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OPERATING INSTRUCTIONS
Maintenance Instructions
Maintenance Instructions
G200.2
DIE078EN - 05.06.2019
05.06.2019/Sp/Wartungsanleitung/20057431

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  • Page 1 OPERATING INSTRUCTIONS Maintenance Instructions Maintenance Instructions G200.2 DIE078EN - 05.06.2019 05.06.2019/Sp/Wartungsanleitung/20057431...
  • 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

    A180 - Clean the work area........................... 28 A267 - Cleaning the chip conveyor........................29 A280 - Clean labyrinth ring of spindles........................31 A330 - Check and clean the INDEX tool magazine for 6 tools................32 Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 4 D455 - Replacing hydraulic fluid..........................84 Service Interval - 8.000 Operating hours.......................89 Maintenance Summary - 8.000 Operating hours....................90 E030 - Check and clean the INDEX tool magazine for 6 tools................91 Service Interval - 5 Years............................93 Maintenance Summary - 5 Years.......................... 94 I020 - Replace the pressure accumulator......................95...
  • Page 5 Table of contents Service Interval - 8 Years............................97 Maintenance Summary - 8 Years.......................... 98 J150 - Replacing the viewing glass........................99 Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 6 Table of contents Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 7: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 8: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 9 “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 10 Preface Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 11: Service Interval - Care Activities

    Service Interval - Care activities Service Interval - Care activities Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 12: Maintenance Summary - Care Activities

    - Check work area light (visual inspection) A180 - Clean the work area A267 - Cleaning the chip conveyor A280 - Clean labyrinth ring of spindles A330 - Check and clean the INDEX tool magazine for 6 tools Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 13: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 14 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 G200.2 DIE078EN - 05.06.2019...

  • Page 15: A022 - 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 G200.2 Filler neck Fill level indicator...
  • Page 16 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 G200.2 DIE078EN - 05.06.2019...

  • Page 17: A036 - Check Pneumatic System (Visual Inspection)

    Drain condensate (not applicable to auto-drain). Check pressure setting on the pressure differential monitoring pressure gauge. Example: Pneumatic maintenance unit G200.2 by Festo Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's...
  • Page 18 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 G200.2 DIE078EN - 05.06.2019...

  • Page 19: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 20 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 G200.2 DIE078EN - 05.06.2019...
  • Page 21 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 G200.2 DIE078EN - 05.06.2019...

  • Page 22: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 23 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 G200.2 DIE078EN - 05.06.2019...

  • Page 24: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 25: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 26: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 27: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 28 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 G200.2 DIE078EN - 05.06.2019...

  • Page 29: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 30 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 G200.2 DIE078EN - 05.06.2019...

  • Page 31: A129 - 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 G200.2 Cooling unit or cooling water supply Cooling manifold Heat exchanger for hydraulic system Hydraulic unit Warm water ( ....
  • Page 32 Only then the machine may be put back into operation. External Machine Cooling Water Supply G200.2 20°C±2°K Technical Data of the Cooling Water Supply G200.2 Machine Water temperature [°C] Cooling water, Qmin / Qmax [l/min] Differential pressure P...

  • Page 33: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 34: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 35: A267 - 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 G200.2 DIE078EN - 05.06.2019...
  • Page 36 Maintenance Summary - Care activities Example: G200.2 with chip conveyor and conveyor belt Clean filter basket and magnetic filter plates (option). 6. 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.

  • Page 37: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 38: A330 - Check And Clean The Index Tool Magazine For 6 Tools

    Maintenance Summary - Care activities A330 - Check and clean the INDEX tool magazine for 6 tools Orientation Tool magazine for 6 tools 1 Tool magazine Tool mounting Clamping spring Cleaning nozzles This maintenance activity is merely a visual inspection. As part of the visual inspection, the general condition of each element, the tool mounting (2), clamping spring (3), and the radial fixation (x), must be assessed.
  • Page 39 Maintenance Summary - Care activities Procedure 1. Perform visual inspections. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 40 Maintenance Summary - Care activities Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 41: Service Interval - 2.000 Operating Hours

    Service Interval - 2.000 Operating hours Service Interval - 2.000 Operating hours Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 42: Maintenance Summary - 2.000 Operating Hours

    - Check backup data carrier C525 - Check control cabinet C540 - Check cable and hose clamps for tight seating C555 - Replace hydraulic fluid filters C580 - Check and clean the INDEX tool magazine for 6 tools Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 43: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 44: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 45 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 46 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 G200.2 DIE078EN - 05.06.2019...
  • Page 47 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 G200.2 DIE078EN - 05.06.2019...
  • Page 48 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 Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 49: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 50 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 G200.2...
  • Page 51 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 G200.2 DIE078EN - 05.06.2019...

  • Page 52: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 53 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 G200.2 DIE078EN - 05.06.2019...

  • Page 54: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 55: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 56: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 57 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 G200.2 DIE078EN - 05.06.2019...

  • Page 58: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 59: 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 60 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 G200.2 DIE078EN - 05.06.2019...

  • Page 61: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 62: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 63: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 64: C540 - Check Cable And Hose Clamps For Tight Seating

    Example: Power cabling, G400 Check strain relief. Check the correct position of the boots and adjust the strain reliefs. 4. Record any damages and initiate repair. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 65: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 66 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 Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 67 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 G200.2 DIE078EN - 05.06.2019...

  • Page 68: C580 - Check And Clean The Index Tool Magazine For 6 Tools

    Maintenance Summary - 2.000 Operating hours C580 - Check and clean the INDEX tool magazine for 6 tools Orientation The tool magazine (1) described here can hold 6 HSK-A40 tools. To ensure a trouble-free production process, the tool mountings (2) and clamping springs (3) on the mounting bar must be checked and, if necessary, cleaned or replaced.
  • Page 69 Maintenance Summary - 2.000 Operating hours 2. After removal of the tool, the tool mounting should close again by spring force. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 70 Maintenance Summary - 2.000 Operating hours Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 71: Service Interval - 4.000 Operating Hours

    Service Interval - 4.000 Operating hours Service Interval - 4.000 Operating hours Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 72: Maintenance Summary - 4.000 Operating Hours

    - Check pneumatic system (visual inspection) D077 - Check tool clamping sets of the milling spindles (from Berg) D107 - Check and clean the INDEX tool magazine for 6 tools D170 - Check the system for reconditioning the cooling lubricant D345...

  • Page 73: D010 - Cleaning Of The Machine

    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. Check plates for damage, repair or replace if necessary. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 74 Sweep the dirt arising from the cleaning of the drive area also in the direction of the chip conveyor and then flush with cooling lubricant. Afterwards rub with rags. 10. Clean and reinstall machine covers. 11. Clean the drip pan under the workpiece handling unit. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 75: D017 - Clean Spring Steel Wiper In The Area Of The Work Area Door

    (X). Fig.: Tool for removing chips After removing the cover panels, remove the spring steel wipers and clean the space behind this cover /these wipers. Avoid pushing the chips into the spaces Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 76 3. Reattach the spring steel wipers and cover panels, making sure that they rest evenly against the work area door so they can cleanly wipe off any chips. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 77: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 78 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 G200.2 DIE078EN - 05.06.2019...

  • Page 79: D067 - Check Pneumatic System (Visual Inspection)

    Drain condensate (not applicable to auto-drain). Check pressure setting on the pressure differential monitoring pressure gauge. Example: Pneumatic maintenance unit G200.2 by Festo Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's...
  • Page 80 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 G200.2 DIE078EN - 05.06.2019...

  • Page 81: D077 - 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 G200.2 DIE078EN - 05.06.2019...
  • Page 82 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 G200.2...
  • Page 83 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 G200.2 DIE078EN - 05.06.2019...

  • Page 84: D107 - Check And Clean The Index Tool Magazine For 6 Tools

    Maintenance Summary - 4.000 Operating hours D107 - Check and clean the INDEX tool magazine for 6 tools Orientation The tool magazine (1) described here can hold 6 HSK-A40 tools. To ensure a trouble-free production process, the tool mountings (2) and clamping springs (3) on the mounting bar must be checked and, if necessary, cleaned or replaced.
  • Page 85 Maintenance Summary - 4.000 Operating hours 2. After removal of the tool, the tool mounting should close again by spring force. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 86: 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 G200.2 DIE078EN - 05.06.2019...

  • Page 87: D345 - Replace Belts And Check Belt Tension

    5. Measure belt tension (frequency meter) and adjust belt. 6. Replace Z3 belt. 7. Measure belt tension (frequency meter) and adjust belt. 8. Replace Z5 belt. 9. Measure belt tension (frequency meter) and adjust belt. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 88 - Chapter “Important notes and manual operation”). Then move the gantry-type receiver to a distance of 500 mm (see Figure: Distance between front wall and gantry type receiver). This value or distance is necessary to accurately adjust the belt tension. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 89 (X) between the drive pulley and the deflection pulley. The value to be set is 20Hz. Correct the belt tension at the belt adjustment 1 if necessary. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 90: D455 - 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 G200.2 DIE078EN - 05.06.2019...
  • Page 91 Maintenance Summary - 4.000 Operating hours Example: Hydraulic unit G200.2 Filler neck Fill level indicator Accumulator drain valve Monitoring (level and temperature) Oil drain plug Monitoring (system pressure) Hydraulic fluid filter hydraulic fluid HLPD32 (VG32) Filter bowl Remove the hydraulic unit base plate (b) and clean the hydraulic fluid tank.
  • Page 92 7. To fill in new hydraulic fluid, use a pump with a min. 10 µm micro filter that is exclusively used for hydraulic fluid. 8. Fill in the prescribed amount of new hydraulic fluid. 9. Switch on the machine and hydraulic system. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 93 Maintenance Summary - 4.000 Operating hours 10. Check and, if necessary, 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 Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 94 Maintenance Summary - 4.000 Operating hours Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 95: Service Interval - 8.000 Operating Hours

    Service Interval - 8.000 Operating hours Service Interval - 8.000 Operating hours Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 96: 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 DIE079EN - 05.06.2019. E030 - Check and clean the INDEX tool magazine for 6 tools Maintenance Instructions G200.2...

  • Page 97: E030 - Check And Clean The Index Tool Magazine For 6 Tools

    Maintenance Summary - 8.000 Operating hours E030 - Check and clean the INDEX tool magazine for 6 tools Orientation The tool magazine (1) described here can hold 6 HSK-A40 tools. To ensure a trouble-free production process, the tool mountings (2) and clamping springs (3) on the mounting bar must be checked and, if necessary, cleaned or replaced.
  • Page 98 Maintenance Summary - 8.000 Operating hours 2. After removal of the tool, the tool mounting should close again by spring force. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 99: Service Interval - 5 Years

    Service Interval - 5 Years Service Interval - 5 Years Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 100: 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 DIE079EN - 05.06.2019. I020 - Replace the pressure accumulator Maintenance Instructions G200.2 DIE078EN - 05.06.2019...

  • Page 101: 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 G200.2 DIE078EN - 05.06.2019...
  • Page 102 Maintenance Summary - 5 Years Example: Pressure accumulator Connect and secure the pressure accumulator. Observe the tightening torque. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 103 Service Interval - 8 Years Service Interval - 8 Years Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 104 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 DIE079EN - 05.06.2019. J150 - Replacing the viewing glass Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 105 Outer pane (design pane made of PMMA - polymethyl methacrylate) Center pane (polycarbonate) Inner pane (glass) Silicone gasket If sealing compounds from other manufacturers are used, their equivalence must be guaranteed by the supplier or manufacturer in writing. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 106 (Fig. 03_1). Remove front cover/pane, carefully place aside and secure against tipping over. Example: G200.2_Arbeitsraumtuere_06 Cut the silicone sealing (S) on the inside of the viewing glass (see Fig. _06) with suitable knife. Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 107 Example: G200.2_Arbeitsraumtuere_07 Remove the clamping frame (x) of the glass package. Loosen and remove all screws from the clamping frame (see Fig_07). Example: G200.2_Arbeitsraumtuere_04 Remove the clamping frame (x) and glass package (y). (See Fig._04) Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 108 Make sure of cleanliness and stress-free installation when mounting the clamping frame into the work area door. Example: G200.2_Arbeitsraumtuere_07 Reinstall the glass package and clamping frame. After installation, tighten all screws (Fig.:_07) to the prescribed torque. Example: G200.2_Arbeitsraumtuere_06 Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 109 Seal the inner pane in the work area with sealant (S) again. After the assembly of the panes and frame parts, the inner pane must be sealed using a sealant (Terostat 930 gray is used at the factory). See Fig.:_06 Maintenance Instructions G200.2 DIE078EN - 05.06.2019...
  • Page 110 INDEX-Werke GmbH & Co. KG Hahn & Tessky Plochinger Str. 92 D-73730 Esslingen, Germany Fon +49 711 3191-0 Fax +49 711 3191-587 info@index-werke.de www.index-werke.de...

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