check telescopic covers and wipers C070 Check outer wipers of linear guides C080 Check all electrical connections and drive belts of the drive motors C130 Replace filter on air conditioner cooling fan C140 Check cooling unit for cooling lubricant C155 Check coolant C190 Clean labyrinth rings of spindles C510 Chec...

Page 39: ...nce intervals The logs may contain important indications as to work that may be necessary beyond the maintenance activities Similarly the logs can be used for determining the cause of malfunctions due to incorrect or inadequate maintenance activities carried out Procedure 1 Check maintenance or inspection logs Maintenance Summary 2 000 Operating hours 35 Maintenance Instructions G220 DIE017EN 05 0...

Page 40: ... inspection Through contact with cooling lubricant the aging process is accelerated even further If the viewing glass is damaged it must be replaced This is necessary regardless of the extent of damage Even with minimal damage the impact resistance of the glass can no longer be guaranteed Heavily soiled or damaged wipers may cause damage to the inner pane Moreover it may be possible that the work ...

Page 41: ... 1 Year of manufacture 2 Protection class and EN standard 3 Manufacturer 4 INDEX part number Check safety label replacement interval every 8 years 5 Check wipers Remove and clean the wipers If the wipers are severely deformed or damaged they must be replaced To be able to clean the door panels evenly be sure to reinstall the wipers after their removal aligned in parallel and ensure that they snugl...

Page 42: ...auses are defective or improperly adjusted wipers or chips on the guide bar or in the guide rollers of the work area door 7 Danger Pinching of limbs due to faulty obstacle detection on the work area door Check obstacle detection Use only appropriate tools such as a broom handle wooden beams or similar for checking The machine must be switched on and fully functional for this test Maintenance Summa...

Page 43: ...g a broomstick see example is held into the travel path of the work area door while it is closing When the work area door contacts the broom stick in the closing area the obstacle detection is triggered and the door should stop its forward movement Maintenance Summary 2 000 Operating hours 39 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 44: ...ion pulley Visual inspection of the drive of the automatic work area door This is in particular an assessment of the toothed belt 2 condition tension Also the condition of the two deflection pulleys 1 4 and the actuator 3 Maintenance Summary 2 000 Operating hours 40 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 45: ...from Berg Spanntechnik These clamping sets HSK and Capto installed in the tool or milling spindles should be checked regularly Regular checks ensure continuous and trouble free operation Based on manufacturer s instructions we recommend replacement of the clamping sets when the clamping force falls below the following values see Table Fmin Table for testing the clamping force of clamping systems B...

Page 46: ...e damage to the clamping set or failure of the entire clamping system Requirement A measuring device required to measure the clamping force can be sourced through INDEX Werke a representative or the tool manufacturer Example Clamping force measuring system from Berg Maintenance Summary 2 000 Operating hours 42 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 47: ...urements can be performed on HSK SK and Capto tool mountings Procedure 1 Check clamping sets of the tool spindles This procedure depends on the measuring device Therefore be sure to follow the manufacturer s documentation of the measuring device Maintenance Summary 2 000 Operating hours 43 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 48: ...cessary at regular intervals Procedure 1 Check and potentially replace the cooling lubricant adapter also for tools inside the tool magazine Check the correct seating of the cooling lubricant adapter and replace the sealing ring at the cooling lubricant adapter 2 Remove the tool including the HSK tool mounting 3 Check the centric position of the cooling lubricant pipe It should be possible to shif...

Page 49: ...in reverse order Ensure proper cleanliness during the installation 8 After assembly check again the central position of the pipe See item 3 Maintenance Summary 2 000 Operating hours 45 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 50: ...telescopic covers and wipers must be coated with low viscosity oil The oil must not resinify and sediments must not form when exposed to other fluids or machining residues e g metallic dust Otherwise the service life of the wipers would be considerably impaired Requirement Before starting the cleaning move the tool slides to positions that are more convenient for the cleaning process Power off the...

Page 51: ...re must be removed from the machine In most cases access to the wipers is best in the end positions of the respective axes To move to the positions in which the wipers can be checked it may be necessary to switch the machine on off several times Procedure 1 Move the tool carrier to the position required for checking 2 Caution Moving tool carriers spindles or belt drives Risk of bruising and lacera...

Page 52: ...sual inspection Requirement Move the tool carriers to a suitable position It may also be necessary to remove various covers or plates for carrying out a visual inspection Furthermore a special pair of pliers is needed for tightening the power and encoder connections Example Special pliers for tightening power and encoder connections on the motors Procedure 1 Loosen connector and check for corrosio...

Page 53: ...en done checking reconnect plugs and tighten with special pliers see the example 3 Check belt on drive motors for any damage or deterioration Maintenance Summary 2 000 Operating hours 49 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 54: ... of the air outlet Use only the original filters according to the spare or wear parts list Otherwise the machine is at risk of sustaining serious damage due to overheating Requirement A sufficient number of filters must be available Procedure 1 Example Filter Remove machine covers and or filter housing cover 2 Replace filter 3 Reinstall all covers Maintenance Summary 2 000 Operating hours 50 Maint...

Page 55: ...e technical data of the respective equipment If in doubt contact the manufacturer of the equipment or the cooling lubricant vendor Requirement Prerequisite for effective operation within the cooling circuit is the condition of the cooling lubricant To check the condition of the cooling lubricant a refractometer is required With the help of this instrument it is possible to determine the concentrat...

Page 56: ...e information in the document Notes on Operating Materials must be observed Requirement Replenish only coolant of the same manufacturer having the same specification Mixing different coolants may lead to corrosion of the cooling system and degradation of the coolant Required glycol concentration min 25 When switching the coolant to another product or changing the manufacturer the cooling system mu...

Page 57: ...brasions and for liquid leaks Replace supply and fluid lines if necessary Record the age or date of replacement of supply and fluid lines in the service testing and maintenance schedules or reports Maintenance Summary 2 000 Operating hours 53 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 58: ... to remove and clean the labyrinth rings Procedure 1 Loosen and remove the screws on the labyrinth ring X of the work spindle The number of screws that are necessary to fasten the labyrinth ring may differ depending on the type of machine 2 Example X Labyrinth ring on the main spindle G200 Remove the labyrinth ring 3 Clean the labyrinth ring Clean the free space behind the labyrinth ring by hand w...

Page 59: ... PC 2 If the data carrier is not recognized it is damaged To create a new backup data carrier contact the machine manufacturer If the data carrier is recognized make a copy to the hard disk Create a folder named Backup Copy at a suitable location in the directory tree 3 Copy the entire contents of the backup data carrier to this folder If the copying process finished without displaying an error me...

Page 60: ... if filters are dirty or doors are not tight Procedure 1 Danger Electric shock Power off the machine and wait approx 30 minutes Check with a meter if there is still voltage applied to the intermediate circuit Check settings of the fuses For this purpose review the information in the wiring diagram 2 Check Sinamics S120 connections control modules connectors bus device bus and intermediate circuit ...

Page 61: ...e removed or replaced For all work in connection with operating materials the information in the data sheets of the respective manufacturers and the information in the document Notes on Operating Materials must be observed Requirement Only filters with retained particle sizes described in the fluid plans must be used Use only the original filters according to the spare or wear parts list A suitabl...

Page 62: ...emove it from the filter unit X 2 Filters are hazardous waste and must be disposed of in a controlled manner Example Filter insert Z Empty filter bowl Y into prepared container Do not fill fluid from the filter bowl Y back into the tank Remove filter Z Maintenance Summary 2 000 Operating hours 58 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 63: ...Y and insert a new filter Z Reinstall the filter bowl and tighten by hand until it stops Then back off the filter bowl 1 8 turn Maintenance Summary 2 000 Operating hours 59 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 64: ...pecifications of the respective manufacturers be sure to review the respective manufacturer s documentation Procedure 1 Perform 2000 h maintenance according to the manufacturer s documentation Maintenance Summary 2 000 Operating hours 60 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 65: ...Service Interval 4 000 Operating hours Service Interval 4 000 Operating hours 61 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 66: ...E018EN 05 06 2019 D015 Clean cover in the area of the work area door D050 Check the lubrication system D055 Check the pneumatic system D105 Wassermann tool change system D170 Check the system for reconditioning the cooling lubricant D335 Replace belts and check belt tension D450 Replacing hydraulic fluid Maintenance Summary 4 000 Operating hours 62 Maintenance Instructions G220 DIE017EN 05 06 2019...

Page 67: ...l may cause a compression of chips at this point This can lead to malfunction and damage to the work area door Procedure 1 Fig G220 G420 chips a After opening the work area door and turn off the hydraulic system loosen and remove the screws X marked in Figure a It may be necessary to loosen and remove the screws of the wipers as well 2 Fig G220 G420 chips c Maintenance Summary 4 000 Operating hour...

Page 68: ...e sure to screw on the cover again Operation of the machine without this cover is not allowed The cover is part of the machine enclosure and serves also as protection in case of a fire in particular in case of deflagration or to minimize exit of flames Fig G220 G420 chips b Then replace the cover b and reinstall and adjust the wipers that may have been removed Maintenance Summary 4 000 Operating h...

Page 69: ... operating materials the information in the data sheets of the respective manufacturers and the information in the document Notes on Operating Materials must be observed Screws on the lubrication system the connected components and the supply lines must be tightened to the manufacturer s specified torques Requirement The maintenance of the lubricating oil supply requires the following auxiliary or...

Page 70: ... protective equipment Check supply and fluid lines damage and leakage Supply and fluid lines must be checked for damage Pre damage such as kinks or abrasions should be logged and replacement should be initiated 2 Check lubrication pressure and related sensors 3 Activate lubrication pulse in the control ten times 4 Monitor the area around the lubricating oil distributor for leakage Maintenance Summ...

Page 71: ... following components are used on the system maintenance unit X and the extension for sealing air on the glass scales Y 1 Switch on valve manual 2 Pressure regulating valve for system pressure 6 8 bar 3 Pressure gauge for system pressure 4 Filter insert with retained particle size 40 µm with automatic condensate drain 5 Filter insert with retained particle size 5 µm with automatic condensate drain...

Page 72: ...lways replaced Filter cartridges are hazardous waste and must be disposed of according to local regulations Only filters with a filter fineness described in the fluid plans must be used Replace filter 5 Condensate is extremely harmful to the environment due to its high pollution impact Condensate must be collected in a container specifically marked for this purpose and properly disposed of Drain c...

Page 73: ... air supply on the components A reliable method is the use of a suitable pressure gauge The pressure gauge is attached to the line that is screwed off to monitor the existing pressure The pressure should be in the range of the preset pressure of the sealing air supply If this is not the case the cause must be determined and the fault must be fixed Alternatively the following procedure can be used ...

Page 74: ...nufacturer s documentation For efficiency reasons we recommend carrying out the 5000 h maintenance interval described in the manufacturer s documentation in the 4000 h maintenance interval Procedure 1 Perform 5000 h maintenance according to the manufacturer s documentation Maintenance Summary 4 000 Operating hours 70 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 75: ...with operating materials the information in the data sheets of the respective manufacturers and the information in the document Notes on Operating Materials must be observed Due to different requirements and or specifications of the respective manufacturers be sure to review the respective manufacturer s documentation Requirement To determine the concentration of cooling lubricant in the cooling l...

Page 76: ... checked or adjusted Setting values in Hertz Hz for belt tension Up to machine number 10310028 drive belts with a width of 20 mm are used for the Z1 Z2 and Z5 axes Starting with machine 10310029 they are replaced by drive belts with a width of 30 mm These drive belts are pretensioned with a value of 94 Hz see table above Procedure 1 Caution Uncontrolled movements of axes or machine components Seve...

Page 77: ...ry type receiver belt The value of 400mm listed in the table refers to the distance between the center of the guide pulley on drive 1 and the center of the belt clamping of this unit 2 see example distance between guide pulley and belt clamping This value or distance is necessary to accurately adjust the belt tension 11 Measure belt tension frequency meter and adjust belt 12 Replace the belt of th...

Page 78: ...ion pulley belt tensioner 3 see examples of Auto_Arbeitsraumtuer_G220_6 5 14 Auto_Arbeitsraumtuer_G220_5 1 Drive 2 Driver 3 Belt tensioner M Measuring point for frequency meter Adjust belt tension Using a frequency meter and the belt tensioner 3 the belt tension can now be set to 100 Hz at the marked poin t M Maintenance Summary 4 000 Operating hours 74 Maintenance Instructions G220 DIE017EN 05 06...

Page 79: ...observed Requirement Specification and quantity of hydraulic fluid as specified in the technical data Before replacing the hydraulic fluid make sure that the required spare parts such as seals and filters are available Use only the original filters according to the spare or wear parts list Procedure 1 Suction off old fluid through the filler neck a or drain the fluid from the drain plug d below th...

Page 80: ...essure g Shut off valve cooling water side h Return flow cooling water side i Inlet flow cooling water side j Oil drain plug X Hydraulic fluid filter hydraulic fluid HLPD32 VG32 Y Filter bowl Ensure absolute cleanliness during the activities described here 3 Dispose of the fluid in the filter bowl Y do not refill into the hydraulic tank Maintenance Summary 4 000 Operating hours 76 Maintenance Inst...

Page 81: ...ters X may be installed depending on the version Unscrew filter bowl Y remove contaminated hydraulic fluid oil sump and used filter Z from the filter bowl Y and dispose of them according to environmental regulations 4 Only filters with retained particle sizes described in the fluid plans must be used Maintenance Summary 4 000 Operating hours 77 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 82: ...ro filter that is exclusively used for hydraulic fluid 6 Fill in the prescribed amount of new hydraulic fluid 7 Switch on the machine and hydraulic system 8 Check and if necessary replenish hydraulic fluid level 9 Vent hydraulic system To bleed the hydraulic system open the accumulator drain valve s for about 10 seconds and then close it again Maintenance Summary 4 000 Operating hours 78 Maintenan...

Page 83: ...Service Interval 8 000 Operating hours Service Interval 8 000 Operating hours 79 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 84: ...the maintenance activities carried out by using the appropriate maintenance log The maintenance log has the document number DIE018EN 05 06 2019 E010 Wassermann tool change system Maintenance Summary 8 000 Operating hours 80 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 85: ... different requirements and or specifications of the respective manufacturers be sure to review the respective manufacturer s documentation For efficiency reasons we recommend carrying out the 2 year maintenance interval described in the manufacturer s documentation in the 8000 h maintenance interval Procedure 1 Perform 2 year maintenance according to the manufacturer s documentation Maintenance S...

Page 86: ...Maintenance Summary 8 000 Operating hours 82 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 87: ...Service Interval 5 Years Service Interval 5 Years 83 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 88: ...he maintenance activities carried out by using the appropriate maintenance log The maintenance log has the document number DIE018EN 05 06 2019 I020 Replace the pressure accumulator Maintenance Summary 5 Years 84 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 89: ...ator after 5 years to avoid an internal inspection that is laborious and expensive for this size of pressure accumulator Due to different requirements and or specifications of the respective manufacturers be sure to review the respective manufacturer s documentation The machine operator is obliged to check the pressure accumulator according to applicable rules and directives Defective pressure acc...

Page 90: ...2 Example Pressure accumulator Connect and secure the pressure accumulator Observe the tightening torque Maintenance Summary 5 Years 86 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 91: ...Service Interval 8 Years Service Interval 8 Years 87 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 92: ... the maintenance activities carried out by using the appropriate maintenance log The maintenance log has the document number DIE018EN 05 06 2019 J140 Replacing the viewing glass Maintenance Summary 8 Years 88 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 93: ...entral pane m made of polycarbonate and the outer pane a also made of polycarbonate The inner pane i is relatively resistant It can be cleaned with any commercially available cleaning agents Only the center pane m is essential for the impact resistance of the viewing glass The polycarbonate panes are subject to natural aging and must be replaced at regular intervals After replacing the inner viewi...

Page 94: ... handle 2 G220 Replacement 5 2 viewing glass Loosen and remove screws 2x M8 on the handle screwed from the inside and two screws 2x M6 3 G220 Replacement 1 viewing glass Slightly pull the left side of the front cover to the front Maintenance Summary 8 Years 90 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 95: ...ass The front cover can now be pushed to the right and detached on the right side 5 G220 Replacement 3 viewing glass The front cover can now be removed Maintenance Summary 8 Years 91 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 96: ...he 4 angle brackets on the sides This allows you to remove the outer pane from the front cover 7 Make sure that the side tabs X have not been bent by the removal If so straighten them again so that the tabs can be inserted again into the holes provided for this purpose G220 Replacement 5 2 3 viewing glass For assembly follow the steps in reverse order Ensure proper cleanliness during the installat...

Page 97: ...is purpose the covers X Y and the screws 30x of the clamping frame must be removed Also the seal of the pane on the inside of the work area door must be cut 9 G220 Replacement 6 4 1 viewing glass Remove the upper part of the front cover X at the work area door Loosen and remove the screws 6x and 4x as shown in the figures Then you can remove the top cover Maintenance Summary 8 Years 93 Maintenance...

Page 98: ...you can tilt the cover forward and detach it 11 Assistance of a second person to hold the pane is recommended This generally also applies to the installation of the new pane in particular when sealing and fastening the clamp frame with screws Make sure the pane is mounted free of tension Maintenance Summary 8 Years 94 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 99: ...ee Fig and remove with the clamping frame Before the cutting the seal S using a suitable knife make sure that the pane cannot fall down 12 For assembly follow the steps in reverse order Ensure proper cleanliness during the installation Maintenance Summary 8 Years 95 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

Page 100: ...ith sealant After the assembly of the panes and frame parts the inner pane must be sealed using a sealant Terostat 930 gray is used at the factory S See Fig G220 G420 Replacement 8 2 viewing glass Maintenance Summary 8 Years 96 Maintenance Instructions G220 DIE017EN 05 06 2019 ...

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