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XYZ Machine Tools Ltd
TRAK
2
OP
Installation, Maintenance, Service & Part List Manual
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Workpiece material
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Type of finish or accuracy required
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Climb or conventional milling
If a fine finish is required, reduce the feed rather than increase the spindle speed. Cutters are dulled by
higher spindle speeds rather than high feedrates.
5.2
The Mechanical Drive Train
The following sections discuss a key number of mechanical items that should be reviewed when a
mechanical problem exists on the 2 OP machine.
5.2.1
Ballscrew Alignment
Ballscrew alignment plays a critical role in making sure the machine performs at its highest level. It is very
important to have consistent rolling torque values across the length of the X and Y-axis ballscrews. The Z
axis has a mechanical brake so it is not possible to measure the rolling torque. When values vary by more
than a few inch-lbs across the length of the ballscrew, then this points to the ballscrew not being properly
aligned.
To measure the rolling torque on the X and Y-axis you need to move the axis to the location you wish to
check and then press the E-stop. This turns the axis motors off and allows you to manually turn the
ballscrew with a torque wrench. The torque wrench is placed on the end opposite of the motor in the hex
drive. We recommend each axis be checked in 3 places. Check the rolling torque in the centre of travel
and at both ends of travel.
Note: Ball screws are inspected throughout their entire travel for backlash and consistent torque. A ball
screw should be good for millions of centimetres of travel, if installed and lubricated 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.
5.2.2
Protecting the Axis from a Crash
The machine has a few means to help prevent crashes. The first line of defense is a soft limit that is built
into the software. The values are set from the factory and can be found in service code 505. In addition to
the software limits, each axis has rubber bumpers on either end to prevent a hard crash into a hard stop.
5.2.3
Z Axis Mechanical Brake
The Z axis contains an electro-mechanical safety brake that automatically engages when the electrical
power is removed from the machine, or when the E-stop is pressed. This brake is required to support the
head and keep it from falling when the servomotor is turned off or disabled. When 24 volts is applied to
the brake, the brake disengages from the ballscrew, allowing the motor to move the Z axis freely. When
power is removed from the brake, the brake engages and stops the ballscrew from rotating.
5.2.4
Linear Guides
The linear guides play a very important role in the drive system of the machine and with proper care and
lubrication, they should last many years. They require no additional service nor are there any provisions for
adjustment. Great care must be taken to protect the linear guides. Never operate the 2 OP with the way
covers removed (except when service requires it). NEVER ALLOW ANY OBJECT TO FALL ONTO THE LINEAR
GUIDEWAYS!
5.2.5
Lubrication
The automatic lubricating system is dedicated exclusively to the ballscrew and the linear guides on this
machine. The amount of oil and how often oil is applied is controlled by service code 300 (section
5.11.4.6).
The ATC linear guide blocks need to be manually lubricated with grease. There is 1 grease fitting for each
of the 2 guide blocks. The lubrication pump reservoir oil level must be checked daily and maintained in the
indicated Min/Max range. If the lube pump level gets too low or the pressure is low, the control will create
a flashing warning message on the screen. If the lubrication problem is not addressed, the machine will
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