XYZ Machine Tools SMX 2500 Guide

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 Mac hine Tools Ltd.
Woodl ands Busi ness P ark
Burle scom be, Tiverton, De vo n EX1 6 7LL
T: 01 823 67 420 0 F: 01 823 6 74201
e-ma il: sale s@xy zmachinet ools.co m
www. xyzma chi neto ols. com

Copyright © 2016 XYZ Machine Tools, Ltd. All rights are reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted, in any form or by any means, mechanical,
photocopying, recording or otherwise, without the prior written permission of XYZ Machine Tools, Ltd.
While every effort has been made to include all the information required for the purposes of this guide,
XYZ Machine Tools assumes no responsibility for inaccuracies or omission and accepts no liability for
damages resulting from the use of the information contained in this guide.
All brand names and products are trademarks or registered trademarks of their respective holders.
XYZ Machine Tools
Woodlands Business Park
Burlescombe, Nr Tiverton
Devon, EX16 7LL
Service Department
Tel: [phone]
Fax: [phone]

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XYZ Machine Tools Ltd
XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual
Table of Contents
1.0 Safety 1
1.1 Introduction 1
1.2 Safe Operating Information 1
1.3 Release of Trapped Persons 2
1.4 Labels and Notices 3
1.5 EC Declaration of Conformity 8
1.6 Airborne Noise emissions 8
2.0 Installation 9
2.1 Floor Plan, space requirements 9
2.2 Uncrating 14
2.3 Installation Checklist 14
2.4 Lifting and Moving the Machine 16
2.5 Releasing the Head Counterweight 17
2.6 Cleaning 18
2.7 Levelling 18
2.8 Electrical Connection 19
2.9 Air Connection 19
2.10 Mounting the Pendant 19
2.11 Cable Interconnections 19
2.12 Lubrication 23
2.13 Machine Specifications 24
2.14 ProtoTrak Control Hardware 24
3.0 Troubleshooting by Symptom 26
3.1 Problems Relating to Machining Results 26
3.2 Problems Regarding Motion 29
3.3 Problems Relating to the Control 32
3.4 Problems with the Measurements 36
3.5 Problems with the Machine 38
4.0 Diagnostics 41
4.1 The Machine Tool and Setup 41
4.2 The Mechanical Drive Train (X, Y) 43
4.3 Computer/Pendant Diagnostics 45
4.4 Motor Diagnostics 46
4.5 Servo Driver 47
4.6 Scales 48
4.7 Electrical 48
4.8 Service Codes 57
5.0 Servicing Procedures 64
5.1 Replacements 64
5.1.1 Servo Motor 64
5.1.2 Servo Driver 64
5.1.3 Pendant 65
5.1.4 Cable Routing 65
5.1.5 Power Drawbar 65
5.1.6 SMX 2500, 3500 Ball Screw (X axis) 65
5.1.7 SMX 2500, 3500 Ball Screw (Y axis) 71
5.1.8 SMX 4000, 5000 Ball Screw (X axis) 78
5.1.9 SMX 4000, 5000 Ball Screw (Y axis) 86
5.1.10 Feed Trip 107
5.1.11 Quill Clock Spring 107
5.1.12 SMX2500 Spindle Motor 108
5.1.13 SMX3500, 4000, 5000 Spindle Motor 108
5.1.14 SMX2500 Drive Belt 109
5.1.15 SMX3500, 4000, 5000 Drive Belt 109
5.1.16 SMX2500 Timing Belt 110
5.1.17 SMX2500 Brake Shoe 110
5.1.18 SMX2500 Spindle 110
5.2 Maintenance 111
5.2.1 Gib Adjustments 111
5.2.2 Calibration & Backlash 117
5.2.3 Head Rotation & Tramming 119
5.2.4 Limit Switches 120
6.0 Figures and Parts Lists 122
1a SMX2500 –Footprint 9
1b SMX2500 –Footprint 10
2a SMX3500 –Footprint 11
2b SMX3500 –Footprint 12
3a SMX4000 –Footprint 12
3b SMX4000 –Footprint 13
4a SMX5000 –Footprint 13
4b SMX5000 –Footprint 14
5 Lifting the Machine –Method 1 16
6 Lifting the Machine –Method 2 17
7 Placement of Levels 18
8 Levelling Screws 19
9 Pendant Cable Connections 20
10 Pendant Right Side (early models) 21
11 Cable Connection Diagram 22
12 Machine Overview 25
13 SMX3500, 4000, 5000 Power Module 51
14 SMX3500, 4000, 5000 Power Module Wiring 53
15a SMX3500, 4000, 5000 Electrical Schematic 55
15b SMX2500 Electrical Schematic 57
16 Servo Driver Replacement 64
17 SMX2500 –X Axis Drive Assembly 67
18 SMX3500 –X Axis Drive Assembly 69
19 SMX2500 –Y Axis Drive Assembly 72
20a SMX3500 –Y Axis Drive Assembly 74
20b SMX3500 –Y Axis Drive Assembly 75
21 SMX4000 –X Axis Drive Assembly 79
22 SMX5000 –X Axis Drive Assembly 82
23 SMX5000 –X Axis Drive Assembly 83
24 SMX4000/5000 –Y Axis Drive Assembly 87
25 SMX4000/5000 –Y Axis Drive Assembly 88
26 SMX4000/5000 –Y Axis Handwheel Assy 89
27 SMX2500 –Z Axis Drive Assembly 92
28a SMX3500 –Z Axis Drive Assembly 94
28b SMX3500 –Z Axis Drive Assembly 95
28c SMX3500 –Z Axis Drive Assembly 95
29a SMX4000 –Z Axis Drive Assembly 98
29b SMX4000 –Z Axis Drive Assembly 99
30a SMX5000 –Z Axis Drive Assembly 104
30b SMX5000 –Z Axis Drive Assembly 105
31 Feed Trip Adjustment 107
32 Quill Clock Spring Replacement 108
33 SMX2500 - Spindle Motor Replacement 109
34 SMX2500 - Drive Belt Replacement 109
35 SMX2500 - Spindle Replacement 110
36 SMX2500 - 3500 Table Gib Adjustment 111
37 SMX3500 - Table Gib Screw 112
38 Table Gib & Saddle Gib Adjustment 113
39 Saddle Side Gib Adjustment 114
40 Saddle Bottom Gib Adjustment 115
41 Head Back Gib 116
42 Head Side Gib Adjustment 117
43 Calibration Set-Up 118
44 Tramming the Head 120
45 SMX2500 - Top Housing Assembly 122

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

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XYZ Machine Tools Ltd
XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual
1.0 Safety
1.1 Introduction
Manual mills were traditionally used by skilled machinists. Prototrak was designed to replace these
manual machines and at the same time enhance productivity by adding CNC control.
But, unlike Machining and Turning Centres that can be operated even with unskilled staff (in some
modes), Prototrak is designed to be used exclusively by skilled or experienced machinists.
The safe operation of the SMX Mill and ProtoTRAK SMX CNC depends on its proper use and the
precautions taken by the operators.
1.2 Safe Operating Information
This machine must only be operated by trained and experienced operators. Any other users should first
be subjected to a risk assessment by a responsible, trained person.
This machine is designed for the milling of cold metal within the stated capacity of the machine with axes
movement occurring by manual use of handwheels, electronic handwheels or CNC control.
This machine must not be used for machining flammable materials (e.g. magnesium, titanium) without
undertaking a risk assessment and incorporating any additional safety measures identified.
It is designed to be used in a standard workshop environment only.
It is the responsibility of the employer, machine owner or machine controller to ensure that this machine
is installed, operated and maintained in accordance with the Provision and Use of Work Equipment
Regulations (1998) or equivalent local regulations.
In particular, the responsible person must:
Undertake a Risk Assessment on the use of this machine, paying particular attention to the
specific characteristics of the Prototrak system, especially:
oUnrestricted operating mode selection
oGuarding height and access to the work zone
Generate and apply Safe Operating Procedures for the use of the Prototrak machine
Provide any additional training or safeguarding identified by the risk assessment.
All operators and maintenance staff must read and study this Safety, Installation, Maintenance Service
and Parts list manual before operating or undertaking any maintenance or repair work on the machine.
Electrical and Mechanical maintenance must only be conducted by trained and experienced machine tool
engineers who fully understand the hazards of working with machine tools.
The electrical supply to the machine must be isolated and locked out before undertaking any maintenance
or repair work on the machine. Ideally, power should be isolated and locked out at the distribution board
supplying the machine. If not possible, isolate and lock out using the machine isolator on the electrical
cabinet at the back of the machine.
All operators must read and study the ProtoTRAK SMX CNC Safety, Programming, Operating, and Care
Manual (document 25040). The machine must not be operated until operators understand the operation
and safety requirements of this machine.
The cutting tool must not be raised above the table guards without additional guarding measures such as
a cutter guard.
The guard vision panels must be replaced in accordance with the stated schedule.
When operating this machine, always observe the following safety precautions
Do not operate this machine without knowing the function of every control key, button, knob, or
handle.
Always wear the appropriate personal protective equipment, including safety glasses and safety
shoes.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual
Do not wear loose fitting gloves whilst operating this machine as they could easily get caught in
moving parts.
Never wear rings, watches, long sleeves, neckties, jewelry, or other loose items when operating
the machine.
Keep your hair away from moving parts. Wear adequate safety head gear.
Never operate any machine tool after consuming alcoholic beverages, or taking strong
medications, or while using non-prescription drugs.
Carry out a COSHH risk assessment and use the correct protection equipment, e.g. barrier
cream/latex gloves, to prevent harm from items such as cutting fluid, lubrication oil and other
substances used on the machine.
Always ensure the appropriate guarding is in place for the machinery operation being undertaken.
Observe and understand the warning and safety information labels affixed to this machine.
Do not attempt to tamper with or override any guarding/safety device fitted to the machine.
Keep the working area clear and remove all tools (spanners, etc.) from the machine before you
start the machine running. Loose items can become dangerous flying projectiles.
Stop the machine spindle and ensure that the CNC control is in the STOP mode:
oBefore changing tools.
oBefore changing parts.
oBefore you clear away the Swarf, oil or coolant. Always use a chip scraper or brush.
oBefore you make an adjustment to the part, vice, coolant nozzle or take measurements.
oBefore you open guards. Never reach around a guard to gain access to the part, tool, or
fixture.
Do not use compressed air to remove swarf or clean the machine.
Keep work area well lit. Ask for additional light if needed.
Be aware that the machine can move unexpectedly so do not lean on the machine while it is
running.
To prevent slippage and personal injury, keep the working area around the machine dry and
clean. Ensure there is no swarf, oil, coolant and obstacles of any kind around the machine.
Avoid getting pinched in places where the spindle, table or guard doors create "pinch points"
whilst the machine is in motion.
For machines fitted with manual handwheels: to prevent injury during powered axes movement,
keep the handle folded inside the hand wheel at all times except when required to hand crank the
table.
Securely clamp and properly locate the workpiece in the vice or in a fixture. Use proper tool
holding equipment.
Use the correct tooling for the process being undertaken. Never use damaged or worn tools and
ensure the correct cutting parameters (speed, feed, and depth of cut) are used in order to
prevent tool breakage.
Prevent damage to the workpiece or the cutting tool. Never start the machine (including the
rotation of the spindle) if the tool is in contact with the part.
Avoid large overhangs on cutting tools when not necessary.
To prevent fires keep flammable materials and fluids away from the machine, hot swarf and
workpieces.
Never change gears when the spindle is rotating
Do not rotate the spindle by hand unless the table guard is open.
Stop and disconnect the power to the machine before undertaking any machine cleaning or
maintenance
1.3 Release of Trapped Persons.
In the event of persons being trapped in the machine:
1. Hit the E-button to kill all power to the spindle and axes.
2. Open the table guards.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual
3. If trapped by spindle or tool, remove the compressed air supply to the machine and rotate the
spindle by hand to free the trapped person.
4. If trapped by the axes, use the manual handwheels to move the axes slowly clear of the trapped
person.
5. If no manual handwheels are fitted, reset the E-stop and put the control into DRO mode. Use the
Electronic Handwheels to move the axes slowly clear of the trapped person.
1.4 Danger, Warning, Caution, and Note Labels and Notices Used in this
Manual
DANGER - Immediate hazards that will result in severe personal injury or death. Danger labels on the
machine are red in colour.
WARNING - Hazards or unsafe practices that could result in severe personal injury and/or damage to
the equipment. Warning labels on the machine are amber in colour.
CAUTION - Hazards or unsafe practices that could result in minor personal injury or equipment/product
damage. Caution labels on the machine are Yellow in colour.
NOTE - Call attention to specific issues requiring special attention or understanding.
Safety & Information Labels Used on SMX Bed Mills
It is forbidden by law to deface, destroy or remove any of these labels

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

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

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

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

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XYZ Machine Tools Ltd
XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual
1.5 EC Declaration of Conformity
The manufacturer, Southwestern Industries, declares that the ProtoTrak SMX mills conform to all the
relevant provisions of the:
•Machinery Directive 2006/42/EC
•Low Voltage Directive 2014/35/EU, and
•EMC Directive 2014/30/EU
The Technical file is available from XYZ Machine Tools, Woodlands Business Park, Burlescombe, Nr
Tiverton, EX16 7LL, United Kingdom.
1.6 Airborne Noise Emissions
The A-weighted emission sound pressure level at the operator’s workstation is 74dB(A).
(Measured in accordance with ISO 3744 with an uncertainty of 2.5dB.)
The figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a
correlation between the emission and exposure levels, this cannot be used reliably to determine whether
or not further precautions are required. Factors that influence the actual level of exposure of the
workforce include characteristics of the work room and other sources of noise,. i.e. the number of
machines and other adjacent processes. Also the permissible exposure level can vary from country to
country. This information, however, will enable the user of the machine to make a better evaluation of the
hazard and risk.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual
2.0 Installation
Read and understand this entire installation section before beginning the installation procedure.
2.1 Floor Plan, Layout & Space Requirements
2.1.1 SMX2500
Figure 1a - SMX 2500 - Machine Footprint
SMX2500
Footprint of Machine
587 x 1029 mm
Weight (approximate) net
1452 kg
Weight (approximate) shipping
1588 kg
Pallet Size
1778 x 1778 mm
A
Overall width
2565 mm
B
Overall length w/ electric box door open
1926 mm
C
Bed width
587 mm
D
Bed width between levelling screws
520.7 mm
E
Distance between levelling screws
825.5 mm
F
Bed length
1029 mm

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XYZ Machine Tools Ltd
XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual
Figure 1b - SMX 2500 - Machine Footprint
SMX2500
G
Height of table from bottom of bed
864 mm
H
Maximum distance from spindle nose to table
597 mm
I
Maximum height of machine from bottom of bed to top of column cover.
1981 mm
J
Height of machine from bottom of bed to top of spindle motor
2261 mm
K
Width of machine including table
1778 mm
L
Length of machine with electric box door closed
1776 mm

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

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XYZ 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

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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

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XYZ Machine Tools Ltd
XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual
Figure 4b - SMX 5000 - Machine Footprint
2.2 Uncrating
Carefully remove the wood crate and protective packaging, paying attention not to scratch, damage, or
mar any parts of the machine.
ATTENTION!
Immediately report, in writing, any damages observed at this time that can be attributed to
the transportation or improper handling/moving of the machine.
2.3 Installation Instructions & Checklist
Installer: Use this checklist to assure a complete set-up of the SMX bed mill.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual
□
1.
Shut off power to the machine.
□
2.
Visually inspect the 415V -wiring going into the electrical panel. Visually verify the
wiring is correct per our wiring diagram. Make sure a strain relief is being used where
the wiring enters the cabinet. Have the customer repair any wiring discrepancies.
□
3.
Clean the machine if needed and remove any remaining grease.
□
4.
Unlock the table, saddle, and ram gib locks.
□
5.
Use an Allen wrench on the Z-axis ball screw end at the top of the column to manually
lower or raise the spindle head/ram.
□
6.
Make and check all the proper electrical connections from the pendant to the electric
box. See the pendant and electric box wiring diagrams.
□
7.
Turn on the power to the machine and to the pendant.
□
8.
Lubricate all the way surfaces and the ball screws.
□
9.
Jog the table, saddle, and ram back and forth until the way surfaces are well lubricated.
Oil should be visible on all the way surfaces.
□
10.
Check the level of the machine. The machine should be level to within 0.01 mm front to
back and 0.01 mm side to side. Even though it is the responsibility of the customer,
make any adjustments if necessary.
□
11.
Check to make sure that the E-Stop button is functioning correctly.
□
12.
Perform Service Code 12, Feed Forward Constant.
□
13.
As necessary, perform Service Code 123 to calibrate the X and Y-axis using a 150mm
standard.
□
14.
Perform Service Code 11 to automatically calculate the backlash for the X and Y-axis of
dual feedback machines (i.e. Newall scales with a motor encoder).
□
15.
As necessary, perform Service Code 127 and 128 to manually calculate the backlash for
the X and Y-axis of single feedback machines (i.e. motor encoder only).
□
16.
Check for positional accuracy and repeatability on the X and Y-axis using programs
XREPEAT.PT4 and YREPEAT.PT4 respectively. Positioning and repeatability values
should be less than or = to 0.01 mm. Programs can be found on flash drive under the
PT4 folder followed by the SWI TEST PROGRAMS folder.
□
17.
As necessary, perform Service Code 123 and press Z to calibrate the Z-axis ram using a
75mm standard.
□
18.
As necessary, perform Service Code 127 and 128 to manually calculate the backlash for
the Z-axis ram.
□
19.
Check for positional accuracy and repeatability on the Z-axis using program
ZREPEAT.PT4 Positioning and repeatability values should be less than or = to 0.01 mm.
□
20.
As necessary, perform Service Code 123 and press QUILL softkey to calibrate the Z-axis
quill using a 75mm standard.
□
21.
Perform Service Code 100 in both directions for the X, Y, and Z-axis to verify that the
feed rate shown on the display is at least 4560 mmpm if you have mechanical hand
wheels or 7620 mmpm if you have electronic hand wheels.
□
22.
Run the spindle at various speeds in both high and low gear for 15 minutes. Verify head
shifts from high to low gear smoothly. Test quill feed and spindle brake.
□
23.
As necessary, install the way covers.
□
24.
Use accessory key on pendant and make sure the coolant pump fires. The accessory
key should be in the ON position to test coolant pump. The control should be in DRO
mode.
□
25.
Check to ensure that the power drawbar tools load and unloads tools properly.
□
26.
Wipe down the machine prior to leaving.

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XYZ Bed Mill Safety, Installation, Maintenance, Service & Parts List Manual
2.4 Lifting and/or Moving the Machine
CAUTION!
Depending on model, the SMX bed mill can weigh up to 3100 kg. Proper equipment of
sufficient capacity must be used when lifting or moving the machine. Only qualified
personnel should operate lifting equipment
Method 1 (see Figure 5):
1. Move the table as far forward as possible.
2. Insert 2 steel bars 50 mm dia. x 1300 mm long through both sides in the existing holes in the
machine base (front and back).
3. Use 4 off, steel cables (with protective sleeving) min. 19 mm dia. or 4 off, 4-ton slings.
4. Use cardboard pieces or other suitable protective sheets on both sides of the machine to prevent
scratching.
5. Remove any fasteners holding the machine to a pallet.
6. Lift the machine (the front of the machine should be lower than the back).
7. Insert the screws for levelling pads in their place in the bed.
8. Place the machine in its location (see floor plan and bed footprint drawing) carefully positioning
each levelling pad under each levelling screw.
9. Remove the lifting cable or sling, the steel bar and all protective cardboard.
Figure 5 - Lifting the Machine* - Method 1
*Machine image for indication only
Method 2 (see Figure 6):
1. Insert 2 steel bars 50 mm dia. x 1300 mm long through both sides in the existing holes in the
machine base (front and back).
2. Position 4 (two each side) wood vee blocks under the steel bars and over a suitable lift truck.