Sales & Service Centers
Contents
1. LLC Vialidad El Pueblito 103 Detroit MI Apex Tool Group Sales amp Service Center 2630 Superior Court Auburn Hills MI 48326 Tel 248 391 3700 Fax 248 391 7824 Seattle WA Apex Tool Group Sales amp Service Center 2865 152nd Avenue N E Redmond WA 98052 Tel 425 497 0476 Fax 425 497 0496 England Cooper Power Tools a company of Apex Tool Group LLC Unit G Quinn Close Seven Stars Industrial Estate Whitlet Coventry CV3 4LH England Tel 44 2476 3089 60 Fax 44 2476 3089 69 Brazil Houston TX Apex Tool Group Sales amp Service Center 6550 West Sam Houston Parkway North Suite 200 Houston TX 77041 Tel 713 849 2364 Fax 713 849 2047 York PA Apex Tool Group Sales amp Service Center 3990 East Market Street York PA 17402 Tel 717 755 2933 Fax 717 757 5063 France Cooper Power Tools SAS a company of Apex Tool Group LLC Zone Industrielle BP 28 Avenue Maurice Chevalier 77831 Ozoir la Ferriere Cedex France Tel 011 33 1 64 43 22 00 Fax 011 33 1 64 40 17 17 Cooper Tools Industrial Ltda a company of Apex Tool Group LLC Av Liberdade 4055 Lexington SC Apex Tool Group 670 Industrial Drive Lexington SC 29072 Tel 800 845 5629 Tel 803 359 1200 Fax 803 358 7681 Canada Apex Tool Group Sales amp Service Center 5925 McLaughlin Road Mississauga Ont L5R 1B8 Canada Tel 905 501 4785 Fax 905 501 4786 China Cooper China Co Ltd a2. company of Apex Tool Group LLC 955 Sheng Li Road Heqing Pudong Shanghai China 201201 Tel 86 21 28994176 Fax 86 21 51118446 Zona Industrial Iporanga 18087 170 Sorocaba SP Brazil Tel 011 55 15 238 3929 Fax 011 55 15 228 3260 Parque Industrial Quer taro Quer taro QRO 76220 Tel 52 442 211 3800 Fax 52 442 103 0443 Apex Tool Group LLC 1000 Lufkin Road Apex NC 27539 Phone 919 387 0099 Fax 919 387 2614 www apextoolgroup com PLxx xxxx Printed in USA 00 2010 Copyright O Apex Tool Group LLC
3. IS for liquid tightness Check DGD IS for tight fit Check tool connector and fixing of the tool plate for tight fit Use grease dissolving agent to clean the gearing components and then regrease see Grease lubricants according to DIN51502 ISO3498 Seite 6 Amount of grease e Size 1 7 cm e Size 2 18 cm e Size 3 28cm e Size 4 35 cm gt Recommendation Recalibrate tool see 12 1 Recalibration Seite 76 At BUTSE gt Check tooth belt and ball bearing for wear and replace if necessary gt General overhaul Send it to Sales amp Service Center 1 For the number of fastening cycles refer to the counter display in 7 3 4 Administration submenu Seite 27 Lubrication In order to ensure faultless functioning and a long service life it is absolutely necessary to use the right type of oil according to the table Grease lubricants according to DIN51502 ISO3498 Lubrica tion gt W Lo KLGBEN ISO elf a SHELL Araib Ener a 0 Special 912554 G POH Fa Mobilplex 44 Se Ng FDOO 0 Microlube Initial lubrication Cooper Power Tools GmnH amp Co OHG P2079WA EN 2010 11 21b_Sicherheit_bedingt en fm 10 12 2010 DGD Removing the DGD IS 3 Removing the DGD IS gt Loosen and remove plug connectors gt Remove the complete DGD IS from the fastening station gt Secure the spanner contact surfaces on the nutsetter spindle or component in a vice Place in position do not tighten gt Turn the
4. LAXI Recalibrating the nutsetter data Tightening torques Gearing Motor Tightening torque Order no Nm 2 6 3 2 913947 3 2 I9 32 Recalibrating the nutsetter data The nutsetter data is stored in the service memory The service memory is located in the transducer com ponents M B offset attachment VM B and angle head attachment WM B in the DGD IS Only trained personnel are permitted to replace these components Otherwise there is a risk that data with out a system reference is stored in the service memory of a transducer e g incorrect nutsetter type and serial number incorrect fastening count incorrect repair data etc The service memory of new components M B VM B WM B does not contain nutsetter data installation possible in different types of DGD IS As a spare part the transducer is not configured for self identification via the nutsetter control unit PDB CPS In this case the nutsetter data must be entered in the service memory manually using the nutsetter control unit No limits are imposed on the torque measuring functions gt To recalibrate the type specific nutsetter data please send the DGD IS to Sales amp Service Center Only this will ensure that after the service work any required nutsetter data update is carried out properly Disposal Injuries and environmental damage from improper disposal Components of the DGD IS pose risks to the health and the en
5. Service Manual P2079WA EN G 2010 11 DGD Intelligente Spindel BTSE Series For additional product information visit our website at http www apextoolgroup com DGD About this service manual This service manual is the translation of the original service manual and provides important information on safe and correct installation Secondary information P2086MA P1919E P1908E P2078MA P2075EL P2074BA PL12EN 1004 P2076EL P1913E P1914E P2085EL P2080EL P2077SB PL12EN 1001 Symbols in text Abbreviations mPro400GC PDB CPS TSE TUSE CPS3 DGD IS Symbols in graphics lt r v Disclaimer Assembly Instruction DGD Intelligent Spindle Assembly instructions Supply module CPS3 Assembly instructions Tightening Torques Assembly of Components Built in Nutrunner Assembly instructions TSE TUSE tightening module Data sheet Transducer Instruction manual Telemetrie system Quick Start mPro400GC Spare parts sheet Attachment Spare parts sheet Gearing Spare parts sheet Motor Spare parts sheet Tightening module TSE TUSE Spare parts sheet Transducer System handbook Modular fastening system mPro400GC DGD Intelligente Spindel System manual nutsetter control unit mPro400GC Identifies instructions to be followed Identifies lists Nutsetter control Power distribution box Tightening module Supply module DGD intelligent spindles Identifies movement in a direction Identif
6. age current Fatal electric shock could occur IN gt Always disconnect the power supply before performing maintenance work on the DGD IS and thePDB CPS gt Always disconnect the system cable motor or motor cable from the PDB CPS or DGD IS before making throughput resistance and short circuit measurements gt Do not attempt to repair possible faults on the fastening system by yourself if you do not have the requi red knowledge Inform the local repair center or your Sales amp Service Center WARNING High temperature IN the motor on the DGD IS may heat up and cause burns during removal max engine temperature 90 C Wear gloves 21b_Sicherheit_bedingt en fm 10 12 2010 P2079WA EN 2010 11 5 Service schedule DGD 2 2 1 Service schedule Only trained personnel are permitted to perform maintenance Regular maintenance reduces operating faults repair costs and downtime In addition to the following service plan implement a safety related main tenance program that takes the local regulations for repair and maintenance for all operating phases of the tool into account After A eyes S 500 000 Only for 4B U TSE 4B A 4M B 4WM B gt Send DGD IS for examination and recalibration to Sales amp Service Center 700 000 Only for 3B U TSE 3B300A 3M2B 3WM2B and 2B U TSE 2B200A 2WM3B gt Send DGD IS for examination and recalibration to Sales amp Service Center 1 million Optical control Check DGD
7. cap nut counterclockwise Hook wrench see table Seite 8 gt Loosen the components 3 1 Dismantling the DGD IS into components 3 2 21b_Sicherheit_bedingt en fm 10 12 2010 P2079WA EN 2010 11 7 Installing the DGD IS DGD 4 Installing the DGD IS NOTE Before replacing a component Q gt always carry out a machine capability study MFU After assembly gt check the calibration of the torque transducer gt Check the function of the angle encoder We recommend servicing by Sales amp Service Center If space is confined by positioning multiple DGD IS you can e Turn size 1 in 15 increments e Turn sizes 4 to 2 in 10 increments gt Position the DGD IS components together via flat toothed interfaces Place in position do not tighten siehe 4 2 Tightening torques Gearing Motor page 9 4 1 Tightening torques lock nut Assemble the components in reverse order to the removal sequence CAUTION Risk of flying parts Components of the DGD IS may rotate come loose and cause injury Observe the tightening torque of the cap nuts The tightening torque is the same for all sizes Tightening torque Tightening torque Hookwrench Torque tightening torque adjustment SEERE wrench Order no 933336 933337 933340 933338 933339 1 Different setting due to leverage effect of the hook wrench 8 P2079WA EN 2010 11 21b Anzugsmomente bedingt en fm 10 12 2010 DGD 4 2 6 CAUTION A
8. ies function and force DGD reserves the right to modify supplement or improve this document or the product without prior notice This document may not be reproduced in whole or in part in any way shape or form or copied to another natural or machine readable language or to a data carrier whether electronic mechanical optical or other wise without the express permission of DGD DGD and Cooper Power Tools GmnH amp Co OHG are trademarks and plant names of the Apex Tool Group Division P2079WA EN 2010 11 79a_Deckbl_bedingt en fm 10 12 2010 DGD Inhalt 1 Safety Service schedule 2 1 Lubrication c ccccccecccceccceccccccacecececeaeccececeueaecesueceneacaceteceatavstereeaeansnens 3 Removing the DGD IS 3 1 Dismantling the DGD IS into COMPONENTS uu2244uusnennnennennn nennen 3 2 Removing the gearing from the DGD IS 4u00424400Bnennn nennen 4 Installing the DGD IS 4 1 TIGHTENING torgues lock ANE uses ine 4 2 Tightening torques Gearing Motor u002222000220nne nennen nennen 5 Recalibrating the nutsetter data 6 Disposal P2079WA EN_2010 11_Wartung_DGD IS_BTSEIVZ fm 10 12 2010 P2079WA EN 2010 11 DGD P2079WA EN 2010 11 P2079WA EN 2010 11 Wartung DGD IS BTSEIVZ fm 10 12 2010 DGD Safety 1 Safety CAUTION AN This document is only valid in conjunction with the assembly instructions for the DGD intelligent spindle gt Read the chapter on safety DANGER High leak
9. vironment gt The DGD IS contains components that can be reused as well as components that require special disposal Separate the components and dispose of them by segregating them clearly gt Catch auxiliary materials oils greases when drained and dispose of them properly gt Separate the components of the packing and dispose of them by segregating them clearly gt Follow the locally applicable regulations Observe generally valid disposal guidelines such as in Germany the Electrical and Electronic Equipment Act ElektroG gt Hand in the DGD IS at your company collection point or return to Sales amp Service Center 21b_Anzugsmomente_bedingt en fm 10 12 2010 P2079WA EN 2010 11 9 Sales amp Service Centers Note All locations may not service all products Please contact the nearest Sales amp Service Center for the appropriate facility to handle your service requirements Dallas TX Apex Tool Group Sales amp Service Center 1470 Post amp Paddock Grand Prairie TX 75050 Tel 972 641 9563 Fax 972 641 9674 Los Angeles CA Apex Tool Group Sales amp Service Center 15503 Blackburn Avenue Norwalk CA 90650 Tel 562 926 0810 Fax 562 802 1718 Germany Cooper Power Tools GmbH amp Co OHG a company of Apex Tool Group LLC Postfach 30 D 73461 Westhausen Germany Tel 49 0 73 63 81 0 Fax 49 0 73 63 81 222 Mexico Cooper Tools de Mexico S A de C V a company of Apex Tool Group
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