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XYZ Machine Tools TRAK 2OP M11 Mill Safety, Installation, Maintenance, Service And Parts List

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Safety, Installation, Maintenance, Service and Parts List
TRAK
TM
XYZ Machine Tools Ltd.
Woodlands Business Park
Burlescombe, Tiverton, Devon EX16 7LL
T: 01823 674200 F: 01823 674201
e-mail: sales@xyzmachinetools.com
www.xyzmachinetools.com
XYZ
2
M11 Mill
OP
Document:
P/N 28170-1
Version:
050919

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Summary of Contents for XYZ Machine Tools TRAK 2OP M11 Mill

  • Page 1 TRAK M11 Mill Safety, Installation, Maintenance, Service and Parts List Document: P/N 28170-1 Version: 050919 XYZ Machine Tools Ltd. Woodlands Business Park Burlescombe, Tiverton, Devon EX16 7LL T: 01823 674200 F: 01823 674201 e-mail: sales@xyzmachinetools.com www.xyzmachinetools.com...
  • Page 2 Copyright © 2019 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

    Setting Spindle Orientation – Service code 510 Machine Tool Problems Maintenance Diagnostics Calibration The Machine Tool & Setup Backlash Compensation The Mechanical Drive Train Periodic Maintenance Computer Module XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 4 Coolant System – 27557 Lubrication System – 27591-1 Home Switch Assembly – 27658-1 Electrical Cabinet Assembly – 27621-5 Electrical Schematic – 27650-5-SCH Enclosure Assembly – Servo Drives – 28156-1 XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 5: Safety

    Do not operate this machine without knowing the function of every control key, button, knob, or handle. Ask your supervisor or a qualified instructor for help when needed. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 6 Always turn off and lock-out power at the main electrical panel before servicing the machine • • Always turn off and lock out the air supply and depressurise the pneumatic system before servicing. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 7 Avoid making sudden or sharp turns when moving the machine. 8. Once at the new location, slowly and carefully lower the machine down to the floor, and stow away the pallet jack. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 8: Danger, Warning, Caution And Note Labels And

    Milling Machine The following safety and information labels are used on the machine. It is forbidden by law to deface, destroy or remove any of these labels XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
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  • Page 12 XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 13 XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 14 • 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. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 15: System Description

    RPM. We recommend no more than 4 hours of continuous running at speeds above 5,000RPM without a 30 minute rest period. Automatic Tool Carrier Tool Capacity XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 16 M11 machine at the spindle. Peak torque and horsepower values can only be attained for a short period of time before the spindle drive will fault out to protect the motor. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 17: Prototrak Tmx Control Hardware

    There are 2 USB ports mounted on the right side of the machine next to the programming panel. They are used to save programs and connect a keyboard and mouse. There are 7 cables that route from the programming panel to the computer module: XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 18: Machine Major Subassemblies

    A spindle ring is also attached to the bottom of the spindle via the drive dogs and prevents debris like coolant from getting up inside the spindle. BT30 tool holders must be used. XYZ Machine Tools Ltd TRAK 2...
  • Page 19 Please refer to the manufacturer for the proper torque. You can order a set of 8 pull studs from XYZ Machine Tools under part number 13631. Our pull studs should be torqued to 40Nm. Figure 2.4.4a...
  • Page 20 The coolant system uses a single pump to provide coolant to the work and also to wash swarf away from the area where the ATC comes out. Wash areas can be controlled by the flexible coolant lines found at the base of the enclosure. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 21 The input voltage to the machine must not exceed 440 volts (line to line). Voltages higher than this may damage internal components and void your warranty The transformer has a number of input taps to adjust for small variations in local supply voltage. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 22 You must turn off and lock out the power to the machine before adjusting any wiring at the transformer. Failure to do so may cause death by electrocution. Figure 2.4.17 – Transformer Input Taps See also drawing 27648-5 at the end of the manual. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 23: Installation

    Attach the 4 levelling feet to each corner of the machine. Thread in the feet until the machine sits about 140mm above the ground. Lower the machine onto the floor see Fig. 3.3. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 24 Move the machine into position. Remove both side maintenance panels (held in place by 4 screws). Undo the 4 screws securing each Z axis transit bracket and remove the brackets from the machine. See figure 3.5: XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 25 SERVO OFF to SERVO ON. Verify the lube pump cycles 1 time when the servos are first turned on. Select Service Code 505 and use the electronic handwheel to raise the head far enough to remove the wooden transit support see Fig 3.6. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 26 “LUBE LEVEL LOW” appears on the display. Replenish the oil reservoir as soon as possible. The message clears automatically when the reservoir level is above minimum. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 27: Installation Checklist

    ATC linear guide blocks. We recommend this be done every 6 months. See figure 3.7. Fig 3.7 Installation Checklist □ 1. make sure there is no power or air connected to the machine XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 28 Re-adjust limit switch cam if it does. Service Code 500 and 520 may need to be performed if major adjustments have been made to the X and Y XYZ Machine Tools Ltd TRAK 2...
  • Page 29 ATC. Try to use actual tools when running this program. 30. Double check the position of lower left hand corner ball lock location. Modify in service Code □ 500 as necessary. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 30 ATC. □ 32. Make sure fine chip filter is installed on top of coolant tank. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 31: Troubleshooting By Symptom

    XZ or YZ perpendicularity. Backlash values set too high or Check code 128. Typically values for backlash should be less than 0.08mm. Reset values as necessary. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 32: Machine Related Problems

    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 or excessive following error on that axis. Following error is when the XYZ Machine Tools Ltd TRAK 2...
  • Page 33 Code 33 Software Identification. This is needed if you call XYZ Customer Service • Code 132 Each revolution of the EHW should display 100 counts on the screen • XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 34: Control Related Problems

    12VDC coming from the computer module through the Overlay Interface PCB. Possible Cause Check This Power failure to the Computer Verify that 115VAC is supplied to the computer module and that the Module. fuse is okay. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 35 To check if the Programming Panel keys are working properly, press each key. If the key is working, the corresponding key on the screen will light up. The pendant will also beep. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 36 This folder is created automatically when you save a program. named properly. USB Drive failure Try the USB in another computer USB device is full Check USB device for memory with service code 327 XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 37 Pump has failed Check voltage at pump and replace as required. 4.3.10 E-Stop Error The machine shows a Critical Error 55 when the E-stop button is not pressed. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 38: Tool Changer (Carrier) Problems

    Make sure the machine is receiving 90psi. The tool carrier should pressure warning should appear still move if the air pressure is low. on the screen when the air pressure falls below 60psi. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 39 These fingers act in the opposite fashion to release the tool holder. Tools can be clamped and unclamped manually by pressing the green button on the head. See also section 4.5.5. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 40: Control Input Or Output Problem

    A low air message would be displayed as ‘AIR PRESSURE LOW’. The following chart describes possible causes to this condition. Possible Cause Check This Air line pinched Check that air hose is not pinched or bent. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 41 5.3 Replace motor brake. A 24 volt signal should turn the brake off, Motor brake has failed which means the head is free to move. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 42: Measurement Problems

    Drive Train. See Mechanical Drive Train (X, Y) Section 5.2. The coupling is the first place you should look. Make sure the coupling is not slipping on the motor or ballscrew end. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 43 Undo the E-stop and press the Servo on button Servo amp failure See Servo amp Section 5.5 Motor Encoder not counting See Motor diagnostics, section 5.5 Computer module failure See Computer module diagnostics, section 5.3 XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 44: Machine Tool Problems

    Spindle run command not See diagnostic section 5.6.2 for how to check this signal. reaching AC Drive Spindle Drive parameters are not Contact Customer Service for assistance. correct XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 45 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 XYZ Machine Tools Ltd TRAK 2...
  • Page 46 Spindle bearings are worn out high RPMs. It may also cause chatter under load. Replace the spindle cartridge if this is the case. See spindle replacement in Section 6.10. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 47: Diagnostics

    It is good machining practice to avoid the use of compressed air to clean swarf off a machine. This risks blowing swarf into the linear way surfaces and compromising the performance of the machine. XYZ Machine Tools Ltd TRAK 2...
  • Page 48 Note: Cutter diameter greatly affects spindle speeds. The larger the diameter, the lower the spindle speed. 5.1.4.2 Feedrates Factors that affect feedrates: • Depth and width of cut • Design or type of cutter • Sharpness of the cutter XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 49: The Mechanical Drive Train

    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 XYZ Machine Tools Ltd TRAK 2...
  • Page 50 LEDs are turned ON and OFF. Note, some of these LEDs are powered by the monitored subsystem and so may be lit even if the computer module is unpowered. Here is a summary of the LED’s: XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 51 2, green power connectors that provide switched 115VAC to the coolant 2. Green connectors and lube pump. 3. X, Y and Z axis ports: Interface to the axes servo amps. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 52 A network cable runs from this port to the top of the machine at the right side. This allows users to network the control. Figure 5.3a – Computer module Front View XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 53 Figure 5.3b – Computer module Side View XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 54 8. SPD_TAP signal is 24VDC volt digital signal from the AC Drive that is used to control the Acceleration and Deceleration time when tapping. This is the MI4 terminal on the AC Drive. Figure 5.3c – Spindle Port Pin Assignments XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 55 141 and 142 must be used to transfer the configuration from the old compact flash to the new compact flash on the new computer module. Do not XYZ Machine Tools Ltd TRAK 2...
  • Page 56 COM port on the computer module is functioning correctly. Verify that the Overlay software is running by using an external USB keyboard and pressing “Ctrl-Alt-Delete” this will bring up a window XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 57 Make sure to first unplug any accessories such as external keyboard/mouse USB thumb drives etc. to eliminate any interference. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 58 6. EHW Cable: Carries the encoder signals from the EHW to the computer module. 6 wires carry the following signals: power, ground, A, NOT A, B and NOT B. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 59 D24 – Rxd (receive exchange data) LED should blink on and off as confirmation from computer module (acknowledgement or command from computer module) that a non-critical key was pressed XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 60 Figure 5.4b – Programming Panel Rear View Figure 5.4c – LCD User Interface Board XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 61 750Watt motor and the Z axis uses a 1kW motor. All motors have a shaft encoder with a resolution of 9,600 ppr (38,400 counts per revolution). The motor encoder also contains one index pulse per revolution which is used for homing. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 62 ±10VDC. The sign of the voltage dictates the direction the motor rotates and the higher the voltage; the faster the motor will turn. Figure 5.5.2a – Inside of Servo Electrical Cabinet XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 63 Figure 5.5.2b – Servo Driver Parts XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 64 The drive corresponds to the wrong motor. Servo Off Error Regeneration AL005 Regeneration control is in error. Servo Off Error AL006 Overload The motor and the drive is overload. Servo Off XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 65 Internal address of the encoder is in error Servo Off internal error Motor Torque AL030 Motor torque exceeds P1-57 for time set by P1-58 Servo Off Overload XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 66 4. Press SET button to see the fault code. 5. Hit MODE to get out of each parameter. Figure 5.5.2f - Fault History Display Monitor and Diagnostics Display XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 67 2. Confirm the drive trains are not binding and causing the fault. If a fault is happening due to a mechanical problem, there is a good chance you will get an overcurrent fault (AL001) on the drive. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 68 3. Verify that the spindle is able to turn freely. 4. Verify that the spindle power wiring is correct and properly fastened. 1. Verify that the deceleration parameter (01-13) on the inverter is set correctly. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 69 Inhibits the drive when the door is open via door relay, K2 (24VDC measured between MI5 and DCM). If the door switch is working, but K2 fails open, then the XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 70 AC Drive and keypad unit. This function is not normally required. Please refer to section 3.1.2 of the AC drive User Manual for more information XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 71 This is the main power to the machine; fed to the spindle motor and power/ control transformer only. Check voltages between each phase, as seen in figure 5.7.1a. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 72 1 of the Overlay Power Port and the chassis ground on the computer module, as seen on figure 5.7.1b. This voltage is monitored by the 5VDC LED on the computer module. Figure 5.7.1a XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 73: Computer Module

    F18 and F19 2 x 12A Axes Servo Drives 10x38mm Spare 220VAC (Indexer) Transformer 24VAC 115VAC-2 (fans and worklight) 115VAC-1 (computer module) Lube Pump Lube pump 5x20mm Slow blow XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 74: Tool Carrier Diagnostics

    Tool change height is set using Service code 520. It will set the position where the Z-axis will clamp or unclamp the tool. Like the spindle orientation, this setting is also very critical. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 75 Error 105 - Check the Spindle Drive Module and related electronics. Repair as needed. The spindle drive may have faulted. This would happen due to an orientation issue or when the spindle is decelerating prior to a tool change. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 76 Check that both limit switches are functioning properly. - During normal operation both switches should not be active. Check the LEDs on the back of the control. Use Service Code 521 to confirm proper inputs. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 77 Use the proper pull stud. during a tool change used. The pull fingers inside the spindle Visually inspect the pull fingers. are damaged, jammed open or missing XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 78: Pneumatic Diagnostics

    Valve labeled “2” – this is a dual solenoid, 4 Way valve and designed to control the direction of flow of air to the ATC carriage cylinder and the ATC door lift cylinder. It moves the ATC front and back XYZ Machine Tools Ltd TRAK 2...
  • Page 79 Note – it is important to route the air lines properly when replacing a flow control valve. Failure to do so will cause the system not to behave properly when adjustments are made. Figure 5.9.1 explains how a flow control valve works. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 80 Compete all initial adjustments. Load the ATC with a full set of tools. Operate the ATC forward and backwards. Slowly wind out the adjustment screw until the deceleration of the ATC is smooth and soft. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 81 Cushion adjustment screws are located in the front and back end cap of the cylinder next to the air line connections. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 82 Too little air is coming down through the spindle which can lead to chips sticking inside of the spindle taper Make sure they are installed properly and air flows in the correct direction. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 83: Coolant System Diagnostics

    Service codes are broken down into the following groups: software, machine setup, diagnostics, user options/defaults. The table below is a quick summary of the service codes; more detailed information follows. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 84 Displays error messages on screen Display Memory Check Displays memory availability of various devices Test Light Indicator Turns on and off some test lights used for troubleshooting blocks per second problems. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 85 When you save the configuration file to a thumb drive, the file structure described above, in service code 141, will be created. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 86 SET SOFT LIMITS – This brings up a table that shows the default soft limits. These values should not have to be changed by the user. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 87 This turns the servos off and allows the X and Y axis ballscrew to be turned by hand. Manually turn the X or Y axis ballscrew to display the actual DRO counts and the raw encoder XYZ Machine Tools Ltd TRAK 2...
  • Page 88 5.11.3.6 Code 326: Error Message Display Displays the content of an error message, where the error number is already known. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 89 The INPUT screen allows you to check all the inputs on the control. Triggering an input, by pressing a switch for example, will highlight the corresponding white box. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 90 ATC cylinder. The range of acceptability is 1 to 1.2 seconds. The Move Time box below will display how long it takes to move the ATC in and out. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 91 This code causes the control to turn on in metric mode. 5.11.4.2 Code 67: Default English This code causes the control to turn on in Imperial mode. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 92 ATC. Setting the spindle operation More severe damage could orientation angle also occur which could be costly to the user XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 93 6. Home switch replaced or a major mounting adjustment is made. 7. Home switch cam replaced or a major adjustment is made 8. Ballscrew replaced 9. Angular contact bearings on motor end replaced XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 94: Replacement Procedures

    6. Remove the 3 SHCS holding the X axis motor to the casting. Remove the belt. 7. Carefully maneuver the motor out from the machine casting exposing the cable connections. See figure 6.1.1b. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 95 45° (do not over tighten). Torque the M6 motor bracket screws to 9.5Nm (7ft-lbs) and re-check belt tension. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 96 6. Loosen the four SHCS that attach the motor to the machine. Note: The lower screws fit into “Slots” on the motor mount casting. Remove the upper screws and lift out the motor and belt. XYZ Machine Tools Ltd TRAK 2...
  • Page 97 Please refer to assembly drawing 27540-1 found at the back of this manual. Warning! Whenever the Z-axis motor is removed, service code 520 must be performed to re-establish the precise tool change height XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 98 10. Use the Z axis brake test in Service Code 521 to release the brake. WATCH THE HEAD DESCENT CAREFULLY and once the head is far enough down, re-enable the brake. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 99 Enter the Z tool change offset that is displayed in the lower right hand grey box. Press ABS Set. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 100: Ac Spindle Drive Replacement

    The replacement drive is already programmed, with the exception of the spindle orientation parameter (10- 19), since it is unique for each machine: WARNING! Failure to perform this step will cause the tool changer to crash and damage may occur. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 101: Computer Module Replacement

    The linear guides that come with the 2 OP should be trouble free for many years as long as they are properly lubricated per the specifications stated in this manual. Should the time come when a linear guide needs to be replaced, this is a major overhaul activity; please contact XYZ machine Tools for assistance. Ballscrew Replacement, X Axis Please refer to assembly drawing 27520-1 at the back of this manual.
  • Page 102 4. Using a 6mm hex key to prevent the ballscrew from rotating, remove the hex nut, star washer, flat washer, pulley, ferrule and the clamp nut. See figures 6.5b and 6.5c. Figure 6.5b XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 103 9. Remove the bearing housing from the right side of the X-axis casting, refer Figure 6.5c disassemble the seal, bearings and the inner spacer. X-axis Ballscrew Installation XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 104 1. Service code 505 to check that the motor index angle is at 180° ± 45°, 2. Service code 520 to reset ATC tool positions, 3. Service code 500 to reset the ball lock location. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 105: Ballscrew Replacement, Y Axis

    14. Remove the four SHCS that secure the bearing cap to the Y-axis casting on the front of the machine. 15. Slide the ballscrew out the front of the machine. 16. Remove the bearing housing from the bearing block. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 106 1. Service code 505 to check that the motor index angle is at 180° ± 45°, 2. Service code 520 to reset ATC tool positions, 3. Service code 500 to reset the ball lock location. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 107: Ballscrew Replacement, Z Axis

    E, fig 6.7a). Disconnect the door from the air cylinder at the pivot bolt. See figure 6.7b. Figure 6.7b 4. Remove the Z-axis ballscrew cover C (figure 6.7a). XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 108 11. Jog the Z-axis upward to near the end of travel, this will align the ballnut with the bearing housing. 12. Attach the oil line to the ballnut. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 109: Spindle Motor Replacement

    Install the new motor in reverse order. Tighten the two clamp screws on the motor coupler. Enter service code 510 to set spindle orientation and follow the on-screen instructions. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 110: Spindle Motor Wiring

    Remove the clamp/unclamp switch bracket assembly (A), air line (B), oil line (C) and the actuator plate (D). Reference figure 6.10 XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 111: Spindle/Motor Coupling Alignment

    Install the spindle in the spindle housing and snug the spindle mtg. screws slightly and then just break them loose. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 112: Setting Atc Locations

    Repeat this procedure for pockets 2 through 8. Press SAVE TABLE after each position is found. For setting the Z height on the ATC, see section 5.8.2. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 113: Coolant Pump Replacement

    Press the unclamp button on the front of the head a number of times over and over until you do not see any more oil bubbles in the oil reservoir. The air should escape from the top of the oil reservoir tank. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 114: Programming Panel Replacement

    (service code 500), tool change height, ATC locations (service code 520). 6.18 Spindle Motor Encoder Replacement Remove Encoder housing cover to gain access to internal connections. Disconnect Spindle fan connector and remove encoder connector jack posts. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 115 Loosen the 2 grub screws securing the encoder to the spindle motor shaft. Remove the 2 screws securing the encoder to the spindle motor end plate. Remove the encoder. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 116: Adjusting The Drawbar Bump Out

    Fasten the 4 mm set screw back down. Press servo on. Load a tool manually in and out of the spindle to verify the bump is now within limits. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 117: Servo Drive Replacement

    X and Y locations can be found in the table, and the DRO display in the lower right side of the screen gives the current spindle position. Without moving the tool carrier or the axes, mode out and enter service code 510 and select ORIENT SPINDLE. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 118 11. Raise the Z Axis clear of the ATC and press RETURN twice to exit the service code. 12. Enter service code 520 and press ATC BACK. Press RETURN to exit theS service code. XYZ Machine Tools Ltd TRAK 2...

  • Page 119: Maintenance

    Set a 2µm dial indicator in the spindle, and touch off on a block or the vice along the direction (X, Y or Z) you wish to check. Load the indicator to zero from one direction and zero out the DRO. XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...

  • Page 120: Periodic Maintenance

    Inspect the tool change air cylinder and grease the ATC linear rail bearing blocks. Inspect machine for any unusual wear and play, check cables and pneumatic lines for any excessive abrasions or cuts. 8 Drawings XYZ Machine Tools Ltd TRAK 2 Installation, Maintenance, Service & Part List Manual...
  • Page 160 1 NC 2 1 NC 2...
  • Page 191 BLACK WHITE...
  • Page 203 This machine is designed to cut common, metallic engineering materials (such as steel and aluminium). DO NOT use to cut special materials (such as composites or abrasives) without agreement from XYZ Machine Tools. Any damage caused to the machine by processing such materials will not be covered by the warranty.

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