Maintenance Checklist for HPM1850U CNC Machine

ASS-0177 e
Version 1.1
Mikron Agie Charmilles AG
ASS-0177
Maintenance Checklist HPM1850U
Rev: 1.1
Date: 27.01.2010
Author: Nicolas Boss
Technical release: Nicolas Boss
Commercial release: Markus Houmard
Internal distribution: ASS, ODS
Mikron Agie Charmilles AG, Ipsachstrasse 16, 2560 Nidau, Switzerland

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ASS-0177 e
Version 1.1
1. Table of contents
1. Table of contents .................................................................................................................... 2
2. General information ................................................................................................................ 2
2.1. Goal and purpose....................................................................................................... 2
2.2. Application / Area / Duration ...................................................................................... 2
2.3. Abbreviations / Concepts / Definitions ....................................................................... 2
3. Preparations ........................................................................................................................... 3
3.1. Special tools required................................................................................................. 3
3.2. Replacement parts and parts needed due to wear and tear ...................................... 3
3.2.1. Components ........................................................................................................... 3
3.3. Preparations by the customer .................................................................................... 4
4. Amount of time required for servicing ..................................................................................... 4
5. Checkpoints ............................................................................................................................ 6
5.1. Basic machine............................................................................................................ 6
5.2. Geometric check ...................................................................................................... 12
6. Data table ............................................................................................................................. 14
7. Final comments .................................................................................................................... 14
2. General information
2.1. Goal and purpose

The machine is serviced to assure that it keeps its value and to identify potential damage early.
The maintenance service is performed by personnel trained by Mikron Agie Charmilles AG and it
is required for the warranty of Mikron Agie Charmilles AG to remain in effect.
This checklist assures that the service technician performs the maintenance service correctly.
The time requirements indicated apply to the testing and inspection of the machine, as well as
the replacement of the necessary parts. Any additional time for repair and diagnosis is not
included.
These instructions are the intellectual property of Mikron Agie Charmilles AG and,
therefore, must be treated as an internal document.
2.2. Application / Area / Duration

Refers to Mikron HPM1850U machines equipped with iTNC 530 controls.
2.3. Abbreviations / Concepts / Definitions

A to K Special tools required
MNI Mikron Agie Charmilles AG, Nidau
Sales Co.’s Sales Corporation of GF AgieCharmilles
ASS After Sales Support – Technical Support Milling
ODS Online Diagnostic System (http://ods.gfac.com)

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ASS-0177 e
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3. Preparations
3.1. Special tools required

A) Power check for measuring the tool clamping power of the spindle
B) Startup set with pressure gauge and flow meter for checking the spindle pressure and
vacuum incl. flow of spindle cooling system
C) Depth gauge for measuring the tool ejection
D) Belt tension meter for measuring belt tension
E) Refractometer for measuring work piece coolant emulsion (oil content)
F) Calibration ring for setting the 3-D touch probe (ball radius)
G) Calibration arbor for calibrating the Renishaw Laser
H) Stone angle: Geometric measurement at least 400 mm long
I) Test arbor: Geometric measurement at least 300 mm long
J) Stone ruler: Geometric measurement at least 600 mm long
K) Operators manual (all procedures can be found in the operators manual)
L) Please check ODS fur further Job Procedures
M) Water Level for machine leveling
N) Adapter for slotted nut AM40 N60.30000.00225 for tightening the slotted nut from ball
screw with the torque wrench
O) conical-reamer Nr.429 Ø14,0 mm (Comp. Gühring) VNDP (conical pin DIN 7978
A14 x 60) for pinning the bearing support for ball screw preload adjustment
3.2. Replacement parts and parts needed due to wear and tear
The maintenance manager must determine the specifications of the machine (e.g., the control
unit, the main maintenance panel) to be serviced beforehand to be able to order the
replacement parts and parts needed due to wear and tear in advance.
3.2.1. Components
Step Tec spindles

Klüber Fettpaste ME 31-52 , grease 1 830.00.00.410
HSK E50 HSK63 Spannsatz komplett Clamping kit, complete 1 N60.30010.00014
HSK E75 HSK100 Spannsatz komplett Clamping kit, complete N60.30010.00024
Drehdurchführung 1K-GD rotary union 1 N60.30010.00016
O-Ring für Drehdurchführung O-Ring for rotary union 1 N60.30010.00017
Air through the spindle

Filterpatrone LFP -D-MiDi 40µm Id.N°.363667 filter cartridge 1 N62.26001.00025
Guideway carriage
Abstreifer ABRU 55 D,#002-256-673 Wiper for Guideway carriage 18 N60.30000.00074
Abstreifer ABRU 45 D,#002-256-673 Wiper for Guideway carriage 12 N60.30000.00075
ATC120N
Zahnriemen GT 5MR-550-15 Tooth belt GT 5MR-550-15 1 810.00.03.399
ATC 175/245
Zahnriemen Z-Achse AT5-50mm, L=4390 m Tooth belt 1 3012731
Hydraulik (81.02, PW ab 81.03)

Rücklaufilter 20µm 10L FTB1A20QP2516X Return-flow filter 1 N60.30010.00033

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Regulated chiller RW12000-N15

SWISSCARE SC 4 000216534
Antifreece Extin D 22 N69.55406.27701
Filtergitter RW 12000-N15 Filter grid 1 N60.30010.00028
Pneumatics with 15'000 1/min / 10'000 1/min Step-Tec Spindle

Filterpatrone LFP -D-MiDi 40µm Id.N°.363667 Filter cartridge 1 N62.26001.00025
Filterpatrone LFP -D-MiDi 5µm Id.N°.159594 Filter cartridge 1 N62.26001.00024
Filterpatrone LFP -D-MINI-0,0 1µm 162674 Filter cartridge 1 N69.21001.00003
Aktivkohlefilterpatrone MS4/D-MINI-LFX Activated-carbon filter 1 N60.20000.00823
Nr.532912 cartridge
Pneumatics with 24'000 1/min Step-Tec Spindle

Filterpatrone LFP-D-MINI-0,01µm Filter cartridge N69.21001.00003
Aktivkohlefilterpatrone MS4/D-MINI-LFX Activated-carbon filter 1 N60.20000.00823
Id.N°.532912 cartridge
Aktivkohlefilter LFX-D-MINI Id.N°.532776 Activated-carbon filter N62.26003.00073
Production package Bürener with Paper Filter

Filterpapierrolle OL60 Art.Nr. 0043494-00265 Filter Paper 1 N60.30000.00171
Filterpatrone Filter cartridge 2 N60.30000.00142
Tooth Belt
Poly-Chain-GT2-Zahnriemen Tooth belt 1 N62.63000.00202
Poly-Chain-GT2-Zahnriemen PC-8MGT-720-50 Tooth belt 1 N62.63000.00201
Poly-Chain-GT2-Zahnriemen 8MGT Tooth belt 1 N62.63000.00158
Special lubricants
Grease KE2P-35 DIN 51825 1 N60.30010.00083
Grease Klüberpaste 46MR401 1 N69.07000.00002
iTNC530
back-up battery: 3V RENATA CR 2450N 1 Heidenhain Nr.
315.876-01
3.3. Preparations by the customer

To facilitate the work of the service technician and to save time, the machine operator must
complete the following tasks before his arrival:
- Empty and clean the coolant container and the chip conveyor.
- On the day before the scheduled servicing, the system cleaner, SWISSCARE SC, must
be added for the old spindle cooling emulsion to reach a concentration of 3%. The
normal use of the machine can be continued during that day.
- Provide the lubricant (for the spindle lubrication).
- Provide free access to the electric panel.
- Backup the data of the control unit to the directory TNC:\.
- Provide tank for the disposal of approx. 150 L of cooling water.
- Provide tank for the disposal of approx. 700 L of coolant emulsion (only belt filter)
4. Amount of time required for servicing

Depends of machine configuration 1-5 Days
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ASS-0177 e
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The time required depends on the number and type of options added to the basic machine. In
case of time constraints, the customer may agree to service certain parts (e.g., coolant, oil mist
extraction or minimum quantity lubrication) himself.

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ASS-0177 e
Version 1.1
5. Checkpoints
5.1. Basic machine

The following checkpoints do not apply to all machines. Therefore, only the checkpoints
relevant for the respective machine and its options should be considered!
The instructions and additional information can be found in the commissioning protocol
and in the operator’s manual chapter maintenance
Checklist (extracted from operators manual)

On
Checkpoints Spec. Tool OK
hand
1. Safety device
1.1. Check the function of the EMERGENCY-STOP key at
the operator’s panel.
1.2. Check the function of the EMERGENCY-STOP key at
the mobile hand wheel.
1.3. Check the function of the key "Power OFF"
1.4. Check the function of the NC-Stop-key.
1.5. Door locking
1.6. Stop key
1.7. Check ON / OFF
1.8. Check all the other function keys.
2. Ball screw and axial bearing

2.1. Re-lubricate the axial bearing
2.2. Check wear of ball screw
2.3. Check preload and adjust if necessary L,N,O
3. Toothed belt x, y, z - Axis
3.1. Check Wearing
3.2. Measure and possible re-adjust of belt tension D
4. Holding brake Z
4.1. Function is to be checked with carriage weight
4.2. Security check with operator’s mod 3&4
5. Scraper chip conveyor

5.1. Clean slotted screen
5.2. Clean level meter
5.3. Chain tension and visual inspection
5.4. Clean the tank

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ASS-0177 e
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On
hand
5.5. Change gear oil drive
5.6. Servicing work at the chip conveyor.
6. Cooling lubricant system / band filter system

6.1. Clean level sonde and hoist float switch.
6.2. Check the filter mat roll.
6.3. Check the quality of the cooling lubricant emulsion. E
6.4. Replace the cooling lubricant emulsion, clean the tank of
the band filter system.
6.5. Remove used filter mat, clean the collactor
6.6. Clean the level sonde (possibly filter).
6.7. Change the Pall filter element.
6.8. Servicing work
7. Spiral chip conveyor

7.1. Inspection contamination, drawn-in chips
8. Pneumatic
8.1. Check the pressures
8.2. Check the condensate discharge
8.3. Discharge oil reservoir 24’000
8.4. Clean air filter
8.5. Outer cleaning of all appliances
8.6. Filter change
9. Hydraulic power pack

9.1. Check oil level
9.2. Check oil temperature
9.3. Check for permeabilities
9.4. Clean oil filter and change oil
9.5. Check gas filling pressure
10. Water cooler

10.1. Check pressure, flow temperature
10.2. Check of the filtering mat for contamination
10.3. Change or clean the filtering mat
10.4. Water change, check all
10.5. Temperature stabilization cooling lubricant, clean
appliance and filtering mat

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ASS-0177 e
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On
hand
11. Central lubrication
11.1. Level inspection (visual inspection)
11.2. Lubrication state Antifriction guide ways, ball screw
12. Tool spindle, tool mounting
12.1. Clean spindle taper
12.2. Check Spindle taper
12.3. Check concentricity I
12.4. Check the clamping set for wear and replace if necessary.
12.5. Check the clamping system for perfect function
12.6. Check ejection distance of spindle clamping device C
12.7. Check the clamping force of the clamping system. A
12.8. Check tool clamping system / functionality
12.9. Tool spindle with inner coolant supply: replace rotary union
12.10. Exchange the spindle
12.11. Annual maintenance acc. to check list from Step-Tec A, B,C,I
13. Working area / observation windows
13.1. Clean inside area, windows and outside area
13.2. Check lighting
13.3. Check function of tool sluice
13.4. Check coolant tightness cab
13.5. Check telescopes and window shade z, visual inspection
13.6. Grease service door guide
13.7. Check window for wear and chracks
13.8. Check, clean and re-grease telescopes x-axis
13.9. Service door- change window
14. Tool changer / Tool magazine

14.1. Visual inspection Tool change
14.2. Complete check
14.3. Clean, check tool sluice
14.4. Clean, maintain magazine guides and gripper

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ASS-0177 e
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On
hand
15. WPC (workpiece changer)
15.1. Clean Setup station & floor pan
15.2. clean taper key, lubricate
15.3. Clean clamping cone
15.4. Check hydraulic security valves at emergency stop
15.5. Lubricate guide ways from set-up station
15.6. Hydraulic Oil change
15.7. Check accumulator of hydraulic system
16. ATC
16.1. Check tool change cycle and adjust if necessary
16.2. Clean floor pan
16.3. Check parts wearing an general functionality
16.4. Check security system ATC-Door and tool-sluice
16.5. lubricate linear axis
17. ATC handling

17.1. functionality check
17.2. general check
17.3. check and clean gripper
17.4. check components and lubricate linear guide
18. Swiveling axis

18.1. Check tightness for oil and water, visual inspection
18.2. Inspection of the component units
19. Anti-friction guide ways

19.1. Visual inspection contamination, wetting with oil
19.2. Check scraper, possibly change
20. Rotary table

20.1. Service table plate
20.2. Visual inspection, impermeability media
20.3. Check clamping pressure
20.4. Inspection locking air
20.5. Inspection component unit

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ASS-0177 e
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On
hand
21. Rotary axis with pallet clamping system
21.1. maintenance of table surface
21.2. check tightness of all medias (water, oil, air)
21.3. check clamping pressure
21.4. check air barrier
21.5. check and clear clamping cones
21.6. check components
22. Oil mist - suction

22.1. Function check, visual inspection
22.2. Check siphon discharge
22.3. Check, clean contamination suction connection and fle-
xible pipe
22.4. Clean filter cartridges and housing
23. Oil separator (skimmer)

23.1. Check skimmer belt, change when necessary
23.2. Discharge oil tank, if necessary
24. Probing system

24.1. Clean probe and check for damages
24.2. Calibrate anew, if necessary F
24.3. Component inspection
25. Laser Tool check

25.1. Clean optical system
25.2. Outer cleaning, function check G
26. Minimum mass rate lubrication MMS and IMMS
26.1. Function check
26.2. Check oil level, re-fill if necessary
27. Linear measuring systems

27.1. Clean covering lips
27.2. Check locking air
27.3. Check cable
27.4. Check for function

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ASS-0177 e
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On
hand
28. Maintenance work at electric component units
28.1. Service operator panel
28.2. Replace operator panel
28.3. Check handwheel
28.4. Check switch cabinet for cleanliness (possibly clean)
28.5. Clean switch cabinet-cooler, discharge heat exchanger
28.6. Replace buffer battery
28.7. Replace control
29. Machine leveling

29.1. Check leveling M
29.2. Check geometry H,I,J

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ASS-0177 e
Version 1.1
5.2. Geometric check

1. Machine run in and operational OK 7.2
Acceptable Measured
Test condition 1 Test description
deviation deviation
Rotation of the internal cone of the milling
0.008 mm
spindle in vertical position X
(0.004
Measured with a check gauge at 20 mm Y
mm)*
[1] in X- [A] and Y- [B] direction.
0.018 mm X
Measured with a check gauge at 300mm
(0.010
[1] in X- [A] and Y- [B] direction.
mm)* Y
Test condition 2
Parallelism of the table to the X- axis

0.033 mm
(0.023
Measured with a stone ruler on a length
mm)*
of 1000 mm.
Test condition 3
Parallelism of the table to the Y- axis.

0.033 mm
(0.023
Measured with a stone ruler on a length
mm)*
of 1000 mm.
* = (The values in brackets are for machines which have an increased accuracy)
all tolerances are with the compensation
Test condition 4
Squareness of the table respective to

the Z- axis.
0.020 mm
Measured in X- direction
(0.014
mm)*
Measured with a stone angle on a length
of 600 mm.

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ASS-0177 e
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Test condition 5
Squareness of the table respective

to the Y- axis. Measured in X- direction 0.020 mm
(0.014
Measured with a stone angle mm)*
on a length of 600 mm.
Test condition 6
Squareness of the X- axis to the Y- axis

(stone angle aligned in +/- 2 µ in X- direction) 0.008 mm
(0.006
Measured with a stone angle mm)*
on a length of 1000 mm.
(compensa
If necessary, must the angle with ted)
compensation at the commissioning optimized
Test condition 7
palette1:
Radial run-out to the reference slot
of the table 0.024 mm
palette2:
(0.017
Measure the complete length mm)*
of the reference slot
palette3:
Test condition 8
Parallelism of the milling spindle in vertical

position respective to the Z- axis 0.018 mm X
(0.013
Measured with a check gauge on a mm)* Y
length of 300 mm in X- [A] and Y- [B] direction.
Test condition 9
Parallelism of the milling spindle in Y- axis

respective to the horizontal position. 0.018 mm X
(0.013
Measured with a check gauge of 300 mm mm)* Y
n X- [A] and Z- [B] direction.

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ASS-0177 e
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Test condition 10
Squareness of the milling spindle in vertical

position respective to the table
0.020 mm X
Measured with a stone ruler positioned at a (0.014
radius of 150mm at the table in X- [1/2] mm)* Y
und Y- [3/4] direction.
Total measuring length 300 mm
Test condition 11
Squareness of the milling spindle in horizontal

position respective to the table.
0.020 mm
(0.014
Measured with a stone angle at a radius at
mm)*
150mm in X- axis direction.
Total measuring length 300 mm
Test condition 12
palette1:
Axial run-out to the table against the C- axis.

0.015 mm
palette2:
(0.011
Measured with a stone ruler at radius 500 mm
mm)*
from the middle of the C- axis.
palette3:
Test condition 13
palette1:
0.010 mm
palette2:
Axial run-out of the center hole of the table. (0.007
mm)*
palette3:
6. Data table
Because of the values may vary depending of serial number and options, please refer to the
values in the operators manual, maintenance instructions, pneumatics plan and Step-Tec
manual, ODS.
7. Final comments
After the maintenance service, the usual service report must be filled out.

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ASS-0177 e

Mikron Agie Charmilles AG

Maintenance Checklist HPM1850U

Mikron Agie Charmilles AG, Ipsachstrasse 16, 2560 Nidau, Switzerland

GF AgieCharmilles – Achieve more…

2.1. Goal and purpose

2.2. Application / Area / Duration

2.3. Abbreviations / Concepts / Definitions

Mikron Agie Charmilles AG, Ipsachstrasse 16, 2560 Nidau, Switzerland

GF AgieCharmilles – Achieve more…

3.1. Special tools required

Step Tec spindles

Air through the spindle

Hydraulik (81.02, PW ab 81.03)

Mikron Agie Charmilles AG, Ipsachstrasse 16, 2560 Nidau, Switzerland

GF AgieCharmilles – Achieve more…

Regulated chiller RW12000-N15

Pneumatics with 15'000 1/min / 10'000 1/min Step-Tec Spindle

Pneumatics with 24'000 1/min Step-Tec Spindle

Production package Bürener with Paper Filter

3.3. Preparations by the customer

4. Amount of time required for servicing

GF AgieCharmilles – Achieve more…

Mikron Agie Charmilles AG, Ipsachstrasse 16, 2560 Nidau, Switzerland

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5.1. Basic machine

Checklist (extracted from operators manual)

2. Ball screw and axial bearing

5. Scraper chip conveyor

Mikron Agie Charmilles AG, Ipsachstrasse 16, 2560 Nidau, Switzerland

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6. Cooling lubricant system / band filter system

7. Spiral chip conveyor

9. Hydraulic power pack

10. Water cooler

Mikron Agie Charmilles AG, Ipsachstrasse 16, 2560 Nidau, Switzerland

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14. Tool changer / Tool magazine

Mikron Agie Charmilles AG, Ipsachstrasse 16, 2560 Nidau, Switzerland

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17. ATC handling

18. Swiveling axis

19. Anti-friction guide ways

20. Rotary table

Mikron Agie Charmilles AG, Ipsachstrasse 16, 2560 Nidau, Switzerland

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22. Oil mist - suction

23. Oil separator (skimmer)

24. Probing system

25. Laser Tool check

27. Linear measuring systems

Mikron Agie Charmilles AG, Ipsachstrasse 16, 2560 Nidau, Switzerland

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29. Machine leveling

Mikron Agie Charmilles AG, Ipsachstrasse 16, 2560 Nidau, Switzerland

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5.2. Geometric check

Parallelism of the table to the X- axis

Parallelism of the table to the Y- axis.

Squareness of the table respective to

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