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OPERATING INSTRUCTIONS
Maintenance Instructions
Maintenance Instructions
G200.3 G220.3
DIE248EN - 15.08.2022
2022-08-15/Sp/Wartungsanleitung/20222366

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Summary of Contents for Index G200.3

  • Page 1 OPERATING INSTRUCTIONS Maintenance Instructions Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022 2022-08-15/Sp/Wartungsanleitung/20222366...
  • 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

    A215 - Check slat/shingle cover on the telescopes (visual inspection)..............39 A255 - Clean the chip conveyor..........................43 A320 - Wassermann tool change system......................45 Service Interval - 1.000 Operating hours......................47 Maintenance Summary - 1.000 Operating hours....................48 B010 - Customer area............................49 Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 4 C545 - Check cable and hose clamps for tight seating..................83 C555 - Replace hydraulic fluid filters........................85 C570 - Wassermann tool change system......................88 C590 - Maintenance of turret steady rest SR2 or SLU X1 (by SMW)..............89 Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 5 I020 - Replace the pressure accumulator......................134 Service Interval - 8 Years............................137 Maintenance Summary - 8 Years.........................138 J005 - Note on replacing the window pane or removing the design pane............139 J150 - Replace the window pane........................142 Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 6 Table of contents Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 7: Preface

    Do not clean the machine with a pressure washer. 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. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 8: Safety Instructions

    The guidelines and regulations applicable in the country of use must be followed. Safety Instructions Safety Instructions and Technical Details The user documentation and, in particular, the document “Safety Instructions and Technical Details” must be observed. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 9 When working on climbing aids at great heights, e.g. on the control cabinet, these must always be secured or fastened (depending on the machine, eyelets are also provided for this purpose). Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 10 6 months. For the flexible, pressurized hydraulic hose lines used by INDEX , empirical values are available for very different periods of use, some of which exceed 10 years.

  • Page 11: Service Interval - Care Activities

    Service Interval - Care activities Service Interval - Care activities Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 12: Maintenance Summary - Care Activities

    - Maintenance of HSK clamping sets (from Berg) A180 - Clean the work area A215 - Check slat/shingle cover on the telescopes (visual inspection) A255 - Clean the chip conveyor A320 - Wassermann tool change system Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 13: A010 - Check The Work Area Door And Window Pane

    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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • 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 work area door. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 15: A024 - Check Hydraulic System (Visual Inspection)

    Electrical monitoring (system pressure) Drain hose for hydraulic unit Hydraulic fluid filter (line filter) Filter bell Screws on the hydraulic system, the connected components, and the supply lines must be tightened to the manufacturer's specified torques. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 16 70-80 bar. 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 17: A027 - Replace The Breathing Filter At The Filler Neck Of The Hydraulic Fluid Tank

    Use only the original filters according to the spare or wear parts list. Only filters with retained particle sizes described in the fluid plans must be used. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 18 Maintenance Summary - Care activities Procedure Example: Filling and breathing filters of hydraulic and lubrication systems (by ARGO-HYTOS GmbH) Replace breathing filter. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 19: A042 - Check Pneumatic System (Visual Inspection)

    4. Filter insert (filter fineness 40 µm) 5. Filter with automatic condensate drain 6. Filter insert (filter fineness 5 µm) 7. Branch module 8. Pressure sensor for system pressure 9. Silencer 10. Electrically actuated switch-on valve Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 20 16. Microfilter insert (filter fineness 0.01 µm) 17. Filter 18. Activated carbon filter no automatic condensate drain 19. Pressure regulating valve with pressure sensor for glass scales sealing air 1.0 bar 20. Display Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 21 Service and maintenance are to be carried out according to the manufacturer’s specifications. Procedure 1. Check pressure setting on pressure gauge and adjust if necessary. An operating pressure of 6 bar has been set at the factory. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 22 Unscrew filter bowl (Y) from filter base (X) and remove activated carbon filter cartridge (2). Check sealing rings and O-rings (1 + 3) , replace if necessary. Reinstall all parts in reverse order. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 23 (4). Unscrew filter bowl (1) from filter base body and remove filter cartridge (3) , check, and replace if necessary. Check O-ring (5) , replace if necessary. Reinstall all parts in reverse order. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 24: A049 - Check The Lubrication System (Visual Inspection)

    The following components must be checked on the lubrication system: a) Filler neck b) Pressure gauge for system pressure (>20 bar) Procedure 1. Check oil level. 2. Check pressure setting on pressure gauge (>20 bar) Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 25: A065 - Lubricate Turret Steady Rest Sr2 Or Slu X1 (By Smw)

    Service and maintenance are to be carried out according to the manufacturer’s specifications. The turret steady rest (type SR2 or SLU X1) used here should be lubricated daily at the points described in accordance with SMW's maintenance instructions. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 26: A075 - Check Fill Levels Of The Fluid Tanks

    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! Procedure Example: Lubricating oil tank Pressure gauge (lubrication pressure) Filter insert and min./max. indicators Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 27 Example: Hydraulic unit C100 C200 C200tandem Filler neck Base plate of hydraulic system Fill-level check Drain plug Accumulator drain valve Check fill level at hydraulic fluid tank. 3. Check fill level at cooling lubricant tank. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 28 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 of the coolant tank (option). Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 29: 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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 30 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 31: 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 / handheld control unit (option). 8. Check electrical lines to other optional attachments. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 32: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 33: A103 - Clean Cooling Lubricant Outlet On Clamping Cylinder

    Example: Cooling lubricant outlet, G420 Remove cover (X) on cooling lubricant tank. 3. Clean cooling lubricant tank and drain hose (Y). 4. For assembly, follow the steps in reverse order. Ensure proper cleanliness during the installation. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 34: 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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 35 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 36: A126 - Check The Cooling Unit And The Coolant

    These activities can be carried out by instructed individuals with appropriate expertise. Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's documentation! Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 37 Return flow - cooling compressor Stopcock PID controller for 35% water-glycol mixture PID controller for hydraulic fluid HLPD 32 Filler neck Sight glass (fill level indicator) Level switch Drain plug for tank drainage Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 38 Replenish only coolant of the same manufacturer having the same specification. Mixing different coolants may lead to corrosion of the cooling system, incompatibility and degradation of the coolant. Be sure to observe the specified concentration of glycol in the respective machine. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 39 Procedure 1. Check coolant. Test criteria for this visual inspection are the clarity and transparency of the coolant. 2. Check fill level on the level indicator. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 40: A132 - Check Work Area Light (Visual Inspection)

    Example: Work lamp Waldmann_ MACH_LED_PRO_MUEL_4S (photo: Herbert Waldmann GmbH & Co. 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 41: A140 - Check Hsk Clamping Set And, If Necessary, Lubricate (Ott-Jakob)

    The use of tools with shank ISO 12164-1 version before 2001 or DIN 69893-1 version before 2003 (HSK-A) can cause serious damage to the tool magazine during automatic tool change and is therefore not permissible. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 42 A faulty seal in the clamping taper. A cleaning spray directed immediately at the collet. Use of a degreasing medium. Determine the causes of rapid defatting of the collet. If in doubt, always contact the respective manufacturer. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 43: A145 - Maintenance Of Hsk Clamping Sets (From Berg)

    69893-1 version before 2003 (HSK-A) can cause serious damage to the tool magazine during automatic tool change and is therefore not permissible. Example: HSK clamping sets from Berg Procedure 1. Clamping sets from Berg are maintenance-free. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 44: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 45: A215 - Check Slat/Shingle Cover On The Telescopes (Visual Inspection)

    Orientation The telescopic plates are additionally fitted with a slat/shingle cover. View of tool carrier 1 Example: General view of slat/shingle cover (STRAPANO - Arnold) G420 Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 46 1. Check the overall condition of the substrate. Assess wear. If individual parts such as sliders, holders or carrier material are destroyed, it is imperative that they be replaced. Cutting injury due to sharp-edged sheet metal parts. Always wear suitable protective gloves. Caution Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 47 Maintenance Summary - Care activities Example: Holder, two-piece (STRAPANO - by Arnold) Before mounting on the bellows, join both parts together and observe the direction of the arrow. Example: Holder, two-piece (STRAPANO - by Arnold) Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 48 Maintenance Summary - Care activities Example: Mounting of holders (STRAPANO - Arnold company) Check holder. 3. Check slider. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 49: A255 - Clean 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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 50 Remove cooling lubricant pump. Remove and clean strainer basket on the cooling lubricant pump. Alternatively, the following procedure can be used! Extract cooling lubricant, remove screen directly from the cooling lubricant pump and clean it. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 51: 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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 52 Maintenance Summary - Care activities Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 53: Service Interval - 1.000 Operating Hours

    Service Interval - 1.000 Operating hours Service Interval - 1.000 Operating hours Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 54: Maintenance Summary - 1.000 Operating Hours

    Maintenance Summary - 1.000 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 DIE249EN - 15.08.2022. B010 - Customer area Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 55: B010 - Customer Area

    Interval for a filter change. Interval for testing the cooling lubricant. Maintenance contents from the user documentation of additionally purchased peripheral devices that were not obtained from INDEX can also be transferred to this area. The procedure for creating your own individual maintenance intervals/contents is described in the iXpanel document.
  • Page 56 Maintenance Summary - 1.000 Operating hours Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 57: Service Interval - 2.000 Operating Hours

    Service Interval - 2.000 Operating hours Service Interval - 2.000 Operating hours Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 58: Maintenance Summary - 2.000 Operating Hours

    - Check cable and hose clamps for tight seating C555 - Replace hydraulic fluid filters C570 - Wassermann tool change system C590 - Maintenance of turret steady rest SR2 or SLU X1 (by SMW) Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 59: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 60: C023 - Clean And Check Wipers Of The Work Area Door

    Requirement Example: Chip hook and chip brush Use appropriate tools to remove coarse chips, chip nests and other debris. Procedure Example: Removing chip nest using appropriate tools (e.g., chip hooks) Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 61 Remove small chips and chip accumulations on the inside of the work area door from top to bottom. Use a chip brush for this purpose. Make sure that the wipers evenly contact the work area door before tightening the screws. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 62 In this case, also clean the area behind the wipers 4. Check the wipers for proper seating. After the work area door has been cleaned, it should open and close again without much effort as usual Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 63: C025 - Check Work Area Door (With Electr. Drive) And Window Pane

    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 window pane for damage. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 64 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 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 65 Danger Check obstacle detection. INDEX recommends an annual check of the obstacle detection function of the automatic work area door. The test should only be carried out with a suitable aid, such as a rectangular strip or a softwood squared timber.
  • Page 66 The machine must not be operated any further. Be sure to contact the INDEX service department or an INDEX representative. Example: View of the automatic work area door G420 with drive...

  • Page 67: C040 - Check And Lubricate Hsk Clamping Set (From Ott-Jakob)

    The use of tools with shank ISO 12164-1 version before 2001 or DIN 69893-1 version before 2003 (HSK-A) can cause serious damage to the tool magazine during automatic tool change and is therefore not permissible. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 68 1. Check the adjustment in the “Released” position – lock with a clamped tool. A measuring device required to measure the clamping force can be sourced through INDEX , a representative or the tool manufacturer. Check the retraction force. If the retraction force is less than 70% of the nominal value, take the following measures in the order given : Regrease and recheck retraction force –...

  • Page 69: C047 - Check Tool Clamping Sets Of The Milling Spindles

    = 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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 70 Requirement A measuring device required to measure the clamping force can be sourced through INDEX , a representative or the tool manufacturer. Example: Clamping force measuring system from Berg Maintenance Instructions G200.3 G220.3...
  • Page 71 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 72: C050 - Check And Potentially Replace The Cooling Lubricant Adapter (Hsk Tool Mountings)

    Clean the tool including the HSK tool mounting before the removal. 5. Loosen and remove groove nut (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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 73 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 74: 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 traversing range of the telescopic cover. If relubrication is required, first stop the travel movement and set feed rate override to “zero” position. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 75: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 76: 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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 77 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 wear. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 78: C095 - Check Slat/Shingle Cover On The Telescopes (Visual Inspection)

    Orientation The telescopic plates are additionally fitted with a slat/shingle cover. View of tool carrier 1 Example: General view of slat/shingle cover (STRAPANO - Arnold) G420 Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 79 1. Check the overall condition of the substrate. Assess wear. If individual parts such as sliders, holders or carrier material are destroyed, it is imperative that they be replaced. Cutting injury due to sharp-edged sheet metal parts. Always wear suitable protective gloves. Caution Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 80 Maintenance Summary - 2.000 Operating hours Example: Holder, two-piece (STRAPANO - by Arnold) Before mounting on the bellows, join both parts together and observe the direction of the arrow. Example: Holder, two-piece (STRAPANO - by Arnold) Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 81 Maintenance Summary - 2.000 Operating hours Example: Mounting of holders (STRAPANO - Arnold company) Check holder. 3. Check slider. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 82: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 83: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 84: C165 - Check Coolant

    1-4. From Machine 5, a concentration of Antifrogen N (34% glycol). When using a water recooler, be sure to follow the manufacturer’s instructions. Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's documentation! Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 85 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 86: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 87: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 88: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 89: C545 - Check Cable And Hose Clamps For Tight Seating

    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. Example: Power cabling G420 Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 90 Maintenance Summary - 2.000 Operating hours G420_Power_Cabling_Example Check strain relief. Check the correct position of the boots and adjust the strain reliefs. 4. Record any damages and initiate repair. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 91: 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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 92 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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 93 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 94: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 95: C590 - Maintenance Of Turret Steady Rest Sr2 Or Slu X1 (By Smw)

    Orientation Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's documentation! Procedure Example: Turret_Steady_Rest_SMW_SR2 Lubrication points Perform 2000 h maintenance according to the manufacturer's documentation. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 96 Maintenance Summary - 2.000 Operating hours Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 97: Service Interval - 4.000 Operating Hours

    Service Interval - 4.000 Operating hours Service Interval - 4.000 Operating hours Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 98: Maintenance Summary - 4.000 Operating Hours

    D458 - Replacing hydraulic fluid D500 - Perform data backup D520 - Check control cabinet and cable assemblies (visual inspection) D570 - Maintenance of turret steady rest SR2 or SLU X1 (by SMW) Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 99: 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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 100 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 collecting tray under the workpiece handling unit. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 101: D015 - Clean The Cover At The Work Area Door

    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. Example: Fig. c G220 G420 Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 102 Example: Fig. b G220 G420 Then replace the cover (Figure (b)) and reinstall and adjust the wipers that may have been removed. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 103: D020 - Check The Pressure Accumulator

    The pressure gauge needle slowly falls to a point where it quickly drops to zero. This point is the approximate accumulator bias tension. This value is 50 +/-2 bar. If this value is below 40 bar, the pressure accumulator must be replaced. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 104: D053 - Check The Lubrication System

    Pressure sensors 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. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 105 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 106: D057 - Check The Pneumatic System

    4. Filter insert (filter fineness 40 µm) 5. Filter with automatic condensate drain 6. Filter insert (filter fineness 5 µm) 7. Branch module 8. Pressure sensor for system pressure 9. Silencer 10. Electrically actuated switch-on valve Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 107 16. Microfilter insert (filter fineness 0.01 µm) 17. Filter 18. Activated carbon filter no automatic condensate drain 19. Pressure regulating valve with pressure sensor for glass scales sealing air 1.0 bar 20. Display Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 108 Service and maintenance are to be carried out according to the manufacturer’s specifications. Procedure 1. Check pressure setting on pressure gauge and adjust if necessary. An operating pressure of 6 bar has been set at the factory. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 109 Unscrew filter bowl (Y from filter base (X) and remove activated carbon filter cartridge (2). Check sealing rings and O-rings (1 + 3) , replace if necessary. Reinstall all parts in reverse order. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 110 (4). Unscrew filter bowl (1) from filter base body and remove filter cartridge (3) , check, and replace if necessary. Check O-ring (5) , replace if necessary. Reinstall all parts in reverse order. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 111: D077 - Check Tool Clamping Sets Of The Milling Spindles

    = 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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 112 Requirement A measuring device required to measure the clamping force can be sourced through INDEX , a representative or the tool manufacturer. Example: Clamping force measuring system from Berg Maintenance Instructions G200.3 G220.3...
  • Page 113 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 114: D087 - Check Main And Counter Spindles

    The following tools and spare parts are required to carry out this maintenance: 1. Sealing rings or O-rings 2. Supply or fluid lines as necessary Procedure Example: Hollow clamping cylinder version O-ring Rotary feeder Anti-twist lock Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 115 Example: Solid clamping cylinder version O-ring Rotary feeder Anti-twist lock Check the tightness of the depth stop/flushing unit and the correct seating of the rotary feeder. 2. Tightness of the solid or hollow clamping cylinder. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 116 In any case, make sure that the seals recommended by the manufacturer are used or installed during maintenance or repair work. 5. Check the condition/tightness of the power and encoder connections as well as the fluid lines of the respective components. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 117: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 118: D110 - Check Hydraulic System

    Electrical monitoring (system pressure) Drain hose for hydraulic unit Hydraulic fluid filter (line filter) Filter bell Screws on the hydraulic system, the connected components, and the supply lines must be tightened to the manufacturer's specified torques. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 119 70-80 bar. 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 120: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 121: D180 - Check Fire Extinguishing System (Visual Inspection)

    Be sure to read the operating instructions of the manufacturer! Procedure 1. Visual inspection for obvious defects. Example: Inspection stickers Kraft & Bauer Check sticker for manufacturing date. 3. Check sticker for inspection date. 4. Check sticker for battery replacement. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 122: D220 - 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 X2 belt. 3. Replace the belt of the work area door drive. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 123 (5) (see examples of work area door drive G420). Example: Work area door drive G420 Drive Driver Belt tensioner (for measuring point M2) Belt tensioner (for measuring point M1) Deflection pulley Deflection pulley Measuring point (181 Hz) Measuring point (100–110 Hz) Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 124 Maintenance Summary - 4.000 Operating hours Adjust belt tension. Using a frequency meter and the belt tensioner (3+4) , the belt tension can now be set to the specified value at the marked point (M1 or M2). Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 125: D458 - Replacing Hydraulic Fluid

    1. Suction off old fluid through the filler neck (a) or drain the fluid from the drain plug (e). Use a suitable collection bin for this purpose. Use only lint-free cleaning cloths or a sponge! Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 126 (Y) , remove contaminated hydraulic fluid (oil sump) and used filter (Z) from the filter bell (Y) and dispose of them according to environmental regulations. Only filters with retained particle sizes described in the fluid plans must be used. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 127 9. Check and, if necessary, replenish hydraulic fluid level. 10. Vent hydraulic system. To bleed the hydraulic system, open the accumulator drain valve (c) for about 10 seconds and then close it again. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 128: D500 - Perform Data Backup

    CD/DVD created when the machine was delivered is restored on the machine. Afterwards, the PLC and NC archive files are loaded from the floppy disk or USB flash drive. Procedure 1. Perform data backup. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 129: D520 - Check Control Cabinet And Cable Assemblies (Visual Inspection)

    5. Check all cabinet seals. They should be free of oil and condensation. 6. Clean the control cabinet. Use a suitable vacuum cleaner for this purpose. 7. Check the cabinet lighting (optional). Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 130 8. Check grounding cable. Grounding cables are located, e.g., between the control cabinet and cabinet doors and between the base and the machine bed. 9. Check cable assemblies for damage, replace if necessary. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 131: D570 - Maintenance Of Turret Steady Rest Sr2 Or Slu X1 (By Smw)

    Orientation Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's documentation! Procedure Example: Turret_Steady_Rest_SMW_SR2 Lubrication points Perform 4000 h maintenance according to the manufacturer's documentation. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 132 Maintenance Summary - 4.000 Operating hours Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 133: Service Interval - 8.000 Operating Hours

    Service Interval - 8.000 Operating hours Service Interval - 8.000 Operating hours Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 134: 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 DIE249EN - 15.08.2022. E010 - Wassermann tool change system E060 - Maintenance of turret steady rest SR2 or SLU X1 (by SMW) Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 135: 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 G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 136: E060 - Maintenance Of Turret Steady Rest Sr2 Or Slu X1 (By Smw)

    Orientation Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's documentation! Procedure Example: Turret_Steady_Rest_SMW_SR2 Lubrication points Perform 8000 h maintenance according to the manufacturer's documentation. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 137: Service Interval - 5 Years

    Service Interval - 5 Years Service Interval - 5 Years Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 138: 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 DIE249EN - 15.08.2022. I010 - Renewing the pneumatically pilot-controlled cooling lubricant valves I020 - Replace the pressure accumulator Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 139: I010 - Renewing The Pneumatically Pilot-Controlled Cooling Lubricant Valves

    To avoid consequential damage, INDEX recommends replacing these valves after 5 years. Requirement Due to different requirements and/or specifications of the respective...

  • Page 140: 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 G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 141 Maintenance Summary - 5 Years Example: Pressure accumulator Connect and secure the pressure accumulator. Observe the tightening torque. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 142 Maintenance Summary - 5 Years Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 143: Service Interval - 8 Years

    Service Interval - 8 Years Service Interval - 8 Years Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 144: 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 DIE249EN - 15.08.2022. J005 - Note on replacing the window pane or removing the design pane J150 - Replace the window pane Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 145: J005 - Note On Replacing The Window Pane Or Removing The Design Pane

    Outer pane (design pane made of PMMA – polymethyl methacrylate) Center pane (polycarbonate) Inner pane (glass) Silicone gasket Depending on the machine type, it may be necessary to remove a handle attached here before dismantling the design disks. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 146 Ordinance (LasthandhabV) be taken into account. When using suction lifters (see example), be sure to select the appropriate size or type according to the table ( example: design pane specifications... ). The locally valid guide lines and regulations must be taken into consideration. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 147 Maintenance Summary - 8 Years Example: Bohle suction lifter 60 kg-100 kg Procedure 1. If you have questions, be sure to contact the INDEX service department or an INDEX representative. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...

  • Page 148: J150 - Replace The Window Pane

    The sealant Terostat 930 is used at the factory for this purpose. Example: G200.2 Work area door 01 1 Outer pane (design pane made of PMMA – polymethyl methacrylate) Center pane (polycarbonate) Inner pane (glass) Silicone gasket Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 149 When mounting and dismounting the front cover/design pane using a crane, INDEX recommends using suitable suction lifters to secure it. To ensure safe handling, both the suction surfaces of the suction lifters used and the corresponding areas of the design pane must be carefully cleaned beforehand.
  • Page 150 Maintenance Summary - 8 Years Example: Transport of design element G420 Install eyebolts Lifting with round slings Lifting with short round slings and small crossbeam Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 151 (Fig. 03 1). Remove front cover/pane, carefully place aside and secure against tipping over. Example: G200.2 Work area door 06 Cut the silicone sealing (s) on the inside of the window pane (see Fig._06) with a suitable knife. Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 152 Remove the clamping frame (x) of the glass package. Loosen and remove all screws from the clamping frame (see Fig_07). Example: G200.2 Work area door 04 Remove the clamping frame (x) and glass package (y). (See Fig._04) Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 153 Example: G200.2 Work area door 07 Reinstall the glass package and clamping frame. After installation, tighten all screws (Fig.:_07) to the prescribed torque. Example: G200.2 Work area door 06 Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 154 Example: G200.2 Work area door 03 1 Refit the front cover or front pane/design pane (a) and screw it on again on both sides along the contour using the screws (M6 – 11 each). Maintenance Instructions G200.3 G220.3 DIE248EN - 15.08.2022...
  • Page 156 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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G220.3G200G220

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