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Maintenance Summary - Care activities

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

maintenance log. The maintenance log has the document number DIE148EN - 17.08.2022.

The maintenance interval is highly dependent on the production and environmental conditions of the

machine. The determination of the appropriate interval must be made by the operator.

The maintenance interval should be between once per shift and once a week!

A010

 - Check the work area door and window pane

A024

 - Check hydraulic system (visual inspection)

A027

 - Replace the breathing filter at the filler neck of the hydraulic fluid tank.

A042

 - Check pneumatic system (visual inspection)

A049

 - Check the lubrication system (visual inspection)

A065

 - Lubricate turret steady rest SR2 or SLU X1 (by SMW)

A075

 - Check 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

A103

 - Clean cooling lubricant outlet on clamping cylinder

A120

 - Check cooling lubricant (visual inspection)

A126

 - Check the cooling unit and the coolant

A132

 - Check work area light (visual inspection)

A140

 - Check HSK clamping set and, if necessary, lubricate (Ott-Jakob)

A145

 - Maintenance of HSK clamping sets (from Berg)

A180

 - Clean the work area

A215

 - Check slat/shingle cover on the telescopes (visual inspection)

A255

 - Clean the chip conveyor

Maintenance Summary - Care activities

6

Maintenance Instructions

G300.2 G320.2 G400.2 G420 G500.2 G520

DIE147EN - 17.08.2022

Summary of Contents for G300.2

Page 1: ...Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 OPERATING INSTRUCTIONS Maintenance Instructions DIE147EN 17 08 2022 2022 08 17 Sp Wartungsanleitung 20112710 ...

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: ... Check electrical lines visual inspection 25 A095 Visual inspection of all fluid lines and electrical cables 26 A103 Clean cooling lubricant outlet on clamping cylinder 27 A120 Check cooling lubricant visual inspection 28 A126 Check the cooling unit and the coolant 30 A132 Check work area light visual inspection 34 A140 Check HSK clamping set and if necessary lubricate Ott Jakob 35 A145 Maintenanc...

Page 4: ...heck outer wipers of linear guides 67 C080 Check all electrical connections and drive belts of the drive motors 68 C095 Check slat shingle cover on the telescopes visual inspection 70 C130 Replace filter on air conditioner cooling fan 74 C140 Check cooling unit for cooling lubricant 75 C165 Check coolant 76 C190 Clean labyrinth rings of spindles 78 C510 Check backup data carrier 79 C525 Check cont...

Page 5: ...cing hydraulic fluid 117 D500 Perform data backup 120 D520 Check control cabinet and cable assemblies visual inspection 121 D570 Maintenance of turret steady rest SR2 or SLU X1 by SMW 123 Service Interval 8 000 Operating hours 125 Maintenance Summary 8 000 Operating hours 126 E010 Wassermann tool change system 127 E060 Maintenance of turret steady rest SR2 or SLU X1 by SMW 128 Service Interval 5 Y...

Page 6: ...Table of contents IV Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 7: ...roller iXpanel Depending on the respective machine type and the different controller types a corresponding message is issued on the controller when a maintenance interval is reached The maintenance instructions stored on the respective controller provide information maintenance log explaining the service and maintenance activities to be performed Cleaning of the machine Do not clean the machine wi...

Page 8: ...ets of the respective manufacturers and the information in the document Notes on Operating Materials Pressure accumulators 1 L Pressure accumulators with a volume of 1 L are not subject to testing and labeling according to the current issue of the pressure equipment directive The guidelines and regulations applicable in the country of use must be followed Safety Instructions Safety Instructions an...

Page 9: ...ne parts suitable lifting gears and a variety of tools must be used Removed machine parts must be placed in a safe position and secured against falling over 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 devices must be used Any n...

Page 10: ...egulations of the country of use with regard to the use of hydraulic hoses We recommend inspection and documentation of the hydraulic hose lines installed inside the machine and not directly visible every 12 months For hydraulic hose lines visible in the work area or mounted outside the machine and connecting components to the machine we recommend inspection and documentation every 6 months For th...

Page 11: ...Service Interval Care activities Service Interval Care activities 5 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 12: ...m visual inspection A049 Check the lubrication system visual inspection A065 Lubricate turret steady rest SR2 or SLU X1 by SMW A075 Check 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 A103 Clean cooling lubricant outlet on clamping cylinder A120 Check cooling lubr...

Page 13: ...rated even further If the window pane is damaged it must be replaced This is necessary regardless of the extent of damage Even with minimal damage the impact resistance of the pane 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 soiling or chip...

Page 14: ...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 work area door Maintenance Summary Care activities 8 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 15: ...ent Notes on Operating Materials must be observed Example Hydraulic unit G420 a Filler neck hydraulic fluid b Fill level indicator c Accumulator drain valve d Monitoring level and temperature e Oil drain plug f Electrical monitoring contamination indicator g Pressure gauge system pressure h Pressure accumulator i Safety valve j Electrical monitoring system pressure k Drain hose for hydraulic unit ...

Page 16: ...termine 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 value to be checked here is specified see hydraulic diagram and should be between 70 80 bar 4 Check supply and fluid lines damage and leakage Supply and fluid lines must be checked for damage Pre da...

Page 17: ...ive manufacturer s documentation Filters are hazardous waste and must be disposed of in a controlled manner Requirement It is essential to keep the filter described here in stock It is not permitted to owner the machine without this filling and breathing filter Use only the original filters according to the spare or wear parts list Only filters with retained particle sizes described in the fluid p...

Page 18: ...ng and breathing filters of hydraulic and lubrication systems by ARGO HYTOS GmbH Replace breathing filter Maintenance Summary Care activities 12 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 19: ...ive 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 X System maintenance unit 1 Switch on valve manual 2 Pressure regulating valve with filter system pressure 6 bar 3 Pressure gauge for system pressure 4 Filter insert filter fineness 40 µm 5 Filter ...

Page 20: ...te drain 14 Microfilter insert filter fineness 1 µm 15 Filter with automatic condensate drain 16 Microfilter insert filter fineness 0 01 µm 17 Filter 18 Activated carbon filter no automatic condensate drain 19 Pressure regulating valve with pressure sensor for glass scales sealing air 1 0 bar 20 Display Maintenance Summary Care activities 14 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 ...

Page 21: ...zardous waste and must be disposed of in a controlled manner Requirement Service and maintenance are to be carried out according to the manufacturer s specifications Procedure 1 Check pressure setting on pressure gauge and adjust if necessary An operating pressure of 6 bar has been set at the factory Maintenance Summary Care activities 15 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G...

Page 22: ...by FESTO X Filter base housing Y Filter bowl 1 Sealing ring 2 Activated carbon filter cartridge 3 O ring Check activated carbon filter replace if necessary When disassembling the filter bowl make sure that sealing rings and O rings 1 3 are also installed Unscrew filter bowl Y from filter base X and remove activated carbon filter cartridge 2 Check sealing rings and O rings 1 3 replace if necessary ...

Page 23: ...essary When removing the filter bowl be sure to include the O ring 5 separating disk 2 and filter receptacle 4 Unscrew filter bowl 1 from filter base body and remove filter cartridge 3 check and replace if necessary Check O ring 5 replace if necessary Reinstall all parts in reverse order Maintenance Summary Care activities 17 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN ...

Page 24: ... be sure to review the respective manufacturer s documentation Example Lubrication system G420 The following components must be checked on the lubrication system a Filler neck b Pressure gauge for system pressure 20 bar Procedure 1 Check oil level 2 Check pressure setting on pressure gauge 20 bar Maintenance Summary Care activities 18 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 ...

Page 25: ...mentation must be carried out as part of maintenance activities Example Turret_Steady_Rest_SMW_SR2 X Lubrication points Procedure 1 Service and maintenance are to be carried out according to the manufacturer s specifications The turret steady rest type SR2 or SLU X1 used here should be lubricated daily at the points described in accordance with SMW s maintenance instructions Maintenance Summary Ca...

Page 26: ... near the 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...

Page 27: ...k b Base plate of hydraulic system c Fill level check 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 21 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 28: ...ll X Fill level indicator Check the fill level at the cooling lubricant reconditioning system option 5 Check fill level of the coolant tank option Maintenance Summary Care activities 22 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 29: ...o 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 cleaning with cotton...

Page 30: ...rer 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 24 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 31: ...ric 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 removal unit 5 Electrical leads for the pedal switches 6 Check electrical lines of...

Page 32: ...ds 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 Procedure 1 Visual insp...

Page 33: ... be cleaned at regular intervals Procedure 1 Disassemble the machine enclosure in the area ofthe spindles 2 Example Cooling lubricant outlet G420 Remove cover X on cooling lubricant tank 3 Clean cooling lubricant tank and drain hose Y 4 For assembly follow the steps in reverse order Ensure proper cleanliness during the installation Maintenance Summary Care activities 27 Maintenance Instructions G3...

Page 34: ...se 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 lubricant emuls...

Page 35: ...d 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 29 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 36: ...art of the servicing and maintenance activities Check for leaks on the system in general as well as at screw connections and supply and fluid lines This visual inspection or monitoring requires no specific knowledge of refrigeration according to the manufacturer s documentation These activities can be carried out by instructed individuals with appropriate expertise Due to different requirements an...

Page 37: ...opcock d PID controller for 35 water glycol mixture e PID controller for hydraulic fluid HLPD 32 f Filler neck g Sight glass fill level indicator h Level switch i Drain plug for tank drainage Maintenance Summary Care activities 31 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 38: ...d 8 Make sure that a concentration of FSK35 35 glycol is used in machines 1 4 From Machine 5 a concentration of Antifrogen N 34 glycol 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 Replenish only coolant of the same manufacturer havi...

Page 39: ...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 review the respective manufacturer s documentat...

Page 40: ... to follow the manufacturer s documentation According to the manufacturer this lighting fixture is maintenance free Procedure 1 Example Work lamp Waldmann_ MACH_LED_PRO_MUEL_4S 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 Summary C...

Page 41: ...s on the tool carrier as well as regular inspection of various wear parts such as O rings or the like on the HSK clamping set Due to different requirements and or specifications of the respective manufacturers be sure to review the respective manufacturer s documentation Example Clamping sets from Ott Jakob When ordering spare parts always note the make manufacturer and or design latching or non l...

Page 42: ...oved ring 2 in clamping taper 2 Replace grooved ring if necessary 3 Check collet according to the manufacturer s instructions Here check in particular the level of pollution clean if necessary and that sufficient lubrication is present relubricate If necessary Relubricate only after cleaning 4 Degreasing of the collets may cause technical problems Possible causes A faulty seal in the clamping tape...

Page 43: ...clamping set Due to different requirements and or specifications of the respective manufacturers be sure to review the respective manufacturer s documentation When ordering spare parts always note the make manufacturer and or design latching or non latching of the parts currently installed The use of tools with shank ISO 12164 1 version before 2001 or DIN 69893 1 version before 2003 HSK A can caus...

Page 44: ...rly 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 by spaying...

Page 45: ...es must only be carried out by staff that has received adequate training by the machine manufacturer Orientation The telescopic plates are additionally fitted with a slat shingle cover View of tool carrier 1 Example General view of slat shingle cover STRAPANO Arnold G420 Maintenance Summary Care activities 39 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 46: ...slider and the holder Procedure 1 Check the overall condition of the substrate Assess wear If individual parts such as sliders holders or carrier material are destroyed it is imperative that they be replaced 2 Caution Cutting injury due to sharp edged sheet metal parts Always wear suitable protective gloves Maintenance Summary Care activities 40 Maintenance Instructions G300 2 G320 2 G400 2 G420 G...

Page 47: ... mounting on the bellows join both parts together and observe the direction of the arrow Example Holder two piece STRAPANO by Arnold Maintenance Summary Care activities 41 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 48: ...Example Mounting of holders STRAPANO Arnold company Check holder 3 Check slider Maintenance Summary Care activities 42 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 49: ...rials 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 the chip conveyor i...

Page 50: ...iner basket on the cooling lubricant pump must be cleaned Remove cooling lubricant pump Remove and clean strainer 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 44 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE...

Page 51: ...Service Interval 1 000 Operating hours Service Interval 1 000 Operating hours 45 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 52: ...tenance activities carried out by using the appropriate maintenance log The maintenance log has the document number DIE148EN 17 08 2022 B010 Customer area Maintenance Summary 1 000 Operating hours 46 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 53: ... cooling lubricant Maintenance contents from the user documentation of additionally purchased peripheral devices that were not obtained from INDEX can also be transferred to this area The procedure for creating your own individual maintenance intervals contents is described in the iXpanel document This document is both the contents of the user documentation in paper form and can be found on the su...

Page 54: ...Maintenance Summary 1 000 Operating hours 48 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 55: ...Service Interval 2 000 Operating hours Service Interval 2 000 Operating hours 49 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 56: ...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 C095 Check slat shingle cover on the telescopes visual inspection C130 Replace filter on air conditioner cooling fan C140 Check cooling unit for cooling lubricant C165 Check coolant C190 Clean labyrinth rings of spindles C510 Chec...

Page 57: ... 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 51 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G5...

Page 58: ...effort it can be expected that the wipers are already destroyed by accumulation of chips and swarf compaction Requirement Example Chip hook and chip brush Use appropriate tools to remove coarse chips chip nests and other debris Procedure 1 Example Removing chip nest using appropriate tools e g chip hooks Maintenance Summary 2 000 Operating hours 52 Maintenance Instructions G300 2 G320 2 G400 2 G42...

Page 59: ...ng chip brooms or brushes Remove small chips and chip accumulations on the inside of the work area door from top to bottom Use a chip brush for this purpose 3 Make sure that the wipers evenly contact the work area door before tightening the screws Maintenance Summary 2 000 Operating hours 53 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 60: ...sociated cover plates should at any rate be completely removed and cleaned In this case also clean the area behind the wipers 4 Check the wipers for proper seating After the work area door has been cleaned it should open and close again without much effort as usual Maintenance Summary 2 000 Operating hours 54 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 61: ...lubricant the aging process is accelerated even further If the window pane is damaged it must be replaced This is necessary regardless of the extent of damage Even with minimal damage the impact resistance of the pane 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 considerabl...

Page 62: ... 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 clean the door panels evenly be sure to reinstall the wipers after their removal aligned in parallel and ensure that they snugly contact the work area door 6 Example View of the a...

Page 63: ...e test should only be carried out with a suitable aid such as a rectangular strip or a softwood squared timber INDEX recommends documenting the results of the inspection and keeping them at the workplace The machine must be switched on and fully functional for this test Example Checking the obstacle detection Check obstacle detection of the automatic work area door During the obstacle detection te...

Page 64: ...NDEX service department or an INDEX representative 9 Example View of the automatic work area door G420 with drive 1 Drive deflection pulley 2 Belt 3 Driver 4 Deflection 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 S...

Page 65: ...ell as regular inspection of various wear parts such as O rings or the like on the HSK clamping set Due to different requirements and or specifications of the respective manufacturers be sure to review the respective manufacturer s documentation Example Clamping sets from Ott Jakob When ordering spare parts always note the make manufacturer and or design latching or non latching of the parts curre...

Page 66: ...urer Check the retraction force If the retraction force is less than 70 of the nominal value take the following measures in the order given Regrease and recheck retraction force replace collet and recheck completely replace tool clamp 3 Example HSK clamping set 1 Brass ring 2 Grooved ring 3 O ring 4 O ring Check grooved ring 2 in clamping taper 4 Remove and check clamping set Remove clamping set c...

Page 67: ...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 F min Table for testing the clamping force of clamping systems F1 nominal clamping force in kN manufacturer data F...

Page 68: ...e clamping set or failure of the entire clamping system Requirement A measuring device required to measure the clamping force can be sourced through INDEX a representative or the tool manufacturer Example Clamping force measuring system from Berg Maintenance Summary 2 000 Operating hours 62 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 69: ...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 63 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 70: ...r 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 the pipe approx...

Page 71: ...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 65 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 72: ... 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 machine and secu...

Page 73: ...ed 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 lacerations Switch off...

Page 74: ...equirement 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 and leaks 2 If ...

Page 75: ...king reconnect plugs and tighten with special pliers see the example 3 Check belt on drive motors for any damage or wear Maintenance Summary 2 000 Operating hours 69 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 76: ...must only be carried out by staff that has received adequate training by the machine manufacturer Orientation The telescopic plates are additionally fitted with a slat shingle cover View of tool carrier 1 Example General view of slat shingle cover STRAPANO Arnold G420 Maintenance Summary 2 000 Operating hours 70 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 77: ...der and the holder Procedure 1 Check the overall condition of the substrate Assess wear If individual parts such as sliders holders or carrier material are destroyed it is imperative that they be replaced 2 Caution Cutting injury due to sharp edged sheet metal parts Always wear suitable protective gloves Maintenance Summary 2 000 Operating hours 71 Maintenance Instructions G300 2 G320 2 G400 2 G42...

Page 78: ...unting on the bellows join both parts together and observe the direction of the arrow Example Holder two piece STRAPANO by Arnold Maintenance Summary 2 000 Operating hours 72 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 79: ...mple Mounting of holders STRAPANO Arnold company Check holder 3 Check slider Maintenance Summary 2 000 Operating hours 73 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 80: ...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 74 Maintenance Instructions...

Page 81: ... 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 concentration of cooling l...

Page 82: ...ocument 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 incompatibility and degradation of the coolant Required glycol concentration min 34 35 When switching the coolant to another product or changing the manufacturer the cooling system must ...

Page 83: ...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 77 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 84: ...ed dirt particles or chips may reach spots where they cause technical problems Do not use cotton waste for cleaning When cleaning with cotton waste fibers or thread can get loose causing safety problems 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...

Page 85: ... 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 message the data ca...

Page 86: ...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 bus for tight se...

Page 87: ...in a certain position Loose or faulty clamps can be 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 f...

Page 88: ...lief Check the correct position of the boots and adjust the strain reliefs 4 Record any damages and initiate repair Maintenance Summary 2 000 Operating hours 82 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 89: ...laced 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 container shou...

Page 90: ... 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 84 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 91: ...w 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 85 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 92: ...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 86 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 93: ...manufacturers be sure to review the respective manufacturer s documentation Procedure 1 Example Turret_Steady_Rest_SMW_SR2 X Lubrication points Perform 2000 h maintenance according to the manufacturer s documentation Maintenance Summary 2 000 Operating hours 87 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 94: ...Maintenance Summary 2 000 Operating hours 88 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 95: ...Service Interval 4 000 Operating hours Service Interval 4 000 Operating hours 89 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 96: ...clamping sets of the milling spindles D087 Check main and counter spindles D105 Wassermann tool change system D110 Check hydraulic system D170 Check the system for reconditioning the cooling lubricant D180 Check fire extinguishing system visual inspection D220 Replace belts and check belt tension D458 Replacing hydraulic fluid D500 Perform data backup D520 Check control cabinet and cable assemblie...

Page 97: ...ularly 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 by spay...

Page 98: ...nufacturer 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 base 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 lubricant in the...

Page 99: ...ion of chips at this point This can lead to malfunction and damage to the work area door Procedure 1 Example Fig a G220 G420 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 Example Fig c G220 G420 Maintenance Summary 4 000 Operating hours 93 Maintenance I...

Page 100: ... 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 Example Fig b G220 G420 Then replace the cover Figure b and reinstall and adjust the wipers that may have been removed Maintenance Summary 4 000 Operating hours 9...

Page 101: ...ews on the hydraulic system the connected components and the supply lines must be tightened to the manufacturer s specified torques Procedure 1 Check the pressure accumulator With the machine powered on not during the program or continuous run slowly open the accumulator drain valve on the hydraulic fluid tank and watch the needle on the system pressure gauge The pressure gauge needle slowly falls...

Page 102: ...orm a visual inspection of all components involved in lubrication for leaks and their visual condition The following components must be examined during maintenance of the lubricating oil system Lubricating oil tank Oil level in lubricating oil tank Lubricating oil pump Supply and fluid lines Pressure gauges Metering valves Pressure sensors For all work in connection with operating materials the in...

Page 103: ...rer s specifications Procedure 1 Danger Pressurized fluids exiting from damaged or incorrectly installed fluid lines General cuts or eye injuries Power off the machine and depressurize the hydraulic system before any maintenance activities Secure the machine against being switched on Wear personal protective equipment Check supply and fluid lines damage and leakage Supply and fluid lines must be c...

Page 104: ...ive 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 X System maintenance unit 1 Switch on valve manual 2 Pressure regulating valve with filter system pressure 6 bar 3 Pressure gauge for system pressure 4 Filter insert filter fineness 40 µm 5 Filter ...

Page 105: ...drain 14 Microfilter insert filter fineness 1 µm 15 Filter with automatic condensate drain 16 Microfilter insert filter fineness 0 01 µm 17 Filter 18 Activated carbon filter no automatic condensate drain 19 Pressure regulating valve with pressure sensor for glass scales sealing air 1 0 bar 20 Display Maintenance Summary 4 000 Operating hours 99 Maintenance Instructions G300 2 G320 2 G400 2 G420 G5...

Page 106: ...dous waste and must be disposed of in a controlled manner Requirement Service and maintenance are to be carried out according to the manufacturer s specifications Procedure 1 Check pressure setting on pressure gauge and adjust if necessary An operating pressure of 6 bar has been set at the factory Maintenance Summary 4 000 Operating hours 100 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500...

Page 107: ...ESTO X Filter base housing Y Filter bowl 1 Sealing ring 2 Activated carbon filter cartridge 3 O ring Check activated carbon filter replace if necessary When disassembling the filter bowl make sure that sealing rings and O rings 1 3 are also installed Unscrew filter bowl Y from filter base X and remove activated carbon filter cartridge 2 Check sealing rings and O rings 1 3 replace if necessary Rein...

Page 108: ...ary When removing the filter bowl be sure to include the O ring 5 separating disk 2 and filter receptacle 4 Unscrew filter bowl 1 from filter base body and remove filter cartridge 3 check and replace if necessary Check O ring 5 replace if necessary Reinstall all parts in reverse order Maintenance Summary 4 000 Operating hours 102 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE14...

Page 109: ...apto 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 F min Table for testing the clamping force of clamping systems F1 nominal clamping force in kN manufacturer data Fm...

Page 110: ...e clamping set or failure of the entire clamping system Requirement A measuring device required to measure the clamping force can be sourced through INDEX a representative or the tool manufacturer Example Clamping force measuring system from Berg Maintenance Summary 4 000 Operating hours 104 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 111: ...erformed 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 105 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 112: ...s in the area of the spindles are checked for leaks on the one hand and for the general condition of the power and encoder connections on the other Requirement The following tools and spare parts are required to carry out this maintenance 1 Sealing rings or O rings 2 Supply or fluid lines as necessary Procedure 1 Example Hollow clamping cylinder version 1 O ring 2 Rotary feeder 3 Anti twist lock M...

Page 113: ...ck Check the tightness of the depth stop flushing unit and the correct seating of the rotary feeder 2 Tightness of the solid or hollow clamping cylinder Maintenance Summary 4 000 Operating hours 107 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 114: ...s documentation Check and potentially replace O rings or other seals on the clamping devices O rings and other seals on the clamping devices prevent that chips or cooling lubricant penetrate into the hydraulic circuit or even into the mechanical components of the respective assemblies where they can cause significant damage In any case make sure that the seals recommended by the manufacturer are u...

Page 115: ...mentation 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 109 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 116: ...Operating Materials must be observed Example Hydraulic unit G420 a Filler neck hydraulic fluid b Fill level indicator c Accumulator drain valve d Monitoring level and temperature e Oil drain plug f Electrical monitoring contamination indicator g Pressure gauge system pressure h Pressure accumulator i Safety valve j Electrical monitoring system pressure k Drain hose for hydraulic unit X Hydraulic f...

Page 117: ...mine 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 value to be checked here is specified see hydraulic diagram and should be between 70 80 bar 4 Check supply and fluid lines damage and leakage Supply and fluid lines must be checked for damage Pre damag...

Page 118: ...terials 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 lubricant a measur...

Page 119: ... manufacturer Be sure to read the operating instructions of the manufacturer Procedure 1 Visual inspection for obvious defects 2 Example Inspection stickers Kraft Bauer Check sticker for manufacturing date 3 Check sticker for inspection date 4 Check sticker for battery replacement Maintenance Summary 4 000 Operating hours 113 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN ...

Page 120: ...erence 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 X2 belt 3 Replace the belt of the work area door drive M...

Page 121: ...ey belt tensioner 5 see examples of work area door drive G420 5 Example Work area door drive G420 1 Drive 2 Driver 3 Belt tensioner for measuring point M2 4 Belt tensioner for measuring point M1 5 Deflection pulley 6 Deflection pulley M1 Measuring point 181 Hz M2 Measuring point 100 110 Hz Maintenance Summary 4 000 Operating hours 115 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 ...

Page 122: ...er and the belt tensioner 3 4 the belt tension can now be set to the specified value at the marked point M1 or M2 Maintenance Summary 4 000 Operating hours 116 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 123: ... 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 th...

Page 124: ...crew the filter bell Y 4 Dispose of the fluid in the filter bell Y do not return it to the hydraulic tank Replace filters Z of the hydraulic fluid filters X A different number of hydraulic filters X may be installed depending on the version Unscrew filter bell Y remove contaminated hydraulic fluid oil sump and used filter Z from the filter bell Y and dispose of them according to environmental regu...

Page 125: ...lusively used for hydraulic fluid 7 Fill in the prescribed amount of new hydraulic fluid 8 Switch on the machine and hydraulic system 9 Check and if necessary replenish hydraulic fluid level 10 Vent hydraulic system To bleed the hydraulic system open the accumulator drain valve c for about 10 seconds and then close it again Maintenance Summary 4 000 Operating hours 119 Maintenance Instructions G30...

Page 126: ...ave been modified as part of maintenance or repair work a data backup must be performed In this case a backup of the PLC and NC archives is sufficient The data can be saved to a floppy disk or USB flash drive depending on the machine control equipment In a system recovery the backup CD DVD created when the machine was delivered is restored on the machine Afterwards the PLC and NC archive files are...

Page 127: ... and must be disposed of in accordance with environmental guidelines and regulations of the country of operation When working in or on the control cabinet switch off the machine and secure it against power on Requirement Even with the machine powered off some devices or components in the control cabinet are still energized Observe the specific electrical diagrams for this machine Procedure 1 Switc...

Page 128: ... the control cabinet and cabinet doors and between the base and the machine bed 9 Check cable assemblies for damage replace if necessary Maintenance Summary 4 000 Operating hours 122 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 129: ...anufacturers be sure to review the respective manufacturer s documentation Procedure 1 Example Turret_Steady_Rest_SMW_SR2 X Lubrication points Perform 4000 h maintenance according to the manufacturer s documentation Maintenance Summary 4 000 Operating hours 123 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 130: ...Maintenance Summary 4 000 Operating hours 124 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 131: ...Service Interval 8 000 Operating hours Service Interval 8 000 Operating hours 125 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 132: ... the appropriate maintenance log The maintenance log has the document number DIE148EN 17 08 2022 E010 Wassermann tool change system E060 Maintenance of turret steady rest SR2 or SLU X1 by SMW Maintenance Summary 8 000 Operating hours 126 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 133: ...ements 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 Summary 8 000 Oper...

Page 134: ...anufacturers be sure to review the respective manufacturer s documentation Procedure 1 Example Turret_Steady_Rest_SMW_SR2 X Lubrication points Perform 8000 h maintenance according to the manufacturer s documentation Maintenance Summary 8 000 Operating hours 128 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 135: ...Service Interval 5 Years Service Interval 5 Years 129 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 136: ...ropriate maintenance log The maintenance log has the document number DIE148EN 17 08 2022 I010 Renewing the pneumatically pilot controlled cooling lubricant valves I020 Replace the pressure accumulator Maintenance Summary 5 Years 130 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 137: ...ol lines To avoid consequential damage INDEX recommends replacing these valves after 5 years Requirement Due to different requirements and or specifications of the respective manufacturers be sure to review the respective manufacturer s documentation Power off the machine to depressurize the pneumatic system and secure against accidental switching on Procedure 1 Renew valves Maintenance Summary 5 ...

Page 138: ...s 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 accumulators must be...

Page 139: ... Pressure accumulator Connect and secure the pressure accumulator Observe the tightening torque Maintenance Summary 5 Years 133 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 140: ...Maintenance Summary 5 Years 134 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 141: ...Service Interval 8 Years Service Interval 8 Years 135 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 142: ... the appropriate maintenance log The maintenance log has the document number DIE148EN 17 08 2022 J005 Note on replacing the window pane or removing the design pane J160 Replace the window pane Maintenance Summary 8 Years 136 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 143: ...anes the inner pane of tempered glass the central pane of polycarbonate and the outer pane also made of polycarbonate The inner pane is relatively resistant It can be cleaned with any commercially available cleaning agents Only the center pane is essential for the impact resistance of the window pane The polycarbonate panes are subject to natural aging and must be replaced at regular intervals Exa...

Page 144: ...example design pane specifications have threaded bushings at the top of the design pane and are therefore crane compatible If the design pane is not removed using a crane or other lifting equipment but by hand using suction lifters it is imperative that the current Load Handling Ordinance LasthandhabV be taken into account When using suction lifters see example be sure to select the appropriate si...

Page 145: ...kg 100 kg Procedure 1 If you have questions be sure to contact the INDEX service department or an INDEX representative Maintenance Summary 8 Years 139 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 146: ...anes the inner pane i made of tempered glass the central pane m made of polycarbonate and an outer pane a made of PMMA polymethyl methacrylate 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 window pane The polycarbonate pane is subject to natural aging and must therefore...

Page 147: ...on surfaces of the suction lifters used and the corresponding areas of the design pane must be carefully cleaned beforehand Personal protective equipment Use gloves with rubberized palm inside Determine and prepare the storage location for the design pane To prevent scratching of the design pane cover the surface at the storage location with suitable tarpaulins foils felt mats or similar Under cer...

Page 148: ...ribed and lift slightly with a crane In the case of the variant shown in example 2 it is essential to secure the round slings in such a way that they cannot slip 3 It is essential to ensure that the slinging angle of the slinging ropes round slings does not fall below an angle of 60 in order to prevent diagonal pull and the associated damage to the design pane Maintenance Summary 8 Years 142 Maint...

Page 149: ...fting with a round sling 2 Lifting with short round slings and small crossbeam Procedure 1 Remove design pane preparation Apply the slings as described Maintenance Summary 8 Years 143 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 150: ...ng the contour on both sides and remove Fig _6 Lift the front cover pane with a crane secure with suitable suction lifters and remove the entire cover Carefully place aside and secure against tipping over 3 Example G420_Workarea door Fig _2 Maintenance Summary 8 Years 144 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 151: ...nerally also applies to the installation of the new pane in particular when sealing and fastening the clamping frame with screws Example G420_work area door Fig _3 Remove the clamping frame x of the glass package Loosen and remove all screws from the clamping frame see Fig_3 Maintenance Summary 8 Years 145 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 152: ... installation 7 Make sure of stress free installation when mounting the clamping frame into the work area door Example G420_work area door Fig _5 Reinstall the glass package and clamping frame After installation tighten all screws z in Fig _5 to the prescribed torque Maintenance Summary 8 Years 146 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 153: ...be sealed using a sealant Terostat 930 gray is used at the factory See Fig _2 9 G420_work area door Fig _6 Refit the front cover or front pane design pane a and screw it on again on both sides along the contour using the screws M6 11 each See Fig _6 Maintenance Summary 8 Years 147 Maintenance Instructions G300 2 G320 2 G400 2 G420 G500 2 G520 DIE147EN 17 08 2022 ...

Page 154: ...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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