OP
Installation, Maintenance, Service & Part List Manual
Table of Contents
1.0 Safety 1
1.1 Safety Publications
1.2 Danger, Warning, Caution and Note Labels and
Notices Used in this Manual
1.3 Safety Precautions
2.0 System Description 11
2.1 Machine Specifications
2.2 Maximum Spindle Torque & HP
2.3 ProtoTRAK TMX Control Hardware
2.4 Machine Major Subassemblies
3.0 Installation 19
3.1 Lifting the 2 OP mill
3.2 Uncrating the 2 OP
3.3 Shortages: Inventory Checklist
3.4 Installation Checklist
3.5 Electrical Connections
3.6 Air Connections
3.7 Cleaning the 2 OP
3.8 Leveling Procedure
3.9 Lubrication
3.10 Moving the 2 OP Around the Shop
3.11 Cutting the Euclid Test Block
4.0 Troubleshooting by Symptom 27
4.1 Machine Related Problems
4.2 Motion Related Problems
4.3 Control Related Problems
4.4 Tool Changer (Carrier) Problems
4.5 Control Input or Output Problem
4.6 Measurement Problems
4.7 Machine Tool Problems
5.0 Diagnostics 43
5.1 The Machine Tool & Setup
5.2 The Mechanical Drive Train
5.3 Computer Module
5.4 Programming Panel
5.5 Axis Motors/Servos
5.6 Spindle Motor & Inverter
5.7 Electrical
5.8 Tool Carrier Diagnostics
5.9 Pneumatic Diagnostics
5.10 Coolant System Diagnostics
5.11 Service Codes
6
.0 Replacement Procedures 90
6.1 Axis Motor Replacement
6.2 AC Spindle Drive Replacement
6.3 Computer Module Replacement
6.4 Linear Guide Replacement
6.5 Ballscrew Replacement – X Axis
6.6 Ballscrew Replacement – Y Axis
6.7 Ballscrew Replacement – Z Axis
6.8 Spindle Motor Replacement
6.9 Spindle Motor Wiring
6.10 Spindle Cartridge Replacement
6.11 Spindle/Motor Coupling Alignment
6.12 Automatic Tool Carrier (ATC) Replacement
6.13 Setting ATC Locations
6.14 Coolant Pump Replacement
6.15 Bleeding Air from Tool Unclamp Cylinder Oil System
6.16 Programming Panel Replacement
6.17 Home Switch Replacement
6.18 Spindle Motor Encoder Replacement
6.19 X, Y & Z Home Switch Adjustments
6.20 Adjusting the Drawbar Bump Out
6.21 Servo Drive Replacement
6.22 Setting Spindle Orientation – Service code 510
7.0 Maintenance 115
7.1 Calibration
7.2 Backlash Compensation
7.3 Periodic Maintenance
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