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Maintenance Summary - 4.000 Operating hours

It is recommended to document the maintenance activities carried out by using the appropriate

maintenance log. The maintenance log has the document number DIE079EN - 05.06.2019.

D010

- Cleaning of the machine

D017

- Clean spring steel wiper in the area of the work area door

D050

- Check the lubrication system

D067

- Check pneumatic system (visual inspection)

D077

- Check tool clamping sets of the milling spindles (from Berg)

D107

- Check and clean the INDEX tool magazine for 6 tools

D170

- Check the system for reconditioning the cooling lubricant

D345

- Replace belts and check belt tension

D455

- Replacing hydraulic fluid

Maintenance Summary - 4.000 Operating hours

Maintenance Instructions

G200.2

DIE078EN - 05.06.2019

Summary of Contents for G200.2

Page 1: ...Maintenance Instructions G200 2 OPERATING INSTRUCTIONS Maintenance Instructions DIE078EN 05 06 2019 05 06 2019 Sp Wartungsanleitung 20057431 ...

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: ...ectrical 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 A129 Check the cooling unit and the coolant 25 A130 Check work area light visual inspection 27 A180 Clean the work area 28 A267 Cleaning the ...

Page 4: ...g 58 C555 Replace hydraulic fluid filters 59 C580 Check and clean the INDEX tool magazine for 6 tools 62 Service Interval 4 000 Operating hours 65 Maintenance Summary 4 000 Operating hours 66 D010 Cleaning of the machine 67 D017 Clean spring steel wiper in the area of the work area door 69 D050 Check the lubrication system 71 D067 Check pneumatic system visual inspection 73 D077 Check tool clampin...

Page 5: ...Service Interval 8 Years 97 Maintenance Summary 8 Years 98 J150 Replacing the viewing glass 99 Table of contents III Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 6: ...Table of contents IV Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 7: ...ntenance 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 cott...

Page 8: ...ies 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 dev...

Page 9: ...rmed 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 depre...

Page 10: ...Preface 4 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 11: ...Service Interval Care activities Service Interval Care activities 5 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 12: ... visual inspection A036 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 lubricant visual ins...

Page 13: ...s 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 soli...

Page 14: ...ed 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 G200 2 DIE078EN 05 06 2019 ...

Page 15: ... information in the data sheets of the respective manufacturers and the information in the document Notes on Operating Materials must be observed Example Hydraulic unit G200 2 a Filler neck b Fill level indicator c Accumulator drain valve d Monitoring level and temperature e Oil drain plug f Monitoring system pressure X Hydraulic fluid filter hydraulic fluid HLPD32 VG32 Y Filter bowl Screws on the...

Page 16: ...y determine the cause and correct the error If in doubt take a sample for analysis and contact the manufacturer of 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 ...

Page 17: ...e to different requirements and or specifications of the respective manufacturers be sure to review the respective manufacturer s documentation The 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...

Page 18: ...s sealing air 0 6 1 0 bar Procedure 1 Check oil level at oiler optional 2 Check pressure setting on pressure gauge and adjust if necessary An operating pressure 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 V...

Page 19: ...e 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 operati...

Page 20: ... 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 G200 2 DIE078EN 05 06 2019 ...

Page 21: ...ycling 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 G200 2 DIE078EN 05 06 2019 ...

Page 22: ...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 clean...

Page 23: ...ollow 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 G200 2 DIE078EN 05 06 2019 ...

Page 24: ...al 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 ele...

Page 25: ...use 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 Proc...

Page 26: ...egular 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 27: ...rating 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 Remove...

Page 28: ...n 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 G200 2 DIE078EN 05 06 2019 ...

Page 29: ...termine 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 30: ... 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 G200 2 DIE078EN 05 06 2019 ...

Page 31: ...stem G200 2 1 Cooling unit or cooling water supply 2 Cooling manifold 3 Heat exchanger for hydraulic system 4 Hydraulic unit 5 Warm water 6 Cold water ______ 7 Warm oil _ _ _ _ _ _ 8 Cold oil _ _ _ _ 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...

Page 32: ... 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 exceed 8 bar Due to different requirements and or specifications of the respective manufacturers be sure to re...

Page 33: ...ced 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 S...

Page 34: ...s 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 parts...

Page 35: ...th 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 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 th...

Page 36: ...cant is insufficient the filter basket on the cooling lubricant pump must be cleaned Remove cooling lubricant pump Remove and clean filter basket 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 30 Maintenance Instructions G200 2 DIE078EN ...

Page 37: ...ular 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 wi...

Page 38: ...s 4 the change area is freed automatically from coarse dirt such as chips when changing the tool A random visual inspection of these cleaning nozzles for damage must also be made Should the visual inspection reveal any imperfections or defects they must be eliminated promptly Defect that are not eliminated may result in further damage to the tool mounting on the milling spindle or even total failu...

Page 39: ...Procedure 1 Perform visual inspections Maintenance Summary Care activities 33 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 40: ...Maintenance Summary Care activities 34 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 41: ...Service Interval 2 000 Operating hours Service Interval 2 000 Operating hours 35 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 42: ...tentially 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 C140 Check cooling unit for cooling lubricant C155 Check coolant C190 Clean labyrinth rings of spindles C510 Check backup data carrier C525 Check control cabinet C540 Check cab...

Page 43: ...ce 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 37 Maintenance Instructions G200 2 DIE078EN 05 ...

Page 44: ...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 a...

Page 45: ...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 snugly...

Page 46: ...uses 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 Summar...

Page 47: ... 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 41 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 48: ...on 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 42 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 49: ...rom 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 Be...

Page 50: ... 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 44 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 51: ...rements 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 45 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 52: ...essary 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 shift...

Page 53: ...n 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 47 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 54: ...elescopic 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 55: ...e 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 lacerat...

Page 56: ...ual 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 corrosion...

Page 57: ...n 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 51 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 58: ... 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 concentrati...

Page 59: ... 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 mus...

Page 60: ...rasions 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 54 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 61: ...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 wi...

Page 62: ...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 mes...

Page 63: ...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 b...

Page 64: ...e abrasive to cables or hoses and damage them Under unfavorable circumstances defective clamps may lead to entangling of the cables hoses which may result in tearing off entire bundles Procedure 1 Check cables for chafing and kinks 2 Check cable and hose clamps for tight seating In case of moving drags or bundles check for any movement within the function 3 Example Power cabling G400 Check strain ...

Page 65: ... 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 suitable...

Page 66: ...move 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 60 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 67: ... 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 61 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 68: ... for 6 tools 1 1 Tool magazine 2 Tool mounting 3 Clamping spring 4 Cleaning nozzles Procedure 1 Tool magazine for 6 tools 2 2 Tool mounting 3 Clamping spring c Radial fixation x HSK A40 tool Using a tool x check the function of the tool mounting a Firmly push and rotate the tool into the tool mounting until it rests against the radial fixation c If the tool x is no longer fixed correctly and no lo...

Page 69: ...2 After removal of the tool the tool mounting should close again by spring force Maintenance Summary 2 000 Operating hours 63 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 70: ...Maintenance Summary 2 000 Operating hours 64 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 71: ...Service Interval 4 000 Operating hours Service Interval 4 000 Operating hours 65 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 72: ...iper in the area of the work area door D050 Check the lubrication system D067 Check pneumatic system visual inspection D077 Check tool clamping sets of the milling spindles from Berg D107 Check and clean the INDEX tool magazine for 6 tools D170 Check the system for reconditioning the cooling lubricant D345 Replace belts and check belt tension D455 Replacing hydraulic fluid Maintenance Summary 4 00...

Page 73: ...s 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 pa...

Page 74: ...ts Follow the manufacturer s documentation Cleaning of the spindle carriers of the main and counter spindles Remove machine covers in the area of the spindles Then remove and clean the spindle covers 9 Clean the machine drag Remove accumulations of chips especially in the area of the counter spindle For this purpose move the counter spindle towards the main spindle and flush the area with cooling ...

Page 75: ...sion of chips at this point This can lead to malfunction and damage to the work area door Procedure 1 Fig G200 2_spring steel wiper After opening the work area door and turning off the hydraulic system loosen and remove the screws of the marked cover panels X 2 Fig Tool for removing chips After removing the cover panels remove the spring steel wipers and clean the space behind this cover these wip...

Page 76: ...hes to remove the chips 3 Reattach the spring steel wipers and cover panels making sure that they rest evenly against the work area door so they can cleanly wipe off any chips Maintenance Summary 4 000 Operating hours 70 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 77: ...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 78: ...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 Summa...

Page 79: ...o different requirements and or specifications of the respective manufacturers be sure to review the respective manufacturer s documentation The 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 wi...

Page 80: ...ealing air 0 6 1 0 bar Procedure 1 Check oil level at oiler optional 2 Check pressure setting on pressure gauge and adjust if necessary An operating pressure 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 Vari...

Page 81: ...rom 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 Be...

Page 82: ... 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 4 000 Operating hours 76 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 83: ...rements 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 4 000 Operating hours 77 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 84: ... for 6 tools 1 1 Tool magazine 2 Tool mounting 3 Clamping spring 4 Cleaning nozzles Procedure 1 Tool magazine for 6 tools 2 2 Tool mounting 3 Clamping spring c Radial fixation x HSK A40 tool Using a tool x check the function of the tool mounting a Firmly push and rotate the tool into the tool mounting until it rests against the radial fixation c If the tool x is no longer fixed correctly and no lo...

Page 85: ...2 After removal of the tool the tool mounting should close again by spring force Maintenance Summary 4 000 Operating hours 79 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 86: ...ith 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 lu...

Page 87: ...ference point may need to be checked or adjusted Setting values in Hertz Hz for belt tension Procedure 1 Caution Uncontrolled movements of axes or machine components Severe cut and crush injuries Secure all axes or components against uncontrolled movements during maintenance or repair work Move the tool slides to a suitable position 2 Replace Z1 belt 3 Measure belt tension frequency meter and adju...

Page 88: ...er belt 15 Preparing to measure the belt tension on the Z8 axis First move the tool magazine fully to the right home position Follow the documentation Operating instructions Options for the machine Tool magazine for 6 tools Chapter Important notes and manual operation Then move the gantry type receiver to a distance of 500 mm see Figure Distance between front wall and gantry type receiver This val...

Page 89: ...aumtuer_1_C200 X Center between the drive pulley and the deflection pulley 1 Belt adjustment Measure belt tension frequency meter and adjust belt The measuring point to check the belt frequency is located in the middle X between the drive pulley and the deflection pulley The value to be set is 20Hz Correct the belt tension at the belt adjustment 1 if necessary Maintenance Summary 4 000 Operating h...

Page 90: ...nt Notes on Operating Materials must be 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 ...

Page 91: ...r bowl Remove the hydraulic unit base plate b and clean the hydraulic fluid tank 3 Replace the seal at the hydraulic unit base plate b 4 Screw on the hydraulic unit base plate b again paying attention to the correct seating of the seal and the base plate b 5 Dispose of the fluid in the filter bowl Y do not refill into the hydraulic tank Maintenance Summary 4 000 Operating hours 85 Maintenance Inst...

Page 92: ...s with retained particle sizes described in the fluid plans must be used Example Filter Z Clean filter bowl Y and insert a new filter Z Reinstall the filter bowl Y and tighten by hand until it stops Then back off the filter bowl Y 1 8 turn 7 To fill in new hydraulic fluid use a pump with a min 10 µm micro filter that is exclusively used for hydraulic fluid 8 Fill in the prescribed amount of new hy...

Page 93: ...c fluid level 11 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 87 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 94: ...Maintenance Summary 4 000 Operating hours 88 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 95: ...Service Interval 8 000 Operating hours Service Interval 8 000 Operating hours 89 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 96: ...nce activities carried out by using the appropriate maintenance log The maintenance log has the document number DIE079EN 05 06 2019 E030 Check and clean the INDEX tool magazine for 6 tools Maintenance Summary 8 000 Operating hours 90 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 97: ... for 6 tools 1 1 Tool magazine 2 Tool mounting 3 Clamping spring 4 Cleaning nozzles Procedure 1 Tool magazine for 6 tools 2 2 Tool mounting 3 Clamping spring c Radial fixation x HSK A40 tool Using a tool x check the function of the tool mounting a Firmly push and rotate the tool into the tool mounting until it rests against the radial fixation c If the tool x is no longer fixed correctly and no lo...

Page 98: ...2 After removal of the tool the tool mounting should close again by spring force Maintenance Summary 8 000 Operating hours 92 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 99: ...Service Interval 5 Years Service Interval 5 Years 93 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 100: ...e maintenance activities carried out by using the appropriate maintenance log The maintenance log has the document number DIE079EN 05 06 2019 I020 Replace the pressure accumulator Maintenance Summary 5 Years 94 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 101: ...tor 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 accu...

Page 102: ...2 Example Pressure accumulator Connect and secure the pressure accumulator Observe the tightening torque Maintenance Summary 5 Years 96 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 103: ...Service Interval 8 Years Service Interval 8 Years 97 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 104: ...the maintenance activities carried out by using the appropriate maintenance log The maintenance log has the document number DIE079EN 05 06 2019 J150 Replacing the viewing glass Maintenance Summary 8 Years 98 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 105: ...y the center pane m is essential for the impact resistance of the viewing glass The polycarbonate pane is subject to natural aging and must therefore be replaced at regular intervals After replacing the inner viewing glass and after the installation activities are complete the glass it must be sealed on the inside of the work area door S It is necessary to provide a suitable sealant The sealant Te...

Page 106: ...rews M6 along the contour on both sides and remove Fig 03_1 Remove front cover pane carefully place aside and secure against tipping over 2 Example G200 2_Arbeitsraumtuere_06 Cut the silicone sealing S on the inside of the viewing glass see Fig _06 with suitable knife Maintenance Summary 8 Years 100 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 107: ...ling and fastening the clamp frame with screws Example G200 2_Arbeitsraumtuere_07 Remove the clamping frame x of the glass package Loosen and remove all screws from the clamping frame see Fig_07 4 Example G200 2_Arbeitsraumtuere_04 Remove the clamping frame x and glass package y See Fig _04 Maintenance Summary 8 Years 101 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 108: ...installation when mounting the clamping frame into the work area door Example G200 2_Arbeitsraumtuere_07 Reinstall the glass package and clamping frame After installation tighten all screws Fig _07 to the prescribed torque 7 Example G200 2_Arbeitsraumtuere_06 Maintenance Summary 8 Years 102 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 109: ...ealant S again 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 See Fig _06 Maintenance Summary 8 Years 103 Maintenance Instructions G200 2 DIE078EN 05 06 2019 ...

Page 110: ...INDEX Werke GmbH Co KG Hahn Tessky Plochinger Str 92 D 73730 Esslingen Germany Fon 49 711 3191 0 Fax 49 711 3191 587 info index werke de www index werke de ...

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