Traub TNX65/42 User manual

142853 - 14.03.2022
03.22/Ru (Transport- und Aufstellanleitung) - 20057384
Transport and
Installation Instructions
TNX65/42
OPERATING INSTRUCTIONS
Transport and installation

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
SafetySafety .............................................................................................................................................................................................................................................................................................. 77
Explanation of symbols ..................................................................................................................... 7
Safety instructions and technical details ......................................................................................... 7
Information on transport, installation, commissioning ....................................................................... 8
General hazards during on-site transport ...................................................................................... 9
Dimensions and masses ............................................................................................................... 9
Transporting and lifting aids ........................................................................................................... 9
Layout and installation planLayout and installation plan .................................................................................................................................................................................................................... 1111
Layout chart ...................................................................................................................................... 11
Simplified installation plan ................................................................................................................. 12
General informationGeneral information .............................................................................................................................................................................................................................................. 1313
Preparations ....................................................................................................................................... 13
Suitable transporting and lifting aids ................................................................................................. 13
Information on transporting the machine with a truck ...................................................................... 14
Dimensions (without attachments) ................................................................................................... 14
TNX 65/42 / TNX 65/42 with milling unit ....................................................................................... 14
Machine weight and machine dimensions ....................................................................................... 15
TNX 65/42 ..................................................................................................................................... 15
TNX 65/42 with milling unit ........................................................................................................... 15
Support points* ............................................................................................................................. 15
Space requirements .......................................................................................................................... 16
Floor condition ................................................................................................................................... 16
Fastening/anchoring ...................................................................................................................... 16
Ambient conditions ............................................................................................................................ 17
Floor trough ....................................................................................................................................... 17
Compressed-air supply ...................................................................................................................... 17
Operating material to be provided ..................................................................................................... 17
Pumps and tanks ............................................................................................................................... 17
Connection to local extraction system by customer ......................................................................... 17
Power supply ..................................................................................................................................... 18
Main circuit breaker ........................................................................................................................... 18
External data transfer ........................................................................................................................ 18
Chip removal ...................................................................................................................................... 19
Disposal of used operating materials ................................................................................................ 19
Observing the ground and wastewater regulations ........................................................................... 19

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Preparing to transport a machine without milling unitPreparing to transport a machine without milling unit .......................................................................................................................... 2121
Close open hose or pipe lines ........................................................................................................... 21
Corrosion protection .......................................................................................................................... 21
Attach transport retainers to the machine ......................................................................................... 22
Attach transport retainers to the control cabinet ............................................................................... 23
Preparing to transport a machine with milling unitPreparing to transport a machine with milling unit ...................................................................................................................................... 2525
Transport retainers ............................................................................................................................. 25
Position of the transport retainers ................................................................................................. 25
Remove the tool chain and chain magazine (only with optional 120 positions) ................................. 27
Remove the cover on the milling unit with tool changer ................................................................... 28
Separate the chain of the chain magazine (only with optional 120 positions) ................................... 29
Remove upper part of chain magazine .......................................................................................... 30
Transporting the machineTransporting the machine .......................................................................................................................................................................................................................... 3131
Delivery of the machine ..................................................................................................................... 31
Transport by crane (min. load capacity 12 t) ...................................................................................... 32
Set of hoisting gear and fittings .................................................................................................... 33
TNX 65/42 Centers of gravity (machine with control cabinet)................................................... 34
Transport by fork lift truck ................................................................................................................. 35
Transport by truck .............................................................................................................................. 36
Installing the machineInstalling the machine ........................................................................................................................................................................................................................................ 3737
Installing the machine by crane ......................................................................................................... 37
Positioning and installing the machine with transport rollers ............................................................ 38
Lifting the machine with hydraulic jacks ........................................................................................ 39
Positioning the transport rollers .................................................................................................... 39
Rough alignment of the machine ...................................................................................................... 39
Set up control cabinet on wheels ...................................................................................................... 40
Remove transport retainers from the control cabinet ................................................................... 40
Aligning the wheels on the control cabinet ................................................................................... 41
Indicator lamp .................................................................................................................................... 41
Remove transport retainers from the machine ................................................................................. 42
Working area door..................................................................................................................... 42
Workpiece handling with remnant removal device ................................................................... 42
Transport retainer for turret (tool carrier / main spindle and opposed spindle / milling unit) .......... 43
Installation of the milling unit componentsInstallation of the milling unit components ................................................................................................................................................................ 4747
Installation of the tool chain and chain magazine (only with optional 120 positions) ......................... 47
Install upper part of chain magazine .............................................................................................. 47
Connect the chain of the chain magazine (only with optional 120 positions) .................................... 49
Install cover on milling unit with tool changer ................................................................................... 51

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Table of Contents
FuelsFuels .................................................................................................................................................................................................................................................................................................. 5353
Overview of fuels .............................................................................................................................. 53
Pneumatic connectionPneumatic connection ........................................................................................................................................................................................................................................ 5555
Supply of compressed air .................................................................................................................. 55
Air consumption ............................................................................................................................ 55
Electrical connectionElectrical connection ............................................................................................................................................................................................................................................ 5757
Important notes ................................................................................................................................. 57
Alignment, component installation and commissioningAlignment, component installation and commissioning .................................................................................................................... 5959
Precise alignment of the machine ..................................................................................................... 59
Check / correct position and torsion of the machine ......................................................................... 59
Check / correct with tool carrier 2 ................................................................................................. 60
Secure machine to the floor .............................................................................................................. 61
Transport and installation of the chip conveyor ................................................................................. 62
Setting the level switch of the chip conveyor ................................................................................... 62
Lubricoolant unit ................................................................................................................................ 62
Bar feeding mechanisms ................................................................................................................... 62
Switching on the machine ................................................................................................................. 63

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Table of Contents

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Safety
Explanation of symbols
This chapter explains the symbols that are used in the user documentation to
call attention to dangers and important notes.
This symbol warns against a direct, imminent danger to the life and
health of individuals. Failure to observe this danger warning may
result in severe health impairment such as perilous injury and even
death.
This symbol warns against a direct, imminent danger from elec-
tricity. Failure to observe this danger warning may result in severe
health impairment such as perilous injury and even death.
This symbol indicates important notes for the proper operation of
the machine. Failure to observe this information may result in dam-
age to or malfunction of the machine or its components.
Safety instructions and technical details
The INDEX TRAUB user documentation and, in particular, the docu-
ment “Safety instructions and technical details” must be observed.
The document is part of the INDEX TRAUB user documentation.

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Information on transport, installation, commissioning
Use only suitable hydraulic jacks, cranes, or forklift to lift
the machine. When transporting with transport or armored
rollers, ensure that the rollers used have the appropriate
load-bearing capacity.
Failure to follow proper procedures for transport, installation and, start-up is
prone to cause accidents and may induce damages to or malfunctions of the
machine for which INDEX TRAUB rejects any liability or warranty.
Prior to delivery of the machine, the procedures for unloading, transporting to
the installation site, installation, and start-up must be carefully planned while
absolutely observing the cautions below in this document.
Associated transport instructions and/or manufacturer documentation exist for
separate units such as chip conveyor, bar feeder, bar loading magazine, and
similar devices that must be observed as well.
Safety

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General hazards during on-site transport
Danger to life!
Do not step under suspended loads.
Machines must be transported by authorized and qualified personnel only.
Act responsibly when transporting the system and always consider the conse-
quences. Avoid dangerous and risky actions.
Slopes and gradients (driveways, ramps, etc.) are particularly dangerous. Use
extra care if such passageways cannot be avoided.
Ensure secure and proper seating of the cargo. If necessary, use additional
fixtures to ensure that the cargo is not able to slip.
The transport vehicles must be able to produce sufficient traction and braking
forces for safe transport.
Dimensions and masses
The machine and control cabinet masses are indicated on the respective ma-
chine installation plan.
The masses of optional separate units, such as chip conveyor, bar feeder, bar
loading magazine, and similar devices, can be found either in the specific trans-
port instructions/manufacturer documentation for these equipment levels or
accessories or in the corresponding machine installation plan.
Transporting and lifting aids
For lifting and transporting the individual units, only lifting and transporting aids
having sufficient capacity and loading platform must be used.
Safety

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Safety

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Layout and installation plan
M. 1:100
M. 1:50
1900
6900
2100
5100
A3
A4
O
E
A1
A2
E
O
E
O
Layout chart
Drawing No. 478503
= Electrical connection
= Operating side
The corresponding installation and layout plan must be requested
before the machine is installed.
Example shown

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Layout and installation plan
Simplified installation plan
Illustrations show examples

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Preparations
This section is addressed to the persons responsible for the installation and
their staff.
The information provided here allows you to prepare the installation site and its
surroundings such that the machine, when delivered, can be installed and put
into operation immediately.
Be sure to carefully plan the delivery, unloading, and transporting of the ma-
chine from the unloading site to the installation site.
The installation plan applicable for this machine was already submit-
ted for approval after the contract award.
Upon delivery of the machine, it is included in Chapter Diagrams and
drawings on the supplied data carrier.
Take the size (dimensions) and masses of each unit into consideration.
Suitable transporting and lifting means must be available when the machine is
delivered.
Any obstacles along the transport route from the unloading site to the installa-
tion site must be eliminated before the machine is delivered.
Check the transport route for load capacity, levelness, damaged pavement,
traverse grooves, slopes, gradients, etc.
Is the width and height of entrances and gates sufficient?
If elevators are to be used, do they have sufficient capacities?
Proper planning will pay off!
Suitable transporting and lifting aids
–Crane
–Truck-mounted crane
–Forklift
–Transport trolley
–Transport rollers
–Armored rollers
–Hydraulic jacks
–Forklift (only for separate units).
General information

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General information
Risk of crushing
The installation site must be chosen such that moving parts of the
machine, including hand-operated doors, flaps, etc., do not create
risks of being crushed against walls, columns, or hall installations.
Danger from falling machine/parts
No persons are allowed to remain under suspended loads!
Transporting the machine
The machine can be transported with a crane, forklift, or armored
rollers.
The machine must be lifted from the operating side when transport-
ed by a forklift.
In any case, the machine, including the bar loading magazine, must
be doweled to the floor.
Information on transporting the machine with a truck
To avoid heavy impact during transport, the truck should have air suspension!
Dimensions (without attachments)
TNX 65/42 / TNX 65/42 with milling unit
Foundation length mm 3690
Foundation width mm 1400
Foundation depth mm 550

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General information
Machine weight and machine dimensions
These specifications refer only to the basic machine (i.e., without
chip conveyor, cooling lubricant system, and oil mist extractor...).
TNX 65/42
Machine weight
Without control cabinet kg 8600
With control cabinet kg 9800
Machine dimensions
Length without chip conveyor mm 3850
Width without control panel
Width without work area door mm 2365 2330
Height with indicator lamp, orange
Height with multi-indicator lamp mm 2286 2450
Height during operation
(prepared for oil mist extraction) mm approx. 2470
TNX 65/42 with milling unit
Machine weight
Without control cabinet kg 8800
With control cabinet kg 10000
Machine dimensions
Length without chip conveyor mm 4744
Width without control panel
Width without work area door mm 2365 2330
Height mm 2700 / 34611)
Height during operation
(prepared for oil mist extraction) mm 2700 / 34611)
Support points*
A1 kN 25
A2 kN 25
A3 kN 25
A4 kN 25
* Support points A, see Chapter “Installation and layout charts”
1) Tool magazine with 120 positions

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Space requirements
The following must be ensured:
– Sufficient free space around the machine.
– Sufficient movement space for the operator.
– Sufficient space for maintenance and repair.
– It must be possible to open all doors of the machine completely.
– Space for placing blank and workpiece pallets, workpiece collectors, chip
trolleys, tool trolleys, etc.
Use the machine installation plan to determine the required space.
There are special installation plans for add-on equipment such as bar feeders,
bar loading magazines, etc.
Floor condition
A special foundation is not necessary. Only the load capacity and strength of
the floor area must be suitable for the machine weight based on constructional
aspects.
Comply with the requirements set out in DIN 18202:2019.
In particular, note the information regarding “Flatness tolerance
for finished floors”.
There must be no expansion joints in the area of the machine
footprint.
The locally valid guide lines and regulations must be taken into con-
sideration.
Les différentes directives et prescriptions en vigueur dans le pays
d’utilisation devront être prises en compte.
Devono essere rispettate di volta in volta le direttive e le prescrizioni
vigenti nel paese di utilizzo.
De gällande riktlinjerna och föreskrifterna i användningslandet måste
följas.
Han de observarse las directivas y prescripciones vigentes del país
de destino.
Devem ser consideradas as recomendações e regulamentos do res-
pectivo país.
Käyttömaassa voimassa olevia direktiivejä ja määräyksiä on noudatet-
tava
Je nutno dodržovat také aktuální směrnice a předpisy platné v zemi
použití.
Należy uwzględnić też obowiązujące dyrektywy i przepisy kraju użyt-
kownika.
Se vor respecta normele şi directivele în vigoare în ţara de destinaţie.
Figyelembe kell venni a felhasználó ország mindenkor érvényes irány-
elveit és előírásait.
Met de geldende richtlijnen en voorschriften van het gebruiksland
moet rekening gehouden worden.
Der skal tages hensyn til de pågældende gældende direktiver og
forskrifter i brugslandet.
Musíte dodržiavať smernice a predpisy práve platné v krajine používa-
nia.
必须对所在国家各现行指令和规定加以考虑。
Es müssen die jeweils geltenden Richtlinien und Vorschriften des
Verwendungslandes berücksichtigt werden.
Ürünün kullanıldığı ülkede geçerli olan direktifler ve yönetmelikler
dikkate alınmalıdır.
Upoštevati je treba direktive in predpise, ki so veljavni v posamezni
državi.
Необходимо учитывать соответствующие действующие директи-
вы и предписания страны, в которой применяется ресивер.
02
en
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fr
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it
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sv
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es
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pt
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sl
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fi
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de
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tr
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ru
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cs
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pl
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ro
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zh
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hu
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nl
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da
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sk
Трябва да се вземат под внимание действащите в съответната
страна директиви и разпоредби. 14
bg
Fastening/anchoring
In any case, the machine must be doweled to the floor.
Bar guides, bar feeders, and bar loading magazines must be anchored to the
floor.
When attaching a robot cell from a third-party manufacturer, be sure to observe
the relevant manufacturer’s documentation.
General information

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General information
Ambient conditions
See Ambient conditions in the “Safety instructions and technical details”.
If the actual conditions at the installation site differ from these
specifications, be sure to contact the machine manufacturer or its
representative..
Floor trough
If a floor trough is required, it must be designed according to the
specifications “Information on floor trough drawing” so that exten-
sion of the corresponding chip conveyor is ensured.
The floor in the area of the floor trough must only be max. 5 mm convex, as flat
or concave as possible. Exceeding the allowable unevenness may cause the
floor trough to contact the machine base / machine components.
Compressed-air supply
See Chapter Pneumatic connection.
Operating material to be provided
See Chapters Operating material and Information on operating material.
Pumps and tanks
A simple pump is sufficient to extract the used cooling lubricant. The same
pump may be used to fill the cooling lubricant tank; however, it must be thor-
oughly flushed with fresh cooling lubricant.
A robust container is required for collecting the extracted fluids. Suitable con-
tainers are metal barrels of sufficient capacity and with proper labels, which can
be tightly closed.
Connection to local extraction system by customer
If a local extraction system is attached to the machine, any existing
fire extinguishing system available on the machine must be adjusted
accordingly.

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General information
Power supply
The directives and regulations applicable in the country of use must
be followed.
The power supply cord to the machine should be as short as possible.
Use a sufficient wire size.
The power supply for the machine requires stable mains conditions; the max.
allowed operating voltage fluctuations are +10% or -10%.
The mains line must comply with the regulations of the local electricity supplier
and the VDE directives.
Main circuit breaker
Check that the building connection has sufficient capacity to cover
the additional load to be protected.
Discuss any unclear conditions with your local electricity supplier.
The main circuit breaker is not included in the delivery of the machine.
It must be installed outside the machine according to DIN EN 60204-1.
If a pre-transformer is required, the main circuit breaker must be installed after the
pre-transformer, i.e., on the secondary side. The fuse protection on the primary
side must be designed according to the connection data of the pre-transformer.
The loads to be protected depend on the existing operating voltage.
For the information on machine connection, operating voltage, main fuse, see
the electrical diagrams or Chapter Electrical connection.
External data transfer
Data cables must not be routed directly next to live cables.
For data transfer to/from external computers or servers/storage devices, suit-
able metal conduits must be installed for the data lines.
The connection to the internal network (DNC) requires an RJ45 network cable.
An additional connection to the external network (IoT) must be made with a
separate RJ45 network cable.

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General information
Chip removal
If the machine is equipped with a chip conveyor, a chip trolley, its height match-
ing the chip conveyor's discharge height, is required.
The chip trolley should have a device for draining the accumulating cooling lubri-
cant so it can be returned to the cooling lubricant tank.
Chip conveyor without discharge chute
If using a chip conveyor without a discharge chute, the collection bin
for the chips must be provided by the customer with a cover.
The cover must be designed such that it is not possible to reach into
the discharge area of the chip conveyor.
Disposal of used operating materials
The directives and regulations applicable in the country of use must
be followed.
Decide in advance on how to dispose of used operating fluids such as hydraulic
fluid, lubricating oil, and cooling lubricant in an environmentally friendly manner.
Observing the ground and wastewater regulations
The directives and regulations applicable in the country of use must
be followed.
The machine contains water-polluting substances such as water-miscible cool-
ing lubricants and mineral oils. These substances may leak from the machine in
case of adverse events.
Therefore, the machine must be installed in a place that excludes any harm by
these substances to waters or groundwater.
Possible preventive measures
• Place the machine inside a tight steel trough (floor trough).
• Seal the floor of the factory hall.

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General information