Index B400 User manual

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

Disclaimer
The illustrations in this documents may deviate from the delivered product. We reserve the right to make changes
due to errors or based on technical advances.
A Word on Copyright
This document is proprietary and was originally written in German. Its reproduction and distribution in whole or in
individual parts without permission of the copyright owner is prohibited and will be prosecuted under criminal or civil
law. All rights reserved, including for translation.
© Copyright by INDEX-Werke GmbH & Co. KG Hahn & Tessky

Table of contents
Preface........................................................................................................................................................................ 1
General notes..........................................................................................................................................................1
Safety Instructions...................................................................................................................................................1
Service Interval - Care activities.............................................................................................................................. 5
Maintenance Summary - Care activities..................................................................................................................6
A010 - Check the work area door and window pane............................................................................................... 7
A023 - Check hydraulic system (visual inspection)..................................................................................................9
A027 - Replace the breathing filter at the filler neck of the hydraulic fluid tank.......................................................11
A043 - Check pneumatic system (visual inspection)............................................................................................. 13
A048 - Check the lubrication system (visual inspection)........................................................................................17
A070 - Check filter on air conditioner cooling fan...................................................................................................18
A080 - Clean and lubricate clamping device......................................................................................................... 19
A090 - Check electrical lines (visual inspection)....................................................................................................21
A095 - Visual inspection of all fluid lines and electrical cables...............................................................................22
A097 - Clean cooling lubricant outlet on clamping cylinder................................................................................... 23
A120 - Check cooling lubricant (visual inspection)................................................................................................ 24
A132 - Check work area light (visual inspection)................................................................................................... 26
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
Table of contents
I
Maintenance Instructions
B400 B500
DIE150EN - 15.08.2022

Service Interval - 2.000 Operating hours.............................................................................................................. 35
Maintenance Summary - 2.000 Operating hours...................................................................................................36
C010 - Check maintenance logs of servicing activities..........................................................................................37
C020 - Clean and check wipers and guide rails of the work area door.................................................................. 38
C035 - Check work area door (optionally with electr. drive) and window pane...................................................... 41
C080 - Check all electrical connections and drive belts of the drive motors.......................................................... 46
C140 - Check cooling unit for cooling lubricant......................................................................................................48
C160 - Checking the guidance and support elements as well as the slidable lattice grate of the telescopic cover
.............................................................................................................................................................................. 49
C190 - Clean labyrinth rings of spindles................................................................................................................ 50
C510 - Check backup data carrier.........................................................................................................................51
C525 - Check control cabinet................................................................................................................................ 52
C540 - Check cable and hose clamps for tight seating..........................................................................................53
Service Interval - 4.000 Operating hours.............................................................................................................. 55
Maintenance Summary - 4.000 Operating hours...................................................................................................56
D010 - Cleaning of the machine............................................................................................................................ 57
D017 - Clean spring steel wiper in the area of the work area door.........................................................................59
D020 - Check the pressure accumulator............................................................................................................... 61
D047 - Check the lubrication system..................................................................................................................... 62
D063 - Check the pneumatic system.....................................................................................................................64
D085 - Check main and counter spindles..............................................................................................................68
D170 - Check the system for reconditioning the cooling lubricant......................................................................... 71
D180 - Check fire extinguishing system (visual inspection)................................................................................... 72
D347 - Replace belts and check belt tension........................................................................................................ 73
D457 - Replacing hydraulic fluid............................................................................................................................ 75
D500 - Perform data backup..................................................................................................................................78
D520 - Check control cabinet and cable assemblies (visual inspection)............................................................... 79
D550 - Check air conditioners in the control cabinet............................................................................................. 81
Service Interval - 5 Years........................................................................................................................................ 83
Maintenance Summary - 5 Years...........................................................................................................................84
I010 - Renewing the pneumatically pilot-controlled cooling lubricant valves..........................................................85
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
Table of contents
II Maintenance Instructions
B400 B500
DIE150EN - 15.08.2022

Preface
General notes
The maintenance activities described in this document essentially pertain only to the
machine. Maintenance activities of auxiliary units (e.g., bar loading magazines,
extraction systems) are described in the documentation of the specific manufacturer.
The maintenance and servicing activities must absolutely be observed. Failure to
conduct maintenance and servicing in accordance with these instructions
(especially not at the respective intervals) rules out any claims for damages. This
does not apply if it is proved that the non-compliance with the maintenance and
servicing activities is unrelated to the defect. Normal wear and tear, especially of
components such as bearings and seals, is not a defect. These components are
therefore excluded from the warranty. It is recommended to keep a written log of all
maintenance activities carried out.
Maintenance intervals
The maintenance intervals are given based on the operating hours
counter / “Hydraulic system On” operating condition.
Maintenance intervals displayed on the controller (iXpanel)
Depending on the respective machine type and the different
controller types, a corresponding message is issued on the controller
when a maintenance interval is reached. The maintenance
instructions stored on the respective controller provide information
(maintenance log) explaining the service and maintenance activities
to be performed.
Cleaning of the machine
Do not clean the machine with compressed air
- Raised dirt particles may cause breathing difficulty or injury
(especially of the sensory organs). Furthermore, raised dirt
particles or chips may reach spots where they cause technical
problems.
Do not use cotton waste for cleaning
- When cleaning with cotton waste, fibers or thread can get loose
causing safety problems.
Solvents
- Do not use highly volatile solvents such as petroleum spirit,
trichloroethylene or similar cleaning agents. These cleaners may
damage the seals, which can lead to safety problems.
Pressure washers
- Do not clean the machine with a pressure washer. Cleaning with
a pressure washer results in strong corrosion. Furthermore,
bearings may be degreased and seals may become leaking,
which can lead to safety problems.
Preface
1
Maintenance Instructions
B400 B500
DIE150EN - 15.08.2022