BETRIEBS-

ANLEITUNG
Operating Instructions · Manuel d’opération

Trouble-Shooting

Synchrospindle
• Synchrospindle mounting
• Locating- and indexing attachment adjustment

INDEX ABC

Control INDEX C 200 - 4

LL16 02.1 018 4

0998 STAND 0998/KR
Note on applicability
Some illustrations in this publication may deviate slightly from the product supplied, but this will not detract
from their instructional value.
The right of alteration by reason of technical progress is reserved by INDEX.

A word on copyright
This publication is protected by the law of copyright. The rights thereby established, particularly those of
translation, reprinting, extraction of illustrations, reproduction by photo-mechanical or similar means, and
storage in data processing installations, are strictly reserved, even for use as extracts.
Photo-copies for personal and other use of one’s own may only be made of individual sections or parts thereof
as single copies.

© Copyright by INDEX-Werke GmbH & Co. KG Esslingen 1997

Inhaltsverzeichnis

Preface ............................................................................................................................................................... 4

Synchrospindle mounting ............................................................................................................................... 5

Preparation for mounting ................................................................................................................................... 5
Machines without compressed air supply ................................................................................................... 6
Machines with compressed air supply ........................................................................................................ 6
Servicing unit ................................................................................................................................................. 6
Removing the old synchro spindle ................................................................................................................... 8
Mounting the new synchro spindle .................................................................................................................. 9
Synchro spindle adjustment .............................................................................................................................. 10

Locating- and Indexing Attachment Adjustment ........................................................................................ 12

Adjustment procedure ....................................................................................................................................... 12
Testing program for the locating- and indexing attachment ........................................................................... 15

Lubrication ......................................................................................................................................................... 16
Synchro spindle lubrication with oil .................................................................................................................. 16

Trouble-Shooting Synchrospindle - INDEX ABC

– 3 –
Preface

For carrying out the works described in this brochure, adequate knowledge of the operation of the control is required.
Pleaserefer to the brochure " Setting up and Operation of the Control INDEX C200-4 "

The adjustment dimensions and the tolerances mentioned are approximate values and are not binding. When more
accurate values are required we recommend to contact the INDEX service department.

For topics on the synchrospindle servicing please read the brochure "Servicing Instructions INDEX ABC".

• Always switch off the machine as follows before starting fitting, maintenance or inspection
work on the machine:
1. Set the isolating switch to OFF and secure against inadvertent switching on.
2. When working on the hydraulic system:
Depressurize the hydraulic system by opening the accumulator drain valve, or accumulator
drain valves.

Trouble-Shooting Synchrospindle - INDEX ABC

– 4 –
Synchrospindle mounting

Preparation for mounting

As from Mach. No.: 400500 the Index ABC synchrospindle is equipped with a
compressed air supply as standard. The compressed air is supplied through a system
of bores through the turret housing and the turret to the synchro spindle.

The pressure in the spindle housing improves the sealing of the synchro spindle
bearings against ingress of coolant.

On delivery of a new synchro spindle the following accessories are supplied:

1 hex. socket set-screw M6x6 ordering No.: 410156.0606

1 sealing ring (O-ring) ordering No.: 479103.0061

Furthermore the connecting bore on the synchro spindle is closed with a cheese head
screw (1). Please remove it.

L1601.10181/1

Trouble-Shooting Synchrospindle - INDEX ABC

– 5 –
Synchrospindle mounting

Machines without compressed air supply

On machines without compressed air supply the supplied set screw
2 must be glued into the connecting bore (2) of the synchro spindle.
Please use the adhesive "Loctite 542 (low strength)".

L1601.10181/2

Machines with compressed air supply

Sealing ring
On machines with compressed air supply the O-ring supplied must
be inserted into the counterbore of the connecting bore (3) before
➞

mounting the synchro spindle. This is in turret station 8.

3

Servicing unit
L1601.10181/3

For the compressed air supply the machine is equipped with a se-
parate servicing unit. This is situated at the back of the machine.
The servicing unit is operated with unoiled air and is equipped with
an automatic water separator at the filter regulator for the operating
pressure and at the high performance compressed air filter each.
• A pressure switch will stop the machine as soon as the pressure
drops below 0,4 bar.
• Main line pressure max. ............................... 17 bar
• Pressure setting (preset by INDEX):
p1 = 1st Pressure reducing valve .................... 2 bar
p2 = 2nd Pressure reducing valve ................ 0,7 bar

In order to obtain an optimum sealing of the synchro

spindle the pressure of p2 0,7 bar must be absolutely
L1601.10181/4 maintained.

The water collecting containers must not be filled

with oil.

Trouble-Shooting Synchrospindle - INDEX ABC

– 6 –
Synchrospindle mounting

4 storing bore for the closing screw

5 oil infeed bore - synchro spindle
6 connecting bore
4 7 cover
8 clamping piece

5 9 pipe - oil infeed

10 adjusting screws
11 retaining screws
12 synchro spindle
6
13 spindle nopse cover

Fig: Turret 1 L1601.10181/6

10

11

12

13

L1601.10181/7
Fig: Synchro spindle

Trouble-Shooting Synchrospindle - INDEX ABC

– 7 –
Synchrospindle mounting

Removing the old synchro spindle

- Index turret to station 8

Only synchro spindle with locating and indexing attachment:

- Position synchro spindle to 0 degr.

Select operating mode "MDI-manual input":

100 1000
10 10000
1 Set NC-Mode selector switch to AUTOMATIK

( M ) -> Operating mode -> MDI-manual input

S125.2
Entries are posible only in key position "I SETTING UP".

Enter the following block for positioning the synchro spindle:

XXXXXXX

XXXXXXX
R10=0 L119
XXXXXXX
M17

Press softkey Select MDI TUR 1.

S120.1 Press key CYCLE START.

- Stop the machine and depressurize the hydraulic systems by opening the accumulator
draining valve.

- Slacken and unscrew the retaining screws (11)

- Loosen and pull out the clamping piece (8)

- Pull out the synchro spindle

- In order to avoid excessive loss of oil through the oil infeed (5), it can be closed
with the closing screw. This is found in the storing bore (4).

Trouble-Shooting Synchrospindle - INDEX ABC

– 8 –
Synchrospindle mounting

Mounting the new synchro spindle

(For operating instructions refer to brochure: "Settig up and Operation").

- Grease the driving gear.

- Possibly remove closing screw from oil infeed (5) and screw it into the storing
bore (4).

Only synchro spindle with locating - and indexing attachment:

- Turn the synchro spindle until the markings on the spindle and the housing
approximately coincide.

L1601.10051/7

- Mounting the synchro spindle.

Please observe that the markings are as close as possible after

mounting.

- Tighten the clamping piece (8) –> 20 Nm.

- Insert and tighten the retaining screws (11).

Check if the oil infeed pipe (9) can still be turned. In case this
should not be possible, the cover (7) must be slightly turned after
loosening the retaining screws.

Trouble-Shooting Synchrospindle - INDEX ABC

– 9 –
Synchrospindle mounting

Synchro spindle adjustment

A special adjusting arbor is used for adjusting the synchro spindlein
the INDEX works. Since this will rarely be vailable with the customers,
the dial indicator is set against the actual synchro spindle nose
diameter (refer to fig. "Dial indicator setting point")

- Switch on the hydraulic system (CYCLE START).

- Approach the reference points of all axes (CYCLE START).
- Traverse the compound slide 1 in operating mode JOG or INCREMENT in position
X120.
- Open the workpiece clamping of the synchro spindle.
- Dismantle the spindle nose front plate (13).
- Mount the dial indicator with 0,01 mm reading on the main spindle.
- Set the dial indicator against the actual synchro spindle nose diameter.

X1+

A B C

Z1+

M D

A Main spindle
B Dial indicator holder
C Dial indicator (0,01 mm reading)
D Synchro spindle
Fig. Dial indicator setting point L1601.10181/8

P1

P4

P3
P2
Fig. Measuring points L1601.10181/9

Trouble-Shooting Synchrospindle - INDEX ABC

– 10 –
Synchrospindle mounting

1. Evaluating the deviation between the measuring points P1 and P2␣ .

- Loosen and the slightly retighten the clamping piece (8.)

100 1000
10 10000 - Loosen the adjusting screws (10).
1

- Turn the NC-MODE SELECTOR SWITCH to INCREMENT 10 or 100.

S125.2

- Set the dial in dicator at the measuring point P2 to zero.

- Swing dial indicator to measuring point P1 and read the deviation.

- Equal out the deviation by traversing the X-axis (in small increments) until the
X+ X- indicator reading between P1 and P2 is less than 0,002 mm.
S121.7 S123.7
- Write down the reading, e.g. "X120.4000" (diameter display).

- Half of the written down value (60,2) is entered as X-tool geometry under the
␣ D-number T8.

1. Evaluating the deviation between the measuring points P3 and P4.

- Set the dial indicator at the measuring point P3 to zero.

- Swing dial indicator to measuring point P4 and read the deviation.

- Adjust the synchro spindle with the adjusting screws (10) until the indicator reading
between P3 and P4 is less than 0,002 mm.

- Lock the adjusting screws (10) with the nuts.

- Tighten the clamping piece (8) –> 20 Nm.

- Check the deviations again and correct if necessary.

- Mount the spindle nose plate (13).

Check if the oil infeed pipe (9) can still be turned. In case this
should not be possible, the cover (7) must be slightly turned after
loosening the retaining screws.

The position of the synchro spindle in relation to the rear end

drilling spindles must be checked and if necessary corrected after
the adjusting procedure.

Trouble-Shooting Synchrospindle - INDEX ABC

– 11 –
Locating- and Indexing Attachment Adjustment

After fitting of a new synchro spindle it is necessary to readjust the locating-

and indexing attachment.

Adjustment procedure
Switch on the machine and approach the reference points (see also brochure "Setting
up and Operation").

Select the picture " Synchro spindle" as follows:

( M ) -> Operate units -> Workpiece clampings -> Counter spindle

The following picture will be displayed:

L1602.10051/8

• Traverse the turret to a position in which indexing without collision is possible.

• Set FEED OVERRIDE to at least 1% and close sliding guard.

• Index turret 1 into pick-up position with softkey set synchron.

• Index turret 1 with softkey set synchron until the markings on the synchro
spindle coincide as closely as possible when the synchro spindle is in pick-up
position.

L1601.10051/7

• When this has been done the obtained position is confirmed with the softkey
store position.

Trouble-Shooting Synchrospindle - INDEX ABC

– 12 –
Locating- and Indexing Attachment Adjustment

Select the mode "MDI-manual input":

100 1000
10 10000
1 Set NC-Mode selector switch to AUTOMATIK
➤ ( M ) -> Operating mode -> MDI-manual input

S125.2 Entries are possible only at key switch position "I SETTING UP"

Enter the folowing block for adjusting the synchro spindle:

R10=0 L119
XXXXXXX
M17
XXXXXXX

XXXXXXX

XXXXXXX
Press softkey Select MDI TUR 1..

Turn synchro spindle by hand (≠ 0).

Press key CYCLE START.

S120.1

The synchro spindle will position to 0°. When no movement occurs

press the RESET-key and repeat the procedure.

S120.0

Press the key OPEN SLIDING GUARD and open the sliding guard.

Check by pushing in the latch pin if it engages in the notched disk. A thin hex.
S120.7
socket wrench may be used for this.

Latch pin

L1601.10181/5

Trouble-Shooting Synchrospindle - INDEX ABC

– 13 –
Locating- and Indexing Attachment Adjustment

When the latch pin does not engage, the synchro spindle must be slightly turned by
hand.
Watch the SPECIFIED/ACTUAL position display in the picture "synchro spindle" till
engagement of the latch pin.

L1601.10051/8 Write down the displayed difference value.

Select the picture "Spindle offset M19" as follows:

M -> -> Machine data -> Mecanic data -> M19 ref. offset

The following picturte will be displayed:

Spindle offset M19

Spindle offset
zero marker

S1 0
S2 0
S3 0
S4 0
S5 0
S6 0

Input 150 = 1.5 degrees

Entries are possible only at key switch position "I SETTING UP"

S122.7 Position the cursor to "S1" and enter the beforehand evaluated difference value under
"offset zero marker".

Entry value 150 = 1,5 degree

Possibly the password might be demanded)

The entries are transferred with INPUT.

To make correction values effective the following steps must be performed:

Press EMERCENCY STOP key and then unlock it again.

S122.3

Trouble-Shooting Synchrospindle - INDEX ABC

– 14 –
Locating- and Indexing Attachment Adjustment

Press both SPINDLE JOG MODE keys simultaneously for ca. 2 seconds.

S123.3 S124.5

Subsequently the hydraulic system must be switches-on again (by pressing CYCLE
START key)

Testing program for the locating- and indexing

attachment
A testing program is written for checking the function of the locating- and indexing
attachment. This can be started in the operating mode "MDI-manual input 1)".

1) For this refer to the brochure "Setting up and operation"

The program contents is as follows:

%SPF444
N005 L100 LF
N010 G0 G53 X280 Z350 LF
N015 M1=13 LF
N020 T8 LF
N025 R10=0 L119 LF
N030 M0 LF (Push in latch pin by hand)
N035 T3=5 LF
N030 M1=3 S1=200 LF
N045 G4 X1 LF
N050 R10=180 L119 LF
N055 M1=12 LF (Engage)
N060 M0 LF (Latch pin check*)
N065 M1=13 LF (Disengage)
N070 T3=4 LF
N075 M1=3 S1=200 LF
N080 G4 X1 LF
N085 R10=225 L119 LF
N090 M1=12 LF (Engage)
N095 M0 LF (Latch pin check*)
N100 M1=13 LF (Disengage)
N999 M17 LF

* Please check if the latch pin has actually engaged.

Trouble-Shooting Synchrospindle - INDEX ABC

– 15 –
Lubrication

Synchro spindle lubrication with oil

In delivered status, synchronized spindle bearings are filled with grease and sealed
against against intrusion of cooling lubricant by means of a packing.

This grease lubricaton is sufficient for the first 200 operating hours until the first oil
lubrication. After this the synchro spindle bearings and the bevel gears must be oiled
every 200 operatig hours.

The oiling nipple is situated on the side of the synchro spindle housing.

Procedure
• Set the main isolating switch to OFF and secure against inadvertent
switching on.

– Place greasing gun with oil cartridge against the oiling nipple.

– Actuate the gresing gun until oil starts penetrating at the front seal of the
synchrospindle.

The specification of the oil used is:

G68 ( ISO 3498 - 1979 )

CL68 ( DIN 8659 T2 )

Trouble-Shooting Synchrospindle - INDEX ABC

– 16 –
INDEX-Werke GmbH & Co. KG
Hahn & Tessky
Postfach 10 03 54
D-73726 Esslingen
Telefax (0711) 3191 - 587