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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 LR1702.10191 - 05.06.2019.

D010

- Cleaning of the machine

D020

- Check the pressure accumulator

D050

- Check the lubrication system

D060

- Check the pneumatic system

D077

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

D095

- Check main and counter spindles

D125

- Replace cooling lubricant adapter (HSK tool mountings)

D170

- Check the system for reconditioning the cooling lubricant

D180

- Check fire extinguishing system (visual inspection)

D330

- Replace belts and check belt tension

D370

- Check and potentially replace the end position dampers

D440

- Replacing hydraulic fluid

D500

- Perform data backup

D520

- Check control cabinet and cable assemblies (visual inspection)

D640

- Check setting of electrical fuses

Maintenance Summary - 4.000 Operating hours

Maintenance Instructions

R200

LR1702.10181 - 05.06.2019

Summary of Contents for R300

Page 1: ...Maintenance Instructions R200 OPERATING INSTRUCTIONS Maintenance Instructions LR1702 10181 05 06 2019 05 06 2019 Sp Wartungsanleitung 20057609 ...

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: ...tion of all fluid lines and electrical cables 20 A100 Clean cooling lubricant outlet on clamping cylinder 21 A110 Clean filter screens on chip conveyor 22 A120 Check cooling lubricant visual inspection 24 A127 Check coolant 26 A130 Check work area light visual inspection 28 A145 Maintenance of HSK clamping sets from Berg 29 A170 Clean telescopic covers and wipers 30 A180 Clean the work area 31 A26...

Page 4: ... 67 C530 Check wipers of Z axes on main and counter spindles 68 C540 Check cable and hose clamps for tight seating 70 C550 Replace hydraulic fluid filters 71 Service Interval 4 000 Operating hours 73 Maintenance Summary 4 000 Operating hours 74 D010 Cleaning of the machine 75 D020 Check the pressure accumulator 77 D050 Check the lubrication system 78 D060 Check the pneumatic system 80 D077 Check t...

Page 5: ...nce Summary 5 Years 110 I020 Replace the pressure accumulator 111 Service Interval 8 Years 113 Maintenance Summary 8 Years 114 J120 Replacing the viewing glass 115 Table of contents III Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 6: ...Table of contents IV Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 7: ...tenance 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 cotto...

Page 8: ...es 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 devi...

Page 9: ...med 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 depres...

Page 10: ...Preface 4 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 11: ...Service Interval Care activities Service Interval Care activities 5 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 12: ...oner cooling fan 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 A100 Clean cooling lubricant outlet on clamping cylinder A110 Clean filter screens on chip conveyor A120 Check cooling lubricant visual inspection A127 Check coolant A130 Check work area ...

Page 13: ... 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 solin...

Page 14: ...d 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 R200 LR1702 10181 05 06 2019 ...

Page 15: ...an 32 according to DIN ISO 3448 is not admissible 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 Example Hydraulic system ABC Screws on the hydraulic system the connected components and the supply lines must be tightened to the manufacturer s spe...

Page 16: ... 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 b...

Page 17: ... the respective manufacturers be sure to review the respective manufacturer s documentation 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 abrasion...

Page 18: ...5 Drain condensate not applicable to auto drain Maintenance Summary Care activities 12 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 19: ...the opening of the air outlet Use only the original filters according to the spare or wear parts list Otherwise the machine is at risk of sustaining serious damage due to overheating Requirement A sufficient number of filters must be available Procedure 1 Remove cover frame 2 Check the filters replace if necessary 3 Reinstall all covers Maintenance Summary Care activities 13 Maintenance Instructio...

Page 20: ... 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 operatin...

Page 21: ...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 15 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 22: ...cling 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 16 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 23: ...he 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 cleani...

Page 24: ...llow 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 18 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 25: ...l 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 elec...

Page 26: ...se 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 Proce...

Page 27: ...be cleaned at regular intervals Procedure 1 Disassemble the machine enclosure in the area ofthe spindles 2 Example Cooling lubricant outlet G160 Remove any screws X and the acrylic glass cover on the cooling lubricant tank 3 Clean cooling lubricant collection bin 4 For assembly follow the steps in reverse order Ensure proper cleanliness during the installation Maintenance Summary Care activities 2...

Page 28: ...ating 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 29: ... 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 23 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 30: ...ermine 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 l...

Page 31: ...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 25 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 32: ...300 1 External cooling unit or customer side cooling 2 Cooling of control cabinets 3 Heat exchanger 4 Spindles a Inlet flow b Return flow c Hydraulic fluid HLPD32 VG32 d Cooling oil HLP5 VG5 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 Requirem...

Page 33: ... system bar The information given in the Technical Data of the cooling water apply at an ambient temperature of max 40 C The values specified in the table must absolutely be observed Deviating from these values will not ensure sufficient cooling of the machine The maximum operating pressure must not exceed 8 bar Due to different requirements and or specifications of the respective manufacturers be...

Page 34: ...ed 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 Su...

Page 35: ...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 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 200...

Page 36: ...fter cleaning the telescopic cover 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 o...

Page 37: ... 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 38: ... Be sure to interrupt the motion of the conveyor belt by opening the work area door or switching off the chip conveyor before commencing cleaning work around the discharge chute The conveyor belt can only move when the chip conveyor is switched on and the work area door is closed Procedure 1 Clean the chip conveyor Sweep accumulated chips from the tool carriers and chip deflectors onto the chip co...

Page 39: ...ystem immersion cooler and single filter 1 Basic tank 1100 liters 2 Low pressure pump 3 High pressure pump 20 bar 4 High pressure pump 80 bar 5 Single filter for low pressure LP and high pressure HP 6 Filler neck with level switch 7 Chip conveyor Maintenance Summary Care activities 33 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 40: ...t screen at the motor side This prevents sludge deposits and chips from entering the suction area of the pump Then remove and clean the dirty screen and have it ready for the next maintenance interval 6 Remove and clean pre filters option on the cooling lubricant pump 7 If the supply of cooling lubricant is insufficient the filter basket on the cooling lubricant pump must be cleaned Remove cooling...

Page 41: ...l devices Also make sure that the beam is not reflected by a mirror or a reflective surface into the eyes of another person The NC4 is a system for non contact laser based tool measurement that enables automatic highly accurate and fast measurement of cutting tools on machining centers under normal operating conditions If a tool is moved through the laser beam the system detects the interruption o...

Page 42: ... Solvent containing cleaner Canned purified compressed air Swabs If the cover of the transmitter unit was removed the power supply must not be switched on again as in the open state hazardous class 3R laser radiation may be emitted Always clean one unit at a time to avoid mixing up the covers Procedure 1 Danger Risk of harmful laser exposure Class 3R at the transmitter s laser output opening Turn ...

Page 43: ...lar 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 wit...

Page 44: ...an the spindle covers labyrinth rings The interval depends on aforementioned influences and must be adapted to them Short intervals increase the operational safety Do not clean the machine with compressed air Raised dirt particles may cause breathing difficulty or injury especially of the sensory organs Furthermore raised dirt particles or chips may reach spots where they cause technical problems ...

Page 45: ...labyrinth ring Loosen and unscrew the screw marked Y and remove the labyrinth ring from the spindle 2 Example MFS_R200_Cleaning_003 Clean the labyrinth ring Clean the free space behind the labyrinth ring by hand with a cloth Maintenance Summary Care activities 39 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 46: ...3 Example MFS_R200_Cleaning_002 Reinstall the labyrinth ring and tighten screw Y to the proper torque Maintenance Summary Care activities 40 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 47: ...Service Interval 2 000 Operating hours Service Interval 2 000 Operating hours 41 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 48: ...g and potentially replacing the cooling lubricant adapter HSK tool mountings C065 Check telescopic covers and wipers C075 Check outer wipers of roller guides C080 Check all electrical connections and drive belts of the drive motors C130 Replace filter on air conditioner cooling fan C140 Check cooling unit for cooling lubricant C155 Check coolant C190 Clean labyrinth rings of spindles C510 Check ba...

Page 49: ...e 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 43 Maintenance Instructions R200 LR1702 10181 05...

Page 50: ...d only with increased 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 1 Removing chip nest using appropriate tools e g chip hooks Maintenance Summary 2 000 Operating hours 44 Maintenance Instructions ...

Page 51: ...p brush for this purpose 3 Example 3 upper wipers G300 Clean wipers Alternatively the following procedure can be used In case of heavy soling or adhesion of chips to the wipers the wipers and associated cover plates should at any rate be completely removed and cleaned In this case also clean the area behind the wipers 4 Make sure that the wipers evenly contact the work area door before tightening ...

Page 52: ... again without much effort as usual 5 If cleaning or replacement of the wipers has not resulted in tangible improvement the soiled rollers and the guide rail of the work area door must also be cleaned Clean rollers and guide rail of the work area door Maintenance Summary 2 000 Operating hours 46 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 53: ...nspection 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 ar...

Page 54: ... 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 55: ...ses 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 Summary...

Page 56: ...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 50 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 57: ...n 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 51 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 58: ...om 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 Ber...

Page 59: ...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 53 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 60: ...ements 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 54 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 61: ...ssary 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 62: ... 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 56 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 63: ...lescopic 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 m...

Page 64: ... 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 lacerati...

Page 65: ...al 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 66: ... 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 60 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 67: ...f the air outlet Use only the original filters according to the spare or wear parts list Otherwise the machine is at risk of sustaining serious damage due to overheating Requirement A sufficient number of filters must be available Procedure 1 Example Filter Remove machine covers and or filter housing cover 2 Replace filter 3 Reinstall all covers Maintenance Summary 2 000 Operating hours 61 Mainten...

Page 68: ...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 concentratio...

Page 69: ...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 must...

Page 70: ...asions 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 64 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 71: ...o 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 wit...

Page 72: ...C 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 mess...

Page 73: ...tric 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 the screw caps of the fuses for tight seating 3 Check the screws of drives 611D terminals control modules connectors bus device bus and intermediate circuit bus ...

Page 74: ... wipers should contact the plates over the entire length or the entire travel of the Z axis see example This ensures that no chips or dirt can settle in the space behind the wipers Requirement Move the tool carriers to a suitable position For checking the outer wipers it may be necessary to remove parts of the machine enclosure To move to the positions in which the wipers can be checked it may be ...

Page 75: ...ates At this point the wipers of the trolleys Z axis can also be checked and replaced if necessary Screw on new wiper and lightly push against the plates underneath Then lightly oil all plates 5 Re check the function of the wiper and adjust if necessary Maintenance Summary 2 000 Operating hours 69 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 76: ... 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 r...

Page 77: ...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 78: ...rolled manner Example Filter Z Empty filter bowl Y into prepared container Do not fill fluid from the filter bowl Y back into the tank Remove filter Z 3 Clean filter bowl Y and insert a new filter Z Reinstall the filter bowl and tighten by hand until it stops Then back off the filter bowl 1 8 turn Maintenance Summary 2 000 Operating hours 72 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 79: ...Service Interval 4 000 Operating hours Service Interval 4 000 Operating hours 73 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 80: ...g spindles from Berg D095 Check main and counter spindles D125 Replace cooling lubricant adapter HSK tool mountings D170 Check the system for reconditioning the cooling lubricant D180 Check fire extinguishing system visual inspection D330 Replace belts and check belt tension D370 Check and potentially replace the end position dampers D440 Replacing hydraulic fluid D500 Perform data backup D520 Che...

Page 81: ... 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 par...

Page 82: ...s 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 l...

Page 83: ...gher loads Screws 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 needl...

Page 84: ...perating 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 w...

Page 85: ...rotective 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 Summar...

Page 86: ...ir Due to different requirements and or specifications of the respective manufacturers be sure to review the respective manufacturer s documentation Example Pneumatic maintenance unit by Festo Norgren Procedure 1 Power off the machine to depressurize the pneumatic system and secure against accidental switching on Check oil level at oiler optional 2 Check supply and fluid lines damage and leakage S...

Page 87: ...mage to the machine Check sealing air supply To protect measuring systems or other components from the ingress of liquids or dirt they are pressurized 0 6 bar In this case a low hiss is noticeable To ensure trouble free operation periodic checks of the sealing air supply are necessary 9 Check all fluid lines of the sealing air supply for damage 10 Check the pressure setting on the sealing air pres...

Page 88: ...he components and cover the opening of the fluid line with your finger A slight counter pressure should be felt Then connect the fluid line again Maintenance Summary 4 000 Operating hours 82 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 89: ...om 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 Ber...

Page 90: ...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 84 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 91: ...ements 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 85 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 92: ... and space behind the rings Clean the encoder wheels Visual inspection of the hydraulic accessory units Check aligning and indexing units clamping cylinder for leaks Check cooling lubricant and stopper unit with cooling lubricant rotary distributor Check aligning and indexing units Check O rings on the clamping devices replace if necessary Procedure 1 Remove machine enclosure in the area ofthe spi...

Page 93: ...ss of the hydraulic accessory units Check the aligning and indexing units solid or open center cylinders for leaks 6 Example Cooling lubricant rotary distributor e g from Hydronic Check cooling lubricant distributor rotary distributor Detach the cooling lubricant rotary distributor and check that cooling lubricant flows out Cooling lubricant should escape from the rotary distributor when the machi...

Page 94: ...ooling lubricant and stopper unit Loosen screws 6 and pull the cooling lubricant and stopper unit 1 out of the spindle from the back The guide ring 2 has an O ring 5 at its outside with which the spindle is sealed towards the work area and a Glyd ring 4 inside that is used to guide the cooling lubricant and stopper unit in the spindle Maintenance Summary 4 000 Operating hours 88 Maintenance Instru...

Page 95: ...hten the screws X 13 Insert guide ring 2 into the spindle from the front position it according to the setting value and retighten the screws 7 14 Screw in and tighten the bar stop 3 15 Reattach the cooling lubricant rotary distributor 16 Do not reinstall any existing screen in the draining outlet of the clamping cylinder The screen may clog to the extent that the cooling lubricant dams up so that ...

Page 96: ...tentially 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 used or installed during main...

Page 97: ...r intervals Procedure 1 Replace 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 approximately 1 mm from the cent...

Page 98: ...sure proper cleanliness during the installation 8 Example Cooling lubricant adapter After assembly check again the central position of the pipe See item 3 Maintenance Summary 4 000 Operating hours 92 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 99: ...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 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 lub...

Page 100: ...rization by the 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 94 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 101: ...he respective axis A frequency meter is required for testing Also the reference 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 po...

Page 102: ...belt tension frequency meter and adjust belt 12 Replace WZW2 belt 13 Measure belt tension frequency meter and adjust belt 14 Example Distance between guide pulley and belt clamping 1 Guide pulley at drive 2 Belt clamping Replace Z8 WHU belt The value of 600mm listed in the table refers to the distance between the center of the guide pulley on drive 1 and the center of the belt clamping of this uni...

Page 103: ...necessary to accurately adjust the belt tension 17 Measure belt tension frequency meter and adjust belt 18 Replace the belt of the work area door drive 19 Example Auto_Arbeitsraumtuer_1_R200 X Center between the drive pulley and the deflection pulley 1 Belt adjustment Measure belt tension and adjust belt The measuring point to check the belt frequency is located in the middle X between the belt pu...

Page 104: ... force of 19 N should deflect the belt by 23 mm Correct the belt tension at the belt adjustment 1 if necessary Maintenance Summary 4 000 Operating hours 98 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 105: ...ring supports of the ballscrews the following utilities and tools are needed servicing testing and maintenance schedules logs of the customer rags for cleaning various sizes of jaw and box wrenches and Allen keys Depressurize the hydraulic system by opening the accumulator drain valve e turn off the machine and prevent it from restarting Procedure 1 Check end position dampers Alternatively the fol...

Page 106: ...r 3 Remove screws and replace dampers 4 The damper has a slit on one side and can be slid over the ballscrew by rotating it 5 For assembly follow the steps in reverse order Ensure proper cleanliness during the installation Maintenance Summary 4 000 Operating hours 100 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 107: ... 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 108: ...e 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 102 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 109: ... according to environmental regulations 6 Only filters 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 hydr...

Page 110: ...ry replenish hydraulic 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 104 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 111: ...ine If machine data have 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 stick 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 ar...

Page 112: ...hazardous waste 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 Pr...

Page 113: ...ted e g between the control cabinet and cabinet doors and between the drag and the machine bed 9 Check cable assemblies for damage replace if necessary Maintenance Summary 4 000 Operating hours 107 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 114: ... has received adequate training by the machine manufacturer 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 setting of electrical fuses note this information in the electrical diagrams Maintenance Summary 4 000 Operating hours 108 Maintenance Instructions R200 LR1702 10181 05 0...

Page 115: ...Service Interval 5 Years Service Interval 5 Years 109 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 116: ...intenance activities carried out by using the appropriate maintenance log The maintenance log has the document number LR1702 10191 05 06 2019 I020 Replace the pressure accumulator Maintenance Summary 5 Years 110 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 117: ...r 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 accumu...

Page 118: ...2 Example Pressure accumulator Connect and secure the pressure accumulator Observe the tightening torque Maintenance Summary 5 Years 112 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 119: ...Service Interval 8 Years Service Interval 8 Years 113 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 120: ... maintenance activities carried out by using the appropriate maintenance log The maintenance log has the document number LR1702 10191 05 06 2019 J120 Replacing the viewing glass Maintenance Summary 8 Years 114 Maintenance Instructions R200 LR1702 10181 05 06 2019 ...

Page 121: ...tative The viewing glass consists of three panes 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 viewing glass The polycarbonate panes are subject to natural aging...

Page 122: ...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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Index R300, Operating Instructions And Maintenance Instructions

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Summary of Contents for R300

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