Traub TNX65/42 Operating and maintenance instructions

142969 - 10.2016
WTAL-en/Ru
Maintenance Instructions
TNX65/42 TX8i-s
TNX65/42 as from serial No. 7060436
TNX65/42 Value package

Note on applicability
Illustrations in this publication may deviate from the product supplied. Errors and omissions due to technical
progress expected.
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
Englisch

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Table of contents
Safety................................................................................................................................................. 7
Symbols.............................................................................................................................................. 7
Documentation safety instructions..................................................................................................... 7
Maintenance Instructions................................................................................................................ 9
Fuels................................................................................................................................................... 9
Visual inspection of all fluid lines and wiring ...................................................................................... 10
Maintenance and repair work ............................................................................................................. 11
Maintenance intervals ........................................................................................................................ 11
Operating hours counter..................................................................................................................... 11
Maintenance kits and spare parts....................................................................................................... 12
Screen display .................................................................................................................................... 12
Fire protection device..................................................................................................................... 15
Testing / servicing the fire protection device ................................................................................. 15
On completion of maintenance work ................................................................................................. 15
Lubrication schedule........................................................................................................................... 16
Daily visual inspection ..................................................................................................................... 17
A01
Complete machine ............................................................................................................................. 18
Check safety mechanisms ............................................................................................................. 18
Check there are no accumulations of metal chips in the working area; any deposits found
must be removed ........................................................................................................................... 18
Look for visible oil or lubricoolant leaks.......................................................................................... 18
A02
Working area door .............................................................................................................................. 19
Examine the window pane............................................................................................................. 19
Cleaning the window pane............................................................................................................. 19
A03
Chip conveyor..................................................................................................................................... 20
Check the pre-filter box on the chip conveyor for accumulations of metal chips and remove
them if necessary........................................................................................................................... 20
A04
Hydraulic system ................................................................................................................................ 21
Check filling level and top up if necessary...................................................................................... 21

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Table of contents
Maintenance work every 200 hours of operation.......................................................................... 23
B01
Hydraulic system ................................................................................................................................ 24
B02
Chip conveyor..................................................................................................................................... 25
Check the chip conveyor for fouling around the level switch and clean it if necessary ................. 25
B03
Central lubrication unit........................................................................................................................ 26
B04
Pneumatic system.............................................................................................................................. 27
B05
Power clamping chuck ....................................................................................................................... 28
Clean and lubricate as specified by the manufacturer.................................................................... 28
B06
Parts conveyor.................................................................................................................................... 29
B07
Lighting in the working area ............................................................................................................... 30
B08
Transition from working area to coolant / oil spray extractor.............................................................. 31
B09
Cover in the working area................................................................................................................... 32
B10
Fluid cabinet ....................................................................................................................................... 33
B11
Bar feeding magazine......................................................................................................................... 34
Check oil level................................................................................................................................. 34
Maintenance work every 1 000 hours of operation ...................................................................... 35
C01
Maintenance work every 200 and 1 000 operating hours .................................................................. 36
C02
Pneumatic system.............................................................................................................................. 37
Replace active-carbon filter cartridge ............................................................................................. 37

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Table of contents
Maintenance work every 2 000 hours of operation ...................................................................... 39
D01
Maintenance work every 200 and 1 000 operating hours .................................................................. 40
D02
Hydraulic system ................................................................................................................................ 41
Replace filter cartridge in the pressure filter .................................................................................. 41
D03
Axes.................................................................................................................................................... 42
D04
Hollow clamping cylinder, main spindle / opposed spindle if applicable............................................. 43
Clean lubricoolant collecting pan .................................................................................................... 43
D05
Ball screw transmission, X-axis, Z-axis, V-axis and Y-axis ................................................................... 44
Determine the reversing backlash.................................................................................................. 44
D06
Covers in the working area................................................................................................................. 45
Check wipers.................................................................................................................................. 45
Replace wipers............................................................................................................................... 45
Maintenance work every 4 000 hours of operation ...................................................................... 47
E01
Maintenance work every 200, 1 000 and 2 000 operating hours....................................................... 48
E02
Hydraulic system ................................................................................................................................ 49
Replace hydraulic fluid.................................................................................................................... 49
E03
Power clamping mechanism .............................................................................................................. 50
E04
Top turrets .......................................................................................................................................... 51
E05
Control cabinet ................................................................................................................................... 52
Clean the interior of the control cabinet ......................................................................................... 52
Check and retighten connections................................................................................................... 52

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Table of contents
Maintenance work every 8 000 hours of operation ...................................................................... 53
F01
Maintenance work every 200, 1 000, 2 000 and 4 000 operating hours............................................ 54
F02
Chip conveyor..................................................................................................................................... 55
Change transmission oil ................................................................................................................. 55
F03
Machine.............................................................................................................................................. 56
F04
O-rings................................................................................................................................................ 57
Check and if necessary replace O-rings ......................................................................................... 57
Safety-related maintenance every 1, 2, 4 and 8 years .................................................................. 59
G01
Annual check of Emergency OFF function ......................................................................................... 60
G02
Annual maintenance of the automatic working area door .................................................................. 61
Check mechanical rail of automatic working area door .................................................................. 61
G03
Annual check of the repeat blowing unit ............................................................................................ 62
Check storage batteries and replace them if necessary................................................................. 62
G04
Maintenance of the repeat blowing unit every 2 years ...................................................................... 63
Replace storage batteries............................................................................................................... 63
G05
Maintenance of the uninterruptible power supply every 2 years (optional)........................................ 64
Replace storage batteries............................................................................................................... 64
G06
Maintenance of control console / control cabinet every 4 years ........................................................ 65
Replace PC/NC buffer batteries...................................................................................................... 65
G07
Maintenance of control cabinet every 4 years.................................................................................... 66
Check buffer batteries .................................................................................................................... 66
Replace buffer batteries ................................................................................................................. 66
G08
Maintenance of the working area door every 8 years ........................................................................ 67
Replace window pane (polycarbonate)........................................................................................... 67
Maintenance checklist TNX65/42.................................................................................................... 69

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Safety
Symbols
This chapter describes the symbols used in the documentation for users to
highlight risks and tips.
This symbol draws attention to imminent danger to life and health.
Failure to observe this danger sign can result in serious damage to
health, as well as potentially fatal injuries and even death.
This symbol draws attention to imminent danger due to electricity.
Failure to observe this danger sign can result in serious damage to
health, as well as potentially fatal injuries and even death.
This symbol draws attention to important information on correct
operation of the machine. The machine or parts of the machine may
be damaged or malfunction if these instructions are not observed.
Documentation safety instructions
The documentation for users and particularly the safety instructions
must be observed.
The safety instructions are set out in a separate document forming
part of the TRAUB documentation for users.

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Safety

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Maintenance Instructions
Risk of fire and explosion!
The machine must not operate unattended when using
inflammable lubricoolants.
Danger due to electricity
Work on motors or other electrical assemblies may only be carried
out by specially trained and instructed personnel!
Danger due to electricity
Even when the machine has been switched off, electricity may still
be stored in the electric components. These components are
identified by a corresponding sign and must not be touched until the
specified discharge time has expired.
Depressurize hydraulic system
Before starting any maintenance or repair work, the entire hydraulic
system must be depressurized via the accumulator drain valve.
Disconnect compressed air supply from the machine
Before starting any maintenance work on the machine, the
compressed air supply must be disconnected from the machine by
turning the manual knob on the air maintenance unit.
Health hazard!
Do not allow lubricoolants to come into contact with the skin.
Appropriate skin care agents must be used.
Vapour extractors must be fitted to prevent inhalation of
physiologically harmful substances.
Safety instructions
The safety instructions contained in this manual must be observed
without fail!
Accumulator ≤ 1 l
Accumulators with a volume ≤ 1 l are not subject to mandatory
testing in accordance with Pressure Equipment Directive (PED)
97/23/EC. CE marking and a declaration of conformity are not
permitted for these accumulators.
Fuels
The information in the data sheets of the fluid manufacturers and in
the document Notes on Operating Materials must be observed
during all work involving fuels and fluids.
The filling quantities of the fuels and fluids are stated in the
respective fluid schedules.
Locally applicable guidelines and regulations must be observed
when disposing of auxiliaries, coolants and lubricants.

10 10.2016
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Maintenance Instructions
Visual inspection of all fluid lines and wiring
It is essential to examine all fluid lines and wiring at regular intervals, in
accordance with the service time and use of the machine, as well as the
different ambient conditions.
In this way, potential faults or problems can be identified and remedied at an
early stage.
Risk of injury due to escaping fluid!
Fluids may escape from damaged fluid lines at high pressure.
Personal protective equipment must therefore always be worn
during visual inspections.
If such visual inspection reveals defects in fluid lines or wiring, the machine
must be switched off and the defective lines or leads replaced without delay.
Fluid lines which have been replaced must be tightened down with
the torque specified by the manufacturer.

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Maintenance Instructions
Maintenance and repair work
Maintenance and repair work may only be carried out by specially trained and
authorised personnel.
In this context, TRAUB recommends that the daily visual inspection,
maintenance after 200 hours and maintenance after 1000 hours of operation be
carried out by the user and that the manufacturer's service be called in for all
other maintenance work.
The machine must normally be switched off before starting any maintenance
work. The main switch must be secured so that it cannot be reactivated.
Even when the main switch is off, parts of the machine (e.g. control cabinet
lamp) may still be live. These parts are identified by a warning sign.
In a small number of cases, the machine must be switched on for
maintenance work (e.g. when replacing back-up batteries). Such maintenance
must be undertaken with particular care.
Upon completing any maintenance or repair work, the machine’s operator must
check that the machine and its safety mechanisms are in perfect working order.
Maintenance intervals
In order to ensure the machine’s correct functioning in the long term, it is
essential to carry out the maintenance work at the specified intervals and to
confirm this by signing and dating the corresponding columns.
Only the reading on the mechanical operating hours counter to the left of the
master switch applies when checking whether and which maintenance
intervals have been observed.
Operating hours counter
The operating hours counter is located beside the master switch and
exclusively counts the hours during which the machine is in operation after
"Drives ON", regardless of whether it is producing workpieces.
The operating hours counter has no effect on the maintenance intervals.

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Maintenance Instructions
Maintenance kits and spare parts
The parts lists needed for maintenance and repair work can be ordered from
the manufacturer's service quoting the 7-digit serial number on the rating plate.
The Article Nos. of the required spare parts can be found in the in the Spare
Parts List.
Screen display
The message block "MAINTENANCE WORK REQUIRED" appears on the
monitor upon expiry of each maintenance interval in order to make it easier for
the user to comply with the specified intervals. The required maintenance
interval can be read off in the line "Maintenance interval" (blue background)
after pressing the keys: Monitor - Supplement - Piece counter.
For example: MAINTENANCE INTERVAL 2 000 hours
The work required in each instance is described in the Maintenance
Instructions. The display can be cleared by pressing the keys: Delete
maintenance - Input in the maintenance menu when the maintenance work is
complete. The alarm on the monitor is cancelled at the same time.

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Maintenance Instructions
Maintenance A A A A AB A A A A ABC
Operating hours 200 400 600 800 1000 1200 1400 1600 1800 2000
Date:
Name:
Maintenance A A A A AB A A A A ABCD
Operating hours 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000
Date:
Name:
Maintenance A A A A AB A A A A ABC
Operating hours 4200 4400 4600 4800 5000 5200 5400 5600 5800 6000
Date:
Name:
Maintenance A A A A AB A A A A ABCDE
Operating hours 6200 6400 6600 6800 7000 7200 74 0 0 7600 7800 8000
Date:
Name:
Maintenance A A A A AB A A A A ABC
Operating hours 8200 8400 8600 8800 9000 9200 9400 9600 9800 10000
Date:
Name:
Maintenance A A A A AB A A A A ABCD
Operating hours 10200 10400 10600 10800 11000 112 0 0 114 0 0 116 0 0 118 0 0 12000
Date:
Name:
Maintenance A A A A AB A A A A ABC
Operating hours 12200 12400 12600 12800 13000 13200 13400 13600 13800 14000
Date:
Name:
Maintenance checklist
It is possible using the maintenance checklist on the following pages to tell
quickly which maintenance work is due when.
The work required can be seen in chapters A to F.

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Maintenance Instructions
Maintenance A A A A AB A A A A ABCDE
Operating hours 14200 14400 14600 14800 15000 15200 15400 15600 15800 16000
Date:
Name:
Maintenance A A A A AB A A A A ABC
Operating hours 16200 16400 16600 16800 17000 17200 174 0 0 17600 17800 18000
Date:
Name:
Maintenance A A A A AB A A A A ABCD
Operating hours 18200 18400 18600 18800 19000 19200 19400 19600 19800 20000
Date:
Name:
Maintenance A A A A AB A A A A ABC
Operating hours 20200 20400 20600 20800 21000 21200 21400 21600 21800 22000
Date:
Name:
Maintenance A A A A AB A A A A ABCDE
Operating hours 22200 22400 22600 22800 23000 23200 23400 23600 23800 24000
Date:
Name:
Maintenance A A A A AB A A A A ABC
Operating hours 24200 24400 24600 24800 25000 25200 25400 25600 25800 26000
Date:
Name:
Maintenance A A A A AB A A A A ABCD
Operating hours 26200 26400 26600 26800 27000 27200 27400 27600 27800 28000
Date:
Name:
Maintenance checklist

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Maintenance Instructions
Fire protection device
Testing / servicing the fire protection device
Note the manufacturer's documentation with regard to servicing the
fire protection device.
It is advisable to conclude a maintenance agreement with the
manufacturer of the fire protection device for its maintenance.
A function test must be performed once per year by an expert authorized by
the manufacturer in writing.
On completion of maintenance work
Danger of being crushed by the control cabinet
During operation, the control cabinet must be moved right up to the
machine to avoid the risk of being crushed.
Whenever maintenance work is complete, the owner or operator of the
machine must check that the machine, including its guards and protective
devices, is in safe operating condition.

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Maintenance Instructions
Lubrication schedule
8
40
200
1000
2000
4000
8000
3
1
2
2
5
49
10
12
14
13
13
11
12
13
13
13
13
910 11 12 13 14
bar
8h
40h
4000h4000h
8h 8h 40h 200h 200h
200h
2000
h2
000h 1000h
8000h
180l 6.0l
478884
Assemblies
Hydraulic system Central lubrication
system
Chip conveyor
gear mechanism
Air
Operating
elements
Level indicator Filler port Drain Pressure
measuring device
Hydraulic fluid
filter, air filter
Activities
Check filling level,
pressure
Top up to
required level
Fill with
fresh fluid
Clean or
replace filter
Further
informations
Tank capacity
Fluids
The information in the data sheets of the fluid manufacturers and in the
document Notes on Operating Materials must be observed during all work
involving fuels and fluids.
The filling quantities of the fuels and fluids are stated in the respective fluid
schedules.

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Daily visual inspection
ADaily visual inspection
No. Where What Comments
01 Complete machine • Check safety mechanisms
• Check there are no accumulations of metal chips
in the working area; any deposits found must be
removed
• Look for visible oil or lubricoolant leaks
02 Working area door • Examine the window pane and clean it if
necessary
03 Chip conveyor • Check the pre-filter box for accumulations of
metal chips and remove them if necessary
04 Hydraulic system • Check filling level and top up if necessary

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Daily visual inspection
Complete machine
Check safety mechanisms
Check that all safety mechanisms on the machine are complete (no missing
covers, gratings, fences, …).
Check there are no accumulations of metal chips in the working area; any
deposits found must be removed
Note personal protection.
Look for visible oil or lubricoolant leaks
A01

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Daily visual inspection
Working area door
Examine the window pane
A damaged window pane can cause accidents!
The window pane must be replaced immediately even if it shows
only small cracks or minor damage or if it has become cloudy!
The window pane becomes less resilient with age and must
therefore be replaced every 8 years.
• Examine the window pane in the working area door for cracks, cloudiness
and other signs of damage.
• Replace the window pane if necessary.
Article No.
without Visiport
Article No.
with Visiport
Mounting kit for window pane 480544 479920
A safety sticker with Article No., year of manufacture and the name of the
manufacturer is affixed to the window pane.
A02
Year of manufacture
Protection class and EN standard
Manufacturer
TRAUB article-No.
Window pane
Example: Safety sticker on window pane
Cleaning the window pane
The side of the window pane facing the operator is susceptible to
scratching!
Sprays, abrasive cleaning agents or cloths must not be used.
Clean the window pane with a commercially available glass cleaning
agent and wipe with a soft cloth or tissues.
The side of the window pane facing the working area is resistant to scratching.
All standard commercial cleaning agents can be used here.

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Pre-filter box
Chip conveyor
Avoid skin contact with the lubricoolant!
Suitable skin protection must be used!
Risk of injury
Suitable aids must be used to remove the metal chips.
Note personal protective equipment.
Check the pre-filter box on the chip conveyor for accumulations of metal
chips and remove them if necessary
Risk of injury
Beware of injuries when reaching into the chain guide.
For this reason, the chip conveyor must be switched off before
removing metal chips from the pre-filter box.
Suitable aids must be used to remove the metal chips.
A03
Daily visual inspection