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OPERATING INSTRUCTIONS
Maintenance Instructions
Maintenance Instructions
ABC.2
DIE244EN - 15.08.2022
2022-08-15/Sp/Wartungsanleitung/20207502

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  • Page 1 OPERATING INSTRUCTIONS Maintenance Instructions Maintenance Instructions ABC.2 DIE244EN - 15.08.2022 2022-08-15/Sp/Wartungsanleitung/20207502...
  • 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

    Table of contents 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 A020 - Check hydraulic system (visual inspection)....................9 A027 - Replace the breathing filter at the filler neck of the hydraulic fluid tank............11 A030 - Clean covers of Tur.
  • Page 4 Table of contents Service Interval - 2.000 Operating hours......................45 Maintenance Summary - 2.000 Operating hours....................46 C010 - Check maintenance logs of servicing activities..................47 C020 - Clean and check wipers and guide rails of the work area door..............48 C070 - Check outer wipers of linear guides......................51 C080 - Check all electrical connections and drive belts of the drive motors............
  • Page 5 Table of contents Service Interval - 5 Years............................103 Maintenance Summary - 5 Years.........................104 I010 - Renewing the pneumatically pilot-controlled cooling lubricant valves............105 I020 - Replace the pressure accumulator......................106 Service Interval - 8 Years............................109 Maintenance Summary - 8 Years.........................110 J020 - Replace the window pane........................
  • Page 6 Table of contents Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 7: Preface

    Preface 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.

  • Page 8: Safety Instructions

    Preface 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.
  • Page 9 Preface 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.
  • 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 ABC.2 DIE244EN - 15.08.2022...

  • Page 12: Maintenance Summary - Care Activities

    Maintenance Summary - Care activities 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 DIE245EN - 15.08.2022. The maintenance interval is highly dependent on the production and environmental conditions of the machine.

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

    Maintenance Summary - Care activities 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.
  • Page 14 Maintenance Summary - Care activities 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.

  • Page 15: A020 - Check Hydraulic System (Visual Inspection)

    Maintenance Summary - Care activities A020 - 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.
  • Page 16 Maintenance Summary - Care activities Procedure 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.

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

    Maintenance Summary - Care activities 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!
  • 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 ABC.2 DIE244EN - 15.08.2022...

  • Page 19: A030 - Clean Covers Of Tur. Ii. Remove And Clean Covers

    Maintenance Summary - Care activities A030 - Clean covers of Tur. II. Remove and clean covers. Procedure 1. Clean covers of Tur. II. Remove and clean covers. Eliminate any damages or replace covers. 2. Clean wipers of Tur. II. Unscrew and clean wipers. Eliminate any damages or replace wiper.

  • Page 20: A040 - Check Pneumatic System (Visual Inspection)

    Maintenance Summary - Care activities A040 - Check pneumatic system (visual inspection) Orientation To ensure trouble-free operation, periodic checks of the pneumatic system are necessary. Check oil level at oiler (optional). Check pressure setting on pressure gauge. Check supply and fluid lines. Check silencers.
  • Page 21 Maintenance Summary - Care activities 5. Drain condensate (not applicable to auto-drain). Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 22: A055 - Check Filters On Main Spindle Cooling Fan

    Maintenance Summary - Care activities A055 - Check filters on main spindle cooling fan Orientation The filters must be replaced regularly depending on the ambient conditions. Whether air flow exists can quickly and easily be made visible by attaching a thread at the opening of the air outlet. Use only the original filters according to the spare or wear parts list! Otherwise the machine is at risk of sustaining serious damage due to overheating.

  • Page 23: A060 - Check Filter On Control Cabinet Cooling Fan

    Maintenance Summary - Care activities A060 - Check filter on control cabinet cooling fan Orientation The filters must be replaced regularly depending on the ambient conditions. Whether air flow exists can quickly and easily be made visible by attaching a thread at the opening of the air outlet. Use only the original filters according to the spare or wear parts list! Otherwise the machine is at risk of sustaining serious damage due to overheating.
  • Page 24 Maintenance Summary - Care activities Example: Filter and filter cover Reinstall all covers. Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 25: A070 - Check Filter On Air Conditioner Cooling Fan

    Maintenance Summary - Care activities A070 - Check filter on air conditioner cooling fan Orientation The filters must be replaced regularly depending on the ambient conditions. Whether air flow exists can quickly and easily be made visible by attaching a thread at the opening of the air outlet. Use only the original filters according to the spare or wear parts list! Otherwise the machine is at risk of sustaining serious damage due to overheating.

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

    Maintenance Summary - Care activities A075 - Check fill levels of the fluid tanks Orientation To ensure the operational safety of the machine, the fill levels of all fluid tanks must be regularly checked, and topped off if necessary. Operating fluids such as hydraulic fluids, cooling lubricants, lubricating greases/oils are also subject to degradation or aging like the components involved in this process, and must therefore be serviced, refilled or changed at regular intervals.
  • Page 27 Maintenance Summary - Care activities Check fill level at lubricating oil tank. 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 ABC.2 DIE244EN - 15.08.2022...
  • Page 28 Maintenance Summary - Care activities Fill level indicator at a cooling lubricant recycling system (Knoll) Fill level indicator Check the fill level at the cooling lubricant reconditioning system (option). 5. Check fill level of the coolant tank (option). Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 29: A080 - Clean And Lubricate Clamping Device

    Maintenance Summary - Care activities A080 - Clean and lubricate clamping device Orientation To ensure reliability and accuracy of the machine, clamping devices must be subjected to periodic maintenance. The interval of this maintenance is strongly influenced by the type of material and daily production time.
  • 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 ABC.2 DIE244EN - 15.08.2022...

  • Page 31: A090 - Check Electrical Lines (Visual Inspection)

    Maintenance Summary - Care activities A090 - Check electrical lines (visual inspection) Orientation Leave the immediate area around the machine and the additional units free; do not use it as storage or warehouse space. This significantly reduces the risk of damage to electrical lines. Electrical lines routed outside the machine (e.g., lines for cooling lubricant systems, chip conveyor, and pedal switch) must be regularly checked for damage (e.g., pinching or cuts).

  • Page 32: A095 - Visual Inspection Of All Fluid Lines And Electrical Cables

    Maintenance Summary - Care activities A095 - Visual inspection of all fluid lines and electrical cables Orientation Depending on the duration of use, usage profile of the machine and different ambient conditions, it is absolutely necessary to subject all fluid lines and electrical cables to regular visual inspections.

  • Page 33: A100 - Clean Cooling Lubricant Outlet On Clamping Cylinder

    Maintenance Summary - Care activities A100 - Clean cooling lubricant outlet on clamping cylinder Orientation During machining, the cooling flow flushes small chips through the spindle in the direction of the clamping cylinder. Therefore, the cooling lubricant outlet on the clamping cylinder must be cleaned at regular intervals.

  • Page 34: A110 - Clean Filter Screens On Chip Conveyor

    Maintenance Summary - Care activities A110 - Clean filter screens on chip conveyor Orientation The chip conveyor is used for removal of swarf from the work area and is also a reservoir for the cooling lubricant. The cooling lubricant is filtered in the chip conveyor. For this purpose, various filters and filter plates are built into the chip conveyor.
  • Page 35 Maintenance Summary - Care activities 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 ABC.2 DIE244EN - 15.08.2022...

  • Page 36: A120 - Check Cooling Lubricant (Visual Inspection)

    Maintenance Summary - Care activities A120 - Check cooling lubricant (visual inspection) Orientation Follow the user documentation Notes on Operating Materials and the documentation of the cooling lubricant manufacturer. 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.
  • Page 37 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 ABC.2 DIE244EN - 15.08.2022...

  • Page 38: A147 - Check Work Area Light (Visual Inspection)

    Maintenance Summary - Care activities A147 - Check work area light (visual inspection) Orientation To ensure even illumination of the working areas in the machine, work area lights are installed in the work area. They enable safe working and should therefore be checked regularly. Damaged lighting fixtures must be replaced immediately.

  • Page 39: A170 - Clean Telescopic Covers And Wipers

    Maintenance Summary - Care activities A170 - Clean telescopic covers and wipers Orientation Depending on the material used and the machining process, the telescopic covers and wipers must be cleaned and checked regularly. In particular, for dry machining and before any prolonged shutdown of the machine (e.g., during weekends). Dirty telescopic covers and wipers affect the accuracy of the machine and its service life.

  • Page 40: A180 - Clean The Work Area

    Maintenance Summary - Care activities A180 - Clean the work area Orientation To ensure consistent quality, high availability and value retention, the machine must be regularly cleaned, depending on the operating conditions. Of course, this is influenced by various factors. The use of emulsion as a cooling lubricant requires a more frequent and intensive cleaning.

  • Page 41: A200 - Lubricate Machine According To Lubrication Chart

    Maintenance Summary - Care activities A200 - Lubricate machine according to lubrication chart Orientation Machines that do not have central lubrication must be lubricated at the relevant points by hand. In doing so, follow the current lubrication chart for the machine. Screws on the lubrication system, the connected components, and the supply lines must be tightened to the manufacturer's specified torques.

  • Page 42: A220 - Lubricate In Sync

    Maintenance Summary - Care activities A220 - Lubricate in sync Orientation Machines that do not have central lubrication must be lubricated at the relevant points by hand within certain intervals. Bearings and bevel gears of the synchronous spindles were factory-filled with grease and sealed with a seal against ingression of cooling lubricant.

  • Page 43: A225 - Clean The Chip Conveyor

    Maintenance Summary - Care activities A225 - Clean the chip conveyor Orientation Be sure to follow the respective manufacturer's documentation. To ensure a smooth production process, the chip conveyor should be cleaned and serviced regularly. With regular cleaning, any defects can be detected and corrected early.
  • Page 44 Maintenance Summary - Care activities Only one insert screen may be present in the chip conveyor during operation. Example: Chip conveyor ABC Sludge tank Cooling lubricant tank Insert screen Fill-level check Example: Screens Screen box Insert screen (dirty) Insert screen (cleaned) Coarse screen Clean screens and magnetic filter plates (option).
  • Page 45 Maintenance Summary - Care activities 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 ABC.2 DIE244EN - 15.08.2022...

  • Page 46: A280 - Clean Labyrinth Ring Of Spindles

    Maintenance Summary - Care activities A280 - Clean labyrinth ring of spindles Orientation When machining short-chipping materials such as brass, cast iron, or in case of residues from the grinding, the work area must be cleaned more frequently due to the special nature of the contamination. Depending on the duration of use, usage profile of the machine and different ambient conditions, it is necessary in particular to remove and clean the labyrinth rings.

  • Page 47: Service Interval - 1.000 Operating Hours

    Service Interval - 1.000 Operating hours Service Interval - 1.000 Operating hours Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 48: Maintenance Summary - 1.000 Operating Hours

    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 DIE245EN - 15.08.2022. B010 - Customer area Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 49: 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 50 Maintenance Summary - 1.000 Operating hours Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 51: Service Interval - 2.000 Operating Hours

    Service Interval - 2.000 Operating hours Service Interval - 2.000 Operating hours Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 52: Maintenance Summary - 2.000 Operating Hours

    Maintenance Summary - 2.000 Operating hours Maintenance Summary - 2.000 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 DIE245EN - 15.08.2022. C010 - Check maintenance logs of servicing activities C020 - Clean and check wipers and guide rails of the work area door C070...

  • Page 53: C010 - Check Maintenance Logs Of Servicing Activities

    Maintenance Summary - 2.000 Operating hours C010 - Check maintenance logs of servicing activities Orientation The maintenance logs on the performed maintenance activities allow you to review the maintenance activities carried out between two maintenance intervals. The logs may contain important indications as to work that may be necessary beyond the maintenance activities.

  • Page 54: C020 - Clean And Check Wipers And Guide Rails Of The Work Area Door

    Maintenance Summary - 2.000 Operating hours C020 - Clean and check wipers and guide rails of the work area door Orientation Regular inspection of the wipers prevents damage to the wipers themselves and to the work area door. If the work area door can be opened and/or closed only with increased effort, it can be expected that the wipers are already destroyed by accumulation of chips and swarf compaction.
  • Page 55 Maintenance Summary - 2.000 Operating hours Remove large chips on the inside of the work area door from top to bottom. Use a chip hook for this purpose. Example: 2 Sweep small chips and other debris from top to bottom using chip brooms or brushes. Remove small chips and chip accumulations on the inside of the work area door from top to bottom.
  • Page 56 Maintenance Summary - 2.000 Operating hours Example: 4 wipers on the sides and bottom, G300 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 If cleaning or replacement of the wipers has not resulted in tangible improvement, the soiled rollers and the guide rail of the work area door must also be cleaned.

  • Page 57: C070 - Check Outer Wipers Of Linear Guides

    Maintenance Summary - 2.000 Operating hours C070 - Check outer wipers of linear guides Carrying out the maintenance activities described below requires special knowledge. For this reason, these maintenance activities must only be carried out by staff that has received adequate training by the machine manufacturer! Orientation Regularly checking wipers of the roller guides prevents accelerated wear of the...

  • Page 58: C080 - Check All Electrical Connections And Drive Belts Of The Drive Motors

    Maintenance Summary - 2.000 Operating hours C080 - Check all electrical connections and drive belts of the drive motors Carrying out the maintenance activities described below requires special knowledge. For this reason, these maintenance activities must only be carried out by staff that has received adequate training by the machine manufacturer! Orientation This activity is merely a test to check the power and encoder connections for proper...
  • Page 59 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 ABC.2 DIE244EN - 15.08.2022...

  • Page 60: C110 - Replace Filter On Main Spindle Cooling Fan

    Maintenance Summary - 2.000 Operating hours C110 - Replace filter on main spindle cooling fan Orientation The filters must be replaced regularly depending on the ambient conditions. Whether air flow exists can quickly and easily be made visible by attaching a thread at the opening of the air outlet. Use only the original filters according to the spare or wear parts list! Otherwise the machine is at risk of sustaining serious damage due to overheating.

  • Page 61: C120 - Replace Filter On Control Cabinet Cooling Fan

    Maintenance Summary - 2.000 Operating hours C120 - Replace filter on control cabinet cooling fan Orientation The filters must be replaced regularly depending on the ambient conditions. Whether air flow exists can quickly and easily be made visible by attaching a thread at the opening of the air outlet. Use only the original filters according to the spare or wear parts list! Otherwise the machine is at risk of sustaining serious damage due to overheating.
  • Page 62 Maintenance Summary - 2.000 Operating hours Example: Filter Reinstall all covers. Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 63: C130 - Replace Filter On Air Conditioner Cooling Fan

    Maintenance Summary - 2.000 Operating hours C130 - Replace filter on air conditioner cooling fan Orientation The filters must be replaced regularly depending on the ambient conditions. Whether air flow exists can quickly and easily be made visible by attaching a thread at the opening of the air outlet. Use only the original filters according to the spare or wear parts list! Otherwise the machine is at risk of sustaining serious damage due to overheating.

  • Page 64: C140 - Check Cooling Unit For Cooling Lubricant

    Maintenance Summary - 2.000 Operating hours C140 - Check cooling unit for cooling lubricant Carrying out the maintenance activities described below requires special knowledge. For this reason, these maintenance activities must only be carried out by staff that has received adequate training by the machine manufacturer! Orientation Water-cooling equipment maintain the temperature in the cooling lubricant circuit on...

  • Page 65: C155 - Check Coolant

    The machine is filled with Nalco VARIDOS FSK25 at the factory. This water-glycol mixture can be ordered in 25 kg pack sizes from INDEX. When using a water recooler, be sure to follow the manufacturer’s instructions.
  • Page 66 Maintenance Summary - 2.000 Operating hours Procedure 1. Check coolant. 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.

  • Page 67: C170 - Lubricate In Sync

    Maintenance Summary - 2.000 Operating hours C170 - Lubricate in sync Orientation Machines that do not have central lubrication must be lubricated at the relevant points by hand within certain intervals. Bearings and bevel gears of the synchronous spindles were factory-filled with grease and sealed with a seal against ingression of cooling lubricant.

  • Page 68: C190 - Clean Labyrinth Rings Of Spindles

    Maintenance Summary - 2.000 Operating hours C190 - Clean labyrinth rings of spindles Orientation When machining short-chipping materials such as brass, cast iron, or in case of residues from the grinding, the work area must be cleaned more frequently due to the special nature of the contamination. Depending on the duration of use, usage profile of the machine and different ambient conditions, it is necessary in particular to remove and clean the labyrinth rings.

  • Page 69: C510 - Check Backup Data Carrier

    Maintenance Summary - 2.000 Operating hours C510 - Check backup data carrier Orientation If data from the control is lost, the backup CD/DVD always provides the ability to quickly restore the operation of the machine. Therefore, regularly checking this data carrier is essential. Procedure 1.

  • Page 70: C520 - Check Control Cabinet

    Maintenance Summary - 2.000 Operating hours C520 - Check control cabinet Orientation To avoid problems and prevent any resulting system failures, simplified control cabinet checks must be carried out at regular intervals on the cabinet and associated components. Additional built-in air conditioning units (option) ensure a constant temperature in the control cabinet.

  • Page 71: C540 - Check Cable And Hose Clamps For Tight Seating

    Maintenance Summary - 2.000 Operating hours C540 - Check cable and hose clamps for tight seating Carrying out the maintenance activities described below requires special knowledge. For this reason, these maintenance activities must only be carried out by staff that has received adequate training by the machine manufacturer! Orientation Cable and hose clamps are used to bundle and/or hold the cables and hoses in a...
  • Page 72 Maintenance Summary - 2.000 Operating hours Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 73: Service Interval - 4.000 Operating Hours

    Service Interval - 4.000 Operating hours Service Interval - 4.000 Operating hours Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 74: Maintenance Summary - 4.000 Operating Hours

    Maintenance Summary - 4.000 Operating hours Maintenance Summary - 4.000 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 DIE245EN - 15.08.2022. D010 - Cleaning of the machine D020 - Check the pressure accumulator D050...

  • Page 75: D010 - Cleaning Of The Machine

    Maintenance Summary - 4.000 Operating hours D010 - Cleaning of the machine Orientation To ensure consistent quality, high availability and value retention, the machine must be regularly cleaned, depending on the operating conditions. Of course, this is influenced by various factors. The use of emulsion as a cooling lubricant requires a more frequent and intensive cleaning.
  • Page 76 Maintenance Summary - 4.000 Operating hours When cleaning the drive area, make sure that the dirt does not penetrate directly into the path measuring systems and the ballscrews. The cleaning process must not aggravate the contamination of the components. Clean drive area. Spray cooling lubricant onto the drive area around the supports of the guide bars and then sweep off the rough dirt down into the drag of the machine with a hand brush.

  • Page 77: D020 - Check The Pressure Accumulator

    Maintenance Summary - 4.000 Operating hours D020 - Check the pressure accumulator Orientation A pressure accumulator consists of two chambers, a liquid and a gas section with a membrane as a separator. The liquid section is connected to the hydraulic circuit, so that the bubble reservoir is filled when the pressure rises, thereby compressing the gas.

  • Page 78: D050 - Check The Lubrication System

    Maintenance Summary - 4.000 Operating hours D050 - Check the lubrication system Orientation Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's documentation! The principle of open lubrication requires refilling of lubricating oil. During maintenance of the lubrication system, first perform a visual inspection of all components involved in lubrication for leaks and their visual condition.
  • Page 79 Maintenance Summary - 4.000 Operating hours Procedure Pressurized fluids exiting from damaged or incorrectly installed fluid lines. Danger General cuts or eye injuries. Power off the machine and depressurize the hydraulic system before any maintenance activities. Secure the machine against being switched on.

  • Page 80: D060 - Check The Pneumatic System

    Maintenance Summary - 4.000 Operating hours D060 - Check the pneumatic system Orientation The pneumatic system is composed of two components. The system section and the sealing air section (option). To ensure trouble-free operation, periodic checks of the pneumatic system are necessary. Check oil level at oiler (optional).
  • Page 81 Maintenance Summary - 4.000 Operating hours Example: Various silencer versions from FESTO/ Norgren Check silencer, replace if necessary. Dirty filter cartridges must never be cleaned but always replaced. Filter cartridges are hazardous waste and must be disposed of according to local regulations. Only filters with a filter fineness described in the fluid plans must be used.
  • Page 82 Maintenance Summary - 4.000 Operating hours Disconnect the fluid line in the area of the components and cover the opening of the fluid line with your finger. A slight counter pressure should be felt. Then connect the fluid line again. Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 83: D080 - Check The Sealing Air On The Synchronizing Device

    Maintenance Summary - 4.000 Operating hours D080 - Check the sealing air on the synchronizing device Orientation To protect the housing of the synchronizing device against ingress of liquids or dirt, compressed air (0.6 bar) is pressed into the housing. This so-called sealing air must regularly be checked for its function.

  • Page 84: D100 - Check Main Spindle

    Maintenance Summary - 4.000 Operating hours D100 - Check main spindle Carrying out the maintenance activities described below requires special knowledge. For this reason, these maintenance activities must only be carried out by staff that has received adequate training by the machine manufacturer! Orientation Checking the main spindle also includes other, additional activities.
  • Page 85 Maintenance Summary - 4.000 Operating hours Example: Encoder wheel Heidenhain ERM Clean encoder wheel. Do not use any metal tools or objects for cleaning. To ensure optimum data exchange between the encoder and the encoder wheel, the encoder wheel must be cleaned regularly. Ensure absolute cleanliness, so that the cleaning does not lead to additional contamination of the encoder wheel or the encoder.
  • Page 86 Maintenance Summary - 4.000 Operating hours Example: Cooling lubricant rotary distributor (e.g., from Hydronic) Check cooling lubricant distributor rotary distributor. Detach the cooling lubricant rotary distributor and check that cooling lubricant flows out. Cooling lubricant should escape from the rotary distributor when the machine and cooling lubricant pump are switched on and the work area door is closed.
  • Page 87 Maintenance Summary - 4.000 Operating hours Example: Stopper unit D42 Remove cooling lubricant and stopper unit. Loosen screws (6) and pull the cooling lubricant and stopper unit (1) out of the spindle from the back. The guide ring (2) has an O-ring (5) at its outside with which the spindle is sealed towards the work area and a Glyd ring (4) inside that is used to guide the cooling lubricant and stopper unit in the spindle.
  • Page 88 Maintenance Summary - 4.000 Operating hours Example: Cooling lubricant outlet on the clamping cylinder Screws on the acrylic glass cover Check the cooling lubricant drain on the clamping cylinder. Check that the drain is free and contains no chips. Loosen screws (X) and remove acrylic glass cover on the cooling lubricant drain of the clamping cylinder.

  • Page 89: D170 - Check The System For Reconditioning The Cooling Lubricant

    Maintenance Summary - 4.000 Operating hours D170 - Check the system for reconditioning the cooling lubricant Orientation Cooling and cleaning equipment for cooling lubricants is used where reconditioning of the cooling lubricant is necessary. Here, in order to achieve high availability of the cooling lubricant, the cooling lubricant is filtered (e.g., using edge gap filters or vacuum rotation filters) and also cooled using coolers to a certain preset temperature.

  • Page 90: D180 - Check Fire Extinguishing System (Visual Inspection)

    Maintenance Summary - 4.000 Operating hours D180 - Check fire extinguishing system (visual inspection) Orientation An examination of a fire extinguishing system may only be conducted directly by the manufacturer or a person with written authorization by the manufacturer. Be sure to read the operating instructions of the manufacturer! Procedure 1.

  • Page 91: D230 - Replace Belts And Check Belt Tension

    Maintenance Summary - 4.000 Operating hours D230 - Replace belts and check belt tension Carrying out the maintenance activities described below requires special knowledge. For this reason, these maintenance activities must only be carried out by staff that has received adequate training by the machine manufacturer! Orientation Use only the original belts according to the spare or wear parts list.
  • Page 92 Maintenance Summary - 4.000 Operating hours 10. Replace S1 belt. 11. Measure belt tension (frequency meter) and adjust belt. 12. Replace S2 (C200-4) belt. 13. Measure belt tension (frequency meter) and adjust belt. 14. Replace S8 (C200–4D) belt. 15. Measure belt tension (frequency meter) and adjust belt. Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 93: D370 - Check And Potentially Replace The End Position Dampers

    Maintenance Summary - 4.000 Operating hours D370 - Check and potentially replace the end position dampers Orientation Besides the software end positions and the emergency stop switches, the end position dampers are another safety device to protect the machine from damage. Their job is to absorb the impact force to the spindle bearings.
  • Page 94 Maintenance Summary - 4.000 Operating hours Example: End position damper (X), G200 Position tool carrier such as to allow safe access to the specific end position damper. 3. Remove screws and replace dampers. 4. The damper has a slit on one side and can be pushed over the ballscrew by rotating it.

  • Page 95: D380 - Replacing Hydraulic Fluid

    Maintenance Summary - 4.000 Operating hours D380 - Replacing hydraulic fluid Orientation Power off the machine and secure it against power on. Use only approved hydraulic fluid. Details can be found in the documentation and on the label of the hydraulic fluid tank. When changing the type of hydraulic fluid, the unit must be flushed with new fluid.
  • Page 96 Maintenance Summary - 4.000 Operating hours Hydraulic unit ABC Filler neck Cleaning cover Fill-level check Drain plug Accumulator drain valve Remove the cleaning cover (b) and clean the hydraulic fluid tank. 3. Replace the seal on the cleaning cover (b). 4.
  • Page 97 Maintenance Summary - 4.000 Operating hours Hydraulic unit ABC Hydraulic fluid filter Filter bowl Replace filters (Z) of the hydraulic fluid filters (X). A different number of hydraulic filters (X) may be installed, depending on the version. Unscrew filter bowl (Y), remove contaminated hydraulic fluid (oil sump) and used filter (Z) from the filter bowl (Y) and dispose of them according to environmental regulations.
  • Page 98 Maintenance Summary - 4.000 Operating hours 7. To fill in new hydraulic fluid, use a pump with a min. 10 µm micro filter that is exclusively used for hydraulic fluid. 8. Fill in the prescribed amount of new hydraulic fluid. 9.

  • Page 99: D460 - Check Blanking Plugs Of The Sliding Tracks On The Linear Guides

    Maintenance Summary - 4.000 Operating hours D460 - Check blanking plugs of the sliding tracks on the linear guides Orientation When mounting the guide bars, align the screw holes of the guide bar and then close them with a brass plug and sand them off. This will prevent damages from sharp edges to the wipers of the tool slides.
  • Page 100 Maintenance Summary - 4.000 Operating hours Punch the new blanking plug into the hole using a plastic mallet. 4. Grind off any excess material with the sanding screen. Be careful that the guide bar is not damaged. 5. Check with the straight edge that the blanking plugs are flush with the linear guide and no longer protrude.

  • Page 101: D480 - Replace Wipers On The Trolleys Of The Linear Guides

    Maintenance Summary - 4.000 Operating hours D480 - Replace wipers on the trolleys of the linear guides Carrying out the maintenance activities described below requires special knowledge. For this reason, these maintenance activities must only be carried out by staff that has received adequate training by the machine manufacturer! Orientation The wipers on the trolleys of the linear guides prevent the ingress of dirt into the...

  • Page 102: D490 - Replacing Wipers

    Maintenance Summary - 4.000 Operating hours D490 - Replacing wipers Orientation Regular inspection of the wipers prevents damage to the wipers themselves and to the work area door. If the work area door can be opened and/or closed only with increased effort, it can be expected that the wipers are already destroyed by accumulation of chips and swarf compaction.
  • Page 103 Maintenance Summary - 4.000 Operating hours Remove large chips on the inside of the work area door from top to bottom. Use a chip hook for this purpose. Example: 2 Sweep small chips and other debris from top to bottom using chip brooms or brushes. Remove small chips and chip accumulations on the inside of the work area door from top to bottom.
  • Page 104 Maintenance Summary - 4.000 Operating hours Example: 4 wipers on the sides and bottom, G300 Check the wipers for proper seating. After the wipers have been replaced, the work area door should open and close again without much effort as usual If replacement of the wipers has not resulted in tangible improvement, the soiled rollers and the guide rail of the work area door must also be cleaned.

  • Page 105: D500 - Perform Data Backup

    Maintenance Summary - 4.000 Operating hours D500 - Perform data backup Carrying out the maintenance activities described below requires special knowledge. For this reason, these maintenance activities must only be carried out by staff that has received adequate training by the machine manufacturer! Orientation If data from the control is lost, the backup CD/DVD always provides the ability to quickly restore the operation of the machine.

  • Page 106: D520 - Check Control Cabinet And Cable Assemblies (Visual Inspection)

    Maintenance Summary - 4.000 Operating hours D520 - Check control cabinet and cable assemblies (visual inspection) Carrying out the maintenance activities described below requires special knowledge. For this reason, these maintenance activities must only be carried out by staff that has received adequate training by the machine manufacturer! Orientation To avoid problems and prevent any resulting system failures, simplified control...
  • Page 107 Maintenance Summary - 4.000 Operating hours 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 ABC.2 DIE244EN - 15.08.2022...

  • Page 108: D640 - Check Setting Of Electrical Fuses

    Maintenance Summary - 4.000 Operating hours D640 - Check setting of electrical fuses Carrying out the maintenance activities described below requires special knowledge. For this reason, these maintenance activities must only be carried out by staff that has received adequate training by the machine manufacturer! Procedure Electric shock...

  • Page 109: Service Interval - 5 Years

    Service Interval - 5 Years Service Interval - 5 Years Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 110: Maintenance Summary - 5 Years

    Maintenance Summary - 5 Years Maintenance Summary - 5 Years It is recommended to document the maintenance activities carried out by using the appropriate maintenance log. The maintenance log has the document number DIE245EN - 15.08.2022. I010 - Renewing the pneumatically pilot-controlled cooling lubricant valves I020 - Replace the pressure accumulator Maintenance Instructions...

  • Page 111: 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 112: I020 - Replace The Pressure Accumulator

    Maintenance Summary - 5 Years I020 - Replace the pressure accumulator Orientation According to the pressure equipment directive 97/23/EC, the pressure accumulators built into the machine are of category I/ module A. They are provided with a CE mark by the manufacturer, and a declaration of conformity has been issued.
  • Page 113 Maintenance Summary - 5 Years Example: Pressure accumulator Connect and secure the pressure accumulator. Observe the tightening torque. Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...
  • Page 114 Maintenance Summary - 5 Years Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 115: Service Interval - 8 Years

    Service Interval - 8 Years Service Interval - 8 Years Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 116: Maintenance Summary - 8 Years

    Maintenance Summary - 8 Years Maintenance Summary - 8 Years It is recommended to document the maintenance activities carried out by using the appropriate maintenance log. The maintenance log has the document number DIE245EN - 15.08.2022. J020 - Replace the window pane Maintenance Instructions ABC.2 DIE244EN - 15.08.2022...

  • Page 117: J020 - Replace The Window Pane

    Maintenance Summary - 8 Years J020 - Replace the window pane Orientation 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.
  • Page 118 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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