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Index B400 Operating Instructions Manual

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OPERATING INSTRUCTIONS
Maintenance Instructions
Maintenance Instructions
B400 B500
DIE150EN - 15.08.2022
2022-08-15/Sp/Wartungsanleitung/20112158

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  • Page 1 OPERATING INSTRUCTIONS Maintenance Instructions Maintenance Instructions B400 B500 DIE150EN - 15.08.2022 2022-08-15/Sp/Wartungsanleitung/20112158...
  • 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

    A210 - Check hydraulic shock absorbers and rubber pads on the telescopic plates..........27 A267 - Clean the chip conveyor..........................29 Service Interval - 1.000 Operating hours......................31 Maintenance Summary - 1.000 Operating hours....................32 B010 - Customer area............................33 Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 4 I020 - Replace the pressure accumulator......................86 Service Interval - 8 Years............................89 Maintenance Summary - 8 Years...........................90 J005 - Note on replacing the window pane or removing the design pane..............91 J150 - Replace the window pane.......................... 94 Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 5: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 6: 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 7 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 8 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 9: Service Interval - Care Activities

    Service Interval - Care activities Service Interval - Care activities Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 10: Maintenance Summary - Care Activities

    - Check cooling lubricant (visual inspection) A132 - Check work area light (visual inspection) A210 - Check hydraulic shock absorbers and rubber pads on the telescopic plates A267 - Clean the chip conveyor Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 11: 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 12 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 13: A023 - Check Hydraulic System (Visual Inspection)

    For all work in connection with operating materials, the information in the data sheets of the respective manufacturers and the information in the document Notes on Operating Materials must be observed. Example: Hydraulic unit B400 B500 Filler neck (hydraulic fluid) Fill level indicator...
  • Page 14 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 15: 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 16 Maintenance Summary - Care activities Procedure Example: Filling and breathing filters of hydraulic and lubrication systems (by ARGO-HYTOS GmbH) Replace breathing filter. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 17: A043 - Check Pneumatic System (Visual Inspection)

    Drain condensate (not applicable to auto-drain). Check pressure setting on the pressure differential monitoring pressure gauge. Example: Pneumatic maintenance unit B400 B500(by FESTO) Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's...
  • Page 18 Pre-damage such as kinks or abrasions should be logged and replacement should be initiated. Example: Various silencer versions from FESTO Check silencer, replace if necessary 4. Drain condensate (not applicable to auto-drain). Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 19 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 20 (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 B400 B500 DIE150EN - 15.08.2022...

  • Page 21: A048 - Check The Lubrication System (Visual Inspection)

    Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's documentation! Example: Lubrication system B400 B500 (by BIJUR DELIMON Sure Fire II) The following components must be checked on the lubrication system (Z): a) Filler neck b) Pressure gauge for system pressure (>20 bar)

  • Page 22: A070 - Check 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 1. Remove cover frame. 2. Check the filters, replace if necessary. 3. Reinstall all covers. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 23: 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 24 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 25: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 26: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 27: A097 - Clean Cooling Lubricant Outlet On Clamping Cylinder

    2. If necessary, remove the acrylic glass cover on the cooling lubricant collection bin. Example: Cooling lubricant outlet unit B400 B500 Clean cooling lubricant collection bin. Check that the cooling lubricant outlet X is free of chips or other debris.

  • Page 28: 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 29 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 30: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 31: A210 - Check Hydraulic Shock Absorbers And Rubber Pads On The Telescopic Plates

    Hydraulic shock absorber Rubber pad Example: View of the telescope on the counter spindle side (viewing from the drive area) The hydraulic shock absorbers and rubber pads can be ordered directly from INDEX or from a representative. Maintenance Instructions B400 B500...
  • Page 32 (+/-) to adjust the damping of the cylinder. Be sure to follow the manufacturer's documentation for this! Example: Pads Check rubber pads on the telescopic plates (visual inspection). If the rubber pads are worn, they must be replaced immediately. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 33: A267 - 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 34 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 35: Service Interval - 1.000 Operating Hours

    Service Interval - 1.000 Operating hours Service Interval - 1.000 Operating hours Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 36: 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 DIE151EN - 15.08.2022. B010 - Customer area Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 37: 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 38 Maintenance Summary - 1.000 Operating hours Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 39: Service Interval - 2.000 Operating Hours

    Service Interval - 2.000 Operating hours Service Interval - 2.000 Operating hours Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 40: Maintenance Summary - 2.000 Operating Hours

    - Checking the guidance and support elements as well as the slidable lattice grate of the telescopic cover C190 - Clean labyrinth rings of spindles C510 - Check backup data carrier C525 - Check control cabinet C540 - Check cable and hose clamps for tight seating Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 41: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 42: C020 - Clean And Check Wipers And Guide Rails 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: 1 Removing chip nest using appropriate tools (e.g., chip hooks) Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 43 In this case, also clean the area behind the wipers. Make sure that the wipers evenly contact the work area door before tightening the screws. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 44 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. Clean rollers and guide rail of the work area door. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 45: C035 - Check Work Area Door (Optionally 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 46 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 47 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 48 If the obstacle detection does not immediately lead to reversal of the moving direction, the complete work area door must be checked immediately. The machine must not be operated any further. Be sure to contact the INDEX service department or an INDEX representative. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 49 Visual inspection of the drive of the automatic work area door. This is in particular an assessment of the toothed belt (2) - condition, tension. Also the condition of the two deflection pulleys (1+4) and the driver (3). Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 50: 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 51 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 52: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 53: C160 - Checking The Guidance And Support Elements As Well As The Slidable Lattice Grate Of The Telescopic Cover

    To do so, position the respective tool carrier in the center between the two end positions and determine the sag of the slidable lattice grate. If the sag is more than 5 mm, the slidable lattice grate must be repaired immediately. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 54: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 55: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 56: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 57: C540 - Check Cable And Hose Clamps For Tight Seating

    Example: Power cabling, G400 Check strain relief. Check the correct position of the boots and adjust the strain reliefs. 4. Record any damages and initiate repair. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 58 Maintenance Summary - 2.000 Operating hours Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 59: Service Interval - 4.000 Operating Hours

    Service Interval - 4.000 Operating hours Service Interval - 4.000 Operating hours Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 60: Maintenance Summary - 4.000 Operating Hours

    - Replace belts and check belt tension D457 - Replacing hydraulic fluid D500 - Perform data backup D520 - Check control cabinet and cable assemblies (visual inspection) D550 - Check air conditioners in the control cabinet Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 61: 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 62 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 63: D017 - Clean Spring Steel Wiper In The Area Of The Work Area Door

    (X). Fig.: Tool for removing chips After removing the cover panels, remove the spring steel wipers and clean the space behind this cover /these wipers. Avoid pushing the chips into the spaces Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 64 3. For assembly, follow the steps in reverse order. Ensure proper cleanliness during the installation. 4. Reattach the spring steel wipers and cover panels, making sure that they rest evenly against the work area door so they can cleanly wipe off any chips. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 65: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 66: D047 - Check The Lubrication System

    The principle of open lubrication requires refilling of lubricating oil. Example: Lubrication system B400 B500 (by BIJUR DELIMON Sure Fire II) During maintenance of the lubrication system, first perform a visual inspection of all components involved in lubrication for leaks and their visual condition. The following...
  • Page 67 2. Check lubrication pressure (pressure gauge >20 bar) and related sensors. 3. Activate lubrication pulse in the control ten times. 4. Monitor the area around the lubricating oil distributor for leakage. 5. Check oil level in lubricating oil tank, replenish if necessary. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 68: D063 - Check The Pneumatic System

    Drain condensate (not applicable to auto-drain). Check pressure setting on the pressure differential monitoring pressure gauge. Example: Pneumatic maintenance unit B400 B500(by FESTO) Due to different requirements and/or specifications of the respective manufacturers, be sure to review the respective manufacturer's...
  • Page 69 Pre-damage such as kinks or abrasions should be logged and replacement should be initiated. Example: Various silencer versions from FESTO Check silencer, replace if necessary 4. Drain condensate (not applicable to auto-drain). Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 70 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 71 O-ring (5), separating disk (2), and filter receptacle (4). Unscrew filter bowl (1) from filter base body and remove filter cartridge (3) , and replace. Check O-ring (5) , replace if necessary. Reinstall all parts in reverse order. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 72: D085 - 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: Variant for depth stop/flushing unit O-ring Rotary feeder Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 73 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. Example: Holding brake (X) B400 B500 Check the tightness of the holding brake (2). Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 74 In any case, make sure that the seals recommended by the manufacturer are used or installed during maintenance or repair work. 6. Check the condition/tightness of the power and encoder connections as well as the fluid lines of the respective components. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 75: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 76: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 77: D347 - Replace Belts And Check Belt Tension

    Move the tool slides to a suitable position. 2. Replace Y1 belt. 3. Measure belt tension (frequency meter) and adjust belt. 4. Replace A8 belt. 5. Measure belt tension (frequency meter) and adjust belt. 6. Replace A11 belt. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 78 (see example: distance between deflection pulley and belt clamping). This value or distance is necessary to accurately adjust the belt tension. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 79: D457 - 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 80 Maintenance Summary - 4.000 Operating hours Example: Hydraulic unit B400 B500 Filler neck (hydraulic fluid) Fill level indicator Accumulator drain valve Monitoring (level and temperature) Oil drain plug Electrical monitoring (contamination indicator) Pressure gauge (system pressure) Pressure accumulator Safety valve...
  • Page 81 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 82: 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 83: 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 84 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 85: D550 - Check Air Conditioners In The Control Cabinet

    1. Check air conditioners in the control cabinet. 2. Check condensate drain. 3. Check air inlets and outlets. Use only the original filters according to the spare or wear parts list. Replace filter. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 86 Maintenance Summary - 4.000 Operating hours Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 87: Service Interval - 5 Years

    Service Interval - 5 Years Service Interval - 5 Years Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 88: 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 DIE151EN - 15.08.2022. I010 - Renewing the pneumatically pilot-controlled cooling lubricant valves I020 - Replace the pressure accumulator Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 89: 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 90: 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 91 Maintenance Summary - 5 Years Example: Pressure accumulator Connect and secure the pressure accumulator. Observe the tightening torque. Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...
  • Page 92 Maintenance Summary - 5 Years Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 93: Service Interval - 8 Years

    Service Interval - 8 Years Service Interval - 8 Years Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 94: 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 DIE151EN - 15.08.2022. J005 - Note on replacing the window pane or removing the design pane J150 - Replace the window pane Maintenance Instructions B400 B500 DIE150EN - 15.08.2022...

  • Page 95: 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 96 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 97 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 B400 B500 DIE150EN - 15.08.2022...

  • Page 98: 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 99 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 100 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 101 (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 B400 B500 DIE150EN - 15.08.2022...
  • Page 102 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 103 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 104 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 B400 B500 DIE150EN - 15.08.2022...
  • Page 106 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...

This manual is also suitable for:

B500

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