User Manual Page 1 SERVICE PARTS REPLACEMENT SCHEMATICS & WORK INSTRUCTIONS USER SECTION CHUCK SWING CASTING ASSEMBLY EXPLODED VIEW: SA12500CA............... PAGE 3 CHUCK SPINDLE DRIVE BELT REPLACEMENT ......................................... PAGE 5 REMOVE/REPLACE CHUCK BELT IDLER ASSEMBLY.................................. PAGE 8 REMOVE/REPLACE CHUCK LOCKING SOLENOID ..................................... PAGE 9 REMOVE/REPLACE NEMA DRIVE GEAR.................................................
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User Manual Page 3 CHUCK SWING CASTING ASSEMBLY SA12500CA
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User Manual Page 5 Removing and Replacing the Chuck Spindle Drive Belt 1. Remove the 3, 3mm button head screws with a 2mm Allen wrench and remove the cover 3MM button head screws plate. 2. Remove the 4, 4mm cap screws from the chuck knob with a 3mm Allen wrench. Lift the chuck knob straight up. The jaw assembly and knob will come out together. Set aside. 4MM cap screws 3. Do not remove the jaws or springs from the assembly. They are ground in position for accuracy and are not to be removed.
User Manual Page 6 4. To loosen and remove belt, insert a flat blade screw driver in the slotted bearing screw. Loosen 6. Replace the belt. Using two fingers on a flat blade screw driver, rotate slotted bearing screw clockwise until belt just pulls to a flat condition. There will be a noticeable increase in resistance past this point of rotation. Continue rotating another 1/16". Hold screw driver in this position and secure bearing lock screw. Tighten 5.
User Manual Page 7 Replace Chuck Spindle Drive Belt 1. 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 below). Make sure jaws are in spindle slots. Slide the assembly all the way in until it 3. 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).
User Manual Page 8 Removing and Replacing the Chuck Belt Idler Assembly Refer to the Chuck Spindle Drive Belt Replacement instructions for cover and chuck removal, belt adjustment and reassembly after replacement of belt idler. See Section 24 Schematics and Work Instructions 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.
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 reassembly after solenoid change. See Section 24 Schematics and Work Instructions page 3. 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 1. Remove the cover and chuck. Disconnect both connectors.
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 Instructions 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.
User Manual Page 11 Removing and Replacing the Rotate Sensor 1. Remove the 3, 3mm button head screws with a 2mm Allen wrench and remove the cover plate. 3MM button head screws 2. Remove the 4, 4mm cap screws from the chuck knob with a 3mm Allen wrench. Lift the chuck knob straight up. The jaw assembly and knob will come out together. Set aside. 4MM cap screws 3. Do not remove the jaws or springs from the assembly. They are ground in position for accuracy and are not to be removed.
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. Using 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.
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 unplug the sensor connector. 2. Note the access hole in the dust shield cover. 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.
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User Manual Page 15 CHUCK ASSEMBLY SA12505TA
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User Manual Page 17 Removing and Replacing Diameter Detect Rod Refer to the Chuck Spindle Drive Belt Replacement instructions for cover and chuck removal and reassembly after diameter detect rod has been replaced. See Section 24 Schematics and Work Instructions page 3. 3. Turn the jaw assembly counter clockwise until it bottoms out in the knob. Knob and jaw assembly 1. Remove cover and chuck only. 2.
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User Manual Page 19 ELECTRICAL WIRING DIAGRAM SA12150EF
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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. They merge into a connector. Disconnect the connector. The panel will swing open further. 6.
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.
User Manual Page 23 Removing and Replacing the LCD Display Removing and Replacing the LCD Display 1. Remove the screws on the door support and top cover. 2. Remove the door support cover and lift the top cover. 3. Located at the bottom of the LCD display is the interface board. Using two fingers on the outside of the board, pull from the LCD receptacle. Leave all wires connected to board. 4. Unplug the green five wire connector from the LCD. 5.
User Manual Page 24 6. Remove the 7, ¼” 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 ¼” socket is necessary for clearance. 2. Plug in interface board, green five wire connector and the RS232 connector and screw.
User Manual Page 25 Removing and Replacing Switches Removing and Replacing The E-Stop, Cycle Start and Feed Hold Switches To remove the power switches, remove the screws from the door support casting and top cover. Remove the support door casting and tilt it up. . E-Stop 1. Using a pair of needle nose pliers, hold the switch block down with your thumb. Grab the connectors and gently pull up while using a rocking motion and remove the 2 wires. 2. Connected to the switch is the switch block.
User Manual Page 26 3. Securing the switch in place is a plastic nut at the base of the threads. Use needle nose pliers to remove the nut and slide the switch out. move the plastic retainer nut, also same as EStop. 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.
User Manual Page 27 GRIND MOTOR ASSEMBLY SA12640MA
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User Manual Page 29 Removing and Replacing Grind Motor Assembly 1. Turn the machine on. 2. Push the check icon. 4. Push the belt change icon. 5. The X-Axis will move into the belt change position and stop. Shut the machine off and disconnect power source. 3. Push the tool icon. 6. Refer to Grind Motor Belt Replacement instructions and remove belt. See Section 24 Schematics and Work Instructions page 29. 7. Unplug the motor connector wires.
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. 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.
User Manual Page 31 Removing and Replacing Grind Motor Belt 1. 2. 3. 4. 5. 6. 7. 8. 9. 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. Remove the belt access panel at back of machine. Loosen the 4 mounting bolts and swing the motor up to loosen the belt. Tighten one bolt and remove the belt. Install the new belt and loosen the bolt.
User Manual Page 32 Removing and Replacing Grind Motor Brushes 1. Refer to Removing and Replacing Grind Motor Assembly instructions to remove and replace 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 noting 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.
User Manual Page 33 SPINDLE CARTRIDGE ASSEMBLY SA12615TA
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User Manual Page 35 Removing and Replacing the Spindle Arbor Cartridge Assembly Removing and Replacing the Spindle Arbor Cartridge Assembly. 5. Remove the 4, 4mm screws holding the wheel casting in place. 1. Refer to Grind Motor Belt Replacement instructions and remove belt. See Section 24 Schematics 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.
User Manual Page 36 7. Loosen the 2, 3mm set screws in the top of the cartridge block that holds the cartridge in place. forward to allow clearance to do this. Leave the pulley set screw loose. 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.
User Manual Page 37 1. Reinstall the wheel. 2. Reinstall the wheel cover. 3. Refer to Grind Motor Belt Replacement to install and set proper tension on belt. See Section 24 Schematics and Work Instructions page 29.
