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

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XYZ Machine Tools SMX 2500 Safety, Installation, Maintenance, Service & Parts List Manual Download Page 1

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 Machine Tools Ltd.  
Woodlands Business Park  

Burlescombe, Tiverton, Devon EX16 7LL 
T: 01823 674200 F: 01823 674201  

e-mail: [email protected]  
www.xyzmachinetools.com

 

Summary of Contents for SMX 2500

Page 1: ...ce Service Parts List Manual Document 25093 Version 042016 Covers Models SMX 2500 SMX 3500 SMX 4000 SMX 5000 XYZ Machine Tools Ltd Woodlands Business Park Burlescombe Tiverton Devon EX16 7LL T 01823 6...

Page 2: ...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 damag...

Page 3: ...1 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 S...

Page 4: ...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 14...

Page 5: ...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 Gener...

Page 6: ...rt 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 l...

Page 7: ...ger 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...

Page 8: ...achine 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...

Page 9: ...achine 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...

Page 10: ...achine 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...

Page 11: ...achine 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...

Page 12: ...ssure 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...

Page 13: ...an 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 Siz...

Page 14: ...eight 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 bot...

Page 15: ...11 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual 2 1 2 SMX3500 Figure 2a SMX 3500 Machine Footprint...

Page 16: ...12 XYZ Machine Tools Ltd 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...

Page 17: ...13 XYZ Machine Tools Ltd 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...

Page 18: ...e 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 th...

Page 19: ...edback 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 en...

Page 20: ...rdboard 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...

Page 21: ...ht 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 t...

Page 22: ...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 l...

Page 23: ...ts to the pendant arm with four 1 4 20 x 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 positioni...

Page 24: ...20 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Left Side Right Side Figure 9 Pendant Cable Connections...

Page 25: ...21 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 10 Pendant Right Side Earlier Models with Floppy Drive...

Page 26: ...XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 11 SMX 3500 4000 5000 Cable Connection Diagram SMX2500 similar less spindle control module and AC dr...

Page 27: ...ice 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...

Page 28: ...d traverse X Y Z standard handwheels 3800 3800 3800 3800 Rapid traverse X Y Z electronic handwheels 3800 6350 6350 6350 Overall Dimensions of Machine height includes 30mm levelling allowance 587 x 102...

Page 29: ...25 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 12 The XYZ SMX Bed mill machine overview Guards not shown for clarity...

Page 30: ...eedrate 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 Lubric...

Page 31: ...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...

Page 32: ...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 Cod...

Page 33: ...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 S...

Page 34: ...n 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...

Page 35: ...l 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...

Page 36: ...e 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 Comput...

Page 37: ...rvo 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 P...

Page 38: ...lues 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...

Page 39: ...wer 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 2...

Page 40: ...saligned 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 p...

Page 41: ...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 Cons...

Page 42: ...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 o...

Page 43: ...uence 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...

Page 44: ...h 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 g...

Page 45: ...ore 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...

Page 46: ...ility 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 t...

Page 47: ...e 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 a...

Page 48: ...ually 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 thr...

Page 49: ...t 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...

Page 50: ...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 C...

Page 51: ...m 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...

Page 52: ...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 hard...

Page 53: ...planation 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...

Page 54: ...he 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...

Page 55: ...51 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 13 SMX3500 4000 and 5000 Power Module...

Page 56: ...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 WIREWA...

Page 57: ...53 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 14 SMX3500 4000 and 5000 Power Module Wiring...

Page 58: ...RAL 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 COL...

Page 59: ...55 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 15a SMX3500 4000 and 5000 Electrical Schematic...

Page 60: ...56 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual...

Page 61: ...ematic 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...

Page 62: ...n 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 t...

Page 63: ...lay 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 pr...

Page 64: ...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 ta...

Page 65: ...ays 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 s...

Page 66: ...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...

Page 67: ...X 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...

Page 68: ...unted by the use of 4 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 castin...

Page 69: ...rupt 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...

Page 70: ...bow 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 bearing...

Page 71: ...67 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 17 SMX2500 X Axis Drive Assembly...

Page 72: ...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 S...

Page 73: ...69 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 18 SMX 3500 X Axis Drive Assembly...

Page 74: ...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 RUBBE...

Page 75: ...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 the...

Page 76: ...72 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 19 SMX2500 Y Axis Drive Assembly...

Page 77: ...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 BE...

Page 78: ...74 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 20a SMX 3500 Y Axis Drive Assembly...

Page 79: ...75 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 20b SMX 3500 Y Axis Drive Assembly Front and Side View...

Page 80: ...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...

Page 81: ...04 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 20NC 1 3 4 L 2 60 ASI614158 SCREW 20NC 1 5 8 L...

Page 82: ...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 yo...

Page 83: ...79 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 21 SMX 4000 X Axis Drive Assembly...

Page 84: ...R 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...

Page 85: ...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 ASI651...

Page 86: ...82 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 22 SMX 5000 X Axis Drive Assembly...

Page 87: ...83 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 23 SMX 5000 X Axis Drive Assembly Other Views...

Page 88: ...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...

Page 89: ...HEEL 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 AN...

Page 90: ...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 f...

Page 91: ...87 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 24 SMX 4000 and 5000 Y Axis Drive Assembly...

Page 92: ...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...

Page 93: ...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...

Page 94: ...000 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 NOZZL...

Page 95: ...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 MM25BS62...

Page 96: ...92 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 27 SMX 2500 Z Axis Drive Assembly...

Page 97: ...ING 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 SPRO...

Page 98: ...94 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 28a SMX 3500 Z Axis Drive Assembly...

Page 99: ...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...

Page 100: ...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...

Page 101: ...4 55 H 93 8 94 8 95 8 ELEVATING LOCK 2 56 HX 002 10 BEARING BUSHING 3 57 HX 007 BEARING COVER 1 58 HX 007 9 BEARING COVER 1 59 HX 028 10 FIXED SUPPORT OF DUST HELMET 2 60 HX 030 10 FIXED SUPPORT OF D...

Page 102: ...98 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 29a SMX 4000 Z Axis Drive Assembly Quill...

Page 103: ...99 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 29b SMX 4000 Z Axis Drive Assembly...

Page 104: ...SLEEVE 1 17 J 054 8 OVERLOAD CLUTCH SLEEVE 1 18 J 055 8 PINION SHAFT HUB 1 19 J 057 KEY 1 20 J 058 8 OVERLOAD CLUTCH 1 21 J 059 8 OVERLOAD CLUTCH RING 1 22 J 060 8 OVERLOAD CLUTCH WORM GEAR 1 23 J 061...

Page 105: ...DUL 2 65 J 348 3 OIL GUIDE 1 66 J 349 3 BEARING 6208ZZ 1 67 J 355 8 HEX NUT 4 68 J 356 NUT 2 69 J 373 SPRING 1 70 F 61 8 QUILL PINION OVERLOAD CLUTCH LOCKNUT 1 71 M 36 8 PINION SHAFT HUB SLEEVE 1 72 M...

Page 106: ...7 STOP BLOCK OF MACRO SWITCH 2 115 H 509 LOCKING NUT 4 116 H 510 WASHER 2 117 H 527 7 LOCKING BLOCK 2 118 H 547 7 KEY 1 119 H 583 7 SCREW 6 120 H 604 8 SCREW 2 121 H 605 8 RETAINING CLIP 1 122 H 606...

Page 107: ...NC 5 1 2 L 2 149 H 643 8 SCREW 6 150 H 644 8 BALANCE WEIGHT 1 151 H 645 8 SPACER 4 152 H 646 8 ROLLER DRIVE SHAFT 4 153 H 647 8 PIN BEARING TA4030 4 154 H 648 8 ROLLER 4 155 H 649 8 ROLLER S RIGHT BRA...

Page 108: ...104 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 30a SMX 5000 Z Axis Drive Assembly...

Page 109: ...105 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 30b SMX 5000 Z Axis Drive Assembly Top View...

Page 110: ...ER S DRIVE SHAFT 4 23 H 148 8 SCREW 4 24 H 149 8A BALANCE WEIGHT 1 25 H 160 9 BEARING BRACKET 1 26 H 165 8 FIXED HOLDER OF COOLANT NOZZLE 2 27 H 167 10B TOP COVER 1 28 H 168 8 FIXED HOLDER OF BALANCE...

Page 111: ...X0 8X12L 5 95 ASM606012 SCREW M6X1 0X12L 15 97 AWIH0138 WASHER 3 8 6 98 AWIH0158 WASHER 5 8 1 i01334 5 1 10 Feed Trip Adjustment If the feed trip is adjusted too light it will inadvertently trip when...

Page 112: ...ove the four bolts that mount the motor to the top head housing and slide motor forward and remove belt CAUTION The motor is heavy about 40kg Use handling equipment or seek assistance 5 Tilt the motor...

Page 113: ...crew B and turn the screw all the way down through the casting Catch it from the motor hole 5 Remove six Screws C holding the belt housing to the subplate 6 Remove the four screws holding the speed ch...

Page 114: ...the timing belt 5 1 17 Brake Shoe Replacement SMX 2500 1 Remove the motor drive belt and complete Steps 1 5 of the timing belt replacement procedure 2 Remove the two M6 cap screws from the bottom of t...

Page 115: ...ends of the table 4 Attach a dial indicator with a magnetic base to the left front of the saddle Place the indicator stylus on the front surface of the table as close to the indicator base as possibl...

Page 116: ...gib until the movement is between 0 013 0 03 mm 4 Move the table to the right and mount the indicator at Point A and move the table back and forth Note the amount of movement of the dial indicator Ad...

Page 117: ...e 2 Centre the saddle on the bed ways 3 Move the table fully to the left side of the saddle 4 Remove the chip wiper guard and chip wiper from the front and rear of the left side box way 5 Attach a dia...

Page 118: ...the left side of the saddle 4 Attach a dial indicator with a magnetic base to the left front of the saddle Place the indicator stylus on the top surface of the box way 5 Lift the end of the table up...

Page 119: ...l and zero out your indicator 4 Then move the table all the way to the right side When the gibs are adjusted properly you should see no more than 0 008mm movement on the indicator 5 Do the same thing...

Page 120: ...underneath the spindle 5 Attach a dial indicator with a magnetic base to the column near the base of the ram on the left side of the machine Place the indicator stylus on the rear surface of the ram n...

Page 121: ...the ram Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the bottom of the ram Tighten the gib lock screw on the top of the ram to lock the gib in place and...

Page 122: ...constant Note this procedure is on systems with Scales only Go to setup mode go to section B and press CODE 11 Refer to service code section for further explanation Code 127 Set X or Y Backlash Const...

Page 123: ...e and load the indicator to zero from one direction against a block or vice and zero out the DRO 2 Move the indicator to 0 05 mm and then back to zero Do not over shoot 0 otherwise start over 3 Whatev...

Page 124: ...ure will take care of the extra 0 013 mm Note Minor adjustments can be made with the back head gibs Tightening the gibs will tend to tilt the head up from the table Loosening the gibs tends to allow t...

Page 125: ...and crash CAUTION The limit switch must be triggered a minimum of 13mm before the machine reaches its travel limits in both directions This allows sufficient room for the servomotors to stop when the...

Page 126: ...122 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual 6 0 Figures and Parts Lists Figure 45 SMX2500 Top Housing Assembly...

Page 127: ...16 VS4 FRU K3 BELT 1 17 20778 6 FRU SK3 UPPER VARI DISC DRIVE SUB ASSY 3VK A6 1 18 VS1 FRU K3 BELT HOUSING 1 19 VS137 FRU K3 SOCKET CAP SCREW M8 P1 25x25L 1 20 VS13 FRU K3 TOP BEARING CAP 1 21 VS13 1...

Page 128: ...ill Safety Installation Maintenance Service Parts List Manual Figure 46 SMX2500 Gear Housing P N 20778 1 ITEM P N DESCRIPTION QTY 1 VS82 FRU K3 GEAR HOUSING 1 2 VS112 FRU K3 GUIDE SPRING 3 3 VS113 FRU...

Page 129: ...125 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 47 SMX 2500 Hi Low Shift Clutch Sub Assembly P N 20778 2...

Page 130: ...OUSING 1 2 23970 FRU K3 BALL BEARING 6908ZZ 1 SET 3 VS78 FRU K3 BEARING SPACER 1 4 VS79 FRU K3 BEARING SPACER 1 5 VS80 FRU K3 SNAP RING R 65 1 6 VS73 FRU K3 SPLINED GEAR HUB 1 7 VS72 FRU K3 KEY 8x7x10...

Page 131: ...RU K3 CLUTCH GEAR SHAFT 1 3 VS92 FRU K3 HI LOW PINION BLOCK 1 4 VS91 FRU K3 SPRING 1 5 VS90 FRU K3 HI LOW DETENT PLUNGER 1 6 VS94 FRU K3 HI LOW SHAFT CRANK 1 7 VS88 FRU K3 PIN 3X19L 1 8 VS93 FRU K3 SC...

Page 132: ...SMX 2500 Pulley Pinion P N 20778 4 ITEM P N DESCRIPTION QTY 1 VS67 FRU K3 BULL GEAR PINION COUNTER SHAFT 1 2 VS69 FRU K3 KEY 5X5X18L 1 3 VS66 FRU K3 BULL GEAR PINION 1 4 VS65 FRU K3 BALL BEARING 2 RE...

Page 133: ...129 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 50 SMX2500 Lower Vari Disc Drive P N 20778 5...

Page 134: ...HOE 2 10 VS48 FRU K3 BRAKE SHOE PIVOT SLEEVE 1 11 VS17 FRU K3 SOCKET CAP SCREW M6 P1 0x35L 1 12 VS17 1 FRU K3 WASHER 6 1 13 VS17 2 FRU K3 NUT M6 P1 0 1 14 VS49 FRU K3 BRAKE SPRING 2 15 VS122 FRU K3 WA...

Page 135: ...131 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 51 SMX 2500 Upper Vari Disc Drive Sub Assembly P N 20778 6...

Page 136: ...G 6012ZZ 1 3 VS44 FRU K3 ADJUSTABLE DRIVEN VARIDISC 1 4 VS36 FRU K3 SPEED CHANGE PLATE 1 5 VS38 FRU K3 WASHER M5 P0 8x20L 2 6 VS37 FRU K3 PIVOT SLEEVE 5 2 7 VS123 FRU K3 SCREW SHCS M5 0 8X20L 2 8 VS39...

Page 137: ...RU K3 WORM 1 6 VS125 FRU K3 WASHER 1 7 VS25 FRU K3 SPEED CHANGE SHAFT 1 8 VS40 FRU K3 ROLL PIN 3x15L 2 9 VS24 FRU K3 COPPER BUSHING 1 10 VS24 1 FRU K3 WASHER WAVE 1 11 VS27 FRU K3 SPEED CHANGE HANDWHE...

Page 138: ...TOR 3 HP 1 2 VS3 1 FRU K3 KEY 6x6x45L 1 3 VS2 FRU K3 STATIONARY MOTOR VARIDISC 1 4 VS6 FRU K3 BUSHING 1 5 VS5 FRU K3 ADJUSTABLE MOTOR VARIDISC 1 6 VS6 1 FRU K3 KEY 7x7x50L 1 7 VS8 FRU K3 SPRING FOR VA...

Page 139: ...135 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 54 SMX 2500 Lower Head Assembly...

Page 140: ...SNAP RING 95 DOWEL PIN 14 1 21 K B32 FRU K3 BEVEL GEAR THRUST SPACER 1 22 K B33 FRU K3 BEVEL GEAR BEARING 1 23 K B31 FRU K3 CLUSTER GEAR SHAFT 6602BB 1 24 20779 1 FRU SK2 SK3 WORM GEAR CRADLE SUB ASS...

Page 141: ...1 75 K B120 FRU K3 COMPRESSION SPRING 1 76 K B158 FRU K3 CHEM BLACKED RD HD SCREWS 2 REQ M5 P0 8x8L 2 77 K B118 FRU K3 CAM ROD SLEEVE ASSY 1 78 K B159 FRU K3 MICROMETER SCALE 1 79 KB 200 FRU K3 SCREW...

Page 142: ...B09 FRU K3 FEED DRIVE WORM GEAR SHAFT 1 7 K B11 FRU K3 KEY 3x3x25L 1 8 K B10 FRU K3 WORM SHAFT KEY 3x3x8L 1 9 K B03 FRU K3 FEED BEVEL PINION 1 10 K B02 FRU K3 BEVEL PINION WASHER 5 1 11 K B01 FRU K3...

Page 143: ...QTY 1 K B66 FRU K3 CLUSTER GEAR COVER 1 2 K B64 FRU K3 CLUSTER GEAR SHAFT CRANK 1 3 K B70 FRU K3 SHIFT CRANK 1 4 K B69 FRU K3 SPRING 3 x 20L 1 5 K B68 FRU K3 GEAR SHIFT PLUNGER 1 6 K B72 FRU K3 SHIFT...

Page 144: ...K B166 FRU K3 QUILL PINION SHAFT 1 2 K B90 FRU K3 QUILL PINION SHAFT BUSHING LEFT 1 3 K B91 FRU K3 WASHER 1 4 K B92 FRU K3 OVERLOAD CLUTCH WORM GEAR 1 5 K B93 FRU K3 OVERLOAD CLUTCH RING 1 6 K B92 1...

Page 145: ...2 K B81 1 FRU K3 KEY 5x8x13L 1 3 K B80 FRU K3 OVERLOAD CLUTCH 1 4 K B79 FRU K3 SAFETY CLUTCH SPRING 1 5 K B78 FRU K3 OVERLOAD CLUTCH LOCKNUT 1 6 K B76 FRU K3 SOCKET SET SCREW M6 P1 0x8L 1 7 K B75 FRU...

Page 146: ...B47 FRU K3 FEED WORM SHAFT THRUST WASHER 1 3 K B44 FRU K3 FEED WORM SHAFT BUSHING 1 4 K B43 FRU K3 WORM 1 5 K B59 FRU K3 PIN 3x12L 1 6 K B49 FRU K3 FEED REVERSE BEVEL GEAR 1 7 K B48 FRU K3 BUSHING 1 8...

Page 147: ...SET 4 K B136 FRU K3 BEARING SPACER SMALL 1 5 K B137 FRU K3 BEARING SPACER LARGE 1 7 K B133 FRU K3 NOSE PIECE 1 8 K B132 FRU K3 SLEEVE 1 9 K B131 FRU K3 BEARING 6206ZZ 1 10 K B130 FRU K3 BEARING LOCKW...

Page 148: ...144 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 61a SMX 3500 Upper Head...

Page 149: ...145 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 61b SMX 3500 Upper Head Assembly...

Page 150: ...Y 8x7x70L 1 17 715 3 SPINDLE BRAKE 1 18 720 TRACTION SPRINGS 1 19 721 7 SLEVE 1 20 723 3 BEARING COVER 1 21 725 3 TOP COVER 1 22 726 3 BRAKE SHAFT 1 23 727 BRAKE CAMS 2 24 729 BRAKE SUPPORTER 1 25 731...

Page 151: ...69 ANI1238 NUT 1 2 12NC 3 70 ANI13858 NUT 5 8 18NF 1 71 ANI151614 NUT 5 16 18NC 2 72 ASR110012 RING 1 2 1 73 ARS112008 RING 8x1 2 1 74 ARS225080 RING 80x2 5 1 75 ASI314112 SCREW1 4 20NC 1 1 2 L 4 76 A...

Page 152: ...148 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 62 SMX 3500 Lower Head Assembly...

Page 153: ...ERLOAD CLUTCH TRIP LEVER 1 14 J 052 OVERLOAD CLUTCH WASHER 1 15 J 018 CLUTCH ARM COVER 1 16 J 048 3 CAM ROD 1 17 J 017 FEED TRIP BRACKET 1 18 J 047 3 CAM ROD SLEEVE ASSEMBLY 1 19 J 045 TRIP PLUNGER 1...

Page 154: ...SPINDLE BEARING FAFNIR 2MM210WIDUL 2 53 J 349 3 BEARING 6210ZZ 1 54 J 019 KEY 1 55 J 142 KEY 1 56 J 057 KEY 1 57 J 154 CLUTCH RING PIN 1 58 J 260 DOWEL PIN 1 59 J 281 PIN 1 60 J 282 PIN 1 61 J 273 3...

Page 155: ...151 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 63a SMX 4000 and 5000 Upper Head...

Page 156: ...152 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 63b SMX 4000 and 5000 Upper Head Assembly...

Page 157: ...KEY 8x7x70L 1 17 715 3 SPINDLE BRAKE 1 18 720 TRACTION SPRINGS 1 19 721 7 SLEVE 1 20 723 3 BEARING COVER 1 21 725 3 TOP COVER 1 22 726 3 BRAKE SHAFT 1 23 727 BRAKE CAMS 2 24 729 BRAKE SUPPORTER 1 25 7...

Page 158: ...1 69 ANI1238 NUT 1 2 12NC 3 70 ANI13858 NUT 5 8 18NF 1 71 ANI151614 NUT 5 16 18NC 2 72 ASR110012 RING 1 2 1 73 ARS112008 RING 8x1 2 1 74 ARS225080 RING 80x2 5 1 75 ASI314112 SCREW1 4 20NC 1 L 4 76 AS...

Page 159: ...155 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 64a SMX 4000 and 5000 Lower Head Assembly Front view...

Page 160: ...WORM CRADLE BUSHING 1 7 HB 007 8 WORM GEAR SPACER 1 8 HB 008 8 FEED DRIVE WORM GEAR 1 9 HB 009 8 FEED DRIVE WORM GEAR SHAFT 1 10 HB 013 WASHER 1 11 HB 015 8 FEED REVERSE BEVEL GEAR 1 12 HB 016 FEED E...

Page 161: ...M GEAR 1 41 HB 096 8 OVERLOAD CLUTCH TRIP LEVER 1 42 HB 099 CLUTCH ARM COVER 1 43 HB 103 8 CAM ROD 1 44 HB 104 TRIP HANDLE 1 45 HB 106 8 FEED TRIP BRACKET 1 46 HB 110 8 REVERSE KNOB 1 47 HB 111 8 FEED...

Page 162: ...L 1 85 ANI112012 QUILL HANDLE LOCK NUT 1 2 12NC 12L 1 86 ARS112018 SNAP RING 1 87 ASI614010 SOCKET SET SCREW 1 4 20NC 1 L 7 88 ASI614034 SOCKET SET CAP SCREW 1 4 20NC 3 4 L 1 89 ASI614038 SCREW 1 4 20...

Page 163: ...159 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 65 SMX 4000 and 5000 Quill Assembly...

Page 164: ...B 093 8 OVERLOAD CLUTCH RING 1 16 HB 096 8 OVERLOAD CLUTCH TRIP LEVER 1 17 HB 097 OVERLOAD CLUTCH WASHER 1 18 HB 099 8 CLUTCH ARM COVER 1 19 HB 103 8 CAM ROD 1 20 HB 106 8 FEED TRIP BRACKET 1 21 HB 11...

Page 165: ...52 AKP105006 DOWEL PIN 15x14L 1 53 AKP1005014 PIN 5x14L 1 54 ANI112012 NUT 1 2 12NC 12L 1 55 ANI120014 NUT 1 4 20NC 2L 1 56 ARS114100 RING 14 1 57 ARS120100 RING 20 1 58 ARS140100 RING 40 1 59 ASI1120...

Page 166: ...162 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 66 SMX 3500 4000 5000 Oil System Figure 67 SMX 3500 Oil System...

Page 167: ...163 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 68 SMX 4000 Oil System...

Page 168: ...164 XYZ Machine Tools Ltd XYZ Bed Mill Safety Installation Maintenance Service Parts List Manual Figure 69 SMX 5000 Oil System...

Page 169: ...E QTY 1 21157 2 LUBRICATION PUMP DPME2 0 3 B 3 DISTRBUTOR OIL REGULATING B 3 0 4 PG004 PLUG M8 X 1 0 0 5 PA4 BUSHING 13 6 PB4 SLEEVE 4 MM 19 8 PAN4 NUT 6 10 JD 4 2 WAY JUNCTION 1 11 L008 TUBE STEEL RO...

Page 170: ...igure 71 SMX2500 Lubrication System X Y Axis ITEM P N DESCRIPTION QTY 2 PH4 8 ELBOW 1 4 L015 PLUG M8 X 1 0 PG004 1 5 L013 BUSHING PA4 9 6 L014 SLEEVE 4 MM PB4 9 10 L012 TEE ADAPTER PKD4 1 11 FHC405 HO...

Page 171: ...a particular purpose and of any other obligations or liability on the part of XYZ or any producing entity if different Warranty repairs exchanges do not cover incidental costs such as installation lab...

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