Maintenance Manual. Note: This document is broken up into the following 6 sections of prescribed maintenance.

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1 How to Perform Maintenance On LPKF Circuit Board Plotters Requirements - LPKF Circuit Board Plotter - BoardMaster Software mm Allen wrench (for earlier model machines) - 3mm Allen Wrench - 4mm Allen Wrench (for large table machines) - Spray Silicone, Teflon or Graphite - Small Brass Wire Brush - Isopropyl Alcohol - 3 in 1 oil or equivalent - Plastic Lubricant for lead screw LPKF p/n (for all models except 95sII, AutoMill, and 101 Hi-P) or - Universal Lubricant for ball tread assembly LPKF p/n (for models 95sII, AutoMill, and 101 Hi-P only) Content Note: This document is broken up into the following 6 sections of prescribed maintenance. I) Lubricating the X-axis lead screw/ball tread assembly and guide bar wipers II) Lubricating the Y-axis lead screw/ball tread assembly and guide bar wipers III) Lubricating the Z-axis Linear Bearings IV) Removing, Cleaning, and Lubricating the Working Depth Limiter V) Cleaning the Collet Assembly VI) Replacing the Working Depth Limiter Requirements... 1 Content... 1 Section I: Lubricating The X-Axis (perform every 6 months)... 2 Section II: Lubricating The Y-Axis (perform every 6 months)... 4 Section III: Lubricating the Z-axis Linear Bearings (perform every 3 months)... 6 Section IV: Cleaning and Lubricating the Working Depth Limiter (perform every 3 months, or whenever the Working Depth Limiter becomes difficult to adjust. Also Perform Section V at the same time)... 7 Section V: Cleaning the Collet Assembly (perform whenever the Working Depth Limiter is being cleaned) Motor Types: Section VI: Replacing the Working Depth Limiter (perform every 3 months, or whenever the Working Depth Limiter becomes difficult to adjust) Also Perform Section V at the same time! References Author Page 1 of18

2 Section I: Lubricating The X-Axis (perform every 6 months) 1) To lubricate the X-axis lead screw/ball tread assembly, it is first necessary to remove the controller box. Please perform steps 1-8 from the How to Remove The Controller Box document. Once removed, you will be able to see the X- axis lead screw/ball tread assembly. 2) Apply a small amount of the appropriate lubricant (see Requirements) to the lead screw on each side of the supernut (see figure 1-1) or to the ball tread assembly (see figure2-1). Figure 1-1 Lead Screw Supernut Figure 2-1 Ball Tread Assembly 3) Due to the tight tolerances of the lead screw and supernut, it is not necessary to place the lubricant across the entire screw. If you do, the lubricant will build up and drip onto the table or board surface during operation (see figure 2-2). Figure 2-2 Only lubricate aproximately 1 inch on each side of the supernut. 4) Some machines will have a set of parallel bars under the table that have wiper pads that traverse with the axis (see figure 2-3). Other machines will have guide bars with linear bearings (see figure 3-1). Page 2 of18

3 Figure wiper pad is shown in this picture. There is an arrow pointing to where the second is located, but it can not be seen in this picture. There are 2 more located on the opposite side. 5) If you have wiper pads as shown in figure 2-3, place several drops of 3 in 1 or equivalent oil on each of the 4 pads. 6) If you have linear bearings as indicated in figure 3-1, place several drops of 3 in 1 or equivalent oil on a rag and wipe it on the guide bars. This will apply a thin film of oil on the guide bars. Figure 3-1 These are the guide bars. Wipe with an oiled rag to apply a thin coat of lubricant. 7) Replace the controller box by performing steps 9-11 of the How to Remove The Controller Box document. Page 3 of18

4 Section II: Lubricating The Y-Axis (perform every 6 months) 1) To lubricate the Y-axis lead screw/ball tread assembly, it is first necessary to remove the Y-Axis hood. This is done by removing the four 3mm Allen screws securing the hood (see figure 3-2 and 3-3). Figure 3-2 Figure 3-3 Remove these four screws to gain access to the Y-axis lead screw. Note: Picture shown is from a newer machine. The cover on some machines may be black. 2) Apply a small amount of the appropriate lubricant (see Requirements) to the lead screw on each side of the supernut (see figure 1-1) or to the ball tread assembly (see figure2-1). 3) Due to the tight tolerances of the lead screw and supernut, it is not necessary to place the lubricant across the entire screw. If you do, the lubricant will build up and drip onto the table or board surface during operation (see figure 4-1). Page 4 of18

5 Figure 4-1 The super nut is located under this plate. Place the approriate lubricant on each side of the super nut. 4) Some machines will have a set of parallel bars under the Y-axis hood that have wiper pads that traverse with the axis (see figure 4-2). Other machines will have guide bars with linear bearings (see figure 5-1). 5) If you have wiper pads as shown in figure 4-2, place several drops of 3 in 1 or equivalent oil on each of the 4 pads. Figure 4-2 Here is one of the 4 wiper pads mentioned in step 11. There are 3 more pads that cannot be seen in this picture. 6) If you have linear bearings as indicated in figure 5-1, place several drops of 3 in 1 or equivalent oil on a rag and wipe it on the guide bars. This will apply a thin film of oil on the guide bars. Page 5 of18

6 Figure 5-1 These are the guide bars. Wipe with an oiled rag to apply a thin coat of lubricant. 7) Replace the Y-axis hood. Section III: Lubricating the Z-axis Linear Bearings (perform every 3 months) 1) Place a couple of drops of 3 in 1 or equivalent oil on the Z-axis linear bearings (see figure 5-2). Figure 5-2 Place a couple of drops of 3 in 1 or equivalent oil in each linear bearing. Micrometer Option for Z-axis depth control. LPKF p/n ) Manually push the head assembly up and down several times to distribute the oil. 3) Plug all the connectors back into the controller box and turn on the power to the LPKF Milling Machine. The head will come to rest in the exchange position. Page 6 of18

7 Section IV: Cleaning and Lubricating the Working Depth Limiter (perform every 3 months, or whenever the Working Depth Limiter becomes difficult to adjust. Also Perform Section V at the same time) 1) If there is a tool in the collet, remove the tool. 2) Now you must remove the entire motor so you can remove the Depth Limiter. Please use the pictures below to determine what type of motor you have. (if you do not see the correct style motor holder for your machine, please skip to step 6. This motor holder is on most of the older machines and is more complicated to remove.) Figure 6-1 You must loosen all 5 of these screws to move the motor up and down. The threeon top the block are 2.5mm, and the two on the side of the block are 3mm. 91S/HS 92S (after 1997) 92SII C30 C30/S M30 & M30/S This is the quick change tool bar. You might have to remove this to raise the motor enough to allow the removal of the depth limiter. Page 7 of18

8 Figure S, 95sII, 101 Hi-P & Automill This collar is set to factory specifications. Loosen these two screws to raise the motor. Figure S/VS C60 93S M60 X60 & C100/HF Loosen these two screws and remove the 3 pin din connector to remove the motor Page 8 of18

9 C20 Figure 7-2 Remove this Connector. Loosen these two quick release levers and pull the motor out. The collar on the motor is set to factory specifications 3) Loosen the appropriate Allen screws based on the pictures above and remove the motor so the motor won t inhibit the removal of the depth limiter. 4) Loosen the following screws to remove the Depth Limiter. Figure 8-1 Do not adjust these ball screws, they are set at the factory. loosen the 3mm allen screw located here. Remove the vacuum hose. Page 9 of18

10 Figure 8-2 Remove the second 3 mm allen screw located here and you will be able to remove the bracket below. 5) Slide the Depth Limiter away from the head. Look for the flat washer shown in the picture below. If you don t see it, it could be stuck to the opening the motor slides through (see figure 8-3) (Now skip to step 8). Note: If you have the Illuminated Working Depth Limiter installed, the Working Depth Limiter cannot be completely removed due to wiring. It can be moved to the side enough to complete the maintenance properly. Metal Washer (not present on all machines.) Figure 8-3 6) Machines with the following style motor holding device must be removed in a different fashion (see figures 9-1 and 9-2) Page 10 of18

11 Figure 9-1 Remove this 7 mm nut. Remove these two 3 mm Allen Screws. Remove this 3 mm allen screw and you will be able to rem ove the bracket below. Remove this side of the vacuum hose. Look into the Depth Limiter and you will be able to see mm allen screws. Remove these 4 screws. In order get the allen wrench to each of these screws, you must spin the Depth Limiter around taking out one screw at a time. Once the all the screws are loose, gently pull up on the motor and slide the Depth Limiter out. Figure mm allen screws (4) 7) Now unscrew the knurled wheel from the aluminum housing (see figure 10-1). Page 11 of18

12 Figure 10-1 Knurled wheel Aluminum housing Most style machines Figure 10-2 OR Older Machines Figure 10-3 Knurled Wheel (Aluminum housing not shown.) Page 12 of18

13 8) Clean the threads on both the Knurled Wheel and the Aluminum housing with a small brass wire brush. 9) Lubricate the threads with silicone, Teflon or graphite. Do not lubricate with oil. It will act like a magnet to the dust created when milling causing you to have to clean the Depth Limiter more often, possibly causing it to seize. 10) Screw the Knurled Wheel and the Aluminum housing back together. 11) Ensure the metal washer from figure 8-3 is put back on top of the Knurled Wheel. 12) Do not put the motor assembly back in yet. Section V: Cleaning the Collet Assembly (perform whenever the Working Depth Limiter is being cleaned) Note: If needed, you can use alcohol as a cleaning agent for the collet. Warning: Do not lubricate the inside of any collet. This can cause the tool to slip out of the collet assembly while milling. 1) Take the motor in your hand and determine which motor you have based on the pictures below. Motor Types: LPKF 91, LPKF 92 (No Picture Available) (13k rpm) 101LC, LPKF 91s, LPKF92s, 91s, 92s (20k rpm) Figure 11-1 C20 (20k rpm) Figure 11-2 Page 13 of18

14 C30, 92sII (30krpm) Figure s/HS, 92s/HS, C30/s (black cap) (30k rpm) Figure 12-1 C30/s (silver cap), M30/s (30k rpm) Figure LC-VS, 91s/VS, 93s (after 1997), C60, H60, M60, X60 (60k rpm) Figure s (prior to 1997) (60k rpm), C100/HF (100k rpm) Figure 12-4 Page 14 of18

15 101 Hi-P, 101 AutoMill, 95s, 95sII (60k rpm) Figure ) For the motor not shown and the motor in figure 11-1, the collet assembly is a seperable unit. Insert a small brush into the collet to clean it. (Now skip to section VI, step 54) Figure 13-1 Insert a small brush into the collet here. 3) For the motors shown in figure 11-2, 11-3, 12-1, and 12-2, the collet assembly and the motor are a balanced unit. Do not take them apart. Insert a small brush into the collet to clean it. (Now skip to section VI, step 1) 4) For the motors in figure 12-3, and 12-4, the collet itself is a removable/replaceable part. 5) To remove the collet, depress the knob on the top of the motor as if you were doing a tool change. 6) Turn the knob in the counter clockwise direction until the collet slides out into your hand. Figure 13-2 Insert a small brush into the collet here. Keyway 7) Insert a small brush into the collet to clean it (see figure 13-2). 8) This collet has a keyway in it (see figure 13-2). In order to place the collet and the motor assembly back together, the Keyway must be aligned. Page 15 of18

16 9) With the collet in your hand, gently insert it into the opening in the motor. 10) If it does not slide smoothly all the way in, twist the collet around while applying little pressure until the keyway in the collet and the keyway in the motor line up and the collet slides all the way into the motor assembly. 11) Turn the knob in the clockwise direction until the collet retracts into the motor. 12) Pull the knob on the top of the motor up. (Now skip to section VI, step 1) 13) For the motor in figure 12-5, the collet itself is a removable/replaceable part. Machines that were shipped with this type of motor were also shipped with a cleaning kit for the motor. The cleaning kit is shown in figure Figure Tool for cleaning the collet 2. Tool for removing the collet. 3. Lubricant for the end of the spindle. 4. Tool for cleaning the motor without the collet installed. 14) Make sure that the motor is hooked up to it s air source (see figure 13-3). Air source fitting Figure 13-3 Air source, this is the air line that is hooked up to the top of the motor. When air is applied, it opens the collet. 15) Flip the motor over in your hand so you are looking at the collet and place the collet-removing tool (tool # 2 in figure 13-2) on the collet (see figure 14-1). Collet removing tool. Figure 14-1 Page 16 of18

17 16) With the assistance of another person, you must now depress the green button on the upper pneumatic block shown in figure This will actuate the collet assembly and allow you to remove the collet. Depress this button to actuate the collet. Figure 14-2 This valve block might vary slightly depending on the model of machine, but the order o f the valves is the same on each machine. 17) While another person is depressing the green button, turn the collet removing tool counter clockwise until you can pull the collet from the motor, then release the green button. 18) Use the cleaning tool (tool # 2 in figure 13-2) to clean the collet (see figure 15-1). Figure ) Take the motor back in your hand and take the tool labeled # 4 in figure 13-2 and place it into the motor where the collet normally goes (see figure 15-2). Figure ) After moving the tool around to remove any debris, remove the tool. 21) Use the lubricant (# 3 in figure 13-2) and place a very small amount on the end of the spindle. Do not put any lubricant inside the collet or where the collet goes (see figure 15-2). Page 17 of18

18 Place a small amount of lubricant here. Do not place any lubricant inside the collet or where the collet goes. Figure ) Put the collet back into the motor. 23) Have someone depress the green button on the upper pneumatic block (see figure 14-2). 24) Using the collet-removing tool (tool # 2 in figure 13-2), turn the collet clockwise until tight. Section VI: Replacing the Working Depth Limiter (perform every 3 months, or whenever the Working Depth Limiter becomes difficult to adjust) Also Perform Section V at the same time! 1) Slide the depth limiter back under the motor block the same way it was taken out. 2) Replace the bracket and any other Allen screws that were taken off in order to remove the Working Depth Limiter (see figure 8-2 or 9-1 for the location of the bracket and what screws need to be replaced or tightened). 3) Replace the vacuum house (see figure 8-1 or 9-1). 4) Try turning the Knurled Wheel to ensure it was reinstalled properly. It should turn smoothly, but with an audible clicking noise. 5) Put the motor back into the motor holder. 6) Now you must reset your motor height. Please refer to the How To Set The Motor Height document to perform this procedure. References All ProtoMat Manuals LPKF Laser & Electronics Technical Support Author Jeff Bengtson Page 18 of18