Index G220 Operating Instructions And Maintenance Instructions
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Index G220 Operating Instructions And Maintenance Instructions

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OPERATING INSTRUCTIONS
Maintenance Instructions
Maintenance Instructions
G220
Control C200-sl
DIE017EN - 05.06.2019
05.06.2019/Sp/Wartungsanleitung/20080649

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  • Page 1 OPERATING INSTRUCTIONS Maintenance Instructions Maintenance Instructions G220 Control C200-sl DIE017EN - 05.06.2019 05.06.2019/Sp/Wartungsanleitung/20080649...
  • Page 2 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: Table Of Contents

    A130 - Check work area light (visual inspection)....................27 A180 - Clean the work area........................... 28 A265 - Cleaning the chip conveyor........................29 A280 - Clean labyrinth ring of spindles........................31 A320 - Wassermann tool change system......................32 Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 4 Service Interval - 5 Years............................83 Maintenance Summary - 5 Years.......................... 84 I020 - Replace the pressure accumulator......................85 Service Interval - 8 Years............................87 Maintenance Summary - 8 Years.......................... 88 J140 - Replacing the viewing glass........................89 Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 5: Preface

    Cleaning with a pressure washer results in strong corrosion. Furthermore, bearings may be degreased and seals may become leaking, which can lead to safety problems. A suitable cleaning tool must be used to clean the hole in the tool mounting. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 6: Safety Instructions

    Damaged power supply and fluid lines must be replaced immediately. It may be necessary to remove or disable protective equipment to carry out repairs. Any removed protective equipment must be reinstalled immediately after finishing the repair. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 7 “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 depressurized.
  • Page 8 Preface Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 9: Service Interval - Care Activities

    Service Interval - Care activities Service Interval - Care activities Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 10: Maintenance Summary - Care Activities

    - Check the cooling unit and the coolant A130 - Check work area light (visual inspection) A180 - Clean the work area A265 - Cleaning the chip conveyor A280 - Clean labyrinth ring of spindles A320 - Wassermann tool change system Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 11: A010 - Check Work Area Door And Viewing Glass

    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 contact the work area door. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 12 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 Instructions G220 DIE017EN - 05.06.2019...

  • Page 13: A025 - Check Hydraulic System (Visual Inspection)

    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 unit G220 G420 Filler neck Heat exchanger (hydraulic unit HLP32)
  • Page 14 4. Check supply and fluid lines (damage and leakage). Supply and fluid lines must be checked for damage. Pre-damage such as kinks or abrasions should be logged and replacement should be initiated. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 15: A037 - Check Pneumatic System (Visual Inspection)

    9. Microfilter insert with retained particle size 1 µm with automatic condensate drain 10. Filter insert with retained particle size 0.01 µm with automatic condensate drain 11. Activated carbon filter no automatic condensate drain Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 16 3. Check supply and fluid lines (damage and leakage). Supply and fluid lines must be checked for damage. Pre-damage such as kinks or abrasions should be logged and replacement should be initiated. Example: Various silencer versions from FESTO Check silencers. 5. Drain condensate (not applicable to auto-drain). Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 17: A075 - Checking Fill Levels Of The Fluid Tanks

    Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's documentation! Procedure Example: Lubricating oil tank Pressure gauge (pressure lubrication) Filter insert and min./max. indicators Check fill level at lubricating oil tank. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 18 Example: Hydraulic unit C100, C200 Filler neck Base plate of hydraulic unit Level control Drain plug Accumulator drain valve Check fill level at hydraulic fluid tank. 3. Check fill level at cooling lubricant tank. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 19 Maintenance Summary - Care activities Fill level indicator at a cooling lubricant recycling system (Knoll) Fill level indicator Check the fill level at the cooling lubricant reconditioning system (option). 5. Check fill level at coolant tank (option). Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 20: A080 - Clean And Lubricate Clamping Device

    When cleaning with cotton waste, fibers or thread can get loose causing safety problems. Procedure Sharp contours on the clamping device Cuts Caution Use personal protective equipment (e.g., protective gloves) Clean clamping devices Alternatively, the following procedure can be used! Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 21 Maintenance Summary - Care activities If necessary, unmount clamping devices for cleaning (follow manufacturer’s instructions). 2. Lubricate clamping devices according to manufacturer’s instructions. 3. Clean labyrinth ring and space behind the labyrinth ring. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 22: A090 - Check Electrical Lines (Visual Inspection)

    5. Electrical leads for the pedal switches. 6. Check electrical lines of the working area light. 7. Check electrical line to sub-panel / hand-held control unit (option). 8. Check electrical lines to other optional attachments. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 23: A095 - Visual Inspection Of All Fluid Lines And Electrical Cables

    Replaced fluid lines must be tightened to the torque specified by the manufacturer. Procedure 1. Visual inspection of all supply and fluid lines. 2. Visual inspection of all electrical cables. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 24: A097 - Clean Cooling Lubricant Outlet On Clamping Cylinder

    2. If necessary, remove the acrylic glass cover on the cooling lubricant collection bin. Example: Cooling lubricant outlet B400 Clean cooling lubricant collection bin. Check that the cooling lubricant outlet X is free of chips or other debris. 4. Reinstall the acrylic glass cover, if applicable. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 25: A110 - Clean Filter Screens On Chip Conveyor

    3. Remove and clean magnetic filter plates (option). 4. Remove and clean pre-filters (option) on the cooling lubricant pump. If the supply of cooling lubricant is insufficient, the filter basket on the cooling lubricant pump must be cleaned. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 26 Remove cooling lubricant pump. Remove and clean filter basket on the cooling lubricant pump. Alternatively, the following procedure can be used! Extract cooling lubricant, remove screen directly from the cooling lubricant pump and clean it. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 27: A120 - Check Cooling Lubricant (Visual Inspection)

    Wear personal protective equipment (e.g., safety gloves and safety goggles). Remove machine enclosure in the area ofthe cooling lubricant tank. 2. Visual and olfactory inspection of the cooling lubricant. 3. Check cooling lubricant emulsion. See document Notes on Operating Materials. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 28 Maintenance Summary - Care activities 4. Check supply and fluid lines. 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 Instructions G220 DIE017EN - 05.06.2019...

  • Page 29: A124 - Check The Cooling Unit And The Coolant

    Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's documentation! Schematic of cooling system G220 G420 External cooling unit, or customer-side cooling Heat exchanger (hydraulic unit) Hydraulic unit Heat exchanger (spindles)
  • Page 30 External Machine Cooling Water Supply G220 20°C±2°K G420 10 - 20°C Technical Data of the Cooling Water Supply G220 G420 Machine Water temperature [°C] Cooling water, Qmin / Qmax [l/min] Differential pressure P and P...

  • Page 31: A130 - Check Work Area Light (Visual Inspection)

    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 Instructions G220 DIE017EN - 05.06.2019...

  • Page 32: A180 - Clean The Work Area

    3. Flush work area with cooling lubricant. 4. Wipe clean with rags. 5. Apply an oil film to bare metal plates and telescopic covers. 6. Examine any visible damage, and repair or replace, if necessary. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 33: A265 - Cleaning The Chip Conveyor

    3. Check the wipers at the discharge chute and the inlet port. 4. Visual inspection of brush-off device (option). Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 34 Only one insert screen may be present in the chip conveyor during operation. Example: G220 G420 with chip conveyor and conveyor belt Clean screens and magnetic filter plates (option). To avoid clogging of the cooling lubricant channels, the insert screen, coarse screen and the magnetic filter plate (option) should be cleaned weekly or as appropriate depending on the degree of contamination of the chip conveyor.

  • Page 35: A280 - Clean Labyrinth Ring Of Spindles

    Remove the labyrinth ring. 3. Clean the labyrinth ring. Clean the free space behind the labyrinth ring by hand with a cloth. 4. Reinstall the labyrinth ring and tighten the screws to the proper torque. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 36: A320 - Wassermann Tool Change System

    The visual inspections described in the manufacturer's documentation must be carried out as part of maintenance activities. Procedure 1. Perform visual inspections according to manufacturer's instructions. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 37: Service Interval - 2.000 Operating Hours

    Service Interval - 2.000 Operating hours Service Interval - 2.000 Operating hours Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 38: Maintenance Summary - 2.000 Operating Hours

    C155 - Check coolant C190 - Clean labyrinth rings of spindles C510 - Check backup data carrier C525 - Check control cabinet C555 - Replace hydraulic fluid filters C570 - Wassermann tool change system Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 39: C010 - Check Maintenance Logs Of Servicing 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 Instructions G220 DIE017EN - 05.06.2019...

  • Page 40: C035 - Check Work Area Door (Optionally With Electr. Drive) And Viewing Glass

    Be sure that the wipers have been checked before testing the automatic work area door. Be sure to remove any chip nests and make sure that the wipers have been cleaned and attached to the plates. Procedure 1. Check viewing glass for damage. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 41 Year of manufacture Protection class and EN standard Manufacturer 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 contact the work area door.
  • Page 42 Danger 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 Instructions G220 DIE017EN - 05.06.2019...
  • Page 43 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 Instructions G220 DIE017EN - 05.06.2019...
  • Page 44 Maintenance Summary - 2.000 Operating hours Example: View of the automatic work area door G220 with drive Drive/deflection pulley Belt Driver 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).

  • Page 45: C047 - Check Tool Clamping Sets Of The Milling Spindles (From Berg)

    = nominal clamping force in kN (manufacturer data) = manufacturer recommendation in kN The values for F listed in the table are based on DIN 69063-1 for HSK and ISO 26623-2 for PSC - CAPTO Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 46 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 Instructions G220 DIE017EN - 05.06.2019...
  • Page 47 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 Instructions G220 DIE017EN - 05.06.2019...

  • Page 48: C050 - Checking And Potentially Replacing The Cooling Lubricant Adapter (Hsk Tool Mountings)

    Clean the tool including the HSK tool mounting before the removal. 5. Loosen and remove groove nuts (1) inside the HSK tool mounting (4) using the supplied special tool. 6. Remove cooling lubricant pipe (2) and replace O-ring (3). Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 49 Maintenance Summary - 2.000 Operating hours 7. For assembly, follow the steps in reverse order. Ensure proper cleanliness during the installation. After assembly, check again the central position of the pipe. See item 3. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 50: C065 - Check Telescopic Covers And Wipers

    4. Switch the machine on and move the tool slides until an even film of oil is visible over the whole travel range of the telescopic cover. If relubrication is required, first stop the traversing motion and set feed rate override to “zero” position. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 51: C070 - Check Outer Wipers Of Linear Guides

    4. Replace wipers. Loosen and remove the mounting screws of the wiper on the trolley. Push the wiper from the guide bar. Clean the guide bar and push a new wiper onto the guide bar. Finally lightly oil the guideway. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 52: C080 - Check All Electrical Connections And Drive Belts Of The Drive Motors

    1. Loosen connector and check for corrosion and leaks. If traces of corrosion or moisture are visible, they must be eliminated and their causes must be determined. If the connectors cannot be cleaned, they must be replaced. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 53 Maintenance Summary - 2.000 Operating hours Example: Tighten motor connector When done checking, reconnect plugs and tighten with special pliers (see the example). 3. Check belt on drive motors for any damage or deterioration. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 54: C130 - Replace Filter On Air Conditioner Cooling Fan

    Otherwise the machine is at risk of sustaining serious damage due to overheating. Requirement A sufficient number of filters must be available. Procedure Example: Filter Remove machine covers and/or filter housing cover. 2. Replace filter. 3. Reinstall all covers. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 55: C140 - Check Cooling Unit For Cooling Lubricant

    4. Check flow rate sensor and record current values. 5. If necessary, readjust flow rate sensor and record new values. 6. Check temperature sensors/thermostats and record current settings. 7. If necessary, readjust temperature sensors/thermostats and record new values. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 56: C155 - Check Coolant

    The machine is filled with Nalco VARIDOS FSK25 at the factory. This water-glycol mixture can be ordered in 25 kg pack sizes from INDEX. When using a water recooler, be sure to follow the manufacturer’s instructions.
  • Page 57 2. Check supply and fluid lines for damage such as buckling and abrasions, 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 Instructions G220 DIE017EN - 05.06.2019...

  • Page 58: C190 - Clean Labyrinth Rings Of Spindles

    Remove the labyrinth ring. 3. Clean the labyrinth ring. Clean the free space behind the labyrinth ring by hand with a cloth. 4. Reinstall the labyrinth ring and tighten the screws to the proper torque. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 59: C510 - Check Backup Data Carrier

    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 carrier is fine. 4. Delete the folder on your hard disk. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 60: C525 - Check Control Cabinet

    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 seating. 3. Clean suction port(s). 4. Check door seals. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 61: C555 - Replace Hydraulic Fluid Filters

    A suitable container should be ready for the disposal of the filter and the residual oil in the filter bowl. Procedure Power off the machine, depressurize the hydraulic system by opening the accumulator relief valve(s), and protect against accidental power on. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 62 Maintenance Summary - 2.000 Operating hours Example: Hydraulic fluid filter G220 G420 Accumulator drain valve Hydraulic filter Filter bowl Using a wrench, loosen the filter bowl (Y) and remove it from the filter unit (X). Filters are hazardous waste and must be disposed of in a controlled manner.
  • Page 63 Maintenance Summary - 2.000 Operating hours 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 Instructions G220 DIE017EN - 05.06.2019...

  • Page 64: C570 - Wassermann Tool Change System

    - Wassermann tool change system Orientation Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's documentation! Procedure 1. Perform 2000 h maintenance according to the manufacturer's documentation. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 65: Service Interval - 4.000 Operating Hours

    Service Interval - 4.000 Operating hours Service Interval - 4.000 Operating hours Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 66: Maintenance Summary - 4.000 Operating Hours

    - Check the pneumatic system D105 - Wassermann tool change system D170 - Check the system for reconditioning the cooling lubricant D335 - Replace belts and check belt tension D450 - Replacing hydraulic fluid Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 67: D015 - Clean Cover In The Area Of The Work Area Door

    This can lead to malfunction and damage to the work area door. Procedure Fig.: G220 G420 chips a After opening the work area door and turn off the hydraulic system, loosen and remove the screws (X) marked in Figure (a). It may be necessary to loosen and remove the screws of the wipers as well.
  • Page 68 The cover is part of the machine enclosure and serves also as protection in case of a fire, in particular in case of deflagration or to minimize exit of flames. Fig.: G220 G420 chips b Then replace the cover (b) and reinstall and adjust the wipers that may have been removed.

  • Page 69: D050 - Check The Lubrication System

    Oil type, specification and quantity as specified in the technical data. Use only the original filters according to the spare or wear parts list! Service and maintenance are to be carried out according to the manufacturer’s specifications. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 70 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 Instructions G220 DIE017EN - 05.06.2019...

  • Page 71: D055 - Check The Pneumatic System

    Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's documentation! Example: G220 Pneumatic maintenance unit by Festo The following components are used on the system maintenance unit (X) and the extension for sealing air on the glass scales (Y): 1.
  • Page 72 7. Check the pressure setting on the system pressure gauge and adjust if necessary. A pressure of 6 bar has been set at the factory. Dirty measuring systems or lack of sealing air can cause damage to the machine. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 73 Disconnect the fluid line in the area of the 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 Instructions G220 DIE017EN - 05.06.2019...

  • Page 74: D105 - Wassermann Tool Change System

    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 Instructions G220 DIE017EN - 05.06.2019...

  • Page 75: D170 - Check The System For Reconditioning The Cooling Lubricant

    Filters are hazardous waste and must be disposed of in a controlled manner. Replace filter. 4. Check and potentially adjust float switch settings. 5. Check and potentially adjust temperature sensor settings. 6. Check and potentially adjust pressure sensor settings. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 76: D335 - Replace Belts And Check Belt Tension

    Secure all axes or components against uncontrolled movements during maintenance or repair work. Move the tool slides to a suitable position. 2. Replace Z1 belt. 3. Measure belt tension (frequency meter) and adjust belt. 4. Replace Z2 belt. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 77 This value or distance is necessary to accurately adjust the belt tension. 11. Measure belt tension (frequency meter) and adjust belt. 12. Replace the belt of the work area door drive. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 78 Measuring point for frequency meter Adjust belt tension. Using a frequency meter and the belt tensioner (3) , the belt tension can now be set to 100 Hz at the marked poin t M. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 79: D450 - Replacing Hydraulic Fluid

    1. Suction off old fluid through the filler neck (a) or drain the fluid from the drain plug (d) below the fill-level glass (c). Use a suitable collection bin for this purpose. Use only lint-free cleaning cloths or a sponge! Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 80 Maintenance Summary - 4.000 Operating hours Example: Hydraulic unit G220 G420 Filler neck Heat exchanger (hydraulic unit HLP32) Heat exchanger (spindle unit HLP5 (VG5)) Fill level indicator Monitoring (level and temperature) Accumulator drain valve Monitoring (system pressure) Shut-off valve (cooling - water side)
  • Page 81 Maintenance Summary - 4.000 Operating hours Hydraulic fluid filter G220 G420 Accumulator drain valve Hydraulic fluid filter Filter bowl Replace the filters (Z) of the hydraulic fluid filters (X). A different number of hydraulic fluid filters (X) may be installed, depending on the version. Unscrew...
  • Page 82 7. Switch on the machine and hydraulic system. 8. Check and, if necessary, replenish hydraulic fluid level. 9. Vent hydraulic system. To bleed the hydraulic system, open the accumulator drain valve (s) for about 10 seconds and then close it again. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 83: Service Interval - 8.000 Operating Hours

    Service Interval - 8.000 Operating hours Service Interval - 8.000 Operating hours Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 84: Maintenance Summary - 8.000 Operating Hours

    Maintenance Summary - 8.000 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 DIE018EN - 05.06.2019. E010 - Wassermann tool change system Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 85: E010 - Wassermann Tool Change System

    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 Instructions G220 DIE017EN - 05.06.2019...
  • Page 86 Maintenance Summary - 8.000 Operating hours Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 87: Service Interval - 5 Years

    Service Interval - 5 Years Service Interval - 5 Years Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 88: Maintenance Summary - 5 Years

    Maintenance Summary - 5 Years It is recommended to document the maintenance activities carried out by using the appropriate maintenance log. The maintenance log has the document number DIE018EN - 05.06.2019. I020 - Replace the pressure accumulator Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 89: I020 - Replace The Pressure Accumulator

    Screws on the hydraulic system, the connected components, and the supply lines must be tightened to the manufacturer's specified torques. Procedure 1. Replace the pressure accumulator. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 90 Maintenance Summary - 5 Years Example: Pressure accumulator Connect and secure the pressure accumulator. Observe the tightening torque. Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 91: Service Interval - 8 Years

    Service Interval - 8 Years Service Interval - 8 Years Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 92: Maintenance Summary - 8 Years

    Maintenance Summary - 8 Years It is recommended to document the maintenance activities carried out by using the appropriate maintenance log. The maintenance log has the document number DIE018EN - 05.06.2019. J140 - Replacing the viewing glass Maintenance Instructions G220 DIE017EN - 05.06.2019...

  • Page 93: J140 - Replacing The Viewing Glass

    After replacing the inner viewing glass, it must be sealed on the inside of the work area door. It is necessary to provide a suitable sealant. The sealant Terostat 930 is used at the factory for this purpose. G220 Overall view of viewing glass 1 Outer pane (polycarbonate) Center pane (polycarbonate)
  • Page 94 1. Unscrew the front cover. The front cover is additionally bolted to the work area door through the handle. G220 Replacement 5 2 viewing glass Loosen and remove screws (2x M8) on the handle (screwed from the inside) and two screws (2x M6).
  • Page 95 Maintenance Summary - 8 Years G220 Replacement 2 viewing glass The front cover can now be pushed to the right and detached on the right side. G220 Replacement 3 viewing glass The front cover can now be removed. Maintenance Instructions G220 DIE017EN - 05.06.2019...
  • Page 96 If so, straighten them again so that the tabs can be inserted again into the holes provided for this purpose. G220 Replacement 5 2 3 viewing glass For assembly, follow the steps in reverse order. Ensure proper cleanliness during the installation. The remaining screws (8x) of the angle brackets may...
  • Page 97 This makes it easier to align the pane within its frame. G220 Replacement 3 1 viewing glass Replace the inner pane. After removing the front cover, the inner pane can be replaced.
  • Page 98 Maintenance Summary - 8 Years G220 Replacement 7 viewing glass Remove the lower part of the front cover (Y) at the work area door. Loosen and remove the screws (2x and 4x) as shown in the figure. Then you can tilt the cover forward and detach it.
  • Page 99 Maintenance Summary - 8 Years G220 Replacement 9 viewing glass G220 Replacement 8 viewing glass Loosen the screws of the clamping frame (30x M10) (see Fig.) and remove with the clamping frame. Before the cutting the seal (S) using a suitable knife, make sure that the pane cannot fall down.
  • Page 100 Seal the inner pane in the work area with sealant. After the assembly of the panes and frame parts, the inner pane must be sealed using a sealant (Terostat 930 gray is used at the factory) (S). See Fig.: G220 G420 Replacement 8 2 viewing glass...
  • Page 102 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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C200-sl

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