XYZ Machine Tools SMX 2500, SMX 3500, SMX 5000, SMX 4000 Safety, Installation, Maintenance, Service & Parts List Manual

XYZ

ProtoTRAK BED MILLS

SMX 2500, 3500, 4000 & 5000

Safety, Installation, Maintenance, Service

& Parts List Manual

Document: 25093 Version: 042016

Covers Models:

 SMX 2500  SMX 3500

 SMX 4000  SMX 5000

XYZ M a chi n e T ool s Ltd. Wood l a n ds B u s ine s s Pa r k Burl e s comb e , Tive r t on, D e vo n E X1 6 7 LL T: 0 1 8 2 3 6 7 4 200 F : 01 8 2 3 67 4 2 0 1 e-ma i l : sa l e s @xy z m a chi n e t ools . c o m

www. x y z ma c h i n eto o l s.co m

Copyright © 2016 XYZ Machine Tools, Ltd. All rights are reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, mechanical, photocopying, recording or otherwise, without the prior written permission of XYZ Machine Tools, Ltd.

While every effort has been made to include all the information required for the purposes of this guide, XYZ Machine Tools assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from the use of the information contained in this guide.

All brand names and products are trademarks or registered trademarks of their respective holders.

XYZ Machine Tools Woodlands Business Park Burlescombe, Nr Tiverton Devon, EX16 7LL

Service Department Tel: 01823 674214 Fax: 01823 674201

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Table of Contents

1.0 Safety 1

1.1 Introduction 1

1.2 Safe Operating Information 1

1.3 Release of Trapped Persons 2

1.4 Labels and Notices 3

1.5 EC Declaration of Conformity 8

1.6 Airborne Noise emissions 8

2.0 Installation 9

2.1 Floor Plan, space requirements 9

2.2 Uncrating 14

2.3 Installation Checklist 14

2.4 Lifting and Moving the Machine 16

2.5 Releasing the Head Counterweight 17

2.6 Cleaning 18

2.7 Levelling 18

2.8 Electrical Connection 19

2.9 Air Connection 19

2.10 Mounting the Pendant 19

2.11 Cable Interconnections 19

2.12 Lubrication 23

2.13 Machine Specifications 24

2.14 ProtoTrak Control Hardware 24

3.0 Troubleshooting by Symptom 26

3.1 Problems Relating to Machining Results 26

3.2 Problems Regarding Motion 29

3.3 Problems Relating to the Control 32

3.4 Problems with the Measurements 36

3.5 Problems with the Machine 38

4.0 Diagnostics 41

4.1 The Machine Tool and Setup 41

4.2 The Mechanical Drive Train (X, Y) 43

4.3 Computer/Pendant Diagnostics 45

4.4 Motor Diagnostics 46

4.5 Servo Driver 47

4.6 Scales 48

4.7 Electrical 48

4.8 Service Codes 57

5.0 Servicing Procedures 64

5.1 Replacements 64

5.1.1 Servo Motor 64

5.1.2 Servo Driver 64

5.1.3 Pendant 65

5.1.4 Cable Routing 65

5.1.5 Power Drawbar 65

5.1.6 SMX 2500, 3500 Ball Screw (X axis) 65

5.1.7 SMX 2500, 3500 Ball Screw (Y axis) 71

5.1.8 SMX 4000, 5000 Ball Screw (X axis) 78

5.1.9 SMX 4000, 5000 Ball Screw (Y axis) 86

5.1.10 Feed Trip 107

5.1.11 Quill Clock Spring 107

5.1.12 SMX2500 Spindle Motor 108

5.1.13 SMX3500, 4000, 5000 Spindle Motor 108

5.1.14 SMX2500 Drive Belt 109

5.1.15 SMX3500, 4000, 5000 Drive Belt 109

5.1.16 SMX2500 Timing Belt 110

5.1.17 SMX2500 Brake Shoe 110

5.1.18 SMX2500 Spindle 110

5.2 Maintenance 111

5.2.1 Gib Adjustments 111

5.2.2 Calibration & Backlash 117

5.2.3 Head Rotation & Tramming 119

5.2.4 Limit Switches 120

6.0 Figures and Parts Lists 122

1a SMX2500 – Footprint 9 1b SMX2500 – Footprint 10 2a SMX3500 – Footprint 11 2b SMX3500 – Footprint 12 3a SMX4000 – Footprint 12 3b SMX4000 – Footprint 13 4a SMX5000 – Footprint 13 4b SMX5000 – Footprint 14 5 Lifting the Machine – Method 1 16 6 Lifting the Machine – Method 2 17 7 Placement of Levels 18 8 Levelling Screws 19 9 Pendant Cable Connections 20 10 Pendant Right Side (early models) 21 11 Cable Connection Diagram 22 12 Machine Overview 25 13 SMX3500, 4000, 5000 Power Module 51 14 SMX3500, 4000, 5000 Power Module Wiring 53 15a SMX3500, 4000, 5000 Electrical Schematic 55 15b SMX2500 Electrical Schematic 57 16 Servo Driver Replacement 64 17 SMX2500 – X Axis Drive Assembly 67 18 SMX3500 – X Axis Drive Assembly 69 19 SMX2500 – Y Axis Drive Assembly 72 20a SMX3500 – Y Axis Drive Assembly 74 20b SMX3500 – Y Axis Drive Assembly 75 21 SMX4000 – X Axis Drive Assembly 79 22 SMX5000 – X Axis Drive Assembly 82 23 SMX5000 – X Axis Drive Assembly 83 24 SMX4000/5000 – Y Axis Drive Assembly 87 25 SMX4000/5000 – Y Axis Drive Assembly 88 26 SMX4000/5000 – Y Axis Handwheel Assy 89 27 SMX2500 – Z Axis Drive Assembly 92 28a SMX3500 – Z Axis Drive Assembly 94 28b SMX3500 – Z Axis Drive Assembly 95 28c SMX3500 – Z Axis Drive Assembly 95 29a SMX4000 – Z Axis Drive Assembly 98 29b SMX4000 – Z Axis Drive Assembly 99 30a SMX5000 – Z Axis Drive Assembly 104 30b SMX5000 – Z Axis Drive Assembly 105 31 Feed Trip Adjustment 107 32 Quill Clock Spring Replacement 108 33 SMX2500 - Spindle Motor Replacement 109 34 SMX2500 - Drive Belt Replacement 109 35 SMX2500 - Spindle Replacement 110 36 SMX2500 - 3500 Table Gib Adjustment 111 37 SMX3500 - Table Gib Screw 112 38 Table Gib & Saddle Gib Adjustment 113 39 Saddle Side Gib Adjustment 114 40 Saddle Bottom Gib Adjustment 115 41 Head Back Gib 116 42 Head Side Gib Adjustment 117 43 Calibration Set-Up 118 44 Tramming the Head 120 45 SMX2500 - Top Housing Assembly 122

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

46 SMX2500 - Gear Housing 124 47 SMX2500 - Hi-Low Shift Clutch 125 48 SMX2500 - Hi-Low Shift Lever 127 49 SMX2500 - Pulley Pinion 128 50 SMX2500 - Lower Vari-Disc Drive 129 51 SMX2500 - Upper Vari-Disc Drive 131 52 SMX2500 - Speed Change Handwheel 133 53 SMX2500 - Spindle motor 134 54 SMX2500 – Lower Head Assembly 135 55 SMX2500 – Worm Gear Cradle 138 56 SMX2500 – Quill Feed Selector 139 57 SMX2500 – Quill Pinion Shaft 140 58 SMX2500 – Overload Clutch Trip 141 59 SMX2500 – Feed Reverse Clutch 142 60 SMX2500 – Spindle Assembly 143 61a SMX3500 – Upper Head 144 61b SMX3500 – Upper Head 145 62 SMX3500 – Lower Head 148 63a SMX4000, 5000 – Upper Head 151 63b SMX4000, 5000 – Upper Head 152 64a SMX4000, 5000 – Lower Head 155 64b SMX4000, 5000 – Lower Head 156 65 SMX4000, 5000 – Quill Assembly 159 66 Oil System 162 67 SMX3500 - Oil System 162 68 SMX4000 - Oil System 163 69 SMX5000 - Oil System 164 70 SMX2500 – Lube Pump 165 71 SMX2500 – Lubrication System 166

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

1.0 Safety

1.1 Introduction

Manual mills were traditionally used by skilled machinists. Prototrak was designed to replace these manual machines and at the same time enhance productivity by adding CNC control.

But, unlike Machining and Turning Centres that can be operated even with unskilled staff (in some modes), Prototrak is designed to be used exclusively by skilled or experienced machinists.

The safe operation of the SMX Mill and ProtoTRAK SMX CNC depends on its proper use and the precautions taken by the operators.

1.2 Safe Operating Information

This machine must only be operated by trained and experienced operators. Any other users should first be subjected to a risk assessment by a responsible, trained person.

This machine is designed for the milling of cold metal within the stated capacity of the machine with axes movement occurring by manual use of handwheels, electronic handwheels or CNC control.

This machine must not be used for machining flammable materials (e.g. magnesium, titanium) without undertaking a risk assessment and incorporating any additional safety measures identified.

It is designed to be used in a standard workshop environment only.

It is the responsibility of the employer, machine owner or machine controller to ensure that this machine is installed, operated and maintained in accordance with the Provision and Use of Work Equipment Regulations (1998) or equivalent local regulations.

In particular, the responsible person must:

 Undertake a Risk Assessment on the use of this machine, paying particular attention to the

specific characteristics of the Prototrak system, especially:

o Unrestricted operating mode selection o Guarding height and access to the work zone

 Generate and apply Safe Operating Procedures for the use of the Prototrak machine  Provide any additional training or safeguarding identified by the risk assessment.

All operators and maintenance staff must read and study this Safety, Installation, Maintenance Service and Parts list manual before operating or undertaking any maintenance or repair work on the machine.

Electrical and Mechanical maintenance must only be conducted by trained and experienced machine tool engineers who fully understand the hazards of working with machine tools.

The electrical supply to the machine must be isolated and locked out before undertaking any maintenance or repair work on the machine. Ideally, power should be isolated and locked out at the distribution board supplying the machine. If not possible, isolate and lock out using the machine isolator on the electrical cabinet at the back of the machine.

All operators must read and study the ProtoTRAK SMX CNC Safety, Programming, Operating, and Care Manual (document 25040). The machine must not be operated until operators understand the operation and safety requirements of this machine.

The cutting tool must not be raised above the table guards without additional guarding measures such as a cutter guard.

The guard vision panels must be replaced in accordance with the stated schedule.

When operating this machine, always observe the following safety precautions

 Do not operate this machine without knowing the function of every control key, button, knob, or

handle.

 Always wear the appropriate personal protective equipment, including safety glasses and safety

shoes.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

 Do not wear loose fitting gloves whilst operating this machine as they could easily get caught in

moving parts.

 Never wear rings, watches, long sleeves, neckties, jewelry, or other loose items when operating

the machine.

 Keep your hair away from moving parts. Wear adequate safety head gear.  Never operate any machine tool after consuming alcoholic beverages, or taking strong

medications, or while using non-prescription drugs.

 Carry out a COSHH risk assessment and use the correct protection equipment, e.g. barrier

cream/latex gloves, to prevent harm from items such as cutting fluid, lubrication oil and other substances used on the machine.

 Always ensure the appropriate guarding is in place for the machinery operation being undertaken.  Observe and understand the warning and safety information labels affixed to this machine.  Do not attempt to tamper with or override any guarding/safety device fitted to the machine.  Keep the working area clear and remove all tools (spanners, etc.) from the machine before you

start the machine running. Loose items can become dangerous flying projectiles.

 Stop the machine spindle and ensure that the CNC control is in the STOP mode:

o Before changing tools. o Before changing parts. o Before you clear away the Swarf, oil or coolant. Always use a chip scraper or brush. o Before you make an adjustment to the part, vice, coolant nozzle or take measurements. o Before you open guards. Never reach around a guard to gain access to the part, tool, or

fixture.

 Do not use compressed air to remove swarf or clean the machine.  Keep work area well lit. Ask for additional light if needed.  Be aware that the machine can move unexpectedly so do not lean on the machine while it is

running.

 To prevent slippage and personal injury, keep the working area around the machine dry and

clean. Ensure there is no swarf, oil, coolant and obstacles of any kind around the machine.

 Avoid getting pinched in places where the spindle, table or guard doors create "pinch points"

whilst the machine is in motion.

 For machines fitted with manual handwheels: to prevent injury during powered axes movement,

keep the handle folded inside the hand wheel at all times except when required to hand crank the table.

 Securely clamp and properly locate the workpiece in the vice or in a fixture. Use proper tool

holding equipment.

 Use the correct tooling for the process being undertaken. Never use damaged or worn tools and

ensure the correct cutting parameters (speed, feed, and depth of cut) are used in order to prevent tool breakage.

 Prevent damage to the workpiece or the cutting tool. Never start the machine (including the

rotation of the spindle) if the tool is in contact with the part.

 Avoid large overhangs on cutting tools when not necessary.  To prevent fires keep flammable materials and fluids away from the machine, hot swarf and

workpieces.

 Never change gears when the spindle is rotating  Do not rotate the spindle by hand unless the table guard is open.  Stop and disconnect the power to the machine before undertaking any machine cleaning or

maintenance

1.3 Release of Trapped Persons.

In the event of persons being trapped in the machine:

1. Hit the E-button to kill all power to the spindle and axes.

2. Open the table guards.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

3. If trapped by spindle or tool, remove the compressed air supply to the machine and rotate the

spindle by hand to free the trapped person.

4. If trapped by the axes, use the manual handwheels to move the axes slowly clear of the trapped

person.

5. If no manual handwheels are fitted, reset the E-stop and put the control into DRO mode. Use the

Electronic Handwheels to move the axes slowly clear of the trapped person.

1.4 Danger, Warning, Caution, and Note Labels and Notices Used in this

Manual

DANGER - Immediate hazards that

will

result in severe personal injury or death. Danger labels on the

machine are red in colour.

WARNING - Hazards or unsafe practices that

could

result in severe personal injury and/or damage to

the equipment. Warning labels on the machine are amber in colour.

CAUTION - Hazards or unsafe practices that

could

result in minor personal injury or equipment/product

damage. Caution labels on the machine are Yellow in colour.

NOTE - Call attention to specific issues requiring special attention or understanding.

Safety & Information Labels Used on SMX Bed Mills

It is forbidden by law to deface, destroy or remove any of these labels

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Safety & Information Labels Used on SMX Bed Mills

It is forbidden by law to deface, destroy or remove any of these labels

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Safety & Information Labels Used on SMX Bed Mills

It is forbidden by law to deface, destroy or remove any of these labels

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Safety & Information Labels Used on SMX Bed Mills

It is forbidden by law to deface, destroy or remove any of these labels

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Safety & Information Labels Used on SMX Bed Mills

It is forbidden by law to deface, destroy or remove any of these labels

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

1.5 EC Declaration of Conformity

The manufacturer, Southwestern Industries, declares that the ProtoTrak SMX mills conform to all the relevant provisions of the:

 •Machinery Directive 2006/42/EC  •Low Voltage Directive 2014/35/EU, and  •EMC Directive 2014/30/EU

The Technical file is available from XYZ Machine Tools, Woodlands Business Park, Burlescombe, Nr Tiverton, EX16 7LL, United Kingdom.

1.6 Airborne Noise Emissions

The A-weighted emission sound pressure level at the operator’s workstation is 74dB(A).

(Measured in accordance with ISO 3744 with an uncertainty of 2.5dB.)

The figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of the workforce include characteristics of the work room and other sources of noise,. i.e. the number of machines and other adjacent processes. Also the permissible exposure level can vary from country to country. This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

2.0 Installation

Read and understand this entire installation section before beginning the installation procedure.

2.1 Floor Plan, Layout & Space Requirements

2.1.1 SMX2500

Figure 1a - SMX 2500 - Machine Footprint

SMX2500

Footprint of Machine

587 x 1029 mm

Weight (approximate) net

1452 kg

Weight (approximate) shipping

1588 kg

Pallet Size

1778 x 1778 mm

A

Overall width

2565 mm

B

Overall length w/ electric box door open

1926 mm

C

Bed width

587 mm

D

Bed width between levelling screws

520.7 mm

E

Distance between levelling screws

825.5 mm

F

Bed length

1029 mm

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 1b - SMX 2500 - Machine Footprint

SMX2500

G

Height of table from bottom of bed

864 mm

H

Maximum distance from spindle nose to table

597 mm

I

Maximum height of machine from bottom of bed to top of column cover.

1981 mm

J

Height of machine from bottom of bed to top of spindle motor

2261 mm

K

Width of machine including table

1778 mm

L

Length of machine with electric box door closed

1776 mm

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

2.1.2 SMX3500

Figure 2a - SMX 3500 - Machine Footprint

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 2b - SMX 3500 - Machine Footprint

2.1.3 SMX4000

Figure 3a - SMX 4000 - Machine Footprint

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 3b - SMX 4000 - Machine Footprint

2.1.4 SMX 5000

Figure 4a - SMX 5000 - Machine Footprint

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 4b - SMX 5000 - Machine Footprint

2.2 Uncrating

Carefully remove the wood crate and protective packaging, paying attention not to scratch, damage, or mar any parts of the machine.

ATTENTION!

Immediately report, in writing, any damages observed at this time that can be attributed to

the transportation or improper handling/moving of the machine.

2.3 Installation Instructions & Checklist

Installer: Use this checklist to assure a complete set-up of the SMX bed mill.

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□

1.

Shut off power to the machine.

□

2.

Visually inspect the 415V -wiring going into the electrical panel. Visually verify the wiring is correct per our wiring diagram. Make sure a strain relief is being used where the wiring enters the cabinet. Have the customer repair any wiring discrepancies.

□

3.

Clean the machine if needed and remove any remaining grease.

□

4.

Unlock the table, saddle, and ram gib locks.

□

5.

Use an Allen wrench on the Z-axis ball screw end at the top of the column to manually lower or raise the spindle head/ram.

□

6.

Make and check all the proper electrical connections from the pendant to the electric box. See the pendant and electric box wiring diagrams.

□

7.

Turn on the power to the machine and to the pendant.

□

8.

Lubricate all the way surfaces and the ball screws.

□

9.

Jog the table, saddle, and ram back and forth until the way surfaces are well lubricated. Oil should be visible on all the way surfaces.

□

10.

Check the level of the machine. The machine should be level to within 0.01 mm front to back and 0.01 mm side to side. Even though it is the responsibility of the customer, make any adjustments if necessary.

□

11.

Check to make sure that the E-Stop button is functioning correctly.

□

12.

Perform Service Code 12, Feed Forward Constant.

□

13.

As necessary, perform Service Code 123 to calibrate the X and Y-axis using a 150mm standard.

□

14.

Perform Service Code 11 to automatically calculate the backlash for the X and Y-axis of dual feedback machines (i.e. Newall scales with a motor encoder).

□

15.

As necessary, perform Service Code 127 and 128 to manually calculate the backlash for the X and Y-axis of single feedback machines (i.e. motor encoder only).

□

16.

Check for positional accuracy and repeatability on the X and Y-axis using programs XREPEAT.PT4 and YREPEAT.PT4 respectively. Positioning and repeatability values should be less than or = to 0.01 mm. Programs can be found on flash drive under the PT4 folder followed by the SWI TEST PROGRAMS folder.

□

17.

As necessary, perform Service Code 123 and press Z to calibrate the Z-axis ram using a 75mm standard.

□

18.

As necessary, perform Service Code 127 and 128 to manually calculate the backlash for the Z-axis ram.

□

19.

Check for positional accuracy and repeatability on the Z-axis using program ZREPEAT.PT4 Positioning and repeatability values should be less than or = to 0.01 mm.

□

20.

As necessary, perform Service Code 123 and press QUILL softkey to calibrate the Z-axis quill using a 75mm standard.

□

21.

Perform Service Code 100 in both directions for the X, Y, and Z-axis to verify that the feed rate shown on the display is at least 4560 mmpm if you have mechanical hand wheels or 7620 mmpm if you have electronic hand wheels.

□

22.

Run the spindle at various speeds in both high and low gear for 15 minutes. Verify head shifts from high to low gear smoothly. Test quill feed and spindle brake.

□

23.

As necessary, install the way covers.

□

24.

Use accessory key on pendant and make sure the coolant pump fires. The accessory key should be in the ON position to test coolant pump. The control should be in DRO mode.

□

25.

Check to ensure that the power drawbar tools load and unloads tools properly.

□

26.

Wipe down the machine prior to leaving.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

2.4 Lifting and/or Moving the Machine

CAUTION!

Depending on model, the SMX bed mill can weigh up to 3100 kg. Proper equipment of

sufficient capacity must be used when lifting or moving the machine. Only qualified

personnel should operate lifting equipment

Method 1 (see Figure 5):

1. Move the table as far forward as possible.

2. Insert 2 steel bars 50 mm dia. x 1300 mm long through both sides in the existing holes in the

machine base (front and back).

3. Use 4 off, steel cables (with protective sleeving) min. 19 mm dia. or 4 off, 4-ton slings.

4. Use cardboard pieces or other suitable protective sheets on both sides of the machine to prevent

scratching.

5. Remove any fasteners holding the machine to a pallet.

6. Lift the machine (the front of the machine should be lower than the back).

7. Insert the screws for levelling pads in their place in the bed.

8. Place the machine in its location (see floor plan and bed footprint drawing) carefully positioning

each levelling pad under each levelling screw.

9. Remove the lifting cable or sling, the steel bar and all protective cardboard.

Figure 5 - Lifting the Machine* - Method 1

*Machine image for indication only

Method 2 (see Figure 6):

1. Insert 2 steel bars 50 mm dia. x 1300 mm long through both sides in the existing holes in the

machine base (front and back).

2. Position 4 (two each side) wood vee blocks under the steel bars and over a suitable lift truck.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

3. Lift the machine up (somewhat tilted towards the front) 100-150 mm from the ground and move

it to its floor plan position.

WARNING!

The lift truck must have sufficient lifting capacity (4 tons) and be equipped with suitably long

forks.

4. Insert the 6 screws for the levelling pads in their place in the bed.

5. Place the machine in its location (see floor plan bed/footprint) carefully positioning each levelling

pad under each levelling screw.

Figure 6 - Lifting the Machine* - Method 2

*Machine image for indication only

2.5 Releasing the Head Counterweight Supports

In order to move (raise or lower) the spindle head, it is first necessary to remove the retaining rod that supports the counterweight located on the right side of the machine. The retaining rod supports the counterweight during shipping to prevent damage to the counterweights chains and sprocket.

1. Using an M8 Allen key, turn the Z-axis ball screw at the top of the column to slowly raise the

spindle head/ram. Remove the wood block that supports the spindle head/ram during shipment.

2. Remove the (3) socket head cap screws that secure the counterweight retaining rod to the

column.

3. Using an M14 Allen key, remove the bolt that secures the retaining rod to the counterweight.

4. Lower the spindle head slowly until the chain between the head and the counterweight is tight.

5. Lower the spindle head a little further until the retaining plug is loose. Remove retaining rod and

store for future use.

6. Do not continue to move the spindle head until all ways have been cleaned.

CAUTION!

Do not remove the steel rods unless they are loose.

2.6 Cleaning

1. Remove rust protective coating from the machine before moving any slideways (table, saddle,

ram, etc.).

2. The coating is best removed with clean, dry rags. Do not use a cleaning solution that may

damage the rubber way scrapers, plastic parts, or paint.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

WARNING!

Do not use petrol or other flammable cleaning agents for cleaning the machine.

3. It may be necessary to move back and forward, left and right, and up and down the table, saddle,

and the ram.

CAUTION!

Never move any of the above parts over ways that were not previously cleaned. Serious

damage to the TURCITE surface of slideways can occur.

4. Be certain the table, saddle, ram, and spindle move freely and smoothly over their entire length.

2.7 Levelling:

Levelling Tolerance for SMX 2500, 3500, 4000 & 5000 is 0.01 mm/2500 mm

1. Set the machine on its levelling pads on a solid, level floor prepared in accordance with the state

and local rules for machine tool installation.

2. Put one or two precision Spirit Levels or Electronic Levels in the centre of the table in the

positions illustrated in Figure 7.

3. Adjust the 4 corner levelling screws on their pads until the machine is level to 0.01 mm/2500 mm.

Snug the 2 middle levelling screws being careful to not affect the level of the machine.

4. If the machine must be anchored to the floor, follow the general instruction for installing machine

tools and use for levelling any well-known methods: shims, etc.).

5. If the machine must be installed on vibration mounts/pads (rubber, commercially available

levelling and vibration mounts, etc.) follow the instructions delivered with the mounts/pads, ordering them to satisfy the load of the machine and the maximum weight of the workpiece.

6. When machine is correctly level, lock the adjusting screws in place with their hex nuts.

Figure 7 - Placement of Levels

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 8 - Levelling Screws

2.8 Electrical Connection

The SMX 2500, 3500, 4000 & 5000 require a 400 volts, 3-phase, 50/60Hz supply plus an Earth connection. No Neutral connection is required.

The incoming supply is wired to the machine through the electric cabinet located on the back of the machine. The cable enters the cabinet through a compression gland fitted into the hole in the top of the cabinet. The wires are connected to the incoming isolator. The main ground wire should be fastened to the isolator mounting bracket with the screw provided.

The earth connection to the machine must be a minimum of 10mm2 (copper) due to high earth leakage current (≤200mA).

DANGER!

The 400 VAC supply should only be wired by a qualified electrician.

2.9 Air Connection

The machines have a PCL/series 19, quick release air connection on the side of the electrical cabinet for the power drawbar (see section 5).

The air preparation unit is fitted with a pressure regulator, factory set to 70 psi, water trap and lubricator.

2.10 Mounting the Display Pendant

The ProtoTRAK SMX display pendant mounts to the pendant arm with four 1/4-20 x ¾ SHCS. There is a locating screw on the pendant arm to help align the pendant with the mounting holes.

CAUTION!

The locating screw in the arm is used for positioning. Keep a hold of the pendant until the

screws are fastened.

If the pendant arm rotates too freely, remove the painted cap on the bracket attached to the column and tighten the hex nut to tension the hinge. Replace the cap.

2.11 Cable Interconnections

All cable interconnections are made at the factory. See Figure 11 for a complete illustration of cable interconnections for all components. If electronic handwheels are fitted, these plug into the two, 15 pin connectors near the top.

Make sure there is sufficient slack in the cables for when the pendant is rotated about the pendant arm. The worst case is when the pendant is all the way forward toward the operator. The following drawing illustrates pendant connectors.

Make sure there is a hardware (option) key plugged into the parallel port of the pendant. This key activates any converters or options ordered. The part # for this key is 22648. The key must be programmed according to the type of machine it is on and the options ordered.

The Machine ID port must have this key or the machine will not run.

CAUTION!

Make sure the main power is turned off on the back of the electrical cabinet before plugging

in the cables.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Left Side

Right Side

Figure 9 - Pendant Cable Connections

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Figure 10 - Pendant - Right Side (Earlier Models with Floppy Drive)

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Figure 11 – SMX 3500, 4000, 5000 Cable Connection Diagram

SMX2500 similar (less spindle control module and AC drive)

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2.12 Lubrication

2.12.1 Way Lubrication

The auto lube system provides centralised, automatic lubrication for the ways and ballscrews. The lube pump has a 2-litre reservoir and should be kept filled with ISO 32 slideway oil or equivalent.

The pump has an audible alarm for low oil pressure or low oil level.

The pump is factory set to:

 Interval Time: 20 min.  Discharge Time: 5 sec  Discharge Pressure: Approximately 690-1030 kPa (100 – 150 psi)

The interval time and discharge time can be set electronically:

 SMX2500:

o Use the buttons on the side of the lube pump:

INT (Interval): this button programs the interval between pumping cycles. Each press of

the button increases the interval by one minute.

DIS (Discharge): this button programs the amount of time the pump will discharge

each pumping cycle. Each press of the button increases the discharge time by one minute.

FEED: this button is used to manually operate the pump. RST: this button tells the pump to discharge for the time programmed.

 SMX3500, 4000, 5000:

o Interval time: Use service code 301. o Discharge time: Use service code 302. o Manually cycle pump: Use service code 300. o See section 4.8 for details of accessing Service Codes within the ProtoTrak control.

The lube pump should be operated manually at the beginning of each shift (using the FEED button or code 300).

CAUTION!

Failure to manually activate the pump at the beginning of each day, or allowing the Auto

Lube to run dry may cause severe damage to the way surfaces and ballscrews.

To adjust the amount of Discharge Pressure displayed on the lube pump gauge, loosen the jam nut and turn the adjustment screw located on the top right side of the lube pump while the lube pump is activated.

See Figures 66 to 71 for machine lubrication drawings.

2.12.2 Head Lubrication

Once Each Week:

1. Fill the oil cup on the front of the head with ISO 32. This oil lubricates the quill feed assembly.

2. Fill the oil cup on the right hand side of the head with ISO 32 oil. This oil lubricates the quill

assembly.

3. Extend the quill fully and apply a coating of ISO 32 oil to the outside diameter of the quill.

Every Four Months:

1. Apply a good grade of general-purpose grease through the grease fittings on the back of the head

and on the left side of the head. This grease lubricates the Low range gear set and the feed change gears respectively.

2. Remove X handwheel drive cover and apply general-purpose grease to the drive gears.

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2.13 Machine Specifications

Model Name

2500

3500

4000

5000

Table Size

1245 x 229

1372 x 356

1474 x 356

1930 x 355

T-Slots (number x width)

3 x 15.9

4 x 15.9

Travel (X, Y, Z axis)

762 x 381 x

560

787 x 508 x

450

1016 x 596 x

520

1524 x 596 x

520

Quill Diameter

86

105

116

Maximum Quill Travel

127

Spindle Taper

R8

40 ISO

Spindle Speed Range

60 - 3500

40 - 5000

Spindle Centre to Column Face

457

520

610

Spindle Motor Power (HP)

3 5 7.5

7.5

Maximum Weight of Workpiece

600 Kg

850 Kg

Height of table from bottom of bed

864

835

956

Max spindle nose to table

597

620

rapid traverse X, Y, Z – standard handwheels

3800

Rapid traverse, X, Y, Z – electronic handwheels

3800

6350

Overall Dimensions of Machine

(height includes 30mm levelling allowance)

587 x 1029 x

2480

3600 x 3143

x 2470

4405 x 3143

x 2690

5805 x 3143

x 2690

Shipping Weight

1900 Kg

2300 Kg

2750 Kg

3100 Kg

Electrical Power Requirements

20 Amp

25 Amp

2.14 ProtoTRAK SMX Control Hardware

 3-axis CNC, 3-axis DRO  Precision ground ballscrews in the table, saddle and ram to ensure smooth accurate contours

without backlash

 Feedrate override of programmed feedrate and rapid  Modular design simplifies service and maximizes uptime  Control Pendant (part number 24000-8):

o 1.66 GHz PC-based processor o 1 Gb of RAM o 1 Gb flash drive o 4 USB connectors o 267 mm colour LCD for clear presentation of prompts, status information and part

graphics

 X, Y and Z Axes Motors (part number 24428-1):

o D.C. Servo Motors o 560 in-oz. continuous torque

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Figure 12 - The XYZ SMX Bed mill machine overview

Guards not shown for clarity

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3.0 Troubleshooting by Symptom

Use this section to begin the process of resolving a problem. Each symptom type is described in a few words and then more fully described in an explanatory paragraph. Following this, is a chart that directs in the most logical steps.

DANGER!

Some of these checks involve accessing potentially hazardous mechanical or electrical

systems. These checks must only be carried out by competent personnel.

3.1 Problems Relating To Machining Results

3.1.1 Poor Finish

The part finish is marred with scallops or is very rough.

Do the following Service Codes and document values:

 Code 33 Software Identification. This is needed if you call Customer Service  Code 11 Measures backlash in the system (Only used on Dual Feedback systems)  Code 12 Feed Forward Constant  Code 127 Measures backlash in the system (not used on Dual Feedback systems)  Code 128 Enter backlash compensation

Possible Cause

Check This

Too much backlash entered for code 128 or calculated with code 11.

Verify nothing is mechanically loose and the backlash values are not higher than what physically is in the system.

Machine Tool & Setup problem

Check for any looseness in the setup (Tool, Tool holder, Part, Vice, or Fixture). Check the condition and type of cutter being used, type of material, RPM and Feedrate, etc. See Machine Tool & Setup Section 4.1

Table, Saddle, or Ram Locks are locked

Make sure the Table, Saddle, and Ram Locks are unlocked. Never use gib locks with a CNC machine.

Inadequate or no Lubrication to Ballscrews and Way surfaces

Make sure all the Way surfaces are getting proper lubrication. If not, check to make sure that the lube pump is functioning properly. Also check for any pinched or blocked oil lines. See Lubrication Section 4.1.3

X, Y, and Z-axis Gibs are not adjusted properly

Check the adjustment of the X, Y, and Z-axis Gibs. See X, Y, and Z-axis Gib Adjustments in Section 5.2.1.

X & Y-axis Drive Trains are loose

Check Repeatability using the Repeatability and Positional Accuracy procedure. Step by step, carefully inspect the Drive Train for any looseness. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 4.2

Way surfaces are pocked, scarred, or excessively worn

Visually check the condition of all the Way surfaces. For machines that may have excessively worn Way surfaces you may need to adjust the Gibs in this area. This will affect performance when using the machine outside of this area. Check lubrication to affected areas.

3.1.2 Circles Out of Round

Circles are not round within 0.05 mm TIR over 75 mm DIA. This is best measured by placing a dial indicator in the quill and sweeping around the part.

Note: The typical slideway-milling machine is not capable of achieving more precise results. If more precise circles are required, then it is recommended to use a precision boring head/boring bar.

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Do the following Service Codes and document values:

 Code 33 Software Identification. This is needed if you call Customer Service  Code 11 Measures backlash in the system (Only used on Dual Feedback systems)  Code 12 Feed Forward Constant  Code 127 Measures backlash in the system (not used on Dual Feedback systems)  Code 128 Enter backlash compensation

Possible Cause

Check This

Torque values on X and Y-axis are too high.

Make sure torque is lower than 20 in-lbs. Normal values for a machine that is aligned and adjusted properly should be between 10 and 15 in-lbs when driving axis. Make sure torque is consistent across axis travel.

Machine Tool and Setup problem

Check for any looseness in the setup (Tool, Tool holder, Part, Vice, or Fixture). See Machine Tool & Setup - Section 4.1

Machine not level

Verify that the machine is level to specification.

Head is not Trammed

Verify that the Head is Trammed to specification. See Tramming the Head

X, Y, and Z-axis Gibs are not adjusted properly

Check the adjustment of the X, Y, and Z-axis Gibs using the X, Y, and Z-axis Gib adjustment procedures.

Calibration or Backlash problem

Recalibrate the machine. Reset the Backlash. Check Repeatability and Positional Accuracy. See Calibration & Backlash Constants Section 5.2.2

Newall Scale problem

Make sure that the Newall Scale is installed correctly according to the Newall Scale Installation procedures. Check for any loose brackets or misalignment etc. Also, check to make sure the Newall Scale assemblies are functioning correctly. See Newall Scales Sections 4.6 & 4.7.

X & Y-axis Drive Trains are loose

Check Repeatability using the Repeatability and Positional Accuracy procedure. Step by step, carefully inspect the Drive Train for any looseness. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 4.2

Head Bolts are loose

Verify that all the head bolts are tight.

3.1.3 Taper Cut on a Programmed Straight Line Move

An unwanted tapered cut occurs, when the machine is programmed to move in a straight line along either the X or Y-axis. The DRO shows motion of a few thousandths of an inch in the axis that is not supposed to be moving.

Explanation: For straight line cuts along the X or Y-axis, the control is designed to lock the motor of the axis that is not moving. A taper is created when there is play in the system. The force of the tool shoves the table or saddle out of position.

The system will respond to being pushed out of position by making an adjustment at the end of the move.

An unwanted tapered cut is the result of looseness in the system.

Do the following Service Codes and document values:

 Code 33 Software Identification. This is needed if you call Customer Service  Code 11 Measure's the backlash in the system. Only used on machines with Dual Feedback

systems

 Code 12 Feed Forward Constant  Code 127 Measure's the backlash in the system. Only used on machines with no Dual Feedback  Code 128 Enter backlash compensation

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Possible Cause

Check This

Machine Tool & Setup problem

Check for any looseness in the setup (Tool, Tool holder, Part, Vice, or Fixture). See Machine Tool & Setup Section 4.1

X, Y, and Z-axis Gibs are loose

Check the adjustment of the X, Y, and Z-axis Gibs using the X, Y, and Z-axis Gib adjustment procedures. See Section 5.2.1

X and Y-axis Drive Trains are loose

Check Repeatability using the Repeatability and Positional Accuracy procedure. Step by step, carefully inspect the Drive Train for any looseness. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 4.2

3.1.4 Parts Have Incorrect Dimensions

Parts are being machined with dimensions that are different than those programmed. Typical accuracy expectations should be:

 Circles: 0.05 mm TIR over 75 mm DIA  Positional Accuracy: 0.01 mm  Repeatability: 0.01 mm

Note: The typical slideway-milling machine is not capable of achieving more precise results.

The system should be expected to repeat within the resolution of the displayed DRO numbers of 0.01 mm.

Do the following Service Code:

 Code 33 Software Identification. This is needed if you call Customer Service  Code 123 Calibration  Code 11 Measure's the backlash in the system. Only used on machines with Dual Feedback

systems

 Code 12 Feed Forward Constant  Code 127 Measure's the backlash in the system. Only used on machines with no Dual Feedback  Code 128 Enter backlash compensation

3.1.4.1 Every Part Has the Same Error

Possible Cause

Check This

Machine Tool & Setup problem

See Machine Tool & Setup Section 4.1

Programming Error

In the program, look for common errors in programming such as transposing numbers, tool diameters, and pressing INC SET when ABS SET is meant. This is especially suspected if the dimensional errors are larger than a few thousandths. See the Controls Programming, Operations and Care manual.

Configuration file that contains calibration file and backlash constants has been erased or corrupted.

Verify configuration file (Code 313) does not read default values. Load saved configuration file from floppy disk in electrics cabinet with Code 141.

Calibration or Backlash problem

Recalibrate the machine. Reset the Backlash. Check Repeatability and Positional Accuracy. See Calibration & Backlash Constants

3.1.4.2 The Dimensional Errors Are Random or Accumulate in Size Over the Part Program Run

Possible Cause

Check This

Machine Tool & Setup problem

See Machine Tool & Setup Section 4.1

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Scale problem

Make sure that the Scale is installed correctly according to the manufacturer’s instructions. Check for any loose brackets or misalignment etc. Also, check to make sure the Scale assemblies are functioning correctly. See Scales Sections 4.6 &

4.7

X and Y-axis Drive Trains are loose

Check Repeatability using the Repeatability and Positional Accuracy procedure. Step by step, carefully inspect the Drive Train for any looseness. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 4.2

3.2 Problems Regarding the Motion of the Machine

3.2.1 Run Away Axis

The axis makes an unwanted move at rapid speed in one direction and faults out. This is usually caused by an encoder signal being interrupted.

Do the following Service Codes:

 Code 33 Software Identification. This is needed if you call Customer Service  Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and if the

encoders are counting properly

Possible Cause

Check This

Newall scales are counting in opposite direction of motor encoder

Reverse directions with codes 321 and 322

The home positions or tools are not set correctly

See the Controls Programming, Operations and Care manual.

The Sensor or Glass Scale is not reading.

See TRAK Sensors or Glass Scales diagnostic Section 4.6 or 4.7 Bad Motor Encoder

See Motor diagnostics Section 4.4

3.2.2 Slow Down Axis

The axis slows down and moves at a feedrate that is lower than rapid or than the programmed feedrate.

Do the following Service Codes:

 Code 33 Software Identification. This is needed if you call Customer Service  Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and if the

encoders are counting

 Code 129 Set's the maximum allowable arc accuracy error. This applies to arcs only

Possible Cause

Check This

The maximum allowable Arc Accuracy is set too low.

This value will only slow down the machine during arc moves. The factory default is set at 0.025 mm. Perform Code 129 to check or change this value. See Service Codes section

Incoming AC voltage is inadequate

Perform Code 100. See Service Codes - Section 4.9 and Electrical Section 4.8

Table, Saddle, or Ram Locks are locked

Make sure the Table, Saddle, and Ram Locks are unlocked.

Inadequate or no Lubrication to Ballscrews and Way surfaces

Make sure all the Way surfaces are getting proper lubrication. If not, check to make sure that the lube pump is functioning properly. Also check for any pinched or blocked oil lines. See Lubrication Section 4.1.3

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X, Y, and Z-axis Gibs are not adjusted properly

Check the adjustment of the X, Y, and Z-axis Gibs using the X, Y, and Z-axis Gib adjustment procedures.

Binding in the Drive Train

Check Repeatability using the Repeatability and Positional Accuracy procedure. Check the torque reading of the Drive Train. Step by step, carefully inspect the Drive Train for any binding. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 4.2

Servo Drive failure

See Servo Drive Section 4.5

Motor failure

See Motor Section 4.4

3.2.3 Axis Will Not Jog

The system powers up but will not respond to the jog command.

Do the following Service Codes and procedures:

 Code 33 Software Identification. This is needed if you call Customer Service  Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and if the

encoders are counting

Possible Cause

Check This

Improper Boot-up

Shut down the system and wait 10 seconds before rebooting

E-Stop is pressed in

Check E-Stop. Especially if both axes will not jog

E-Stop reset button

Press the E-Stop reset button on the side of the pendant

Servo Drive failure

Especially, if only one axis will not jog;

See Servo Driver Section 4.5

Shorted motor

See Motor Section 4.4

Poor cable or wiring connections

See Electrical Connection Section 2.12

Computer/Pendant failed

See Computer/Pendant diagnostics Section 4.3

3.2.4 Axis Motor Motion is not Smooth

While under motor power, the motion is not smooth. The motion appears to be "rough" or jerky”.

Do the following Service Codes and procedures:

 Code 33 Software Identification. This is needed if you call Customer Service  Code 11 Measure's the backlash in the system. Only used on machines with Dual Feedback

systems

 Code 12 Feed Forward Constant. High feed forward constants will cause an unstable servo

system

 Code 127 Measure's the backlash in the system. Only used on machines with no Dual Feedback  Code 128 Enter backlash compensation  Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and if the

encoders are counting

Possible Cause

Check This

X, Y, and Z-axis Gibs are not adjusted properly

Check the adjustment of the X, Y, and Z-axis Gibs using the X, Y, and Z-axis Gib adjustment procedures.

Scale problem

Make sure that the Scale is installed correctly according to the manufacturer’s instructions. Check for any loose brackets or misalignment etc. Also, check to make sure the Scale assemblies are functioning correctly. See Scales Section 4.6 &

4.7.

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Calibration or Backlash problem

Recalibrate the machine. Reset the Backlash. Check Repeatability and Positional Accuracy. See Calibration & Backlash Constants section.

Binding in the Drive Train

Check Repeatability using the Repeatability and Positional Accuracy procedure. Check the torque reading of the Drive Train. Step by step, carefully inspect the Drive Train for any binding. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 4.2

3.2.5 Vibration in Motion

While axis is moving there is vibration or noise coming from the X or Y-axis.

Do the following Service Codes and procedures:

 Code 11 Measure's the backlash in the system. Only used on machines with Dual Feedback

systems

 Code 12 Feed Forward Constant. High feed forward constants will cause an unstable servo

system

 Code 127 Measure's the backlash in the system. Only used on machines with no Dual Feedback  Code 128 Enter backlash compensation  Code 123 Calibrate

Possible Cause

Check This

Too much backlash entered in Code 128 or Code 11.

Recheck the machines backlash.

Inadequate or no Lubrication to Ballscrews and Way surfaces

Make sure all the Way surfaces are getting proper lubrication. If not, check to make sure that the lube pump is functioning properly. Also check for any pinched or blocked oil lines. See Lubrication section

X, Y, and Z-axis Gibs are not adjusted properly

Check the adjustment of the X, Y, and Z-axis Gibs using the X, Y, and Z-axis Gib adjustment procedures.

Gibs not making good contact.

Pull gibs out and mark with a blue die to check where the gibs are making contact. It is recommended that the gibs uniformly contact at least 80% of the surface.

Binding or looseness in the Drive Train

Check Repeatability using the Repeatability and Positional Accuracy procedure. Check the torque reading of the Drive Train. Step by step, carefully inspect the Drive Train for any binding or looseness. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 4.2

Axis Motor belt too tight.

Loosen belt.

Misalignment of ball screw

See Mechanical Drive Train (X, Y) Section 4.2

3.2.6 Searching Axis

The handwheels are slowly turning back and forth when the servos are engaged. Several thousandths of motion are observed on the vernier dial and the frequency is one cycle every couple of seconds.

Do the following Service Code and procedures:

 Code 11 Measures backlash in system. (Used only with glass scales and sensors.)  Code 12 Sets a feed forward power constant to drive axis motors  Code 128 Backlash compensation on single feedback machines

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Possible Cause

Check This

Most often causes by excess backlash compensation

Check physical backlash in system and re-enter in code 128. Run code 11 on single feedback machines

High feed forward values

Check ball screw torque. Typical values should be between 10 to 15 in-lbs for the 2500 & 3500 & 15-20 in-lbs for the 4000 &

5000.

Excessive friction in the sliding ways

Lubrication, gib adjustments, gib locks. See Machine Tool & Setup - Section 4.1

Looseness in the drive train

The drive train of the axis that is searching, especially the tightness of the drive assembly.

See Mechanical Drive Train (X, Y) - Section 4.2

3.3 Problems Relating to the Operation of the Control

3.3.1 Display Blanks

The display is completely blank.

Possible Cause

Check This

Screen saver has been activated

Press any key to turn back on. All LED keys on pendant will blink when the screen saver is on. Press any key to deactivate. Hitting this key will not activate any feature on the control.

The system has shut down

Turn the power switch off, check the computer/ pendant fuses and cable connections. See Electrical Section 4.8

Fuse blown in pendant

Remove fuse and check continuity

Display/Computer/Pendant failed

See Computer/Pendant Section 4.3

3.3.2 Bad Picture on the Display

The display has strange characters, horizontal bars or other unfamiliar images, or the display continually rolls.

Possible Cause

Check This

Display/Computer/Pendant failed

See Computer/Pendant Section 4.3

3.3.3 Keyboard Lockup

The screen display is normal, but the system will not respond to key presses.

Do the following Service Codes and procedures:

 Code 81 press each key on the pendant. The screen will display a keypad that signifies if a key

is working. The pendant will also beep.

Possible Cause

Check This

Voltage drop/spike has occurred

Shut down the system and wait 10 seconds to reboot the system.

Remote Stop-Go (RSG) switch has a short (if connected)

Remove the RSG. Turn the system off and then on again. If the problem goes away and then re-appears when the RSG is plugged-in, replace the RSG.

Computer/Pendant failed

See Computer/Pendant Section 4.3

3.3.4 Axes Fault (X, Y or Z)

The program run or jogging operation is interrupted with a Fault Message on the display.

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Do the following Service Codes and procedures:

 Code 33 Software Identification. This is needed if you call Customer Service  Code 11 Measures the backlash in the system. Only used on machines with Dual Feedback

systems

 Code 12 Feed Forward Constant. High feed forward constants will cause an unstable servo

system

 Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and if the

encoders are counting

Possible Cause

Check This

Cable connection problems

Check umbilical 1 and 2. Check #1 for X and Y-axis problems and #2 for the Z-axis.

X, Y, and Z-axis Gibs are adjusted extremely tight

Check the adjustment of the X, Y, and Z-axis Gibs using the X, Y, and Z-axis Gib adjustment procedures. See X, Y, and Z-axis Gib Adjustments Section 5.2.1

Excessive friction in the slideways

See Machine Tool & Setup Section 4.1

Binding or looseness in the Drive Train

See Mechanical Drive Train (X, Y) Section 4.2 Incoming electrical power

Incoming voltage. See Electrical Section 4.8

Measurement system not functioning properly

See Section 4.6 or 4.7 Servo Drive failure

See Servo Driver - Section 4.5

Motor failure

See Motor diagnostics, Section 4.4

Computer/Pendant failure

See Computer/Pendant diagnostics, Section 4.3

3.3.5 Problems Reading the Floppy Disk; Programs Not Saved Properly. The floppy

drive will not read or write programs from a disk.

Possible Cause

Check This

Improper Boot-up

Shut down the system and wait 10 seconds before rebooting

Floppy Disk failure

The Floppy Disk may be bad. See if the Floppy Disk can be read by a Personal Computer. Does the green light on the floppy drive come on when you access the disk? If so, power is getting to the floppy drive. If not check connections of floppy drive inside the computer module. See Computer/Pendant Section 4.3 for more information.

Floppy Disk full

Put the Floppy Disk into a Personal Computer to see how many bytes remain. A floppy can typically hold 1.4 MB of information.

3.3.6 System Will Not Boot-Up

The system does not boot-up when the switch is turned on.

Possible Cause

Check This

Flash Drive failure

When the Computer Module starts the boot-up process, look at the 8th line on the Display Screen. If the Mother Board of the Computer Module is communicating with the Flash Drive you will see "Detecting IDE Primary Master…Scan Disk SDCFB-256". If the Mother Board of the Computer Module is not communicating with the Flash Drive you will see "Detecting IDE Primary Master … None".

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Also, check the wiring connection between the Flash Drive and the Mother Board. See Computer/Pendant diagnostics Section

4.3.

Computer/Pendant has failed

See Computer/Pendant diagnostics Section 4.3.

3.3.7 System Reboots by Itself

During operation, the screen suddenly blanks and then shows that the system has begun the boot-up sequence.

Possible Cause

Check This

Interruption of 110 V power to pendant

Using a Voltmeter, check the incoming 110VAC to the pendant. Poor wiring and cable connections

Check for any loose wiring or cables

Computer/Pendant failed

See Computer/Pendant diagnostics Section 4.3

3.3.8 System Shuts Off

During operation, the system shuts off and will not turn back on.

Possible Cause

Check This

Fuse blown in pendant

Remove fuse and check continuity

Poor wiring and cable connections

Check for any loose wiring.

Transformer output

Check 110 V Transformer output

Computer/Pendant has failed

See Computer/Pendant diagnostics Section 4.3.

3.3.9 Will Not Hold Calibration

The control will not hold calibration. Go to the "Configuration Values" screen and write down the calibration values for the motor encoders (Encoder) and the position feedback encoders (Scales). The calibration values are written in Hexadecimal. Recalibrate the system and see if the values change. Turn the system off and on and see if the values are held.

Do the following service codes and procedures:

 Code 33 Software Identification. This is needed if you call Customer Service.  Code 313 Configuration Values  Code 123 Calibration Mode

Possible Cause

Check This

Configuration file corrupt

Load default configuration by going to code 313

Not saving Calibration values

Replace Computer/Pendant module.

If calibration factors are being saved, but the measurements are not repeating or are not accurate:

 See Measurements Are Not Repeating  See Measurements Are Not Accurate

3.3.10 Auxiliary Functions Not Working

The Auxiliary Functions will not turn on or off at the programmed times. There are 3 Auxiliary Functions:

1. Turns coolant pump on or off.

2. Sends an electrical signal to rotate the turret on an indexer.

3. Turns the "Spindle Off" at the end of a programmed event.

In order to run the above auxiliary functions in run mode the accessory key on the front of the pendant must be in the AUTO mode.

All of the auxiliary function signals are carried down to the cable breakout box through umbilical #2. Each function then has its own relay inside this box. If one of these relays fail then these features will not work.

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Do the following service code and procedures:

 Code 33 Software Identification. This is needed if you call Customer Service.  Code 329 Control Outputs. Enables the outputs to be turned on/off manually (Press Code F first

to access codes 328 through to 330)

Possible Cause

Check This

Blown fuse

Check the fuses feeding the coolant pump and also the coolant pump control circuit.

Poor cable connections

Check all the cable connections on the cable breakout box and Coolant Pump. In particular, check umbilical # 2 cable, which carries the auxiliary function signals.

Bad cable breakout box

Check for continuity between the following pins when the corresponding aux function is activated:

 Coolant connector: 1 and 4  Indexer connector: 3 and 4  Spindle connector: 1 and 4

3.3.11 Emergency Stop Error (E-Stop)

The E-Stop turns the power off to the axis and spindle motors. SMX Bed Mills have an E-stop on the front of the pendant and a reset button on the side of the pendant. (See figures 9 & 10). When the E-stop is activated:

 Power to the cable break out box (from the pendant AC E-stop Out connector) is isolated via the

E-stop relay inside the pendant. This isolates power to the axes motors.

 The spindle AC drive power is turned off by a contactor (K1), located on the power module. The

contactor (K1) is turned off by the dual channel safety relay, which monitors the pendant E-stop. (for SMX2500, the safety relay removes 24VAC power to the spindle contactors)

The E-stop LED on the spindle control module will be on when the e-stop is in the out position. The LED will turn off when the E-stop is depressed. (See figure 10).

If the E-Stop button is depressed, and no message is displayed on the screen, then either the pendant, spindle control module, cables from pendant to spindle control module, or cables from spindle control module to dual channel relay (safety relay) are at fault.

Possible Cause

Check This

E-Stop reset button

Press the E-Stop reset button on the side of the pendant.

Bad pendant

Does 110 V power come out of the AC E-stop Out connector on the pendant? If yes and the screen has an E-stop message then replace the pendant.

Poor cable connection

Check spindle control cable connection and Euro connector connections.

3.3.12 Limit Switch Error

Limit switches are installed on the table, saddle, and head to prevent serious damage to the machine in the event of overtravel. In the event a limit switch is triggered, a limit switch error will appear on the screen.

To return the machine to its normal state of operation, perform the following procedure:

1. Jog the table, saddle, or head off the switch.

2. Press the "Mode" or "Return" key to reset the control

3. Press the "DRO" key to access the Jog function again.

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Limit switches can be turned on or off with Service Code 312, however, limit switches should normally be kept on.

Possible Cause

Check This

Limit Switches are triggered

Reset the Limit Switches using the procedure described above.

Poor Limit Switch Cable connection

Check for any pins that are loose, pushed in, or bent. Verify that there is a good connection between the cables on the cable breakout box.

Limit Switch failure, try this: Swap over 2 limit switch cables

on the cable breakout box.

Does the limit switch problem move to the other axis? If it does then the switch is most likely the problem. If it stays with the original axis then it could be the cable breakout box or pendant.

3.4 Problem with the Measurements

3.4.1 X, Y and Z-Axis Measurements Do Not Repeat

With a dial indicator mounted to the bottom of the spindle, touch off a fixed surface either in the X or Yaxis direction and then set the DRO equal to 0. Crank away several centimetres and then touch off again at the same place. If the reading has not returned to 0 on the DRO, zero the display and repeat the procedure. If the measurement does not repeat, you have a repeatability problem that must be resolved.

Test for accumulative error by moving the axis a number of times to see if the error gradually grows by a small amount. If so, it may be caused by a misaligned sensor or scale. If the error abruptly changes by a large amount, it may be caused by a bad encoder.

Expected repeatability numbers should be 0.01 mm or less.

Do the following service codes and procedures:

 Code 304 Toggle X sensor/glass scale on/off  Code 305 Toggle Y sensor/glass scale on/off

Possible Cause

Check This

Machine Tool & Setup problem

Check for any looseness in the setup (Tool, Tool holder, Part, Vice, or Fixture). Make sure there is sufficient contact between the tool holder and the spindle. See Machine Tool & Setup Section 4.1

X, Y, and Z-axis Gibs are loose

Check the adjustment of the X, Y, and Z-axis Gibs using the X, Y, and Z-axis Gib adjustment procedures.

Scale problem

Make sure that the Scale is installed correctly according to the manufacturer’s instructions. Check for any loose brackets or misalignment etc. Also, check to make sure the Scale assemblies are functioning correctly. Use service codes 304 for X and 305 for Y to turn off the suspect encoder. Does problem still exist after turning it off?

X and Y-axis Drive Trains are loose

Check Repeatability using the Repeatability and Positional Accuracy procedure. Step by step, carefully inspect the Drive Train for any looseness. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 4.2

Encoder Disk or Reader Head on motor are loose

Swap the motor in question with a known good motor. For example, swap the X-axis motor with the Y-axis motor. If the symptom stays with the motor in question, then replace the motor. If not, then the motor is not at fault and something else is causing the problem.

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Spindle and/or Quill are loose

Use a Dial Indicator and check for side-to-side movement between the Spindle and the Head. Next, check for side-to-side movement between the Quill and the Head. There should be no more than

0.01 mm of side-to-side movement. Make sure that there is a few thousandths gap between the Spindle Collar and the Quill after tightening.

Head bolts are loose

Tighten Ram bolts

3.4.2 X, Y, and Z-Axis Measurements are not Accurate

Measurements repeat, but with a dial indicator mounted to the bottom the spindle, traversing the length of a gage block or some other measurement standard, the measurement is not accurate.

Note: If your part has incorrect dimensions, see Parts Have Incorrect Dimensions, Section 3.1.4.

Note: First check for repeatability of the DRO: With a dial indicator mounted to the bottom of the spindle, touch off a fixed surface either in the X, Y, or Z-axis direction and set the DRO equal to 0. Crank away several centimetres and touch off again at the same place. If the reading has not returned to 0 on the DRO, zero the display and repeat the procedure. If the measurement does not repeat, you have a repeatability problem that must be resolved before the accuracy problem can be resolved. See Measurements That Do Not Repeat, Section 3.4.1.

Possible Cause

Do This

The Calibration is incorrect

Recalibrate the machine.

See Calibration & Backlash Constants

Incorrect backlash values

If the machine does not repeat bi-directionally check the backlash on the axis in question.

See Section 5.2.2.

3.4.3 The DRO is not Counting

The DRO for one axis is not counting when an axis is moved. Often times if this is the case the axis will fault. See section on faulting.

Do the following Service Codes:

 Code 33 Software Identification. This is needed if you call Customer Service.  Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and if the

encoders are counting.

 Code 304 & 305 Turns off X and Y sensor or scale.

Possible Cause

Check This

Servo driver failure

See Servo driver Section 4.5

Motor Encoder not counting

See Motor diagnostics (not applicable with Glass Scale option)

Glass Scale or Sensor Failure

Does axis now count? If so, replace scale.

Computer/Pendant failure

See Computer/Pendant diagnostics

3.4.4 X, Y, and Z-Axis DRO Counting in Wrong Direction

The DRO is counting in the wrong direction or axes jog in the wrong direction.

The positive directions for each axis should be:

 X-axis – Table moves to the left  Y-axis – Saddle moves toward the front of the machine  Z-axis – Head moves up

Do the following service code and procedures:

 Code 33 Software Identification. This is needed if you call Customer Service.

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 Code 313 Check the line that specifies the product. If the product does not match the machine

then either the machine ID key is incorrect or else the pendant is faulty.

 Code 921 (922): Toggles the direction in which the X (Y) motor drives the table (saddle).  See also Codes 321 and 322, in sections 4.8.2.10 and 4.8.2.11.

3.4.5 X, Y, & Z-Axis Electric Handwheels Turn in Wrong Direction

The Electric Handwheels turn in the wrong direction.

The positive directions for each Electric Handwheel should be:

 X-axis - Electric Handwheel turns clockwise  Y-axis - Electric Handwheel turns anti-clockwise

Do the following service code and procedures:

 Code 308 Reverse X-axis Handwheel Direction  Code 309 Reverse Y-axis Handwheel Direction

3.5 Problems with the Machine

3.5.1 3.5.1 Z-Axis Noisy

While jogging or cutting in the Z-axis direction, the axis makes unusual noises. See below for head noise.

Possible Cause

Check This

Machine Tool and Setup problem

Check for any looseness in the setup (Tool, Tool holder, Part, Vice, or Fixture). See Machine Tool & Setup Section 4.1

Inadequate or no Lubrication to the Ballscrew and Way surfaces

Make sure all the Way surfaces are getting proper lubrication. If not, check to make sure that the lube pump is functioning properly. Also check for any pinched or blocked oil lines. See Lubrication Section 4.1.3

Z-axis Gibs are not adjusted properly

Check the adjustment of the Z-axis Gibs using the Z-axis Gib adjustment procedure. See Z-axis Gib Adjustments Section 5.2.1

Mechanical Drive Train

Misalign ballscrew, or top and lower bearing failure.

Z-axis motor failure

Replace Z-axis motor, see Motor Diagnostics Section 4.4

3.5.2 3.5.2 Spindle Stalls or Turns-Off During Machining

During machining, the spindle turns off and loses power. First check incoming voltage and connections.

Possible Cause

Check This

Machine Tool and Setup problem

Check the type of material being cut, type and size of cutting tool, RPM, and Feed rate. Also check the condition of the cutter to verify that the cutter is not dull. See Machine Tool & Setup Section 4.1

Drive Belt in the head is slipping

Check the alignment, condition, and tension of the Drive Belt.

Cutting more than the machine is capable

Check width and depth of cut

Spindle Drive thermal Overload has tripped

Check AC drive fault history (for SMX2500, check spindle overload relay in electrical cabinet)

Spindle Drive incorrectly configured.

Contact Customer Service for assistance.

Spindle run command not reaching AC Drive

Verify spindle run LED is on Spindle Control Module.

3.5.3 Spindle Motor Hums or Will Not Run

The spindle motor makes a constant humming noise during operation or will not turn on.

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Possible Cause

Check This

Wrong voltage

Check the voltage to the machine. Also, check the voltage to the Spindle Drive (L1, L2, and L3).

Poor wiring connections

Check all the wiring connections to the Spindle Drive and Spindle Motor. See Electrical Connection

Spindle Drive may be in "Local Mode"

On the Spindle Drive, check the LED on the LO/RE button – it should be unlit. If lit, press the button once.

Spindle Motor is bad

Check the resistance of the Spindle Motor windings on the Spindle Motor between L1 & L2, L2 & L3, and L1 & L3, using an Ohmmeter. The resistance should be 3 Ohms or less and approximately equal. If the Ohmmeter reads "0 Ohms" or "OL", then replace Spindle Motor. Next, check the resistance between L1 & Ground, L2 & Ground, and L3 & Ground, using an Ohmmeter. The resistance should read "OL". If not then replace Spindle Motor.

Spindle Drive incorrectly configured.

Contact Customer Service for assistance.

Spindle enable signal not reaching AC Drive

Verify LED on Spindle Control module is on.

Forward/Reverse Switch is bad or Spindle Control Board

Verify Forward or Reverse LED on Spindle Control module is lit.

3.5.4 Spindle Runs Backwards

The spindle motor runs in the opposite direction. The spindle will run in opposite directions from high to low gear.

Possible Cause

Check This

3-Phase sequence incorrect.

Swap any two wires leading to the spindle motor (U, V & W).

3.5.5 Head Noise

Head noise pertains to any unusual noises coming from the head under load and no load situations. Most often head noise will only be noticeable under load situations. It is important to try to distinguish between problems with components in the head versus problems caused by the setup or tooling being used on a particular job.Use the table below to try to pinpoint the possible cause. Also try to isolate the noise by seeing if it exists in high, low or neutral speed range. For example, if the noise is evident in neutral then this eliminates the spindle bearings.

Possible Cause

Check This

Machine setup or tooling problem

If the noise is most evident under load (cutting situations) then it is important to look at setup and tooling being used. Ask the following questions:

Is the cutter dull? Is the tool loose in the holder? Am I taking a bigger cut than is possible on this machine? Is the part moving in the vice? Am I using realistic speeds and feeds?

Any one of these can have a significant impact.

Upper spindle bearing is worn.

Remove the upper bearing plate above the spindle. This will unload the bearing. If the noise goes away then this bearing should be replaced.

Verify nosepiece is tight on bottom of spindle.

To check if the nosepiece is bottomed out try to insert a piece of paper in between the nosepiece and the quill. If a piece of paper does fit then this may be the problem. Before tightening or loosening the nosepiece make sure to loosen the setscrew that holds it in place.

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Spindle bearings are worn.

This is categorized by a high pitch sound and is most evident at high RPM’s. It should also cause chatter under load. Replace the spindle if this is the case. See spindle replacement in Section 5.

The belt is not lined up with the grooves on the pulleys.

Make sure the 10-ribs on the belt are lined up with the 10-grooves on the 2-pulleys. If the belt is frayed then replace the belt.

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4.0 Diagnostics

This section explains the diagnostic procedures used to isolate machine problems.

DANGER!

Some of these procedures involve accessing potentially hazardous mechanical or electrical

systems. These checks must only be carried out by competent personnel.

4.1 The Machine Tool & Set-Up

4.1.1 The Milling Machine Checklist

The following is a quick reference for the types of problems that may arise if problems are noticed in these areas.

Problems With:

Can Contribute To:

Most Suspect When (and why):

Spindle bearings See Spindle Replacement

Noisy head Parts incorrect Circles out of round

Older machines, machines that are pushed hard

Lubrication system

Premature wear of ball screws, wear surfaces

Poor finish

New installations (may not be hooked up or line sheared)

Inadequate lubrication habits

Premature wear of ball screws, wear surfaces

Poor finish

New installations (more motion than the machinist is used to with a manual mill).

Lubricate machine every morning before use.

X and Y gibs loose See Gib Adjustment - Section

5.2.1

Taper on straight Y moves Poor finish Circle out of round

When machine hasn’t been serviced

in a long while.

Gibs too tight

Not getting to position, does not repeat, axis faults

Poor finish

N/A

Gibs floating

Not getting to position, does not repeat, axis faults

Poor finish

Contact area of gibs. May need to be scraped. Very old machines may not have any more adjustments on gib; new gib must be fitted.

Gibs defective - bowed, scarred

Excess play when gib is checked side to side

Inadequate gib contact

Way surfaces pocked, scarred, or excessively worn

Poor finish Out of round circles Faulting

Inadequate lubrication Ram gibs loose

Parts incorrect dimensions Head out of tram in Y direction

Vibration or jerky motion in Z axis

Machine not level Weight not distributed evenly

on all six screws See Levelling procedures

Parts incorrect, Machine geometry off, i.e.

tram.

New installation or heavy crash. Head out of tram See Tramming Head - Section

5.2.3

Leaves uneven surfaces on bottom of pockets.

Machine not level, ram gibs loose.

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4.1.2 A Special Word About X/Y/Z Gibs

The slideway surfaces are vital to the performance of the bed mill.

Gibs should be:

 flat  free of twist  free of burrs  free of blockages in the oil passages and channels

Defective or scarred gibs must be replaced. Shimming of gibs will not yield acceptable results.

It is good machining practice to avoid the use of shop air to clean the swarf off a machine. This risks blowing swarf into the sliding way surfaces and compromising the performance of the machine.

Gibs that are not adjusted correctly will affect the performance of the machine. It will lead to positioning and repeatability problems. The gibs should be adjusted at least twice a year.

See Gib Adjustments Section 5.2.1.

4.1.3 Lubrication

Lubrication is one of the single, most important maintenance issues and plays a key role in assuring the performance and durability of the bed mill. At the beginning of each day manually supply oil to the way surfaces.

Lack of lubrication can lead to a variety of problems with your machine motion due to increased friction in the sliding ways. This increased friction may lead to part inaccuracies and decreased life expectancies of your ball screws and way surfaces.

4.1.4 Machining Set-Up

The machining set-up itself is always something that can greatly influence the performance of the mill. The following are some things to keep in mind:

Problems With

Can Contribute To:

Feed and Speeds (spindle rpm)

See below

Poor finish

Machine chatter

Excessive speeds and feeds can break cutting tools or wear tools prematurely.

Tooling

Using the wrong cutter for an application

Entering the wrong size diameter and programming with tool compensation.

Poor finish Parts incorrect size

Cutting too deep

Part dimensions incorrect

Driving and cutting forces cause deflections, since no material is totally rigid

Machine chatter

No coolant

Poor finish, decrease the life of the cutter

4.1.4.1 Spindle Speeds

Spindle speeds are influenced by a number of variables:

 Material  Rigidity of the Machine Setup

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 Coolant  Cutter type, material and diameter  Cutting Depth

As a general rule:

 Lower spindle speeds are used to machine hard or tough material or where heavy cuts are

taken.

 Higher spindle speeds are used to machine softer materials in order to achieve better surface

finishes. Higher speeds also apply when using small diameter cutters for light cuts on frail work pieces and delicate setups.

Note: Cutter diameter greatly affects spindle speeds. The larger the diameter, the lower the spindle speed.

4.1.4.2 Feedrates

Factors that affect feedrates:

 Depth and width of cut  Design or type of cutter  Sharpness of the cutter  Workpiece material  Type of finish or accuracy required  Climb or conventional milling

If a fine finish is required, reduce the feed rather than increase the spindle speed. Cutters are dulled by high spindle speeds rather than high feedrates.

4.2 The Mechanical Drive Train (X, Y)

Indications:

 Troubleshooting instructions indicate that the drive train is potentially the problem and other

(more easily checked variables) have been exhausted.

 Roughness, looseness, tightness or jamming movement in the table or saddle.

Actions:

1. Check for machine considerations, especially gib adjustments. See Gib Adjustments section

2. Check the torque of the axis in three places (both ends and centre of ball screw) along the length

of the ball screw. The torque should be the same within 2 or 3 in-lbs across the length of the ball screw. If it is not, chances are the ball screw is misaligned. A misaligned ball screw can lead to parts being out of round and servo problems at low feedrates. A bad ball screw can also cause high torque, although this is highly unlikely. See Sections 4.2.1 and 4.2.2 for more information.

The following steps take you in logical sequence through the machine assemblies. For drawings of these assemblies see Section 5. These instructions break the machine down from fully assembled and point out the areas to look at specifically:

1. Check that the belt is properly tightened. A loose belt can lead to excessive backlash

compensation values on motor encoder only machines. To adjust belt tension, loosen the (4) screws that secure the motor to the bracket. Adjust motor for proper belt tension as necessary. See the drawings for illustrations.

2. Check that the nut that tightens up against the ball screw pulley is tight. If this is loose the pulley

may not run true on the ball screw.

3. 2500 & 3500 X-axis only - Check that the tapered sleeve that seats the pulley has not clamped to

the ball screw prematurely. It should be seated firmly against the pulley. Tightening the nut may not have ensured this. Also make sure the pulley is keyed to the ball screw.

4. 2500 & 3500 X-axis & Y-axis bearing housings - Ensure that the bearing housing is clamped in

place by the bracket. This design uses the bracket to secure the bearing housing in place. It should not allow the bearing housing to float between the bracket and machine. For the 4000 & 5000, verify the bearing housing cover is properly fastened.

5. 2500 & 3500 X-axis & y-axis - Ensure that the Clamp Nut is secured. The following applies to the

clamp nut:

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 When loosening, make sure to back out the 10-32 screw from the clamp nut.  When tightening, snug the 10-32 screw so the clamp goes onto the ball screw thread with

some drag. Thread it onto the ball screw and torque the clamp nut to 50 ft/lbs and then tighten the screw down.

6. For the 4000 & 5000 verify the nut on the X axis, and double nut on the Y axis is tight.

7. Take out the angular contact bearings and inspect them. They should roll smoothly and be lightly

greased. If not, replace them. When putting the bearings back into the housing make sure to put them in correctly. Failure to do this will cause problems. The thin race of each bearing should be facing inward toward the spacer ring.

Note: 2500 & 3500 - the bearing housing and spacer ring are matched sets - keep them together.

8. Check the ball screw mounting to the yoke. Make sure the SHCS are tight.

9. Inspect the ball screw, ball nut and yoke for the potential problems shown in the chart below and

on the next page.

CAUTION!

Unlike a lead screw, do not unscrew the ball screw from its nut. This will destroy the ball

screw!

Potential Problem:

Check This:

Bad ball screw

 Visually inspect the ball nut - if the nylon seal

is broken or deformed, if contamination has visibly entered the ball nut or if balls are out of the ball nut, replace the ball screw.

 Crank the ball screw through a significant

part of its travel. If it jams, feel loose or has rough spots, replace the ball screw.

 Use the dial indicator on a vertical flat of the

ball screw to check for backlash between the ball screw and ball nut.

Ball nut not tightened to the yoke

 Inspect for space between the head of the

bolt and the ball nut i.e. the retaining bolt has bottomed out in its thread and is not securing the ball nut to the yoke properly.

Yoke loose in the saddle

 Inspect for any motion of the yoke or

looseness in the Yoke mounting screws.

Oil lines sheared

 Visual inspection.

Oil line blockage

 Pump the oil and ensure that it flows evenly

to the ways and ball screw.

Ball screws not aligned properly

 Measure from the ball screw to the back of

the saddle on both sides of the yoke (the table must be removed). The measurements must be within ±0.13 mm end to end. See above explanations.

Note: Ball screws are inspected throughout their entire travel for backlash and consistent torque. A ball screw should be good for millions of inches of travel if installed properly. Do not be too quick to replace a ball screw if there is insufficient indication that it is bad; this will just be a costly delay to resolving the real problem.

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4.2.1 Keys to SMX 2500 & 3500 Ball Screw Alignment

 X-axis – there are 3 components that can cause misalignment: the yoke, the left side bearing

housing bracket, and the right side bearing housing.

o Yoke – the yoke is aligned at the factory and pinned in place. It is aligned to within 0.01mm

with a precise alignment tool. The yoke most likely is not causing the problem. If this were the problem you would need to remove the pins and align the X ball screw with the back of the saddle. Drill new holes and pin the yoke in place. The Y-axis ball screw bore is machined perpendicular to the X bore. If the X-axis is aligned the Y-axis will also be aligned.

o Left side table bearing housing – this is most likely the cause of the misalignment. To

align the bracket and bearing housing, move them as close to the yoke as possible. Loosen the bracket bolts and bearing housing bolts and then retighten. This should allow the bearing housing to align itself up with the yoke.

o Right side table bearing housing – once again move the bearing housing as close to the

yoke as possible. Loosen the bearing housing and retighten. This should allow the bracket to align itself. If you do not move the table toward the yoke the ball screw will tend to bend down slightly and cause misalignment.

 Y-axis – the only component that can cause a misalignment problem is the motor mounting

bracket. To align this bracket, move the saddle as far to the front of the machine as possible. Loosen the bracket and then retighten it. Once again moving the saddle forward allows the yoke to be as close to the bearing housing as possible.

4.2.2 Keys to SMX 4000 & 5000 Ball Screw Alignment

 X-axis – there are 3 components that can cause misalignment: the yoke, the left side bearing

housing bracket, and the right side bearing housing. This machine has 2 separate yokes for the X and Y-axis. The yoke is bolted to the table on the X-axis.

o X Axis Yoke – the yoke is aligned at the factory. If you suspect the yoke is misaligned, the

bolts for the yoke can be accessed from an opening on the bottom left side of the saddle. Break these bolts free and move the table back and forth along its travel and then retighten the bolts.

o Left side table bearing housing – To align the bracket, move the yoke (table left) as

close to the bracket as possible. Loosen the bracket bolts and then retighten. This should allow the bearing housing to align itself up with the yoke.

o Right side table bearing housing – once again move the yoke as close to the bearing

housing as possible (table right). Loosen the bearing housing and retighten. This should allow the bracket to align itself. If you do not move the table toward the yoke the ball screw will tend to bend down slightly and cause misalignment. Make sure the mechanical handwheel is not causing the misalignment.

 Y-axis – the only component that can cause a misalignment problem is the motor mounting

bracket. To align this bracket, move the saddle as far to the front of the machine as possible. Loosen the bracket and then retighten it. Once again moving the saddle forward allows the yoke to be as close to the bearing housing as possible.

4.3 Computer/Pendant Diagnostics

The pendant consists of 2 separate modules: the computer module and LCD screen/enclosure.

In general, the pendant/computer module is best diagnosed by eliminating all other possible alternatives. The following table lists some problems and what these problems can lead to.

Possible problems

Check This:

Poor cable connections

There are 6+ cable connections to the left side of the pendant. Make sure all cables are properly secured.

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Pendant locks up

Press the E-stop button and see if lock up clears. If not, then do the following:

Turn the pendant off, wait at least 30 seconds, and turn it back on and check to see if the malfunction has been reset.

No voltage to RSG port

RSG will not work – should be 5 DC volts present across pins 1 and 4. Check with a voltmeter.

Flash disk failure

If the flash disk fails, the system will not boot up or operate. It will need to be replaced. Contact Service. All programs and machine configurations will be lost. Make sure to back up your flash disk from time to time.

Floppy disk failure

Will not allow user to save or pull up programs from a floppy disk. Can the floppy drive format a disk? See Section 4.3.1.

No display

Faulty display or computer, please contact service.

Faulty Emergency Stop (E-stop) switch

It can be stuck open or closed (pressed). If it is stuck closed the pendant will need to be replaced because the user will have no way to get rid of the error message. If it is open it will allow the machine to operate but it will be unsafe. The pendant MUST BE REPLACED.

Overlay failure (keys on pendant)

Certain buttons on overlay do not work. Do code 81 to verify each key beeps.

Low voltage to pendant or current spikes

1 amp fuse in pendant blows. Pendant will not turn on.

4.3.1 Checking Floppy Drive by Formatting a Disk

1. Find a new disk and install in floppy drive.

2. Connect keyboard to pendant.

3. Press CTRL ESC to get to start menu.

4. Press R for run.

5. Type Format A: - press enter.

6. If the format works your disk drive is working. If format does not work, reboot control and see if

it now works. If it does not work replace the pendant.

7. Press ALT ESC to get back to PT4 software.

4.4 Motor Diagnostics

The Motor subsystem is comprised of 2 parts: The Motor Encoder and the Motor. The motors are powered by 110 VAC voltage. The servo driver is also an integral part of the servo system, which is discussed in detail in the next section.

WARNING!

Do not work with the motors unless the power is disconnected from the machine. The

motors are run by 110 VAC. There is possibility of death by electrocution!

Rarely do both the X and Y motor/servo systems fail at the same time and in the same way. So, if your problem is occurring on both axes, its source is probably somewhere else.

The motors on the X, Y and Z axis are identical.

4.4.1 Cable Connections

Check the motor cable connections on the cable breakout box. Verify there are no pushed in pins on the connector.

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4.4.2 To Check the Motor Encoders

If the motor encoder inside the motor has failed or is not reading the machine will fault out on that axis. Do the following to verify this problem:

 Motor encoder only machines – run Service Codes 100 or 131. This will display on the DRO if the

motor encoder is counting. If the axis does not count, the encoder is not counting. This means either the encoder or the cable is the problem. Visually check the cable for any problems. If the encoder has failed the motor must be replaced.

 Motor encoder and secondary feedback machines – run Service Code 100 or 131. Both the motor

encoder and Newall scale encoder should count on the DRO screen. The motor value should be displayed under the Z-axis and the Newall scale under the X or Y-axis depending on which axis you are doing.

4.4.3 Encoder Counts to Pendant

Before replacing the motor due to a bad encoder, it is a good idea to check the cables that take those signals back to the pendant. If these signals are not getting back to the pendant then the axis will fault. Check the following cable connections:

 Umbilical #1 and #2 at the cable breakout box  Umbilical #1 and #2 at the pendant  Umbilical #1 carries the X and Y axis signals and Umbilical #2 carries the Z signals.

4.4.4 Moving Problem from One Axis to Another

Another way to troubleshoot a problem with a particular axis is to swap parts from 1 axis to another to see if the problem moves. If the problem moves then that component is faulty. See the example below.

Symptom – X Axis will not move and faults

This particular problem can happen because of any of following reasons: bad motor, servo driver, or computer module. In some cases it is not always obvious which component is causing the problem. This example will help us pinpoint the problem through a trial and error process.

Let’s assume we have narrowed it down to the servo or electrical systems and the Y-axis has no problems. Let’s also assume it is not an obvious problem like a loose connection. This particular example was done on a machine with motor encoders only.

Swap these components

Results

Physically switch the X and Y motors

Has problem moved to Y-axis? If yes, replace motor. If no, the motor is not the problem.

Note: motors are always replaced with the servo driver.

4.5 Servo Driver

Note: the Servo Driver is located in the black box on the side of each motor.

X, Y and Z servos are

identical

Indications:

 Problems moving just one axis, including hard turning in one direction.

Objective:

 Isolate the problem to the particular Servo Driver

Steps:

1. Turn off and isolate the electrical supply to the machine.

WARNING!

Do not work with the Servo Driver unless the power is disconnected from the machine. There

is possibility of death by electrocution!

2. Physically swap the servo module from the axis that is not working to one that is.

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Note: To avoid pulling the wires out of the connector, use the loop to pull the connector from the Servo Driver.

If the problem moves to the other axis and clears up from the original axis, replace the Servo Driver.

4.6 Scales

4.6.1 Measurements Do Not Repeat

1. Determine if the error in repeatability is random or accumulating:

 Mount a dial indicator in the quill.  Touch off a fixed point on the table and set the DRO to 0.  Traverse away approximately 150 mm.  Return the touch off again.  Write down the reading on the DRO.  Do not Re-zero the DRO, traverse away and return several times.  Write down the DRO readings

Random error will be unpredictable and give scattered readings, adding and/or subtracting the error after each traverse with no pattern. See Step 2.

Accumulating error will add roughly the same amount to the reading after each traverse. See Step 3.

2. For random error, look for problems in the set-up of the scale that have resulted in a loss of

rigidity. Common sources of random error include:

 Loose scale mounting hardware.  Loose reader head.  Very loose motion of the table or saddle.

3. Accumulating error is commonly the result of:

 Scale out of parallel to the axis travel.  Dirt or chip on the Newall scale.  Broken Newall scale.

4.7 Electrical

DANGER!

Hazardous voltages exist within the machine. Danger of death by electrocution.

Only electrically competent personnel should undertake diagnostics on the electrical systems

of the machine

4.7.1 Checking AC Voltage

This procedure tests for the 115V power for the control.

 Use a voltmeter on AC volts range.  Acceptable range is 100V to 130V.

Note: systems running consistently close to the low values may have problems when normal voltage fluctuations push the voltage out of the acceptable range.

Test at the following locations:

Problems Here:

May Indicate:

Power in and out of transformer.

Fuses blown.

Check the 110 power cord to the pendant.

Power cord defective

Check fuse on pendant.

Fuse blown.

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4.7.2 Checking Fuses

There are up to 11 fuses that make up the system on the bed mills. There are 2 fuses in the pendant, 3 fuses on the spindle control module and 6 fuses on the power module. The SMX2500 does not have a spindle control module.

To check fuses:

1. Use a Volt/Ohmmeter; select “OHM”.

2. Remove the fuse completely from the pendant, electrics box or cable breakout box.

3. Place a lead of the meter on each end of the fuse.

 A good fuse reads 0 (zero) or close to it.  A bad fuse reads Open or infinity.

4.7.3 Cable Breakout Box Connections

This module is located on the back side of the machine (inside the electrical cabinet for SMX 3500, 4000 and 5000). It consists of 3 motor connections, 3 limit-switch connections, 3 encoder connections, a door guard connection, volts free contacts for the coolant pump and spindle control and an indexer outlet.

4.7.4 Cable Connections

The SMX machines use 10+ cables to communicate between systems. It is often the case that what appears to be the failure of an electrical component is actually attributable to a poor connection.

Indications:

 Control problems, chronic or intermittent.  Motor problems  Measurement problems

Explanation:

1. Turn off and isolate the supply to the machine.

WARNING!

Do not plug and unplug connectors with the system power on. This may cause damage to the

connector board and harm to the technician.

2. Visually inspect the connections for excessive debris, moisture, or obvious damage.

3. Carefully clean any swarf away from the connectors.

4. One-by-one, take out each connector and then plug them back in. Do the same at the

computer/display.

5. Make sure to tighten up the screws on each of the connectors.

4.7.5 Electrical Box – SMX 3500, 4000 & 5000

The electrical box is made up of the following main components:

1. AC drive – used to control the spindle motor.

2. 3 braking resistors – used to brake the spindle motor. To verify the resistors are good, measure

the resistance across B1 and B2 of the AC drive. The resistance should read 33 ohms. Values lower or higher than this could mean one or more resistors are bad.

3. Transformer (400 volt to 110 volt).

4. Control contactors for spindle and coolant pump, fuses and E-stop safety relay.

5. Spindle control module - controls the auxiliary signals from the pendant to the AC drive and

electrical outlets.

a. Power Outlets:

i. Non-Estopped: for pendant and worklight

ii. E-stopped: For lube pump, spindle fan, electrical cabinet fans and spare (use for

indexer for example).

b. Diagnostic LEDs: The following explains the LED lights on the spindle control board.

There are two banks of 10 LEDs on the board. Not all of the LED’s are used.

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1st 10 LEDs

1. Gear 1 – this light should be on whenever the machine is in low gear. LEDs labelled Gear 2 thru

Gear 4 are not used.

2. SPD-FAULT – this light will be on whenever the AC drive is in a fault condition, which includes an

Emergency-stop message from the pendant.

3. SPD-RUN – this light should be on whenever the spindle is running

4. LED labelled SPD-ENABLE – this light should be on whenever you are in DRO, tool setup or RUN

mode.

2nd 10 LEDs

1. E-STOP OUT – this light should be on whenever the Emergency stop is in the out position. When

the E-stop is pressed, this light should go off.

2. LATCH RELAY – this light should be on when the spindle is running or if the spindle is not running

and the fwd/rev switch is in the off position when in DRO, tool setup or RUN mode. Note – if spindle won’t turn on and the spindle is enabled and the E-stop is out, then either the fwd/rev switch is bad or the spindle control module is bad.

3. TAP MODE – light should be on whenever you are not tapping. Light will be off when in the tap

event. Not applicable to SMX2500.

4. TAP REVERSE – this light will be on when the spindle changes direction at the bottom of a tap

event and back off after the spindle changes direction once outside of the tap event. Not applicable to SMX2500.

5. REV-RELAY – when fwd/rev switch is in reverse this light will be on. Note – this does not mean

necessarily that the spindle will be running this direction.

6. FWD-RELAY – when fwd/rev switch is in forward this light will be on. Note – this does not mean

necessarily that the spindle will be running this direction.

7. Z-LIMIT PLUS – this light will be on only when the Z axis plus limit switch is triggered.

8. Z-LIMIT MINUS – this light will be on only when the Z axis minus limit switch is triggered.

4.7.6 Electrical Box – SMX 2500

The electrical box is made up of the following main components:

1. Safety Relay – disconnects power during an E-stop condition,

2. Transformer (415 volt to 110 volt),

3. Contactors for spindle motor and coolant pump,

4. Overloads and fuses for protection.

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Figure 13 –SMX3500, 4000 and 5000 Power Module

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Parts List - SMX3500, 4000 and 5000 - Power Module (Figure 13)

Item

P/N

Title

Qty

1

24397

SHEETMETAL-SMX EURO 3500 POWER MODULE

1 2 25107-EURO

AC DRIVE- 7.5 HP V1000 -400V

1

4

22571-12

RAIL-DIN

1

5

23036

FUSE HOLDER-32 AMP-690V

7 6 22283-3/4-2-15

WIREWAY- TYPE G LIGHT GRAY

2 7 22392-3/4-15

COVER- WIREWAY- TYPE G

2 8 22891

RELAY-DUAL CHANNEL

1 9 22892-1

CONTACTOR - RELAY - 3 PHASE

1

10

22892-3

CONTACTOR - RELAY - 3 PHASE

1

11

22557

TERMINAL BLOCK-IEC-800V

10

13

23152-25

FUSE- 25A gG, 500V, 10x38 (F1, F2 and F3)

3

14

21258-3

TRANSFORMER-1.6kVA

1

15

23821

OVERLOAD-RELAY-12-18A

1

17

M5-0.8X10 10Z

SCREW-PH-PHIL-STL-ZINC

25

18

M6-1.0X12 10B

SCREW-PH-PHIL-STL-BO

8

19

22283-1-3-15

WIREWAY- TYPE G LIGHT GRAY

1

20

22392-1-15

COVER- WIREWAY- TYPE G

1

21

23152-2

FUSE- 2A, gG, 500V, 10x38 (F7))

1

22

24394

FILTER-EMC/FRI

1

23

23152-6

FUSE- 6A gG, 500V, 10x38 (F4 and F5)-

2

24

23152-16

FUSE- 16A gG, 500V, 10x38 (F6)

1

25

21953-10

TERMINAL- RING TONGUE

4

26

21953-14

TERMINAL- RING TONGUE

1

28

22406-BK-10G

WIRE- UL 83 THHN

7845

29

22406-BK-16G

WIRE- UL 83 THHN

9685

30

22406-GR-10G

WIRE- UL 83 THHN

1280

31

22406-GR-16G

WIRE- UL 83 THHN

790

32

24429-1

CABLE ASSY-350 SMX POWER CABLE

1

33

22684-5

CABLE ASSY - DOOR GUARD LOGIC

1

34

21455-2

CABLE ASSY-SX AUX SAFETY I/O

1

i24396

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Figure 14 - SMX3500, 4000 and 5000 Power Module Wiring

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TERMINATION

ASSEMBLY CONNECTION

FUNCTION

TB1

COOLANT ENABLE - OUT/24VAC

COOLANT PORT (CABLE BREAK OUT BOX)

TB2

COOLANT ENABLE - IN/24VAC

TB3

110 VAC - HI

POWER DRAWBAR / SPINDLE BRAKE

TB4

110VAC - NEUTRAL

TB5

110 VAC - HI

SPINDLE CONTROL MODULE TB6

110VAC - NEUTRAL

TB7

DOOR GUARD - OUT/24VAC

DOOR GUARD (24 VAC) TB8

DOOR GUARD - IN/24VAC

TB9

DOOR GUARD - LOGIC/AUXIN9

DOOR GUARD (LOGIC) TB10

DOOR GUARD - LOGIC/GND

i01351a

E-stop Safety Relay Wiring:

ALT WIRE COLOR

WIRE COLOR

EURO CONNECTOR

PIN NO.

SIGNAL

SAFETY RELAY

TERMINAL

BLACK

PINK

1

E STOP-SW1A

24

WHITE

RED

2

E STOP-SW2A

S13

RED

ORANGE

3

E STOP-SW3A

S23

WHITE/BLACK

BLUE

7

RESET-BT-A

X1

GREEN/BLACK

WHITE

9

E STOP-SW1B

23

ORANGE/BLACK

BLACK

10

E STOP-SW2B

S14

BLUE/BLACK

GREEN

11

E STOP-SW3B

S24

GREEN/WHITE

YELLOW

14

RESET-BT-B

X2

DRAIN WIRE

SHIELD

i01351b

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Figure 15a - SMX3500, 4000 and 5000 Electrical Schematic

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Figure 15b – SMX 2500 Electrical Schematic

4.8 Service Codes

Service codes are broken down into the 4 categories: software, machine setup, diagnostics and user options/defaults.

All Service Codes are accessed in the SET-UP Mode by pressing the soft key for “SERV CODES”. The service codes can be found via one of the headings listed on the main screen. Press the heading you

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want to access the code in question. If you know the code # you want, press the CODE # softkey, enter the number you want and press SET.

4.8.1 Software Codes

The following codes pertain to software functions in the control. To get to any of these codes go to Service Codes, press “A” and press the code you wish to view.

Note: If you are working with Customer Service, write the values down for Code 33 or Code 313. These values will be valuable for troubleshooting.

4.8.1.1 CODE 33: Software ID

The Code 33 is the software identification procedure. The two types of software in the control include:

 Software Version - the version of the system you have installed  Firmware Version - the version of firmware software that is responsible for control to servo

interface.

 Converter Version – the version of software that is responsible for converters and options.  Operating System Version – shows the version of the XP operating system.

4.8.1.2 CODE 141: Load Configuration File from USB (Floppy) drive

This code allows you to load your configuration file from the USB/floppy disk to your hard drive. The configuration file consists of items such as calibration and backlash constants. This code is used when a computer module or hard drive has been replaced.

4.8.1.3 CODE 142: Save Configuration File to USB (Floppy) drive

This code allows you to save your configuration file to a USB/floppy disk. The configuration file consists of items such as calibration and backlash constants. This code is used when a computer module or hard drive needs to be replaced. This stores the configuration file from the hard drive to the floppy disk. It is a good idea to do this code after the machine is initially setup so these values can be saved and used in the future. If the computer or hard drive fails, then you will not have the ability to save the configuration file and the machine will need to be re-setup when the computer or hard drive is replaced.

Note: All machines will have a copy of the configuration file in the back of the electric’s cabinet.

4.8.1.4 CODE 313: Display Configuration File

This code displays the configuration file. This file contains pertinent information about the machine. The file will look similar to the following. If the file becomes corrupt you can load default values by pressing the F4 softkey.

Product = SMX 3500 (displays machine ID key of machine) Motor encoder calibration constants X=1143.9002 Y=1143.8982 Z=1143.7922 Secondary feedback calibration constants X=3302.6122 Y=3302.6045 Z=3302.7122

(These numbers above are typical numbers for the calibration constants, the numbers for secondary feedback are default numbers, which means no calibration has been done, or the machine does not have secondary feedback)

Arc accuracy – 0.025 mm Secondary feedback – 0, 1, 2 or 3 (0 = off, 1 = X on only, 2 = Y on only, 3 = XY both on) Code 11 values X = 0.002 Y = 0.001” Code 128 X=0.025 Y=0.027 Z=0.012 Code 12 (+) X=000005 Y=000006 Z=000006

(-) X=000005 Y=000005 Z=000006

Code 100 (+) X=4560 Y=4580 Z=4520

(-) X=4480 Y=4470 Z=4530

4.8.1.5 CODE 316: Update Master Software

Load upgrade disk in floppy drive and press this service code. New software will automatically download and control will reboot.

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4.8.1.6 CODE 317: Update Slave Software

Load upgrade disk in floppy drive and press this service code. New software will automatically download and control will reboot.

4.8.1.7 CODE 318: Activate Converters or Options

See programming and operating manual. To turn software features on and off, see Service Code 334 in Section 4.8.4.6 of this service manual.

4.8.2 Machine Set-Up Codes

The following codes are used primarily when setting up a new machine. To get to any of these codes go to Service Codes, press “B” and press the code you wish to view.

4.8.2.1 CODE 11: Hysteresis

Note: This code is use only for systems with Scales on the table and saddle.

The Code 11 service routine checks the readings of the motor encoder against the Newall encoder. It is a measurement of how much motor motion is necessary to create table or saddle motion. This test helps us to look at two things:

 Play: How much backlash must be taken up when motion is reversed.  Friction: How much the mechanical components must be "torqued up" in order to break the

friction and create motion.

The Code 11 procedure is very useful and will help in diagnosing all types of motion and performance problems.

1. Position the table and saddle in the centre of travel. Note: You will lose your DRO position

reference.

2. Go into the Service Codes and input Code 11.

3. The system will run the checking routine automatically and then display the values in the

position readout.

Explanation:

As an overall measure of the system hysteresis, we are looking for the X and Y values to be less than

0.10 mm. A value greater than this indicates a problem with either excessive friction or play that may

affect the finish or accuracy of machined parts.

4.8.2.2 CODE 12: Feed Forward Constant

The Code 12 procedure helps the control “learn” the friction characteristics of the machine by sending

a graduated series of motor signals and observing the results. The process takes less than 30 seconds to run. It is both a diagnostic routine that displays values, and a routine that sets the parameters of the control for the particular machine.

The Code 12 is used for diagnosing and resolving:

 Problems with machine motion.  Machined parts come out bad – especially poor finish.

Note: Code 12 routine will set the parameters for the particular machine and its particular situation. If the machine changes its friction characteristic, the Feed Forward Constant should change too, or the system will not servo properly. Whenever gibs are adjusted or a heavy workpiece has been added to the table, you should run a Code 12. When the heavy workpiece is removed, Code 12 should be run again.

1. Position the table and saddle in the centre of travel.

Note: You will lose your DRO position

reference.

2. Go into the Service Codes and input the Code 12.

3. Press Auto

4. The system will run the routine automatically and then display values on the position readout.

Explanation

Typical values between 4.04 and 11.11 are considered normal for each axis. Higher values indicate excessive friction in the system. Lower values indicate a loose system and may mean a gib

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adjustment is necessary. Value 4.04 means the friction is a factor of 4 in one direction, and 4 in the other direction. The values should be within 3 or 4 of each other in both directions. A value of 6.08 would still be considered normal.

The feed forward gain can be adjusted manually by pressing the manual button. Choose the axis you would like to change and then enter values in the positive and negative direction to adjust. Adjusting the gain can help solve circularity problems. Default values can be set by pressing the Reset button. The manual feature should only be used in extreme cases where the AUTO routine did not solve the problem. Manual adjusts above 12 may lead to servo related problems.

4.8.2.3 CODE 100: Axis Open Loop Test

Code 100 procedure is used to diagnose problems with the configuration of the system, the encoders and incoming A/C voltage.

IMPORTANT -- SAFETY NOTICE

During this procedure the designated axis will be given a command to move at maximum

speed for 1 second in the direction you choose. Avoid crashes by making sure the quill is out

of the way and by starting with the table and saddle centred. MAKE SURE THAT NO ONE IS

STANDING IN THE WAY OF THE TABLE OR SADDLE!

Note: You will lose the DRO reference position.

This procedure is to be run for each axis that is servo-driven, and for both the plus and minus direction for each axis.

1. Centre the table and saddle and raise the head.

2. On the Pendant display, go into the Service Codes and input the Code 100.

3. The conversation line will say: “SELECT AXIS”. Input the axis. Either X, Y or Z.

4. In the conversation line it will say “WHICH DIRECTION? PLUS”.

 If you want to run in the plus direction, press INC SET.  If you want to run in the minus direction, press +/-, then INC SET

5. In the conversation line it will say “PRESS GO”. Press Go after you are sure that the machine

will not crash in the direction and axis that you have specified.

6. Afterward the screen will display values next to the DRO position axes. The table below

assumes machine has secondary feedback scales. Machines with motor encoders only will display the reading next to the axis in question.

Your input

Display

Data displayed.

X +

X

Table encoder reading

Y

nothing (should be 0)

Z

Motor encoder reading

Feedrate

the maximum feedrate attained

X -

X

Table encoder reading

Y

nothing (should be 0)

Z

Motor encoder reading

Feedrate

the maximum feedrate attained

Y +

X

nothing (should be 0)

Y

Table encoder reading

Z

Motor encoder reading

Feedrate

the maximum feedrate attained

Y -

X

nothing (should be 0)

Y

Table encoder reading

Z

Motor encoder reading

Feedrate

the maximum feedrate attained

Z + X

nothing (should be 0)

Y

nothing (should be 0)

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Z

Motor encoder reading

Feedrate

the maximum feedrate attained

Z -

X

nothing (should be 0)

Y

nothing (should be 0)

Z

Motor encoder reading

Feedrate

the maximum feedrate attained

Interpretation of the resulting values displayed:

 The values for the encoder displays should be in the range of 75 mm to 125 mm.  If the motor encoder and scale reading is not within this value, then the one that is out of

specification may be the problem. If one of the encoders is not reading then it will need to be replaced.

 The feedrate should be a minimum of 4560 mmpm for mechanical hand wheel machines and

7620 mmpm for electronic hand wheel machines. The SMX2500 will run a maximum of 4560 mmpm.

 If the feedrate is less than these values or inconsistent in both directions, check the incoming

AC voltage and mechanics of the drive train.

4.8.2.4 CODE 123: Calibration

See Section 5.2.2.1 for a further explanation of this code.

4.8.2.5 CODE 127: Set X or Y Backlash Constant

See Section 5.22 for a further explanation of this code.

4.8.2.6 CODE 128: Input Backlash Constant

Code 128 allows you to enter the backlash values for each axis. It displays the value after it enters. This code is only used on machines with motor encoders only.

4.8.2.7 Code 304: Toggle X Secondary Feedback Scale On/Off

This service code toggles the X secondary feedback scale on or off. It is used to configure the machine and also is a useful tool for troubleshooting. Code 313 (configuration file) displays whether the sensors have been turned on or off. The line labelled secondary feedback explains which scales are turned on. This line can read any one of the following:

0 = Scale turned off

1 = X scale turned on only

2 = Y scale turned on only

3 = both X and Y scale turned on.

4.8.2.8 Code 305: Toggle Y Secondary Feedback Scale On/Off

This service code toggles the Y scale on or off. See Code 304 (section 5.2.4) for further explanation.

4.8.2.9 Code 312: Toggles Limit Switch On/Off

This code turns the limit switches on and off. It is strongly recommended to leave limit switches on.

4.8.2.10 Code 321: Reverse Y Position Secondary Feedback Direction

This service code reverses the direction of the encoder. It may be needed if scales are mounted on different sides of the machine.

4.8.2.11 Code 322: Reverse X Position Secondary Feedback Direction

This service code reverses the direction of the encoder. It may be needed if scales are mounted on different sides of the machine.

4.8.2.12 Code 325: Reverse Quill Secondary Feedback Direction

This service code reverses the direction of the encoder.

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4.8.2.13 Code 337: Spindle calibration

This service code is used to calibrate the programmable spindle. You will need a tachometer to complete the calibration.

4.8.3 Diagnostic Codes

The following codes are used primarily when diagnosing a problem with the machine. To get to any of these codes go to Service Codes, press “C” and press the code you wish to view.

4.8.3.1 Code 54: Program Continuous Run

This Code runs a programme continuously without stopping for SET Z or CHECK Z commands. It is helpful in running a programme for a long period to identify an intermittent problem.

1. Prepare a programme as you normally would.

2. Press MODE, SET UP, “C”, Code 54, INC SET. The program run will start automatically.

3. Press STOP to pause, and GO to continue.

4.8.3.2 Code 81: Keyboard Test

This code is used to check if the keyboard is functioning correctly. It allows you to test each key on the pendant individually. When you press the keys, the corresponding box for that key will highlight on the screen. The pendant will also beep, indicating that the key is working correctly. If one or more of the keys do not work, the pendant assembly will have to be replaced.

4.8.3.3 Code 131: Manual DRO

This code is used to check the motor encoder and table encoders. Turn the X hand wheel or, if EHW are fitted, turn the motor or ballscrew directly to display the encoder readings. E-stop the mill before touching the motors/ballscrews. This code will display the actual DRO counts and the raw encoder counts before the calibration and backlash factors have been applied.

4.8.3.4 Code 132: Electronic Handwheel Test

This service code tests the accuracy of the handwheel in fine and course modes.

Turn the X, Y, or Z-axis electronic hand wheel. The display should show movement as the hand wheel is being turned. There should be no skipping and it should count smoothly while the hand wheel is being turned. One revolution of the hand wheel should read 5mm (0.2”) in fine mode and 20mm (0.8“) in course mode.

4.8.3.5 Code 314: Toggle Test Lights ‘On’ in Status Line

This code toggles on and off 2 test lights that appear in status line on the pendant display. The top light signifies if the master software is working. If functioning it should flash a green light. The bottom light signifies if the slave firmware is functioning. It will appear orange in run mode when it is processing information. Pressing the mode key will change this orange box to black. The orange box will also change to black when the program you are running reaches the 3rd event from the end of the program. If the firmware is locked up no keys will work. This code is useful for diagnosing intermittent problems with the control locking up.

4.8.3.6 Code 319: Error Log

This code when turned on captures the commands that were sent to the servo system. It includes items such as positioning commands, errors, stop and go commands, etc. It may be helpful for identifying problems between programmed commands and executed commands. To turn on the error log press the F6 softkey. The page forward and backward keys allow you to scroll through the file one page at a time. The data forward and data backward keys allow you to scroll through the file one line at a time. The data bottom key takes you to the bottom of the file and then changes to data top which will take you back to the top. The file will capture data until the file reaches a size of approximately 600 Kb. At this time the file is saved to a backup file and the original file is cleared and data is once again captured. Once again as the file reaches a size of 600 Kb it copies over the previous backup file.

The user can save the file to the floppy drive by pressing the F8 softkey. Once this is done, it prompts you for which file you want to save to disk. The F1 key saves the current file and the F2 key saves the backup file. To clear the files press the F7 softkey.

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4.8.3.7 Code 324: Toggle Simulation Mode

Simulation Mode allows the control to run a program without actually moving the table. It is helpful in diagnosing Computer/display problems.

4.8.4 Operator Defaults/Options Codes

The following codes allow the user to set programming defaults or turn features on or off. To get to any of these codes go to Service Codes, press “D” and press the code you wish to view.

4.8.4.1 Code 66: Default Metric

This code causes the control to turn on in the metric mode.

4.8.4.2 Code 67: Default English

This code causes the control to turn on in the English mode.

4.8.4.3 Code 79: Beeper On

This turns on the beeper to the control keys.

4.8.4.4 Code 80: Beeper Off

This turns off the beeper to the control keys.

4.8.4.5 Code 129: Arc Accuracy

When the SMX control operates at high feedrates it may create small part machining errors as it goes

around sharp corners. This exists on all CNC’s and is commonly called a “following error.” The control is factory preset to allow a maximum following error of 0.025 mm (.001”). The feedrate will

automatically be adjusted around sharp corners so as to not violate this limit. This code only applies to arcs that are programmed and ones that are created in the tool path to generate the shape you want. This code will not make a difference on mill moves.

You may adjust the maximum following error to a value as small as .005 mm. However, the smaller the value, the slower the feedrate around corners.

To input a new Following Error: follow the instructions on the screen and input the Following Error value (from 0.005 to 0.25 mm) and press INC SET.

4.8.4.6 Code 334: Set Control Options

This code turns software features on and off.

4.8.4.7 Code 335: Toggles spindle on/off during pause events

This code toggles between leaving the spindle on or, turning it off, during PAUSE events in the programme.

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5.0 Procedures for Replacements & Maintenance

WARNING!

Risk of death or serious injury by electrocution or crushing

Before undertaking any repair or maintenance work, turn off and lock out power to the

machine at the machine supply or isolator on the electrical cabinet.

Work should only be conducted by trained and experienced machine tool engineers who fully

understand the hazards of working with machine tools.

5.1 Replacements

5.1.1 Servo Motor Replacement

1. Isolate and lock out power to the machine.

2. Each motor is mounted by the use of (4) ¼-20 screws. Be careful not to over- tighten these bolts

and strip the threads.

5.1.2 Servo Driver Replacement

The Servo Driver for each axis is integrated into the servo motor casting.

 Part Number: 24101-7

1. Isolate and lock out power to the machine.

2. Remove the servo motor/driver assembly from its mounting bracket (the Y axis assembly is

located inside the front of the bed).

3. Remove the 10 cap screws that hold the servo driver and its heat sink plate to the motor casting.

4. Disconnect the cable connector. Do not pull on the wires.

5. Reinstall the new servo driver with its heat sink plate. Be certain the gasket properly seals the

assembly.

6. Reinstall the motor/driver assembly. Make certain the belt is tight so that there is little play if

pinched in the middle.

Figure 16 - Servo Driver Replacement

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5.1.3 Pendant Replacement

1. If possible save the machine configuration using service code 142. Shutdown the pendant.

2. Isolate and lock out power to the machine.

3. Unplug all the connectors on the pendant arm side of the pendant. Make sure the cable idents

are legible, if not label cables as they are removed.

4. Remove the switch box front panel to gain access to the pendant mounting screws. Remove the

(4) ¼-20 x ¾” SCHS that secure the pendant in place.

5. Remove the machine ID key and options key and install into the replacement pendant.

6. Fit the replacement pendant by reversing the previous operations.

7. The original pendant must be returned to XYZ for repair or exchange.

8. When fitting the replacement pendant: ENSURE CABLES ARE INSERTED INTO THE

CORRECT CONNECTOR. Incorrect connections may damage the pendant (not covered by warranty).

NOTE!

It is wise to back up your flash disk from time to time via a network or USB disk. If your

pendant needs to be replaced you will lose all of your programs (see programming manual).

5.1.4 Cable Routing on Machine

Whenever you replace a cable or reroute a cable it is very important to keep the power cables and logic cables separated from each other. The power cables consist of the (3) 110-volt motor cables and (2) 110-volt power cables for the pendant. The logic cables are used to carry encoder signals between the cable breakout box and computer module. Mixing of the power and logic cables may cause noise from the power cables to interrupt the signals in the logic cables. This can lead to intermittent axis faults or repeatability problems. See Figures 9 and 11 for a layout of the cable connections.

5.1.5 Power Drawbar

A power drawbar is a standard item on the SMX 2500, 3500, 4000 & 5000 machines. It is bolted to the top of the head by the use of 3 SHCS. Some machines may require a washer to space the unit up to the proper height to allow the drawbar to engage properly.

The power drawbar is supplied with air from a regulator/lubricator set. The pressure regulator should be set at around 65-70psi. Increasing the pressure may shear the drawbar.

Make sure the lubricator is kept filled with oil. Fill the reservoir about 2/3 full using AIR TOOL OIL ONLY. Failure to do this will not allow oil to lubricate the internal components of the unit and it may wear out prematurely. It is also important to make sure the lubricator dispensing rate is set properly. There is a sight glass to the top of the regulator. Whilst using the Drawbar, count the seconds per drop. The unit needs to be set to one drop every three seconds. This can be adjusted using the adjusting screw on the lubricator.

5.1.6 Ball Screw Replacement, X-Axis (Table) – 2500 & 3500

CAUTION!

Never screw a ball screw partially or totally out of its nut. They cannot be reassembled.

1. Position the table in the centre of travel.

2. Remove the left side table tray by pulling it up, and remove the X motor.

3. Remove the motor mounting bracket and bearing housing.

4. Remove the right side bearing housing.

5. Loosen the table gibs. Slide the table to the right and on to a lift that will support the table's

weight. Slide the table until the yoke is exposed.

CAUTION!

The weight of the table must be supported by the left to prevent damage or breakage to the

dovetails.

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6. Remove the (2) 5/16 x 1" screws holding the ball nut to the yoke and loosen the 4 screws that

mount the yoke to the saddle. Remove the oil line.

7. Tilt the yoke (it is pinned) to remove the ball screw.

8. Remove the elbow and setscrew from the old ball screw flange and fit them similarly in the new

ball screw.

9. Pump oil to be certain it flows through the oil line and then attach the oil line to the elbow.

10. Reassemble all assemblies.

Important: The clamp nut must be reassembled as follows:

 Install rear bearing and seal into bearing housing and slide housing onto the ball screw.

(Note:

Letters on bearings must face each other in the housing.)

 Thread the split nut onto the ball screw and tighten the #10-32 clamp screw until you feel the

split nut contact the ball screw threads. It should drag as you tighten the clamp nut.

 Torque the split nut to 50 ft. lb.  Firmly tighten the #10-32 clamp screw to lock the clamp nut in place.

See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw.

See Figures 17 and 18 for an illustration of the X-axis drive train.

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Figure 17 - SMX2500 - X-Axis Drive Assembly

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Parts List - SMX2500 - X-Axis Drive Assembly (Figure 17)

Item

P/N

Title

Qty

1

15621

DRIVE HOUSING

1

4

15624

FRONT COVER

1 5 15622

BACK COVER

1 6 15616

HANDWHEEL ASSY-MX

1 8 15612

HOUSING - BEARING

1

9

15885

RING-BEARING HOUSING

1

10

15638

STOP - X-AXIS (not shown on drawing)

1

11

15626

SEAL-BEARING HOUSING

1

12

16983-1

PULLEY-SOLID 44 TEETH W/O GUIDES

1

13

16452

NUT CLAMP-X ,Y, & Z AXIS

1

14

16350

FERRULE-SPROCKET

1

15

98481A090

KEY WOODRUFF #404-1/8 X 1/2

1

16

14772

SPACER - .100" THICK

5

19

425-5M-15

BELT - TIMING 5MM POWERGRIP

1

20

23930

BEARING-ANGULAR CONTACT- 7204 BECBP

SET

22

14772-2

SPACER - .020" THICK

2

23

14772-5

SPACER - .050" THICK

2

41

8-32X3/8 25B

SCREW-SHCS-STL-BO

6

42

5/16-18X1 25B

SCREW-SHCS-STL-BO

1

43

3/8-16X2 1/2 25B

SCREW-SHCS-STL-BO

4

44

M8-1.25X65 25B

SCREW-SHCS-STL-BO

4

45

M10-1.5X65 25B

SCREW-SHCS-STL-BO

4

46

1/4-20X1 24B

SCREW-HEX HD-STL-BO

7

47

8-32X3/8 20B

SCREW-RH-PHIL-STL-BO

3

48

10-32X3/4 25B

SCREW-SHCS-STL-BO

1

49

1/2-20 51Z

NUT-HEX JAM-STL-ZINC

2

51

M8 70P

WASHER-FLAT USS-STL-PLAIN

4

52

15759

WASHER-1/4 HARD BLK OX 1/8 THK

7

53

3/8 70P

WASHER-FLAT USS-STL-PLAIN

4

54

M10 70P

WASHER-FLAT USS-STL-PLAIN

4

55

1/2 73B

WASHER-SPLIT LOCK-STL-BO

1

56

1/2 70P

WASHER-FLAT USS-STL-PLAIN

1

57

22008

BEARING- 204KTT

1

i00911

Parts List - SMX2500 - X-Axis Electronic Handwheel Option (Figure 17)

Item

P/N

Description

Use As

Qty

57

22718

SPACER - 45 DEGREES X-AXIS

EA 1 58

21992

BUSHING-BALL SCREW

EA

1

59

14772

SPACER - .100” THICK

EA

1

60

M6-1.0X75 25B

SCREW – SHCS-STL-BO

EA 4 61

21946

ELECTRONIC HANDWHEEL

EA

1

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Figure 18-SMX 3500 - X Axis Drive Assembly

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Parts List – SMX 3500 - X-Axis Drive Assembly (figure 18)

No.

Part Number

Description

QTY

1

H-026-A

ADJUSTING SCREW

3 2 H-026-3

SCREW

2 3 H-028-3

GIB 1 4

H-031-3

GIB

4

5

H-032-3A

ALUMINUM PLATE

1

6

H-034-3

SADDLE

1 7 H-042-3

CHIP GUARD COVER PLATES(SMALL)

1 8 H-043-3

CHIP GUARD COVER PLATES(LARGE)

1 9 H-044-3

CHIP GUARD COVER PLATES(MIDDLE)

1

10

H-067-10A

MACHINE BASE

1

11

H-106-3

GIB SEAT

1

12

H-107-3

GIB SEAT

1

13

H-108-3

GIB 2 14

H-122-6

STOP BLOCK

2

15

H-124-7

MICRO SWITCH

1

16

H-124-7A

MICRO SWITCH COVER

1

17

H-134-3

PROTECTED COVER

1

18

HT-011-10A

RIGHT BEARING BRACKET

1

19

HT-012-2A

BEARING BRACKET

1

20

HT-012-2B

BEARING BRACKET

1

21

HT-015-3B

LONGITUDINAL FEED SCREW

1

22

HT-022-3

CROSS SCREW BRACKET

1

23

HT-029-10

TABLE

1

24

HT-032

RUBBER PLUNGER

8

25

HT-090-10

COVER

1

26

HT-149

BEARING BLOCK

1

27

HT-152

NUT 1 28

HT-162-10

BUSHING

1

29

HT-166

BUSHING

1

30

HT-181

OIL SEAL

1

31

24428-1

MOTOR

1

32

425-5M-15

BELT 1 33

16983-1

BELT PULLEY

1

35

AB6204ZZ

BEARING:6204ZZ

3

36

98481A090

KEY

1

37

AKP205030

PIN:φ5×30

2

38

ANI12012

NUT:1/2”-20NF

2

39

ASI631638

SCREW:3/16”-24NC-3/8”L

2

40

ASI231612

SCREW:3/16”-24NC-1/2”L

10

41

ASI61412

SCREW:1/4”-20NC-1/2”L

3

42

ASI61478

SCREW:1/4”-20NC-7/8”L

2

43

ASI6141

SCREW:1/4”-20NC-1”L

4

44

ASI6516134

SCREW:5/16”-18NC-1 3/4”L

2

45

ASI6381

SCREW:3/8”-16NC-1”L

12

46

ASI612112

SCREW:1/2”-12NC-1 1/2”L

8

47

ASI6121

SCREW:1/2”-12NC-1”L

2

48

15977

TRAY PAD

1

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5.1.7 Ball Screw Replacement, Y-Axis (Saddle) – 2500 & 3500

CAUTION!

Never screw a ball screw partially or totally out of its nut. They cannot be reassembled.

1. Position the saddle all the way forward.

2. Remove the hand wheel assembly and bracket.

3. Remove the sheet metal covers on the front of the machine bed and on the motor mounting

bracket.

4. Remove the motor, then remove the motor mounting bracket.

5. Remove the rest of the parts on the ball screw journal. Note the orientation of the bearings for

reassembly.

6. Remove the (2) 5/16 x 1 inch screws that attach the ball nut to the yoke.

7. Remove the ball screw and oil line attached to the elbow fitting on the ball nut.

8. Remove the elbow and setscrew from the old ball screw flange and fit them similarly in the new

ball screw.

9. Pump oil to be certain it flows through the oil line, and then attach the oil line to the elbow.

10. Reassemble all assemblies.

Important: The clamp nut must be reassembled as follows:

 Install rear bearing and seal into bearing housing and slide housing onto the ball screw.

(Note:

Letters on bearings must face each other in the housing.)

 Thread the split nut onto the ball screw and tighten the #10-32 clamp screw until you feel the

split nut contact the ball screw threads. It should drag as you tighten the clamp nut.

 Torque the split nut to 50 ft. lb.  Firmly tighten the #10-32 clamp screw to lock the clamp nut in place.

See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw.

See Figures 19 and 20 for an illustration of the Y-axis drive train.

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Figure 19 - SMX2500 - Y Axis Drive Assembly

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Parts List - SMX2500 - Y-Axis Drive Assembly (Figure 19)

ITEM

P/N

DESCRIPTION

QTY

1

15966-3

BRACKET-Y AXIS MOTOR MOUNT

1 2 M10-1.5X60 25B

SCREW-SHCS-STL-BO

4

3

15968-2

LOWER COVER

1

4

15967-2

UPPER COVER

1 5 6-32X3/8 31Z

SCREW-PH-PHIL-EXT SEMS-STL-ZINC

8 7 1/2 70P

WASHER-FLAT USS-STL-PLAIN

1 8 30922

HANDLE FOLD-A-WAY

1 9 15616

HANDWHEEL ASSY-MX

1

10

1/2 75Z

WASHER-EXT TOOTH-STL-ZINC

1

11

1/2-20 51Z

NUT-HEX JAM-STL-ZINC

1

12

15614

TAB WASHER

1

13

14772

SPACER - .100" THICK

1

14

15980

BEARING HOUSING

1

15

20373

BEARING-ANGULAR CONTACT- 7204 BECBP

2

16

15885

RING-BEARING HOUSING

1

17

15626

SEAL-BEARING HOUSING

1

18

16350

FERRULE-SPROCKET

1

19

16983-1

PULLEY-SOLID 44 TEETH W/O GUIDES

1

20

16452

NUT CLAMP-X ,Y, & Z AXIS

1

21

565-5M-15

TIMING BELT

1

22

15627-1

DIAL HOLDER

1

27

10-32X3/4 25B

SCREW-SHCS-STL-BO

1

28

1/4-20X1 24B

SCREW-HEX HD-STL-BO

4

29

15759

WASHER-1/4 HARD BLK OX 1/8 THK

4

30

98481A090

KEY WOODRUFF #404-1/8 X 1/2

1

31

15836

DIAL NUT

1

32

M5-0.8X10 10Z

SCREW-PH-PHIL-STL-ZINC

2

33

21946

ELECTRONIC HANDWHEEL-X & Y AXIS

1

34

M6-1.0X75 25B

SCREW-SHCS-STL-BO

4

35

M6-1.0X25 25B

SCREW-PH-PHIL-STL-ZINC

4

36

21985

SPACER - 30 DEGREE Y-AXIS DRIVE ASSY

1

37

21992-1

BUSHING-BALLSCREW

1

38

1/4-20X5/8 26B

SCREW-FHCS-STL-BO

4

39

14772-2

SPACER-.020" THICK

1

40

21984

WAY COVER FRONT Y-AXIS DRIVE

1

41

25729

HANDLE REPLACEMENT KIT

1 15609-16

BALLSCREW - Y AXIS

1

i01132-Y-SX2

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Figure 20a – SMX 3500 - Y Axis Drive Assembly

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Figure 20b – SMX 3500 - Y Axis Drive Assembly - Front and Side View

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Parts List – SMX 3500 - Y Axis Drive Assembly (Figure 20a & b)

ITEM

P/N

DESCRIPTION

QTY

1

H-026

SCREW

1 2 H-026-A

ADJUSTING SCREW

3

H-026-B

SCREW

3

4

H-032-3A

ALUMINUM PLATE

1 5 H-034-3

SADDLE

1 6 H-067-10A

MACHINE BASE

1

7

H-075

FIXED HOLDER OF COOLANT NOZZLE

1 8 H-102-8

SCREW

6

9

H-103

ADJUSTING BLOCK

6

10

H-106-3

GIB SEAT

1

11

H-107-3

GIB SEAT

1

12

H-108-3

GIB

2

13

H-165-8

CONNECTION PIPE

1

14

H-166-10

COVER

1

15

H-166-10A

COVER

1

16

H-170-8

WASHER

1

17

H-237-8

COVER

1

18

H-237-10

COVER

1

19

H-239-A

OIL NETWORK

2

20

H-254

OIL NETWORK

5

21

H-258

COOLANT PUMP

1

22

H-259

COOLANT NOZZLE

1

23

H-261-10

UP-DOWN CHIP GUARD

1

24

H-263-10

BRACKET OF UP-DOWN CHIP

1

25

H-264-10

AUTO LUBRICATION PUMP

1

26

H-267-10

TEFLON(L)

1

27

H268-10

TEFLON(R)

1

28

H-280-10

FIXED PLATE (L)

1

29

H-281-10

FIXED PLATE (R)

1

30

H-022-3

CROSS SCREW BRACKET

1

31

HT-028-3C

CROSS FEED BEARING BRACKET

1

32

HT-028-10B

CROSS FEED BEARING BRACKET

1

33

HT-029-10

TABLE

1

34

HT-034-10A

EXTENSION

1

35

16983-1

PULLEY-BALL SCREW

1

37

HT-096-3

COVER

1

38

HT-097-3

COVER

1

39

HT-151

BEARING COVER

1

40

HT-152

NUT

1

41

HT-166

BUSHING

1

42

HX-046

STOP BLOCK OF LIMIT SWITCH

2

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ITEM

P/N

DESCRIPTION

QTY

43

HX-054-10D

COVER

1

44

HY-065-8

CROSS DUST GUARD

1

45

HY-066-8

FOOT REST

1

46

HY-066-8A

FOOT REST

1

47

KEY 1 48

KEY 1 49

24428-1

MOTOR

1

50

450-5M-15

BELT 1 51

OIL SEAL

1

52

PIPE: 1/2”

2

53

PIPE: 3/8”

1

54

AB6204

BEARING:6204ZZ

2

55

AKP10628

PIN: dia 6.6×28

2

56

ANI110034

NUT: 3/4”-10NC

6

57

ANI118516

NUT: 5/16”-18NC

6

58

ANI120012

NUT: 1/2”-20NF

1

59

ASI614134

SCREW: ¼“ -20NC – 1 3/4”L

2

60

ASI614158

SCREW: ¼“ -20NC – 1 5/8”L

2

61

ASI61434

SCREW: ¼“ -20NC – 3/4”L

18

62

ASI61458

SCREW: ¼“ -20NC – 5/8”L

18

63

ASI631612

SCREW: 3/16“ -24NC – 1/2”L

4

64

ASI6381

SCREW: 3/8“ -16NC – 1”L

4

65

ASI651612

SCREW: 5/16“ -18NC – 1/2”L

4

66

ASI651634

SCREW: 5/16“ -18NC – 3/4”L

6

67

ASI678312

SCREW: 7/8“ - 9NC – 3 1/2”L

6

68

ASM60510

SCREW: M5 X 0.8 X 10L

13

69

AWIH0112

WASHER: ½“

1

70

AWIH01516

WASHER: 5/16“

6

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5.1.8 Ball Screw Replacement, X-Axis (Table) – 4000, 5000

1. Remove table way covers from each side of the table.

2. Remove the left bearing housing cover by removing the (8) 10-24 truss head screws that secure it

to the left-bearing bracket.

3. Remove the motor cover/housing by removing the (4) 10-24 truss head screw secures it to the

left bearing housing.

4. Remove the X-axis motor and belt from the left side of the table.

5. Using a #8 Allen hex key at the end of the ball screw to hold it, remove the hex nut and lock

washer securing the ball screw pulley.

6. Remove pulley, key, and locking sleeve on the ball screw.

7. Remove the (4) 3/8”-16 SHCS securing the left bearing housing to the saddle.

8. Remove left bearing housing and ball screw bushing.

9. Remove the (3) ¼-20 SHCS securing the right bearing housing cover.

10. Remove the housing cover.

11. Disengage the lock washer tab from the two lock nut.

12. Loosen and remove the (2) lock nut.

13. Remove the (4) 3/8-16 SHCS securing the right bearing housing

14. Remove the right bearing housing and bushing.

15. Slide the table to the right; remove the oil line and the (3) 5/16-18 SHCS that secure the ball nut

to the yoke.

16. Pull the ball screw out.

To reassemble

17. Install the new ball screw into the yoke.

18. Reconnect oil line and fasten ball nut into yoke.

19. Slide table back to the centre and assemble the left side of the X-axis.

20. Slide the left bearing housing bushing onto the ball screw.

21. Slide left bearing housing with bearing onto ball screw.

22. Mount bearing housing to saddle with the (4) 3/8-16 SHCS.

23. Slide locking sleeve onto ball screw with the short side out.

24. Install key and slide pulley onto ball screw.

25. Secure pulley with the lock washer and hex nut. (Note: Use a #8 Allen hex key to hold ball

screw.)

26. Install motor, mounting bracket, motor spacer bracket, woodruff key, ferrule, pulley, star washer

and nut. Before tightening down the motor mounting bracket move the table all the way to the left.

27. Move table to the right and assemble right side bearing housing.

28. Assemble motor to bracket. The servo should be facing toward the rear of the machine.

29. Install belt. Tighten lower 2 bolts followed by the top 2 bolts to properly tension belt.

30. Attach the sheet metal to the motor mounting bracket.

31. Install the table trays.

See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw.

See Figures 21 through 23 for an illustration of the X-axis drive train.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 21 – SMX 4000- X Axis Drive Assembly

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Parts List – SMX 4000– X Axis Drive Assembly (Figure 21)

ITEM

P/N

DESCRIPTION

QTY

1

H-026-A

ADJUSTING SCREW

3 2 H-026-3

SCREW

2

3

H-028-3

GIB

1

4

H-031-8

GIB 4 5

H-032-8

ALUMINUM PLATE

1 6 H-034-8

SADDLE

1 7 H-042-8

CHIP GUARD COVER PLATES(SMALL)

1 8 H-043-8

CHIP GUARD COVER PLATES(LARGE)

1 9 H-044-8

CHIP GUARD COVER PLATES(MIDDLE)

1

10

H-067-12A

MACHINE BASE

1

11

H-106-8

GIB SEAT

1

12

H-107-8

GIB SEAT

1

13

H-108-3

GIB

2

14

H-120-6

COVER

1

15

H-122-6

STOP BLOCK

2

16

H-124-7

MICRO SWITCH

1

17

H-124-7A

MICRO SWITCH COVER

1

18

H-134-8

PROTECTED COVER

2

19

HT-011-8B

RIGHT BEARING BRACKET

1

20

HT-012-8B

RIGHT BEARING BRACKET

1

21

HT-015-8C

LONGITUDINAL FEED SCREW

1

22

HT-022-8

FEED NUT BRACKET

1

23

HT-022-8B

CROSS SCREW BRACKET

1

24

HT-029-8

TABLE

1

25

HT-032

RUBBER PLUNGER

8

26

HT-040-7

BEARING COVER

1

27

HT-041-6

LOCKING SLEEVE

1

28

HT-042-8C

BELT PULLEY

1

29

HT-090-8

COVER

1

30

HT-098-8

COVER

1

31

HT-157-8

HANDWHEEL BRACKET

1

32

HT-166-8

BUSHING

1

33

HT-167

OIL SEAL

1

34

HT-181

OIL SEAL

1

35

HX-002

BUSHING

1

36

24428-1

MOTOR

1

37

615-5M-15

BELT

1

39

AB2562

BEARING:25BS62DH

2

40

AB6305ZZ

BEARING:6305ZZ

1

42

AK0505020

KEY:5x5x20

1

43

AKP205030

PIN:Ø5x30

6

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

ITEM

P/N

DESCRIPTION

QTY

44

ANN115025

LOCKING NUT:M25x1.5

2

45

ANI11858

NUT:5/8”-18NF

1

46

ANI118516

NUT:5/16”-18NC

2

47

ASM206010

SCREW:M6x1.0x15L

4

48

ASI231612

SCREW:3/16”-24NC-1/2”L

24

49

ASI231658

SCREW:3/16”-24NC-5/8”L

4

50

ASI61412

SCREW:1/4”-20NC-1/2”L

5

51

ASI61458

SCREW:1/4”-20NC-5/8”L

3

52

ASI61434

SCREW:1/4”-20NC-3/4”L

3

53

ASI61478

SCREW:1/4”-20NC-7/8”L

4

54

ASI651634

SCREW:5/16”-18NC-3/4”L

8

55

ASI65161

SCREW:5/16”-18NC-1”L

4

56

ASI6516134

SCREW:5/16”-18NC-1 3/4”L

2

57

ASI6381

SCREW:3/8”-16NC-1”L

12

58

ASI638178

SCREW:3/8”-16NC-1 7/8”L

4

59

ASI6121

SCREW:1/2”-12NC-1”L

2

60

ASI612112

SCREW:1/2”-12NC-1 1/2”L

8

61

AWIH01516

WASHER:5/16”-18NC

2

62

AWIH0158

WASHER:5/8”-18NF

1

63

AWMS01025

WASHER:M25x1.5

1

i01332

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 22 – SMX 5000 - X Axis Drive Assembly

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 23 – SMX 5000 - X Axis Drive Assembly, Other Views

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Parts List – SMX 5000 - X Axis Drive Assembly (Figures 22 & 23)

ITEM

P/N

DESCRIPTION

QTY

1

H-005

SCREW

15 2 H-026-A

ADJUSTING SCREW

3 3 H-026-3

SCREW 2 4

H-028-3

GIB

1

5

H-031-8

GIB

4

6

H-029-8A

ALUMINUM PLATE

1 7 H-034-14B

SADDLE

1 8 H-042-8

CHIP GUARD COVER PLATES(SMALL)

1 9 H-043-8

CHIP GUARD COVER PLATES(LARGE)

1

10

H-044-8

CHIP GUARD COVER PLATES(MIDDLE)

1

11

H-062

4

12

H-064

BEARING COVER

1

13

H-065

COVER 2 14

H-067-14J

MACHINE BASE

1

15

H-069

DIAL LOCK NUT

1

16

H-076

BEARING 6204 ZZ

3

17

H-078

CROSS FEED DIAL

1

18

H-079

DIAL HOLDER

1

19

H-103

SCREW

11

20

H-106-8

GIB SEAT

1

21

H-107-8

GIB SEAT

1

22

H-108-3

GIB 2 23

H-122-6

STOP BLOCK

2

24

H-124-7

MICRO SWITCH

1

25

H-124-7A

MICRO SWITCH COVER

1

26

H-417-3

SLEEVE

1

27

H-418

SPRING WASHER

1

28

H-503

PROTECTED CHIP COVER

1

29

H-504

GEAR

1

30

H-505

KEY

1

31

H-506

SET SCREW

5

32

H-507

SLEEVE

1

33

H-508

COVER 1 34

H-509

LOCKING NUT

2

35

H-510

WASHER

1

36

H-511

BEARING 6305Z

2

37

H-512

BEARING 6203ZZ

2

38

H-513

COVER

2

39

H-514

KEY 1 40

H-515

GEAR 1 41

H-516

GEAR 1 42

H-517

KEY

1

43

H-518

LOCKING NUT

2

44

H-519

GEAR

1

45

H-520

KEY 1 46

H-521

KEY 1 47

H-522

KEY

1

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

ITEM

P/N

DESCRIPTION

QTY

48

H-523

SAFETY CLUTCH

1

49

H-524

COMPRESSION SPRING

1

50

H-525

LONGITUDINAL FEED DRIVE SHAFT

1

51

H-526

SCREW

4

52

H-531

HANDLE

1

53

H-533

HANDWHEEL

1

54

HT-011-8A

RIGHT BEARING BRACKET

1

55

HT-012-8B

LEFT BEARING BRACKET

1

56

HT-015-14

LONGITUDINAL FEED SCREW

1

57

HT-022-8

FEED NUT BRACKET

1

58

HT-029-8A

TABLE

1

59

HT-032

RUBBER PLUNGER

8

60

HT-040-7

BEARING COVER

1

61

HT-041-6

LOCKING SLEEVE

1

62

24428-1

MOTOR

1

63

HT-090-8B

COVER

1

64

670-5M-15

BELT 1 65

HT-157-8

HANDWHEEL BRACKET

1

66

HT-181

OIL SEAL

1

67

HX-002

BUSHING

1

68

24428-1

MOTOR

1

69

615-5M-15

BELT

1

70

BELT PULLEY

1

71

AB2562

BEARING:25BS62DH

2

72

KEY 1 73

AK0505020

KEY:5x5x20

1

74

PIN: dia 5x25L

2

75

ANI11858

NUT: 5/8”-18NF

1

76

ANI118516

NUT: 5/16”-18NC

2

77

ASM206010

SCREW: M6x1.0x15L

4

78

ASI231612

SCREW: 3/16”-24NC-1/2”L

24

79

ASI231658

SCREW: 3/16”-24NC-5/8”L

4

80

ASI61412

SCREW: 1/4”-20NC-1/2”L

5

81

ASI61434

SCREW: 1/4”-20NC-3/4”L

3

82

ASI61478

SCREW: 1/4”-20NC-7/8”L

4

83

ASI651634

SCREW: 5/16”-18NC-3/4”L

8

84

ASI65161

SCREW: 5/16”-18NC-1”L

4

85

ASI6516134

SCREW: 5/16”-18NC-1 3/4”L

2

86

ASI6381

SCREW: 3/8”-16NC-1”L

4

87

ASI638178

SCREW: 3/8”-16NC-1 7/8”L

4

88

ASI6121

SCREW: 1/2”-12NC-1”L

2

89

ASI612112

SCREW: 1/2”-12NC-1 1/2”L

8

90

AWIH01516

WASHER: 5/16”-18NC

2

91

AWIH0158

WASHER: 5/8”-18NF

1

92

H-081

NUT

2

i01337

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

5.1.9 Ball Screw Replacement, Y-Axis – 4000 & 5000

1. Move the y-axis to the front of the machine.

2. Remove the electronic handwheel (or mechanical handwheel) and axis motor cover.

3. Remove the front ball screw bearing and housing.

4. Remove the Y-axis motor and belt.

5. Remove the double nut that holds the pulley and slide the ball screw pulley from the ball screw

along with the key.

6. Remove the bearing cover, locking nut, axis bearings and bearing housing (block). When

removing the bearings, take note to how they are mounted.

7. Now go to the bottom of the column and rear of bed and remove the access cover to the rear

bearing on the Y-axis.

8. Remove the nut, bearing and bushing that is found at the end of the ball screw.

9. Now go to the front of the machine and remove the ball nut from the yoke. Slide the ball screw

toward you to remove. Make sure to disconnect the oil line. Reassemble.

10. Install the Y ball screw to the yoke and install the oil line.

11. Install the axis bearings in the housing and into the ball screw in the same manner as you

removed them. Tighten the lock nut & install the bearing cover.

12. Install the ball screw pulley and key. Lock the pulley with the double nut.

13. Install the axis motor and belt.

14. Install the front bearing and housing.

15. Install the motor bracket cover & electronic handwheel or mechanical handwheel.

Note: See the diagnostic section under mechanical drive train for an explanation on how to align the ball screw.

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 24 –- SMX 4000 and 5000- Y Axis Drive Assembly

88

XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 25 –- SMX 4000 and 5000- Y Axis Drive Assembly - Side and Front

89

XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 26 – SMX 4000 and 5000 - Y Axis Handwheel Assembly

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Parts List – SMX 4000 and 5000 - Y-Axis Drive Assembly (Figures 24-26)

ITEM

P/N

DESCRIPTION

QTY

1

H-026-A

SCREW

3

2

H-026-B

SCREW

3

H-031-8

GIB

1

4

H-032-8

ALUMINUM PLATE

4

5

H-034-8B

SADDLE – SMX 4000

1

H-034-14B

SADDLE – SMX 5000

1

6

H-056

NUT 1 7

H-060

BEARING COVER

1

8

H-067-8

MACHINE BODY

1

9

H-067-12A

MACHINE BASE

1

10

H-075

FIXED HOLDER OF COOLANT NOZZLE

1

11

H-102-8

SCREW

6

12

H-103

ADJUSTING BLOCK

6

13

H-106-8

GIB SEAT

1

14

H-107-8

GIB SEAT

1

15

H-108-3

GIB 2 16

H-124-7B

ELECTRIC DEVICE BOX

1

17

H-165-8

CONNECTION PIPE

1

18 H-166-14B

FRONT COVER – SMX 4000

1

H-166-14C

FRONT COVER – SMX 5000

19

H-170-8

WASHER

6

20

H-173-8A

COVER

1

21

H-237-8

COVER

1

22

H-237-9

COVER

1

23

H-239

OIL NETWORK

2

24

H-239-10

OIL NETWORK

2

25

H-254

OIL NETWORK

5

26

H-258

COOLANT PUMP

1

27

H-259

COOLANT NOZZLE

1

28

H-261-8

UP-DOWN CHIP GUARD – SMX 4000

1

H-261-14

UP-DOWN CHIP GUARD - SMX 5000

1

29

H-263-10

BRACKET OF UP-DOWN CHIP GUARD - SMX4000

1

H-263-14

BRACKET OF UP-DOWN CHIP GUARD - SMX5000

1

30

H-264-10

AUTO LUBRICATION PUMP

1

31

H-267-10

TEFLON(L) – SMX 4000

1

H-267-14

TEFLON(L) – SMX 5000

1

32

H-268-10

TEFLON(R) – SMX 4000

1

H-268-14

TEFLON(R) – SMX 5000

1

33

H-279-8

GUARD

1

34

H-280-8

FIXED PLATE(L) – SMX 4000

1

H-280-14

FIXED PLATE(L) – SMX 5000

1

35

H-281-8

FIXED PLATE(R) – SMX 4000

1

H-281-14

FIXED PLATE(R) – SMX 5000

1

36

HT-002-6

HANDWHEEL

1

37

HT-002-6A

CLUTCH

1

38

HT-004

CROSS FEED DIAL

3

39

HT-005-3

DIAL HOLDER

1

40

HT-022-8

FEED NUT BARCKET

1

41

HT-022-8B

FIXED HOLDER OF BALL SCREW (SMX4000 ONLY)

1

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

ITEM

P/N

DESCRIPTION

QTY

42

HT-027-8D

BALL SCREW

1

43

HT-028-7A

CROSS FEED BEARING BRACKET

1

44

HT-028-8B

CROSS FEED BEARING BRACKET

1

45

HT-029-8

TABLE

1

46

HT-041-8

BUSHING

1

47

HT-042-8A

BELT PULLEY

1

48

HT-077-7

BEARING BLOCK

1

49

HT-078-7

BEARING COVER

1

50

HT-096-8A

COVER

1

51

HT-142-8

COVER – SMX 4000

1

HT-142-8A

COVER – SMX 5000

1

52

HX-005

LOCKING NUT

2

53

HX-046

STOP BLOCK OF LIMT SWITCH

2

54

HY-065-8

CROSS DUST GUARD – SMX4000

1

HY-065-14

CROSS DUST GUARD – SMX5000

1

55

HY-066-8

FOOT REST

1

56

HY-066-8A

FOOT REST

1

57

HY-073-8

BEARING BRACKET OF BALL SCREW

1

58

HY-083-9

BUSHING

2

59

HANDLE

1

60

MICRO SWITCH

1

61

24428-1

MOTOR (INCLUDES ITEM 62)

1

62

24427

BELT PULLEY

63

670-5M-15

BELT 1 64

AB6204ZZ

BEARING:6204ZZ

2

65

AB2562

BEARING:MM25BS62DH – SMX4000

2

AB2552

BEARING:MM25BS52DH – SMX5000

2

66

AK0303015

KEY:3x3x15

1

67

AK0505020

KEY:5x5x20

2

68

AK0505022

KEY:5x5x22

1

69

AKP138

PIPE:3/8”

2

70

AKP212

PIPE:1/2”

2

71

ANN115025

NUT:M25x1.5

2

72

ANI118516

NUT:5/16”-18NC

6

73

ASM105010

SCREW:M5x0.8x10L

5

74

ASI231638

SCREW:3/16”-24NC-3/8”L

26

75

ASI61458

SCREW:1/4”-20NC-5/8”L

29

76

ASI61434

SCREW:1/4”-20NC-3/4”L

10

77

ASI614158

SCREW:1/4”-20NC-1 5/8”L

2

78

ASI614134

SCREW:1/4”-20NC-1 3/4”L

2

79

ASI651612

SCREW:5/16”-18NC-1/2”L

4

80

ASI651634

SCREW:5/16”-18NC-3/4”L

14

81

ASI65161

SCREW:5/16”-18NC-1”L

6

82

ASI678312

SCREW:7/8”-9NC-3 1/2”L

6

83

AWIH0114

WASHER:1/4”

1

84

AWIH01516

WASHER:5/16”

18

i01300

92

XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 27 - SMX 2500 - Z-Axis Drive Assembly

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XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Parts List - SMX 2500 - Z-Axis Drive Assembly (Figure 27)

ITEM

P/N

TITLE

USE AS

QTY

1

16806-M

BALLSCREW ASSY- Z-AXIS

EA 1 2

PJ540015

BRACKET LOWER ELEVATING BALL SCREW

EA

1

3

2205E-2RS1TN9

BEARING SELF ALIGNMENT SKF

EA

1

4

16774

COVER - BEARING

EA 1 5

16795

MODIFIED BEVEL GEAR BS1236-2A

EA 1 6

M10-1.5X10 40B

SCREW-SOC SET-STL-BO-CUP

EA 1 7

16770

MODIFICATION OF 3 HP RAM PING JENG PART

EA 1 8

M6 73B

WASHER-SPLIT LOCK-STL-BO

EA 6 9

M6-1.0X25 25B

SCREW-SHCS-STL-BO

EA 6 10

7205-AVH

NILOS RING-7205

EA 1 11

16295-1

HOUSING- BEARING Z-AXIS

EA

1

12

16302

RING-BEARING HOUSING

EA

1

13

20374

BEARING-ANGULAR CONTACT-7205 BECBP

EA

2

14

16773

NUT CLAMP-Z AXIS

EA

1

15

10-32X3/4 25B

SCREW-SHCS-STL-BO

EA 1 16

16350

FERRULE-SPROCKET

EA 1 17

16983

PULLEY-SOLID 44 TEETH Z-AXIS

EA 1 18

N01

LOCKNUT

EA 1 19

W01

LOCKWASHER

EA 1 20

M8 73B

WASHER-SPLIT LOCK-STL-BO

EA 4 21

98481A090

KEY WOODRUFF #404-1/8 X 1/2

EA 1 22

M8-1.25X20 25B

SCREW-SHCS-STL-BO

EA 4 23

710-5M-15

BELT - TIMING

EA 1 24

21944

PLATE BALLSCREW SUPPORT - Z AXIS

EA 1 25

1/4-20X1 1/4 25B

SCREW-SHCS-STL-BO

EA

4

26

15759

WASHER-1/4 HARD BLK OX 1/8 THK

EA

4

27

23197

BRACKET-Z AXIS MOTOR-DPMS

EA 1 28

24421-8

MOTOR

EA 1 31

M10 73B

WASHER-SPLIT LOCK-STL-BO

EA 8 32

17030

LOUVRE- SPACER

EA 1 34

M10-1.5X45 25B

SCREW-SHCS-STL-BO

EA 8 35

M10 71B

WASHER-FLAT SAE-STL-BO

EA

4

i16790-XX

94

XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 28a – SMX 3500 – Z Axis Drive Assembly

95

XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Figure 28b – SMX 3500 – Z Axis Drive Assembly

Figure 28c – SMX 3500 – Z Axis Drive Assembly (Top View)

96

XYZ Machine Tools Ltd

XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual

Parts List - 3500 – Z Axis Drive Assembly (Figures 28a-c)

ITEM

PART NUMBER

DESCRIPTION

QTY

1

H-001

WORM GEAR

1 2 H-005

SCREW

20

3

H-026-A

ADJUSTING SCREW

3

4

H-045-10

KNEE 1 5

H-067-10

MACHINE BODY

1 6 H-077-3

BOLT 1 7

H-089-10

BALL SCREW

1 8 H-103

SCREW

20 9 H-109-8

ELEVATING FIXED PLATE(L)

1

10

H-110-8

ELEVATING FIXED PLATE(R)

1

11

H-111-8

ELEVATING FIXED PLATE FOR GIB

2

12

H-136

SCREW

18

13

H-140-10

FIXED HOLDER OF MOTOR

1

14

H-140-10B

FIXED HOLDER

1

15

16983-1

PULLEY - BALLSCREW

1

16

H-149-10

BALANCE WEIGHT

1

17

H-160-9

BEARING BRACKET

1

18

H-165-8

FIXED HOLDER OF COOLANT NOZZLE

1

19

H-167-10B

TOP COVER

1

20

H-168-10

FIXED HOLDER OF BALANCE WEIGHT

1

21

H-170-8

WASHER

1

22

H-254

OIL NETWORK

1

23

H-294-10

COOLANT NOZZLE

1

24

H-296

SCREW

2

25

H-297

SPRING PIN

1

26

H-331-8

ARM BRACKET

1

27

H-332-10

ARM COVER

1

28

H-418

SPRING WASHER

4

29

H-423-8

SPRING

2

30

H-443-5

MICRO SWITCH

2

31

H-444-5

ELECTRIC DEVICE BOX

1

32

H-445-5

CAP OF ELECTRIC DEVICE BOX

1

33

H-446-7

STOP BLOCK OF MACRO SWITCH

2

34

H-527-7

LOCKING BLOCK

2

35

H-547-7

KEY 1 36

H-583-7

SCREW

6

37

H-620-8

FIXED HOLDER OF MICRO SWITCH

1

38

H-621-8

FIXED HOLDER OF COOLANT NOZZLE

1

39

H-622-8

SCREW

4

40

H-637-8

MOTOR COVER

1

41

H-644-8

BALANCE WEIGHT

1

XYZ Machine Tools SMX 2500, SMX 3500, SMX 5000, SMX 4000 Safety, Installation, Maintenance, Service & Parts List Manual

Specifications and Main Features

Frequently Asked Questions

User Manual