Index ABC User manual

LL1602.10043 - 04.08.2014
0814/Pr/Sp (Transport, Aufstellung, Inbetriebnahme)
Transportation,
Installation,
Commissioning
ABC
OPERATING INSTRUCTIONS
Refer to additional sheet: Important information before commissioning

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ABC
Note on applicability
Illustrations in this publication may deviate from the product supplied. Errors and omissions due to technical
progress excepted.
A word on copyright
This document is protected by copyright and was originally compiled in German.
The duplication and distribution of this document or parts thereof is prohibited without prior consent of
the copyright owner, and any violators will be prosecuted. All rights, including the right to translate, are
reserved.
©Copyright by INDEX-Werke GmbH & Co. KG, TRAUB Drehmaschinen GmbH & Co. KG 2014
Englisch

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CONTENTS
Contents............................................................................................................................................................................. 3
Safety Instructions .......................................................................................................................................................... 5
Instructions for shipment, installation, commissioning .................................................................................................. 5
General sources of danger during in-house transportation...................................................................................... 5
Dimensions and masses.............................................................................................................................................. 6
Shipping- and lifting equipment................................................................................................................................... 6
Transport equipment, ropes......................................................................................................................................... 6
Preparations ...................................................................................................................................................................... 7
Suitable transport- and lifting equipment........................................................................................................................ 7
Space requirements .......................................................................................................................................................... 8
Foundations ........................................................................................................................................................................ 8
Environmental Conditions ................................................................................................................................................. 8
Power supply ..................................................................................................................................................................... 9
Compressed Air Supply .................................................................................................................................................... 9
Main fuse ........................................................................................................................................................................... 9
External data transfer........................................................................................................................................................ 10
Media to be provided ....................................................................................................................................................... 10
Pumps and Tanks.............................................................................................................................................................. 11
Chip disposal...................................................................................................................................................................... 11
Disposal of used media.................................................................................................................................................... 11
Compliance with waterbalance regulations .................................................................................................................... 11
Transport ............................................................................................................................................................................ 12
Delivery............................................................................................................................................................................... 12
Machine ......................................................................................................................................................................... 12
Pressure accumulator ................................................................................................................................................... 12
Other separate units..................................................................................................................................................... 12
Transportation equipment............................................................................................................................................. 12
Unloading the machine with a crane .............................................................................................................................. 14
Quick start manual for Transport ABC ...................................................................................................................... 15
Preparations ...................................................................................................................................................................... 17
Transportation with a fork lift ........................................................................................................................................... 17
Transportation with casters .............................................................................................................................................. 18
Placing the machine.......................................................................................................................................................... 20
...with a crane or a mobile crane .......................................................................................................................... 20
...with hydraulic jacks (Fig.)..................................................................................................................................... 20
Unloading and transporting separate units ..................................................................................................................... 22
Unpacking the accessories and checking them for completeness ............................................................................. 22

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CONTENTS
Installation......................................................................................................................................................................... 23
Electrical connection ........................................................................................................................................................ 23
Important notes............................................................................................................................................................. 23
Putting-up and Levelling the Machine ............................................................................................................................ 24
Putting-up and alignment of attachments ...................................................................................................................... 25
Anchoring the Machine................................................................................................................................................ 25
Commissioning................................................................................................................................................................. 26
Cleaning the Machine ....................................................................................................................................................... 26
Checking supplies, restocking .......................................................................................................................................... 26
Pressure accumulator ...................................................................................................................................................... 26
Removing the shipping brackets...................................................................................................................................... 27
Attaching the filler/breather filter ..................................................................................................................................... 28
Bleeding the Hydraulic System........................................................................................................................................ 28
Loss of data after a longer idle period ........................................................................................................................... 28
Switching-on the Machine................................................................................................................................................ 28
Changing the location .................................................................................................................................................... 29
Applicable only for machines with a chip conveyor...................................................................................................... 29
Applicable only for machines with a bar feeder or a bar loading magazine.............................................................. 29
Mounting the shipping braces ......................................................................................................................................... 30

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SAFETY INSTRUCTIONS
Instructions for shipment, installation, commissioning
Safety Instructions
Instructions for shipment, installation, commissioning
When the working area door is open, the interlocking switch
remains open after disconnecting the mains supply.
Shipping brackets are identified by their red color.
Improper shipment, installation or commissioning often leads to accidents, damage
or malfunction of the machine which INDEX will accept no liability for and which
will not be covered by the warranty.
Before the delivery, you should carefully plan the shipment to the installation site,
the unloading, the installation and the commissioning of the machine. Please pay
attention to the following instructions in this document.
For separate units e.g. chip conveyor, bar feeder, bar loading magazine etc., please
see the corresponding shipping instructions.
General sources of danger during in-house transportation
Machines may be shipped only by authorized and qualified personnel.
Act consciously during shipping. Please omit hazardous and risky actions. Consider
the consequences before acting.
Slopes and pitches can be particularly dangerous (e.g. ramps etc.). If passage is
unavoidable extra precautions must be taken.
Make sure that the load will not slide off and that vehicle's traction and brake force
are sufficient. Provide the load with additional securing devices, if necessary.

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SAFETY INSTRUCTIONS
Instructions for shipment, installation, commissioning
Dimensions and masses
For the masses of the machine and the control cabinet see the appropriate ma-
chine installation diagram in the chapter "Working data."
For the masses of separate units e.g. chip conveyor, bar feed, bar loading magazine
etc. see the additional transportation instructions for these attachments or the ap-
propriate machine installation diagram in the chapter "Working data".
Shipping- and lifting equipment
For lifting and moving individual units use only lifting and moving equipment with
adequate load bearing capacity and loading area.
Transport equipment, ropes
For lifting the machine with a crane use only the provided transportation gear. This
also applies to certain separate units such as bar feeder and the bar loading maga-
zine.
For lifting all other separate units with a crane no special transportation equipment
will be provided.
When selecting your own transportation equipment and ropes make sure that they
have the recommended capacity and length.
When selecting and applying the transportation equipment and ropes/round slings
respectively, consider the following instructions in this document, e. g.:
– Unloading the machine with a crane or a mobile crane.
– Unloading and transporting of separate units.

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PREPARATIONS
Preparations
This chapter is addressed to all personnel in charge of the installation.
On the basis of the following instructions, the installation site can be prepared for
immediate installation and commissioning of the machine.
Make sure that the delivery, the unloading and the placement of the machine from
the unloading location to the installation site are planned carefully.
Take into account the size (dimensions) and the masses of the individual units.
Suitable transport and lifting equipment must be provided on delivery of the ma-
chine.
Remove potential obstacles along the way from the unloading location to the instal-
lation site.
Inspect the route for load bearing capacity, evenness, damage to surface, ridges,
gradients and slopes etc.
Is there sufficient clearance through gates and door ways?
Do elevators have sufficient load bearing capacity?
Good preparation pays off!
Suitable transport- and lifting equipment
– Crane
– Mobile crane
– Fork lifter
– Trolley
– Conveyor rolls
– Hydraulic jacks
– Pallet truck (only for separate units; not suitable for machines).

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PREPARATIONS
Space requirements
Make sure to provide for the following:
– Sufficient clear space around the machine.
– Sufficient moving space for the operator.
– Sufficient space for maintenance and repair works.
– It must be possible to open all machine doors completely.
– Floor area must be provided for blanks- and workpiece palettes, workpiece con-
tainer, chip pan, tool trolley etc.
See the machine installation diagram in the chapter "Working Data" for determining
the space requirements.
For attachments such as bar feeders, bar loading magazines etc., see separate
installation diagrams in the chapter "Working Data".
Foundations
Special foundations are not necessary as long as the floor quality complies with the
usual building regulations according to the weight of the machine.
Within the machine standing area there must not be expansion joints.
The machine may be anchored. For anchoring holes refer to the machine installa-
tion diagram in the chapter "Working Data".
Bar supports, bar feeders and bar loading magazines must always be anchored.
(For instructions see the appropriate operating instructions and the machine installa-
tion diagram in the chapter "Working Data").
When using a bar feed or a bar loading magazine INDEX recommends anchoring
the machine as well.
Environmental Conditions
See Environmental Conditions in the document “Safety instructions”
If the data at the installation site deviate from the values
above, please, contact INDEX or an INDEX agency.

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PREPARATIONS
Power supply
Keep the cables for mains supply to the machine as short as
possible. Cable cross section must be adequate.
Power supply for the PLC and for the NC must be stable, i.e. the voltage fluctua-
tion must not exceed +10% - 10%.
The cables must comply with the regulations of the local electricity suppliers and
the locally valid regulations.
For additional data see chapter "Working Data".
Compressed Air Supply
Be aware of the max. permissible pressure for the machine.
See pneumatic diagram in the chapter "Working Data".
Machines with elements operating with compressed air require compressed air sup-
ply with the following capacity:
Working pressure.....................................6 to 10 bar
Consumption ............................................according to machine equipment
For compressed air feed into the machine, see machine installation diagram in the
chapter "Working Data".
Main fuse
Check if the service line can be loaded with an extra value that
requires fusing.
In case of doubt have the situation clarified by the local elec-
tricity provider.
The main fuse is not provided with the machine delivery. According to the regula-
tions DIN EN 60204-1 this must be installed externally i.e. outside of the machine.
If a pre-transformer is required, the main fuse must be installed ahead of the pre-
transformer i.e. in the primary circuit.
The fusing depends on the operating voltage.
For the values for
– mains connection,
– operating voltage,
– main fuse
see machine installation diagram in the chapter "Working Data".

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PREPARATIONS
External data transfer
Data lines must not run directly next to power lines.
When you intend to transmit data from/to an external computer or memory, appro-
priate metal ducts for the data lines must be installed.
Media to be provided
– Hydraulic oil 1)
– Lubricating oil 1)
– Appr. 1 kg heavy duty grease for chucks
– Coolant
For types of lubricating oil, hydraulic oil, grease and coolant as well as filling
amounts see chapter "Maintenance Instructions" and the "machine installation dia-
gram" in chapter "Working Data".
Attention!
Only hydraulic oil according to ISO 4406 with a purity 15/12 (10 µm
absolute) may be filled. Hydraulic oil: HLP 32; HLPD 32; VG 32.
Lubrication oil CG 68; G68
1) Machine supplied with tank filled.

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PREPARATIONS
Pumps and Tanks
Change of hydraulic oil and coolant is part of regular maintenance.
For filling the hydraulic oil tank of the machine a pump with a 10 µm-microfilter
(absolute) is required. The pump may be used only for this purpose.
For emptying the hydraulic oil tank and the coolant tank an ordinary pump is suf-
ficient. The same pump can be used for filling the coolant tank, however, it has to
be flushed with clean coolant beforehand.
The drained-off liquids are best collected in stable containers with adequate capac-
ity. Best suitable are metal barrels which can be sealed and should be labelled.
Chip disposal
When the machine is equipped with a chip conveyor, a chip trolley to suitable for
the discharge height of the chip conveyor is required.
The chip trolley should have a tap for draining-off the coolant trapped from the
chips.
This is environmentally beneficial and money saving.
Disposal of used media
Please ensure in time how used media such as hydraulic oil, lubricating oil and
coolant can be disposed of in compliance with environment pollution regulations.
Compliance with waterbalance regulations
The locally valid guide lines and regulations must be taken into con-
sideration
The machine contains water polluting liquids, such as water soluble coolants and
mineral oils. These can leak out of the machine accidentally. Therefore the machine
must be installed in a manner that no detrimental effects are possible to waters or
ground water by these media.
Possible precautions:
– Placing the machine into a steel tray.
– Sealing the workshop floor.

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TRANSPORT
Delivery
Delivery
Machine
The machine is delivered by truck it is either on planks or packed in a box standing
on a transportation platform.
Machine state on delivery:
– Hydraulic oil and lubricant oil tanks are filled.
– Coolant tank is empty. (The machine is equipped with a chip conveyor with
integrated coolant tank. The chip conveyor is packed separately.)
– Certain moving parts of the machine e.g. sliding doors and pivoting operator’s
panel are secured by appropriate brackets.
– Overhanging parts that hamper the transportation are dismantled.
– All bright parts of the machine are coated with a rust preventive.
Pressure accumulator
When the machine has been transported as airfreight all pressure accumulators fit-
ted will be depressurized.
Before commissioning all pressure accumulators must be filled with nitrogen (N2) by
a specialist. Please keep to the recommended pressures.
For recommended pressures see the "Hydraulic diagrams" in the chapter "Working
data".
Other separate units
Certain attachments like chip conveyor, bar feeder, bar loading magazine etc. are
generally packed separately
Chip conveyors are usually shipped on a platform.
Bar feeder and bar loading magazine are shipped in a separate box.
Loose parts, such as spanners, small tools and instruments etc. are packed in a
separate cardboard box. This might be enclosed with one of the separate units.
Transportation equipment
The transportation equipment is either packed separately or enclosed with other
units.
The transportation equipment is generally charged for. When returning it to INDEX
after installation, a refund will be paid.

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TRANSPORT
Delivery
First check the machine, the enclosed accessories and optional units for external
damage and completeness (Bill of loading, delivery note).
Missing goods or damages can confirmed on the note of delivery by the shipping
company.
In case of damage it is recommended to take photographs for easier proof.
Please notify INDEX or INDEX agency.

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TRANSPORT
Unloading the machine with a crane
Unloading the machine with a crane
Suspended loads!
Fatal danger by a crushing machine.
Do not step under suspended loads and use only the permitted
transportation equipment.
Height of crane hook above ground level:
Height of the unit (e.g. Machine, control cabinet etc)
+Lifting gear or length of slings above the unit ............................ see Fig.
+Floor height of truck........................................................................ approx. 1,3 m
+Hoisting ........................................................................................... 0,2 m
Remove all securing devices for transportation on the truck.
Attach the supplied lifting gear.
Use a crane with sufficient carrying capacity. Unload the ma-
chine as close as possible installation site.
Short transportation distances reduce the risk of accidents.
Lift machine slowly and carefully.
Make sure to keep the machine in a horizontal position. The
centre of gravity is not exactly in the middle of the machine.
If necessary put down the machine again and correct the tilt
by adjusting the hooks on the beam.
Lift machine off the truck or move truck from under the suspended machine.
Place the transportation (e. g. trolley) means under the machine.
Ensure that the selected transportation equipment has suf-
ficient load bearing capacity. It must be at least equal to the
machine mass.
When using a trolley the load bearing area must be larger than
the machine area (floor area).
Lower machine slowly and carefully onto the trolley, remove the lifting equipment
and move the machine to the installation site.

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QUICK START MANUAL FOR TRANSPORT ABC
LL 26 02.1 0013 - 04.08.2014
0814/Pr/Sp
Unloading the machine with a crane
Pos. No off Name Ordering No.
Transporting tackle
1
2
3
4
5
6
7
1
2
1
2
2
12
4
6
6
1
Girder 3t
Sling rope/ Ø12 x 1600
Sling rope/ Ø12 x 1750
Hook
Hook long
Cheese Head Screws M12 x 35 DIN 912-12.9
Retaining eye
plain washer
truss-head screw M16x260 DIN 603
Sling rope/ Ø20 x 1870
208315.1406
2 0 8111.12 3 2
2 0 8111.12 3 5
208310.4601
208310.4604
410 260.1235
208310.4622
419 0 21.16
410986.1660
2 0 8111. 2 0 37
Fig. 1 L16 0 1.10 0 41_11
1
3
2
4+6
5+6
7
appr. 2000appr. 1700
6
Attention!
Check the slings/chains for proper attachment in the
transport hooks before lifting the machine. If other ropes
are used for transport than those indicated here, make
sure when lifting the machine that the ropes do not
touch the housing. Transport the machine in horizontal
position only (fig.1).
For transport with a fork-lift truck, the machine must be
placed on planks. For minimum length and spacing of
the prongs, see fig. 2.
The girder and slings/chains neces-
sary for transporting the machine
are supplied with the machine at
extra charge and can be returned
to INDEX-works after installation of
the machine.
INDEX ABC
Method of Slinging
Mass of machine
ca. 2900 kg
Mass of tackle,
complete
ca. 75 kg
Kunde: _______________________________________________________
Auftr.-Nr.: ________________ Masch. Nr: ______________________
L1301.10 0 81_4.tif

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QUICK START MANUAL FOR TRANSPORT ABC
INDEX-Werke GmbH & Co. KG
Hahn & Tessky
D-73726 Esslingen
Fax [phone] - 587
E-Mail: [e-mail]
Unloading the machine with a crane
min. 1700
ca. 1250
min. 1700
ca. 1250
Securing devices for Transport
Before start-up all securing devices for the transport must be removed. Shipping brackets are identi-
fied by their red color.
Siding guard Turret 1 ( Z-axis) Turret 2 ( Z-axis)
L1601.100 41_ 4 L1601.100 41_ 21 L1601.100 41_ 6
L1601.10 0 41_15 L1601.10 0 41_17/18 L16 01.100 41_19
1 2 2 3
Connec t the leakage oil-line from the chuck-
ing cylinder (1) to the oil tank (36mm A /F).
Unscrew the closing plug (2), and replace it
with the filling and airing filter (3).
Fig. 2
Transport of the machine by fork lift truck
L16 01.10 041_10

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PREPARATIONS
Transportation with a fork lift
Transportation with a fork lift
The fork may be placed under the machine only from the front
of the machine.
The minimum specified length of the fork must be observed.
See Fig. 2.
For mass of the machine refer to chapter "Transport instructions".
(Quick start manual for Transport ABC)

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PREPARATIONS
Transportation with casters
077001.0277
077001.0276
Transportation with casters
Use transportation casters when there is no suitable crane, a mobile crane or when
a fork lift truck cannot be used at the installation site.
The advantage of casters is the low loading height which allows loading and un-
loading the machine using a hydraulic jack.
The disadvantages are the relatively small wheels (casters) which require a solid
smooth floor with appropriate load bearing capacity, transport is very slow and
must not be jerky.
Depending on the size of the machine two or three casters are needed, one of
which must be a swivel caster.
The load bearing capacity of the individual trolley may be less than the mass of the
machine.
When using 2 trolleys their load bearing capacity should be 2/3 of the machine
mass.
When using 3 trolleys the two rigid ones should be able to take at least 1/3, the
steerable one 2/3 of the machine mass.
Castor trolleys are placed under the short sides of the machine base. If the ma-
chine sits on planks, the transport rolls may also be pushed under them. Lower the
machine slowly until it rests on the castor trolleys as shown in the picture.
The casters must always run in parallel to the load, otherwise they will "rub" and
the coating of the castors will get damaged.
Connect the swivel caster and the fix ones with steel ropes
(Fig) to prevent them from moving apart.
Secure the load with suitable straps.

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PREPARATIONS
Transportation with casters
Notes on lifting with hydraulic jacks:
– Always put first the fix castors under the machine first and then the swivel cas-
tors.
– With the fix castors the resting plates must always protrude over the edges of
the load to be transported
– The load must be secured against rolling away.
– With the swivel casters the load must be placed in the middle of the turn table
to ensure that the steering rod can be moved freely.
Notes on transportation with a crane:
– The load must be lowered gently on the casters.

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PREPARATIONS
Placing the machine
P120 1.10 0 51 _ 21
Placing the machine
When the final installation site has been determined and prepared, the machine can
be directed there and put down carefully.
Placing the machine ...
...with a crane or a mobile crane
Lift the machine with the crane until it is suspended.
When you have moved the machine on casters to the installation site pull these
out from under the machine.
...with hydraulic jacks (Fig.)
Hydraulic jacks are required when the use of a crane is not possible at the installa-
tion site.
When lifting or lowering the machine with hydraulic jacks
make sure that a three-point bearing is provided for: Seat the
machine on the floor or on two Conveyor rolls on one side –
two hydraulic jacks on the other side.
Always jack up one narrow side of the machine. The other
narrow side must stand on the transportation means or on the
floor.
Never lift the machine higher than absolutely necessary.
As the centre of gravity does not lie in the middle of the ma-
chine the load bearing capacity of one jack should be at least
1/3 of the machine mass when using 2 hydraulic jacks.
When working with only one hydraulic jack its load bearing
capacity should be minimum 2/3 of the machine mass.
Lift the machine step by step and support the machine after
each step by packing suitable blocks of wood underneath.
Same applies for lowering.