Index G200.3 User manual

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

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 the work area door and window pane............................................................................................... 7
A024 - Check hydraulic system (visual inspection)..................................................................................................9
A027 - Replace the breathing filter at the filler neck of the hydraulic fluid tank.......................................................11
A042 - Check pneumatic system (visual inspection)............................................................................................. 13
A049 - Check the lubrication system (visual inspection)........................................................................................18
A065 - Lubricate turret steady rest SR2 or SLU X1 (by SMW)...............................................................................19
A075 - Check fill levels of the fluid tanks................................................................................................................20
A080 - Clean and lubricate clamping device......................................................................................................... 23
A090 - Check electrical lines (visual inspection)....................................................................................................25
A095 - Visual inspection of all fluid lines and electrical cables...............................................................................26
A103 - Clean cooling lubricant outlet on clamping cylinder................................................................................... 27
A120 - Check cooling lubricant (visual inspection)................................................................................................ 28
A126 - Check the cooling unit and the coolant...................................................................................................... 30
A132 - Check work area light (visual inspection)................................................................................................... 34
A140 - Check HSK clamping set and, if necessary, lubricate (Ott-Jakob)............................................................. 35
A145 - Maintenance of HSK clamping sets (from Berg)........................................................................................ 37
A180 - Clean the work area................................................................................................................................... 38
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
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I
Maintenance Instructions
G200.3 G220.3
DIE248EN - 15.08.2022

Service Interval - 2.000 Operating hours.............................................................................................................. 51
Maintenance Summary - 2.000 Operating hours...................................................................................................52
C010 - Check maintenance logs of servicing activities..........................................................................................53
C023 - Clean and check wipers of the work area door.......................................................................................... 54
C025 - Check work area door (with electr. drive) and window pane...................................................................... 57
C040 - Check and lubricate HSK clamping set (from Ott-Jakob)...........................................................................61
C047 - Check tool clamping sets of the milling spindles........................................................................................63
C050 - Check and potentially replace the cooling lubricant adapter (HSK tool mountings)................................... 66
C065 - Check telescopic covers and wipers..........................................................................................................68
C070 - Check outer wipers of linear guides...........................................................................................................69
C080 - Check all electrical connections and drive belts of the drive motors.......................................................... 70
C095 - Check slat/shingle cover on the telescopes (visual inspection)................................................................. 72
C130 - Replace filter on air conditioner cooling fan............................................................................................... 76
C140 - Check cooling unit for cooling lubricant......................................................................................................77
C165 - Check coolant............................................................................................................................................78
C190 - Clean labyrinth rings of spindles................................................................................................................ 80
C510 - Check backup data carrier.........................................................................................................................81
C525 - Check control cabinet................................................................................................................................ 82
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
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II Maintenance Instructions
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DIE248EN - 15.08.2022

Service Interval - 4.000 Operating hours.............................................................................................................. 91
Maintenance Summary - 4.000 Operating hours...................................................................................................92
D010 - Cleaning of the machine............................................................................................................................ 93
D015 - Clean the cover at the work area door........................................................................................................95
D020 - Check the pressure accumulator............................................................................................................... 97
D053 - Check the lubrication system..................................................................................................................... 98
D057 - Check the pneumatic system...................................................................................................................100
D077 - Check tool clamping sets of the milling spindles......................................................................................105
D087 - Check main and counter spindles............................................................................................................108
D105 - Wassermann tool change system............................................................................................................ 111
D110 - Check hydraulic system........................................................................................................................... 112
D170 - Check the system for reconditioning the cooling lubricant....................................................................... 114
D180 - Check fire extinguishing system (visual inspection)................................................................................. 115
D220 - Replace belts and check belt tension...................................................................................................... 116
D458 - Replacing hydraulic fluid.......................................................................................................................... 119
D500 - Perform data backup................................................................................................................................122
D520 - Check control cabinet and cable assemblies (visual inspection)............................................................. 123
D570 - Maintenance of turret steady rest SR2 or SLU X1 (by SMW)...................................................................125
Service Interval - 8.000 Operating hours............................................................................................................ 127
Maintenance Summary - 8.000 Operating hours.................................................................................................128
E010 - Wassermann tool change system............................................................................................................ 129
E060 - Maintenance of turret steady rest SR2 or SLU X1 (by SMW)................................................................... 130
Service Interval - 5 Years...................................................................................................................................... 131
Maintenance Summary - 5 Years.........................................................................................................................132
I010 - Renewing the pneumatically pilot-controlled cooling lubricant valves........................................................133
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
Table of contents
III
Maintenance Instructions
G200.3 G220.3
DIE248EN - 15.08.2022

Table of contents
IV Maintenance Instructions
G200.3 G220.3
DIE248EN - 15.08.2022

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,
extraction 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.
Maintenance intervals
The maintenance intervals are given based on the operating hours
counter / “Hydraulic system On” operating condition.
Maintenance intervals displayed on the controller (iXpanel)
Depending on the respective machine type and the different
controller types, a corresponding message is issued on the controller
when a maintenance interval is reached. The maintenance
instructions stored on the respective controller provide information
(maintenance log) explaining the service and maintenance activities
to be performed.
Cleaning of the machine
Do not clean the machine with compressed air
- Raised dirt particles may cause breathing difficulty or injury
(especially of the sensory organs). Furthermore, raised dirt
particles or chips may reach spots where they cause technical
problems.
Do not use cotton waste for cleaning
- When cleaning with cotton waste, fibers or thread can get loose
causing safety problems.
Solvents
- Do not use highly volatile solvents such as petroleum spirit,
trichloroethylene or similar cleaning agents. These cleaners may
damage the seals, which can lead to safety problems.
Pressure washers
- 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.
Preface
1
Maintenance Instructions
G200.3 G220.3
DIE248EN - 15.08.2022

Cleaning of tool mountings
A suitable cleaning tool must be used to clean the hole in the tool
mounting.
Ordering spare parts
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.
Operating material
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.
Pressure accumulators ≤ 1 L
Pressure accumulators with a volume of ≤ 1 L are not subject to
testing and labeling according to the current issue of the pressure
equipment directive. 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.
Preface
2Maintenance Instructions
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DIE248EN - 15.08.2022

Carrying out maintenance work
Authorized and trained personnel
- 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.
Allow the machine to cool down
- Prior to working on the machine, it must be allowed to cool
down, as hot parts may be located under the covers.
Maintenance work on machine being switched off
- In general, maintenance is to be carried out with the machine
switched 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.
Required tools
- For removing machine parts, suitable lifting gears and a variety
of tools must be used. Removed machine parts must be placed
in a safe position and secured against falling over.
- 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.
Performing maintenance, repair or service work
- The currently valid safety regulations, as well as the specific
manufacturer’s information for the intended use must be
observed for these activities.
Use of climbing aids (ladders or steps)
- In addition, appropriate climbing aids may be required to carry
out these activities. 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).
Preface
3
Maintenance Instructions
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DIE248EN - 15.08.2022

Procurement/use of spare parts
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.
Cellular and cordless phones
When the control cabinet is open or the machine covers are open or
removed, no cellular or cordless phones may be used within a 2 m
radius.
Handling hydraulic and hose lines
Damaged hydraulic hose lines must be replaced immediately. Typical
types of damage include chafing, kinks, cracks, deformations, or
visible leaks.
Flexible, pressurized hydraulic hose lines of INDEX equipment are
generally designed as thermoplastics or metallic hydraulic hose lines.
The machine operator/owner is responsible for compliance with the
laws and regulations of the country of use with regard to the use of
hydraulic hoses.
We recommend inspection and documentation of the hydraulic hose
lines installed inside the machine and not directly visible every 12
months. For hydraulic hose lines visible in the work area or mounted
outside the machine and connecting components to the machine, we
recommend inspection and documentation every 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.
Maintenance work on fluid systems (hydraulic, lubrication, and
pneumatic systems)
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).
Dry run or functional test
After all maintenance work and work on electrical assemblies, a dry
run or functional test must be performed.
Preface
4Maintenance Instructions
G200.3 G220.3
DIE248EN - 15.08.2022

Service Interval - Care activities
Service Interval - Care activities
5
Maintenance Instructions
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Maintenance Summary - Care activities
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.
The maintenance interval is highly dependent on the production and environmental conditions of the
machine. The determination of the appropriate interval must be made by the operator.
The maintenance interval should be between once per shift and once a week!
A010 - Check the work area door and window pane
A024 - Check hydraulic system (visual inspection)
A027 - Replace the breathing filter at the filler neck of the hydraulic fluid tank.
A042 - Check pneumatic system (visual inspection)
A049 - Check the lubrication system (visual inspection)
A065 - Lubricate turret steady rest SR2 or SLU X1 (by SMW)
A075 - Check fill levels of the fluid tanks
A080 - Clean and lubricate clamping device
A090 - Check electrical lines (visual inspection)
A095 - Visual inspection of all fluid lines and electrical cables
A103 - Clean cooling lubricant outlet on clamping cylinder
A120 - Check cooling lubricant (visual inspection)
A126 - Check the cooling unit and the coolant
A132 - Check work area light (visual inspection)
A140 - Check HSK clamping set and, if necessary, lubricate (Ott-Jakob)
A145 - 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 Summary - Care activities
6Maintenance Instructions
G200.3 G220.3
DIE248EN - 15.08.2022

A010 - Check the work area door and window pane
Orientation
Inspection and maintenance of the work area door includes several steps:
- Inspection of the window pane for damage.
- Checking the safety label on the window pane (replacement interval 8 years).
- Checking/adjusting or replacing, if necessary, the wipers.
- Check the work area door for smooth opening/closing.
- Automatic work area door (optional). Hydraulic valves and motor, control panel,
rack and spur gear. (for hydraulic door drive)
- Automatic work area door (optional – electric door drive – follow the
manufacturer’s documentation).
The window pane consists of three panes. The inner pane made of tempered glass,
the central pane made of polycarbonate, and the outer pane also made of
polycarbonate. The inner pane is relatively resistant. It can be cleaned with any
commercially available cleaning agents. Only the center pane is essential for the
impact resistance of the window pane.
The polycarbonate panes are subject to natural aging and therefore must be
subjected to regular visual inspection. Through contact with cooling lubricant, the
aging process is accelerated even further
If the window pane is damaged, it must be replaced. This is
necessary regardless of the extent of damage. Even with minimal
damage, the impact resistance of the pane can no longer be
guaranteed.
Heavily soiled or damaged wipers may cause damage to the inner pane. Moreover,
it may be possible that the work area door can be moved only with considerable
effort due to heavy soiling or chip deposits in the wipers.
Check the guide rails of the work area door. The guide bars must be checked and
cleaned regularly so that the work area door can be moved without much effort.
Procedure
1. Check window pane for damage.
2. Clean the outer pane with a soft cloth or sponge and glass
cleaner or soap and water. Do not use abrasive or alkaline
cleaners (e.g., benzene, acetone or carbon tetrachloride) and no
sharp tools or sharp objects (such as razor blades or
screwdrivers).
Clean outer pane.
3. Clean inner pane.
4. 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.
Maintenance Summary - Care activities
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Maintenance Instructions
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5. Check the work area door for ease of movement. To do so, open and close the
work area door. If the work area door can be moved only with effort, determine
the cause. Possible causes include – depending on the work area door –
defective or improperly adjusted wipers. Chips on the guide bar or between the
door and wiper, or in the guide rollers of work area door.
Maintenance Summary - Care activities
8Maintenance Instructions
G200.3 G220.3
DIE248EN - 15.08.2022

A024 - Check hydraulic system (visual inspection)
Orientation
To ensure trouble-free operation, periodic checks of the oil level are necessary. The
fill level must be between the upper and lower marks on the oil sight glass.
Only use hydraulic fluid grade 15/13/10 in accordance with ISO 4406.
Viscosity other than 32 according to DIN ISO 3448 is not admissible.
For all work in connection with operating materials, the information in
the data sheets of the respective manufacturers and the information
in the document Notes on Operating Materials must be observed.
Example: Hydraulic unit G420
aFiller neck (hydraulic fluid)
bFill level indicator
cAccumulator drain valve
dMonitoring (level and temperature)
eOil drain plug
fElectrical monitoring (contamination indicator)
gPressure gauge (system pressure)
hPressure accumulator
iSafety valve
jElectrical monitoring (system pressure)
kDrain hose for hydraulic unit
XHydraulic fluid filter (line filter)
YFilter bell
Screws on the hydraulic system, the connected components, and the
supply lines must be tightened to the manufacturer's specified
torques.
Maintenance Summary - Care activities
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Maintenance Instructions
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Procedure
1. The hydraulic fluid level should always be near the top mark
when the machine is switched off. During production, the oil
level may drop after several consumers have been connected.
Check oil level at the oil sight glass.
2. Visual inspection of the hydraulic fluid. The hydraulic fluid may not exhibit any
foaming or cloudiness at the oil sight glass. In case of problems of this kind,
immediately determine the cause and correct the error. If in doubt, take a
sample for analysis and contact the manufacturer of the hydraulic fluid.
3. Check pressure setting on pressure gauge and adjust if necessary. The value
to be checked here is specified (see hydraulic diagram) and should be between
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 Summary - Care activities
10 Maintenance Instructions
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A027 - Replace the breathing filter at the filler neck of the hydraulic fluid tank.
Orientation
The breathing filter on the oil filler neck of the oil tank must be
Regular regularly replaced depending on the ambient conditions.
Due to different requirements and/or specifications of the respective
manufacturers, be sure to review the respective manufacturer's
documentation!
Filters are hazardous waste and must be disposed of in a controlled
manner.
Requirement
It is essential to keep the filter described here in stock. It is not permitted to owner
the machine without this filling and breathing filter.
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 Summary - Care activities
11
Maintenance Instructions
G200.3 G220.3
DIE248EN - 15.08.2022

Procedure
1.
Example: Filling and breathing filters of hydraulic and lubrication systems (by ARGO-HYTOS GmbH)
Replace breathing filter.
Maintenance Summary - Care activities
12 Maintenance Instructions
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DIE248EN - 15.08.2022

A042 - Check pneumatic system (visual inspection)
Orientation
To ensure trouble-free operation, periodic checks (visual inspection) of the
pneumatic system are necessary.
- Check system pressure and sealing air settings.
- Check supply and fluid lines.
- Check silencers.
- Drain condensate (not applicable to auto-drain).
- Check pressure setting on the pressure differential monitoring pressure gauge.
Example: Pneumatic maintenance unit G420 (by FESTO)
Due to different requirements and/or specifications of the respective
manufacturers, be sure to review the respective manufacturer's
documentation!
The following components are used on the system maintenance unit (X) and the
extension for sealing air on the glass scales (Y) :
-X System maintenance unit
- 1. Switch-on valve (manual)
- 2. Pressure regulating valve (with filter) system pressure 6 bar
- 3. Pressure gauge for system pressure
- 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 Summary - Care activities
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Maintenance Instructions
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Example: Pneumatic maintenance unit G420 (by FESTO)
-Y extension sealing air - “consumer” and sealing air - “glass scale”
- 11. Pressure regulating valve for “load” sealing air
- 12. Differential pressure sensor
- 13. Filter with automatic condensate drain
- 14. Microfilter insert (filter fineness 1 µm)
- 15. Filter with automatic condensate drain
- 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 Summary - Care activities
14 Maintenance Instructions
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