Trumpf TC 2020R User manual

TC 2020R Install with SMC
Student Guide
For TRUMPF Service Engineers
TR22.1
July 2003

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1. Check power: 460V, 480V, Wye-configuration (Y) as required according
to the pre-installation manual.
2. Check to make sure clean, dry air is supplied to the machine.
3. Make sure there is at least 40 gallons of Mobile DTE25 oil on-site.
4. Inventory all the parts that came with the machine and inspect the parts
for damage. If the parts are damaged, record the damage, take
pictures, and call TRUMPF Service department 860-678-8584.
5. Verify machine options according to the list.
6. Inspect the installation area, making sure there is adequate room. Make
sure there are no cracks between the support feet of the machine.
Check floor for proper thickness and level.
7. Make sure there is sufficient test tooling (at least 2 cartridges).

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8. Determine the center point of the
machine. Go 3 feet each direction
from the center point. Swing a 5
feet arc from each of the 3f mark.
Center
4 f
5 f
5 f
3 f
3 f
Figure 1. Mark the center of the machine
Figure 2. Measure the distance from 3f mark to the center point

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9. Make sure the arc intersection is 4f
perpendicular from the center
point.
Figure 3. Determine the center of the machine
Figure 4. Use plumb bob to determine the center
Figure 5. Make sure the plumb bob is in the center

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10. Observe the different sizes of the
wedge pads. Big pads (P3, P4) go
to the front of the machine; small
pads (P1, P2) go to the back of the
machine.
Figure 6. Wedge pads come in 2 different sizes
11. Set pads to the correct locations.
Lay pads down with rubber side
facing up and adjusting bolts
facing outward.
Figure 7. Front left wedge pad
Figure 8. Back left wedge pad

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Figure 9. Back right wedge pad
Figure 10. Front right wedge pad
12. Remove shipping wood blocks
under the machine.
Figure 11. Wood block for the back for the machine

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13. Use crane to lift the machine and
carefully position it on wedge
pads.
Figure 12. Front left wedge pad
Figure 13. Back right wedge pad
14. Front pads should be flush with
machine feet.
Figure 14. Front right wedge pad

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15. Make sure the leveling pads are
positioned correctly (according to
the pre-installation manual).
Figure 15. Adjusting leveling pads
16. Using strap (not chains), remove
the carriage from the mounting
brackets.
Set the X-axis carriage in place
and clean and dress all the mating
surfaces.
Figure 16. Remove the carriage from the mounting brackets
17. Using a forklift or overhead crane
position the carriage.
!
Caution
Do not attempt to move by hand.
Figure 17. Forklift

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18. Place a wooden plank between the
lifting strap and X-rail to protect the
X-rail from damage.
Figure 18. Wooden plank between the lifting strap and X-rail
19. Find at least two people to assist
in guiding the carriage to its
correct location.
Figure 19. Guiding the carriage to its correct location
20. Remove the bolts and prepare the
mounting surface for installation.
Note: Observe the location of the
bolts upon removal, since not all of
the bolts are the same length.
Figure 20. Bolts on the mounting surface

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Note: Care must be taken when
mounting the carriage to prevent
damage to the precision mounting
surfaces.
Figure 21. X-axis rail carriage
21. Make sure all the shims and
spacers are underneath the
carriage.
22. Install stiffeners and outriggers.
Figure 22. Outriggers

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Figure 23. Shoulder bolts mounted to the frame are used to support
the outrigger upon installation.
23. Install the X-axis carriage stiffing
bars to both sides of the Y-axis.
Note: Alignment pins are installed
at the front and back of the stiffing
bar.
Figure 24. X-axis carriage stiffing bars
24. Tighten bolts on the support strut.
Figure 25. Support struts

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25. Install the stiffing bar to the
underside of the X-carriage.
Figure 26. Underside of the X-carriage
26. Install the left and right tables.
Figure 27. Install right and left tables
27. Install two bolts in each table.
Figure 28. Two bolts

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28. Install two screw caps in each
table. Note: These caps are
found in the tool kit for the
machine.
Figure 29. Two screw caps
29. Roughly level the machine using a
precision machinist’s level
positioned in the die base.
Adjust the pads so that the height
of machine is 1020 mm.
Make sure the weight is distributed
equally on all pads.
Figure 30. Precision machinist’s level
30. Remove all the shipping brackets,
7 in total.
Clean rails thoroughly, make sure
all mating surface is chip-free.
Figure 31. Orange shipping brackets

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31. Remove shipping bracket for the
energy chain.
Figure 32. Energy chain shipping bracket
32. Pay attention to the energy chain.
Do not snap the chain.
Figure 33. Lay the energy chain on a support
33. Remove the energy chain hold-
down bracket.
Figure 34. Energy chain hold-down bracket

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34. Remove the machine hold-down
shipping bracket.
Figure 35. Machine hold-down shipping bracket
35. For shipping purposes, measure
the height of the shipping brackets.
It should read 32 mm.
Figure 36. Measuring the height of the bracket
36. Measure the Y-axis guide rail in
front of the bearing block. It should
read 452 mm.
Figure 37. Measure the Y-guide rail

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37. Remove the shipping brackets for
the X-axis rail carriage.
Figure 38. Shipping brackets
38. Remove the two rail covers from
the X-axis rail carriage.
Figure 39. X-axis carriage cover
39. Remove the bolts on the X-axis rail
carriage cover.
Figure 40. Bolts on X-axis rail carriage cover

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40. Remove X-axis rail carriage cover.
Figure 41. Remove X-axis rail carriage cover
41. Connect the energy chain to the
carriage. Make sure all the
hydraulic, pneumatic, and electrical
connections are in place. Check for
proper labeling.
Figure 42. Energy chain
Figure 43. Connect energy chain to the rail carriage

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42. Connect the two black hydraulic
hoses. Make sure the hoses stay
down in the tough.
Figure 44. Connect lube lines
43. Make sure all fittings and
connections are tight.
Figure 45. Connect air hoses
44. Make sure not to kink any of the
pneumatic lines.
Figure 46. Pneumatic lines

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Figure 47. Make all electrical connections
45. Connect the X-axis motor cable.
Make sure plugs are properly
aligned.
Make sure motor cables are tight.
Figure 48. X-axis motor cable
46. After all the connections are made,
do not put the X-axis rail cover on
just yet. Power up the machine and
check to see if the hydraulic lines
are leaking.
!
Caution

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47. Connect 2 the pneumatic lines for
the load pin.
Figure 49. Pneumatic line for the load pin
48. Connect cables for the proxy
switches.
Figure 50. Load pin for automatic sheet loader SMC