XPS-16 Drill Grinder And Sharpener User Manual
Contents
1. Note the small key the center left to the Remove the support door casting and tilt it up right is a release clip With a small blade screw driver reach down on the side of the clip and press inward while pulling up The block will slide off User Manual Page 26 3 Securing the switch in place is plastic nut at move the plastic retainer nut also same as E the base of the threads Use needle nose pli Stop ers to remove the nut and slide the switch out 5 Slide the switch from the casting but note the rubber gasket and locator pin that protrudes through the gasket and locates the switch on the top cover It must locate in this position Feed Hold amber 1 Follow Cycle Start switch replacement steps to replace Feed Hold switch 4 Slip the new switch in place with the key to the left or inside of the casting and the clip to the right or wall side of the casting 5 Secure with the plastic nut but do not over tighten 6 Slide the switch block over the keyed switch prong side up until it snaps in place 7 Connect the wires as follows The green wire connects to the inside prong and the white to the wall side prong Cycle Start switch green 1 Before removing the wires note the pattern of connection Two green to top inside prongs Black then red on the bottom inside prong The top outside or wall side prong is vacant 2 Follow the same connector removal procedure as for2. 2 4 F 1 i i 3 Swing the dust shield up or down to access the 2 2mm screws securing the sensor 4 Unscrew the screws and remove the sensor 5 To replace the sensor reverse the process and snap the connector together User Manual Page 14 User Manual Page 15 CHUCK ASSEMBLY SA12505TA 9 gow 193139 ONIYdS_ 316962144 A 440952 l dd 9 156982199 M349S 9 150102 315992199 ONIYdS 31064414444 YSHSVM LSNYHL Re x V3 v X YW SISHJ 6 X EN 11020Cldd HAN VLIH N ON14V38 O RL 316162144 A ON1 4V38 es ge JR N 76 0 110466144 va S SH4 6 X EN 33100061444 IXSZSZLdd 9V714 1 31940 316646144 216082199 2 User Manual Page 16 User Manual Page 17 Removing and Replacing Diameter Detect Rod Refer to the Chuck Spindle Drive Belt Replacement 3 Turn the jaw assembly counter clockwise until instructions for cover and chuck removal and re it bottoms out in the knob assembly after diameter detect rod has been re placed See Section 24 Schematics and Work In structions page 3 Knob andjaw assembly 4 Slide each jaw down the spring and lay flat on chuck knob Continue this process until you have s
3. 27 the motor See Section 24 Schematics and Work Instructions page 27 2 Once the motor is removed note the slotted brush retaining screws on each side of the motor 3 Unscrew and check brushes one at a time not ing how they were oriented in the guide Marking them is a good idea 4 Check each brush for damage to the springs or for excessive wear They should measure no less than 275 from the lowest point of the radius to the top of the brush 5 If either one needs replacement you must re place both brushes with new ones If not carefully replace them the same way they came out 6 If you are replacing with new brushes be sure to install them with the radius of the brush in line with the rotation of the motor 7 After brushes are installed refer to Removing and Replacing Grind Motor Assembly instruc User Manual Page 33 SPI NDLE CARTRI DGE ASSEMBLY SA12615TA ATSNISSY 1901414V9 310 145 VISLOCLVS 4ICN IdS 31029214444 N 116090144 ONIY dVNS 140692144 A YSHSVM AAVM 11259 lLdd 4901 400718 158158099 en 3901 1 2 JIGNI ds 380192144 LAN JJS 416192 ida 4191 80dd User Manual Page 34 User Manual Page 35 Removing and Replacing the Spindle Arbor Cartridge Assembly Removing and Replacing the Spindle Arbor Car 5 Remove the 4 4mm screws holding the wheel tridge Assembly casting in place 1 Refe
4. Manual Page 7 Replace Chuck Spindle Drive Belt 1 Take the knob and jaw assembly and position 3 With the beveled side up slip the knob all jaws in slots Holding in your hand align retainer under the knob and locate threaded the black diameter detect rod in the holes under counter bored holes in the knob corresponding notch in the spindle cone See Note the dotted lines Hold in position with drawing below Make sure jaws are in spindle Slots Slide the assembly all the way in until it Bevel side down Top Diameter detect rod Notch your finger and secure with 2 cap screws Rotate the chuck 180 and repeat the Zo process Replace the cover and secure with 3 button head screws stops 2 With the solenoid engaged in the locking hole rotate the chuck to the illustrated position User Manual Page 8 Removing and Replacing the Chuck Belt I dler Assembly Refer to the Chuck Spindle Drive Belt Replacement instructions for cover and chuck removal belt ad justment and reassembly after replacement of belt idler See Section 24 Schematics and Work In structions page 3 1 Remove the 4mm locking screw and lift the idler assembly out of the housing 4MM locking screw Idler assembly To install the idler position over screw hole outside of belt and thread screw into idler just until snug Adjust belt per the Chuck Spindle Drive Belt Replacement instructions See Sec tion 24 Schematics and Wo
5. 020044144 SOHS Or 7 146022144 YOLOW 9315 No 313714W09 TL dd MONS PEELS User Manual Page 4 User Manual Page 5 Removing and Replacing the Chuck Spindle Drive Belt 1 Remove the 3 3mm button head screws with 3 Do not remove the jaws or springs a 2mm Allen wrench and remove the cover from the assembly They are ground in position for accuracy and are not to be 3MM button removed head screws plate 2 Remove the 4 4mm screws from the Knob and Jaw chuck knob with a 3mm Allen wrench Lift the assembly chuck knob straight up The jaw assembly and knob will come out together Set aside Now rotate the crescent shaped knob retainers and remove 4 screws User Manual Page 6 4 To loosen and remove belt insert a flat blade 6 Replace the belt Using two fingers on a flat screw driver in the slotted bearing screw blade screw driver rotate slotted bearing screw clockwise until belt just pulls to a flat condition There will be noticeable increase in resistance past this point of rotation Continue rotating another 1 16 Hold screw driver in this position and secure bearing lock 5 Onthe back of the casting is a 4 mm button head screw that locks the bearing in place Loosen with a 2 5mm Allen wrench Rotate the bearing screw counterclockwise and loosen the belt Slip the belt off the sprockets and remove AMM locking screw Q xe OW User
6. Reconnect the cooling hose and slip the motor shaft with the pulley in place up the slotted bracket and aligned with slots and screw hole 12 Install screws and washers just until they bring surfaces together 13 Reconnect motor wires and zip tie if needed 14 Refer to Grind Motor Belt Replacement instruc tions for belt replacement and proper belt ten sion See Section 24 Schematics and Work In structions page 29 User Manual Page 31 Removing and Replacing Grind Motor Belt Turn the machine on and push check Push the tool icon Push the belt icon in upper right hand corner The X Axis moves to the center and stops Turn the machine off and unplug from power source 6 Remove the belt access panel at back of ma chine 7 Loosen the 4 mounting bolts and swing the motor up to loosen the belt 8 Tighten one bolt and remove the belt 9 Install the new belt and loosen the bolt Place your finger tip on the rear of the motor to keep it level Let the weight of the motor swing down and tension the belt This will ap ply the proper tension without stressing the motor or spindle bearings Tighten the bolts evenly and replace the access panel OUR EN RON Tighten Loosen User Manual Page 32 Removing and Replacing Grind Motor Brushes 1 Refer to Removing and Replacing Grind Motor tions to replace the motor See Section 24 Assembly instructions to remove and replace Schematics and Work Instructions page
7. User Manual Page 1 SERVICE PARTS REPLACEMENT SCHEMATICS amp WORK INSTRUCTIONS USER SECTION CHUCK SWING CASTING ASSEMBLY EXPLODED VIEW SA12500CA CHUCK SPINDLE DRIVE BELT REPLACEMENT REMOVE REPLACE CHUCK BELT IDLER ASSEMBLY REMOVE REPLACE CHUCK LOCKING SOLENOID REMOVE REPLACE NEMA DRIVE GEAR REMOVE REPLACE ROTATE SENSOR REMOVE REPLACE A AXIS SWING SENSOR CHUCK ASSEMBLY EXPLODED VIEW SA12505TA PAGE 15 REMOVE REPLACE DIAMETER DETECT ROD PAGE 17 ELECTRICAL WIRING DIAGRAM PP12150EF REMOVE REPLACE COOLING FAN REMOVE REPLACE LCD DISPLAY REMOVE REPLACE SWITCHES E STOP CYCLE START amp FEED HOLD GRIND MOTOR ASSEMBLY EXPLODED VIEW SA12640MA REMOVE REPLACE GRIND MOTOR ASSEMBLY REMOVE REPLACE GRIND MOTOR BELT REMOVE REPLACE GRIND MOTOR BRUSHES SPINDLE CARTRIDGE ASSEMBLY EXPLODED VIEW SA12615TA PAGE 33 REMOVE REPLACE SPINDLE ARBOR CARTRIDGE ASSEMBLY PAGE 35 User Manual Page 2 User Manual Page 3 CHUCK SWING CASTING ASSEMBLY SA12500CA 5 15 2 5 4890 Gcldd SOH8 G X EW 31371dW09 18 41355 YOSNAS 61 9 109 21 5 HOLIMS 1309 2144 55 VLOZSZLVS 1139 310866144 ATSN3SSY 010 3105 V1G6GcIVvS SIH8 6 X EW XZ 41G CCldd 9 van 4108Gcldd ATSNISSV 41141 1138 VIZIGCIVS 1138 JHL 404 GION310S 3HL 401 SOH CL X L X PW XE ONILSVO 5
8. eplacing the LCD Display 3 Located at the bottom of the LCD display is 1 Remove the screws on the door support and the interface board Using two fingers on the top cover outside of the board pull from the LCD recep tacle Leave all wires connected to board Nez i pa ae gt 2 Remove the door support cover and lift the 6 4 Unplug the green five wire connector from the LCD 5 Remove the single screw on the RS232 con nector and unplug from the LCD User Manual Page 24 6 Remove the 7 acorn nuts from the LCD Note One is inaccessible and has no nut Slide the LCD out 1 To replace the LCD slip back through the front of the top cover Hold in place with your hand and install acorn nuts just until one to two threads protrude past the surface of the nut A thin wall socket is necessary for clearance 2 Plug in interface board green five wire con nector and the RS232 connector and screw User Manual Page 25 Removing and Replacing Switches Removing and Replacing The E Stop Cycle Start E Stop and Feed Hold Switches 1 Using pair of needle nose pliers hold the switch block down with your thumb Grab the To remove the power switches remove the connectors and gently pull up while using a screws from the door support casting and top rocking motion and remove the 2 wires cover 28 2 Connected to the switch is the switch block
9. ey merge into a connector Disconnect the connector The panel will swing open further 6 Using a nut driver to hold the nuts inside the panel remove the 4 screws holding the fan in place The front cover comes off and the fan can be removed from the inside along with the aluminum baffle 4 Note the white and green wires that go to the switch Pull the 2 blade connectors from the switch User Manual Page 22 7 Disconnect the 2 sets of red and black wires that go to a connector above the fan on the back board Replace the Cooling Fan 1 Snap the connector with the red and black wires into the connector above the fan on the back board 2 Slip the fan into the panel with the red and black wires facing you and exiting to the left 3 Put the 4 screws through the front fan cover and line up the fan with the screw holes from the inside Push the front fan cover flush against the outside of the panel and the screws through the fan 4 Hold the top screws with a screw driver and secure nuts in place with a nut driver 5 Slip the baffle over the bottom screws and re peat the process 6 Connect the large and small connectors of the blue wires to the blades on the power switch The small one is on the back of the switch and the large one is the angled one on the bottom 7 Snap the filter cover and foam filter over the front fan cover User Manual Page 23 Removing and Replacing the LCD Display Removing and R
10. g a 2mm Allen wrench remove the 2 button head screws and lift the sensor out Screw the new sensor in place and snap the connectors together Tuck the connectors back into place Sensor flag Solenoid lock pin 2 With the solenoid engaged in the locking hole rotate the chuck to the illustrated position With the beveled side up slip the knob retainer under the knob and locate threaded holes under counter bored holes in the knob Note the dotted lines Hold in position with your finger and secure with 2 cap screws Rotate the chuck 180 and repeat the process Replace the cover and secure with 3 button head screws Sensor Replace Rotate Sensor 1 Rotate the spindle until the solenoid lock pin snaps back into the locking hole Take the knob and jaw assembly and position all jaws in slots Holding in your hand align the black diameter detect rod in the corresponding notch in the spindle cone See drawing be low Make sure jaws are in spindle slots Slide the assembly all the way in until it stops Bevel side down Top Diameter detect rod Notch User Manual Page 13 Removing and Replacing the A Axis Swing Sensor Removing and Replacing the A Axis Swing Sensor 1 Locate the marked swing sensor cable and un plug the sensor connector r 7 2 Note the access hole in the dust shield cover EL 7 i 4
11. ge 3 User Manual Page 10 Removing and Replacing the Nema Drive Gear Refer to the Chuck Spindle Drive Belt Replacement instructions for cover chuck and belt removal and reassembly after Nema drive gear has been replaced See Section 24 Schematics and Work In structions page 3 1 Rotate until set screw is easily accessible Using a 1 16 Allen wrench loosen the set screw and remove the gear To replace slip the gear over the shaft with the set screw over the flat Bring the top of the gear flush with the top of the shaft and tighten the set screw Nema drive gear Set screw User Manual Page 11 Removing and Replacing the Rotate Sensor 1 Remove the 3 3mm button head screws with 3 Do not remove the jaws or springs a 2mm Allen wrench and remove the cover from the assembly They are ground in plate position for accuracy and are not to be removed 3MM button head screws 2 Remove the 4 4mm cap screws from the Knob and jaw chuck knob with a 3mm Allen wrench Lift the assembly chuck knob straight up The jaw assembly and knob will come out together Set aside Now rotate the crescent shaped knob retainers and remove 4 cap screws User Manual Page 12 4 With a small flat blade screw driver reach down and pull the solenoid lock pin back out of the locking hole Rotate the chuck so the sensor flag is out of the way as illustrated Depress the clip on the sensor connector and pull apart Usin
12. r to Grind Motor Belt Replacement instruc tions and remove belt See Section 24 Sche matics and Work Instructions page 29 2 Remove the 4 3mm screws on the wheel cover Remove leaving hose attached to cover The casting is pinned to the cartridge block With gentle pressure pull the casting from the block but do not disconnect any wires It may be necessary to tap with a soft mallet Care fully place the casting out of the way 3 Slide the arbor lock pin through the hole in the wheel guard casting and rotate wheel until it engages 6 Loosen the 3mm set screw from the drive pul ley but do not remove 4 With a 2 socket remove the wheel retainer nut and remove the wheel User Manual Page 36 7 Loosen the 2 3mm set screws in the top of forward to allow clearance to do this Leave the cartridge block that holds the cartridge in the pulley set screw loose place 11 Take the wheel casting and align the dowel pins with the holes in the cartridge block Push or tap into place Secure with 4mm screws 8 Slide the cartridge forward allowing enough room to remove the drive pulley 12 Now slide the cartridge all the way forward until it stops against the wheel casting Using a torque wrench torque the set screws to inch lbs Do not over tighten Remove the pulley and pull the cartridge out through the front of the block 9 To replace the cartridge slide into block but do not
13. rk Instructions page 3 User Manual Page 9 Removing and Replacing the Chuck Locking Solenoid Refer to the Chuck Spindle Drive Belt Replacement instructions for cover and chuck removal and re assembly after solenoid change See Section 24 Schematics and Work Instructions page 3 1 Remove the cover and chuck Disconnect both connectors Place the wires out of the way Sensor connectors Solenoid connectors assembly 2 Unscrew the 2 4mm screws that secure the solenoid in place from the back of the housing Take a small flat blade screw driver and pull the lock pin back and out of the locking hole Rotate the spindle cone so the pin remains out of the locking hole 3 Continue holding the pin back while gently lifting the solenoid upward out of the recess and tilting it to the bottom of the housing Once it is free remove it To replace the solenoid rotate the spindle cone so the locking hole is visible and in the center of the solenoid mounting recess Keep the solenoid in straight alignment with the locking hole Hold the pin back and tuck it under and into the locking hole and seat it in the recess Secure with the 2 screws and connect the connectors Tuck the connectors back into place With the wires secured refer to the Chuck Spindle Belt Drive Belt Replacement instructions for reassembly of the chuck and cover See Section 24 Schematics and Work Instructions pa
14. the E Stop and remove all wires 3 Though different the switch block removes and installs the same as the E Stop switch Follow the same instructions as above 4 Once the switch block has been removed re User Manual Page 27 X Ei 14666 4 Tg gt SOHS a X 02 1 449 S 0dd A371Nd JANG 3 3199921 2 YOLON GNIND 94 YIHSYM 1 2 4 0 92146 44 26 EN 94 2 Ny 9 HSNYE YOLOW YS VNSEYZLVS NNNOVA 31870214 4 2 i HOLON 380692144 GNOYHS HOLON 160 92144 User Manual Page 28 User Manual Page 29 Removing and Replacing Grind Motor Assembly 4 Push the belt change icon 1 Turn the machine on 2 Push the check icon 5 The X Axis will move into the belt change po sition and stop Shut the machine off and dis connect power source 6 Refer to Grind Motor Belt Replacement instruc tions and remove belt See Section 24 Sche matics and Work Instructions page 29 7 Unplug the motor connector wires m User Manual Page 30 8 Remove the 4 screws and washers holding the motor in place 9 Slide the motor down the slotted bracket and out of the machine Remove the cooling hose connected to the motor 10 To replace the motor assembly the machine must in the belt change position 11
15. tighten set screws 10 Slip the drive pulley over the end of the arbor Shaft It will be necessary to slide the cartridge User Manual Page 37 1 Reinstall the wheel 3 Refer to Grind Motor Belt Replacement to in stall and set proper tension on belt See Sec tion 24 Schematics and Work Instructions page 29
16. ufficient room between the springs to engage a 4mm wrench on the flats of the rod Apply pressure until the rod breaks loose Ro tate the rod out by moving the wrench be 1 Remove cover and chuck only tween the springs be careful not to damage 2 Rotate the 2 jaws next to the diameter detect them Place a drop of 243 blue loctite on the rod by gently pushing forward on the spring new rod threads and screw in place Do not and rotating the jaws outward and up 180 over tighten Reposition jaws and reassemble User Manual Page 18 User Manual Page 19 ELECTRICAL WIRING DIAGRAM SA12150EF wawawa ra VS HOLDANNODONIHOO 7 mm STINMHALLOINNOTSIO PS HE wann PL OZE HONTH 22 d RER 2 WESSAWNN 208243434 338 TENYA LLVOO 1 LEW TWNLOV LOIdSO __ 2 20 1 a JON 00 AVOHEENEL JO ENOLLVOOT LON SHOLOMEHAL SOTAGE Nv cz E 1 Ede Ha 0789 L A0 Z OBY User Manual Page 20 User Manual Page 21 Removing and Replacing the Cooling Fan Removing the Cooling Fan 1 Remove the 2 screws holding the panel to the machine 5 On the front of the panel snap the fan filter cover from the fan 2 Swing the panel open 3 There are red and black wires coming from the fan and a white and green wire coming from the power switch Th
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