Index G200.2 Istruzioni operative e di manutenzione
Maintenance Instructions
G200.2
OPERATING INSTRUCTIONS
Maintenance Instructions
DIE078EN - 05.06.2019
05.06.2019/Sp/Wartungsanleitung/20057431
Disclaimer
The illustrations in this documents may deviate from the delivered product. We reserve the right to make changes
due to errors or based on technical advances.
A Word on Copyright
This document is proprietary and was originally written in German. Its reproduction and distribution in whole or in
individual parts without permission of the copyright owner is prohibited and will be prosecuted under criminal or civil
law. All rights reserved, including for translation.
© Copyright by INDEX-Werke GmbH & Co. KG Hahn & Tessky
Table of contents
Preface........................................................................................................................................................................1
General notes..........................................................................................................................................................1
Safety Instructions...................................................................................................................................................1
Service Interval - Care activities.............................................................................................................................. 5
Maintenance Summary - Care activities..................................................................................................................6
A010 - Check work area door and viewing glass.....................................................................................................7
A022 - Check hydraulic system (visual inspection)................................................................................................. 9
A036 - Check pneumatic system (visual inspection)............................................................................................. 11
A075 - Checking fill levels of the fluid tanks...........................................................................................................13
A080 - Clean and lubricate clamping device......................................................................................................... 16
A090 - Check electrical lines (visual inspection)....................................................................................................18
A095 - Visual inspection of all fluid lines and electrical cables...............................................................................19
A097 - Clean cooling lubricant outlet on clamping cylinder................................................................................... 20
A110 - Clean filter screens on chip conveyor........................................................................................................ 21
A120 - Check cooling lubricant (visual inspection)................................................................................................ 23
A129 - Check the cooling unit and the coolant...................................................................................................... 25
A130 - Check work area light (visual inspection)................................................................................................... 27
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
Table of contents
I
Maintenance Instructions
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DIE078EN - 05.06.2019
Service Interval - 2.000 Operating hours...............................................................................................................35
Maintenance Summary - 2.000 Operating hours...................................................................................................36
C010 - Check maintenance logs of servicing activities..........................................................................................37
C035 - Check work area door (optionally with electr. drive) and viewing glass......................................................38
C047 - Check tool clamping sets of the milling spindles (from Berg).....................................................................43
C050 - Checking and potentially replacing the cooling lubricant adapter (HSK tool mountings)............................46
C065 - Check telescopic covers and wipers..........................................................................................................48
C070 - Check outer wipers of linear guides...........................................................................................................49
C080 - Check all electrical connections and drive belts of the drive motors.......................................................... 50
C140 - Check cooling unit for cooling lubricant..................................................................................................... 52
C155 - Check coolant............................................................................................................................................53
C190 - Clean labyrinth rings of spindles................................................................................................................ 55
C510 - Check backup data carrier.........................................................................................................................56
C525 - Check control cabinet................................................................................................................................ 57
C540 - Check cable and hose clamps for tight seating..........................................................................................58
C555 - Replace hydraulic fluid filters..................................................................................................................... 59
C580 - Check and clean the INDEX tool magazine for 6 tools...............................................................................62
Service Interval - 4.000 Operating hours...............................................................................................................65
Maintenance Summary - 4.000 Operating hours...................................................................................................66
D010 - Cleaning of the machine............................................................................................................................ 67
D017 - Clean spring steel wiper in the area of the work area door.........................................................................69
D050 - Check the lubrication system.....................................................................................................................71
D067 - Check pneumatic system (visual inspection)............................................................................................. 73
D077 - Check tool clamping sets of the milling spindles (from Berg)..................................................................... 75
D107 - Check and clean the INDEX tool magazine for 6 tools...............................................................................78
D170 - Check the system for reconditioning the cooling lubricant......................................................................... 80
D345 - Replace belts and check belt tension........................................................................................................ 81
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
Table of contents
II Maintenance Instructions
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Service Interval - 8 Years........................................................................................................................................ 97
Maintenance Summary - 8 Years.......................................................................................................................... 98
J150 - Replacing the viewing glass....................................................................................................................... 99
Table of contents
III
Maintenance Instructions
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Table of contents
IV Maintenance Instructions
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DIE078EN - 05.06.2019
Preface
General notes
The maintenance activities described in this document essentially pertain only to the
machine. Maintenance activities of auxiliary units (e.g., bar loading magazines,
exhaust systems) are described in the documentation of the specific manufacturer.
The maintenance and servicing activities must absolutely be observed. Failure to
conduct maintenance and servicing in accordance with these instructions
(especially not at the respective intervals) rules out any claims for damages. This
does not apply if it is proved that the non-compliance with the maintenance and
servicing activities is unrelated to the defect. Normal wear and tear, especially of
components such as bearings and seals, is not a defect. These components are
therefore excluded from the warranty. It is recommended to keep a written log of all
maintenance activities carried out.
The maintenance intervals are given based on the operating hours
counter / "Hydraulic system On" operating condition.
Do not clean the machine with compressed air.
Raised dirt particles may cause breathing difficulties or injuries
(especially of the sensory organs).
Furthermore, raised dirt particles or chips may reach spots where
they cause technical problems.
Do not use cotton waste for cleaning.
When cleaning with cotton waste, fibers or thread can get loose
causing safety problems.
Do not use highly volatile solvents such as benzene,
trichloroethylene or similar cleaning agents.
These cleaners may damage the seals, which can lead to safety
problems.
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.
A suitable cleaning tool must be used to clean the hole in the
tool mounting.
Preface
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Maintenance Instructions
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Always specify the machine type and machine number when
ordering spare parts. This and other information about the machine
are located on the nameplate under the main switch of the control
cabinet.
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
(accumulator drain valve / manual slide valve / emergency stop).
Safety Instructions
Maintenance is to be performed only by authorized and trained personnel. This
applies particularly to work on motors (spindle motors) or other electrical
assemblies. The instructions in the respective manufacturer documentation must be
followed for such work.
We recommend the use of original spare parts and accessories. For damages
caused by the use of parts from third-party providers, liability and warranty are
excluded. The use of such products may change the structural characteristics of the
machine and negatively affect the active or passive safety.
In general, maintenance is to be carried out with the machine turned off. The main
switch must be locked out. Even when the main switch is switched off, parts of the
machine (e.g., the control cabinet light) may still carry electricity. These parts are
labeled. In a few cases, maintenance work needs to be performed with the machine
turned on (e.g., replacement of backup batteries). These maintenance activities
must be carried out with special care.
Prior to working on the machine, it must be allowed to cool down, as hot parts may
be located under the covers.
All maintenance work on the machine must be carried out with utmost care.
Fasteners must be loosened carefully and parts must be secured against falling
down. When elastic items (springs) are removed/replaced, appropriate devices
must be used. Any (non-horizontal) axes that pose a risk of falling down must be
moved to their end positions or secured against falling down. Pedal switches must
be put aside to avoid inadvertent actuation.
For removing machine parts, suitable lifting gears must be used. Removed machine
parts must be placed in a safe position and secured against falling over.
When the control cabinet is open or the machine covers are open or removed, no
cellular or wireless phones may be used within a 2 m radius.
Flexible hydraulic hoses made of elastomer-based plastics are subject to a natural
aging process and should be replaced regularly. The machine operator is
responsible for compliance with the laws and regulations of the country of use with
regard to the use of hydraulic hoses. In Germany, the relevant institutions
recommend a renewal cycle of 6 years for the hydraulic hoses.
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.
Preface
2Maintenance Instructions
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Suitable climbing aids (ladders or steps) may be required to
perform maintenance or service work.
The currently valid safety regulations, as well as the specific
manufacturer’s information for the intended use must be
observed.
After all maintenance work and work on electrical assemblies, a test run or
functional test must be performed.
Additionally, the general safety precautions in the operating manual
“Safety instructions for CNC turning machines” must be
observed. The safety precautions, as a separate document, are part
of the INDEX-TRAUB user documentation.
When carrying out maintenance work on fluid systems, (hydraulic,
lubrication, and pneumatic systems), make sure before starting the
work that the respective system has been depressurized.
(accumulator drain valve/manual slide valve/emergency stop)
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Maintenance Instructions
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Preface
4Maintenance Instructions
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Indice
Altri manuali Index Sistema di controllo
