Index MS24-6 Operating and maintenance instructions

Maintenance Instructions
MS24-6
OPERATING INSTRUCTIONS
Maintenance Instructions
DIM123EN - 26.04.2022
2022-04-26/Sp/Wartungsanleitung/20184817

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
AM012 - Check the work area door and window pane............................................................................................ 7
AM014 - Check the pressures on the machine........................................................................................................9
AM025 - Check hydraulic and lubrication systems................................................................................................ 10
AM030 - Visual inspection of all fluid lines and electrical cables........................................................................... 13
AM032 - Check pre-pressure of pressure accumulators....................................................................................... 15
AM035 - Replace the breathing filter at the filler neck of the hydraulic fluid tank....................................................17
AM043 - Check pneumatic system (visual inspection).......................................................................................... 19
AM055 - Cleaning of the machine......................................................................................................................... 22
AM060 - Swiveling synchronous: Check swivel axes.............................................................................................24
AM080 - Clean and lubricate chucks.....................................................................................................................25
AM095 - Check work area light (visual inspection)................................................................................................26
AM098 - Clean cooling lubricant outlet on spindle carrier......................................................................................28
AM110 - Check the window pane at the level sensor of the vacuum rotation filter.................................................30
AM123 - Check coolant.........................................................................................................................................32
AM128 - Removing clamping element holder........................................................................................................34
AM220 - Locking the spindle.................................................................................................................................37
AM270 - Clean collets and base body...................................................................................................................38
AM330 - Remove, inspect, lean and reinstall the spindle liner tubes..................................................................... 43
AM340 - Visual inspection of the fire extinguishing system................................................................................... 46
AM370 - Check gas springs on the control cabinet door, replace if necessary......................................................47
Service Interval - 1.000 Operating hours.............................................................................................................. 51
Maintenance Summary - 1.000 Operating hours...................................................................................................52
BM010 - Customer area........................................................................................................................................53
Table of contents
I
Maintenance Instructions
MS24-6
DIM123EN - 26.04.2022

Service Interval - 2.000 Operating hours.............................................................................................................. 55
Maintenance Summary - 2.000 Operating hours...................................................................................................56
CM010 - Checking the inspection and maintenance schedules/logs.................................................................... 57
CM025 - Check hydraulic system..........................................................................................................................58
CM046 - Replace hydraulic fluid filters.................................................................................................................. 61
CM060 - Check pre-pressure of pressure accumulators....................................................................................... 63
CM080 - Inspection of water cooling equipment (option) ......................................................................................65
CM150 - Inspection of the pneumatic system .......................................................................................................66
CM180 - Checking the window pane.....................................................................................................................69
CM260 - Check MS guard switch/interlock............................................................................................................70
CM290 - Check IEMCA loading and unloading system.........................................................................................71
CM330 - Check gas springs on the control cabinet door, replace if necessary......................................................72
CM480 - Check operating panel for general condition...........................................................................................75
Service Interval - 5 Years........................................................................................................................................ 77
Maintenance Summary - 5 Years...........................................................................................................................78
IM020 - Replace the pressure accumulator...........................................................................................................79
Service Interval - 8 Years........................................................................................................................................ 83
Maintenance Summary - 8 Years...........................................................................................................................84
JM020 - Replace the window pane....................................................................................................................... 85
Table of contents
II Maintenance Instructions
MS24-6
DIM123EN - 26.04.2022

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.
INDEX multi-spindle lathes generally require cutting oil (based on
mineral oil) as a cooling lubricant. The use of unsuitable water-based
cooling lubricants (so-called emulsions) or of cutting oils that are not
based on mineral oil can cause considerable damage to the
machine. Therefore, such cooling lubricants may be used only with
prior written approval by INDEX . The resulting requirements for
increased maintenance must be followed carefully. Considering the
interactions between cooling lubricant, the material used in each
case, any additives, etc., INDEX 's approval is limited to the basic
safety of using the cooling lubricant on the machine. The testing and
avoidance of interactions are the responsibility of the operator,
INDEX rejects any liability. Be sure to conduct adequate tests prior to
production use.
Maintenance intervals
The maintenance intervals are given based on the operating hours
counter / “Hydraulic system On” operating condition.
Maintenance intervals displayed on the controller (XPanel)
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.
Preface
1
Maintenance Instructions
MS24-6
DIM123EN - 26.04.2022

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.
Cleaning of tool mountings
A suitable cleaning tool must be used to clean the hole in the tool
mounting.
Ordering spare parts
Always specify the machine type and machine number when ordering
spare parts. This and other information about the machine are
located on the nameplate under the main switch of the control
cabinet.
Operating material
For all work in connection with operating materials, the information in
the data sheets of the respective manufacturers and the information
in the document Notes on Operating Materials.
Pressure accumulators ≤ 1 L
Pressure accumulators with a volume of ≤ 1 L are not subject to
testing and labeling according to the current issue of the pressure
equipment directive. The directives and regulations applicable in the
country of use must be followed.
Preface
2Maintenance Instructions
MS24-6
DIM123EN - 26.04.2022

Safety Instructions
Safety Precautions and Technical Details The INDEX TRAUB
user documentation and, in particular, the document “Safety
Precautions and Technical Details” must be observed. The
document is part of the INDEX TRAUB user documentation.
Carrying out maintenance work
Authorized and trained personnel
- Maintenance is to be performed only by authorized and trained
personnel. This applies particularly to work on motors (spindle
motors) or other electrical assemblies. The instructions in the
respective manufacturer documentation must be followed for
such work.
Allow the machine to cool down
- Prior to working on the machine, it must be allowed to cool
down, as hot parts may be located under the covers.
Maintenance work on machine being switched off
- In general, maintenance is to be carried out with the machine
switched off. The main switch must be locked out. Even when
the main switch is switched off, parts of the machine (e.g., the
control cabinet light) may still carry electricity. These parts are
labeled. In a few cases, maintenance work needs to be
performed with the machine turned on (e.g., replacement of
backup batteries). These maintenance activities must be carried
out with special care.
Required tools
- For removing machine parts, suitable lifting gears and a variety
of tools must be used. Removed machine parts must be placed
in a safe position and secured against falling over.
- All maintenance work on the machine must be carried out with
utmost care. Fasteners must be loosened carefully and parts
must be secured against falling down. When elastic items
(springs) are removed/replaced, appropriate devices must be
used. Any (non-horizontal) axes that pose a risk of falling down
must be moved to their end positions or secured against falling
down. Pedal switches must be put aside to avoid inadvertent
actuation.
Performing maintenance, repair or service work
- The currently valid safety regulations, as well as the specific
manufacturer’s information for the intended use must be
observed for these activities.
Use of climbing aids (ladders or steps)
- In addition, appropriate climbing aids may be required to carry
out these activities. When working on climbing aids at great
heights, e.g. on the control cabinet, these must always be
secured or fastened (depending on the machine, eyelets are
also provided for this purpose).
Preface
3
Maintenance Instructions
MS24-6
DIM123EN - 26.04.2022

Procurement/use of spare parts
We recommend the use of original spare parts and accessories. For
damages caused by the use of parts from third-party providers,
liability and warranty are excluded. The use of such products may
change the structural characteristics of the machine and negatively
affect the active or passive safety.
Cellular and cordless phones
When the control cabinet is open or the machine covers are open or
removed, no cellular or cordless phones may be used within a 2 m
radius.
Handling hydraulic and hose lines
Damaged hydraulic hose lines must be replaced immediately. Typical
types of damage include chafing, kinks, cracks, deformations, or
visible leaks.
Flexible, pressurized hydraulic hose lines of INDEX TRAUB
equipment are generally designed as thermoplastics or metallic
hydraulic hose lines.
The machine operator/owner is responsible for compliance with the
laws and regulations of the country of use with regard to the use of
hydraulic hoses.
We recommend inspection and documentation of the hydraulic hose
lines installed inside the machine and not directly visible every 12
months. For hydraulic hose lines visible in the work area or mounted
outside the machine and connecting components to the machine, we
recommend inspection and documentation every 6 months.
For the flexible, pressurized hydraulic hose lines used by INDEX
TRAUB , empirical values are available for very different periods of
use, some of which exceed 10 years.
Maintenance work on fluid systems (hydraulic, lubrication, and
pneumatic systems)
When carrying out maintenance work on fluid systems (hydraulic,
lubrication, and pneumatic systems), make sure before starting the
work that the respective system has been depressurized
(accumulator drain valve / manual slide valve).
Test run or functional test
After all maintenance work and work on electrical assemblies, a test
run or functional test must be performed.
Preface
4Maintenance Instructions
MS24-6
DIM123EN - 26.04.2022

Service Interval - Care activities
Service Interval - Care activities
5
Maintenance Instructions
MS24-6
DIM123EN - 26.04.2022

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 DIM124EN - 26.04.2022.
The maintenance interval is highly dependent on the production and environmental conditions of the
machine. The determination of the appropriate interval must be made by the operator.
The maintenance interval should be between once per shift and once a week!
AM012 - Check the work area door and window pane
AM014 - Check the pressures on the machine
AM025 - Check hydraulic and lubrication systems
AM030 - Visual inspection of all fluid lines and electrical cables
AM032 - Check pre-pressure of pressure accumulators
AM035 - Replace the breathing filter at the filler neck of the hydraulic fluid tank.
AM043 - Check pneumatic system (visual inspection)
AM055 - Cleaning of the machine
AM060 - Swiveling synchronous: Check swivel axes
AM080 - Clean and lubricate chucks
AM095 - Check work area light (visual inspection)
AM098 - Clean cooling lubricant outlet on spindle carrier
AM110 - Check the window pane at the level sensor of the vacuum rotation filter
AM123 - Check coolant
AM128 - Removing clamping element holder
AM220 - Locking the spindle
AM270 - Clean collets and base body
AM330 - Remove, inspect, lean and reinstall the spindle liner tubes
AM340 - Visual inspection of the fire extinguishing system
AM370 - Check gas springs on the control cabinet door, replace if necessary
Maintenance Summary - Care activities
6Maintenance Instructions
MS24-6
DIM123EN - 26.04.2022

AM012 - Check the work area door and window pane
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
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,
- Checking the work area door for smooth opening/closing,
- Functional testing of the safety interlock.
The window pane consists of four panes, the inner pane made of tempered glass,
two center panes made of polycarbonate, and an outer pane also made of
polycarbonate. The inner pane is relatively resistant to chemical substances. It can
be cleaned with any commercially available cleaning agents. Only the center pane is
essential for the impact resistance of the window pane.
The polycarbonate panes are subject to natural aging and therefore must be
subjected to regular visual inspection. Through contact with cooling lubricant, the
aging process is accelerated even further.
Damage to the window pane by improper cleaning.
- Do not use sharp objects such as razors or screwdrivers.
- Do not use abrasive or alkaline cleaning agents such as
petroleum spirit, benzene, acetone, or carbon tetrachloride
(tetrachloromethane).
If a workpiece has hit an inspection window, the viewing and
laminated panes must be replaced immediately by the INDEX
service. This is necessary regardless of the extent of damage.
Even with minimal damage, the impact resistance of the pane
can no longer be guaranteed.
Check the guide rails of the work area door. The guide bars must be checked and
cleaned regularly so that the work area door can be moved without much effort.
Requirement
For cleaning, only:
- a soft cloth or sponge
- cleaning solution of water and soap
- isopropyl alcohol (45%)
- isobutyl alcohol
- ethyl alcohol
- methyl alcohol
- white spirit
must be used.
Maintenance Summary - Care activities
7
Maintenance Instructions
MS24-6
DIM123EN - 26.04.2022

Procedure
1. Check window pane for damage.
2.
Example: Safety label – window pane 2006
1Year of manufacture
2Protection class and EN standard
3Manufacturer
4INDEX part number
Check safety label of the window pane.
3. Clean outer pane (window pane).
4. Clean inner pane (single-pane compound glass).
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 are chips on the guide bar or in the guide rollers of
the work area door.
6. Check the locked/unlocked function of the safety interlock.
Maintenance Summary - Care activities
8Maintenance Instructions
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DIM123EN - 26.04.2022

AM014 - Check the pressures on the machine
Orientation
The different pressures of the central lubrication system, hydrostatic system and the
system pressure must be checked regularly.
If there are ambiguities regarding the pressure values, be sure to
consult the fluid diagrams included in the machine documentation/
documentation CD.
Requirement
Pressures on the machines: MS24-6, MS32-6.3
- Central lubrication system 30 bar
- Hydrostatic pressure 50 bar
- System pressure (hydraulics) 95 bar
Procedure
1. The pressure values specified here must absolutely be
observed. If the values specified here differ from the values on
the machine, be sure to contact the INDEX hotline, INDEX
service or an INDEX representative.
Check pressure values
Maintenance Summary - Care activities
9
Maintenance Instructions
MS24-6
DIM123EN - 26.04.2022

AM025 - Check hydraulic and lubrication systems
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
Operating fluids such as hydraulic fluids, cooling lubricants, lubricating greases/oils
are also subject to degradation or aging as the components involved in this process,
and must therefore be serviced, refilled or replaced at regular intervals. Do not use
cotton waste and highly volatile solvents such as petroleum spirit, trichloroethylene
or similar cleaning agents. The machine must not be cleaned with compressed air.
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.
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
components must be examined during maintenance of the lubricating oil system:
- Pressure gauges
- Metering valves
- Pressure sensors
- Fluid lines belonging to the lubricating oil supply
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.
Screws on the hydraulic system, the connected components, and the
supply lines must be tightened to the manufacturer's specified
torques.
Maintenance Summary - Care activities
10 Maintenance Instructions
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DIM123EN - 26.04.2022

Example: Hydraulic unit MS24-6
aAccumulator drain valve
1Pressure gauge for system pressure
2Hydrostatic pressure gauge
XHydraulic fluid filter
YFilter bowl
Requirement
Depressurize the hydraulic and lubrication systems by opening the
accumulator drain valve.
Power off the machine and secure it against accidental power on.
The maintenance of the lubricating oil supply requires the following auxiliary or
working equipment:
- servicing, testing and maintenance schedules/logs of the customer.
- Use an ample supply of cleaning rags – no cotton waste.
- A sufficient amount of hydraulic fluid or lubricating oil. - Oil type, specification
and quantity as specified in the technical data.
- To avoid impurities in the hydraulic system, pre-filter the oil to be refilled
with 3µ.
- Replacement filters. – Use only original filters.
- Various sizes of jaw and box wrenches, and Allen keys.
Procedure
1. The hydraulic fluid and lubricating oil levels 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.
Maintenance Summary - Care activities
11
Maintenance Instructions
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DIM123EN - 26.04.2022

2. Visual inspection of the hydraulic fluid or lubricating oil. The fluid or oil may not
exhibit any foaming or cloudiness at the oil sight glass. In case of problems of
this kind, immediately determine the cause and correct the error. If in doubt,
take a sample for analysis and contact the manufacturer of the fluid or oil.
3. If more than 50 L of hydraulic fluid have to be refilled within 21
working shifts or one week, the hydraulic system must be
checked for leaks.
Check for leakage. Also check all screw connections and fluid lines, as well as
all hydraulic devices such as valves, sensors and filters of the system
4.
Danger
Pressurized fluids exiting from damaged or incorrectly
installed fluid lines.
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. Wear personal protective equipment.
Check fluid lines for damage such as buckling and abrasions, and for liquid
leaks. If necessary, replace fluid lines. Record the age or date of replacement of
the fluid lines. Enter in the service, testing and maintenance schedules or logs.
Alternatively, the following procedure can be used!
If immediate replacement of the fluid line(s) is not possible, determine the part
data and order the fluid line(s). If necessary, consult the machine manufacturer
or its representative as when schedule the replacement.
5. Conduct a finger test of screw connections, fittings, etc. to see whether they are
wet, and check for tightness.
Alternatively, the following procedure can be used!
Tighten loose and/or wet screw connections.
6. Check components for damage.
Alternatively, the following procedure can be used!
Log damage to components and initiate follow-up measures such as ordering,
and schedule the replacement with the machine manufacturer or its country
representative.
Maintenance Summary - Care activities
12 Maintenance Instructions
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DIM123EN - 26.04.2022

AM030 - 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. This allows that any faults or problems can be
detected and eliminated early on.
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).
Damaged fluid lines may cause leakage of fluids under high
pressure. Be sure to use personal protective equipment during visual
inspection.
Requirement
Should defective points be found on fluid lines or electrical cables during the visual
inspection, the machine must be switched off and the damaged lines or cables must
be promptly replaced.
Replaced fluid lines must be tightened to the torque specified by the
manufacturer.
Procedure
1. Visual inspection of all fluid lines.
2.
Caution
Electrical equipment or parts thereof are under dangerous
voltage.
Electric shock.
Switch off the machine and lock it out.
Maintenance Summary - Care activities
13
Maintenance Instructions
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DIM123EN - 26.04.2022

Checking the supply lines of add-on equipment:
1. Chip conveyor
2. Cooling oil/lubricant supply
3. Workpiece feeders (robots, bar loaders or bar loading
magazines)
4. Workpiece removal units (robots)
5. Additional or hand-held control unit
6. Other optional accessories
Have damaged cables replaced immediately by a qualified
electrician.
Visual inspection of all electrical cables.
Maintenance Summary - Care activities
14 Maintenance Instructions
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DIM123EN - 26.04.2022

AM032 - Check pre-pressure of pressure accumulators
Carrying out the maintenance activities described below requires
special knowledge. For this reason, these maintenance activities
must be carried out only by authorized personnel of the
manufacturer!
Orientation
The activities described here are only permitted to be carried out
after training or instruction by the manufacturer of the pressure
accumulator.
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. When the pressure drops, the compressed gas expands and displaces the
stored pressurized liquid into the circulation. This ensures that the pressure level is
maintained during load changes or temporary higher loads.
Screws on the hydraulic system, the connected components, and the
supply lines must be tightened to the manufacturer's specified
torques.
Requirement
If there are ambiguities regarding the pressure values, be sure to
consult the fluid diagrams included in the machine documentation/
documentation CD.
The values for pressure accumulator pre-tension of each machine
type 1 are:
- MS16-6, MS22-6, MS22-8, MS24-6 68 bar
- MS32-6.2, MS32-6.3, MS40-6, MS40-8, MS52-6.3 68 bar
1) The pressures of the accumulator pre-tension is indicated on a
label on the pressure accumulators.
Procedure
1. Check the pressure accumulator. While the machine is switched on (not during
a program or continuous run), press the emergency stop switch, while watching
the system pressure gauge. The indication on the pressure gauge should drop
noticeably within a few seconds. From a certain value (see info – Pretension
pressures), the pressure drops rapidly to 0 bar. It is assumed that the
accumulator pre-tension, the accumulator membrane, the gas fill, and thus the
entire pressure accumulator are in order. If the pressure continuously drops to 0
bar within a few seconds without any clearly visible delay in the area of the pre-
tension pressure, the bubble reservoir is defective and the pressure
Maintenance Summary - Care activities
15
Maintenance Instructions
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DIM123EN - 26.04.2022

accumulator needs to be replaced. Be sure to observe the maintenance
interval IM... (5 years) and the associated maintenance activities at the end of
the maintenance instructions.
Maintenance Summary - Care activities
16 Maintenance Instructions
MS24-6
DIM123EN - 26.04.2022