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

Prototrak bed mills series
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Safety, Installation, Maintenance, Service
Covers Models:
 SMX 2500
 SMX 3500
SMX 4000
SMX 5000
ProtoTRAK BED MILLS
SMX 2500, 3500, 4000 & 5000
XY Z Ma c hi ne T o ols Ltd .
Wo odl a n ds B us i ne s s P a rk
Bu rle s com be , Ti ve rt on , De v o n E X 1 6 7 L L
T : 0 1 82 3 67 4 2 0 0 F : 0 1 8 23 6 74 2 0 1
e -ma il : sa le s @ xy zma c hi ne t o ols . co m
www. x yzma c hi ne to ol s. co m
XYZ
& Parts List Manual
Document:
Version:
25093
042016

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Summary of Contents for XYZ Machine Tools SMX 2500

  • Page 1 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  XY Z Ma c hi ne T o ols Ltd .
  • Page 2 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.

  • Page 3: Table Of Contents

    5.1.4 Cable Routing Feed Trip Adjustment 5.1.5 Power Drawbar Quill Clock Spring Replacement 5.1.6 SMX 2500, 3500 Ball Screw (X axis) SMX2500 - Spindle Motor Replacement 5.1.7 SMX 2500, 3500 Ball Screw (Y axis) SMX2500 - Drive Belt Replacement 5.1.8 SMX 4000, 5000 Ball Screw (X axis) SMX2500 - Spindle Replacement 5.1.9 SMX 4000, 5000 Ball Screw (Y axis)
  • Page 4 SMX4000, 5000 – Quill Assembly Oil System SMX3500 - Oil System SMX4000 - Oil System SMX5000 - Oil System SMX2500 – Lube Pump SMX2500 – Lubrication System XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 5: Safety

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 6: 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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 7: Labels And Notices

    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 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 8 Safety & Information Labels Used on SMX Bed Mills It is forbidden by law to deface, destroy or remove any of these labels XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 9 Safety & Information Labels Used on SMX Bed Mills It is forbidden by law to deface, destroy or remove any of these labels XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 10 Safety & Information Labels Used on SMX Bed Mills It is forbidden by law to deface, destroy or remove any of these labels XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 11 Safety & Information Labels Used on SMX Bed Mills It is forbidden by law to deface, destroy or remove any of these labels XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 12: Ec Declaration Of Conformity

    •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).

  • Page 13: Installation

    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...

  • Page 14: Smx2500 - Footprint

    Figure 1b - SMX 2500 - Machine Footprint SMX2500 Height of table from bottom of bed 864 mm Maximum distance from spindle nose to table 597 mm Maximum height of machine from bottom of bed to top of column cover.

  • Page 15: Smx3500 - Footprint

    2.1.2 SMX3500 Figure 2a - SMX 3500 - Machine Footprint XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 16: Smx3500 - Footprint

    Figure 2b - SMX 3500 - Machine Footprint 2.1.3 SMX4000 Figure 3a - SMX 4000 - Machine Footprint XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 17: Smx4000 - Footprint

    Figure 3b - SMX 4000 - Machine Footprint 2.1.4 SMX 5000 Figure 4a - SMX 5000 - Machine Footprint XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 18: Installation Checklist 14 3A

    2.3 Installation Instructions & Checklist Installer: Use this checklist to assure a complete set-up of the SMX bed mill. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 19 ON position to test coolant pump. The control should be in DRO mode. □ Check to ensure that the power drawbar tools load and unloads tools properly. □ Wipe down the machine prior to leaving. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 20: Lifting And Moving The Machine 16 3B

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 21: Releasing The Head Counterweight 17 4A

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 22: Levelling

    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.

  • Page 23: Electrical Connection

    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.

  • Page 24: Pendant Cable Connections

    Left Side Right Side Figure 9 - Pendant Cable Connections XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 25: Pendant Right Side (Early Models)

    Figure 10 - Pendant - Right Side (Earlier Models with Floppy Drive) XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 26: Cable Connection Diagram

    Figure 11 – SMX 3500, 4000, 5000 Cable Connection Diagram SMX2500 similar (less spindle control module and AC drive) XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 27: Lubrication

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 28: Machine Specifications

    267 mm colour LCD for clear presentation of prompts, status information and part graphics  X, Y and Z Axes Motors (part number 24428-1): D.C. Servo Motors 560 in-oz. continuous torque XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 29: Machine Overview

    Figure 12 - The XYZ SMX Bed mill machine overview Guards not shown for clarity XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 30: Troubleshooting By Symptom

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 31 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 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 32 3.1.4.2 The Dimensional Errors Are Random or Accumulate in Size Over the Part Program Possible Cause Check This Machine Tool & Setup problem See Machine Tool & Setup Section 4.1 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 33 Also check for any pinched or blocked oil lines. See Lubrication Section 4.1.3 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 34 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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 35 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 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 36 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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 37 "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". XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 38 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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 39 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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 40: Problems With The Measurements

    If not, then the motor is not at fault and something else is causing the problem. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 41 Z-axis – Head moves up Do the following service code and procedures:  Code 33 Software Identification. This is needed if you call Customer Service. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 42: Problems With The Machine

    AC Drive 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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 43 Before tightening or loosening the nosepiece make sure to loosen the setscrew that holds it in place. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 44 Make sure the 10-ribs on the belt are lined up with the 10-grooves grooves on the pulleys. on the 2-pulleys. If the belt is frayed then replace the belt. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 45: Diagnostics

    See Levelling procedures Head out of tram Leaves uneven surfaces on Machine not level, ram gibs loose. bottom of pockets. See Tramming Head - Section 5.2.3 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 46 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 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 47: The Mechanical Drive Train (X, Y)

    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: XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 48 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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 49: Computer/Pendant Diagnostics

    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. Yoke – the yoke is aligned at the factory and pinned in place. It is aligned to within 0.01mm with a precise alignment tool.

  • Page 50: Motor Diagnostics

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 51: Servo Driver

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 52: Scales

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 53 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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 54 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.

  • Page 55: Smx3500, 4000, 5000 Power Module

    Figure 13 –SMX3500, 4000 and 5000 Power Module XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 56 22406-GR-16G WIRE- UL 83 THHN 24429-1 CABLE ASSY-350 SMX POWER CABLE 22684-5 CABLE ASSY - DOOR GUARD LOGIC 21455-2 CABLE ASSY-SX AUX SAFETY I/O i24396 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 57: Smx3500, 4000, 5000 Power Module Wiring

    Figure 14 - SMX3500, 4000 and 5000 Power Module Wiring XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 58 ORANGE E STOP-SW3A WHITE/BLACK BLUE RESET-BT-A GREEN/BLACK WHITE E STOP-SW1B ORANGE/BLACK BLACK E STOP-SW2B BLUE/BLACK GREEN E STOP-SW3B GREEN/WHITE YELLOW RESET-BT-B DRAIN WIRE SHIELD i01351b XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 59: Smx3500, 4000, 5000 Electrical Schematic

    Figure 15a - SMX3500, 4000 and 5000 Electrical Schematic XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 60 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 61: Service Codes

    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.
  • Page 62 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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 63 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 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 64 (should be 0) Table encoder reading Motor encoder reading Feedrate the maximum feedrate attained nothing (should be 0) nothing (should be 0) XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 65 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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 66 The F1 key saves the current file and the F2 key saves the backup file. To clear the files press the F7 softkey. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 67 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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 68: Servicing Procedures

    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 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 69: Cable Routing

    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.

  • Page 70: Xyz Machine Tools Ltd

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 71: Smx2500 - X Axis Drive Assembly

    Figure 17 - SMX2500 - X-Axis Drive Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 72: Xyz Machine Tools Ltd

    Description Use As 22718 SPACER - 45 DEGREES X-AXIS 21992 BUSHING-BALL SCREW 14772 SPACER - .100” THICK M6-1.0X75 25B SCREW – SHCS-STL-BO 21946 ELECTRONIC HANDWHEEL XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 73: Smx3500 - X Axis Drive Assembly

    Figure 18-SMX 3500 - X Axis Drive Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 74: Xyz Machine Tools Ltd

    ANI12012 NUT:1/2”-20NF ASI631638 SCREW:3/16”-24NC-3/8”L ASI231612 SCREW:3/16”-24NC-1/2”L ASI61412 SCREW:1/4”-20NC-1/2”L ASI61478 SCREW:1/4”-20NC-7/8”L ASI6141 SCREW:1/4”-20NC-1”L ASI6516134 SCREW:5/16”-18NC-1 3/4”L ASI6381 SCREW:3/8”-16NC-1”L ASI612112 SCREW:1/2”-12NC-1 1/2”L ASI6121 SCREW:1/2”-12NC-1”L 15977 TRAY PAD XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 75: Xyz Machine Tools Ltd

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 76: Smx2500 - Y Axis Drive Assembly

    Figure 19 - SMX2500 - Y Axis Drive Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 77: Xyz Machine Tools Ltd

    SPACER - 30 DEGREE Y-AXIS DRIVE ASSY 21992-1 BUSHING-BALLSCREW 1/4-20X5/8 26B SCREW-FHCS-STL-BO 14772-2 SPACER-.020" THICK 21984 WAY COVER FRONT Y-AXIS DRIVE 25729 HANDLE REPLACEMENT KIT 15609-16 BALLSCREW - Y AXIS i01132-Y-SX2 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 78: Smx3500 - Y Axis Drive Assembly

    Figure 20a – SMX 3500 - Y Axis Drive Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 79: Smx3500 - Y Axis Drive Assembly

    Figure 20b – SMX 3500 - Y Axis Drive Assembly - Front and Side View XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 80: Xyz Machine Tools Ltd

    CROSS FEED BEARING BRACKET HT-029-10 TABLE HT-034-10A EXTENSION 16983-1 PULLEY-BALL SCREW HT-096-3 COVER HT-097-3 COVER HT-151 BEARING COVER HT-152 HT-166 BUSHING HX-046 STOP BLOCK OF LIMIT SWITCH XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 81: Xyz Machine Tools Ltd

    SCREW: 5/16“ -18NC – 3/4”L ASI678312 SCREW: 7/8“ - 9NC – 3 1/2”L ASM60510 SCREW: M5 X 0.8 X 10L AWIH0112 WASHER: ½“ AWIH01516 WASHER: 5/16“ XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 82: Xyz Machine Tools Ltd

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 83: Smx4000 - X Axis Drive Assembly

    Figure 21 – SMX 4000- X Axis Drive Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 84: Xyz Machine Tools Ltd

    HT-157-8 HANDWHEEL BRACKET HT-166-8 BUSHING HT-167 OIL SEAL HT-181 OIL SEAL HX-002 BUSHING 24428-1 MOTOR 615-5M-15 BELT AB2562 BEARING:25BS62DH AB6305ZZ BEARING:6305ZZ AK0505020 KEY:5x5x20 AKP205030 PIN:Ø5x30 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 85: Xyz Machine Tools Ltd

    SCREW:1/4”-20NC-7/8”L ASI651634 SCREW:5/16”-18NC-3/4”L ASI65161 SCREW:5/16”-18NC-1”L ASI6516134 SCREW:5/16”-18NC-1 3/4”L ASI6381 SCREW:3/8”-16NC-1”L ASI638178 SCREW:3/8”-16NC-1 7/8”L ASI6121 SCREW:1/2”-12NC-1”L ASI612112 SCREW:1/2”-12NC-1 1/2”L AWIH01516 WASHER:5/16”-18NC AWIH0158 WASHER:5/8”-18NF AWMS01025 WASHER:M25x1.5 i01332 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 86: Smx5000 - X Axis Drive Assembly

    Figure 22 – SMX 5000 - X Axis Drive Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 87: Smx5000 - X Axis Drive Assembly

    Figure 23 – SMX 5000 - X Axis Drive Assembly, Other Views XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 88: Xyz Machine Tools Ltd

    LOCKING NUT H-510 WASHER H-511 BEARING 6305Z H-512 BEARING 6203ZZ H-513 COVER H-514 H-515 GEAR H-516 GEAR H-517 H-518 LOCKING NUT H-519 GEAR H-520 H-521 H-522 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 89: Xyz Machine Tools Ltd

    SCREW: 5/16”-18NC-1 3/4”L ASI6381 SCREW: 3/8”-16NC-1”L ASI638178 SCREW: 3/8”-16NC-1 7/8”L ASI6121 SCREW: 1/2”-12NC-1”L ASI612112 SCREW: 1/2”-12NC-1 1/2”L AWIH01516 WASHER: 5/16”-18NC AWIH0158 WASHER: 5/8”-18NF H-081 i01337 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 90: Xyz Machine Tools Ltd

    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. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 91: Smx4000/5000 - Y Axis Drive Assembly

    Figure 24 –- SMX 4000 and 5000- Y Axis Drive Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 92: Smx4000/5000 - Y Axis Drive Assembly

    Figure 25 –- SMX 4000 and 5000- Y Axis Drive Assembly - Side and Front XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 93: Smx4000/5000 - Y Axis Handwheel Assy

    Figure 26 – SMX 4000 and 5000 - Y Axis Handwheel Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 94: Xyz Machine Tools Ltd

    FIXED PLATE(R) – SMX 5000 HT-002-6 HANDWHEEL HT-002-6A CLUTCH HT-004 CROSS FEED DIAL HT-005-3 DIAL HOLDER HT-022-8 FEED NUT BARCKET FIXED HOLDER OF BALL SCREW HT-022-8B (SMX4000 ONLY) XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 95: Xyz Machine Tools Ltd

    SCREW:3/16”-24NC-3/8”L ASI61458 SCREW:1/4”-20NC-5/8”L ASI61434 SCREW:1/4”-20NC-3/4”L ASI614158 SCREW:1/4”-20NC-1 5/8”L ASI614134 SCREW:1/4”-20NC-1 3/4”L ASI651612 SCREW:5/16”-18NC-1/2”L ASI651634 SCREW:5/16”-18NC-3/4”L ASI65161 SCREW:5/16”-18NC-1”L ASI678312 SCREW:7/8”-9NC-3 1/2”L AWIH0114 WASHER:1/4” AWIH01516 WASHER:5/16” i01300 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 96: Smx2500 - Z Axis Drive Assembly

    Figure 27 - SMX 2500 - Z-Axis Drive Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 97: Xyz Machine Tools Ltd

    Parts List - SMX 2500 - Z-Axis Drive Assembly (Figure 27) ITEM TITLE USE AS 16806-M BALLSCREW ASSY- Z-AXIS PJ540015 BRACKET LOWER ELEVATING BALL SCREW 2205E-2RS1TN9 BEARING SELF ALIGNMENT SKF 16774 COVER - BEARING 16795 MODIFIED BEVEL GEAR BS1236-2A M10-1.5X10 40B...

  • Page 98: Smx3500 - Z Axis Drive Assembly

    Figure 28a – SMX 3500 – Z Axis Drive Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 99: Smx3500 - Z Axis Drive Assembly

    Figure 28b – SMX 3500 – Z Axis Drive Assembly Figure 28c – SMX 3500 – Z Axis Drive Assembly (Top View) XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 100: Xyz Machine Tools Ltd

    LOCKING BLOCK H-547-7 H-583-7 SCREW H-620-8 FIXED HOLDER OF MICRO SWITCH H-621-8 FIXED HOLDER OF COOLANT NOZZLE H-622-8 SCREW H-637-8 MOTOR COVER H-644-8 BALANCE WEIGHT XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 101: Xyz Machine Tools Ltd

    HEXAGON SOCKET CAP HD SCREW:1/4”-20NC-3/4”L FLAT HEAD SCREW:3/16”-24NC-1/2”L WASHER:3/8” 24427 PULLEY (PART OF MOTOR) 425-5M-15 BELT SPRING WASHER NUT:M12x32THD LOCKNUT:YSF M30x1.5 BEARING:MM25BS62DH OIL RING FIXED SUPPORT BEARING:6305ZZ i01322 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 102: Smx4000 - Z Axis Drive Assembly

    Figure 29a – SMX 4000 - Z Axis Drive Assembly & Quill XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 103: Smx4000 - Z Axis Drive Assembly

    Figure 29b – SMX 4000 - Z Axis Drive Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 104: Xyz Machine Tools Ltd

    J-171-3 BEARING SPACER(SMALL) J-172-3 NOSEPIECE J-256 COMPRESSION SPRING J-260 DOWEL PIN J-264 CAP SCREW J-268 SOCKET SET SCREW J-269 J-270-3 STELL PLATE J-272-3 LOCK NUT XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 105: Xyz Machine Tools Ltd

    BEVEL GEAR H-87-8 ELEVATING GIB H-88 ADJUSTING SCREW H-88-1 SET SCREW H-93-8+94-8+95-8 ELEVATING LOCK H-96-8 ALUMINUM PLATE (L) H-103 SCREW H-136 SCREW H-271-8 MACHINE BODY XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 106: Xyz Machine Tools Ltd

    BELT PULLEY FOR UP AND DOWN H-632-8 H-633-8 H-634-8 SPRING WASHER H-635-8 PPOTECTIVE COVER OF BELT PULLEY H-636-8 FIXED HOLDER OF MOTOR H-637-8 MOTOR COVER XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 107: Xyz Machine Tools Ltd

    ROLLER’S LEFT BRACKET H-650-8 TOP COVER H-651-8 CHAIN H-652-8 H-653-8 WASHER H-654-8 COTTER PIN H-655-8 BOLT H-656-8 H-657-8 THRUST BEARING H-756-8 SCREW HX-43 COOLANT NOZZLE i01328 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 108: Smx5000 - Z Axis Drive Assembly

    Figure 30a – SMX 5000 - Z-Axis Drive Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 109: Smx5000 - Z Axis Drive Assembly

    Figure 30b – SMX 5000 - Z-Axis Drive Assembly - Top View XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 110: Xyz Machine Tools Ltd

    STOP BLOCK OF LIMIT SWITCH HY-043-14 NAME PLATE 24427 PULLEY (PART OF MOTOR 24428-1) 450-5M-15 BELT 90 DEG. TUBE BEARING: TA3025 AB2562 BEARING: MM25BS62DH AB6305ZZ BEARING: 6305ZZ XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 111: Feed Trip Adjustment

    Figure 31 - Feed Trip Adjustment 5.1.11 Quill Clock Spring Replacement and Adjustment The quill clock spring counterbalances the weight of the quill and tool. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 112: Quill Clock Spring Replacement

    8. Tilt the motor toward the rear of the machine, and remove the belt from the motor pulley. Remove the motor. 9. To reinstall motor, do these steps in reverse. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 113: Smx2500 - Spindle Motor Replacement

    Figure 33 - SMX 2500 - Spindle Motor Removal & Replacement 5.1.14 Drive Belt Replacement – SMX 2500 1. Remove the motor. 2. Remove the draw bar and its bushing. 3. Remove the three Screws A and use M6 x 35mm screws in the adjacent tapped holes to remove the Bearing Cap.

  • Page 114: Smx2500 - Spindle Replacement

    6. Continue to tap the spindle out of the quill. The spindle bearings will come out with the spindle. Figure 35 – SMX 2500 - Spindle Replacement XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 115: Maintenance

    Tighten the gib lock screw on the left end of the saddle to lock the gib in place, and recheck. Repeat as necessary. Figure 36 – SMX 2500 & 3500 - Table Gib Adjustment XYZ Machine Tools Ltd...

  • Page 116: Smx3500 - Table Gib Screw

    Once the clearance has been taken up tighten each nut against the gib bracket. Do this for each end of the table. 5. Replace the table trays. See Figure 38. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 117 6. Move the left end of the table back and forth and note the amount of movement on the dial indicator. Adjust the Y-axis side gib until the registered movement is 0.02-0.04mm. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 118: Saddle Side Gib Adjustment

    7. Replace the front and rear chip wiper, and chip wiper guard. Figure 39 - Saddle Side Gib Adjustment 5.2.1.4 Saddle Bottom Gib Adjustment, Y-Axis – SMX 2500 & 3500 See Figure 40. 1. Clean all swarf, dirt and excess oil from the table and saddle.

  • Page 119: Saddle Bottom Gib Adjustment

    Figure 40 - Saddle Bottom Gib Adjustment – SMX 2500 & 3500 5.2.1.5 Saddle Bottom Gib Adjustment, Y-Axis – SMX 4000 & 5000 It is unrealistic to adjust the Y bottom ways the same way as we do on the SMX 3500 because of the extra weight of the saddle and table.

  • Page 120: Head Back Gib

    7. Run Service Code 12 to set the feed forward constant. 8. Repeat the procedure for the back gib on the right side of the machine. Figure 41 - Head Back Gib XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 121: Calibration & Backlash

    Calibration is used teach the machine a known distance. We typically calibrate our machines over a 150 mm distance. There is no limit to the distance over which the machine can be calibrated. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 122: Calibration Set-Up

    2. Turn on the ProtoTRAK and at the Main Menu, follow the procedure below precisely: Conversation Says You Do a. Press MODE b. Select Mode b. Press SET UP XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 123: Head Rotation & Tramming

    5. Adjust the Z ram so that the dial indicator will reach the table. 6. Move the dial indicator to 6 o’clock position and adjust the face so the needle is zero. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 124: Limit Switches

    3. Slowly move the table to one side by hand until the end of the travel is reached. 4. In DRO mode set X = 0 ABS. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 125 The limit switch-stops for the Z-axis are mounted on the side of the column. The limit switch is triggered by hitting the cam on the column. The cam is placed to ensure maximum travel. XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 126: Figures And Parts Lists

    6.0 Figures and Parts Lists Figure 45 - SMX2500 - Top Housing Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 127 VS136 FRU-K3-SCREW- SOC HD CAP M6-P1.0x10L VS54 FRU-K3-HANDLE FIX BLOCK VS55 FRU-K3-SET SCREW VS56 FRU-K3-BRAKE LOCK HANDLE VS57 FRU-K3-BAKELITE BALL HANDLE OIL-1 FRU-K3-OIL CUP i00690-K2-K3 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 128: Smx2500 - Gear Housing

    Figure 46 - SMX2500 - Gear Housing - P/N: 20778-1 ITEM DESCRIPTION VS82 FRU-K3-GEAR HOUSING VS112 FRU-K3-GUIDE SPRING VS113 FRU-K3-SPRING GUIDE PIN i00691-K2-K3 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 129: Smx2500 - Hi-Low Shift Clutch

    Figure 47 – SMX 2500 - Hi-Low Shift Clutch Sub-Assembly - P/N: 20778-2 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 130 Parts List – SMX 2500 - High-Low Shift Clutch (Figure 47) ITEM DESCRIPTION VS75 FRU-K3-BEARING SLIDING HOUSING 23970 FRU-K3-BALL BEARING 6908ZZ 1 SET VS78 FRU-K3-BEARING SPACER VS79 FRU-K3-BEARING SPACER VS80 FRU-K3-SNAP RING R-65 VS73 FRU-K3-SPLINED GEAR HUB VS72 FRU-K3-KEY 8x7x10L...
  • Page 131 Figure 48 – SMX 2500 - Hi-Low Shift - P/N: 20778-3 ITEM DESCRIPTION VS89 FRU-K3-HI-LOW DETENT PLATE VS87 FRU-K3-CLUTCH GEAR SHAFT VS92 FRU-K3-HI-LOW PINION BLOCK VS91 FRU-K3-SPRING VS90 FRU-K3-HI-LOW DETENT PLUNGER VS94 FRU-K3-HI-LOW SHAFT CRANK VS88 FRU-K3-PIN Ø 3X19L VS93 FRU-K3-SCREW M5-P0.8x15L...

  • Page 132: Smx2500 - Pulley Pinion

    Figure 49 – SMX 2500 - Pulley Pinion - P/N: 20778-4 ITEM DESCRIPTION VS67 FRU-K3-BULL GEAR PINION COUNTER SHAFT VS69 FRU-K3-KEY 5X5X18L VS66 FRU-K3-BULL GEAR PINION VS65 FRU-K3-BALL BEARING (2 REQ.) 6203ZZ FRU-K3-SOCKET SET SCREW M6-P1.0x6L 23954 BEARING SET (2) BEARING 6203ZZ...

  • Page 133: Smx2500 - Lower Vari-Disc Drive

    Figure 50 - SMX2500 - Lower Vari-Disc Drive - P/N: 20778-5 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 134 FRU-K3-SPINDLE PULLY ASSY VS100 FRU-K3-SPINDLE PULLY SPACER VS71 FRU-K3-KEY 8x7x20L VS97 FRU-K3-SNAP RING Ø 40 VS50-1 FRU-K3-DUST COVER VS50-2 FRU-K3-SCREW-FH-PH-STL-BO M6-1.0X6L 24055 BRAKE SHOE ASSY i00695-K2-K3 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 135: Smx2500 - Upper Vari-Disc Drive

    Figure 51 – SMX 2500 - Upper Vari-Disc Drive Sub-Assembly - P/N: 20778-6 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 136 VS41 FRU-K3-WASHER Ø 8.2 VS40 FRU-K3-ROLL PIN Ø3x15L VS35 FRU-K3-ADJUSTMENT NUT VS34 FRU-K3-CHAIN END STUD VS33 FRU-K3-CHAIN FRONT SCREW M4-P0.7x5L 24564 BEARING HOUSING ASSEMBLY i00696-K2-K3 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 137: Smx2500 - Speed Change Handwheel

    FRU-K3-HANDLE 3/8-16NC VS32 FRU-K3-CHAIN #310X9.525 VS31-1 FRU-K3-DOWEL PIN Ø3x25L VS30 FRU-K3-SPEED CHANGE STUD VS16-1 FRU-K3-SPEED DIAL VS95 FRU-K3-NUT-ACORN 5/16-18 NC VS16-2 FRU-K3-NAME PLATE VS19 FRU-K3-SCREW-DRIVE i00697-K2-K3 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 138: Smx2500 - Spindle Motor

    Figure 53 – SMX 2500 - Spindle Motor - P/N: 20819-1 ITEM DESCRIPTION VS110 FRU-K3-MOTOR 3 HP VS3-1 FRU-K3-KEY 6x6x45L FRU-K3-STATIONARY MOTOR VARIDISC FRU-K3-BUSHING FRU-K3-ADJUSTABLE MOTOR VARIDISC VS6-1 FRU-K3-KEY 7x7x50L FRU-K3-SPRING FOR VARIDISC MOTOR SHAFT FRU-K3-ADJUSTABLE VARIDISC SPRING COLLAR VS10 FRU-K3-SCREW- SOC HD CAP M8-P1.25x30L...

  • Page 139: Smx2500 – Lower Head Assembly

    Figure 54 – SMX 2500 - Lower Head Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 140 Parts List – SMX 2500 - Lower Head Assembly (Figure 54) ITEM DESCRIPTION K-B125-2 FRU-K3-HANDWHEEL HANDLE (AVAILABLE ONLY IN ASSY. 20835) K-B113 FRU-K3-HAND WHEEL CLUTCH K-B117 FRU-K3-ROLL PIN Ø3x15L K-B103 FRU-K3-CAM ROD K-B108 FRU-K3-SOCKET SET SCREW M6-P1.0x8L K-B119-1 FRU-K3-ROLL PIN Ø3x20L K-B103-1 FRU-K3-CAM ROD PIN Ø6x15L...
  • Page 141 20835 HANDWHEEL ASSY 20849 HANDLE - FEEDS HANDLE ASSY 20847 MICRO SCREW, MICRO-STOP NUT &MICROMETER NUT ASSY 24051 CLOCK SPRING 24052 TRIP HANDLE ASSY i00699-K2-K3 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 142: Smx2500 – Worm Gear Cradle

    Figure 55 – SMX 2500 - Worm Gear Cradle - P/N: 20779-1 ITEM DESCRIPTION K-B17 FRU-K3-WORM GEAR CRADLE K-B07 FRU-K3-WORM GEAR SPACER K-B08 FRU-K3-FEED DRIVEWORM GEAR K-B05 FRU-K3-WORM CRADLE BUSHING K-B04 FRU-K3-FEED WORM GEAR SHAFT SLEEVE K-B09 FRU-K3-FEED DRIVE WORM GEAR SHAFT...

  • Page 143: Smx2500 – Quill Feed Selector

    Figure 56 – SMX 2500 - Quill Feed Selector - P/N: 20779-2 ITEM DESCRIPTION K-B66 FRU-K3-CLUSTER GEAR COVER K-B64 FRU-K3-CLUSTER GEAR SHAFT CRANK K-B70 FRU-K3-SHIFT CRANK K-B69 FRU-K3-SPRING Ø 3 x 20L K-B68 FRU-K3-GEAR SHIFT PLUNGER K-B72 FRU-K3-SHIFT KNOB-5/16-18NC K-B71 FRU-K3-ROLL PIN Ø...

  • Page 144: Smx2500 – Quill Pinion Shaft

    Figure 57 – SMX 2500 - Quill Pinion Shaft - P/N: 20779-3 ITEM DESCRIPTION K-B166 FRU-K3-QUILL PINION SHAFT K-B90 FRU-K3-QUILL PINION SHAFT BUSHING- LEFT K-B91 FRU-K3-WASHER K-B92 FRU-K3-OVERLOAD CLUTCH WORM GEAR K-B93 FRU-K3-OVERLOAD CLUTCH RING K-B92-1 FRU-K3-SCREW SOC HD CAP M4-P0.7x15L K-B94 FRU-K3-SNAP RING 95 DOWEL PIN Ø...

  • Page 145: Smx2500 – Overload Clutch Trip

    Figure 58 – SMX 2500 - Overload Clutch Trip - P/N: 20779-4 ITEM DESCRIPTION K-B81 FRU-K3-OVERLOAD CLUTCH SLEEVE K-B81-1 FRU-K3-KEY 5x8x13L K-B80 FRU-K3-OVERLOAD CLUTCH K-B79 FRU-K3-SAFETY CLUTCH SPRING K-B78 FRU-K3-OVERLOAD CLUTCH LOCKNUT K-B76 FRU-K3-SOCKET SET SCREW M6-P1.0x8L K-B75 FRU-K3-CLUTCH RING...

  • Page 146: Smx2500 – Feed Reverse Clutch

    Figure 59 – SMX 2500 - Feed Reverse Clutch - P/N: 20779-5 ITEM DESCRIPTION K-B57 FRU-K3-FEED WORM SHAFT K-B47 FRU-K3-FEED WORM SHAFT THRUST WASHER K-B44 FRU-K3-FEED WORM SHAFT BUSHING K-B43 FRU-K3-WORM K-B59 FRU-K3-PIN Ø 3x12L K-B49 FRU-K3-FEED REVERSE BEVEL GEAR...

  • Page 147: Smx2500 – Spindle Assembly

    Figure 60 – SMX 2500 - Spindle Assembly - P/N: 20836 ITEM DESCRIPTION K-B127 FRU-K3-SPINDLE R8 K-B134 FRU-K3-SPINDLE DIRT SHIELD 20838 FRU-K3-BEARING 7207ZZ 1 SET K-B136 FRU-K3-BEARING SPACER-SMALL K-B137 FRU-K3-BEARING SPACER-LARGE K-B133 FRU-K3-NOSE-PIECE K-B132 FRU-K3-SLEEVE K-B131 FRU-K3-BEARING-6206ZZ K-B130 FRU-K3-BEARING LOCKWASHERØ 30 K-B129 FRU-K3-SPINDLE BEARING LOCK NUT- Ø30-20N...

  • Page 148: A Smx3500 – Upper Head

    Figure 61a – SMX 3500 Upper Head XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 149: B Smx3500 – Upper Head

    Figure 61b – SMX 3500 Upper Head Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 150 753-3 BOLT DRIVE RING BEARING COVER 758-3 GEAR SHAFT LOCKING SHAFT 760-7 INVERTER MOTOR 5Hp 764-3 LOCKING NUT 770-7 SPEED CHANGE BOX 786-7 NAME PLATE XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 151 AWIH0158 SPRING WASHER: Ø 5/8" AWIH11014 SPINDLE WASHER: Ø 1/4" AWMD0150 WASHER: Ø 50 AWMH0116 WAVE WASHER: Ø 16 AWMH0126 WAVE WASHER: Ø 26 i01292-1 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 152: Smx3500 – Lower Head

    Figure 62 – SMX 3500 Lower Head Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 153 QUILL STOP KNOB J-037 QUILL STOP MICRO SCREW J-063-3 QUILL PINION SHAFT J-148 PINION SHAFT HUB SCREW J-055-3 PINION SHAFT HUB M-036 PINION SHAFT HUB SLEEVE XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 154 J-143 SOCKET SET SCREW J-350 LOCKSCREW J-264 CAP SCREW J-268 SOCKET SET SCREW J-275 SOCKET SET SCREW J-313 SCREW J-356-5 SET SCREW J-278 SCREW i01324 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 155 Figure 63a – SMX 4000 and 5000 Upper Head XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 156 Figure 63b – SMX 4000 and 5000 - Upper Head Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 157 BOLT DRIVE RING BEARING COVER 758-3 GEAR SHAFT LOCKING SHAFT 760-8-1 INVERTER MOTOR 7.5 HP 764-3 LOCKING NUT 770-7 SPEED CHANGE BOX 786-7 NAME PLATE XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 158 AWIH0158 SPRING WASHER: Ø 5/8" AWIH11014 SPINDLE WASHER: Ø 1/4" AWMD0150 WASHER: Ø 50 AWMH0116 WAVE WASHER: Ø 16 AWMH0126 WAVE WASHER: Ø 26 i01292 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 159 Figure 64a – SMX 4000 and 5000 - Lower Head Assembly (Front view) XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 160 GEAR SHIFT PLUNGER HB-023 SHIFT CRANK HB-027-8 SLEEVE HB-028 FEED DRIVE CLUSTER GEAR HB-031&HB-035-8 FEED REVERSE BEVEL GEAR PINION HB-033-8 DRIVE SHAFT BUSHING HB-034-8 SPACER XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 161 QUILL STOP KNOB HB-164-8 QUILL STOP MICRO BOLT HB-166-3 QUILL PINION SHAFT HB-183 REVERSE TRIP BALL LEVER HB-184 FEED REVERSE TRIP PLUNGER HB-185 BOLT HB-192-8A QUILL HOUSING XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 162 SOCKET SET SCREW:M4x0.7-25L ASM608016 SCREW:M8x1.25-16L OIL CLIP GREASE TUBE STEEL BALL: 3"/16 SPRING COMPRESSION SPRING COMPRESSION SPRING COMPRESSION SPRING COOLANT NOZZLE:PT1/8" LOCKING NUT:M12x1.0-6L LOCKING NUT:M8x1.25-1.2L i01290 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 163 Figure 65 – SMX 4000 and 5000 - Quill Assembly XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 164 QILL MICRO STOP NUT HB-162-8 MICROMETER NUT HB-163-8 QUILL STOP KNOB HB-164-8 QUILL STOP MICRO SCREW HB-166-8 QUILL PINION SHAFT HB-172 PINION SHAFT HUB SCREW XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 165 SCREW:1/4”-20NC-21L ASI451618 SCREW:5/16”-18NC-18L ASI614221 SCREW:1/4”-20NC-2 1/2”L ASI6381 SCREW:3/8”-24NF-1”L ASM105010 SCREW:M5x0.8x10L ASM105018 SCREW:M5x0.8x18L ASM108009 SCREW:M8x1.25x9L ASM405010 SCREW:M5x0.8x10L ASM608016 SCREW:M8x1.25x16L COMPRESSIVE SPRING SPRING STEEL BALL: 1/4” i01289 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 166: Oil System

    Figure 66 – SMX 3500, 4000, & 5000 - Oil System Figure 67 – SMX 3500 - Oil System XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 167: Smx4000 - Oil System

    Figure 68 – SMX 4000 - Oil System XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...

  • Page 168: Smx5000 - Oil System

    Figure 69 – SMX 5000 - Oil System XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 169 Figure 70 – SMX 2500 - Lubrication Pump & Manifolds ITEM TITLE 21157-2 LUBRICATION PUMP-DPME2 DISTRBUTOR-OIL REGULATING B-3 PG004 PLUG- M8 X 1.0 BUSHING SLEEVE-4 MM PAN4 JD-4 2-WAY JUNCTION L008 TUBE- STEEL ROPE & HOSE DISTRIBUTOR PSS4 OIL DISTRIBUTOR...

  • Page 170: Smx2500 – Lubrication System

    ELBOW L015 PLUG- M8 X 1.0-PG004 L013 BUSHING-PA4 L014 SLEEVE-4 MM-PB4 L012 TEE ADAPTER-PKD4 FHC405 HOSE L006 DISTRIBUTOR-DB10 PSS4 OIL DISTRIBUTOR L005 TUBING-4MM ALUM-A4 i00783-E2 XYZ Machine Tools Ltd XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual...
  • Page 171 XYZ Machine Tools Ltd. ProtoTRAK UK Warranty Policy Warranty ProtoTRAK products are warranted to the original purchaser to be free from defects in workmanship and materials for the following periods: Product Warranty Period New ProtoTRAK Machine 12 Months Any Exchange Unit or Spare Part...

This manual is also suitable for:

Smx 3500Smx 5000Smx 4000

Table of Contents