Traub TNL12.2 User manual

Maintenance Instructions
TNL12.2
OPERATING INSTRUCTIONS
Maintenance Instructions
DTE072EN - 22.11.2022
2022-11-29/Ru/Wartungsanleitung/20182482

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
AL012 - Check the work area door and window pane............................................................................................. 7
AL013 - Clean the guide rail/gutter at the work area door........................................................................................9
AL047 - Check pneumatic unit (visual inspection).................................................................................................10
AL051 - Check the filter mat of the main and counter spindle cooling, clean if necessary.....................................11
AL076 - Check fill levels of the fluid tanks..............................................................................................................13
AL095 - Visual inspection of all fluid lines and electrical cables.............................................................................15
AL122 - Check cooling lubricant (visual inspection).............................................................................................. 16
AL137 - Check the fan in the control cabinet, clean if necessary...........................................................................18
AL149 - Check work area light (visual inspection)................................................................................................. 19
AL164 - Clean and check all telescopic covers and telescopes of the tool carrier units........................................ 20
AL168 - Pneumatic clamping device, clamping without collet............................................................................... 21
AL169 - Clean and lubricate clamping device....................................................................................................... 22
AL170 - Check pneumatic hollow clamping device (spring tension) on main and counter spindles.......................24
AL171 - Clean covers and wipers..........................................................................................................................26
AL180 - Clean the work area................................................................................................................................. 27
AL241 - Clean the chip pan................................................................................................................................... 28
AL250 - Clean the strainer baskets (twin strainer basket) of the cooling lubricant unit...........................................30
AL264 - Clean the chip conveyor...........................................................................................................................31
AL312 - Lubricate all linear axes by moving the axes............................................................................................ 33
Service Interval - 2.000 Operating hours.............................................................................................................. 35
Maintenance Summary - 2.000 Operating hours...................................................................................................36
CL010 - Check maintenance logs of servicing activities........................................................................................37
CL020 - Clean and check wipers and guide rails of the work area door................................................................ 38
CL120 - Replace post-filter for cutting oil mist....................................................................................................... 41
CL500 - Perform data backup................................................................................................................................42
CL520 - Check control cabinet.............................................................................................................................. 43
Table of contents
I
Maintenance Instructions
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DTE072EN - 22.11.2022

Service Interval - 4.000 Operating hours.............................................................................................................. 45
Maintenance Summary - 4.000 Operating hours...................................................................................................46
DL010 - Cleaning of the machine.......................................................................................................................... 47
DL031 - Check coolant..........................................................................................................................................49
DL052 - Check central lubrication unit...................................................................................................................51
DL056 - Check pneumatic unit.............................................................................................................................. 53
DL072 - Check pneumatic hollow clamping device (spring tension) on main and counter spindles...................... 55
DL076 - Check the cycloidal gear on the upper and lower turrets..........................................................................57
DL160 - Determine axis ball screw backlash......................................................................................................... 58
DL170 - Axes.........................................................................................................................................................60
DL180 - Check fire protection system (visual inspection)...................................................................................... 61
DL227 - Replace belts and check belt tension...................................................................................................... 62
DL485 - Replace the wiper and telescopic plates..................................................................................................64
DL493 - Replace wiper in guide sleeve for fixed headstock operation...................................................................68
DL510 - Perform data backup................................................................................................................................69
DL520 - Check control cabinet and cable assemblies (visual inspection)............................................................. 70
DL590 - Check inspection/replacement date of the backup batteries in the control cabinet (NC)......................... 72
DL636 - Check the replacement interval of the servo backup batteries at the axis servos.................................... 74
DL640 - Check the check valve of the workpiece pickup/gripper unit....................................................................76
Service Interval - 8.000 Operating hours.............................................................................................................. 77
Maintenance Summary - 8.000 Operating hours...................................................................................................78
EL021 - Check pneumatic hollow clamping device (spring tension) on main and counter spindles, replace if
necessary..............................................................................................................................................................79
Service Interval - 5 Years........................................................................................................................................ 81
Maintenance Summary - 5 Years...........................................................................................................................82
IL010 - Replacing the pneumatically pilot- controlled cooling lubricant valves.......................................................83
Service Interval - 8 Years........................................................................................................................................ 85
Maintenance Summary - 8 Years...........................................................................................................................86
JL012 - Replace the window pane of the work area door...................................................................................... 87
Table of contents
II Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

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 (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.
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
TNL12.2
DTE072EN - 22.11.2022

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 media, observe the
information in the data sheets from 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 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.
Preface
2Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

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
TNL12.2
DTE072EN - 22.11.2022

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 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 ,
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).
Dry run or functional test
After all maintenance work and work on electrical assemblies, a dry
run or functional test must be performed.
Preface
4Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

Service Interval - Care activities
Service Interval - Care activities
5
Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

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 DTE073EN - 22.11.2022.
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!
AL012 - Check the work area door and window pane
AL013 - Clean the guide rail/gutter at the work area door
AL047 - Check pneumatic unit (visual inspection)
AL051 - Check the filter mat of the main and counter spindle cooling, clean if necessary
AL076 - Check fill levels of the fluid tanks
AL095 - Visual inspection of all fluid lines and electrical cables
AL122 - Check cooling lubricant (visual inspection)
AL137 - Check the fan in the control cabinet, clean if necessary
AL149 - Check work area light (visual inspection)
AL164 - Clean and check all telescopic covers and telescopes of the tool carrier units
AL168 - Pneumatic clamping device, clamping without collet
AL169 - Clean and lubricate clamping device
AL170 - Check pneumatic hollow clamping device (spring tension) on main and counter spindles
AL171 - Clean covers and wipers
AL180 - Clean the work area
AL241 - Clean the chip pan
AL250 - Clean the strainer baskets (twin strainer basket) of the cooling lubricant unit
AL264 - Clean the chip conveyor
AL312 - Lubricate all linear axes by moving the axes.
Maintenance Summary - Care activities
6Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

AL012 - Check the work area door and window pane
Orientation
The work area door consists of the basic door with a glued-in viewing
pane made of polycarbonate (work area side) and the attached
design pane made of PMMA (operator side).
Inspection and maintenance of the work area door includes several steps:
- Inspection of the window pane and design pane for damage.
- Check the protective film and the circumferential overlapping bond on the
window pane for damage.
- Check the safety label on the window pane (replacement interval 8 years).
- Check/adjust or replace, if necessary, the wipers.
- Check the work area door for smooth opening/closing.
- Automatic work area door (optional). Hydraulic valves and motor, control panel,
rack and spur gear. (for hydraulic door drive)
- Automatic work area door (optional - electric door drive - follow the
manufacturer’s documentation ).
The window pane is subject to natural aging and must be replaced at regular
intervals. There is a safety label on the window pane indicating the part no., year of
manufacture, and manufacturer. The first replacement of the window pane (basic
door with glued-in window pane) must be carried out 8 years after the manufacture
of the machine (see type plate).
If the window pane is damaged, it must be replaced. This is
necessary regardless of the extent of damage. Even with minimal
damage, the impact resistance of the pane can no longer be
guaranteed.
The protective film and the all-round overlapping bond must be
checked for damage at regular intervals. If there is any damage to the
bond or protective film, the window pane must be replaced
immediately.
Heavily soiled or damaged wipers may cause damage to the inner pane. Moreover,
it may be possible that the work area door can be moved only with considerable
effort due to heavy soiling or chip deposits in the wipers.
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.
Procedure
1. Check the window pane and design pane for damage.
2. The window pane (work area side) is scratch-resistant. Any
commercial cleaning agent can be used here.
Clean the window pane.
Maintenance Summary - Care activities
7
Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

3. Use a soft cloth or sponge and glass cleaner or soapy water to
clean the design pane (operator side). Do not use abrasive or
alkaline cleaners (e.g., benzene, acetone or carbon
tetrachloride) and no sharp tools or sharp objects (such as razor
blades or screwdrivers).
Clean the design pane.
4. 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.
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 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 Summary - Care activities
8Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

AL013 - Clean the guide rail/gutter at the work area door
Orientation
The guide rail/gutter located at the underside must be cleaned regularly around the
work area door.
Procedure
1.
TNL12.2 guide rail/gutter 1
TNL12.2 guide rail/gutter 2
Remove the front cover from the work area door. Clean guide rail/gutter at the
work area door.
2. Reinstall the front cover.
Maintenance Summary - Care activities
9
Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

AL047 - Check pneumatic unit (visual inspection)
Orientation
The pneumatic unit is composed of system parts 1a–1h. To ensure trouble-free
operation, periodic checks (visual inspection) of the pneumatic unit are necessary.
- Check system pressure and sealing air settings.
- Check fluid lines.
- Drain condensate (not applicable to auto-drain).
Due to different requirements and/or specifications of the respective
manufacturers, be sure to review the respective manufacturer's
documentation!
Example: Pneumatic unit TNL12.2
1a Manual switch-on valve
1b Filter regulating valve / system pressure gauge 6 bar
1c Filter insert 40 μm
1d Filter insert 5 μm
1e Branch module with system pressure sensor
1f Electrical turn-off valve
1 g Branch module for functions
Procedure
1. Check the pressure setting on system pressure gauge and adjust if necessary.
An operating pressure of 6 bar has been set at the factory.
2. Check the pressure setting on the sealing air pressure gauge and adjust if
necessary. A pressure of 1 bar has been set at the factory.
3. Check fluid lines (damage and leakage). Fluid lines must be checked for
damage. Pre-damage such as kinks or abrasions should be logged and
replacement should be initiated.
4. Drain condensate (not applicable to auto-drain).
Maintenance Summary - Care activities
10 Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

AL051 - Check the filter mat of the main and counter spindle cooling, clean if necessary
Orientation
The filter must be cleaned regularly depending on the environmental conditions.
Use only the original filters according to the spare or wear parts list!
Otherwise the machine is at risk of sustaining serious damage due to
overheating.
Follow the corresponding manufacturer’s documentation.
Procedure
1.
TNL12.2_Filter mat_FLKS-1 (example shown)
Maintenance Summary - Care activities
11
Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

TNL12.2_Filter mat_FLKS-2 (example shown)
2. If necessary, clean the filter mat according to the manufacturer’s instructions.
(size FLKS-1 or FLKS-2).
Maintenance Summary - Care activities
12 Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

AL076 - Check fill levels of the fluid tanks
Orientation
To ensure the operational safety of the machine, the fill levels of all fluid tanks must
be regularly checked, and topped off if necessary.
Operating fluids such as cooling lubricants, lubricating greases/oils are also subject
to degradation or aging like the components involved in this process, and must
therefore be serviced, refilled or changed 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 interval for this maintenance activity is strongly dependent on the operating
profile of the machine. If the machine is used in three-shift operation, this
maintenance activity must be carried out much more frequently.
Requirement
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.
Due to different requirements and/or specifications of the respective
manufacturers, be sure to review the respective manufacturer's
documentation!
Procedure
1. Only oil of viscosity class ISO VG 220 must be used to lubricate
the TNL12.2.
Maintenance Summary - Care activities
13
Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

Central lubrication unit_TNL12.2
aSystem pressure gauge
bLubricating oil filler neck.
cLubricating oil level indicator
Check fill level of the central lubrication unit, refill if necessary.
2. The cooling lubricant must be checked or refilled with the
machine switched on so that the cooling lubricant lifting pump of
the chip conveyor / chip pan is active.
TNL12.2 Example shown
Open the fill level indicator for the cooling lubricant at the control unit and check
the fill level; refill if necessary. a) Up to machine no. 12520006 With the work
area door open, refill the cooling lubricant directly into the chip conveyor/chip
pan near the work area. b) Machine no. 12520007 and higher Refill the
cooling lubricant in the cooling lubricant tank.
Maintenance Summary - Care activities
14 Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

AL095 - 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.
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. Visual inspection of all electrical cables.
Maintenance Summary - Care activities
15
Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022

AL122 - Check cooling lubricant (visual inspection)
Orientation
Follow the user documentation Notes on Operating Materials and
the documentation of the cooling lubricant manufacturer.
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.
The cooling lubricant is subject to wear depending on the material and the
generated temperature. Regular inspection is therefore essential.
In case of strong formation of odor, fungus or mold, the cooling lubricant emulsion
must be changed at once. The principle of open lubrication may cause a slight
commixture between cooling lubricant and hydraulic fluid. If the surface of the
cooling lubricant tank is covered with a layer of oil, the cooling lubricant must be
replaced. Furthermore, determine the cause of the oil ingression.
Synthetic cooling lubricants or cooling lubricant based on esters are
not admissible.
If the type of cooling lubricant or the manufacturer is changed, make
sure that the cooling lubricant meets the required specifications.
See the manufacturer's documentation for the fill quantities.
Regularly checking the cooling lubricant is necessary in particular if
cooling lubricant emulsions containing mineral oil are used, so that
the required properties are ensured.
Requirement
A refractometer is required to determine the concentration.
Procedure
1.
Caution
Biological and chemical changes in the cooling lubricant.
Skin irritation or respiratory and circulatory problems.
Wear personal protective equipment (e.g., safety gloves and
safety goggles).
Remove a cover (e.g., at the filter basket) on the chip pan or the chip conveyor.
2. Visual and olfactory inspection of the cooling lubricant.
3. Check cooling lubricant emulsion. See document Notes on Operating
Materials
Maintenance Summary - Care activities
16 Maintenance Instructions
TNL12.2
DTE072EN - 22.11.2022