ProtoTRAK SMX
K2, K3, K4 & Retrofit
®
Safety, Installation, Maintenance, Service & Parts List Manual
Document: P/N 24319
Version:
060911
Southwestern Industries, Inc
P. O. Box 9066
Compton, CA 90224-9066 USA
T | 310.608.4422 | F | 310. 764.2668
Plant location: 2615 Homestead Place
Rancho Dominguez, CA 90220-5610 USA
Service Department: 800.367.3165
e-mail: sales@southwesternindustries.com | service@southwesternindustries.com |web: southwesternindustries.com
Copyright  2010, Southwestern Industries, Inc. 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 Southwestern Industries, Inc.
While every effort has been made to include all the information required for the purposes of this
guide, Southwestern Industries, Inc. 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.
Southwestern Industries, Inc.
2615 Homestead Place
Rancho Dominguez, CA 90220-5610
Phn 310.608.4422  Fax 310.764.2668
Service Department
Phn 800.367.3165  Fax 310.886.8029
Table of Contents
1.0
1.1
1.2
Safety
1.3
Safety Publications
Danger, Warning, Caution & Note Labels &
Notices as used in this Manual
Safety Precautions
2.0
Installation
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.16
Floor Plan, Layout & Space Requirements
Uncrating
Shortages: Inventory Checklist
Installation Instructions & Checklist
Machine Specifications
Maximum Work Capacities
ProtoTRAK SMX Control Hardware
Lifting and/or Moving the Machine
Cleaning
Leveling: Leveling Tolerance is .0005”/10”
Electrical Connection
2.11.1 Phase Converters
2.11.2 Flange Disconnect/Transformer
Option
Air Connection (Optional)
Mounting the Display Pendant
Cable Interconnections
Lubrication
2.15.1 Manual Lubrication
2.15.2 Head Lubrication
ProtoTRAK SMX Euclid Block Procedure
3.0
Troubleshooting by Symptom
2.12
2.13
2.14
2.15
3.1
3.2
3.3
3.3.11
3.3.12
1
3.4
6
3.5
4.0
4.1
4.2
4.3
4.4
Problems Relating to Machining Results
38
3.1.1
Poor Finish
3.1.2
Circles Out of Round
3.1.3
Taper Cut on a Programmed Straight
Line Move
3.1.4
Parts Have Incorrect Dimensions
Problems Regarding the Motion of the
Machine
3.2.1
Run Away Axis
3.2.2
Slow Down Axis
3.2.3
Axis Will Not Jog
3.2.4
Axis Motor Motion is Not Smooth
3.2.5
Vibration in Motion
3.2.6
Searching Axis
Problems Relation to the Operation of
the Control
3.3.1
Display Blanks
3.3.2
Bad Picture on the Display
3.3.3
Keyboard Lockup
3.3.4
Fault X or Y
3.3.5
Problems Reading Floppy Disk
3.3.6
System Will Not Turn On or Boot Up
3.3.7
System Reboots by Itself
3.3.8
System Shuts Off
3.3.9
Will Not Hold Calibration
3.3.10 Auxiliary Functions Not Working
4.5
4.6
4.7
4.8
4.9
Stop Error
Limit Switch Error (optional)
Problem with the Measurements
3.4.1
X, Y & Z-Axis Measurements Do
Not Repeat
3.4.2
X, Y & Z-Axis Measurements Are
Not Accurate
3.4.3
The DRO is Not Counting
3.4.4
X, Y, & Z-Axis DRO Counting In
Wrong Direction
3.4.5
X, Y & Z Axis Electric Handwheels
Turn in Wrong Direction
Problems with the Machine Tool
3.5.1
Spindle Stalls or Turns Off
3.5.2
Spindle Motor Hums or Will Not Run
3.5.3
Spindle Runs Backwards
3.5.4
Head Noise
Diagnostics
The Machine Tool & Set-Up
4.1.1
The Milling Machine Checklist
4.1.2
A Special Work About X & Y Gibs
4.1.3
Lubrication
4.1.4
Machining Set-Up
The Mechanical Drive Train (X, Y)
4.2.1
Keys to Ballscrew Alignment
Computer/Pendant Diagnostics
4.3.1
Checking Floppy Drive
Motor Diagnostics
4.4.1
Cable Connections
4.4.2
To Check Motor Encoders
4.4.3
Encoder Counts to Pendant
4.4.4
Moving Problem from One Axis
To Another
Servo Driver
Glass Scales
4.6.1
Alignment of Scales
4.6.2
Measurements Do Not Repeat
TRAK Sensors
4.7.1
Faulting Axis
4.7.2
Measurements to not Repeat
Electrical
4.8.1
Checking A/C Voltage
4.8.2
Checking Fuses
4.8.3
Cable Breakout Box Connections
4.8.4
Cable Connections
4.8.5
Spindle Control Electrical Box
Service Codes
4.9.1
Software Codes
4.9.2
Machine Set-Up Codes
4.9.3
Diagnostic Codes
4.9.4
Operator Defaults/Options Codes
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ProtoTRAK
SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
57
5.0
5.1
5.2
Procedures for Replacements &
Maintenance
Replacements
5.1.1
Servo Motor Replacement
5.1.2
Servo Driver Replacement
5.1.3
Computer Module Replacement
5.1.4
System Flash Disk Replacement
5.1.5
Cable Routing on Machine
5.1.6
TRAK Sensor
5.1.6.1 Replacing the M5 Base
5.1.6.2 Replacing The TRAK
Sensor
5.1.7
Glass Scale Replacement
5.1.8
Power Drawbar
5.1.9
Ball Screw Replacement, X-Axis
5.1.10 Ball Screw Replacement, Y-Axis
5.1.11 Air Solenoid Replacement:
Auxiliary Function Machines Only
5.1.12 Spindle Motor Wiring
5.1.13 Feed Trip Adjustment
5.1.14 Quill Clock Spring Replacement &
Adjustment
5.1.15 Spindle Motor Removal &
Replacement
5.1.16 Drive Belt Replacement
5.1.17 Timing Belt Replacement
5.1.18 Brake Shoe Replacement
5.1.19 Spindle Replacement
Maintenance
5.2.1
Gib Adjustments
5.2.2
Calibration & Backlash Constants
5.2.3
Head Rotational and Tramming
5.2.4
Limit Switch Option
6.0
Retrofit Installation
7.0
Installation Procedures
6.1
6.2
6.3
6.4
7.1
7.2
7.3
7.4
7.5
7.6
Installation Tools & Hardware
Required Tools/Hardware
Suggested Fastener Stock
Pre-Installation Requirements
7.6.1
X & Y-Axis Sensor
X & Y Glass Scale Installation (Optional)
7.7.1
X-Axis Scale Installation
7.7.2
Y-Axis Scale Installation
Limit Switch Installation
System Interconnection
7.9.1
ProtoTRAK SMX Basic System
Configuration
7.9.2
Cable Routing
7.7
80
7.8
7.9
8.0
8.1
8.2
8.3
8.4
9.0
9.1
9.2
9.3
Z Motor/Ball Screw Assembly
Installation of the Base Plate
Installation of the Ball Screw
Installation of the Motor Assembly
Lagun Z-Axis Cut-Out
Introduction to Self-Service
When You Have a Service Problem
157
9.1.1
Communication with the Customer
Service Group
Warranty
9.2.1
Disclaimers of Warranties
9.2.2
This Warranty Extends to
Self-Service
Replacements
9.3.1
Exchange Program
9.3.2
Return Authorization (RA) Number
Figures and Parts Lists
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
117
X & Y Ball Screw Installation
119
7.1.1
Removing the Table & Lead Screws
7.1.2
X-Axis Ball Screw Installation,
Part 1
7.1.3
Y-Axis Ball Screw Installation
7.1.4
X-Axis Ball Screw Installation,
Part 2
Motor/Servo Driver Installation
7.2.1
X-Axis Motor/Servo Driver
Installation
7.2.2
Y-Axis Motor & Servo Driver
Installation
Pendant Installation
7.3.1
Pendant Arm Installation
7.3.2
Installation of the Pendant Display
Cable Breakout Box Mounting
Z-Axis Glass Scale Installation
TRAK Sensor Installation (Optional)
1
2
3
4
5
6
7
8
9
9-1
10
11
12
13
14
15
Fig. 16
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
17
18
19
20
21
22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Machine Footprints
Overall Dimensions
Knee Mill Component Identification
Knee Mill Rear View
Lifting the Machine
Placement of Levels
Leveling Screws
Wiring the K2, K3 or K4 Non-Spindle Control
Wiring the K2, K3 or K4 Spindle Control
Wiring the K2, K3 or K4 Spindle Control
Flange Disconnect/Transformer Option
Transformer Option Schematic
Air Regulator/Solenoid Assembly
Pendant Cable Connections, Left Side
Pendant, Right Side
Cable Connection Diagram, Non-Spindle
Control
Cable Connection Diagram, Spindle Control
Options
Knee Mill Lubrication
Euclid Block
Electrical Box Schematic
Schematic Diagram of Spindle Control Option
LED’s on Spindle Control Board
Computer Module & LCD/Enclosure
Replacement
Compute Module & LCD/Enclosure
Replacement
Flash Disk Replacement
M5 Base Mounting
TRAK Sensor Mounting
ii
ProtoTRAK
147
SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
27
28
29
30
31
32
33
34
35
K-Mill Sensor Assembly
K-Mill Z-Axis Glass Scale Assembly
Glass Scale Alignment
Power Drawer Assembly
X-Axis Drive Assembly
Y-Axis Drive Assembly
Spindle Motor Wiring
Feed Trip Adjustment
Quill Clock Spring Replacement
& Adjustment
Fig. 36
Spindle Removal & Replacement
Fig. 37
Drive Belt Replacement
Fig. 38
Spindle Replacement
Fig. 39
Table Gib Adjustment
Fig. 40
Table Gib Screen
Fig. 41
Saddle Side Gib Adjustment
Fig. 42
Saddle Bottom Gib Adjustment
(K3 & K4 only)
Fig. 43
Calibration Set Up
Fig. 44
Tramming of Head
Fig. 45
1 Input Limit Switch
Fig. 45-1 2 Input Limit Switch
Fig. 46
X-Leadscrew Assembly
Fig. 47
Y-Leadscrew Assembly
Fig. 48
Leadscrew/Yoke Assembly
Fig. 49
X-Axis Ball Screw
Fig. 50
Ball Screw/Yoke Assembly
Fig. 51
Y-Axis Ballscrew
Fig. 52
Y A-Axis Drive Assembly
Fig. 53
Bearing Housing
Fig. 54
Backing Plate
Fig. 55
X-Axis Drive Assembly
Fig. 56
X Motor Mounting
Fig. 57
Pendant Arm Assembly
Fig. 58
X-Axis Glass Scale Assembly
Fig. 59
X-Bracket Installation
Fig. 60
Y-Bracket Installation
Fig. 61
Other X & Y Brackets Supplied with Kits
Fig. 62
Readerhead Mounting
Fig. 63
Scale Mounting
Fig. 64
X & Y-Axis Limit Switch Installation Drawing
Fig. 65
X & Y-Axis Limit Drilling Chart
Fig. 66
Installation of the Base Plate
Fig. 67
Base Plate & Ball Screw Mounting
Fig. 68
Z-Axis Motor, Electronic Handwheel &
Covers Assembly
Fig. 68-1 Ball Screw Module
Fig. 69
Lagun X Axis Cut Out
Figures found in Section 10.0
Fig. 100 Top Housing Assembly, K4
Fig. 101 Gear Housing Sub-Assembly, K4
Fig. 102 Hi-Low Slip Clutch Sub-Assembly, K4
Fig. 103 Hi-Low Shift Sub-Assembly, K4
Fig. 104 Pulley Pinion Sub-Assembly, K4
Fig. 105 Lower Vari-Disc Sub-Assembly, K4
Fig. 106 Upper Vari-Disk Sub Assembly, K4
Fig. 107 Speed Change Handwheel Sub-Assembly
Fig. 108 Spindle Motor Sub Assembly, K4
Fig. 109 Bottom Housing Assembly, K4
110
111
112
113
114
115
Worm Gear Cradle Sub-Assembly, K4
Quill Feed Selector Sub-Assembly, K4
Quill Pinion Shaft Sub-Assembly, K4
Overload Clutch Trip Sub-Assembly, K4
Feed Reverse Clutch Sub-Assembly, K4
Quill Spindle Sub-Assembly, K4
Fig. 116 K2/K3 & K4 Head Top Assembly w/ Spindle
Control Option
Fig. 117 K2/K3 & K4 Electrical Enclosure-Spindle
Control Option
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
118
119
120
121
122
123
Fig. 124
Fig. 125
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
126
127
128
129
130
131
132
133
134
135
136
137
Top Housing Assembly, K2/K3
Gear Housing Sub-Assembly, K2/K3
Hi-Low Shift Clutch Sub-Assembly, K2/K3
Hi-Low Shift Sub-Assembly, K2/K3
Pulley Pinion Sub-Assembly, K2/K3
Lower Vari-Disc Drive Sub-Assembly,
K2/K3
Upper Vari-Disc Drive Sub-Assembly,
K2/K3
Speed Change Handwheel Sub-Assembly,
K2/K3
Spindle Motor Sub-Assembly, K2/K3
Bottom Housing Assembly, K2/K3
Worm Gear Cradle Sub-Assembly, K2/K3
Quill Feed Selector Sub-Assembly, K2/K3
Quill Pinion Shaft Sub-Assembly, K2/K3
Overload Clutch Trip Sub-Assembly, K2/K3
Feed Reverse Clutch Sub-Assembly, K2/K3
Spindle Sub-Assembly, K2/K3
K2/K3 Base Machine
K4 Base Machine
Transformer Option 220/440V
Transformer Option/Safety Switch
160
iii
ProtoTRAK
SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
1.0 Safety
The safe operation of the TRAK K Mills depends on its proper use and the precautions taken by
each operator.
•
Read and study this manual and the ProtoTRAK SMX Programming, Operating, and Care
Manual. Be certain every operator understands the operation and safety requirements of
this machine before its use.
•
Always wear safety glasses and safety shoes.
•
Always stop the spindle and check to ensure the CNC control is in the stop mode before
changing or adjusting the tool or workpiece.
•
Never wear gloves, rings, watches, long sleeves, neckties, jewelry, or other loose items
when operating or around the machine.
•
Use adequate point of operation safeguarding. It is the responsibility of the employer to
provide and ensure point of operation safeguarding per OSHA 1910.212 - Milling
Machine.
1.1 Safety Publications
Refer to and study the following publications for assistance in enhancing the safe use of this
machine.
Safety Requirements for Manual Milling, Drilling and Boring Machines with or without
Automatic Control (ANSI B11.8-2001). Available from The American National Standards
Institute, 1819 L Street N.W., Washington D.C. 20036
Concepts And Techniques Of Machine Safeguarding (OSHA Publication Number 3067).
Available from The Publication Office - O.S.H.A., U.S. Department of Labor, 200 Constitution
Avenue, NW, Washington, DC 0210.
1.2 Danger, Warning, Caution, and Note Labels & Notices
As Used In This Manual
DANGER - Immediate hazards that will result in severe personal injury or death. Danger labels
on the machine are red in color.
WARNING - Hazards or unsafe practices which could result in severe personal injury and/or
damage to the equipment. Warning labels on the machine are orange in color.
CAUTION - Hazards or unsafe practices, which could result in minor personal injury or
equipment/product damage. Caution labels on the machine are yellow in color.
NOTE - Call attention to specific issues requiring special attention or understanding.
1
Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Safety & Information Labels Used On The
TRAK K Milling Machines
It is forbidden by OSHA regulations and by law to deface, destroy or remove any
of these labels
2
Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Safety & Information Labels Used On The
TRAK K2, K3 & K4 Milling Machines
It is forbidden by OSHA regulations and by law to deface, destroy or remove any
of these labels
Power Requirements at 220 and 440 Volts, 3-phase 60 Hz
SMX K2/K3
Vari-speed Head
Overload Setting
220 V
Overload Setting
440 V
FLA of Largest
Motor at 220 V
FLA of Largest
Motor at 440 V
FLA of Machine
at 220 V
FLA of Machine
at 440 V
SMX K4
Spindle Control
Vari-speed Head
8.5 A
11 A
14 A
4.25 A
n/a
7A
8.5 A
11 A
14 A
4.25 A
n/a
7A
8.5 A
11 A
14 A
4.25 A
n/a
7A
Spindle Control
17.5 A
n/a
17.5 A
n/a
17.5 A
n/a
1.3 Safety Precautions
3
Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
1. Do not operate this machine before the TRAK K Mill Installation, Maintenance,
Service and Parts List Manual, and ProtoTRAK SMX Programming, Operating &
Care Manual have been studied and understood.
2. Do not run this machine without knowing the function of every control key, button, knob,
or handle. Ask your supervisor or a qualified instructor for help when needed.
3. Protect your eyes. Wear approved safety glasses (with side shields) at all times.
4. Don't get caught in moving parts. Before operating this machine remove all jewelry
including watches and rings, neckties, and any loose-fitting clothing.
5. Keep your hair away from moving parts. Wear adequate safety headgear.
6. Protect your feet. Wear safety shoes with oil-resistant, anti-skid soles, and steel toes.
7. Take off gloves before you start the machine. Gloves are easily caught in moving parts.
8. Remove all tools (wrenches, chuck keys, etc.) from the machine before you start. Loose
items can become dangerous flying projectiles.
9. Never operate a milling machine after consuming alcoholic beverages, or taking strong
medication, or while using non-prescription drugs.
10. Protect your hands. Stop the machine spindle and ensure that the CNC control is in the
stop mode:
• Before changing tools
• Before changing parts
• Before you clear away the chips, oil or coolant. Always use a chip scraper or brush
• Before you make an adjustment to the part, fixture, coolant nozzle or take
measurements
• Before you open safeguards (protective shields, etc.). Never reach for the part,
tool, or fixture around a safeguard.
11. Protect your eyes and the machine as well. Don't use compressed air to remove the
chips or clean the machine.
12. Disconnect power to the machine before you change belts, pulley, and gears.
13. Keep work areas well lighted. Ask for additional light if needed.
14. Do not lean on the machine while it is running.
15. Prevent slippage. Keep the work area dry and clean. Remove the chips, oil, coolant and
obstacles of any kind around the machine.
16. Avoid getting pinched in places where the table, saddle or spindle head create "pinch
points" while in motion.
17. Securely clamp and properly locate the workpiece in the vise, on the table, or in the
fixture. Use stop blocks to prevent objects from flying loose. Use proper holding
clamping attachments and position them clear of the tool path.
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
18. Use correct cutting parameters (speed, feed, depth, and width of cut) in order to prevent
tool breakage.
19. Use proper cutting tools for the job. Pay attention to the rotation of the spindle: Left
hand tool for counterclockwise rotation of spindle, and right hand tool for clockwise
rotation of spindle.
20. After an emergency stop, always turn the FORWARD/REVERSE switch to "Off" (STOP)
before releasing or resetting the E-Stop.
21. 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.
22. Check the direction (+ or -) of movement of the table, saddle, and quill when using the
jog or power feed or ram out.
23. Don't use dull or damaged cutting tools. They break easily and become airborne.
Inspect the sharpness of the edges, and the integrity of cutting tools and their holders.
Use proper length for the tool.
24. Large overhang on cutting tools when not required result in accidents and damaged
parts.
25. Handwheels must have the crank folded inside when using CNC programmed machining
or rapid feeds, power feed or jog.
26. Prevent fires. When machining certain materials (magnesium, etc.) the chips and dust
are highly flammable. Obtain special instruction from you supervisor before machining
these materials. Keep flammable materials and fluids away from the machine and hot,
flying chips.
27. Changing the speed of rotation of the spindle must be done while the rotation is on. It is
recommended to stop and start the spindle at a low rate of speed.
28. For non-spindle control machines - interlocked table guards. Interlocked table guards
may be purchased from Southwestern Industries, Inc. if deemed necessary by the user.
5
Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit 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 – K2, K3 & K4
Figure 1 – Machine Footprints
Weight (approximate) net
Weight (approximate) shipping
Pallet Size
A
Overall width
B
Overall length
C
Base width
D Width between leveling screws
E
Distance between leveling screws
F
Base length
K2
2200 lbs
2500 lbs
6’ x 6’
101”
66”
24.2”
21.9”
29.1”
37.4”
K3
2800 lbs
3100 lbs
6’ x 6’
103”
70”
24.2”
21.9”
29.7”
38.8”
K4
3600 lbs
3900 lbs
6’ x 6’
103”
72.5”
24”
22.8”
33.1”
42.5”
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 2 - Overall Dimensions
Table Size
T-Slots (number x width)
Dimension G
Dimension G Min
Dimension H Min
Dimension H Max
Dimension I Min
Dimension I Max
Dimension J Max
Dimension K
K2
9” x 49”
3” x 5/8”
86”
65”
56”
67”
36”
49”
18”
69”
K3
10” x 50”
3” x 5/8”
87”
65”
64”
78”
38”
49’
17”
69”
K4
10” x 50”
3” x 5/8”
92”
73”
64”
78”
36”
54.5
23”
77”
7
Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
2.2 Uncrating
Carefully remove the wood crate and protective packaging, paying attention not to scratch,
damage, or mar any parts of the machine.
Remove the cardboard boxes with the PENDANT DISPLAY (handle carefully) and the box
containing the TOOL BOX. The leveling pads and screws for the machine can be found in the
toolbox. The Y way covers are shipped in a separate tube.
Loosen and remove 4 screws and nuts holding the machine to the wood pallet.
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 Shortages: Inventory Checklist
_____ Machine (check model and serial number)
______ Manual drawbar with washer
______ Leveling pads (FC114), screws (FC112) and leveling nuts (FC113) (4 each)
______ Pendant Display with four 1/4-20 screws for mounting
______ Pendant Arm assembled to the column
______ Toolbox with various tools
______ ProtoTRAK SMX Safety, Operation & Programming Manual (P/N 24493)
______ TRAK K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List
Manual (P/N 24319)
______ Way covers K2 – front of saddle - 20875
______ Way covers K3 & K4 – front of saddle - 20872
______ Way covers K2 – rear of saddle - 20874
______ Way covers K3 & K4 – rear of saddle - 20871
In case of shortages, contact the representative from whom you purchased the machine.
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
2.4 Installation Instructions & Checklist
Installer: Use this checklist to assure a complete set-up of the K2, K3, K4 or SMX 2 or 3-axis retrofit.

1. Shut off power to the machine.

2. Visually inspect the 220 or 440V 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. NOTE:
Machine with Spindle Control Option is only available in 220V configuration.

3. Clean the machine if needed and remove any remaining grease.

4. Unlock the table, saddle, and knee gib locks.

5. Mount the pendant to the pendant arm using (4) 1/4-20 x 3/4" socket head cap screws.

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. On retrofits, place the nameplate serial # plate (21934) on the pendant arm. This serial #
plate is the main system # for that machine. Place the serial # plate using 2 drive screws to
the front of the pendant arm near the pivot point of the arm. Use a #36 drill bit for drive
screws. See figure 57.

8. If applicable, load TRAK sensors.

9. On retrofits and TRAK knee mills make sure to plug in the machine ID key on the top corner
of pendant before powering up the pendant. Failure to do so may cause an improper
configuration file. If this happens, go to service code 313 and load the defaults. Loading
defaults will erase any calibration factors that have been done. See pendant connection –
Figure 13.

10. Turn on the power to the machine and to the pendant.

11. Loadmaster and slave software from software upgrade disk. The pendant may or may not
have the latest software loaded. (Retrofits only.)

12. Lubricate all the way surfaces and the ball screws.

13. Jog the table and saddle back and forth until the way surfaces are well lubricated. Oil should
be visible on all the way surfaces.

14. Check the level of the machine. The machine should be level to within 0.0005" front to back
and 0.0005" side to side. Even though it is the responsibility of the customer, make any
adjustments if necessary.

15. Check to make sure that the E-Stop button is functioning correctly. N/A to retrofits for
spindle.

16. Perform Service Code 12, Feed Forward Constant.

17. Perform Service Code 123 to calibrate the X and Y-axis using a 150mm standard.

18. Perform Service Code 11 to automatically calculate the backlash for the X and Y-axis of dual
feedback machines (i.e. TRAK sensor or glass scale with a motor encoder).

19. 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).

20. Check for positional accuracy and repeatability on the X and Y-axis using programs XREPEAT
2 AXIS.PT4 and YREPEAT 2 AXIS.PT4 respectively. Positioning and repeatability values should
be less than or = to 0.0005”. Programs can be found on flash drive under the PT4 folder
followed by the SWI TEST PROGRAMS folder.

21. For 2 axis machines - perform Service Code 123 and press QUILL softkey to calibrate the Zaxis quill using a 75mm standard.

22. For 3 axis machines - perform Service Code 123 and press Z softkey to calibrate the Z-axis
ball screw encoder using a 75mm standard.

23. 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 120 ipm.

24. 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. N/A to retrofits.

25. Install the Y-axis front and rear way covers.

26. 3 axis machines only - If machine has an auxiliary function option, then use accessory key on
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual


pendant and make sure the coolant pump or solenoid for the mister fires. The accessory key
should be in the ON position to test coolant pump or solenoid. The control should be in DRO
mode. Make sure air is hooked up to the machine during the test. If the machine has a
separate coolant pump switch mounted on the pendant arm then turn this on and off to test.
27. If the machine has a power drawbar option, check to make sure that the tools load and
unload properly. N/A to retrofits.
28. Wipe down the machine prior to leaving.
2.5 Machine Specifications
Spindle to Column
Quill Feeds Per Revolution of Spindle
K2
33” x 12” x 16”
5”
86 mm
R8
60-4200 RPM
Low: 40 – 600
High: 300 – 5000
8” to 20”
.0015/.003/.006”
K3
32” x 16” x 16”
5”
86 mm
R8
60-4200 RPM
Low: 40 – 600
High: 300 – 5000
8” to 32”
.0015/.003/.006”
K4
32” x 16 ½” x 16.5”
5”
100 mm
# 40 taper
70-3950 RPM
Low: 40 – 600
High: 300 – 5000
7” to 31”
.0015/.003/.006”
Head Tilt
Head Swivel
Spindle Motor Power
Voltage
Machine with Optional Speed Control
Phase/Cycle
Current- Non Spindle Control
Current – Spindle Control
Maximum Weight of Workpiece
+/- 90°
+/- 45°
3 HP
220/440 V
220 V
3 phase/60 Hz
8.5/4.3 amps
11 amps
750 lbs
+/- 90°
+/- 45°
3 HP
220/440 V
220 V
3 phase/60 Hz
8.5/4.3 amps
11 amps
850 lbs
+/- 90°
N/A
5 HP
220/440 V
220 V
3 phase/60 Hz
14/7 amps
17.5 amps
850 lbs
Movement and ranges (X, Y, Z axis)
Quill Travel (maximum)
Quill Diameter
Spindle Taper
Speed Range
Optional Spindle Control Speed Range
(Not applicable on three axis)
2.6 Maximum Work Capacities
K2/K3
K4
Drilling Mild Steel (2-axis manual feed)
1 ¼”
1 ½”
Tapping Mild Steel
Milling (metal removal rate/mild steel)
Drilling (3-axis systems)
1”
1 ½ inch3/min
½”
1”
2 inch3/min
½”
Maximum work capacities are dependent on a lot of variables that cannot be controlled by the machine
manufacturer. Each one of the following will have an impact on the above numbers: speeds, feeds,
cutter, cutter sharpness, material, setup, coolant and machine adjustments. The numbers above
assume all conditions are optimal and may be higher or lower depending on material composition.
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
2.7 ProtoTRAK SMX Control Hardware
•
•
•
•
•
•
•
•
•
•
•
•
2 or 3-axis CNC, 3-axis DRO
400 PC-based processor
256 MB of RAM
D.C. Servo Motors rated at 280 in-oz continuous torque for X, Y and Z-axes
Precision ground ballscrews in the table and saddle to ensure smooth accurate contours without
backlash
Feedrate override of programmed feedrate and rapid
Polycarbonate sealed membrane and gasket sealed control enclosure to lock out contamination
10 ½" color LCD for clear presentation of prompts, status information and part graphics
Modular design simplifies service and maximizes uptime
256 MB flash drive
Single floppy disk drive for additional part program storage
Optional auxiliary function box for control of coolant pump or spray mist coolant, spindle off and
a programmable rotary table or indexer – 3 axis machines only
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 3
Knee Mill Component
Identification
Item
Part Number
SMX K2 + K3
1
2
3
4
5
20819
SMX K2 + K3
Spindle Control
24162
24000-1
15616
15616
20296
Description
SMX K4
20820
SMX K4
Spindle Control
24163
Spindle Motor
SMX Pendant
Y-Axis Handwheel (Saddle)
X-Axis Handwheel (Table)
X, Y or Z Motor
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 4 - Knee Mill Rear View
Item
Part Number
SMX K2/K3
Description
2
3
220V=20676
440V=20676
24999
24999-1
SMX K2/K3
Spindle Control
24060-1
220V only
24999
24999-1
220V=20676-1
440V=20676
24999
24999-1
SMX K4
Spindle Control
24060-2
220V only
24999
24999-1
4
5
9001
20676-2
9001
n/a
9001
20676-2
9001
n/a
1
SMX K4
Electrical Box
Cable Breakout Box
Cable Breakout Box
with AUX Functions
Lube Pump
Electrical box (if
have tableguard
option)
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
2.8 Lifting and/or Moving the Machine
CAUTION!
The K2, K3 & K4 machines weighs approximately 2200, 2800 & 3600 lbs respectively. Proper
equipment of sufficient capacity must be used when lifting and/or moving the machine.
(See Figure 5 To Prepare the Mill before Lifting):
1.
Using a steel cable with protective sleeving (min 3/4” diameter) or a 3-ton
sling, position sling loops on machine as shown in Figure 5.
2.
Use cardboard pieces or other suitable protective sheets on both sides of
the machine to prevent scratching.
3.
Remove the 4 nuts and screws holding the machine to the wood skid.
4.
Lift the machine (the machine should lift approximately level).
5.
Insert the 4 screws for leveling pads in their place in the bed.
6.
Place the machine in its location (see floor plan and bed footprint drawing).
Carefully positioning each leveling pad under each leveling screw.
7.
Remove the lifting cable or sling and all protective cardboard.
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 5
Lifting the Machine
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
2.9 Cleaning
1. Remove rust protective coating from the machine before moving any slideways (table,
saddle, knee, etc.).
2. The coating is best removed with clean, dry rags. Do not use a cleaning solution that may
damage the rubber way scrapers, plastic parts, or paint.
WARNING!
Do not use gasoline or other flammable cleaning agents for cleaning the machine.
3. It may be necessary to move back and forward, left and right, and up and down the
table, saddle and the ram. Always release the clamp levers (two in front of the table,
one underneath the saddle on each side, and two ram lockbolts on the
right side of the column) before attempting to move the above parts.
CAUTION!
Never move any of the above parts over ways that were not previously cleaned. Serious damage
to the TURCITE surface of slideways can occur.
4. Be certain the table, saddle and spindle move freely and smoothly over their entire length.
2.10
Leveling: Leveling Tolerance is .0005”/10”
1. Set the machine on its 4 leveling pads on a solid, level floor prepared in accordance with the
state and local rules for machine tool installation.
2. Put one or two precision Spirit Levels or Electronic Levels in the center of the table in the
positions illustrated in Figure 6.
3. Adjust the 4 corner leveling screws on their pads until the machine is level to .0005 in/10 in.
4. If the machine must be anchored to the floor, follow the general instruction for installing
machine tools and use for leveling any well-known methods: shims, etc.).
5. If the machine must be installed on vibration mounts/pads (rubber, commercially available
leveling and vibration mounts, etc.) follow the instructions delivered with the mounts/pads,
ordering them to satisfy the load of the machine and the maximum weight of the workpiece.
6. When machine is correctly level, lock the adjusting screws in place with their hex nuts.
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 6
Placement of Levels
I00138
Item
1
2
3
P/N
FC112
FC113
FC114
Title
LEVEL SCREW
LOCK HEX NUT
LEVELING PAD
i00138
Figure 7
Leveling Screws
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
2.11
Electrical Connection
The TRAK K2, K3 & K4 Knee Mills can be configured for 220 or 440 volt 3 phase electricity.
These machines also require a 110V power source to power the control. NOTE: Machines
with Optional Spindle Control is only available in 220 V configurations.
DANGER!
Be certain that 200-volt electricity (typical range 208 – 240V) is used only with a machine labeled
220 volts at the motor and at the electrics box on the back of the column.
Be certain that 400-volt electricity (typical range 415 - 460V) is used only with a machine labeled
440 volts at the motor and at the electrics box on the back of the column.
DANGER!
The 220 or 440-volt line must originate from a dedicated and independent fused box with a
manual shut-off lever. It is the responsibility of the purchaser to supply a wired box that meets
all local codes and regulations.
Incoming 220 or 440-volt power connects to the machine through the electrical box located on
the back of the column. The power cable enters the black box through a hole on the top of the
box.
DANGER!
Only a qualified electrician should wire the 220 or 440-volt 3-phase electricity.
To convert a K2 or K3 machine from 220 to 440 volt power or vice versa 3 things must happen:
spindle motor must be rewired, overload relay must be set to 8.5 amps for 220 V and 4.25 for
440 volts and the voltage stickers on the electric’s box must be replaced.
To convert a K4 machine from 220 to 440 volt power 3 things must happen: spindle motor must
be rewired, overload relay must be replaced and set to 14 amps for 220 V and 7 for 440 volts
and the voltage stickers on the electric’s box must be replaced.
NOTE: Voltage conversion from 220V to 440V not applicable to machine fitted with
the Spindle Control Option.
See Section 5.1.12 for a diagram of how to rewire the spindle motor.
Southwestern Industries recommends the machine be earth grounded by driving a copper rod
into the ground. It is the responsibility of the customer to install this rod.
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 8
Wiring K2, K3 or K4 – Non Spindle Control
Not for retrofit
Part Number
Description
K2/K3/K4
220V & 440V = 20676
220V & 440V = 23438-3
23436
Electrical Box
Overload
Contactor (Qty = 2) (Reverse or Forward)
NOTE: If equipped with Table Guard Option, the Electrical Box the P/N is 20676-2.
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 9
Wiring the K2, K3 or K4 – Spindle Control
Item
1
5
8
12
14
15
Part Number
Description
K2/K3
K4
24060-1
24060-2
22890-500-120
22890-500-64
25105-K2/K3SX
25106-K4SX
22961
21824-5
21824-8
Electrical Box
Resistor (Qty = 2)
AC Drive - Mini Vector - 220V
Relay - Power - 115V DPST
Fuse - 3 AG - Slow Blow 5 AMP
Fuse - 3 AG - Slow Blow 8 AMP
See Figure 117 in the rear of the manual for a more detailed breakdown of parts.
Southwestern Industries recommends the machine be earth grounded by driving a copper rod into the ground. It is
the responsibility of the customer to install this rod.
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 9-1
Wiring the K2, K3 or K4 – Spindle Control
2.11.1
Phase Converters
2.11.2
Flange Disconnect/Transformer (Optional)
For those machines that will be run with a phase converter it is recommended that it is a rotary
type rather than a static phase converters. Rotary phase converters allow for varying loads in
the system. The electrical load on the machine will vary based on the type of cut taken. Static
phase converters can only be used on machines with a non-varying load. The phase converter
for the K mill machines must be rated at a minimum of 5 KVA for the K2 and K3 and 7 KVA for
K4.
The Flange Disconnect Option eliminates the need for the user to provide a power disconnect
for the machine on their own, while the Transformer Option allows the user to provide one
power source to the machine. Note: This option is not available to machine fitted with
the Spindle Control Option.
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 10 – Flange Disconnect/Transformer Option
P/N: 23440-220, 23440-1-220, & 23440-440
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Parts List – Flange Disconnect/Transformer
Item
1
4
5
6
7
8
9
11
13
14
16
17
18
19
20
22
23
24
25
26
40
41
42
45
48
P/N
21258
23434
23435
23436
23437
23438
23438-1
22199-1
21871
23297-1
21820
21824-5
21830-12
22868
22869
21753-3
21901-150
23036
23153-3
22303-16G
22557-1
24299-3
22571-8.125
23429
24407
Title
Qty
TRANSFORMER 1000VA EI
1
SOCKET-RELAY
1
RELAY-POWER-100-120 VAC-DPDT
1
CONTACTOR-4 POLE
2
MECHANICAL INTERLOCK
1
OVERLOAD RELAY-440V
1
OVERLOAD RELAY-220V
1
RECEPTACLE- PANEL MOUNT NEMA STD 15A 125V
4
CONNECTOR-4 POSITION-SIZE 11
1
CONNECTOR-REVERSE SEX-13-7-CPC
1
FUSE HOLDER
2
FUSE-3AG-SLOW BLOW
1
FUSE-TYPE 3AB-12A-SLO BLO
1
TERMINAL BLOCK
4
END PLATE
1
GROUND BAR- 6 HOLE
1
MOV-V150LA20B
5
FUSE HOLDER-32 AMP-690V
2
FUSE-600 VAC-TIME DELAY-CLASS CC
2
WIRE-BUSS-16 GA AWG 12" STRAIGHT
12.25
TERMINAL BLOCK - 6mm BLOCK
3
TERMINAL BLOCK-RAIL END STOP/ GROUND
2
RAIL-DIN
8.13
SHEETMETAL-COVER PLATE LEFT-PT4-SM TRANSFORMER OPTION
1
NAMEPLATE - TRANSFORMER
1
i23440-220
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 11
Transformer Option Schematic
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
2.12 Air Connection - Optional
The K mill machines have an air hookup in the rear of the machine if the machine has a power
drawbar or auxiliary function option. Auxiliary function options are only found on 3 axis mills.
If the machine has a power drawbar option then the machine will include an air regulator, air
manifold and an oiler. The air fitting is ¼” NPT. Within the manifold there is an additional air
line port in case the user wants to hook up an air line to clean chips. Remove the plug to gain
access to this port. If the machine has an auxiliary function option then the machine will include
an air solenoid as shown below.
The air regulator is set to 90 psi at the factory for the power drawbar unit and solenoid. See
Section 5 for more information on the power drawbar unit. The air comes in through the
manifold, and then into the air regulator that tees off into an oiler for the power drawbar unit
and into an air solenoid. The solenoid is used for a misting system the user may install later on
this machine. There is a ¼” quick disconnect air fitting on the solenoid where the mister air
hose can be plugged into. See the figure below for an illustration.
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 12 - Air Regulator/Solenoid Assembly - P/N: 22380-1
Item
2
3
8
9
11
12
18
19
20
24
25
P/N
22378
22607
22644-4
22645-4
22646-4
22647-2
4-40X3/8 31B
10-32X3/8 10B
M6-1.0X25 25B
22772
22581-5
Title
MANIFOLD-PT4 AIR
FILTER/REGULATOR-PT4
PLUG-1/4 NPT HEX SOCKET
NIPPLE-1/4 NPT x 1.37 LG
ADAPTOR-ELBOW MALE 1/4 x 1/8 NPT
NIPPLE-1/8 NPT x 0.750" LG
SCREW-PH-PHIL-EXT SEMS-STL-BO
SCREW-PH-PHIL-STL-BO
SCREW-SHCS-STL-BO
SOLENOID ASSY- AIR REGULATOR
OILER
Qty
1
1
3
1
1
1
2
2
2
1
1
i22380-1
2.13 Mounting the Display Pendant
The ProtoTRAK SMX display pendant mounts to the pendant arm with four 1/4-20 x ¾ SHCS
that are shipped screwed into the left side of the display. There is a locating screw on the
pendant arm to help align the pendant with the mounting holes.
CAUTION!
The locating screw in the arm is used for positioning. Keep a hold of the pendant until the
screws are fastened.
If the pendant arm rotates too freely, remove the painted cap on the bracket attached to the
column and tighten the hex nut to adjust it. Replace the cap.
2.14 Cable Interconnections
All cable interconnections are made at the factory except for those connecting to the pendant
display. There are a total of 4 cables that need to be connected to the pendant for non-spindle
control machines. See Figure 15 & 16 for a complete illustration of cable interconnections for all
components. There are an additional 2 cables for the electronic handwheel option and 2 more
cables for the spindle control option (digital I/O and spindle control ports).
With the main power to the machine turned off, plug in the connectors that are bundled on the
pendant arm. Each cable mates to only one connector on the pendant display back panel. Use
the key on the pendant to match up the connectors with the correct port. The machine ID port
(or called LPT) and parallel port (hardware key) will have a key plugged into it. The monitor
port and network ports will be left empty during installation.
Make sure there is sufficient slack in the cables for when the pendant is rotated about the
pendant arm. The worst case is when the pendant is all the way forward toward the operator.
The following drawing describes all of the cable connections to the pendant.
Make sure there is a hardware (option) key plugged into the parallel port of the pendant. This
key activates any converters or options ordered. The part # for this key is 22648. The key
must be programmed according to the type of machine it is on and the options ordered.
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Make sure the machine ID key is plugged into the machine or it will not run. Note: Spindle
control machines use a different machine ID key then non-spindle control machines.
Whenever you replace a cable or reroute a cable it is very important to keep the power cables
and logic cables separated from each other. The power cables consist of the (3) 110-volt motor
cables and (2) 110-volt power cables for the pendant, and a coolant pump or solenoid power
cable. The logic cables are used to carry encoder signals between the cable breakout box and
computer module. Mixing of the power and logic cables may cause noise from the power cables
to interrupt the signals in the logic cables. This can lead to intermittent axis faults or
repeatability problems. See Figure 15 and 16 for a layout of the cable connections.
CAUTION!
Make sure the main power is turned off on the back of the electrical cabinet before plugging in
the cables.
Figure 13
Pendant Cable
Connections
Left Side
P/N: 24000-1
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 14
Pendant - Right Side
P/N: 24000-1
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 15
Cable Connection Diagram
Non-Spindle Control
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 15
Cable Connection Part List
Non-Spindle Control
Item
1
2
3
4
5
6
Part Number
K2/K3
220V = 20676
440V = 20676
Description
K4
220V = 20676-1
440V = 20676-1
21856
24999
22648-7
22758-SKNEE2X
24000-1
Electrical Box
Cable Assembly
Cable Breakout Box (-1 with AUX Functions)
Option Key—SMX
Key—Machine ID
SMX Pendant
Figure 16 Part List for
Cable Connection Diagram with Spindle Control
See next page
Item Part Number
1
24000-1
2
24060-1
2
24060-2
3
24999
3
24999-1
4
22555-10
5
22555-10
6
22556-10
7
22556-10
8
22608
9
20267
Description
SMX Pendant Assembly
Enclosure Assembly, SX2
Enclosure Assembly, SX3 and SX5
Cable Breakout Box No Aux
Cable Breakout Box With Aux
Cable Assy - Logic
Cable Assy - Logic
Cable Assy - Parallel
Cable Assy - Parallel
Power Cord
Cable Assy - AC to Computer
i01113
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 16
Cable Connection Diagram with Spindle Control
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
2.15
Lubrication
CAUTION!
Failure to properly lubricate the mill will result in the premature failure of bearings, sliding
surfaces & ballscrews
2.15.1 Manual Lubrication
The TRAK mill X & Y way surfaces and ball screws need to be manually lubricated. The
Manual Lube automatically discharges about 4ml of oil
every plunge.
1. At the beginning of each day, manually pull the pump handle.
Note: If the machine has been sitting for a long while, run the machine through the full length of
its travel to ensure lubrication reaches all surfaces.
2. At the beginning of each day, check the oil level in the system. If low, fill with Mobil
Vactra Oil No. 2 or equivalent.
CAUTION!
Failure to manually activate the pump at the beginning of each day and allowing the pump to run
dry may cause severe damage to the TRAK mill way surfaces and ball screws.
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 17
Knee Mill Lubrication
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Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Parts List – Figure 17, Knee Mill Lubrication
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
P/N
9001
9002
9003
9004
9005
9006
9007
9008
9009
9010
9011
9012
9013
Title
HAND OILER
ALUMINUM PIPE
ELBOW
T-JOINT - 4 HOLES- M8 X 1.0
CONNECTOR
REGULATING DISTRIBUTOR
FLEXIBLE TUBE - 21 inches
SCREW NUT - M8 X 1.0 MALE
SCREW NUT - PD 1/8- 19MM
SCREW - M5 X 20 mm LG
SCREW NUT - M8 X 1.0 FEMALE
ADAPTER
SLEVE - 4.1 mm I.D.
i00889
Qty
1
6
6
1
3
1
1
15
2
8
3
1
18
2.15.2 Head Lubrication
Once Each Week:
1. Fill the oil cup on the front of the head with SAE 30 or 30 W oil. This
oil lubricates the Hi/Lo range shifter.
2. Extend the quill fully and apply a coating of SAE 30 or 30W oil to the
outside diameter of the quill.
Every Four Months:
1. Apply a good grade of general-purpose grease through the grease
fitting on the back of the head. This grease lubricates the Low-range
gear set and the feed-change gears.
2. Grease vari-disk on spindle motor through the grease fitting on the motor shaft.
2.16 ProtoTRAK SMX Euclid Block Procedure
The test part should be machined at the completion of the installation.
The material for the Euclid block test part is found in the toolbox.
•
Material Specification: Aluminum, 6061-T6 or T4
•
Blank Size: (minimum dimensions) 3 x 3 x 1”, provided in tool box
•
Tool: .750 end mill, 2 flute, high speed steel, sharp
•
Coolant: Flood coolant or Cool-Tool
1. Mount vise and indicate the back jaw parallel to the table within .0005”.
2. Clamp material in vice with a minimum of .800” above the vise jaws.
3. Load in the Euclid block program from the ProtoTRAK SMX flash disk, which is Part Number
Euclid 2 axis.PT4. It is found under the PT4 folder followed by the SWI TEST PROGRAMS
folder.
4. Use an edge finder to set Absolute 0 on X and Y. Absolute zero is the front left corner of
the block as viewed from in front of the machine.
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5. Load the .750 end mill and set Z Absolute 0 at the top of the part.
6. Begin to run the program. Set the spindle to 2000 RPM and follow the instructions on the
control for SETTING Z and CHECKING Z. The part will be machined in the following
sequence:
Event #
Description
Depth of Cut
1
Circle pocket – cuts middle circle
-0.250”
2
Circle frame – cuts outer 1.830 diameter circle
-0.250”
3
Circle frame – cuts material from corners remaining on Euclid block
-0.250”
4
Roughs material in upper right-hand corner
-0.500”
5-12
Cuts triangle on Euclid block with finish cut
-0.500”
13
Rectangular frame – cuts outer 2.750” rectangle
-0.750”
7. After the program run, the program will locate to the following position.
• X = 1.318
•
Y = 1.318
8. Mount a dial indicator in the quill and check the circles.
9. Check the runout of the sides of the square frame.
10. Inspect the machined surfaces for smoothness.
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Figure 18
Euclid Block
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3.0
Troubleshooting by Symptom
Use this section to begin the process of resolving a service problem. Each symptom type is
described in a few words and then more fully described in an explanatory paragraph. Following
this is a chart that directs in the most logical steps
3.1 Problems Relating to Machining Results
3.1.1 Poor Finish
The part finish is marred with scallops or is very rough.
Do the following Service Codes and document values:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
•
Code 11 Measures backlash in the system (Only used on Dual Feedback systems)
•
Code 12 Feed Forward Constant
•
Code 127 Measures backlash in the system (for Z-axis on three-axis systems; not
used on Dual Feedback systems,)
•
Code 128 Enter backlash compensation (for Z-axis on three-axis systems; not used
on Dual Feedback systems)
Possible Cause
Too much backlash entered for code
128 or calculated with code 11.
Machine Tool & Setup problem
Table, Saddle, or Knee Locks are locked
Inadequate or no Lubrication to
Ballscrews and Way surfaces
X, Y, and knee Gibs are not adjusted
properly
X & Y-axis Drive Trains are loose
Way surfaces are pocked, scarred, or
excessively worn
Check This
Verify nothing is mechanically loose and the backlash
values are not higher than what physically is in the
system.
Check for any looseness in the setup (Tool, Tool holder,
Part, Vise, or Fixture). Check the condition and type of
cutter being used, type of material, RPM and Feedrate,
etc. See Machine Tool & Setup Section 4.1
Make sure the Table and Saddle Locks are unlocked.
Never use gib locks with a CNC machine.
Make sure all the Way surfaces are getting proper
lubrication. If not, check to make sure that the lube pump
is functioning properly. Also check for any pinched or
blocked oil lines. See Lubrication Section 4.1.3
Check the adjustment of the X and Y gibs. See X and Y
Gib Adjustments in Section 5.2.1.
Check Repeatability using the Repeatability and Positional
Accuracy procedure. Step by step, carefully inspect the
Drive Train for any looseness. It may be necessary to
disassemble and then reassemble the Drive Train. See
Mechanical Drive Train (X, Y) Section 4.2
Visually check the condition of all the Way surfaces. For
machines that may have excessively worn Way surfaces
you may need to adjust the Gibs in this area. This will
affect performance when using the machine outside of
this area. Check lubrication to affected areas.
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3.1.2 Circles Out of Round
Circles are not round within 0.002” TIR over 3.0” DIA. This is best measured by placing
a dial indicator in the quill and sweeping around the part.
Note: The typical slideway-milling machine is not capable of achieving more precise results
although careful adjustments to a new milling machine may produce better results. If more
precise circles are required, then it is recommended to use a precision boring head/boring bar.
Do the following Service Codes and document values:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
•
Code 11 Measures backlash in the system (Only used on Dual Feedback systems)
•
Code 12 Feed Forward Constant.
•
Code 127 Measures backlash in the system (not used on Dual Feedback systems).
•
Code 128 Enter backlash compensation.
Possible Cause
Torque values on X and Y-axis are too
high.
Machine Tool and Setup problem
Machine not level
Head is not Trammed
X and Y Gibs are not adjusted properly
Calibration or Backlash problem
TRAK Sensor or Glass Scale problem
X & Y-axis Drive Trains are loose
Head Bolts are loose
Check This
Make sure torque is lower than 20 in-lbs. Normal values for a
machine that is aligned and adjusted properly should be
between 10 and 15 in-lbs. Make sure torque is consistent across
axis travel.
Check for any looseness in the setup (Tool, Tool holder, Part,
Vise, or Fixture). See Machine Tool & Setup - Section 4.1
Verify that the machine is level to specification.
Verify that the Head is Trammed to specification. See Tramming
the Head Sec 5.2.3
Check the adjustment of the X and Y Gibs using the X and Y Gib
adjustment procedures.
Recalibrate the machine. Reset the Backlash. Check
Repeatability and Positional Accuracy. See Calibration &
Backlash Constants Section 5.2.2
Make sure that the Sensor or Glass Scale is installed correctly
according to the Sensor or Glass Scale Installation procedures.
Check for any loose brackets or misalignment etc. Also, check to
make sure the Sensor or Glass Scale assemblies are functioning
correctly. See TRAK Sensors or Glass Scales Sections 4.6 & 4.7.
Check Repeatability using the Repeatability and Positional
Accuracy procedure. Step by step, carefully inspect the Drive
Train for any looseness. It may be necessary to disassemble and
then reassemble the Drive Train. See Mechanical Drive Train (X,
Y) Section 4.2
Verify that all the head bolts are tight. 50 lbs.
3.1.3 Taper Cut on a Programmed Straight Line Move
An unwanted tapered cut occurs, when the machine is programmed to move in a straight
line along either the X or Y-axis. The DRO shows motion of a few thousandths of an inch
in the axis that is not supposed to be moving.
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Explanation: For straight line cuts along the X or Y-axis, the control is designed to lock
the motor of the axis that is not moving. A taper is created when there is play in the
system. The force of the tool shoves the table or saddle out of position.
The system will respond to being pushed out of position by making an adjustment at the
end of the move.
An unwanted tapered cut is the result of looseness in the system.
Do the following Service Codes and document values:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
•
Code 11 Measure's the backlash in the system. Only used on machines with Dual
Feedback systems.
•
Code 12 Feed Forward Constant.
•
Code 127 Measure's the backlash in the system. Only used on machines with single
Feedback.
•
Code 128 Enter backlash compensation.
Possible Cause
Machine Tool & Setup problem
X and Y Gibs are loose
X and Y-axis Drive Trains are loose
Check This
Check for any looseness in the setup (Tool, Tool holder, Part,
Vise, or Fixture). See Machine Tool & Setup Section 4.1
Check the adjustment of the X and Y Gibs using the X and Y
Gib adjustment procedures. See Section 5.2.1
Check Repeatability using the Repeatability and Positional
Accuracy procedure. Step by step, carefully inspect the Drive
Train for any looseness. It may be necessary to disassemble
and then reassemble the Drive Train. See Mechanical Drive
Train (X, Y) Section 4.2
3.1.4 Parts Have Incorrect Dimensions
Parts are being machined with dimensions that are different than those programmed.
Typical accuracy expectations should be:
•
Circles: 0.002” TIR over 3.00” DIA
•
Positional Accuracy: +/- 0.0005"
•
Repeatability: 0.0005"
Note: The typical slideway-milling machine is not capable of achieving more precise results.
Although careful adjustments to a new milling machine have produced better results, you should
not expect the same level of accuracy from an older or worn machine.
Furthermore, the system should be expected to repeat within the resolution of the
displayed DRO numbers of 0.0005”.
Do the following Service Code:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
•
Code 123 Calibration.
•
Code 11 Measure's the backlash in the system. Only used on machines with Dual
Feedback systems.
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•
Code 12 Feed Forward Constant.
•
Code 127 Measure's the backlash in the system. Only used on machines with single
feedback.
•
Code 128 Enter backlash compensation.
3.1.4.1
Every Part Has the Sam e Error
Possible Cause
Machine Tool & Setup problem
Programming Error
Configuration file that contains
calibration file and backlash constants
has been erased or corrupted.
Calibration or Backlash problem
3.1.4.2
Check This
See Machine Tool & Setup Section 4.1
In the program, look for common errors in programming
such as transposing numbers, tool diameters, and
pressing INC SET when ABS SET is meant. This is
especially suspected if the dimensional errors are larger
than a few thousandths. See the Controls Programming,
Operations and Care manual.
Verify configuration file (Code 313) does not read default
values. Load saved configuration file from floppy disk in
electrics cabinet with Code 141.
Recalibrate the machine. Reset the Backlash. Check
Repeatability and Positional Accuracy. See Calibration &
Backlash Constants
The Dim ensional Errors Are R andom or Accum ulate in Size
Over the Part Program Run
Possible Cause
Machine Tool & Setup problem
TRAK Sensor or Glass Scale problem
X and Y-axis Drive Trains are loose
Check This
See Machine Tool & Setup Section 4.1
Make sure that the Sensor or Glass Scale is installed
correctly according to the Sensor or Glass Scale
Installation procedures. Check for any loose brackets or
misalignment etc. Also, check to make sure the Sensor or
Glass Scale assemblies are functioning correctly. See
TRAK Sensors or Glass Scales Sections 4.6 & 4.7
Check Repeatability using the Repeatability and Positional
Accuracy procedure. Step by step, carefully inspect the
Drive Train for any looseness. It may be necessary to
disassemble and then reassemble the Drive Train. See
Mechanical Drive Train (X, Y) Section 4.2
3.2 Problems Regarding the Motion of the Machine
3.2.1 Run Away Axis
The axis makes an unwanted move at rapid speed in one direction and faults out. This is
usually caused by an encoder signal being interrupted.
Do the following Service Codes:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
•
Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting properly.
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Possible Cause
Sensors or glass scales are counting in
opposite direction of motor encoder
The home positions or tools are not set
correctly
The Sensor or Glass Scale is not
reading.
Bad Motor Encoder
Check This
Reverse directions with codes 321 and 322
See the Controls Programming, Operations and Care
manual.
See TRAK Sensors or Glass Scales diagnostic Section
4.6 or 4.7
See Motor diagnostics Section 4.4
3.2.2 Slow Down Axis
The axis slows down and moves at a feedrate that is lower than rapid or than the
programmed feedrate.
Do the following Service Codes:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
•
Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting.
•
Code 129 Set's the maximum allowable arc accuracy error. This applies to arcs only.
Possible Cause
The maximum allowable Arc Accuracy is
set too low.
Incoming AC voltage is inadequate
Table and Saddle Locks are locked
Inadequate or no Lubrication to
Ballscrews and Way surfaces
X and Y Gibs are not adjusted properly
Binding in the Drive Train
Servo Drive failure
Motor failure
Check This
This value will only slow down the machine during arc moves.
The factory default is set at 0.001". Perform Code 129 to
check or change this value. See Service Codes section
Perform Code 100. See Service Codes - Section 4.9 and
Electrical Section 4.8
Make sure the Table and Saddle Locks are unlocked.
Make sure all the Way surfaces are getting proper lubrication.
If not, check to make sure that the lube pump is functioning
properly. Also check for any pinched or blocked oil lines. See
Lubrication Section 4.1.3
Check the adjustment of the X and Y Gibs using the X and Y
Gib adjustment procedures.
Check Repeatability using the Repeatability and Positional
Accuracy procedure. Check the torque reading of the Drive
Train. Step by step, carefully inspect the Drive Train for any
binding. It may be necessary to disassemble and then
reassemble the Drive Train. See Mechanical Drive Train (X, Y)
Section 4.2
See Servo Drive Section 4.5
See Motor Section 4.4
3.2.3 Axis Will Not Jog
The system powers up but will not respond to the jog command.
Do the following Service Codes and procedures:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
•
Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting.
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Possible Cause
Improper Boot-up
E-Stop is pressed in
Servo Drive failure
Check This
Shut down the system and wait 10 seconds before rebooting
Check E-Stop. Especially if both axes will not jog
Especially, if only one axis will not jog;
See Servo Driver Section 4.5
See Motor Section 4.4
See Electrical Connection Section 2.12
See Computer/Pendant diagnostics Section 4.3
Shorted motor
Poor cable or wiring connections
Computer/Pendant failed
3.2.4 Axis Motor Motion Is Not Smooth
While under motor power, the motion is not smooth. The motion appears to be "rough" or jerky”.
Do the following Service Codes and procedures:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
•
Code 11 Measure's the backlash in the system. Only used on machines with Dual
Feedback systems.
•
Code 12 Feed Forward Constant. High feed forward constants will cause an
unstable servo system.
•
Code 127 Measure's the backlash in the system. Only used on machines with single
feedback. Also used on SMX3 Z axis.
•
Code 128 Enter backlash compensation. Also used on SMX3 Z axis.
•
•
Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting.
Possible Cause
X and Y Gibs are not adjusted properly
TRAK Sensor or Glass Scale problem
Calibration or Backlash problem
Binding in the Drive Train
Check This
Check the adjustment of the X and Y Gibs using the X
and Y Gib adjustment procedures.
Make sure that the Sensor or Glass Scale is installed
correctly according to the Sensor or Glass Scale
Installation procedures. Check for any loose brackets or
misalignment etc. Also, check to make sure the Sensor or
Glass Scale assemblies are functioning correctly. See
TRAK Sensors or Glass Scales Section 4.6 & 4.7
Recalibrate the machine. Reset the Backlash. Check
Repeatability and Positional Accuracy. See Calibration &
Backlash Constants section.
Check Repeatability using the Repeatability and Positional
Accuracy procedure. Check the torque reading of the
Drive Train. Step by step, carefully inspect the Drive
Train for any binding. It may be necessary to
disassemble and then reassemble the Drive Train. See
Mechanical Drive Train (X, Y) Section 4.2
3.2.5 Vibration in Motion
While axis is moving there is vibration or noise coming from the X or Y-axis.
Do the following Service Codes and procedures:
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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
•
Code 11 Measure's the backlash in the system. Only used on machines with Dual
Feedback systems.
•
Code 12 Feed Forward Constant. High feed forward constants will cause an
unstable servo system.
•
Code 127 Measure's the backlash in the system. Only used on machines with no Dual
Feedback.
•
Code 128 Enter backlash compensation.
•
Code 123 Calibrate.
Possible Cause
Too much backlash entered in Code 128
or Code 11.
Inadequate or no Lubrication to
Ballscrews and Way surfaces
X and Y Gibs are not adjusted properly
Gibs not making good contact.
Binding or looseness in the Drive Train
Axis Motor belt too tight.
Misalignment of ball screw
Check This
Recheck the machines backlash.
Make sure all the Way surfaces are getting proper
lubrication. If not, check to make sure that the lube pump
is functioning properly. Also check for any pinched or
blocked oil lines. See Lubrication section
Check the adjustment of the X and Y Gibs using the X
and Y Gib adjustment procedures.
Pull gibs out and mark with a blue die to check where the
gibs are making contact. It is recommended that the gibs
uniformly contact at least 80% of the surface.
Check Repeatability using the Repeatability and Positional
Accuracy procedure. Check the torque reading of the
Drive Train. Step by step, carefully inspect the Drive Train
for any binding or looseness. It may be necessary to
disassemble and then reassemble the Drive Train. See
Mechanical Drive Train (X, Y) Section 4.2
Loosen belt.
See Mechanical Drive Train (X, Y) Section 4.2
3.2.6 Searching Axis
The handwheels are slowly turning back and forth when the servos are engaged. Several
thousandths of motion are observed on the vernier dial and the frequency is one cycle
every couple of seconds.
Do the following Service Code and procedures:
•
•
•
Code 11
Code 12
Code 128
Measures backlash in system. (Used only with glass scales and sensors.)
Sets a feed forward power constant to drive axis motors.
Backlash compensation on single feedback machines.
Possible Cause
Most often causes by excess backlash
compensation
High feed forward values
Excessive friction in the sliding ways
Looseness in the drive train
Check This
Use code 127. Check physical backlash in system and
re-enter in code 128. Run code 11 on dual feedback
machines
Check ball screw torque. Typical values should be
between 10 to 15 in-lbs.
Lubrication, gib adjustments, gib locks.
See Machine Tool & Setup - Section 4.1
Especially the tightness of the drive assembly.
See Mechanical Drive Train (X, Y) - Section 4.2
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3.3 Problems Relating to the Operation of the Control
3.3.1 Display Blanks
The display is completely blank.
Possible Cause
Screen saver has been activated
The system has shut down
Poor cable connection from Computer
Module to LCD (Liquid Crystal Display)
Fuse blown in pendant
Computer/Pendant failed
Check This
Press any key to turn back on. All LED keys on
pendant will blink when the screen saver is on. Press
any key to deactivate. Hitting this key will not
activate any feature on the control.
Turn the power switch off, check the computer/
pendant fuses and cable connections. See Electrical
Section 4.8
Double-check the connection from the computer
module to the LCD.
Remove fuse and check continuity
See Computer/Pendant Section 4.3
3.3.2 Bad Picture on the Display
The display has strange characters, horizontal bars or other unfamiliar images, or the
display continually rolls.
Possible Cause
Computer/Pendant failed
Check This
See Computer/Pendant Section 4.3
3.3.3 Keyboard Lockup
The screen display is normal, but the system will not respond to key presses.
Do the following Service Codes and procedures:
•
Code 81 To check if the pendant keys are working properly, press each key. If a
key is working properly, the corresponding key on the screen will light up in yellow.
The pendant will also beep.
Possible Cause
Voltage drop/spike has occurred
Remote Stop-Go (RSG) switch has a
short (if connected)
Computer/Pendant failed
Check This
Shut down the system and wait 10 seconds to reboot
the system.
Remove the RSG. Turn the system off and then on
again. If the problem goes away and then re-appears
when the RSG is plugged-in, replace the RSG.
See Computer/Pendant Section 4.3
3.3.4 Fault X or Y
The program run or jogging operation is interrupted with a Fault Message on the display.
Do the following Service Codes and procedures:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
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•
Code 11 Measure's the backlash in the system. Only used on machines with Dual
Feedback systems.
•
Code 12 Feed Forward Constant.
•
Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting.
Possible Cause
Cable connection problems
Table and Saddle Locks are locked
X and Y Gibs are adjusted extremely
tight
Excessive friction in the slideways
Binding or looseness in the Drive Train
Incoming electrical power
Measurement system not functioning
properly
Servo Drive failure
Motor failure
Computer/Pendant failure
Check This
Check umbilical 1 and 2. Check #1 for X and Y-axis
problems and #2 for the Z-axis.
Make sure the Table and Saddle Locks are unlocked.
High torque on any axis may cause faulting problems
during alignment routine.
Check the adjustment of the X and Y Gibs using the X
and Y Gib adjustment procedures. See X and Y Gib
Adjustments Section 5.2.1
See Machine Tool & Setup Section 4.1
See Mechanical Drive Train (X, Y) Section 4.2
Incoming voltage. See Electrical Section 4.8
See Section 4.6 or 4.7
See Servo Driver - Section 4.5
See Motor diagnostics, Section 4.4
See Computer/Pendant diagnostics, Section 4.3
3.3.5 Problems Reading the Floppy Disk; Programs Not Saved Properly;
The floppy drive will not read or write programs from a disk.
Possible Cause
Improper Boot-up
Floppy Disk failure
Check This
Shut down the system and wait 10 seconds before
rebooting
The Floppy Disk may be bad. See if the Floppy Disk
can be read by a Personal Computer. Does the green
light on the floppy drive come on when you access the
disk? If so, power is getting to the floppy drive. If
not check connections of floppy drive inside the
computer module. See Computer/Pendant Section 4.3
for more information.
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3.3.6 System Will Not Turn On or Boot-Up
Nothing happens when the switch is turned on or the system does not boot-up.
Possible Cause
110 V line is not plugged in
Pendant On/Off switch is Off.
Fuse blown in pendant or electrical
cabinet
Flash Drive failure
Computer/Pendant has failed
Check This
Check incoming 110 V power source to black electrical
cabinet
Check the Pendant On/Off switch
Remove fuses and check continuity.
When the Computer Module starts the boot-up
process, look at the 8th line on the Display Screen. If
the Mother Board of the Computer Module is
communicating with the Flash Drive you will see
"Detecting IDE Primary Master…Scan Disk SDCFB-64".
If the Mother Board of the Computer Module is not
communicating with the Flash Drive you will see
"Detecting IDE Primary Master … None".
Also, check the wiring connection between the Flash
Drive and the Mother Board. See Computer/Pendant
diagnostics Section 4.3
See Computer/Pendant diagnostics Section 4.3
3.3.7 System Reboots by Itself
During operation, the screen suddenly blanks and then shows that the system has begun
the boot-up sequence.
Possible Cause
Interruption of 110 V power to pendant
Poor wiring and cable connections
Computer/Pendant failed
Check This
Using a Voltmeter, check the incoming 110VAC to the
pendant.
Check for any loose wiring or cables
See Computer/Pendant diagnostics Section 4.3
3.3.8 System Shuts Off
During operation, the system shuts off and will not turn back on.
Possible Cause
Fuse blown in pendant
Poor wiring and cable connections
Computer/Pendant has failed
Check This
Remove fuse and check continuity
Check for any loose wiring. Also, check the 110VAC
Power Cable connection from the 110VAC Power Strip
to the Pendant. See Electrical Section 4.8
See Computer/Pendant diagnostics Section 4.3
3.3.9 Will Not Hold Calibration
The control will not hold calibration. Go to the "Configuration Values" screen and write
down the calibration values for the motor encoders (Encoder) and the position feedback
encoders (scales or sensors). The calibration values are written in Hexadecimal.
Recalibrate the system and see if the values change. Turn the system off and on and
see if the values are held.
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Do the following service codes and procedures:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
•
Code 313 Configuration Values
•
Code 123 Calibration Mode.
Possible Cause
Configuration file corrupt
Not saving Calibration values
Check This
Load default configuration by going to code 313
Replace Computer/Pendant module.
See Computer/Pendant
If calibration factors are being saved, but the measurements are not repeating or are not accurate:
•
See Measurements Are Not Repeating
•
See Measurements Are Not Accurate
3.3.10 Auxiliary Functions Not Working (Option on 3 Axis
Machines Only)
The Auxiliary Functions will not turn on or off at the programmed times. There are 3
Auxiliary Functions:
1. Activates or deactivates a "110VAC Receptacle" typically used for a coolant pump or
solenoid for mister.
2. Sends an electrical signal to rotate the turret on a "Haas Indexer".
3. Turns the "Spindle Off" at the end of a programmed event. (Note: This function is
not available for retrofits.).
In order to run the above auxiliary functions in run mode, the accessory key on the front
of the pendant must be in the AUTO mode. Press and hold to activate AUTO mode.
All of the auxiliary function signals are carried down to the cable breakout box through
umbilical #2. Each function then has its own relay inside this box. If one of these relays
fail then these features will not work.
Do the following service code and procedures:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
Possible Cause
Bad 110VAC "Coolant or solenoid"
receptacle fuse
Poor cable connections
Faulty "Indexer" connector
Bad cable breakout box
Check This
Check if the fuse light indicator next to the plug is lit.
Verify that the fuses are good or bad by checking the
resistance of the fuses using an Ohmmeter.
Check all the cable connections on the cable
breakout box, Coolant Pump, and Air Solenoid
(Located on the Air Regulator). In particular, check
umbilical # 2 cable, which carries the auxiliary
function signals.
Check for continuity between pins 3 and 4, when the
output of the Haas Indexer connector is activated.
Check 110 V power coming out of the AC E-stop port
with the E-stop in the out position. This will cause
the spindle to not run.
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3.3.11 E-Stop Error
The E-Stop turns the power off to the axis and spindle motors. This is done by stopping
110V power from reaching the cable breakout box through the use of a relay in the
pendant.
Once power reaches the cable breakout box it distributes power to the axis motors,
auxiliary functions and 110V power to the spindle contactor for non-spindle control
machines. If power does not reach the cable breakout box then none of these functions
will work.
Spindle Control Electrical Box
A 5-volt logic signal is sent to the spindle control board, which energizes a relay that
enables the AC drive.
Non Spindle Control Electrical Box
110V Power reaches the electrical box through the AC E-stop cable. It is used to
energize the spindle motor contactor. If this contactor is not energized the spindle will
not turn on. See Figure 19.
If the E-Stop button is depressed, and no message is displayed on the screen, then
either the E-Stop button or the Computer Module is at fault.
Possible Cause
Faulty E-Stop switch
Bad Computer Module
3.3.12
Check This
Check the cable connections from the computer
module to the E-Stop switch. Check the E-Stop switch
for functionality.
Does 110 V power come out of the cable breakout box
power cord on the pendant? If yes, and the screen
has an E-stop message, replace the computer module.
Limit Switch Error - Optional
Limit switches are installed on the table, saddle, and ram to prevent serious damage to
the machine in the event of a crash. In the event a limit switch is triggered, a limit
switch error will appear on the screen.
Critical Error 52: Servo Error
X-axis Limit Switch
Correct the fault condition and continue.
To return the machine to its normal state of operation, perform the following procedure:
1. Use mechanical handwheels on X and Y to move switch off of trigger. For the Z-axis,
manually lift the arm on the trigger to return the limit switch to its normal position.
Then jog the ram up or down as necessary.
2. Press the "Mode" or "Return" key to reset the control
3. Press the "DRO" key to enable the machine to once again jog.
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Possible Cause
Limit switch jumpers in cable breakout
box are making poor contact.
Limit Switches are triggered
Poor Limit Switch Cable connection
Limit Switch failure
Try this
Switch 2 limit switch cables on the cable
breakout box.
Check This
Remove and reseat jumpers.
Reset the Limit Switches using the procedures
described above.
Check for any pins that are loose, pushed in, or bent.
Verify that there is a good connection between the
cables on the cable breakout box.
Does the limit switch problem move to the other axis?
If it does then the switch is most likely the problem.
If it stays with the original axis then it could be the
cable breakout box.
3.4 Problem with the Measurements
3.4.1 X, Y and Z-Axis Measurements Do Not Repeat
With a dial indicator mounted to the bottom of the spindle, touch off a fixed surface
either in the X or Y-axis direction and then set the DRO equal to 0. Crank away several
inches and then touch off again at the same place. If the reading has not returned to 0
on the DRO, zero the display and repeat the procedure. If the measurement does not
repeat, you have a repeatability problem that must be resolved.
Test for accumulative error by moving the axis a number of times to see if the error
gradually grows by a small amount. If so, it may be caused by a misaligned sensor or
scale. If the error abruptly changes by a large amount, it may be caused by a bad encoder.
Expected repeatability numbers should be 0.0005” or less.
Do the following service codes and procedures:
•
Code 304 Toggle X sensor/glass scale on/off
•
Code 305 Toggle Y sensor/glass scale on/off
Possible Cause
Machine Tool & Setup problem
X and Y Gibs are loose
TRAK Sensor or Glass Scale problem
Check This
Check for any looseness in the setup (Tool, Tool
holder, Part, Vise, or Fixture). Make sure there is
sufficient contact between the tool holder and the
spindle. See Machine Tool & Setup Section 4.1
Check the adjustment of the X and Y Gibs using the X
and Y Gib adjustment procedures.
Make sure that the Sensor or Glass Scale is installed
correctly according to the Sensor or Glass Scale
Installation procedures. Check for any loose brackets
or misalignment etc. Also, check to make sure the
Sensor or Glass Scale assemblies are functioning
correctly. Use service codes 304 for X and 305 for Y
to turn off the suspect encoder. Does problem still
exist after turning it off?
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Possible Cause
X and Y-axis Drive Trains are loose
Encoder Disk or Reader Head on motor
are loose
Spindle and/or Quill are loose
Head bolts are loose
Check This
Check Repeatability using the Repeatability and
Positional Accuracy procedure. Step by step, carefully
inspect the Drive Train for any looseness. It may be
necessary to disassemble and then reassemble the
Drive Train. See Mechanical Drive Train (X, Y) Section
4.2
Swap the motor in question with a known good motor.
For example, swap the X-axis motor with the Y-axis
motor. If the symptom stays with the motor in
question, then replace the motor. If not, then the
motor is not at fault and something else is causing the
problem.
Use a Dial Indicator and check for side-to-side
movement between the Spindle and the Head. Next,
check for side-to-side movement between the Quill
and the Head. There should be no more than 0.0003"
of side-to-side movement. Make sure that there is a
few thousandths gap between the Spindle Collar and
the Quill after tightening.
Tighten Ram bolts
3.4.2 X, Y, and Z-Axis Measurements Are Not Accurate
Measurements repeat, but with a dial indicator mounted to the bottom the spindle,
traversing the length of a gage block or some other measurement standard, the
measurement is not accurate.
Possible Cause
The Calibration is incorrect
Do This
Recalibrate the machine.
See Calibration & Backlash Constants
Incorrect backlash values
If the machine does not repeat bi-directionally check
the backlash on the axis in question.
See Section 5.2.2.
3.4.3 The DRO Is Not Counting
The DRO for one axis is not counting when an axis is moved. Often times if this is the
case the axis will fault. See section on faulting.
Do the following Service Codes:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
•
Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting.
•
Code 304 & 305 Turns off X and Y sensor or scale.
Possible Cause
Motor Encoder not counting
Glass Scale or Sensor Failure
Computer/Pendant failure
Check This
See Motor diagnostics (not applicable with Glass Scale
option). Single feedback only.
Does axis now count? If so, replace scale or sensor.
See Computer/Pendant diagnostics
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3.4.4 X, Y, and Z-Axis DRO Counting in Wrong Direction
The DRO is counting in the wrong direction.
The positive directions for each axis are:
•
X-axis – Table moves to the left.
•
Y-axis – Saddle moves toward the front of the machine.
•
Z-axis – Quill moves up.
Do the following service code and procedures:
•
Code 33 Software Identification. This is needed if you call SWI Customer Service.
•
Code 313 Check the line that specifies the product.
If the product does not match the machine then the machine ID key will need to be replaced.
3.4.5 X, Y, & Z-Axis Electric Handwheels Count in Wrong
Direction
The Electric Handwheels count in the wrong direction.
The positive directions for each Electric Handwheel are:
•
X-axis - Electric Handwheel turns clockwise.
•
Y-axis - Electric Handwheel turns counterclockwise.
Do the following service code and procedures:
•
Code 308 Reverse X-axis Handwheel Direction.
•
Code 309 Reverse Y-axis Handwheel Direction.
3.5 Problems with the Machine Tool
3.5.1 Spindle Stalls or Turns-Off During Machining
During machining, the spindle turns off and loses power. First check incoming voltage
and connections.
Possible Cause
Machine Tool and Setup problem
Drive Belt in the head is slipping
Cut more than the machine is capable
Insufficient voltage, excessive amp load
Check This
Check the type of material being cut, type and size of
cutting tool, RPM, and Feed rate. Also check the
condition of the cutter to verify that the cutter is not
dull. See Machine Tool & Setup Section 4.1
Check the alignment, condition, and tension of the
Drive Belt.
Check width and depth of cut
Check incoming power. Check overload setting.
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3.5.1.1
Spindle Stalls or Turns-Off During Machining (For Machine
with the Optional Spindle Control Drive)
During machining, the spindle turns off and loses power. First check incoming voltage
and connections.
Possible Cause
Machine Tool and Setup problem
Drive Belt in the head is slipping
Cut more than the machine is capable
Spindle Drive Thermal Overload Relay
has tripped
Spindle Drive parameters are not
correct
Spindle Run Command not reaching AC
Drive
Check This
Check the type of material being cut, type and size of
cutting tool, RPM, and Feed rate. Also check the
condition of the cutter to verify that the cutter is not
dull. See Machine Tool & Setup Section 4.1
Check the alignment, condition, and tension of the
Drive Belt.
Check width and depth of cut
IOUT - Current Out (located on the Spindle Drive)
cannot exceed 12.75A for K2/K3 and 21A for K4 for
more than a few minutes. When the Overload Relay is
tripped, an "oL1" error occurs shutting off the Spindle
Drive. The harder the Spindle Motor works trying to
make heavy cuts, the more current the Spindle Motor
utilizes. This can be caused by a cut so large that it
exceeds the machine capability, or a problem with the
spindle motor or AC drive.
May need to re-download the Spindle Drive
parameters. Contact Customer Service for assistance.
Verify Spindle Run LED is on Spindle Control Board.
3.5.2 Spindle Motor Hums or Will Not Run
If the spindle will not run, you must ensure that 110V power is reaching the spindle
motor contactors in the electrics box. Check your 110V power across terminals
wire 3 and ground. If power is not reaching the electrical cabinet but is reaching the
cable breakout box, most likely a relay has failed in the cable breakout box. The cable
breakout box will need to be replaced. This relay is in series with the 110V power in the
E-stop circuit. See Section 3.3.11. If power has reached the electrical box, use the
schematic in Section 4.8 to see how the power is routed.
If the spindle motor makes a constant humming noise during operation, check
the 3-phase power to the machine by checking line to line.
Possible Cause
Wrong voltage
Check This
Check the 220V/440V voltage to the machine
Poor wiring connections
Defective cables or poor cable
connections
Spindle Motor is bad
Check all the wiring connections to the electric’s box.
Check all cable connections
Check the resistance of the Spindle Motor windings on the Spindle
Motor between L1 & L2, L2 & L3, and L1 & L3, using an
Ohmmeter. The resistance should range from ".7 to 1.2 Ohm" for
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Spindle will not run because 110 V
power is not reaching the spindle
contactor
3.5.2.1
the K2 and K3, and “.5 to .9 OHM” for the K4. If the Ohmmeter
reads "0 Ohms" or "OL", then replace Spindle Motor. Next, check
the resistance between L1 & Ground, L2 & Ground, and L3 &
Ground, using an Ohmmeter. The resistance should read "OL". If
not then replace Spindle Motor.
Check 110 V coming out of the AC e-stop port on the cable
breakout box. Relay failure in cable breakout box. Replace cable
breakout box.
Spindle Motor Hums or Will Not Run (for machine with the
optional Spindle Control Drive)
The spindle motor makes a constant humming noise during operation or will not turn on.
Note: machines can only be wired for 220 volts. 440 volts will ruin electrical components in the
machine. These components will not be covered under warranty.
Possible Cause
Wrong voltage
Poor wiring connections
Improper wiring/jumper configuration
on the Spindle Motor
Spindle Drive may be in "Local Mode"
and cannot be run from the Pendant
Spindle Motor is bad
Spindle Drive contains incorrect
parameters and is not programmed
correctly
Spindle Enable Signal not reaching AC
Drive
Forward/Reverse Switch is bad or
Spindle Control Board
Check This
Check the voltage to the machine before and after the
Spindle Drive with a Voltmeter. Also, check the
voltage to the Spindle Drive (L1, L2, and L3).
Check all the wiring connections to the Spindle Drive
and Spindle Motor. See Electrical Connection
Check to make sure that the Spindle Motor has the
correct wiring/jumper configuration for 220VAC. See
Electrical wiring section.
On the Spindle Drive, push the "DSPL" button until
"LO/RE" lights up. Use the "Up" and "Down" arrow
keys to choose between "Lo"- Local (Run Spindle
Motor from Spindle Drive) or "rE" - Remote (Run
Spindle Motor from the Pendant).
Check the resistance of the Spindle Motor windings on
the Spindle Motor between L1 & L2, L2 & L3, and L1 &
L3, using an Ohmmeter. The resistance should range
from "1.0 Ohms" to "1.5 Ohms" for K2/K3 and “.5
Ohms” to “.9 Ohms” for K4. If the Ohmmeter reads "0
Ohms" or "OL", then replace Spindle Motor. Next,
check the resistance between L1 & Ground, L2 &
Ground, and L3 & Ground, using an Ohmmeter. The
resistance should read "OL". If not then replace
Spindle Motor.
Contact customer service.
Verify LED on Spindle Control Board is on.
Verify Forward or Reverse LED on Spindle Control
Board is lit.
3.5.3 Spindle Runs Backwards
The spindle motor runs in the opposite direction. The spindle will run in opposite
directions from high to low gear.
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Possible Cause
3-Phase wires backwards
Check This
Need to switch any 2 of the 3 wires either coming into the
machine or motor. Note: For machine fitted with the optional
Spindle Control, switch any 2 of the 3 wires either coming out
of the AC Drive (T1, T2 & T3) or going into the Spindle Motor
(U, V & W). Warning: Be sure to shut off all power to the
machine before attempting to switch any wires.
3.5.4 Head Noise
Head noise pertains to any unusual noises coming from the head under load and no load
situations. Most often head noise will only be noticeable under load situations. It is
important to try to distinguish between problems with components in the head versus
problems caused by the setup or tooling being used on a particular job. Use the table
below to try to pinpoint the possible cause. Also try to pinpoint the noise by seeing if it
exists in high, low or neutral. For example, if the noise is evident in neutral then this
eliminates the spindle bearings.
Non Spindle Control Drive M achines
Possible Cause
Machine setup or tooling problem
Upper spindle bearing is worn out.
Verify nosepiece is tight on bottom
of spindle.
Spindle bearings are worn out
Check This
If the noise is most evident under load (cutting situations)
then it is important to look at setup and tooling being used.
Ask the following questions.
Is the cutter dull? Is the tool loose in the holder? Am I
taking a bigger cut then is possible on the machine? Is the
part moving in the vice? Am I using realistic speeds and
feeds?
Any one of these can have a significant impact.
Remove the upper bearing plate above the spindle. This will
unload the bearing. If the noise goes away then this bearing
should be replaced.
To check if the nosepiece is bottomed out try to insert a piece
of paper in between the nosepiece and the quill. If a piece of
paper does fit then this may be the problem. Before
tightening or loosening the nosepiece make sure to loosen the
setscrew that holds it in place.
This is categorized by a high pitch sound and is most evident
at high RPM’s. It should also cause chatter under load.
Replace the spindle if this is the case. See spindle
replacement in Section 5.
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M achines w ith spindle control drive
Possible Cause
Machine setup or tooling problem
Upper spindle bearing is worn out.
Verify nosepiece is tight on bottom
of spindle.
Spindle bearings are worn out
The belt is not lined up with the
grooves on the pulleys.
Check This
If the noise is most evident under load (cutting situations)
then it is important to look at setup and tooling being used.
Ask the following questions.
Is the cutter dull? Is the tool loose in the holder? Am I
taking a bigger cut then is possible on the machine? Is the
part moving in the vice? Am I using realistic speeds and
feeds?
Any one of these can have a significant impact.
Remove the upper bearing plate above the spindle. This
will unload the bearing. If the noise goes away then this
bearing should be replaced.
To check if the nosepiece is bottomed out try to insert a
piece of paper in between the nosepiece and the quill. If a
piece of paper does fit then this may be the problem.
Before tightening or loosening the nosepiece make sure to
loosen the setscrew that holds it in place.
This is categorized by a high pitch sound and is most
evident at high RPM’s. It should also cause chatter under
load. Replace the spindle if this is the case. See spindle
replacement in Section 5.
Make sure the 10-ribs on the belt are lined up with the 10grooves on the 2-pulleys. If the belt is frayed then replace
the belt.
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4.0
Diagnostics
This section explains the diagnostic procedures used to isolate service problems.
4.1 The Machine Tool & Set-Up
4.1.1 The Milling Machine Checklist
The following is a quick reference for the types of problems that may arise if problems are
noticed in these areas.
Problems With:
Spindle bearings
See Spindle Replacement
Lubrication system
Inadequate lubrication habits
Gib locks - on X and Y axis
X and Y gibs loose
See Gib Adjustment - Section 5.2.1
Gibs too tight
Gibs floating
Can Contribute To:
Noisy head
Parts incorrect
Circles out of round
Premature wear of ball screws,
wear surfaces. Faulting
Poor finish
Premature wear of ball screws,
wear surfaces
Poor finish
Faulting
If locked can lead to axis faults.
Taper on straight Y moves
Poor finish
Circle out of round
Not getting to position, does not
repeat, axis faults
Poor finish
Not getting to position, does not
repeat, axis faults
Poor finish
Most Suspect When (and why):
Older machines, machines that are
pushed hard
New installations (may not be
hooked up or line sheared)
New installations (more motion than
the machinist is used to with a
manual mill) Lubricate machine every
morning before use.
Note: when using the CNC to machine,
never tighten the gib locks!
When machine hasn’t been serviced
in a long while.
N/A
Contact area of gibs. May need to
be scraped. Very old machines may
not have any more adjustments on
gib. A new gib will need to be fit on
the machine.
Inadequate gib contact
Gibs defective - bowed, scarred
Excess play when gib is checked
side to side
Way surfaces pocked, scarred, or
excessively worn
Poor finish
Out of round circles
Faulting
Parts incorrect
Machine geometry off, i.e. tram.
Inadequate lubrication
Leaves uneven surfaces on
bottom of pockets.
Machine not level
Machine not level
Weight not distributed evenly on all
four screws
See Leveling procedures
Head out of tram
See Tramming Head - Section 5.2.3
New installation or heavy crash.
Relocation of mill.
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4.1.2 A Special Word About X & Y Gibs
The slideway surfaces are vital to the performance of the bed mill.
Gibs should be:
•
•
•
flat
free of twist
free of burrs
• free of blockages in the oil passages and channels
Defective or scarred gibs must be replaced. Shimming of gibs may not yield acceptable
results.
It is good machining practice to avoid the use of shop air to clean the chips off a machine.
This risks blowing chips into the sliding way surfaces and compromising the performance of
the machine.
Gibs that are not adjusted correctly will affect the performance of the machine. It will lead to
positioning and repeatability problems. The gibs should be adjusted at least twice a year.
See Gib Adjustments Section 5.2.1.
4.1.3 Lubrication
Lubrication is one of the single, most important maintenance issues and plays a key role in
assuring the performance and durability of the Knee mill. At the beginning of each day
manually supply oil to the way surfaces.
Lack of lubrication can lead to a variety of problems with your machine motion due to
increased friction in the sliding ways. This increased friction may lead to part inaccuracies and
decreased life expectancies of your ball screws and way surfaces.
4.1.4 Machining Set-Up
The machining set-up itself is always something that can greatly influence the performance of
the your mill. The following are some things to keep in mind.
Problems With
Feed and Speeds (spindle rpm)
See below
Tooling
Using the wrong cutter for an application
Entering the wrong size diameter and
programming with tool compensation.
Cutting too deep
No coolant
Can Contribute To:
Poor finish
Machine chatter
Excessive speeds and feeds can break cutting
tools or wear tools prematurely.
Poor finish
Parts incorrect size
Part dimensions incorrect
Driving and cutting forces cause deflections,
since no material is totally rigid
Machine chatter
Poor finish, decrease the life of the cutter
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4.1.4.1 Spindle Speeds
Spindle speeds are influenced by a number of variables:
•
Material
•
Rigidity of the Machine Setup
•
Coolant
•
Cutter type, material and diameter
•
Cutting Depth
As a general rule:
•
Lower spindle speeds are used to machine hard or tough material or where heavy cuts
are taken.
•
Higher spindle speeds are used to machine softer materials in order to achieve better
surface finishes. Higher speeds also apply when using small diameter cutters for light
cuts on frail work pieces and delicate setups.
Note: Cutter diameter greatly affects spindle speeds. The larger the diameter, the lower the spindle speed.
4.1.4.2 Feedrates
Factors that affect feedrates:
•
Depth and width of cut
•
Design or type of cutter
•
Sharpness of the cutter
•
Workpiece material
•
Type of finish or accuracy required
•
Climb or conventional milling
If a fine finish is required, reduce the feed rather than increase the spindle speed. Cutters
are dulled by higher spindle speeds rather than high feedrates.
4.2 The Mechanical Drive Train (X, Y)
Indications:
• Troubleshooting instructions indicate that the drive train is potentially the problem and
other (more easily checked variables) have been exhausted.
•
Roughness, looseness, tightness or jamming movement in the table or saddle.
1. Check for machine considerations, especially gib locks and gib adjustments.
See Gib Adjustments section
2. Check the torque of the axis in three places (both ends and center of ball screw) along
the length of the ball screw. The torque should be within 2 or 3 in-lbs across the length
of the ball screw. If it is not, chances are the ball screw is misaligned. A misaligned ball
screw can lead to parts being out of round and servo problems at low feedrates. A bad
ball screw can also cause high torque, although this is highly unlikely. See Sections 4.2.1
and 4.2.2 for more information.
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The following steps take you in logical sequence through the assemblies for the knee
mills. For drawings of these assemblies see Figures 31 and 32 in Section 5. These
instructions break the machine down from fully assembled and point out the areas to look
at specifically.
3. Check that the belt is properly tightened. A loose belt can lead to excessive backlash
compensation values on motor encoder only machines.
4. Check that the nut that tightens up against the ball screw pulley is tight. If this is
loose the pulley may not run true on the ball screw.
5. Check that the tapered sleeve that seats the pulley has not clamped to the ball screw
prematurely. It should be seated firmly against the pulley. Tightening the nut may
not have ensured this. Also make sure the pulley is keyed to the ball screw.
6. Ensure that the screws that hold the bearing housing in place to the bracket are not
loose.
7. Ensure that the Clamp Nut is secured. The following applies to the clamp nut:
•
When loosening, make sure to back out the 10-32 screw from the clamp nut.
•
When tightening, snug the 10-32 screw so the clamp goes onto the ball screw
thread with some drag. Thread it onto the ball screw and torque the clamp nut
to 50 ft/lbs and then tighten the screw down.
8. Take out the angular contact bearings and inspect them. They should roll smoothly
and be lightly greased. If not, replace them. When putting the bearings back into
the housing make sure to put them in correctly. Failure to do this will cause
problems. The thin race of each bearing should be facing inward toward the spacer
ring.
Note: the bearing housing and spacer ring are matched sets - keep them together.
9. Check the ball screw mounting to the yoke. Make sure the SHCS are tight.
10. Inspect the ball screw, ball nut and yoke for the potential problems shown in the
chart on the next page.
CAUTION!
Unlike a lead screw, do not unscrew the ball screw from its nut. This will destroy the ball screw!
Potential Problem:
Bad ball screw
Check By:
• Visually inspecting the ball nut - if the nylon seal is broken or deformed,
if contamination has visibly entered the ball nut or if balls are out of the
ball nut, replace the ball screw.
• Cranking the ball screw through a significant part of its travel. If it
jams, feels loose or has rough spots, replace the ball screw.
• Using the dial indicator on a vertical flat of the ball screw to check for
backlash between the ball screw and ball nut.
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Potential Problem:
Ball nut not tightened to
the yoke
Yoke loose in the saddle
Oil lines sheared
Oil line blockage
Ball screws not aligned
properly
Check By:
• Inspection for space between the head of the bolt and the ball nut i.e.
the retaining bolt has bottomed out in its thread and is not securing the
ball nut to the yoke properly.
• Inspection for any motion of the yoke or looseness in the Yoke
mounting screws.
• Visual inspection.
• Pump the oil and ensure that it flows evenly to the ways and ball
screw.
• Measure from the ball screw to the back of the saddle on both sides of
the yoke (the table must be removed). The measurements must be
within ±.005” end to end. See above explanations.
Note: Ball screws are inspected throughout their entire travel for backlash and consistent torque. A
ball screw should be good for millions of inches of travel if installed properly. Do not be too quick to
replace a ball screw if there is insufficient indication that it is bad; this will just be a costly delay to
resolving the real problem.
4.2.1 Keys to Ball Screw Alignment
•
X-axis – there are 3 components that can cause misalignment: the yoke, the left side
bearing housing bracket, and the right side bearing housing.
•
Yoke – the yoke is aligned at the factory and pinned in place. It is aligned to within
+/-0.0005” with a precise alignment tool. The yoke most likely is not causing the
problem. If this were the problem you would need to remove the pins and align the X
ball screw with the back of the saddle. Drill new holes and pin the yoke in place. The Yaxis ball screw bore is machined perpendicular to the X bore. If the X-axis is aligned the
Y-axis will also be aligned.
•
Left side table bearing housing – this is most likely the cause of the misalignment.
To align the bracket and bearing housing, move them as close to the yoke as possible.
Loosen the bracket bolts and bearing housing bolts and then retighten. This should allow
the bearing housing to align itself up with the yoke.
•
Right side table bearing housing – once again move the bearing housing as close to
the yoke as possible. Loosen the bearing housing and retighten. This should allow the
bracket to align itself. If you do not move the table toward the yoke the ball screw will
tend to bend down slightly and cause misalignment.
•
Y-axis – the only component that can cause a misalignment problem is the motor
mounting bracket. To align this bracket, move the saddle as close to the front of the
machine as possible. Loosen the bracket and then retighten it. Once again moving the
saddle forward allows the yoke to be as close to the bearing housing as possible.
4.3 Computer/Pendant Diagnostics
The pendant consists of 2 separate modules: the computer module, and LCD
screen/enclosure.
In general, the pendant/computer module is best diagnosed by eliminating all other possible
alternatives. The following table lists some problems and what these problems can lead to.
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Possible problems
Poor cable connections
Pendant locks up
No voltage to RSG port
Low voltage to flash drive or slave board.
Flash disk failure
Floppy disk failure
LCD backlight burns out
Faulty E-stop switch
Overlay failure (keys on pendant)
Low voltage to pendant or current spikes
Can lead to
There are 4 cable connections (6 spindle control) to
the left side of the pendant. Make sure all cables are
properly fastened.
Press the E-stop button and see if lock up clears if not
then do the following:
Turn the pendant off, wait at least 30 seconds, and
turn it back on and check to see if the malfunction has
been reset.
RSG will not work – should be 5 DC volts present
Check with a voltmeter.
Can cause the system to lock up and the flash drive to
act abnormally. Check voltage to power cable at flash
drive module with voltmeter. It should be 4.8 DC
volts and above. Lower values than this can cause
problems.
If the flash disk fails, the system will not boot up or
operate. It will need to be replaced. All programs
and machine configurations will be lost. Make sure to
back up your flash disk from time to time.
Will not allow user to save or pull up programs from a
floppy disk. Can the floppy drive format a disk? See
Section 4.3.1.
Check all cable connections to LCD, distribution board
and computer module. Make sure the power is turned
off before doing so.
It can be stuck open or closed (pressed). If it is stuck
closed the pendant will need to be replaced because
the user will have no way to get rid of the message. If
it is open it will allow the machine to still operate but it
will be unsafe for the user. The pendant will still need
to be replaced.
Certain buttons on overlay do not work. Do code 81
to verify each key beeps.
1 amp fuse in pendant blows. Pendant will not turn
on.
4.3.1 Checking Floppy Drive by Formatting a Disk
1.
2.
3.
4.
5.
6.
Find a new disk and install in floppy drive.
Install keyboard into middle port.
Press CTRL ESC to get to start menu.
Press R for run.
Type Format a: - press enter.
If the format works your disk drive is working. If format does not work, reboot control
and see if it now works. If it does not work replace the computer module.
7. Press ALT ESC to get back to PT4 software.
4.4 Motor Diagnostics
The Motor subsystem is comprised of 3 parts: The Motor Encoder and the Motor and Servo Driver.
The motors are powered by 110 VAC voltage. The servo driver is also an integral part of servo
system, which is discussed in detail in the next section.
WARNING!
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Do not work with the motors unless the power is disconnected from the machine. The motors
are run by 110 VAC. There is possibility of death by electrocution!
Rarely do both the X and Y motor/servo systems fail at the same time and in the same way. So, if
your problem is occurring on both axes, its source is probably somewhere else.
4.4.1 Cable Connections
Check the motor cable connections on the cable breakout box. Verify there are no pushed in
pins on the connector.
4.4.2 To Check the Motor Encoders
If the motor encoder inside the motor has failed or is not reading the machine will fault out
on that axis. Do the following to verify this problem:
Motor encoder only machines – run Service Codes 100 or 131. This will display on the DRO if
the motor encoder is counting. If the axis does not count, the encoder is not counting. This
means either the encoder or the cable is the problem. Visually check the cable for any
problems. If the encoder has failed the motor must be replaced.
Motor encoder and secondary feedback machines – run Service Codes 100 or 131. Both the
motor encoder and sensor or glass scale encoder should count on the DRO screen. The
motor value should be displayed under the Z-axis and the sensor or glass scale under the X
or Y-axis depending on which axis you are doing.
4.4.3 Encoder Counts to Pendant
Before replacing the motor due to a bad motor encoder it is a good idea to check the cables
that take those signals back to the pendant. If these signals are not getting back to the
pendant then the axis will fault. Check the following cable connections.
•
•
•
Umbilical #1 and #2 at the cable breakout box
Umbilical #1 and #2 at the pendant
Umbilical #1 carries the X and Y-axis signals and Umbilical #2 carries the Z signals.
4.4.4 Moving Problem from One Axis to Another
Another way to troubleshoot a problem with a particular axis is to swap parts from 1 axis to
another to see if the problem moves. If the problem moves then that component is faulty.
See the example below.
Symptom – X Axis will not move and faults
This particular problem can happen because of any of following reasons: bad motor, servo
driver, or computer module. In some cases it is not obvious which component is causing the
problem. This example will help us pinpoint the problem through a trial and error process.
Let’s assume we have narrowed it down to the servo or electrical systems and the Y-axis has
no problems. Lets also assume it is not an obvious problem like a loose connection.
Swap these components
Physically switch the X and Y
motors
Results
Has problem moved to Y-axis? If yes, replace motor. If no,
the motor is not the problem.
4.5 Servo Driver
Note: the Servo Driver is located in the black box on the side of each motor.
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Indications:
• Problems moving just one axis, including hard turning in one or both directions.
Servo Types:
• X and Y servos are identical
Objective:
• Isolate the problem to the particular Servo Driver
Steps:
1. Turn off and unplug the system.
WARNING!
Do not work with the Servo Driver unless the power is disconnected from the machine. There is
possibility of death by electrocution!
2. Physically swap the servo module from the axis that is not working to one that is.
Note: To avoid pulling the wires out of the connector, use the loop to pull the connector from the Servo
Driver.
If the problem moves to the other axis and clears up from the original axis, replace the Servo
Driver.
4.6 Glass Scales
Glass scales are used on the X and Y-axis for secondary feedback. They are optional on the
TRAK Knee mill machines. The Z glass scale comes standard with the machine.
4.6.1 Alignment of scales
•
X Axis - The X-axis scale must be aligned within 0.005” in the up and down direction over
the length of the scale for proper operation. Misalignment can cause the scale to not
read in the certain areas of the scale that are not aligned with the reader head. If this
happens, the axis will mostly likely fault out in this area. Also make sure the mounting
hardware for the reader head is tight. Loose hardware can cause excess backlash when
reversing direction.
To align the scale, place a 0.001” indicator on the bed ways and on top of the scale
extrusion. Move the table along its full travel from one end to another to verify it is
aligned. If the scale is misaligned loosen the 2 screws at either end to shift the scale up
or down as needed. You will also need to loosen the center support bracket to allow the
scale to pivot.
•
Y Axis - The Y-axis must be aligned in the up and down direction and must be parallel to
the Y-axis way surface. Both surfaces must be aligned to within 0.005”. Failure to align
the scale properly could cause the same problems as mentioned above. Mount your
0.001” indicator on the saddle and move the Y-axis back and forth along its travel.
•
Z Axis – The Z scale must be aligned parallel with the quill. Make sure the gap on the
readerhead is consistent along the length of travel. Align the scale within 0.005” up and
down.
See Figure 28 in Section 5 for an illustration of the Z glass scales.
4.6.2 Measurements Do Not Repeat
1. Determine if the error in repeatability is random or accumulating:
•
Mount a dial indicator in the quill.
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•
•
•
•
•
•
Touch off a fixed point on the table and set the DRO to 0.
Traverse away approximately 6 inches.
Return the touch off again.
Write down the reading on the DRO.
Do not Re-zero the DRO, traverse away and return several times.
Write down the DRO readings
Random error will be unpredictable and give scattered readings, adding and/or subtracting
the error after each traverse with no pattern. See Step 2.
Accumulating error will add roughly the same amount to the reading after each traverse.
See Step 3.
2. For random error, look for problems in the set-up of the glass scale that have resulted in
a loss of rigidity. Common sources of random error include:
•
•
•
•
Loose scale mounting hardware.
Loose reader head.
Very loose motion of the table or saddle.
Loose cable connection
3. Accumulating error is commonly the result of:
•
•
•
Scale out of parallel to the axis travel.
Dirt or chip on the glass scale.
Broken glass.
4.7 TRAK Sensors
TRAK Sensors are used on the X and Y-axis for secondary feedback. They are optional on
the TRAK SMX knee mill machines. The following section talks about some of the common
symptoms associated with a problem sensor and how to isolate or fix the problem.
Common symptoms
•
Faulting Axis
•
The DRO measurements do not repeat
•
The DRO measurements are not accurate
Objectives:
•
To determine if the TRAK Sensor is bad and needs to be replaced.
•
To determine if there is a problem with the sensor set-up
4.7.1 Faulting Axis
If a sensor has stop reading and you try to move an axis, the axis will run away and fault.
Our control uses the counts from the sensor and motor when reading position. If either one
of these signals is not working our system will fault.
1. The first thing that can be done to see if the sensor is at fault is to turn off the sensor on
the axis in question. This will allow the system to run only on the motor encoders. If the
fault continues then the sensor was not the problem. Turn the sensor back on. See the
service code section for a codes needed to turn the sensors on and off. Also, run code
100.
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2. The next thing to do is to visually inspect the sensor and base to determine if there has
been a crash. A damaged base will usually have crinkles in the small, spring plates on
the front and back.
3. Next make sure the sensor is preloaded correctly against the running surface. There is a
setscrew on the base that allows for adjustment.
4. If no outward signs of damage are present, remove the sensor from its base, and inspect
the wheel for damage and wear.
If the wheel is worn smooth in the center, replace the sensor.
Note: Sensors should not wear smooth for many years of normal operation.
5. If the sensor looks normal, it is probably OK and there is a mechanical obstruction
somewhere in the set-up. Look for the following possible problems:
•
Broken sensor base
•
Broken bracket
•
Sensor tilted too much (so that the wheel is not engaging the running surface)
•
Sensor chip scraper has doubled back and is pushing the wheel away from the
running surface
•
Sensor chip scraper is defective or has worn and is pushing the sensor unevenly
4.7.2 Measurements Do Not Repeat
1. Determine if the error in repeatability is random or accumulating:
•
Mount a dial indicator in the quill
•
Touch off a fixed point on the table and set the DRO to 0.
•
Traverse away approximately 6 inches
•
Return and touch off again
•
Write down the reading on the DRO.
•
Do not re-zero the DRO, traverse away and return several times
•
Write down the DRO readings
Random error will be unpredictable and give scattered readings, adding and/or
subtracting the error after each traverse with no pattern. See Step 2.
Accumulating error will add roughly the same amount to the reading after each
traverse. See Step 3.
2. For random error, look for problems in the set-up of the TRAK Sensor that have resulted
in a loss of rigidity. Common sources of random error include:
•
broken base
•
broken bracket
•
loose puller screws
•
loose run bar
•
very loose motion of the table or saddle
•
loose clamp screw
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3. Accumulating error is almost always the result of the wheel not traveling in a path
parallel to the motion of the axis. This causes the wheel to skip at certain regular points
in its travel.
•
•
Inspect the base to determine if it has been damaged. A damaged base will usually
have crinkles in the small, triangle-shaped plates on the front and back.
Use a bubble level or an indicator to adjust the puller screws so that the base is
parallel to the running surface.
•
Inspect that the sensor is not cocked so that the case contacts the running surface.
•
Inspect the wheel for chips that are adhered or for gouges.
4.8 Electrical
4.8.1 Checking A/C Voltage
This procedure tests for the 115V power for the control.
• Use a Voltmeter, reading A/C volts.
• Acceptable range is 100V to 130V.
Note: systems running consistently close to the low values may have problems when normal voltage
fluctuations push the voltage out of the acceptable range.
Test the following in the order presented:
Problems Here:
1. The wall outlet.
•
•
2. The control power cord from the wall.
Check the end that goes to the electrics
box.
3. Check the top fuse on the electrical cabinet.
It should be an 8-amp fuse.
3. Check the 110-power cord to the pendant.
4.8.2
•
•
•
May Indicate:
Fuse blown in the shop electrical panel.
Incoming service from local utility is bad.
Call the electric company.
Power cord defective.
If this is blown then power will not reach
the 4 outlets on the electrical box.
Power cord defective
Checking Fuses
CAUTION!
Turn off power before removing and replacing
There are 4 fuses to check in the system. There are 2 in the pendant and 2 in the electrical
cabinet, and one on the breakout box. The top fuse in the electrical cabinet is 8 amps and
fuses power to the pendant. The bottom fuse is 5 amps and fuses power to the auxiliary 1,
auxiliary 2 and lube pump outlets. The 2 fuses in the pendant are 1 amp and 12 amps. The
12-amp fuses the cable breakout box, and the 1 amp the pendant.
If you have the auxiliary function option then there is 1 more fuse to check on the cable
breakout box for the coolant or mister option.
To check fuses:
1. Use a Volt/Ohmmeter; select “OHM”.
2. Remove the fuse completely from the pendant, electrics box or cable breakout box.
3. Place a lead of the meter on each end of the fuse.
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•
•
A good fuse reads 0 (zero) or close to it.
A bad fuse reads Open or Infinity.
4.8.3
Cable Breakout Box Connections
This module is located on the back side of the machine. It consists of 3 motor connections, 3 limit
switch connections, 3 encoder connections and an E-stop connection.
Machines with an auxiliary function option have 2 more outlets. A 110 V outlet for a coolant
pump or air solenoid and an indexer outlet.
The coolant pump signal and indexer signal comes down from umbilical #2.
4.8.4
Cable Connections
The TRAK knee mill machines use 10+ cables to communicate between systems. It is often
the case that what appears to be the failure of an electrical component is actually attributable
to a poor connection.
Indications:
•
•
•
Control problems, chronic or intermittent.
Motor problems
Measurement problems.
Explanation:
1. Turn off and unplug the system from the wall.
CAUTION!
Do not plug and unplug connectors with the system power on. This may cause damage to the
connector board and harm to the technician.
2. Visually inspect the connections for excessive debris, moisture, or obvious damage.
3. Carefully clean any chips away from the connectors.
4. One-by-one, take out each connector and then plug them back in. Do the same at the
computer/display.
5. Make sure to tighten up the screws on each of the connectors.
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Figure 19
Electrical Box Schematic
4.8.5
Spindle Control Electrical Box
The spindle control electrical box is made up of the following main components:
1. AC drive – used to control the spindle motor.
2. 4 output 110 volt outlets – 1 outlet is used to power the pendant, 1 is used to power the
lube pump and is turned on based on the spindle being on, 2 additional outlets.
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3. 2 braking resistors – used to brake the spindle motor. The mechanical brake should not
be used to brake the spindle. To verify the resistors are good, measure the resistance
across B1 and B2 of the AC drive. For 3 HP machines it should read 60 ohms and for 5
HP machines it should read 32 ohms. Values lower or higher than this could be one or
both resistors are bad.
4. Relay – used to turn on and off the lube pump and spindle motor fan.
5. Spindle control PCB board - controls the auxiliary signals from the pendant to the AC
drive and electrical outlets. The following explains the LED lights on the spindle control
board. There are (2) 10 LED segments on the board. Not all of the LEDs are used. See
figure 21 for an illustration.
1st 10 LED Segment
4. LED labeled Gear 1 – this light should be on whenever the machine is in low gear. LEDs
labeled Gear 2 thru Gear 4 are not used.
5. LED labeled SPD-FAULT – this light will be on whenever the AC drive is in a fault
condition, which includes an E-stop message from the pendant.
6. LED labeled SPD-RUN – this light should be on whenever the spindle is on.
7. LED labeled SPD-ENABLE – this light should be on whenever you are in DRO, tool setup
and RUN mode.
2nd 10 LED Segment
1. LED labeled E-STOP OUT – this light should be on whenever the E-stop is in the out
position. When the E-stop is pressed, this light should go off.
2. LED labeled LATCH RELAY – this light should be on when the spindle is running or if the
spindle is not running and the fwd/rev switch is in the off position when in DRO, tool
setup or RUN mode. Note – if spindle won’t turn on and the spindle is enabled and the
e-stop is out, then either the fwd/rev switch is bad or the spindle control board is bad.
3. LED labeled TAP MODE – light should be on whenever you are not tapping. Light will be
off when in the tap event. Not applicable to 2-axis knee mills or retrofits.
4. LED labeled TAP REVERSE – this light will be on when the spindle changes direction at
the bottom of a tap event and back off after the spindle changes direction once outside
of the tap event. Not applicable to 2-axis knee mills or retrofits.
5. LED labeled REV-RELAY – when fwd/rev switch is in reverse this light will be on. Note –
this does not mean necessarily that the spindle will be running this direction.
6. LED labeled FWD-RELAY – when fwd/rev switch is in forward this light will be on. Note –
this does not mean necessarily that the spindle will be running this direction.
7. LED labeled Z-LIMIT PLUS – this light will be on only when the Z-axis plus limit switch is
triggered. This only applies to a 3rd axis product.
8. LED labeled Z-LIMIT MINUS – this light will be on only when the Z-axis minus limit switch
is triggered. This only applies to a 3rd axis product.
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Figure 20
Schematic Diagram of Spindle Control Option
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Figure 21
LEDs on Spindle
Control Board
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4.9
Service Codes
Service codes are broken down into the 4 following categories: software, machine setup,
diagnostics and user options/defaults.
All Service Codes are accessed in the SET-UP Mode by pressing the soft key for “SERV
CODES”. The service codes can be found under one of the headings listed on the main
screen. Press the heading you want to access the code in question. If you know code # you
want press the CODE # softkey and it will take you directly to the code in question. Press
CODE #, enter the number you want, press SET.
4.9.1
Software Codes
The following codes pertain to software functions in the control. To get to any of these codes
go to Service Codes, press “A” and press the code you wish to view.
Note: If you are working with the SWI Customer Service Group, write the values down for Code 33 or
Code 313. These values will be valuable for troubleshooting.
4.9.1.1
CODE 33: Softw are ID
The Code 33 is the software identification procedure. The two types of software in the
control include:
•
Software Version - the version of the system you have installed
•
Firmware Version - the version of firmware software that is responsible for control to
servo interface.
•
Converter Version – the version of software that is responsible for converters and
options.
•
Operation System Version – shows the version of the XP Operating System.
4.9.1.2 CODE 141: Load Configuration file from ex ternal drive
This code allows you to load your configuration file from the floppy disk or external drive to
your hard drive. The configuration file consists of items such as calibration and backlash
constants. This code is used when a computer module or hard drive has been replaced.
4.9.1.3
CODE 142: Save Configuration file to an ex ternal drive
This code allows you to save your configuration file to a floppy disk or external drive. The
configuration file consists of items such as calibration and backlash constants. This code is
used when a computer module or hard drive needs to be replaced. This stores the
configuration file from the hard drive to the floppy disk. It is a good idea to do this code
after the machine is initially setup so these values can be saved and used in the future. If
the computer or hard drive fails, then you will not have the ability to save the configuration
file and the machine will need to be re-setup when the computer or hard drive is replaced.
Note: All machines will have a copy of the configuration file in the back of the electric’s cabinet.
4.9.1.4
CODE 313: Display Configuration File
This code displays the configuration file. This file contains pertinent information about the
machine. The file will look similar to the following. If the file becomes corrupt you can load
default values by pressing the F4 softkey.
Product = KNEE2X (displays machine ID key of machine)
Motor encoder calibration constants
X=610.0711
Y=610.0812
Secondary feedback calibration constants X=3302.6122 Y=3302.5955
Z=610.0678
Z=3302.5877
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(These numbers above are typical numbers for the calibration constants, the numbers for
secondary feedback are default numbers, which means no calibration has been done, or the
machine does not have secondary feedback)
Arc accuracy – 0.001”
Secondary feedback – 0, 1, 2 or 3
(0 = off, 1 = X on only, 2 = Y on only, 3 = XY both on)
Code 11 values X = 0.002
Y = 0.001”
Code 128
X=0.001”
Y=0.0014”
Z=0.0016”
Code 12 (+)
X=000005
Y=000006
Z=000006
(-)
X=000005
Y=000005
Z=000006
Code 100 (+) X=210.5
Y=208.9
Z=200.1
(-)
X=207.1
Y=208.4
Z=203.6
4.9.1.5
CODE 316: Update M aster Softw are
Load upgrade disk in floppy drive or add software to an external drive and press this service
code. New software will automatically download and control will reboot. Please perform
alignment routine afterwards.
4.9.1.6
CODE 317: Update Slave Softw are
Load upgrade disk in floppy drive or add software to an external drive and press this service
code. New software will automatically download and control will reboot. Please perform
alignment routine afterwards.
4.9.1.7 CODE 318: Activate Converters or Options
See programming and operating manual.
4.9.2
Machine Set-up Codes
The following codes are used primarily when setting up a new machine. To get to any of
these codes go to Service Codes, press “B” and press the code you wish to view.
4.9.2.1 CODE 11: Hysteresis
Note: This code is use only for systems with Sensors or Glass Scales on the table and saddle.
The Code 11 service routine checks the readings of the motor encoder against the sensor
encoder. It is a measurement of how much motor motion is necessary to create table or
saddle motion. This test helps us to look at two things:
•
Play: How much backlash must be taken up when motion is reversed.
•
Friction: How much the mechanical components must be "torqued up" in order to break
the friction and create motion.
The Code 11 procedure is very useful and will help in diagnosing all types of motion and
performance problems.
1. Position the table and saddle in the center of travel. Note: You will lose your DRO position
reference.
2. Go into the Service Codes and input Code 11.
3. The system will run the checking routine automatically and then display the values in the
position readout.
Explanation:
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As an overall measure of the system hysteresis, we are looking for the X and Y values to be
less than .004". A value greater than this indicates a problem with either excessive friction or
play that may affect the finish or accuracy of machined parts.
4.9.2.2
CODE 12: Feed Forw ard Constant
The Code 12 procedure helps the control “learn” the friction characteristics of the machine by
sending a graduated series of motor signals and observing the results. The process takes
less than 30 seconds to run. It is both a diagnostic routine that displays values, and a
routine that sets the parameters of the control for the particular machine.
The Code 12 is used for diagnosing and resolving:
•
Problems with machine motion.
•
Machined parts come out bad – especially poor finish.
Note: Code 12 routine will set the parameters for the particular machine and its particular situation.
If the machine changes its friction characteristic, the Feed Forward Constant should change too, or
the system will not servo properly. Whenever gibs are adjusted or a heavy workpiece has been added
to the table, you should run a Code 12. When the heavy workpiece is removed, Code 12 should be run
again.
1. Position the table and addle in the center of travel. Note: You will lose your DRO position
reference.
2. Go into the Service Codes and input the Code 12.
3. Press Auto
4. The system will run the routine automatically and then display values on the position
readout.
Explanation
Typical values should be between 4.04 and 11.11 are considered normal for each axis. Higher
values indicate excessive friction in the system. Lower values indicate a loose system and
may mean a gib adjustment is necessary. Value 4.04 means the friction is a factor of 4 in
one direction, and 4 in the other direction. The values should be within 3 or 4 of each other
in both directions. A value of 6.08 would still be considered normal.
On S products, do not equate Code 12 values to torque on ballscrew. Measure friction in
system with an in-lb torque wrench.
The feed forward gain can be adjusted manually by pressing the manual button. Choose the
axis you would like to change and then enter values in the positive and negative direction to
adjust. Adjusting the gain can help solve circularity problems. Default values can be set by
pressing the Reset button. The manual feature should only be used in extreme cases where
the AUTO routine did not solve the problem. Manual adjusts above 12 may lead to servo
related problems.
4.9.2.3
CODE 100: Ax is Open Loop Test
Code 100 procedure is used to diagnose problems with the configuration of the system, the
encoders and incoming A/C voltage.
CAUTION!
During this procedure, the designated axis will be given a command to move at maximum speed for 1
second in the direction you choose. Avoid crashes by making sure the quill is out of the way and by
starting with the table and saddle centered. MAKE SURE THAT NO ONE IS STANDING IN THE WAY
OF THE TABLE OR SADDLE!
Note: You will lose the DRO reference position.
This procedure is to be run for each axis that is servo-driven, and for both the plus and minus
direction for each axis.
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1. Center the table and saddle and raise the head. Make sure the gib locks are released.
2. On the Pendant display, go into the Service Codes and input the Code 100.
3. The conversation line will say: “SELECT AXIS”. Input the axis. Either X, Y or Z.
4. In the conversation line it will say “WHICH DIRECTION? PLUS”.
•
If you want to run in the plus direction, press INC SET.
•
If you want to run in the minus direction, press +/-, then INC SET
5. In the conversation line it will say “PRESS GO”. Press Go after you are sure that the
machine will not crash in the direction and axis that you have specified.
6. Afterward the screen will display values next to the DRO position axes. The table below
assumes machine has secondary feedback. Machines with motor encoders only will
display the reading next to the axis in question.
Your input
X+
Display
X
Y
Z
Feedrate
Data displayed.
table encoder reading
nothing (should be 0 )
Motor encoder reading
the maximum feedrate attained
Your input
X-
X
Y
Z
Feedrate
table encoder reading
nothing (should be 0 )
Motor encoder reading
the maximum feedrate attained
Your input
Y+
X
Y
Z
Feedrate
nothing (should be 0 )
table encoder reading
Motor encoder reading
the maximum feedrate attained
Your input
Y-
X
Y
Z
Feedrate
nothing (should be 0 )
table encoder reading
Motor encoder reading
the maximum feedrate attained
Your input
Z+
X
nothing (should be 0 )
Y
nothing (should be 0 )
Z
motor encoder reading
Feedrate
the maximum feedrate attained
Your input
X
nothing (should be 0 )
ZY
nothing (should be 0 )
Z
motor encoder reading
Feedrate
the maximum feedrate attained
Interpretation of the resulting values displayed:
The values for the encoder displays should be in the range of 3.0000” to 5.0000”.
•
If the motor encoder and sensor or glass scale reading is not within this value, then the
one that is out of specification may be the problem. If one of the encoders is not reading
then it will need to be replaced.
•
The feedrate should be a minimum of 120 ipm.
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•
If the feedrate is less than 120 ipm and inconsistent in both directions, check the
incoming AC voltage and mechanics of the drive train.
4.9.2.4
CODE 123: Calibration
See Section 5.2.2 for a further explanation of this code.
4.9.2.5
CODE 127 - Set X or Y Backlash Constant
See Section 5.2.2 for a further explanation of this code.
4.9.2.6
CODE 128: Input Backlash Constant
Code 128 allows you to enter the backlash values for each axis. It displays the value after it
enters. This code is only used on machines with motor encoders only.
4.9.2.7
Code 304: Toggles X sensor or glass scale on/ off
This service code toggles the X sensor or glass scale on or off. It is used to configure the
machine and also is a useful tool for troubleshooting. Code 313 (configuration file) displays
whether the sensors have been turned on or off. The line labeled secondary feedback
explains which sensors or glass scales are turned on. This line can read any one of the
following:
0 = sensors or glass scales turned off
1 = X sensor or glass scale turned on only
2 = Y sensor or glass scale turned on only
3 = both X and Y sensor or glass scale turned on
4.9.2.8
Code 305: Toggles Y sensor or glass scale on/ off
4.9.2.9
Code 321: R everse Y position sensor direction
This service code toggles the Y sensor or glass scale on or off. See Code 304 for further
explanation.
This service code reverses the direction of the encoder. It may be needed if sensors or glass
scales are mounted on different sides of the machine.
4.9.2.10
Code 322: R everse X position sensor direction
4.9.2.11
Code 325: R everse Quill Sensor Direction
This service code reverses the direction of the encoder. It may be needed if sensors or glass
scales are mounted on different sides of the machine.
This service code reverses the direction of the encoder.
4.9.3
Diagnostic Codes
The following codes are used primarily when diagnosing a problem with the machine. To get
to any of these codes go to Service Codes, press “C” and press the code you wish to view.
4.9.3.1
Code 54: Program Continuous R un
This Code runs a program continuously without stopping for SET Z or CHECK Z commands. It
is helpful in running a long period to identify an intermittent problem.
1. Prepare a program as you normally would.
2. Press MODE, SET UP, “C”, Code 54, INC SET. The program run will start automatically.
3. Press STOP to stop, and GO to continue.
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4.9.3.2
Code 81: K eyboard Test
This code is used to check if the keyboard is functioning correctly. It allows you to test each
key on the pendant individually. When you press the keys, the corresponding box for that
key will highlight on the screen. The pendant will also beep, indicating that the key is
working correctly. If one of the keys does not work the pendant assembly may need to be
replaced. If none of the keys are working chances are that the computer module will need to
be replaced.
4.9.3.3
Code 131: M anual DR O
A manual diagnostic routine to check the motor encoder and table encoders. Turn the X
hand wheel to display the encoder readings. This code will display the actual DRO counts
and the raw encoder counts.
4.9.3.4
Code 132: Electronic Hand W heel Test
4.9.3.5
Code 314: Toggle test lights ‘on’ in status line
Turn the X, Y, or Z-axis electronic hand wheel. The display should show movement as the
hand wheel is being turned. There should be no skipping and it should count smoothly while
the hand wheel is being turned. One revolution of hand wheel should read 0.2000” when in
fine mode and 0.800” in course mode
This code toggles on and off 2 test lights that appear in status line. The top light signifies if
the master software is working. If functioning it should flash a green light. The bottom light
signifies if the slave firmware is functioning. It will appear orange in run mode when it is
processing information. Pressing the mode key will change this orange box to black. The
orange box will also change to black when the program you are running reaches the 3rd event
from the end of the program. If the firmware is locked up no keys will work. This code is
useful for diagnosing intermittent problems with the control locking up.
4.9.3.6 Code 319: Error Log
This code when turned on captures the commands that were sent to the servo system. It
includes items such as positioning commands, errors, stop and go commands, etc. It may be
helpful for identifying problems between programmed commands and executed commands.
To turn on the error log press the F6 softkey. The page forward and backward keys allow
you to scroll through the file one page at a time. The data forward and data backward keys
allow you to scroll through the file one line at a time. The data bottom key takes you to the
bottom of the file and then changes to data top which will take you back to the top. The file
will capture data until the file reaches a size of approximately 600 Kb. At this time the file is
saved to a backup file and the original file is cleared and data is once again captured. Once
again as the file reaches a size of 600 Kb it copies over the previous backup file. From here
the user can save the file to the floppy drive or an external drive by following the instructions
on the screen. Once this in done it prompts you for which file you want to save to disk. The
F1 key saves the current file to disk and the F2 key saves the backup file to disk. To clear
the files press the F7 softkey.
4.9.3.7
Code 324: Toggle Sim ulation M ode
Simulation Mode allows the control to run a program without actually moving the table. It is
helpful in diagnosing Computer/display problems.
4.9.4
Operator Defaults/Options Codes
The following codes allow the user to set programming defaults or turn features on or off.
To get to any of these codes go to Service Codes, press “D” and press the code you wish to
view.
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4.9.4.1
Code 66: Default M etric
This code causes the control to turn on in the metric mode.
4.9.4.2
Code 67: Default English
This code causes the control to turn on in the English mode.
4.9.4.3
Code 79: Beeper On
This turns on the beeper to the control keys.
4.9.4.4
Code 80: Beeper Off
This turns off the beeper to the control keys.
4.9.4.5
Code 129: Arc Accuracy
When the SMX control operates at high feedrates it may create small part machining errors
as it goes around sharp corners. This exists on all CNC’s and is commonly called a “following
error.” The control is factory preset to allow a maximum following error of 0.001 inch. The
feedrate will automatically be adjusted around sharp corners so as to not violate this limit.
This code only applies to arcs that are programmed and ones that are created in the tool
path to generate the shape you want. This code will not make a difference on mill moves.
You may adjust the maximum following error to a value as small as .0001 inch. However, the
smaller the value, the slower the feedrate around corners.
To input a new Following Error use the following procedure:
Follow the instructions on the screen and input the Following Error value (from .0001 to
.0100) and press INC SET.
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5.0
Procedures for Replacements
& Maintenance
5.1 Replacements
5.1.1 Servo Motor Replacement
WARNING!
Do not work with the Servo Motors unless the power is disconnected from the machine. The
servomotors are run by 110 VAC. There is possibility of death by electrocution!
1. Turn off power to the machine.
2. Each motor is mounted by the use of (4) ¼ - 20 screws. Be careful not to over tighten
these bolts and strip the threads.
5.1.2 Servo Driver Replacement
WARNING!
Do not work with the Servo Drivers unless the power is disconnected from the machine. The
servo drivers are run by 110 VAC. There is possibility of death by electrocution!
The Servo Driver for each axis is integrated into the servo motor casting.
WARNING!
Always engage (push in) the Emergency Stop switch, turn the ProtoTRAK SM Control off, and
disconnect the servo motor/driver cable at the cable breakout box.
1. Press in the Emergency Stop.
2. Remove the servo motor/driver assembly from its mounting bracket.
3. Remove the 10 cap screws that hold the servo driver and its heat sink plate to the motor
casting.
4. Disconnect the cable connector. Do not pull on the wires.
5. Reinstall the new servo driver with its heat sink plate. Be certain the gasket properly
seals the assembly.
6. Reinstall the motor/driver assembly. Make certain the belt is tight so that there is little
play if pinched in the middle.
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Figure 22
Part #
20201
5.1.3 Computer Module and
LCD/Enclosure Replacement
Description
X, Y or Z Servo Driver
1. Turn off power to the machine and control.
2. Unplug all the connectors on the pendant arm side of the pendant.
3. Remove the pendant from the pendant arm by removing the (4) ¼ - 20 x 3/4” SCHS
that secure it in place.
4. Place the pendant assembly on a clean and secured table with the display pointing away
from you.
5. Remove the (6) 10-32 x 3/8” Pan Phillips Head Screws and (4) 10-32 x 3/8” FHCS
securing the computer module to the LCD/enclosure.
6. Pull the computer module a few inches and stop. Pulling the computer module too far
will damage the ribbon cables.
7. Now reach from the top and remove the 37-pin LCD cable, 37-pin distribution cable and
the 9-pin E/Stop cables. The cables are to stay with the computer module.
8. Now slide the module about ½ way out of the LCD/enclosure.
9. Remove the ground wire from the LCD/enclosure side.
10. Lastly, slide the unit completely out of the LCD/enclosure.
11. Replace computer module or LCD/enclosure.
12. Follow the instructions in reverse order when reinstalling the new computer module or
LCD/enclosure.
Make sure that all connectors are properly seated before fastening the unit back in place.
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Figure 23
Computer Module & LCD/Enclosure Replacement
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5.1.4 System Flash Disk Replacement
1. From the control, go to SETUP, SERV CODES, SECTION A, and then code 142 and save your
Configuration file (calibration values, etc.) on a floppy disk or USB drive. Label this disk as
“Backup Configuration” and store it for later use.
2. Turn power off to the machine and control.
3. Unplug all the connectors on the pendant arm side of the pendant.
4. Remove the pendant from the pendant arm by removing the (4) ¼-20 x 3/4” SCHS that
secure it in place.
5. Place the pendant assembly on a clean and secured table with the display pointing away
from you.
6. Remove the (6) 10-32 x 3/8” Pan Phillips Head Screws and (4) 10-32 x 3/8” FHCS securing
the computer module to the LCD/enclosure.
7. Pull the computer module a few inches and stop. Pulling the computer module too far will
damage the ribbon cables. If need be, remove 4 cables that connect the computer module
to the enclosure. Make sure to reattach them securely before re-assembling the pendant.
8. Remove the defective System Flash Disk (located on the back side of the mother board) by
pushing the eject button on the flash drive.
9. Firmly insert the replacement System Flash Disk into the drive, making sure that the label
with the serial number is pointing towards the motherboard.
10. Secure the computer module back to the LCD/enclosure by following the instructions in
reverse order.
11. Make sure that all connectors are properly seated before fastening the unit back in place.
12. Turn power on to the machine and control.
13. When the system boots, you may get a message stating that the system cannot find your
configuration file. Clear this message and continue.
14. From the control, go to SETUP, SERV CODES, SECTION A, and then code 33 and verify your
software and firmware versions are current.
15. To verify the current version, go to www.southwesternindustries.com, click on support and
then Software for current Prototrak CNC’s, locate the download for the control.
16. If your software is an older version and does not match the one on the website, follow the
instructions for updating your control using a USB thumb drive.
17. Restore the Configuration file saved on your backup configuration disk with service code 141
found in section A of the service code section.
18. If your control was networked prior to this change, you will have to reset your network
settings.
CAUTION!
It is a good idea to back up your flash disk from time to time via a network, external drive or
floppy disk. If your flash disk needs to be replaced you will loose all of your programs. See your
programming manual for instruction on how to do this.
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Figure 24
Flask Disk Replacement
Figure 24
Flash Disk Replacement
Flash Disk Parts List
Item
1
2
3
P/N
24008-1
24030-1
25078
25078-1
Description
PENDANT WITHOUT COMPUTER MODULE
COMPUTER MODULE
FLASH DISK (used on Revision D or later pendant)
FLASH DISK (used on Revision C or earlier pendant)
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5.1.5
Cable Routing on Machine
5.1.6
TRAK Sensor
5.1.6.1
R eplacing the M 5 Base
Whenever you replace a cable or reroute a cable it is very important to keep the power cables
and logic cables separated from each other. The power cables consist of the (3) 110-volt motor
cables and (2) 110-volt power cables for the pendant, and a coolant pump or solenoid power
cable. The logic cables are used to carry encoder signals between the cable breakout box and
computer module. Mixing of the power and logic cables may cause noise from the power cables
to interrupt the signals in the logic cables. This can lead to intermittent axis faults or
repeatability problems. See Figure 15 and 16 for a layout of the cable connections.
See Figures 25 and 26.
1. Remove the sensor by removing the clamp screw and then backing the load screw out a few
turns. The sensor should lift off the base easily.
2. Remove the old M5 Base by removing the two 1/4-20 hex head screws that are threaded
into the base.
3. Assemble the new base as per Figure 25.
4. Use a bubble level to align the raised bumps on the base with the table for X axis or saddle
ways for Y-axis.
5. A dial indicator may be used to align the bumps on the base instead of a bubble level.
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Figure 25
M5 Base Mounting
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5.1.6.2
R eplacing the TR AK Sensor
1. Remove the old sensor by removing the clamp screw and then backing the load screw
out a few turns. The sensor should lift off the base easily.
2. Install the new sensor on the M5 base using the clamp screw.
3. Load the sensor against the running surface (table or run bar) using the load screw.
The white lines on the side of the M5 base tell you when it is loaded correctly.
Note: You want to load the gage wheel against the running surface using the flat spring of the M5
base. Do not tighten the clamp screw fully until after loading the sensor.
Figure 26
TRAK Sensor Mounting
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Figure 27
K Mill Sensor Assembly
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K Mill Sensor Assembly Parts List
Item
1
2
3
4
5
6
7
8
9
10
11
P/N
M250C
M5
LDCEL-C
M5 HDWR
16023-1
21511
14600
13384-4
15346
16023-2
13777-1
DESCRIPTION
SENSOR - ALL TRAK PRODUCTS
M-5 BASE
LOADCELL - M250C
HARDWARE - M5 BASE
BRACKET-SENSOR X-AXIS (K2)
EXTENSION
BAR-RUN Y-AXIS
BRACKET-SENSOR Y-AXIS (K2)
CHIP SCRAPER-M250C
BRACKET-SENSOR X-AXIS (K3 & K4)
BRACKET UNIVERSAL BR17-RY MODIFIED (K3 & K4)
i01117
5.1.7 Glass Scale Replacement
5.1.7.1
R em ove the X, Y or Z Glass Scale
1. Unplug the glass scale connector from the cable breakout box.
2. Unbolt the reader head of the glass scale from its mounting surface.
3. Unbolt the glass scale enclosure from the table on X or the mounting spar on Y.
4. Install the head alignment bracket that came with the replacement scale to this scale to
secure it for shipping back to SWI. Failure to do this may cause the glass scale to get
damaged during shipment. The head alignment bracket secures the reader head so it
cannot move and damage the glass in the scale.
Note: 1st align the reader head on the new scale before removing it to fasten the old scale.
CAUTION!
Once the head alignment bracket is installed, do not traverse the axis or the
reader head will break.
5.1.7.2
Install the X or Y Replacem ent Scale
CAUTION!
If the scale is not long enough for the table, it will break when the machine is
traversed past the scale travel.
1. Mount the scale to the back of the table or Y-axis mounting spar.
2. Align the sale so that it is within +/- 0.005" end to end.
Notes: For the Y-axis, the mounting spar should already be aligned. It must be parallel to the Y-axis
travel within +/-.005" end to end both horizontally and vertically. The mounting spar can be aligned
in and out by the use of the adjustment screw.
3. Line the reader head up with the mounting holes on the back of the saddle for the Xaxis or the bracket on the Y-axis.
4. Install the reader head bolts but leave them loose.
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5. Use the jackscrews on the reader head to compensate for some gap between the reader head
and the reader head mounting bracket. Leave the alignment brackets attached to the reader
head. This bracket assures the reader head is aligned to the glass scale.
6. Tighten each jackscrew until it touches the bracket and then back it off 0.001” or
0.002”. Use a feeler gage to set the gap.
7. Tightening the reader head mounting screws. This ensures the reader head is aligned
within a few thousandths.
8. Remove the shipping bracket that fixes the reader head to the scale for shipping.
CAUTION!
After the reader head is attached to the reader head-mounting bracket, do not move
the machine axis until the shipping bracket is removed. This will break the reader
head. This is not covered under warranty.
See Figure 29 for an illustration of how to align glass scales.
5.1.7.3
Install the Z-Ax is Glass Scale
See Figure 28.
1. Check the tram of the head in the X direction. If it is within a few thousands then
continue on. If not tram.
2. Assemble Z-axis glass scale mounting bracket and mount to head. Items 1, 2, 3 and 4.
Tap items 3 and 4 together and tap item 3 into the quill stop knob. Leave the bolt loose.
Use 2 screws (item 6) and mount item 4 to the side of item 2 using a spacer between
both items to provide a gap of approximately 0.040” between Items 2 and 4. This is to
make sure item 2 does not rub against item 4.
3. Align the glass scale bracket (Item 2) with an indicator and tighten the mounting screws.
Leave the quill stop knob screws loose. Remove the spacer and bolts from Item 4.
4. Unscrew the shipping protection screw from the scale.
5. Mount the glass scale to the mounting bracket and align it with an indicator. It needs to
be aligned within 0.008" with respect to the quill. Tighten the screws down.
6. Fasten the readerhead to the readerhead bracket.
7. Move the readerhead up and down the glass scale and make sure the gap is consistent
between the readerhead and the glass scale. Tighten the screw to the quill stop knob.
8. Remove the red head securing plate.
9. If the gap is not consistent between the readerhead and the glass scale when moving
the quill up and down then adjust the angle of the scale to make the gap consistent.
CAUTION!
The gap must be no larger than 0.060” between the readerhead and glass scale.
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Part #
22800-4
20586
Description
Z Glass Scale
Bracket Assembly
Figure 28
K Mill Z-Axis Glass Scale Assembly
Item
1
2
3
4
5
6
7
8
9
P/N
20550
20551
20548
20549
10-32X3/4 25B
10-32X1 1/4 25B
15759
1/16X1/2 81B
1/4-28X3/8 25B
Description
ARM- Z-AXIS MOUNTING PLATE
MOUNTING PLATE-Z-AXIS GLASS SCALE
ADAPTER-Z-AXIS GLASS SCALE
ADAPTER PLATE- Z-AXIS GLASS SCALE
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
WASHER-1/4 HARD BLK OX 1/8 THK
SPRING PIN
SCREW-SHCS-STL-BO
i00891
Qty
1
1
1
1
4
3
1
1
1
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Figure 29
Glass Scale Alignment
Part #
22800-35
22800-13
22800-16
QTY
4
4
4
2
2
2
4
2
1
2
1
1
PART NUMBER
91120A130
91166A230
1/4-20x1.00 25B
1/4 72Z
1/4 71Z
1/4x1.00-79Z
1/4 73Z
1/4-20x2.00 25B
20904
20545
20546-1
20544
DESCRIPTION
WASHER - EXTERNAL SERRATED LOCK
WASHER - FLAT M4 70B
SCREW-SHCS-STL-BO
WASHER-SPHERICAL (1 SET)
WASHER-USS FLAT-STL-BO
WASHER-FENDER 1/4" x1.00 O.D.
WASHER-SPLIT LOCK-STL-BO
SCREW-SHCS-STL-BO
MOUNTING BRACKET
ADJUSTMENT SCREW
SPACER-Y AXIS
MOUNTING PLATE, Y AXIS
i00894
Description
X Glass Scale – K2/K3/K4
Y Glass Scale – K2
Y Glass Scale – K3 & K4
NO.
12
11
10
9
8
7
6
5
4
3
2
1
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5.1.8 Power Drawbar
A power drawbar is an optional item on a TRAK Knee mill machine. It is bolted to the top of
the head by the use of 3 SHCS. Some machines may require a washer to space the unit up
to the proper height to allow the drawbar to engage properly.
Air Regulator and Oiler - This unit requires between 80 and 100 psi to operate properly.
Some units work fine at 80 psi while others may need 90 or 100 psi. It is also important to
make sure the oiler for this unit is kept filled with oil. Fill the reservoir about 2/3 full using
AIR TOOL OIL ONLY. Failure to do this will not allow oil to lubricate the internal
components of the unit and it may wear out prematurely. It is also important to make sure
the oiler is set properly. To set the oiler, first close the adjustment screw (CW) on top of
the oiler completely making sure to not over tighten. Then open the screw (CCW) between
½ to ¾ of a turn. Any more than this will cause too much oil to get into the unit and oil
may come out of the exhaust port of the unit.
Tool Alignment Device - This unit also comes with a tool alignment device, which
attaches to the bottom of the spindle. This device allows the tool to easily be aligned with
the dogs when loading a tool.
Note: Only used on K4 machines
CAUTION!
Some tools may not work with this device and the original spindle dogs will need to be used.
The original spindle dogs are shipped with each machine in the toolbox. Some boring bar
holders may not work with this device.
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Figure 30
Power Drawbar Assembly
For item 4, see section 2.12 for a breakdown of parts.
Item
1
2
3
4
5
6
7
8
9
10
11
12
P/N
22581-1
22605
20893
22380-1 or -2
23888
22581-2
22581-4
13
TR220
22641-NMTB
22641-CAT
Title
AIR GUN ASSY ONLY- TORQUE RITE
DRAWBAR-R8 SPINDLE
SPACER - DRAWBAR - R8 SPINDLE
AIR REGULATOR ASSY (-2 with solenoid)
SPACER - DRAWBAR - 40 TAPER SPINDLE
SWITCH - CONTROL HEAD - TORQUE RITE
NOSEPIECE FOR SPINDLE (40 taper heads only)
1/4" NPT AIR FITTING 90°
3/8 O.D. TUBING 132" LG.
3/8 O.D. TUBING 27" LG.
DRAWBAR - NMTB -40 TAPER
DRAWBAR - CAT - 40 TAPER
SOCKET - AIR GUN REPLACEMENT (not shown
on drawing)
i00875-1
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5.1.9
Ball Screw Replacement, X-Axis (Table)
CAUTION!
Never screw a ball screw partially or totally out of its nut. They cannot be reassembled.
1. Y-axis motor mounting bracket and hardware must be removed to remove X yoke.
2. Position the table in the center of travel.
3. Remove the left side table tray by pulling it up, and remove the X motor (If machine has tray).
4. Remove the motor mounting bracket and bearing housing.
5. Remove the right side bearing housing.
6. Loosen the table gibs. Slide the table to the right and on to a lift that will support the table's
weight. Slide the table until the yoke is exposed.
CAUTION!
The weight of the table must be supported by the lift to prevent damage or
breakage to the dovetails.
7. Remove the 5/16 x 1" screws holding the ball nut to the yoke and loosen the 4 screws
that mount the yoke to the saddle. Remove the oil line.
8. Tilt the yoke (it is pinned) to remove the ball screw.
9. Remove the elbow and setscrew from the old ball screw flange and fit them similarly in
the new ball screw.
10. Pump oil to be certain it flows through the oil line and then attach the oil line to the elbow.
11. Reassemble all assemblies.
Important: The clamp nut must be reassembled as follows:
•
Install rear bearing and seal into bearing housing and slide housing onto the ball
screw. (Note: Letters on bearings must face each other in the housing.).
•
Thread the split nut onto the ball screw and tighten the #10-32 clamp screw until
you feel the split nut contact the ball screw threads. It should drag as you tighten
the clamp nut.
•
Torque the split nut to 50 ft. lb.
•
Firmly tighten the #10-32 clamp screw to lock the clamp nut in place.
See the diagnostics section under Mechanical Drive Train for an explanation of how to align
the ball screw.
See Figure 31 for an illustration of the X-axis drive train.
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Figure 31
X-Axis Drive Assembly
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X-Axis Drive Assembly Parts List
Item
1
2
4
5
6
8
9
10
11
12
13
14
15
16
17
19
20
22
23
41
42
43
44
45
46
47
48
49
51
52
53
54
55
56
62
63
P/N
15621
25729
15624
15622
15616
15612
15885
15638
15626
16983-1
16452
16350
98481A090
14772
22008
400-5M-15
23930
14772-2
14772-5
8-32X3/8 25B
5/16-18X1 25B
3/8-16X2 1/2 25B
M8-1.25X65 25B
M10-1.5X65 25B
1/4-20X1 24B
8-32X3/8 20B
10-32X3/4 25B
1/2-20 51Z
M8 70P
15759
3/8 70P
M10 70P
1/2 73B
1/2 70P
22007
15181
15608-48
Title
DRIVE HOUSING
HANDLE REPLACEMENT KIT
FRONT COVER
BACK COVER
HANDWHEEL ASSY-MX
HOUSING - BEARING
RING-BEARING HOUSING
STOP - X-AXIS (not shown on drawing)
SEAL-BEARING HOUSING
PULLEY-SOLID 44 TEETH W/O GUIDES
NUT CLAMP-X ,Y, & Z AXIS
FERRULE-SPROCKET
KEY WOODRUFF #404-1/8 X 1/2
SPACER - .100" THICK
BEARING- 204KTT
BELT - TIMING 5MM POWERGRIP
BEARING-ANGULAR CONTACT- 7204 BECBP
SPACER - .020" THICK
SPACER - .050" THICK
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
SCREW-HEX HD-STL-BO
SCREW-RH-PHIL-STL-BO
SCREW-SHCS-STL-BO
NUT-HEX JAM-STL-ZINC
WASHER-FLAT USS-STL-PLAIN
WASHER-1/4 HARD BLK OX 1/8 THK
WASHER-FLAT USS-STL-PLAIN
WASHER-FLAT USS-STL-PLAIN
WASHER-SPLIT LOCK-STL-BO
WASHER-FLAT USS-STL-PLAIN
END CAP
BALLSCREW EXTENSION
BALLSCREW - X AXIS
i01118
X-Axis Electronic Handwheel Option Parts List
Item
57
58
59
60
61
P/N
22718
21992
14772
M6-1.0X75 25B
21946
Description
SPACER-45 DEGREES X-AXIS
BUSHING-BALLSCREW (X-AXIS)
SPACER-.100” THICK
SCREW-SHCS-STL-BO
ELECTRONIC HANDWHEEL
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
1
SET
2
2
6
1
4
4
4
7
3
1
2
4
7
4
4
1
1
1
1
1
Qty
1
1
1
4
1
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5.1.10
Ball Screw Replacement, Y-Axis (Saddle)
CAUTION!
Never screw a ball screw partially or totally out of its nut. They cannot be reassembled.
1. Position the saddle all the way forward.
2. Remove the hand wheel assembly and bracket.
3. Remove the sheet metal covers on the front of the machine bed and on the motor
mounting bracket.
4. Remove the motor, then remove the motor mounting bracket.
5. Remove the rest of the parts on the ball screw journal. Note the orientation of the
bearings for reassembly.
6. Remove the 5/16 x 1 inch screws that attach the ball nut to the yoke.
7. Remove the ball screw and oil line attached to the elbow fitting on the ball nut.
8. Remove the elbow and setscrew from the old ball screw flange and fit them similarly in
the new ball screw.
9. Pump oil to be certain it flows through the oil line, and then attach the oil line to the elbow.
10. Reassemble all assemblies.
Important: The clamp nut must be reassembled as follows:
•
Install rear bearing and seal into bearing housing and slide housing onto the
ball screw. (Note: Letters on bearings must face each other in the housing.)
•
Thread the split nut onto the ball screw and tighten the #10-32 clamp screw until
you feel the split nut contact the ball screw threads. It should drag as you tighten
the clamp nut.
•
Torque the split nut to 50 ft. lb.
•
Firmly tighten the #10-32 clamp screw to lock the clamp nut in place.
See the diagnostics section under Mechanical Drive Train for an explanation of how to align
the ball screw.
See Figure 32 for an illustration of the Y-axis drive train.
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Figure 32 - Y-Axis Drive Assembly
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Y-Axis Drive Assembly Parts List
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
30
31
P/N
15626
23930
15885
15980
16452
20623
16983-1
16350
890-5M-15
16533
20621
15627-2
15836
15614
15616
1/2 71Z
1/2 75Z
1/2-20 51Z
10-32X1 25B
M10-1.5X65 25B
23082
1/4-20X1 24B
15759
6-32X3/8 10B
23141
10-32X3/8 10B
10 73B
30922
98481A090
14772-2
20296R
15609-12
15609-16
i00912
Description
Qty
SEAL-BEARING HOUSING
1
BEARING SET-ANGULAR CONTACT- 7204 BECBP
1
RING-BEARING HOUSING
1
BEARING HOUSING
1
NUT CLAMP-X ,Y, & Z AXIS
1
MOTOR BRACKET-KNEE MILLS-40 DEGR
1
PULLEY-SOLID 44 TEETH W/O GUIDES
1
FERRULE-SPROCKET
1
BELT - TIMING 5MM POWERGRIP (Y AXIS)
1
VERNIER DIAL-PT4
1
COVER-SPORT 40 DEGREE
1
DIAL HOLDER
1
DIAL NUT
1
TAB WASHER
1
HANDWHEEL ASSY-MX
1
WASHER-FLAT SAE-STL-ZINC
1
WASHER-EXT TOOTH-STL-ZINC
1
NUT-HEX JAM-STL-ZINC
1
SCREW-SHCS-STL-BO
4
SCREW-SHCS-STL-BO
4
WASHER-.75X.394X.10-STL
4
SCREW-HEX HD-STL-BO
4
WASHER-1/4 HARD BLK OX 1/8 THK
4
SCREW-PH-PHIL-STL-BO
10
SHEET METAL-PT4-COOLANT MOTOR COVER ASSY
1
SCREW-PH-PHIL-STL-BO
3
WASHER-SPLIT LOCK-STL-BO
3
HANDLE FOLD-A-WAY
1
KEY WOODRUFF #404-1/8 X 1/2
1
SPACER - .020" THICK
1
MOTOR ASSY
1
Y BALLSCREW – K2
1
Y BALLSCREW – K3/K4
1
Y-Axis Electronic Handwheel Option Parts List
Item
32
33
34
35
36
37
38
39
P/N
21984
¼-20X5/8 26B
21992-1
14772
21985
M6-1.0X25 25B
21946
M6-1.0X75 25B
Description
BRACKET-WAY COVER FRONT Y-AXIS DRIVE
SCREW-FHCS-STL-BO
BUSHING-BALL SCREW (Y-AXIS)
SPACER-.100” THICK
SPACER-30 DEGREES Y-AXIS
SCREW-SHCS-STL-BO
ELECTRONIC HANDWHEEL
SCREW-SHCS-STL-BO
Qty
1
2
1
1
1
4
1
4
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40
25729
5.1.11
HANDLE REPLACEMENT KIT
1
Air Solenoid Replacement – Auxiliary Function Machines Only
1. Unhook the air from the machine.
2. Unplug the power cable that connects to the right side of the air regulator bracket.
3. Remove the 2 screws that hold the connector to the bracket.
4. Undo the airline that runs from the oiler to the power drawbar if that option is installed
on the machine.
5. Remove the 2 screws on the left side of the bracket that holds the air manifold to the Ushaped bracket.
6. With the assembly in hand, unthread the solenoid from the rear of the air regulator.
The solenoid and cable will be replaced as a unit.
See Section 2.12, Figure 12, for an illustration of this assembly.
5.1.12
Spindle Motor Wiring
The K Mill spindle motors are wired for 220 or 440 volts. See Figure 33 for how to wire the
motor. NOTE: Machine with the Spindle Control Option can only be wired for
220V.
Figure 33
Spindle Motor Wiring
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5.1.13
Feed Trip Adjustment (not applicable to 3 axis controls)
If the feed trip is adjusted too light it will inadvertently trip when drilling. If too heavy, it
will not trip accurately and stress the mechanism. The correct adjustment depends on the
operation to be performed. To adjust:
1. Release the lock nut.
2. Engage the trip handle--move it left.
3. Adjust the micrometer nut against the quill stop knob.
4. Slowly turn the adjusting screw until the handle trips.
5. Tighten the lock nut.
6. Check the reaction. If too sensitive, lower the adjusting screw slightly. If too heavy,
raise it.
Figure 34
I00153
5.1.14
Quill Clock Spring Replacement and Adjustment
The quill Clock Spring counterbalances the weight of the quill and tool.
Figure 35
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1. Move the quill to its top position and lock it in place.
2. Remove the quill handle, hub (by removing Screw A) and key.
3. Remove Screws B and allow the spring housing to unwind.
4. Remove the spring. It is held by a pin on the shaft and slot in the housing.
5. Replace the spring. Rotate the housing clockwise until the spring catches the shaft pin.
6. Rotate (wind up) the housing 1 1/2 turns, replace Screws B, key hub, Screw A, and handle.
5.1.15
Spindle Motor Removal and Replacement
1. While the spindle is running, change the RPM to its lowest value.
2. Disconnect the power to the motor. It is recommended that the power disconnect be
made from the shop feeder box.
3. Disconnect the electrical connection in the conduit box attached to the motor.
4. Crank the speed changer to the highest RPM value.
5. Remove the two screws that fasten the motor to the top of the housing.
CAUTION!
The motor is heavy--about 60 pounds. Be certain you have the proper equipment or assistance.
6. Tilt the motor toward ram and remove the belt from the motor pulley. Remove motor.
7. If the motor is to be replaced, remove the M8 socket head cap screw at the end of the
motor shaft. Slide the pulley assembly off the motor shaft and onto the new motor.
Figure 36
I00155
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5.1.15.1
Spindle M otor Rem oval and R eplacem ent for m achine w ith
the Spindle Control option
1. Disconnect the power to the motor. It is recommended that the power disconnect
be made from the shop feeder box.
2. Disconnect the electrical connection in the conduit box attached to the motor.
3. Remove the three bolts that hold the motor pulley cover in place to gain access to
the belt.
4. Remove the four bolts that mount the motor to the top head housing and slide motor
forward and remove belt.
CAUTION!
The motor is heavy--about 80 pounds. Be certain you have the proper equipment or assistance.
5. Tilt the motor towards the back and remove the belt from the motor pulley. Remove the
motor.
5.1.16
Drive Belt Replacement
1. Remove the motor.
2. Remove the draw bar and its bushing.
3. Remove the three Screws A and use M6 x 35mm screws in the adjacent tapped holes to
remove the Bearing Cap.
4. Remove the nut from the fine speed adjustment Screw B and turn the screw all the way
down through the casting. Catch it from the motor hole.
5. Remove six Screws C holding the belt housing to the subplate.
6. Remove the four screws holding the speed changer.
7. Remove the belt housing.
8. Replace the belt by sliding it over the speed changer.
9. In reassembly be certain the fine speed adjustment Screw B goes into the slot of
the Speed Change Plate D in the area in which the screw is not threaded.
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Figure 37
i00156
5.1.16.1
Drive Belt Replacem ent for m achine w ith the Spindle
Control option
1.
Remove the draw bar and its bushing (remove power drawbar if present).
2.
Remove the three Screws A and use M6 x 35mm screws in the adjacent tapped
holes to remove the Bearing Cap (see Figure 36).
3.
Follow instructions for spindle motor removal and remove motor so top head
housing can be removed with ease.
4.
Remove the six screws “C” that hold the belt housing to the subplate.
5.
Disconnect the spindle control harness at the head control box.
6.
Lift off the belt housing, then remove belt.
5.1.17
Timing Belt Replacement
1. Remove the motor and drive belt.
2. Slide the top or adjustable vari-disc pulley assembly off the shaft.
3. Remove the three M8 screws holding the belt housing base to the gear housing.
4. Lower the quill about 4 inches.
5. Remove the belt housing base and lower or stationary vari-disc pulley assembly.
6. Replace the timing belt.
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5.1.18
Brake Shoe Replacement
1. Remove the motor, drive belt and complete Steps 1-5 of the timing belt replacement
procedure.
2. Remove the two M6 cap screws from the bottom of the belt housing base.
3. Separate the belt housing base from the lower or stationary vari-disc pulley. This is a
slight press fit.
4. Remove the 2 springs.
5. Replace the brake shoes.
5.1.19
Spindle Replacement
1. Remove the draw bar and its bushing.
2. Lower the quill about 1 inch and lock.
3. Remove the setscrew from the back of the spindle.
4. Loosen (unscrew) the large black ring (nosepiece) with a spanner wrench.
Note: The nosepiece has a left hand thread-- rotate counterclockwise to loosen.
5. Using a soft bar about 12 inches long, alternately tap on the top of the spindle and
loosen a few threads on the nosepiece until fully unscrewed (the nosepiece will remain
attached to the spindle).
6. Continue to tap the spindle out of the quill. The spindle bearings will come out with the spindle.
Figure 38
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5.2 Maintenance
5.2.1 Gib Adjustments
The objective of adjusting the gibs is to eliminate as much play in the table, saddle and ram
sliding surfaces as possible without having the tightness of the gib interfere with their free
movement and cause a decrease in the accuracy and/or performance of the machine due to
excessive friction.
5.2.1.1
Table Gib Adjustm ent, X-Axis
See Figure 39.
1. Clean all chips, dirt and excess oil from the table and saddle.
2. Center the saddle on the bed ways.
3. Move the table fully to the left side of the saddle.
Note: For machines that have excessive wear in the center of the table way, it will be
necessary to center the table on the saddle. The resulting adjustment of the gib will be
compromised to account for the varying clearance from the center to the ends of the table.
4. Attach a .0001 dial indicator with a magnetic base to the left front of the saddle.
Place the indicator stylus on the front surface of the table as close to the indicator
base as possible.
Figure 39
Table Gib Adjustment
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5. Move the left end of the table back and forth and note the amount of movement on
the dial indicator. Adjust the X-axis gib until the registered movement is .0010-.0015.
•
To adjust the gib for excessive clearance: Loosen the gib lock screw on the right
end of the saddle. Estimate the amount of gib lock screw adjustment required,
and tighten the gib lock screw on the left end of the saddle. Tighten the gib lock
screw on the right end of the saddle to lock the give in place, and recheck.
Repeat as necessary.
•
To adjust the gib for too small of a clearance: Loosen the gib lock screw on the
left end of the saddle. Estimate the amount of gib lock screw adjustment
required, and tighten the gib lock screw on the right end of the saddle. Tighten
the gib lock screw on the left end of the saddle to lock the gib in place, and
recheck. Repeat as necessary.
Figure 40
Table Gib Screw
5.2.1.2
Saddle Side Gib Adjustm ent, Y-Ax is
See Figure 41.
1. Clean all chips, dirt and excess oil from the table and saddle.
2. Center the saddle on the bed ways.
3. Move the table fully to the left side of the saddle.
4. Remove the chip wiper guard and chip wiper from the front and rear of the left side box
way.
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Figure 41
Saddle Side Gib Adjustment
5. Attach a .0001 dial indicator with a magnetic base to the left front of the saddle. Place
the indicator stylus on the edge of the large box way.
6. Move the left end of the table back and forth and note the amount of movement on the
dial indicator. Adjust the Y-axis side gib until the registered movement is .0010-.0015.
•
To adjust the gib for excessive clearance:
Loosen the gib lock screw on the back of the saddle. Estimate the amount of gib
lock screw adjustment required, and tighten the gib lock screw on the front of the
saddle. Tighten the gib lock screw on the back end of the saddle to lock the gib in
place, and recheck. Repeat as necessary
•
To adjust the gib for too small of a clearance:
Loosen the gib lock screw on the front of the saddle. Estimate the amount of gib
lock screw adjustment required, and tighten the gib lock screw on the back of the
saddle. Tighten the gib lock screw on the front of the saddle to lock the gib in
place, and recheck. Repeat as necessary.
7. Replace the front and rear chip wiper, and chip wiper guard.
5.2.1.3
Saddle Bottom Gib Adjustm ent, Y-Axis (K3 and K4 Only)
See Figure 42.
1. Clean all chips, dirt and excess oil from the table and saddle.
2. Center the saddle on the bed ways.
3. Move the table fully to the left side of the saddle.
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4. Attach a .0001 dial indicator with a magnetic base to the left front of the saddle. Place
the indicator stylus on the top surface of the box way.
5. Lift the end of the table up and note the amount of movement on the dial indicator.
Adjust the Y-axis left bottom gib until the registered movement is .0010-.0015.
6. Move the table fully to the right.
7. Reposition the indicator to the right front of the saddle.
8. Lift the right end of the table up and note the amount of movement on the dial indicator.
Adjust the Y-axis right bottom gib until the registered movement is .0010-.0015.
•
To adjust the gib for excessive clearance:
Loosen the gib lock screw on the back of the saddle. Estimate the amount of gib
lock screw adjustment required, and tighten the gib lock screw on the front of the
saddle. Tighten the gib lock screw on the back end of the saddle to lock the gib in
place, and recheck. Repeat as necessary.
•
To adjust the gib for too small of a clearance:
Loosen the gib lock screw on the front of the saddle. Estimate the amount of gib
lock screw adjustment required and tighten the gib lock screw on the back of the
saddle. Tighten the gib lock screw on the front of the saddle to lock the gib in
place, and recheck. Repeat as necessary.
Figure 42
Saddle Bottom Gib Adjustment (K3 & K4 Only)
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5.2.2 Calibration & Backlash Constants
Calibration and backlash constants were set as part of the installation and set-up of your
system. They should be re-set when indicated in the Troubleshooting section or after the
replacement of the Computer module, or any parts of the drive train.
5.2.2.1
X, Y, Z and Quill Calibration
Calibration is used teach the machine a known distance. We typically calibrate our
machines over a 150 mm distance. There is no limit to how far you can calibrate the
machine.
1. If you have installed TRAK Sensors, move each axis through its travel 4-6 times in order
to allow the gage wheel to establish its track.
2. Set-up a gauge block or standard and indicate it parallel to the axis you are calibrating.
Note: Put the display in Inch or mm to match your gage block. Recommended gage blocks are:
•
X and Y -- 150mm or 6”
•
Z -- 75 mm or 3”
3. Set a 0.0001” indicator in the spindle and move it up to one side of the gage block or
standard.
4. Go to setup mode, go to section “B” and press CODE 123.
5. Select the axis you want to calibrate X, Y or Z. For the quill press the F1 key labeled
QUILL. The Z key is used to calibrate 3 axis machines only.
6. Follow the instructions on the screen to complete calibration.
Figure 43
Calibration Set-Up
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5.2.2.2
Backlash Com pensation
Code 11: Set X or Y backlash constant
Note: this procedure is on systems with TRAK Sensors or Glass Scales only.
Go to setup mode, go to section “B” and press CODE 11. Refer to service code section for
further explanation.
Code 127: Set X or Y Backlash Constant
Note: this procedure is only for systems without TRAK Sensors or Glass Scales.
Every mechanical system has at least a little backlash or lost motion. It is produced by the
small amount of play between the gibs and ways, and mostly by the accumulative bending
or elasticity of all the parts of the drive train under load. The backlash constant is factory
set, but may need to be adjusted periodically.
a.
b.
c.
d.
e.
f.
1.
Set a .0001-inch dial indicator in the spindle, and touch off on a block or the vise along
the direction (X or Y) you wish to check, or set the backlash constant.
2.
Turn on the ProtoTRAK and at the Main Menu, follow the procedure below precisely:
Conversation Says
--Select Mode
Select
Select
Select Code 127
Backlash Value = _ _ _ _
g. The following is an example of what you
might see when running this code.
You Do
Press MODE
Press SET UP
Press SERV CODES
Press “B”
Press X or Y
What is shown is the current value.
Follow the instruction on the screen
and press the appropriate soft keys.
Wait a few seconds between each
INCR VALUE or DECR VALUE
press.
For example, if the up and down "Oscillation
Value" shown in the conversation line is .00278
inch, and the dial indicator is moving back and
forth .0012, then the true backlash value is
.00278 -.0012 = .00158 inch. Input this by
pressing MODE, SET UP, SERV CODE, 128, SET
and then .00158, SET, RETURN.
a.
b.
c.
d.
e.
f.
3. The X backlash identified and stored in Step 2 should be less than 0.003” on a new
machine. If it is appreciably larger, inspect the drive train for loose bolts, brackets,
bearings, etc.
The backlash can also be found manually with a 0.0001” indicator with the following
method.
•
Load the indicator to zero from one direction and zero out the DRO.
•
Move the indicator to 0.002” and then back to zero. Do not over shoot 0,
otherwise start over.
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•
Whatever number appears on the screen is the backlash value.
•
Enter this value into service code 128.
•
After entering this number redo the process. The DRO and indicator should
now both read 0.
CODE 128: Input Backlash Constant
Code 128 allows you to enter the backlash values for each axis. It displays the value after it
enters. This code is only used on machines with single feedback.
5.2.3 Head Rotational and Tramming
The TRAK knee head is free to rotate up to 90 degrees to the right or left. The K2 and K3
can also rotate 45° front to back. The K4 machine cannot rotate front to back.
5.2.3.1
To R otate the Head Side to Side:
1. Loosen the four locknuts.
2. Rotate the head with the adjusting worm shaft. When rotating to greater than a
45o angle, support head by hand.
3. Tighten the locknuts. Snug each locknut, then lightly tighten each locknut, then fully
tighten each locknut in a crisscross pattern.
4. Use the method shown in the figure below and a parallel bar to square the head to the
table.
5.2.3.2
Tram m ing the Head
The purpose of tramming the head is make sure the head is perpendicular to the top of the
table from both side to side and back to front.
Side to side tolerance – 0.001”
Side-to-Side Alignm ent
1. Make sure the machine is level.
2. Make sure the table has been clean and the Z gibs are adjusted properly.
Mount a dial indicator in a tool holder and mount in the quill.
3. Adjust the Y-axis so that the spindle is in the center of the table.
4. Adjust the Knee so that the dial indicator will reach the table.
5. Move the dial indicator to 6 o’clock position and adjust the face so the needle is zero.
6. Do a series of sweeps from 9 o’clock to 3 o’clock and check for the repeatability of the
setup. The head should be trammed within ± 0.002”
7. If the head is out of tram from side to side then loosen the 4 head bolts and rotate the
head with the worm shaft.
8. Once the head has been trammed, tighten the 4 heads bolts. Be careful not to move
the head while tightening. Tighten the bolts in a criss-cross pattern. Torque = 30-35
lb.ft.
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Figure 44
Tramming of Head
Back to Front Adjustm ent
Note: The head of the K4 milling machine is adjusted at the factory.
With the dial indicator sweep the table from 6 o’clock to 12 o’clock. The head should be
trammed within ± 0.0006” over 9 or 10” tram diameter. 9 or 10” is based on the table
width.
5.2.3.3 Back to Front Adjustment – K2/K3 only
1. Make sure the table has been clean and the gibs are adjusted properly.
2. Mount a dial indicator in a tool holder and mount in the quill.
3. Adjust the Y-axis so that the spindle is in the center of the table.
4. Adjust the knee so that the dial indicator will reach the table and lock the 2 clamps on
the knee.
5. Move the dial indicator to 6 o’clock position and adjust the face so the needle is zero.
6. Do a series of sweeps from 6 o’clock to 12 o’clock and check for the repeatability of the
setup. The head should be trammed as close as possibility to ± 0.0005”
7. Loosen the three bolts and adjust the tram with the bolt mounted on the top of the
ram.
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Once the head has been trammed tighten the three bolts. Be careful not to move the head
while tightening. Tighten the bolts a little at a time. (Note: the head must droop down
rather than up because tool pressure will take care of the extra 0.0005”.)
5.2.4 Limit Switch Option
See figures 64 and 65 in section 7.
The limit switch option design was changed from when we first released the SX control.
Early limit switch kits came with a single input limit switch as shown in the figure.
Figure 45 – 1 Input Limit Switch
#
1
Part Number
16117
Description
Limit Switch Assembly with cable
The latest design consists of a limit switch with 2 inputs as shown in the figure. This means
1 input for each direction. On machines with electronic handwheels, when you hit a limit
the EHW will only allow you to move the machine in the direction away from the limit
switch. This will prevent the user from damaging the machine by hitting a hard stop.
Figure 45-1– 2 Input Limit Switch
Part number – 22408
#
1
2
3
Part Number
22408
22551-1
22551-2
Description
Limit Switch (no cable)
Limit Switch Assembly with cable – right
Limit Switch Assembly with cable – left
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5.2.4.1
X-Ax is Lim it Sw itch-Stop Installation and Adjustm ent
The limit switch-stops/cams for the X-axis are mounted to the front side of the table and
can be adjusted along the length of the T slot. Each limit switch-stop must be set to a
specific distance from the end of the table in order to maximize travel and simultaneously
prevent serious damage to the machine in the event of a crash. All limit switches are set at
the factory for maximum travel.
Procedure for Setting X Lim it Sw itch
1. Loosen the stops or cams on each side of the table.
2. Slide each stop or cam within the T-slot to the end of the table.
3. Slowly move the table to one side by hand until the end of the travel is reached.
4. In DRO mode set X = 0 ABS.
CAUTION!
The limit switch must be triggered a minimum of ½” before the machine reaches its travel
limits in both directions. This allows sufficient room for the servomotors to stop when the
limit switch is hit at 150 ipm.
5. Using the DRO display, back the table off 1/2".
6. Lock the limit switch bracket in place.
7. Jog the table at 100ipm to each side and verify that the limit switch is working properly.
Also, make sure that the table does not exceed its travel and crash.
5.2.4.2
Y Ax is Lim it Sw itch-Stops
The limit switch-stops for the Y-axis are mounted on the side of the knee. The limit switch is
triggered by hitting the cam stop on the saddle. The cam is placed to ensure maximum
travel. The 2 input limit switch design allows for slight adjustment of each cam.
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6.0
Retrofit Installation
This section of the manual is intended to provide step-by-step instructions for installing a
ProtoTRAK SMX 2 or 3-axis control on a vertical knee milling machine. Within Sections 6,
7 and 8 it may refer to other sections of the manual for certain procedures or figures.
6.1 Installation Tools and Hardware
The following section lists the required tools and hardware for installing a ProtoTRAK SM
control. It also lists the pre-installation requirements needed to complete the retrofit at
the customers shop.
6.2 Required Tools/Hardware
The following tools are necessary for a typical installation:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Allen wrenches, set, inch and metric
Drill motor
Drills, set
Taps, set, and tap handle
Machinist square
Bubble level
Crescent wrench, 10”
Torque wrench, up to 60 ft/lbs.
Crowfoot wrench, 1 1/4” open end to fit torque wrench
Socket set with 3” and 6” extension and ratchet wrench
Dial calipers
Flat blade screwdriver set
Phillips screwdriver set
Standard or gauge blocks, 6”/150mm
Gauge block, 75mm or 3”
.0001” dial indicator and magnetic base
Center punch
Hammer, small
Combination wrenches, set, 3/8” to 15/16”
Counterbores or step drills set
Combination wrench, 10mm
Transfer punch set
Transfer screw set
Feeler gage (Z glass scales)
Pliers set
File set
Xacto knife with flat blade
3/4” 2 flute end mill
Safety glasses
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6.3 Suggested Fastener Stock
It is suggested that the ProtoTRAK installer have on hand the following fasteners in the event
that they are inadvertently left out of the kit or lost during installation:
Qty
8
6
7
4
4
4
2
10
1
6
6
3
2
4
2
12
3
2
1
1
1
2
1
3
Fastener
5/16-18”x1 1/2” shcs, ballnut to yoke (BP)
10-32x3/8 shss, ballnut oil plug
1/4-20x1” hhcs, bearing housing to drive housing bracket
3/8-16x2 1/2 shcs, drive bracket to table
oil line elbow, 15187
brass fitting, 15696
T-fitting, P2 TUB-2
Washers, 15759
3/8-24 screw, 16355-1
Spacer, 14772
8-32x3/8: shcs, mounting bracket plate
8-32x7/8 round head Phillips
1/2-20 nut
Washer, flat 3/8, 98017A200
Lockwasher, 91114A033
6-32x3/8 flat head Phillips
5/16-18x2 shss
5/16-18x1 shcs
M10-1 screw, 16364-1
M10-1.5 screw, 16364-2
M10-1.5 screw, 16355-2
10-32x1
5/8-11 nut
M6 x 20 shcs – used to mount cable breakout box
SWI offers a complete set of spare fasteners and spare parts for ProtoTRAK installers at a special
price. Contact the SWI Customer Service Group for details.
6.4 Pre-Installation Requirements
•
Power requirements: 115V, 60Hz, 1100VA, 12-amp power line dedicated to the
ProtoTRAK.
•
Adequate working area around the machine to slide the table completely off the
saddle.
•
Availability of a lift table or cart capable of supporting the table once it is removed
from the machine.
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7.0 Installation Procedures
7.1 X and Y Ball Screw Installation
7.1.1 Removing the Table and Leadscrews
Note: Before removing any of the assemblies as directed below, crank the table all the way to the right
or left in order to be able to position the lift table next to the machine.
1. Remove the left and right bearing assemblies. Save the parts removed from the right
side for use in installing the X-Axis ball screw.
Note: If the machine has a power feed on the right end, save the left end assembly to mount later to the
right end.
Figure 46
X Leadscrew Assembly
2. Center the table and remove the X gib.
3. Slide the machine’s table onto a lift table and move it away from the machine.
CAUTION!
When removing the table, make sure it does not cock or it may
break the dovetails as it slides out.
4 . Crank the saddle all the way forward and remove the Y-axis bearing assembly.
Save the vernier dial for use with the Y-axis ball screw.
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Figure 47
Y Leadscrew Assembly
5. Remove the X and Y leadscrews.
Note: to remove a leadscrew, remove the nut retaining screw and slide the brass acme nut and the
leadscrew out of the yoke together.
Figure 48
Leadscrew/Yoke Assembly
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6. Remove the yoke from the saddle. Disconnect the oil lines from the yoke. If the yoke is
to be re-used, it will be necessary to remove the brass nut key and pins. If the kit came with
a yoke, the original yoke may be discarded.
7. Clean the X and Y-axis gibs, oil grooves and slideways thoroughly. Also remove the
sliding covers and clean them. Inspect the operation of the oiling system.
Note: Step 7 is worth extra care, especially with machines that have some wear, or new machines that
may have some protective covering on the ways. System performance depends on smooth motion.
7.1.2 X-Axis Ball Screw Installation - Part 1
The ball screws are to be installed in the following order:
• First - part of the X-axis ball screw assembly.
• Second - the entire Y-axis ball screw assembly.
• Third - the rest of the X-axis ball screw assembly.
Parts required:
• Yoke kit 15844-xx
• X-Axis drive kit 20255 -xx
• X-Axis ball screw
Fi
gure 49
X-Axis Ball Screw
Note: There are wrench flats on the X and Y ballscrews for convenience.
CAUTION!
Unlike a leadscrew, never unscrew a ball screw from its nut.
This will destroy the ball screw.
8. Position the yoke in the saddle with the threaded hole on the left. Do not secure the
yoke to the saddle yet, you will need to lift the yoke to slide in the ball screw.
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Figure 50
Ball Screw/Yoke Assembly
9. In the ballnut flange there are two tapped 10-32 holes. One for the provided elbow oil
fitting, and one for a 10-32 setscrew. For the X ball screw put the elbow oil fitting in the
hole on the radius of the flange, and the setscrew in the hole on the flat. The function of
the setscrew is only to prevent oil from flowing out of the ballnut. Screw it as far as
possible being careful not to contact and deform the nylon wiper.
10. Attach the provided plastic oil line to the elbow oil fitting.
11. Slide the ball screw into the yoke with the flange of the ballnut to the left. Do not install
the 5/16-18 x 1 3/4” screw yet.
12. Secure the yoke to the saddle with the 4 screws, make it snug but not tight. You will
need to move the yoke a little to align the ball screw.
13. Secure the ballnut to the yoke with 5/16-18 x 1 3/4” screws.
14. (Optional) If the yoke was pinned previously, replace the pins and then tighten the yoke
to the saddle.
15. If the yoke was not pinned, it will be necessary to align the ball screw:
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Take measurement “A” on the left and right
sides of the saddle casting. So that the
measurements are comparable, measure from
the OD of the thread of the ballscrew on both
sides.
Note: If the back of the saddle casting is not a
suitable reference, it may be necessary to position
a piece of round stock inside the back dovetail to
be used as a reference point.
Adjust the position of the yoke until the two measurements are within 0.005” end to end
(maximum).
CAUTION!
The alignment of the ballscrew is crucial.
Misalignment can cause damage to the ballscrews and drive assemblies
as well as poor system performance.
16. Tighten the yoke to the saddle casting. Check the alignment again to be sure
the yoke did not move as it was tightened. Pin the yoke in position using the
provided roll pin.
7.1.3
Y-Axis Ball Screw Installation
Parts required
• Yoke kit (already opened)
• Y-Axis drive assembly 23083-xx
• Y-Axis ball screw
Figure 51
CAUTION!
Unlike a leadscrew never unscrew a ball screw from its nut.
This will destroy the ball screw.
17. In the Y-axis ball screw, put the 10-32 set screw in the hole on flat part of the
ballnut flange and the elbow oil fitting in the hole on the radius.
18. Attach the provided plastic oil line to the elbow oil fitting.
19. Pull the saddle all the way forward and install the ball screw into the yoke with 5/1618 x 1 3/4” screws. The flat of the
ballnut flange should match up with the flat on
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the yoke. These flats are there so that the yoke and ballnut will clear the bevel gear.
Check that these clear now by pushing the saddle back.
If the yoke provided in the kit does not clear the bevel gear, it will be necessary to
remove enough material from it so that it will clear.
Also check that the elbow fitting will clear the casting at the top front of the knee. If
it interferes, it will be necessary to screw it down more, or grind away the casting to
clear.
20. Route the oil line up through the hole in the saddle to the right rear of the yoke, trim it
appropriately and attach it to one of the oil lines of the machine.
(Kit Variation: some machines do not have separate oil lines running to each leadscrew. Use the
supplied T fitting to route oil to each ball screw.)
CAUTION!
Make sure that the oil line will not be sheared by the sliding
covers when the saddle moves.
(Kit Variation: on machines with oil restrictors on the yoke, use the supplied brass fitting and the
original restrictor.)
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Figure 52 - Y-Axis Drive Assembly
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Y-Axis Drive Assembly Parts List
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
30
31
P/N
15626
23930
15885
15980
16452
20623
16983-1
16350
890-5M-15
16533
20621
15627-2
15836
15614
15616
1/2 71Z
1/2 75Z
1/2-20 51Z
10-32X1 25B
M10-1.5X65 25B
23082
1/4-20X1 24B
15759
6-32X3/8 10B
23141
10-32X3/8 10B
10 73B
30922
98481A090
14772-2
20296R
15609-12
15609-16
i00912
Description
SEAL-BEARING HOUSING
BEARING SET-ANGULAR CONTACT- 7204 BECBP
RING-BEARING HOUSING
BEARING HOUSING
NUT CLAMP-X ,Y, & Z AXIS
MOTOR BRACKET-KNEE MILLS-40 DEGR
PULLEY-SOLID 44 TEETH W/O GUIDES
FERRULE-SPROCKET
BELT - TIMING 5MM POWERGRIP (Y AXIS)
VERNIER DIAL-PT4
COVER-SPORT 40 DEGREE
DIAL HOLDER
DIAL NUT
TAB WASHER
HANDWHEEL ASSY-MX
WASHER-FLAT SAE-STL-ZINC
WASHER-EXT TOOTH-STL-ZINC
NUT-HEX JAM-STL-ZINC
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
WASHER-.75X.394X.10-STL
SCREW-HEX HD-STL-BO
WASHER-1/4 HARD BLK OX 1/8 THK
SCREW-PH-PHIL-STL-BO
SHEET METAL-PT4-COOLANT MOTOR COVER
ASSY
SCREW-PH-PHIL-STL-BO
WASHER-SPLIT LOCK-STL-BO
HANDLE FOLD-A-WAY
KEY WOODRUFF #404-1/8 X 1/2
SPACER - .020" THICK
MOTOR ASSY
Y BALLSCREW – K2
Y BALLSCREW – K3/K4
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
4
4
10
1
3
3
1
1
1
1
1
1
Y-Axis Electronic Handwheel Option Parts List
Item
32
33
34
35
36
37
38
39
40
P/N
21984
¼-20X5/8 26B
21992-1
14772
21985
M6-1.0X25 25B
21946
M6-1.0X75 25B
25729
Description
BRACKET-WAY COVER FRONT Y-AXIS DRIVE
SCREW-FHCS-STL-BO
BUSHING-BALL SCREW (Y-AXIS)
SPACER-.100” THICK
SPACER-30 DEGREES Y-AXIS
SCREW-SHCS-STL-BO
ELECTRONIC HANDWHEEL
SCREW-SHCS-STL-BO
HANDLE REPLACEMENT KIT
Qty
1
2
1
1
1
4
1
4
1
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21. Place the bearing housing on a flat surface and install the following as shown below:
Figure 53
Bearing Housing
22. With the saddle all the way forward, install the assembly from the previous step
on the ball screw with the bearing seal towards the machine.
(Kit Variation: the Y-Axis bearing housing is designed to float to find its own center. For some
machines, the hole in the knee is too large for the flange of the bearing housing to contact. Use the
supplied backing plate shown below.)
Figure 54
Backing Plate
23. Install the bearing housing A on the ballscrews as shown in Figure 53. The angular
contact bearing should have the inner race, thin side in.
24. Install the clamp nut and torque to 50 ft/lb. Tighten the 10-32 x 3/4” screw on the
clamp nut.
Note: To keep the clamp nut from expanding while using the torque wrench, put in and snug the 10-32
x 3/4 setscrew. Tighten the cap screw after proper torque is obtained.
25. Turn the clamp nut until the flange of the bearing housing contacts the knee (or
backing plate, if one is used) and the saddle begins to move forward.
26. Install the Y motor mounting bracket. This bracket can vary from machine to
machine.
27. Install the remaining items on Figure 52.
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28. Hang the timing belt over the pulley now.
29. Install the top cover of the motor mounting bracket and check for clearance between
the vernier dial and the cover. If the dial rubs, add shims to the vernier dial holder.
Note: Sometimes it will be necessary to use the shims from the original X-axis hardware.
30. Tighten the 1/2 - 20 hex nut to 50 ft/lb. Move the saddle back and forth through full
travel to inspect for smoothness.
7.1.4 X-Axis Ball Screw Installation - Part 2
CAUTION!
Unlike a leadscrew never unscrew a ball screw from its nut.
This will destroy the ball screw.
31. Attach the X-Axis ball screw oil line. Liberally lubricate all way surfaces.
32. Screw the X-Axis ball screw out of the way and remount the table. Oil and reinstall
the X gib.
CAUTION!
Make sure the gib locks have not fallen into the saddle
before you slide the table back on.
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Figure 55
X-Axis Drive Assembly
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X-Axis Drive Assembly Parts List
Item
1
2
4
5
6
8
9
10
11
12
13
14
15
16
17
19
20
22
23
41
42
43
44
45
46
47
48
49
51
52
53
54
55
56
62
63
P/N
15621
25729
15624
15622
15616
15612
15885
15638
15626
16983-1
16452
16350
98481A090
14772
22008
400-5M-15
23930
14772-2
14772-5
8-32X3/8 25B
5/16-18X1 25B
3/8-16X2 1/2 25B
M8-1.25X65 25B
M10-1.5X65 25B
1/4-20X1 24B
8-32X3/8 20B
10-32X3/4 25B
1/2-20 51Z
M8 70P
15759
3/8 70P
M10 70P
1/2 73B
1/2 70P
22007
15181
15608-48
Title
DRIVE HOUSING
HANDLE REPLACEMENT KIT
FRONT COVER
BACK COVER
HANDWHEEL ASSY-MX
HOUSING - BEARING
RING-BEARING HOUSING
STOP - X-AXIS (not shown on drawing)
SEAL-BEARING HOUSING
PULLEY-SOLID 44 TEETH W/O GUIDES
NUT CLAMP-X ,Y, & Z AXIS
FERRULE-SPROCKET
KEY WOODRUFF #404-1/8 X 1/2
SPACER - .100" THICK
BEARING- 204KTT
BELT - TIMING 5MM POWERGRIP
BEARING-ANGULAR CONTACT- 7204 BECBP
SPACER - .020" THICK
SPACER - .050" THICK
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
SCREW-HEX HD-STL-BO
SCREW-RH-PHIL-STL-BO
SCREW-SHCS-STL-BO
NUT-HEX JAM-STL-ZINC
WASHER-FLAT USS-STL-PLAIN
WASHER-1/4 HARD BLK OX 1/8 THK
WASHER-FLAT USS-STL-PLAIN
WASHER-FLAT USS-STL-PLAIN
WASHER-SPLIT LOCK-STL-BO
WASHER-FLAT USS-STL-PLAIN
END CAP
BALLSCREW EXTENSION
BALLSCREW - X AXIS
i01118
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
1
SET
2
2
6
1
4
4
4
7
3
1
2
4
7
4
4
1
1
1
1
1
X-Axis Electronic Handwheel Option Parts List
Item
57
58
59
60
61
P/N
22718
21992
14772
M6-1.0X75
25B
21946
Description
SPACER-45 DEGREES X-AXIS
BUSHING-BALLSCREW (X-AXIS)
SPACER-.100” THICK
SCREW-SHCS-STL-BO
ELECTRONIC HANDWHEEL
Qty
1
1
1
4
1
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33. Install the left end assembly items as shown in Figure 55.
34. Slide the table so that the left end of the table is approximately over the left end of the
ball screw and install the drive housing onto the table with the four 3/8 -16 x 2 1/2”
socket head cap screws.
35. Slide the table to the right and secure the drive housing bracket to the bearing housing
per Figure 55.
36. Install the rest of the items of Figure 55 and tighten 1/2-20 nut to 50 ft/lb.
37. Screw the ball screw so that the table is positioned with the right side of table almost
flush with the right edge of the saddle.
Note: Temporarily install the 1/2 - 20 nut on the right of the ball screw and use this to turn the
ball screw.
38. Install the original machine right side assembly and the SWI provided handwheel as per
Figure 55.Tighten 1/2-20 nut to 50 ft/lb. (If the machine had a power feed, use the
hardware from the left side).
Note: if the ball screw requires a ball screw extension see Step 39 - “Installing ball screw
extensions”. Otherwise go to Step 40.
39. Ball screw Extension Installation
1. Slide bushing onto end of ball screw.
2. Screw threaded extension snugly onto ball screw.
3. Tighten setscrew (inside of threaded extension) finger-tight.
4. Back off the threaded extension 1/16 of a turn.
5. Tighten setscrew.
6. Using two wrenches, tighten the threaded extension to the ball screw.
Note: The 6” extension uses a pin inside the threaded extension in addition to the setscrew.
40. Make a preliminary gib adjustment for each of the table and saddle gibs. Tighten the
gibs until there is a noticeable drag on the table and saddle and then gradually loosen
until the drag goes away and the motion is smooth again. There is additional information
on gib adjustments in Section 5.
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7.2
Motor/Servo Driver Installation
7.2.1
X-Axis Motor/Servo Driver Installation
Parts required:
• motor assembly 20296
• X drive assembly (opened in previous step)
Figure 56
X Motor Mounting
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1. Hang the belt on the pulley.
2. Install the front cover with the six 8-32 socket head screws.
3. Install the motor/servo driver assembly with the servo driver toward the rear of the
machine. Install the motor so that there is very little play in the belt, a ¼ turn when
twisting in the middle of the belt.
4. Install the back cover plate.
7.2.2
Y-Axis Motor and Servo Driver Installation
Parts required:
• Motor servo/driver 20296
• Y drive kit (opened in a previous step)
Note: Mount the assembly so that the servo driver is oriented toward the right, and the cable will be
routed to the left of the machine.
1. Mount the motor on the motor mounting bracket. Tighten so that there is very little play
in the belt, a ¼ turn when twisting in the middle of the belt.
Note: The belt should have been installed previously. Take extra care that the belt is seated on the
pulley and is tight.
2. Install the bottom cover plate for the motor mounting bracket with the 10 Phillips
head screws provided.
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7.3
Pendant Installation
7.3.1 Pendant Arm Installation
Figure 57
Pendant Arm Assembly
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Pendant Arm Assembly Parts List
Item
2
3
4
5
6
7
9
10
11
16
17
18
19
22
27
28
29
30
31
P/N
15896
16797
16738
20695
16919
16920
1/4-20X3/4 40B
10-32X1 1/4 25B
1/2-13X6 24P
9712K93
3/16X3/4 80P
5/8 71P
1/4-20X3/4 25B
5/8-18 57Z
1/4-20X5/8 25B
23139
10-32X3/8 31B
21934
#4 x 3/8 34J
Description
PENDANT CUP
RAM SUPPORT MACHINED
PENDANT ARM MACHINED-M2/B5/SK2
PLUG-SPORT E-STOP
PLATE-LEVELING
CLAMP - CABLE
SCREW-SOC SET-STL-BO-CUP
SCREW-SHCS-STL-BO
SCREW-HEX HD-STL-PLAIN
WASHER - BELLEVILLE
PIN-DOWEL-STL-PLAIN
WASHER-FLAT SAE-STL-PLAIN
SCREW-SHCS-STL-BO
NUT-NYLON LOCK-JAM-STL-ZINC
SCREW-SHCS-STL-BO
SHEETMETAL-COVER-PENDANT ARM
SCREW-PH-PHIL-EXT SEMS-STL-BO
NAMEPLATE-EDGE S/N
SCREW-DRIVE
i00893
Qty
1
1
1
1
1
1
4
1
1
2
4
2
3
1
1
1
2
1
2
1. Prepare the assembly as shown in Figure 57.
2. Insert the two bellville washers (Item 16) opposing each other. They should create a
hollow portion between the washers.
3. Tighten the nut to set tension on the arm. The arm should rotate freely with some
resistance.
4. Assemble the ram support (Item 3) on the machine using the machine’s lifting hook
threaded hole. There are four different bolts provided to match the threaded hole. Use
the cup point set screws to adjust the level of the plate.
5. Install the cap.
6. Install the cable clamp and cable cover.
7.3.2
Installation of the Pendant Display
1. Fasten the pendant onto the pendant arm using (4) ¼-20 x1” SHCS.
2. Install the cable cover to the pendant arm as shown in Figure 53 above.
3. Next route 3 cables down to the cable breakout box. One power cord and (2) 37 pin
umbilical cables. Fasten cables to the pendant arm with the cable clamps provided. See
Figure 12 for a description of cable routing.
4. Install the machine ID key to the LPT port on the pendant. The key can be found in the
hardware kit.
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7.4
Cable Breakout Box Mounting
The cable breakout box can come in 2 different configurations, one with auxiliary functions
and one without. The physical size of the box is the same for both versions. The only
difference is the 2 auxiliary ports found on the right side of the box. The auxiliary function
box will have a 110 V outlet and a 4-pin amp connector to run an indexer. Mount the cable
breakout box on the rear of the machine as shown in Figure 4 in Section 2. It will mount
with the use of (3) M6 x 20 SHCS. You may need to add washers to the back of the box to
offset it from the machine it case of casting interference.
7.5
Z-Axis Glass Scale Installation
See Figure 58.
1. Check the tram of the head in the X direction. If it is within a few thousands then
continue on. If not tram.
2. Mount the upper mounting bracket loosely to the upper mounting surface of the head
with a 10-32 cap screw.
3. Mount the lower mounting bracket loosely to the lower mounting surface of the head
with a 10-32 cap screw.
Caution!
Do not drill through the threaded quill stop rod.
4. Install the 2 each, 6-32 leveling screws to each mounting bracket.
5. Mount the scale loosely to the mounting brackets with a 1/4-20x 1/2” bhcs and M6
washer.
6. Indicate the front of the scale and the right side of the scale to within .005” over the
travel of the quill. Tighten the bracket mounting screws and use the leveling screws to
adjust the alignment.
7. Mount the readerhead bracket to the quill stop knob with the pin and 1/4-20x 1” shcs.
8. Remove the readerhead cover plate and position the readerhead bracket so its holes line
up with the holes in the readerhead. Use shims as necessary between the pin and
bracket if the holes do not line up side-to-side with the readerhead holes. There should
be a gap of 0.030”-0.180” between the readerhead and bracket.
Kit Variation: some scale brackets require the transfer of the hole pattern of the readerhead to
the readerhead bracket.
9. The rest of the scale installation is the same as the X-axis, Steps 5 through 7.
Key Notes:
1. Move the readerhead up and down the glass scale and make sure the gap is consistent
between the readerhead and the glass scale. Tighten the screw to the quill stop knob.
2. Remove the red head securing plate.
3. If the gap is not consistent between the readerhead and the glass scale when moving the
quill up and down then adjust the angle of the scale to make the gap consistent.
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WARNING
The gap must be no larger than 0.060” between the readerhead and glass scale.
Part #
22800-4
20586
Description
Z Glass Scale
Bracket Assembly
Figure 58
Z-Axis Glass Scale Assembly
Item
1
2
3
4
5
6
7
8
9
P/N
20550
20551
20548
20549
10-32X3/4 25B
10-32X1 1/4 25B
15759
1/16X1/2 81B
1/4-28X3/8 25B
Description
ARM- Z-AXIS MOUNTING PLATE
MOUNTING PLATE-Z-AXIS GLASS SCALE
ADAPTER-Z-AXIS GLASS SCALE
ADAPTER PLATE- Z-AXIS GLASS SCALE
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
WASHER-1/4 HARD BLK OX 1/8 THK
SPRING PIN
SCREW-SHCS-STL-BO
Qty
1
1
1
1
4
3
1
1
1
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7.6
TRAK Sensor Installation - Optional
See Section 5 of this manual for more sensor information.
Parts required:
• Sensor M250C
• X Y bracket kit, one of the following:
15926
16191
15927
15929
16105
7.6.1 X and Y Axis Sensor
1. Install the brackets and run bar to the machine. The bracket should position the TRAK
Sensor so that it is:
•
•
•
•
As low as possible on the back of the table
Does not run the gage wheel over the drain hole or any other existing holes in the
table.
Does not run the gage wheel off the end of the table.
Clears the machine column when the saddle is cranked all the way back and the knee
is lowered.
Figure 59
X Bracket Installation
Caution!
For the X-axis, make sure the drain tube is removed from the path of the TRAK Sensor. A
crash of the sensor will break the Sensor or mounting base. Install the drain plug provided
to discourage the re-attachment of the drain tube.
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Figure 60
Y Bracket Installation
The Run Bar should be:
•
•
•
•
Installed with 2 screws - minimum size 1/4 - 20
Spaced from the knee appropriately to reach the sensor
Free of twist
Parallel to the saddle travel within 0.010”
Note: Before installing the bracket, it is a good idea to assemble the bracket, mounting base and TRAK Sensor
and hold the assembly against the planned mounting area.
Kit Variation: Figures 60 and 61 show the bracket that comes with the ProtoTRAK SMX 2-1 and other kits.
Examples of other brackets and mountings are:
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Figure 61
Other X & Y Brackets Supplied with Kits
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1. Install the M5 Base on the bracket. See Section 5.1.6.1, Figure 25.
Parts required: M250C sensor and included hardware
a) Put in pusher screws. These are the screws with the rounded ends.
b) Position base and install puller screws and spherical washer sets. Use the pusher
screws to square the M5 base to the running surface.
c) Adjust the puller screws so that the raised bumps on the front of the base are
parallel to the table.
Note: The drawing shows a bubble level used for this adjustment. Alternatively, you may use a
dial indicator set-up on the table.
2. Install the sensor on the M5 Base using the clamp screw. See Section 5.1.6.2,
Figure 26.
3. Load the sensor against the running surface (table or run bar) using the load screw.
The white lines on the side of the M5 base tell you when it is loaded correctly.
Note: You want to load the gage wheel against the running surface using the flexure of the M5
Base. Do not tighten the clamp screw fully until after loading the sensor.
7.7 X and Y Glass Scale Installation - Optional
The Acu-Rite Glass Scales are shipped with complete installation instructions including
illustrations. This section gives summary instructions for the installation of the glass scales
on knee mills. If more instructions are needed, please see the booklet provided with the
scales.
See Figure 29 in Section 5.
7.7.1 X Axis Scale Installation
Note: New Bridgeport machines have Acu-Rite scale mounting holes pre-drilled.
Caution!
If the scale is not long enough for the table, it will break when the machine is
traversed past the scale travel.
1. With the table centered, position the scale and readerhead to make sure that the scale is the
correct length. The readerhead mounting bracket is attached to the saddle and the scale is
attached to the table.
2. Mount the readerhead mounting bracket to the saddle. Snug the screws, but do not tighten
at this time, you will be making fine adjustments to the bracket’s position after the scale is
installed.
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3. Mount the scale to the table:
•
•
•
•
Transfer the center hole first to use as a pivot point.
Align the scale so that it is within 0.005” end to end.
Transfer the holes on the ends and install the screws.
Re-check the alignment.
4. From the readerhead on the scale, remove the nameplate, shield and wires so that the
mounting holes are accessible.
5. Attach the readerhead to the readerhead mounting bracket:
•
•
There are jackscrews on the readerhead to compensate for some gap between the
readerhead and the readerhead mounting bracket.
Before tightening the readerhead to the bracket, there must be a .002 - .003” gap
between the readerhead mounting bracket and the jackscrews. Tightening the mounting
screws will eliminate this gap.
6. Replace the wires, shield and nameplate.
Caution!
Do not pinch the wires.
7. Remove the shipping brackets that fix the readerhead to the scale for shipping.
Caution!
After the readerhead is attached to the readerhead mounting bracket, do not move the
machine axis until the shipping brackets are removed. This will break the readerhead.
7.7.2
Y Axis Scale Installation
1. Install the readerhead mounting bracket to the side of the saddle.
Note: Once the readerhead mounting bracket is installed, position the scale and mounting spar
assembly in position in order to determine the amount of spacers needed for the mounting spar. Also
ensure that the scale is long enough for the saddle travel.
2. Transfer the mounting spar holes to the saddle and mount it.
Note: the mounting spar must be parallel to the Y-axis travel within .005” end to end both horizontally
and vertically. Use spacers and shims as necessary.
3. Slide the scale into the mounting spar and fasten.
Note: the rest of the installation is the same as for the X-axis, Steps 5 through 7.
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Figure 62
Readerhead Mounting
Figure 63
Scale Mounting
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7.8 Limit Switch Installation Drawing
Figure 64
X & Y Limit Switch Assembly
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Figure 65
X & Y Limit Drilling Chart
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Limit Switch Installation Drawing Part List
Item
P/N
1
22108
2
24920
3
4
Title
UseAs
Qty
CAM-LIMIT SWITCH
EA
2
BALLS - STAINLESS STEEL
EA
8
22547
CAM HOLDER-PT4-Y & Z AXIS
EA
2
22113
NUT TEE- X AXIS
EA
4
5
22438
SPACER-DPMV3-LIMIT SWITCH-RH
EA
1
6
22437
CAM-LIMIT SWITCH-RH
EA
1
7
22439
CAM-LIMIT SWITCH-LH
EA
2
8
22440
SPACER-DPMV3-LIMIT SWITCH-LH
EA
1
9
22551-1
LIMIT SWITCH ASSY-RIGHT
EA
1
10
22551-2
LIMIT SWITCH ASSY-LEFT
EA
1
11
22436-1
SHEET METAL - SUPPORT LIMIT SWITCH X-AXIS
EA
1
12
M6-1.0X40 27B
SCREW-BHCS-STL-BO
EA
2
13
M6-1.0X30 25B
SCREW-SHCS-STL-BO
EA
2
14
24918-1-DOC
LIMIT SWITCH KIT -RETROFIT (DWG)
EA
1
15
M6-1.0X25 25B
SCREW-SHCS-STL-BO
EA
6
16
M6-1.0X16 25B
SCREW-SHCS-STL-BO
EA
6
17
M6 70B
WASHER-FLAT USS-STL-BO
EA
20
18
M6 73B
WASHER-SPLIT LOCK-STL-BO
EA
8
NUT-HEX-STL-BO
EA
2
SCREW-SOC SET-STL-BO-CUP
EA
4
19
M6-1.0 50B
20
M5-0.8X6 40B
21
24922
BRACKET - Y LIMIT SWITCH
EA
1
22
24277
SPACER-LIMIT SWITCH
EA
2
23
M6-1.0X60 25B
SCREW-SHCS-STL-BO
EA
4
24
24278
BRACKET-EXTENSION
EA
1
i24918-1
7.9 System Interconnection
7.9.1 ProtoTRAK SMX Basic System Configuration
See Figure 15 and 16 for all system cable connections.
7.9.2 Cable Routing
Tips for routing the cables on the machine.
•
Before tying up cables, it is a good idea to position them loosely, complete the system
interconnection and ensure that all the cables are plugged in correctly, and that the
system is responding properly.
•
Make sure that no motor cable is tied up next to a power line.
•
Position the table all the way to the left and the saddle all the way forward before
securing the X motor cables.
•
Ensure the knee travel is not restricted.
•
Do not bend umbilical cables. Coil up in a minimum of a 6” diameter.
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8.0
Z Motor/Ball Screw Assembly
Note: This section is for the installation of ProtoTRAK SMX 3 axis controls only.
Note: Tram the head before beginning this procedure.
8.1 Installation of the Base Plate
For the microfeed assembly, remove in this
order:
1.
2.
3.
4.
D, E
F, G, H
J
K, L
Figure 66
1. Remove the mill head assemblies indicated in Figure 66.
Caution!
After the quill stop knob is removed, take care that the quill is not allowed to fall out.
Kit Variation: For Lagun mills, substantial modification of the mill is required. See Fig 69
Note: Reposition the quill lock handle so that it is in the back. Once the baseplate is installed, it will be difficult
to get to it.
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Figure 67 - Base Plate& Ball Screw Mounting
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Note: Various components on Figure 67 have multiple balloons due to these parts varying on
different machines.
Note: The overall strategy is:


The position locator (9), and the hex head screw (18) align the baseplate side to
side.
The leveling nuts (17) align the baseplate front to back.
2. Replace the machine’s head bolts with the Jackscrew nuts (items 12 through 16) on the
right side. Replace the machine’s head bolts with the socket head couplers on the left
side. Items 12 through 16 vary depending on the type of head the kit is being installed
on.
3. Tighten these incrementally to 50 ft/lb. or the mill manufacturer’s spec for the head
bolts.
4. Install the fork on the quill. Tighten to 25 ft/lb. Use locktite, a lockwasher and the
setscrews provided. The forks vary from kit to kit.
Caution!
Do not over tighten the bolt; this may damage the bolt, the quill threads or
deform the quill.
Note: The fork must move smoothly in the slot, otherwise it will have to be modified.
5. Install the position locator (Item 9) where the feed control was located.
6. Install the leveling nuts on the position locator and the jackscrew nuts.
7. Install the base plate with the hex head screw (Item 18) through the hole where the
threaded rod used to be. Use shim between the block and baseplate if necessary.
Note: for shipping, the ball screw and covers are mounted to the base plate. Remove them
before installing the base plate.
8. Install the baseplate with the nut and washers as shown. Use the leveling nuts to
align the baseplate to the travel of the quill front to back. Also, align the baseplate
side to side by placing the level on the right edge of the baseplate and comparing it
to the extended quill. Tighten the nuts to 25 - 35 ft/lb.
Note: The baseplate must be parallel to the travel of the quill for the assembly to work
properly. Use a bubble level on the quill to compare it to the front and side of the base plate.
Check the alignment frequently, especially after installing and tightening the 1/2 - 13 x 1 1/2”
socket screws (Item 30).
Parts List – Base Plate & Ball Screw Mounting
Item
1
2
4
5
7
8
9
10
11
P/N
16215
16353-1
16357-1
16355-1
16364-1
16364-2
16210
16212-12
16212-13
Description
BRACKET BALLNUT-MACHINED (FORK)
BRACKET BALLNUT MACHINED - ACER/MILLPORT
BRACKET BALLNUT FORK EXTENDED LAGUN SM16
SCREW 3/8-24 BRKT BALLNUT MOUNTING
SCREW M10-1.0 BRKT BALLNUT MOUNTING
SCREW M10 X 1.5 BRKT BALLNUT MOUNTING
POSITIONER LOCATOR
COUPLING SOCKET HEAD
COUPLING SOCKET HEAD
Use As
EA
EA
EA
EA
EA
EA
EA
EA
EA
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Qty
1
1
1
1
1
1
1
2
2
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
16213-13
16213-12
16213-175L
16213-12L
16213-175
16214
16216
98029A036
3/4-16 51Z
16364-3
16739
14932
15759
16355-3
16365
16212-175
1/4-20 56Z
16357-2
1/2-13X1 1/2 25B
1/4-20X1 3/4 25B
1/4-20X1 40B
1/4-20X3/4 25B
1/4-20X3/8 40B
3/8-16 50B
3/8 70P
3/8 73B
16210-1
M6-1.0X25 25B
M10 73B
16740
M6-1.0X75 25B
3/8-24 x 2 ¼ 25B
JACKSCREW NUT 1/2-13--1/2-13
JACKSCREW NUT 1/2-12--1/2-13
JACKSCREW NUT M12-1.75--1/2--13
JACKSCREW NUT 1/2-12--1/2--13
JACKSCREW NUT M12-1.75--1/2-13
NUT LEVELING 3/4-16
SCREW HEX HD
WASHER-FINISHED FLAT-CASE HARDENED STL
NUT-HEX JAM-STL-ZINC-GRADE 2
SCREW 3/8-24 BRKT BALLNUT MOUNTING
JACKSCREW NUT
WASHER-LOWER BOLT
WASHER-1/4 HARD BLK OX 1/8 THK
SCREW M10.-1.0. BRKT. BALLNUT MOUNTING
SPACER CENTERING HOLE
COUPLING SOCKET HEAD
NUT-NYLON LOCK-STL-ZINC
BRACKET BALLNUT FORK EXT SUPERMAX 16VS
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
SCREW-SOC SET-STL-BO-CUP
SCREW-SHCS-STL-BO
SCREW-SOC SET-STL-BO-CUP
NUT-HEX-STL-BO
WASHER-FLAT USS-STL-BO
WASHER-SPLIT LOCK-STL-BO
POSITIONER LOCATOR
SCREW-SHCS-STL-BO
WASHER-SPLIT LOCK-STL-BO
COUPLING SOCKET HEAD
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
i25000-XX
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
8.2 Installation of the Ball Screw
1. Install the ball screw assembly as shown in Figure 67. Run the quill up and down
over its full travel at each step to ensure that there is no binding. Adjust as necessary.
You can mount a dial indicator on the top of the table, locating off the ballscrew. Move
the knee up and down and tram in the ballscrew from front to back with the leveling
nuts.
Note: Loosely install the ball screw at first, and then attach the fork with the quill near the top of
its travel.
Caution!
Binding in the quill travel will impair system performance and may
damage the ball screw assembly.
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2
2
2
2
2
3
1
1
1
1
1
2
2
1
1
2
2
1
2
2
4
2
4
1
1
2
2
2
1
1
4
1
8.3 Installation of the Motor and Remaining Components
See figure 67 & 68
1. Install the motor mounting bracket to the top of the base plate.
2. Install the motor to this bracket. Install the belt between the pulleys and tension it
by sliding the motor away from the head. Tighten the 4 screws that hold the motor
down.
3. Install the limit switch brackets that hold the upper and lower quill limit switches in
place. Manually move the ballscrew up until you reach a hard stop. Now move the
ballscrew down 1 turn of the ballscrew and set the upper limit switch. The brackets
are slotted to allow up and down adjustment. Move the ballscrew down to the
bottom of its travel and once again turn the ballscrew 1 turn and set the lower limit
switch. In other words, the limit switch should trip about 0.200” from the top and
bottom of travel.
4. The limit switch cable plugs into the digital I/O port on the pendant for non-spindle
control machines. For spindle control mills, the limit switch cable plugs into the
digital I/O port on the spindle control electrics box
5. Temporarily install the Z electronic handwheel to the right side of the baseplate with
2 socket head cap screws. The Z electronic handwheel plugs into the Z-axis
secondary feedback port on the cable breakout box.
6. Power up the control and verify the Z electronic handwheel works.
7. Verify the locations of the switches are set correctly to prevent a hard crash when
the machine is moving at maximum rapid speed. Adjust switches as necessary.
8. Remove the Z electronic handwheel and install the covers and then re-mount the
Z electronic handwheel.
See Figure 68-1 for an illustration of the ballscrew assembly.
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Figure 68
Z-Axis Motor, Electronic Handwheel
& Covers Assembly
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Parts List Z-Axis Motor, Electronic Handwheel & Covers Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
12
14
15
16
P/N
24217
24221
24222
24240-1
24250
21774
710-5M-15
22585
24251
5/16-18X2 1/4 25B
10-32X3/8 31B
24231
9688K321
10-32X1/2 25B
10 70B
Description
BRACKET-SERVO MOTOR
COVER - FRONT
COVER LATERAL
BASE PLATE
BALLSCREW MODULE Z-AXIS
ELECTRONIC HANDWHEEL-DPMV Z-AXIS
BELT - TIMING
CABLE ASSY-ADAPTOR (DB15 TO AMP)
LIMIT SWITCH ASSY
SCREW-SHCS-STL-BO
SCREW-PH-PHIL-EXT SEMS-STL-BO
BRACKET-LIMIT SWITCH
PLUG-BLK
SCREW-SHCS-STL-BO
WASHER-FLAT USS-STL-BO
i24230-1
Use As
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
Qty
1
1
1
1
1
1
1
1
1
2
8
2
2
4
4
153
Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 68-1
Ball Screw Module
P/N 24250
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Parts List Ball Screw Module
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
P/N
Description
Use As
24223
NUT CLAMP-Z AXIS
EA
16263
PLUG BRASS
EA
10-32X1/4 41B SCREW-SOC SET-STL-BO-FLAT
EA
10-32X3/4 25B SCREW-SHCS-STL-BO
EA
16268
FERRULE
EA
24218
PULLEY-Z AXIS
EA
6002-AV
NILOS RING
EA
20372
BEARING-ANGULAR CONTACT 7202 BECBP
EA
24220
BEARING HOUSING-Z AXIS
EA
1/2 73B
WASHER-SPLIT LOCK-STL-BO
EA
1/2-13X2 3/4 25B SCREW-SHCS-STL-BO
EA
16226
RING BEARING
EA
95571A837
WASHER- FLAT FELT 3/4 X 1/4 X 1/4
EA
16224
BALLSCREW Z-AXIS
EA
98481A090
KEY WOODRUFF #404-1/8 X 1/2
EA
14940
RING-ALIGNMENT
EA
14898
RING-ALIGNMENT
EA
24232
CAM-LIMIT SWITCH
EA
1/4-20X1 1/2 25B SCREW-SHCS-STL-BO
EA
1/4-20 56Z
NUT-NYLON LOCK-STL-ZINC
EA
i24250
Qty
1
1
1
1
1
1
2
2
1
2
2
1
1
1
1
1
1
1
1
1
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8.4
Lagun Z Axis Cutout
The ProtoTRAK SMX3 installation for the Lagun FTV2 requires the following material to be
removed from the box that holds the Lagun nameplate.
Figure 69
Unfortunately, there is not a really good way to do this. Your choices are:
•
•
•
Have the head machined
Use a hacksaw
Drill a series of holes and use a wrench to break away pieces (our favorite)
The good news is that the resulting mess will be completely covered with the Z-axis
assembly.
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9.0
Introduction to Self-Service
The objective of this section of the manual is to allow the user of the ProtoTRAK Control
to resolve the majority of potential service problems.
This manual assumes that the user is not experienced with CNC troubleshooting and
repairs. Special tools are not required for the procedures described in the manual.
Please see Sections 3, 4 and 5 for in depth troubleshooting, diagnostics and procedure
sections of the manual.
9.1 When You Have a Service Problem
SWI recommends that you consult this manual or our web site first. Often it will be possible
for you to resolve the problem yourself or isolate the problem to a particular cause.
Your next step is to contact the SWI Customer Service Group for assistance.
9.1.1 Communication with the SWI Customer Service Group
•
•
SWI Service Department Direct Line: (800) 367-3165
Web Address – www.southwesternindustries.com
This phone line rings directly into the SWI Customer Service Group. If a Customer
Service Representative (CSR) is not available within the first few of minutes, your call is
transferred into our voice mail system.
Our voice mail is continuously monitored. If you have an emergency, indicate this in your
message. Our Service Voice Mail box number is 555.
•
SWI Service Department Direct Fax number (310) 886-8029
Customer Service Group hours:
Monday - Friday 7:00 AM to 4:30 PM Pacific Time.
SWI observes a normal holiday schedule.
9.2 Warranty
TRAK products are warranted to the original purchaser to be free from defects in workmanship
and materials for the following periods:
Product
New TRAK
Any Exchange Unit
Warranty Period
1 Year
90 Days*
*If installed within the original warranty period, the longer of the warranties applies.
The warranty period starts on the date of the invoice to the original purchaser from Southwestern
Industries, inc. (SWI) or their authorized distributor.
If a unit under warranty fails, it will be repaired or exchanged at our option for a properly
functioning unit in similar or better condition. Such repairs or exchanges will be made FOB
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Factory/Los Angeles or the location of our nearest factory representative or authorized distributor.
9.2.1
Disclaimers of Warranties
•
This warranty is expressly in lieu of any other warranties, express or implied,
including any implied warranty of merchantability or fitness for a particular purpose,
and of any other obligations or liability on the part of SWI (or any producing entity, if
different).
•
Warranty repairs/exchanges do not cover incidental costs such as installation, labor,
freight, etc.
•
SWI is not responsible for consequential damages from use or misuse of any of its
products.
•
TRAK products are precision mechanical/electromechanical measurement systems
and must be given the reasonable care that these types of instruments require.
•
Accidental damage, beyond the control of SWI, is not covered by the warranty.
Thus, the warranty may not apply if an instrument has been abused, dropped, or hit.
•
Improper installation by or at the direction of the customer in such a way that the
product consequently fails, is considered to be beyond the control of the
manufacturer and outside the scope of the warranty.
9.2.2 This Warranty Extends to Self-Service
SWI will not penalize a customer under our warranty terms for accidental damage to systems
that results from attempting the procedures in this manual.
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9.3 Replacements
9.3.1 Exchange Program
SWI keeps in stock the major subassemblies required to resolve service problems. With
very few exceptions, the part needed to resolve any given service problem is on the shelf
and ready to ship.
A little bit of troubleshooting on your part means that we can get the right part to you
fast.
After replacing the failed unit with the replacement unit, simply put the failed unit in the
same box that the replacement part came in and ship it back to us via UPS ground
service.
This unique Exchange program gives our customers access to re-built “like-new”
subassemblies that have been brought up to current design revisions and go through the
same QC procedures as our new products. These high-quality replacement units are
available at a fraction of the price of a new subassembly.
9.3.2 Return Authorization (RA) Number
All shipments of replacement parts are accomplished through our Return Authorization
(RA) system. At the same time the CSR is diagnosing the problem and ordering the part,
they will issue an RA number that will allow us to efficiently process the return part.
159
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10.0
Figures and Parts Lists
Figure 100
Top Housing Assembly – 40 Taper
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Parts List - Top Housing Assembly – 24688-1
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
P/N
20697-1
20697-2
20697-3
FVS12
20697-4
FVS64
FVS93
FVS117
FVS62
FVS126
FVS61
20697-5
FVS63
FVS135
DESCRIPTION
GEAR HOUSING SUB-ASSY (4VK-A1)
HI-LOW SHIFT CLUTCH SUB-ASSY (4VK-A2)
HI-LOW SHIFT SUB-ASSY (4VK-A3)
SOCKET CAP SCREW M6-P1.0x15L
PULLY PINION SUB-ASSY (4VK-A4)
BULL GEAR PINION BEARING CAP
SCREW SOC HD M5-P0.8x15L
KEY 5x520L
TIMING BELT PULLEY
WASHER Ø 5/8
JAM NUT 5/8-11NC
LOWER VARI-DISC DRIVE SUB-ASSY (4VK-A5)
BELT 8YU-600L
KEY 8x7x60L
15
16
17
18
19
20
21
22
23
20697-6
FVS4
FVS1
FVS17
FVS13
FVS15
FVS129
20697-7
FVS10
UPPER VARI-DISC DRIVE SUB-ASSY (4VK-A6) (Shown for
reference only - See figure 106)
BELT
BELT HOUSING
SOCKET CAP SCREW M6-P1.0x35L
TOP BEARING CAP
BALL BEARING (6909VV)
SCREW- SOC HD CAP M6-P1.0x18L
SPEED CHANGE HANDWHEEL SUB-ASSY (4VK-A7)
SCREW- SOC HD CAP M8-P1.25x30L
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
20820
FVS130
FVS111
FVS11
FVS104
FVS131
FVS132
FVS133
FVS96
FVS101
FVS136
FVS16-1
FVS95
FVS16-2
FVS19
OIL-1
MOTOR ASSY-DPM5-5HP-GREEN (shown for reference only, not
part of upper head housing assembly)
WASHER- FLAT Ø 10.2
SOC HD SCREW- 3/8-16NCx32L
MOTOR PULLEY COVER
COPPER CHIP(2REQ.)
SCREW- FLAT HD PHILIP M5-P0.8x10L
STUD Ø 7/16-92L
STUD Ø 7/16-56L
JAM NUT 3/8-16NC
VENTILATOR(2REQ.)
SCREW- SOC HD CAP M6-P1.0x10L
VARI-SPEED DIAL
HEX CAP NUT 5/16-18NC
NAME PLATE
DRIVE SCREW
FRU-K3-OIL CUP
i00593-K4
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Qty
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
2
1
2
1
1
2
12
1
1
1
1
1
Figure 101
Gear Housing Sub-Assembly
P/N: 20697-1
Item
1
2
3
P/N
Description
FVS82 GEAR HOUSING
FV112 GUIDE SPRING
FV113 SPRING GUIDE PIN
i00594-K4
Qty
1
3
3
162
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Item
1
2
3
4
5
6
7
8
9
10
11
12
13
P/N
FVS75
23943
FVS78
FVS79
FVS80
FVS73
FVS72
FVS74
FVS114
FVS115
FVS81
FVS76
20818
DESCRIPTION
Qty
BEARING SLIDING HOUSING
1
BALL BAEARING (2 REQ.) 6910ZZ
1 SET
BEARING SPACER
1
BEARING SPACER
1
SNAP RING R-75
1
SPLINED GEAR HUB
1
KEY 8x7x10L
1
SPINDLE BULL GEAR
1
WASHER
1
EXTERNAL TOOTH WASHER Ø 50
1
LOCK WASHER Ø 50-18NC
1
RING
1
SPACER, BEARING
1
i00595-K4
Figure 102
Hi-Low Slip Clutch
Sub-Assembly
P/N: 20697-2
163
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Item
1
2
3
4
5
6
7
8
9
10
11
12
13
P/N
FVS89
FVS87
FVS92
FVS91
FVS90
FVS94
FVS88
FVS93
FVS92-1
FVS92-2
FVS57
FVS116
24083
DESCRIPTION
HI-LOW DETENT PLATE
CLUTCH GEAR SHAFT
HI-LOW PINION BLOCK
SPRING
HI-LOW DETENT PLUNGER
HI-LOW SHAFT CRANK
PIN Ø 319L
SCREW SOC HD M5-P0.8x15L
SET SCREW M5-P0.8x5L
WASHER- FLAT Ø 11
BAKELITE BALL HANDLE
WASHER- FLAT Ø 6
SHAFT HI/LOW SHAFT ASSY
Qty
1
1
1
1
1
1
1
3
1
1
1
1
1
i00596-K4
Figure 103
Hi-Low Shift Sub-Assembly
P/N: 20697-3
164
Southwestern Industries, Inc.
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Item
1
2
3
4
5
6
P/N
FVS67
FVS69
FVS66
AK118
FVS3
23954
DESCRIPTION
BULL GEAR PINION COUNTER SHAFT
KEY 5518L
BULL GEAR PINION
BALL BEARING (2 REQ.) 6203ZZ
SOCKET SET SCREW M6-P1.0x6L
BEARING SET (2) -BEARINGS 6203ZZ
i00597-K4
Qty
1
1
1
2
1
1
Figure 104
Pulley Pinion Sub-Assembly
P/N: 20697-4
165
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 105
Lower Vari-Disc Sub-Assembly
P/N: 20697-5 (assembly not available, order parts separately)
166
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Parts List - Lower Vari-Disc Sub-Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
P/N
FVS50
FVS59
FVS58
FVS103
FVS51
FVS53
FVS52
FSV119
FVS47
FVS48
FVS17
FVS49
FVS122
FVS120
FVS46
AK048
FVS14
FVS45
FVS70
FVS100
FVS71
FVS97
FVS52-1
FVS56
FVS54
FVS55
FVS57-1
24055
FVS98
DESCRIPTION
BELT HOUSING BASE
BRAKE BLOCK
TURNING BLOCK SHAFT
RETAINING RING Ø 7
SET SCREW M6-P1.06L
BRAKE LOCK BUSHING
BRAKE LOCK SHAFT
RETAINING RING Ø 11
BRAKE SHOE
BRAKE SHOE PIVOT SLEEVE
SOCKET CAP SCREW M6-P1.0x35L
BRAKE SPRING
WASHER Ø 6
SCREW- PHILLIP PAN HD 3/16-24NC6L
BRAKE BEARING CAP
BALL BEARING 6012ZZ
SOCKET CAP SCREW M 5-PO.8x12L
STATIONARY DRIVEN VARIDISC
SPINDLE PULLEY ASSY
SPINDLE PULLEY SPACER
KEY 8x8x20L
SNAP RING Ø 50
BRAKE LOCK SHAFT SWIVEL
BRAKE LOCK HANDLE
HANDLE FIX BLOCK 3/8-16NC
SPRING PIN Ø 6x20L
BAKELITE BALL HANDLE 3/8-16NC
BRAKE SHOE ASSY
CLUTCH WASHER
i00598-K4
Qty
1
2
1
1
2
1
1
1
2
1
1
2
4
4
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
167
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 106
Upper Vari-Disc Sub-Assembly
P/N: 20697-6
168
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Parts List - Upper Vari-Disc Sub-Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
P/N
FVS44
FVS42
FVS43
FVS36
FVS38
FVS37
FVS3123
FVS39
FVS41
FVS40
FVS35
FVS34
FVS33
FVS97
FVS96
24599
24603
DESCRIPTION
ADJUSTABLE-DRIVEN VARIDISC
SPINDLE PULLEY BEARING HOUSING
BALL BEARING 6013ZZ
SPEED CHANGE PLATE
PIVOT SLEEVE Ø 5
WASHER M5-P0.8x20L
SOCKET CAP SCREW
SPEED CHANGE PLATE PIVOT STUD
WASHER Ø 8.2
ROLL PIN Ø3x15L
CHAIN END STUD
ADJUSTMENT NUT
CHAIN FRONT SCREW M4-P0.7x5L
SNAP RING Ø 50
JAM NUT 3/8-16NC
BEARING HOUSING ASSY-K4
VARIDISC ASSY-ADJUSTABLE
i20697-6
Qty
1
1
1
1
2
2
2
1
1
2
1
1
1
1
1
1
1
169
Southwestern Industries, Inc.
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Item
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
P/N
FVS16
FVS20
FVS22
FVS31
FVS21
FVS25
FVS40
FVS24
FVS32
FVS31-1
FVS30
FVS27
FVS18
FVS28
VS24-1
Title
SPEED CHANGE HOUSING
BEARING SELF LUBRICATING
SPEED CHANGER GEAR
SPEED CHANGE CHAIN DRUM
WORM
SPEED CHANGE SHAFT
ROLL PIN Ø3x15L
COPPER BUSHING
CHAIN #3109.525
DOWEL PIN Ø3x25L
SPEED CHANGE STUD
SPEED CHANGE HANDWHEEL
FULL DOG SOCKET SET SCREW M6-P1.0x10L
HANDLE 3/8-16NC
WASHER-WAVE
i20697-7
Qty
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
Figure 107
Speed Change Handwheel Sub-Assembly,
P/N: 20697-7
170
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Item
1
2
3
4
5
6
7
8
9
10
P/N
FVS110
FVS3-1
FVS2
FVS6
FVS5
FVS6-1
FVS8
FVS9
FVS10
24054
Title
MOTOR 5 HP
KEY 6x6x45L
STATIONARY MOTOR VARIDISC
BUSHING
ADJUSTABLE MOTOR VARIDISC
KEY 7x7x50L
SPRING FOR VARIDISC MOTOR SHAFT
ADJUSTABLE VARIDISC SPRING COLLAR
SCREW- SOC HD CAP M8-P1.25x30L
VARIDISC ASSY
i00601-K4
Qty
1
1
1
1
1
1
1
1
1
1
Notes
only available as 20820
only available as 20820
only available as 20820
available as 24054 or 20820
available as 24054 or 20820
available as 24054 or 20820
only available as 20820
only available as 20820
only available as 20820
Figure 108
Spindle Motor Sub-Assembly
P/N: 20820
171
Southwestern Industries, Inc.
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Figure 109
Bottom Housing Assembly
172
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Parts List - Bottom Housing Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
26
27
28
29
30
31
32
33
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
P/N
FB192
FB31
FB33
FB94
FB29
FB28
FB41
FB27
20698-1
FB19
FB18
FB20
FB24
FB25-A
FB23
FB68
20698-2
FB67
FB186
FB189
FB187
20698-3
FB178
FB177
FB176
FB171
FB89
FB88
FB88-1
20698-4
FB99
FB73
FB101
20698-5
FB109
FB106
FB118
FB120
FB121
FB123
FB103
FB117
FB104
FB105
FB119-1
FB107
FB113
Title
QUILL HOUSING
CLUSTER GEAR SHAFT
BEVEL GEAR BEARING
SNAP RING 95 DOWEL PIN Ø 14
CLUSTER GEAR KEY 3x3x45L
CLUSTER GEARS ASSEMBLY
NEEDLE BEARING KO-BA66Z
CLUSTER GEAR SHAFT UPPER BEARING
WORM GEAR CRADLE SUB-ASSY (4VK-H1)
SHIFT SLEEVE
WORM GEAR CRADLE THROW-OUT
CAP SCREW M5-P0.8x12L
STEEL BALL
SPRING
SHIFT CRANK
SET SCREW M6-P1.0x8L
QUILL FEED SELECTOR SUB ASSY (4VK-H2)
CAP SCREW M6-P1.0x18L
WORM GEAR
ADJ WORM SHAFT
KEY 4x4x18L
SUB-ASSY-QUILL PINION SHAFT-40 TAPER
CLOCK SPRING (CLOCK SPRING ASSY.)
SPRING COVER
PINION SHAFT HUB SLEEVE
KEY 3x3x20L
OVERLOAD CLUTCH LEVER SPRING PLUNGER
COMPRESSION SPRING
INTERNAL COMPRESSION SPRING
OVERLOAD CLUTCH TRIP SUB-ASSY (4VK-H4)
CLUTCH ARM COVER
CAP SCREW M5-P0.8x40L
CHEM BLACKED LOCKNUT M6-P1.0
FEED REVERSE CLUTCH SUB-ASSY (4VK-H5)
KEY 3x3x20L
FEED TRIP BRACKET
CAM ROD SLEEVE ASSY.
COMPRESSION SPRING
TRIP PLUNGER
TRIP PLUNGER BUSHING
CAM ROD
ROLL PIN Ø 3x15L
TRIP HANDLE
BLACK PLASTIC BALL
ROLL PIN Ø 3x20L
CAP SCREW M6-P1.0x25L
HAND WHEEL CLUTCH
173
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
0
1
1
1
1
1
1
1
1
1
2
1
51
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
FB115
FB108
FB42
20836-1
FB148
FB148-1A
FB153
FB152
FB149
FB149-1
FB149-2
FB175
FB114
FB175-2A
FB116
FB175-3
FB190
FB191
FB169
FB163
FB200
FB164
FB160
FB161
FB162
FB184
FB183
FB185
FB202
FB201
FB124
FB145
FB144
OIL-1
FB125
FB125-1
FB125-2
FB111
FB100
FB124-1
FB124-2
FB128
FVS109
FVS109-1
25041
25043
25044
20834
20835
COMPRESSION SPRING
SET SCREW M6-P1.0x8L
BUSHING
SPINDLE ASSY-40 TAPER
QUILL LOCK SLEEVE TAPPED
COMPRESSION SPRING
QUILL LOCK SLEEVE
QUILL LOCK BOLT
LOCK HANDLE
CONICAL COMPRESSIONAL SPRING
SCREW- PHILLIP HD
RACK FEED HANDLE HUB
STEEL BALL
COMPRESSION SPRING
HANDWHEEL CLUTCH SPRING SCREW M8-P1.25x6L
DOWEL PIN
PINION SHAFT HUB HANDLE
PLASTIC BALL HANDLES
SOC HEAD SCREW M5-P0.8x15L
QUILL STOP KNOB
SCREW- SOC HD 3/8-24NF x 1 1/4
QUILL STOP MICRO-SCREW
SNAP RING Ø16
QUILL MICRO-STOP NUT
MICROMETER NUT
FEED REVERSE TRIP PLUNGER
REVERSE TRIP BALL LEVER
REVERSE TRIP BALL LEVER SCREW
INDICATOR ROD
INDICATOR ROD SCREW
FEED TRIP PLUNGER
FEED TRIP LEVER
SOCKET SET SCREW
FRU-K3-OIL CUP
HANDWHEEL
HANDWHEEL SPRING PIN - Ø 3x3x10L
HANDWHEEL HANDLE
REVERSE KNOB
SOCKET SET SCREW M6-P1.0x20L
FEED TRIP PLUNGER SOC SET SCREW M4-P0.7x20L
FEED TRIP PLUNGER NUT M4-P0.7x20L
QUILL SKIRT
DRAWBAR 5/8-11NC
SPACER
SCALE-HEAD ROTATION-NT40
POINTER SCALE
DRIVE SCREW-SCALE
FEED REVERSE KNOB ASSY
HANDWHEEL ASSY
174
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
4
1
1
101
102
103
104
105
106
107
108
24099
20833
20847
20846
20850
24095
20844
FB142
109
A071
TRIP HANDLE ASS'Y (INCLUDES PLASTIC BALL)
FRU-K4-FEED TRIP ASSY
QUILL MICRO NUT & SCREW ASSY
QUILL LOCK HANDLE ASSY
FEED HANDLE ASSY
CLOCK SPRING ASSEMBLY (SPRING & COVER)
QUILL LOCK SLEVE ASSY
QUILL
T BOLT ASSY (includes A070, A071, A069) (not shown on
drawing)
i20698
175
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
1
1
1
1
1
1
1
1
4
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
P/N
FB17
FB5
FB6
FB8
FB4
FB9
FB11
FB10
FB3
FB2
FB1
FB16
FB36
FB36-1
FB15
FB13
FB14
FB37
FB40
Title
WORM GEAR CRADLE
WORM CRADLE BUSHING
SETSCREW M6-PP1.0x10L
FEED DRIVEWORM GEAR
FEED WORM GEAR SHAFT SLEEVE
FEED DRIVE WORM GEAR SHAFT
KEY 3x3x20L
WORM SHAFT KEY 3x3x8L
FEED BEVEL PINION
BEVEL PINION WASHER Ø 5
SOC.HD.SCREW M5-P0.8x10L
FEED ENGAGE PIN
FEED DRIVING GEAR
KEY 3x3x8L
FEED REVERSE BEVEL GEAR
WASHER Ø 6 Ø 22
SOC HD SCREW M6-P1.0x15L
KEY 3x3x10L
FEED DRIVE GEAR
i00603-K4
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Figure 110
Worm Gear Cradle Sub-Assembly
P/N: 20698-1
176
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
2
3
4
5
6
7
8
9
10
P/N
FB66
FB64
FB69-1
FB69
FB71
FB70
FB68
FB63
FB60
FB61
DESCRIPTION
CLUSTER GEAR COVER
CLUSTER GEAR SHIFT CRANK
DIAL
SHIFT KNOB
SPRING
STEEL BALL
SET SCREW M6-P1.0x8L
FEED GEAR SHIFT FORK
FEED SHIFT ROD
KP.SET SCREW M5-P0.8x6L
i00604-K4
Qty
1
1
1
1
1
1
1
1
1
1
Figure 111
Quill Feed Selector Sub-Assembly
P/N: 20698-2
177
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
3
4
5
6
7
8
P/N
FB166
K-B92
K-B93
K-B92-1
K-B94
K-B168
25707
Title
QUILL PINION SHAFT
OVERLOAD CLUTCH WORM GEAR
OVERLOAD CLUTCH RING
SCREW SOC HD CAP M4-P0.7x15L
SNAP RING 95 DOWEL PIN Ø 14
SCREW PIN
BUSHING KIT-PINION SHAFT-40 TAPER
UseAs
EA
EA
EA
EA
EA
EA
EA
i20698-3
Figure 112
Quill Pinion Shaft Sub-Assembly
P/N: 20698-3
178
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Qty
1
1
1
3
1
(1)
1
Item
1
2
3
4
5
6
7
8
9
10
11
12
P/N
FB81
FB81-1
FB80
FB79
FB78
FB76
FB75
FB97
FB98
FB96
FB74
FB77
Title
OVERLOAD CLUTCH SLEEVE
KEY 5x8x13L
OVERLOAD CLUTCH
SAFETY CLUTCH SPRING
OVERLOAD CLUTCH LOCKNUT
SOCKET SET SCREW M6-P1.0x8L
CLUTCH RING
OVERLOAD CLUTCH WASHER
SNAP RING Ø 10
OVERLOAD CLUTCH TRIP LEVER
CLUTCH RING PIN (2REQ.)
BRASS PLUG
i00606-K4
Qty
1
1
1
1
1
1
1
1
1
1
2
1
Figure 113
Overload Clutch Trip Sub-Assembly
P/N: 20698-4
179
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
P/N
FB57
FB44
FB47
FB43
FB59
FB49
FB48
FB62
FB50
FB50-1
FB55
FB52
FB51
Title
FEED WORM SHAFT
FEED WORM SHAFT BUSHING
FEED WORM SHAFT THRUST WASHER
WORM
PIN Ø 3x12L
FEED REVERSE BEVEL GEAR
BUSHING
KEY 3x3x15L
FEED REVERSE CLUTCH
PIN Ø 3x19L
REVERSE CLUTCH ROD
BUSHING
FEED REVERSE BEVEL GEAR
i00607-K4
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
Figure 114
Feed Reverse Clutch Sub-Assembly
P/N: 20698-5
180
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 115
Quill Spindle Sub-Assembly
P/N: 20836-1
181
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Parts List - Spindle Sub-Assembly
Item
1
2
3
4
5
6
7
8
10
11
12
13
14
P/N
FB127
FB133
FB134
20839
FB136
FB137
FB139
FB139-1
A112H
FB143
FB140
FB141
20841
DESCRIPTION
SPINDLE BT-40
NOSE-PIECE
SPINDLE DIRT SHIELD
BEARING (7010CP4) SET of 2
BEARING SPACER-LARGE
BEARING SPACER-SMALL
SPINDLE BEARING KNOCK NUT
SET SCREW M8-P1.25x6L
BEARING 6008ZZ
LOCK RING Ø 40
SPINDLE FIXED NUT
COLLET ALIGNMENT SCREW M8-P1.25x20L
BEARING SPACER SET
i00608-K4
Qty
1
1
1
1 Set
1
1
1
2
1
1
2
2
1
182
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 116
Head Top Assembly with Spindle Control Option
183
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Parts List - Head Top Assembly – K4SX with Spindle Control
Option
Item
1
2
3
4
5
6
8
10
11
12
13
14
17
P/N
24163
23965
23967
23597
24169
3/8 70P
3/8-16X1 1/4 24B
23968
23969-2
M4-0.7X16 25B
M5-0.8X12 25B
24164
24172 or 23986-2
DESCRIPTION
MOTOR ASSY-SPINDLE-5 HP
NAMEPLATE - E-HEAD OPTION
PULLEY - SPINDLE - NT 40
BELT-MICRO-V-J PROFILE 10 RIBS "J"
KEY 8 mm X 8 mm
WASHER-FLAT USS-STL-BO
SCREW-HEX HEAD-STL-BO
SWITCH ASSY- LIMIT-HI/LOW
BRACKET - GEAR SWITCH-5 HP
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
PLUG-PRY-OUT
COLLAR-LOCK CCM-050
I01127-K4
Qty
1
1
1
1
1
4
4
1
1
2
2
1
1
Parts List – Head Top Assembly – K2SX/K3SX with Spindle
Control Option
Item
1
2
3
4
5
6
8
10
11
12
13
14
16
P/N
24162
23965
23632
23597
24169
3/8 70P
3/8-16X1 1/4 24B
23968
23969-1
M4-0.7X16 25B
M5-0.8X12 25B
24164
24172-1 or 23986-1
DESCRIPTION
MOTOR-SPINDLE-ASSY-3 HP
NAMEPLATE - E-HEAD OPTION
PULLEY - SPINDLE- R8
BELT-MICRO-V-J PROFILE 10 RIBS "J"
KEY 8 mm X 8 mm
WASHER-FLAT USS-STL-BO
SCREW-HEX HEAD-STL-BO
SWITCH ASSY- LIMIT-HI/LOW
BRACKET - GEAR SWITCH-3 HP
SCREW-SHCS-STL-BO
SCREW-SHCS-STL-BO
PLUG-PRY-OUT
COLLAR-CLAMP
I01127-K2-K3
184
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Qty
1
1
1
1
1
4
4
1
1
2
2
1
1
Figure 117
Electrical Enclosure-Spindle Control Option
PART #
24060-1
24060-2
DESCRIPTION
SPINDLE CONTROL-3HP
SPINDLE CONTROL-5HP
i01128
185
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Parts List – Electrical Enclosure – K4SX with Spindle Control
Option
Item
2
5
7
8
12
13
14
15
16
17
21
25
26
P/N
24063-3
22890-500-64
23433-04
25106-K4SX
22961
21820
21824-5
21824-8
22199
21827
22443
24182
24183
DESCRIPTION
PCB ASSY-SMX-SPINDLE CONTROL
RESISTOR-500W-64ohm (5 HP MACHINES)
TERMINAL BLOCK 4 POLE
AC DRIVE - 5 HP MINI VECTOR-220V
RELAY-POWER - 115V DPST
FUSE HOLDER
FUSE-3AG-SLOW BLOW
5 AMP
FUSE-3AG-SLOW BLOW
8 AMP
RECEPTACLE- PANEL MOUNT NEMA STD 15A 125V
SNAP RING 35X1.5
CABLE ASSY-PT4 VL/VM 15 PIN SPINDLE CONTROL
DISCONNECT SWITCH
ROD-DISCONNECT/HANDLE
i01128-K4
Qty
1
2
1
1
1
2
1
1
1
1
1
1
1
Parts List – Electrical Enclosure – K2SX/K3SX with Spindle
Control Option
Item
2
3
5
7
8
12
13
14
15
16
17
21
25
26
P/N
24063-3
24066
22890-500-120
23433-04
25105-K2/K3SX
22961
21820
21824-5
21824-8
22199
21827
22443
24182
24183
DESCRIPTION
PCB ASSY-SMX-SPINDLE CONTROL
SHEETMETAL-RESISTOR COVER
RESISTOR-500W-120ohm (3 HP MACHINES)
TERMINAL BLOCK 4 POLE
AC DRIVE - 3 HP MINI VECTOR-220V
RELAY-POWER - 115V DPST
FUSE HOLDER
FUSE-3AG-SLOW BLOW
5 AMP
FUSE-3AG-SLOW BLOW
8 AMP
RECEPTACLE- PANEL MOUNT NEMA STD 15A 125V
RECEPTACLE-AC INPUT
CABLE ASSY-PT4 VL/VM 15 PIN SPINDLE CONTROL
DISCONNECT SWITCH
DISCONNECT/HANDLE
i01128-K2-K3
186
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Qty
1
1
2
1
1
1
2
1
1
1
1
1
1
1
Figure 118
Top Housing Assembly – R8
187
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Parts List
Head Top Assembly - 24692
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
P/N
20778-1
20778-2
20778-3
VS12
20778-4
VS64
VS93
VS117
VS62
VS126
VS61
20778-5
VS63
VS14-1
VS135
VS4
20778-6
VS1
VS137
VS13
VS13-1
VS15
VS129
20778-7
VS07
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
20819
VS130
VS111
VS11
VS104
VS131
VS132
VS96
VS101
VS136
VS54
VS55
VS56
VS57
OIL-1
Title
GEAR HOUSING SUB-ASSY (3VK-A1)
HI-LOW SHIFT CLUTCH SUB-ASSY (3VK-A2)
HI-LOW SHIFT SUB-ASSY (3VK-A3)
SOCKET CAP SCREW M6-P1.0x15L
PULLY PINION SUB-ASSY (3VK-A4)
BULL GEAR PINION BEARING CAP
SCREW M5-P0.8x15L
KEY 5x525L
TIMING BELT PULLEY
WASHER Ø 5/8
JAM NUT 5/8-11NC
LOWER VARI-DISC DRIVE SUB-ASSY (3VK-A5)
BELT 3/8"-#225
SCREW M8-P1.25x18L
KEY 8x7x60L
BELT
UPPER VARI-DISC DRIVE SUB-ASSY (3VK-A6)
BELT HOUSING
SOCKET CAP SCREW M8-P1.25x25L
TOP BEARING CAP
WAVE WASHER
BEARING-DEEP GROVE-6007V
SCREW- SOC HD CAP M6-P1.0x18L
SPEED CHANGE HANDWHEEL SUB-ASSY (3VK-A7)
SCREW- SOC HD CAP M6-P1.0x35L
MOTOR ASSY- K2 & K3- 3HP (reference only, not part of upper
head housing assembly)
WASHER- FLAT Ø 10.2
SOC HD SCREW- 3/8-16NCx32L
MOTOR PULLEY COVER
COPPER CHIP(2REQ.)
SCREW- FLAT HD PHILIP M5-P0.8x10L
STUD Ø 7/16-100L
JAM NUT 3/8"-16NC
VENTILATOR(2REQ.)
SCREW- SOC HD CAP M6-P1.0x10L
HANDLE FIX BLOCK
SET SCREW
BRAKE LOCK HANDLE
BAKELITE BALL HANDLE
OIL CUP
i00690-K2-K3
Qty
1
1
1
2
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
2
1
2
1
2
12
1
1
1
1
1
188
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
2
3
P/N
VS82
VS112
VS113
Title
GEAR HOUSING
GUIDE SPRING
SPRING GUIDE PIN
i00691-K2-K3
Qty
1
3
3
Figure 119
Gear Housing
P/N: 20778-1
189
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 120
Hi-Low Shift Clutch
Sub-Assembly
P/N: 20778-2
190
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Parts List – High-Low Shift Clutch
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
P/N
VS75
23970
VS78
VS79
VS80
VS73
VS72
VS74
VS114
VS115
VS81
VS76
20817
DESCRIPTION
BEARING SLIDING HOUSING
BALL BEARING 6908ZZ
BEARING SPACER
BEARING SPACER
SNAP RING R-65
SPLINED GEAR HUB
KEY 8x7x10L
SPINDLE BULL GEAR
WASHER
EXTERNAL TOOTH WASHER Ø 40
LOCK WASHER Ø 9/16-18NC
RING
SPACER-BEARING
i00692-K2-K3
Qty
1
1 SET
1
1
1
1
1
1
1
1
1
1
1
191
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 121
Hi-Low Shift
P/N: 20778-3
Item
1
2
3
4
5
7
8
9
10
12
13
P/N
VS89
VS87
VS92
VS91
VS90
VS88
VS93
VS92-1
VS92-2
VS116
24083
DESCRIPTION
HI-LOW DETENT PLATE
CLUTCH GEAR SHAFT
HI-LOW PINION BLOCK
SPRING
HI-LOW DETENT PLUNGER
PIN Ø 3X19L
SCREW M5-P0.8x15L
SET SCREW M5-P0.8x5L
WASHER- FLAT Ø 11
WASHER- FLAT Ø M5
SHAFT-HI/LOW SHAFT ASSY
i00693-K2-K3
Qty
1
1
1
1
1
1
2
1
1
1
1
192
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
2
3
4
5
6
P/N
VS67
VS69
VS66
AK118
VS3
23954
DESCRIPTION
BULL GEAR PINION COUNTER SHAFT
KEY 5X5X18L
BULL GEAR PINION
BALL BEARING (2 REQ.) 6203ZZ
SOCKET SET SCREW M6-P1.0x6L
BEARING-DEEP GROOVE-SET (2)-6203ZZ
i00694-K2-K3
Qty
1
1
1
2
1
1
Figure 122
Pulley Pinion
P/N: 20778-4
193
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 123
Lower Vari-Disc Drive
P/N: 20778-5
(assembly not available, order parts separately)
194
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Parts List – Lower Vari-Disc Drive
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
P/N
VS50
VS59
VS58
VS103
VS51
VS53
VS52
VS52-2
VS47
VS48
VS17
VS17-1
VS17-2
VS49
VS122
VS120
VS46
VS43-1
VS14
VS45
VS70
VS100
VS71
VS97
VS50-1
VS50-2
24055
DESCRIPTION
BELT HOUSING BASE
BRAKE BLOCK
TURNING BLOCK SHAFT
RETAINING RING Ø 7
SET SCREW M6-1.0X6L
BRAKE LOCK BUSHING
BRAKE LOCK SHAFT
BRAKE LOCK PIN DIA 3 X 5/8"L
BRAKE SHOE
BRAKE SHOE PIVOT SLEEVE
SOCKET CAP SCREW M6-P1.0x35L
WASHER Ø 6
NUT M6-P1.0
BRAKE SPRING
WASHER DIA 3.3
SCREW-PAN HEAD PHILIP 5-40NC
BRAKE BEARING CAP
BALL BEARING 6010ZZ
SOCKET CAP SCREW M5-0.8x12L
STATIONARY DRIVEN VARIDISC
SPINDLE PULLY ASSY
SPINDLE PULLY SPACER
KEY 8x7x20L
SNAP RING Ø 40
DUST COVER
SCREW-FH-PH-STL-BO M6-1.0X6L
BRAKE SHOE ASSY
i00695-K2-K3
Qty
1
2
1
1
2
1
1
1
2
1
1
1
1
2
4
4
1
1
4
1
1
1
1
1
1
4
1
195
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 124
Upper Vari-Disc Drive Sub-Assy
P/N: 20778-6
196
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Parts List – Upper Vari-Disc Drive Sub-Assy
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
P/N
VS42
VS43
VS44
VS36
VS38
VS37
VS123
VS39
VS41
VS40
VS35
VS34
VS33
VS7
FVS96
24564
24631
DESCRIPTION
SPINDLE PULLEY BEARING HOUSING
BALL BEARING 6210ZZ
ADJUSTABLE-DRIVEN VARIDISC
SPEED CHANGE PLATE
PIVOT SLEEVE Ø 5
WASHER M5-P0.8x20L
SCREW-SHCS M5-0.8X20L
SPEED CHANGE PLATE PIVOT STUD
WASHER Ø 8.2
ROLL PIN Ø3x15L
ADJUSTMENT NUT
CHAIN END STUD
CHAIN FRONT SCREW M4-P0.7x5L
SNAP RING Ø 35
JAM NUT 3/8-16NC
BEARING HOUSING ASSY
VARI DISC ADJUSTABLE ASSY
Qty
1
1
1
1
2
2
2
1
1
2
1
1
1
1
1
1
1
i20778-6
197
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
P/N
VS16
VS20
VS22
VS31
VS21
VS25
VS40
VS24
VS24-1
VS27
VS18
VS28
VS32
VS31-1
VS30
VS16-1
VS95
VS16-2
VS19
M5-0.8X14 40B
M5-0.8X5 40B
DESCRIPTION
SPEED CHANGE HOUSING
BEARING SELF LUBRICATING
SPEED CHANGER GEAR
SPEED CHANGE CHAIN DRUM
WORM
SPEED CHANGE SHAFT
ROLL PIN Ø3x15L
COPPER BUSHING
WASHER-WAVE
SPEED CHANGE HANDWHEEL
FULL DOG SOCKET SET SCREW M6-P1.0x10L
HANDLE 3/8-16NC
CHAIN #310X9.525
DOWEL PIN Ø3x25L
SPEED CHANGE STUD
SPEED DIAL
NUT-ACORN 5/16-18 NC
NAME PLATE
SCREW-DRIVE
SCREW-SOC SET-STL-BO-CUP
SCREW-SOC SET-STL-BO-CUP
Qty
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
4
1
1
i20778-7
Figure 125
Speed Change Handwheel
P/N: 20778-7
198
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 126
Spindle Motor
P/N: 20819
Item
1
2
3
4
5
6
7
8
9
10
P/N
VS110
VS3-1
VS2
VS6
VS5
VS6-1
VS8
VS9
VS10
23953
DESCRIPTION
MOTOR 3 HP
KEY 6x6x45L
STATIONARY MOTOR VARIDISC
BUSHING
ADJUSTABLE MOTOR VARIDISC
KEY 7x7x50L
SPRING FOR VARIDISC MOTOR SHAFT
ADJUSTABLE VARIDISC SPRING COLLAR
SCREW- SOC HD CAP M8-P1.25x30L
VARIDISC ASSY-ADJUSTABLE MOTOR
i00698-K2-K3
Qty
1
1
1
1
1
1
1
1
1
1
Notes
only available as 20819
only available as 20819
only available as 20819
available as 23953 or 20819
available as 23953 or 20819
available as 23953 or 20819
only available as 20819
only available as 20819
only available as 20819
199
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 127
Lower Head Assembly
200
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Parts List – Lower Head Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
P/N
K-B125-2
K-B113
K-B117
K-B103
K-B108
K-B119-1
K-B103-1
K-B107
K-B106
20779-4
K-B73
K-B101
K-B99
20779-2
K-B67
K-B29
K-B27
K-B28
K-B94
K-B32
K-B33
K-B31
20779-1
K-B18
K-B19
K-B25
K-B20
K-B21
K-B22
K-B23
K-B186
K-B128
K-B189-1
K-B42
K-B187
K-B189
K-B171
K-B178
K-B177
K-B169
K-B170
K-B175-3
K-B175-2
K-B175-1
K-B176
K-B175
Title
HANDWHEEL HANDLE (AVAILABLE ONLY IN ASSY. 20835)
HAND WHEEL CLUTCH
ROLL PIN Ø3x15L
CAM ROD
SOCKET SET SCREW M6-P1.0x8L
ROLL PIN Ø3x20L
CAM ROD PIN Ø6x15L
CAP SCREW M6-P1.0x25L
FEED TRIP BRACKET
OVERLOAD CLUTCH TRIP SUB-ASSY (3VK-B4)
SOCKET SET SCREW M6-P1.0x20L
CHEM BLACKED LOCKNUT M6-P1.0
CLUTCH ARM COVER
QUILL FEED SELECTOR SUB-ASSY (3VK-B2)
CAP SCREW M6-P1.0x18L
CLUSTER GEAR KEY 3x3x45L
CLUSTER GEAR SHAFT UPPER BEARING
CLUSTER GEARS ASSEMBLY
SNAP RING 95 DOWEL PIN Ø 14
BEVEL GEAR THRUST SPACER
BEVEL GEAR BEARING
CLUSTER GEAR SHAFT 6602BB
WORM GEAR CRADLE SUB-ASSY (3VK-B1)
WORM GEAR CRADLE THROW-OUT
SHIFT SLEEVE
CAP SCREW(3REQ.) M5-P0.8x12L
GEAR SHIFT PLUNGER
COMPRESSION SPRING
ROLL PIN Ø3x20L
SHIFT CRANK
WORM GEAR
QUILL SKIRT
ADJ WORM SHAFT SET SCREW M6-P1.0x6L
BUSHING
KEY 4x4x18L
ADJ WORM SHAFT
KEY 3x3x20L
CLOCK SPRING(CLOCK SPRING ASSY.)
SPRING COVER
RD.HEAD SCREW(2REQ.) M5-P0.8x15L
ROLL PIN
SET SCREW M8-P1.25x6L
COMPRESSION SPRING
STEEL BALL
PINION SHAFT HUB SLEEVE
RACK FEED HANDLE HUB
201
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Qty
1
1
1
1
1
1
1
2
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
2
2
2
1
1
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
K-B172
20836
VS109
VS109-1
K-B191
K-B190
K-B148
K-B148-1
K-B153
KB-201
K-B149
KB-202
K-B164
K-B160
K-B124-2
K-B124-1
K-B145
K-B124
K-B185
K-B144
K-B183
K-B161
K-B162
K-B123
K-B184
K-B121
K-B120
K-B158
K-B118
K-B159
KB-200
K-B163
20779-5
OIL-1
K-B109
K-B17-1
K-B88-1
K-B89
20779-3
K-B167
K-B27-1
K-B41
K-B192
K-B104
K-B105
K-B125-1
K-B125
K-B111
K-B100
PINION SHAFT HUB SEREW
SPINDLE ASSY-R8
DRAWBAR 7/16-20UNF
SPACER
BLACK PLASTIC BALL HANDLES (sold as assy 20849 only)
PINION SHAFT HUB HANDLE (sold as assy 20849 only)
QUILL LOCK SLEEVE
COMPRESSION SPRING
QUILL LOCK SLEEVE TAPPED
INDICATOR ROD SCREW
LOCK HANDLE
INDICATOR ROD
QUILL STOP MICRO-SCREW
SNAP RING Ø16
FEED TRIP PLUNGER NUT M40-P0.7
FEED TRIP PLUNGER SOC SET SCREW M4-P0.7x20L
FEED TRIP LEVER
FEED TRIP PLUNGER
REVERSE TRIP BALL LEVER SCREW
SOCKET SET SCREW
REVERSE TRIP BALL LEVER
QUILL MICRO-STOP NUT
MICROMETER NUT
TRIP PLUNGER BUSHING
FEED REVERSE TRIP PLUNGER
TRIP PLUNGER
COMPRESSION SPRING
CHEM BLACKED RD.HD.SCREWS(2 REQ.) M5-P0.8x8L
CAM ROD SLEEVE ASSY
MICROMETER SCALE
SCREW- SOC HD 3/8-24NFx15L
QUILL STOP KNOB
FEED REVERSE CLUTCH SUB-ASSY (3VK-B5)
OIL CUP
KEY 3x3x20L
WORM GEAR SET SCREW M6-P1.0x8L
COMPRESSION SPRING
OVERLOAD CLUTCH LEVER SPRING PLUNGER
SUB - ASSY - QUILL PINION SHAFT - R8
KEY 5x5x25L
SET SCREW M6-P1.0x8L
NEEDLE BEARING BA66 BEARING SIZE KO-BA66Z
QUILL HOUSING
TRIP HANDLE
BLACK PLASTIC BALL
HANDWHEEL SPRING PIN Ø3x3x10L
HANDWHEEL
REVERSE KNOB
CAP SET SCREW M5-P0.8x35L
202
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
1
0
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
98
99
100
101
102
103
104
105
106
107
108
109
110
25042
25043
25044
20835
20834
24052
20832
20847
24051
20849
20843
K-B142
K-B155
SCALE-HEAD ROTATION-R8
POINTER SCALE
DRIVE SCREW-SCALE
HANDWHEEL ASSY
FEED REVERSE KNOB ASSY
TRIP HANDLE ASSEMBLY (INCLUDES PLASTIC BALL)
FEED TRIP ASSY
QUILL MICRO NUT & SCREW ASSY
CLOCK SPRING ASSEMBLY (SPRING & COVER)
FEED HANDLE ASSY (QUILL HANDLE)
QUILL LOCK SLEVE ASSY
QUILL
T BOLT ASSY (not shown on drawing)
1
1
4
1
1
1
1
1
1
1
1
1
1
i20779
203
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
P/N
K-B17
K-B07
K-B08
K-B05
K-B04
K-B09
K-B11
K-B10
K-B03
K-B02
K-B01
K-B36
K-B36-1
K-B15
K-B13
K-B14
K-B37
K-B40
K-B16
K-B06
Title
WORM GEAR CRADLE
WORM GEAR SPACER
FEED DRIVEWORM GEAR
WORM CRADLE BUSHING
FEED WORM GEAR SHAFT SLEEVE
FEED DRIVE WORM GEAR SHAFT
KEY 3x3x25L
WORM SHAFT KEY 3x3x8L
FEED BEVEL PINION
BEVEL PINION WASHER Ø 5
SOC.HD.SCREW M5-P0.8x10L
FEED DRIVING GEAR
KEY 3x3x8L
FEED REVERSE BEVEL GEAR
WASHER Ø 6, 22 OD
SOC HD SCREW M6-P1.0x15L
KEY 3x3x10L
FEED DRIVE GEAR
FEED ENGAGE PIN
SETSCREW M6-P1.0x6L
Figure 128
Worm Gear Cradle
P/N: 20779-1
i00700-K2-K3
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
204
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
2
3
4
5
6
7
8
9
10
P/N
K-B66
K-B64
K-B70
K-B69
K-B68
K-B72
K-B71
K-B63
K-B65
K-B61
Title
CLUSTER GEAR COVER
CLUSTER GEAR SHAFT CRANK
SHIFT CRANK
SPRING Ø 3 x 20L
GEAR SHIFT PLUNGER
SHIFT KNOB-5/16-18NC
ROLL PIN Ø 3 x 20L
FEED GEAR SHIFT FORK
SHAFT
CAP SET SCREW M5-P0.8x5L
i00701-K2-K3
Qty
1
1
1
1
1
1
1
1
1
1
Figure 129
Quill Feed Selector
P/N: 20779-2
205
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
2
3
4
5
6
7
8
P/N
K-B166
25706
K-B91
K-B92
K-B93
K-B92-1
K-B94
K-B168
Title
UseAs
EA
EA
EA
EA
EA
EA
EA
EA
QUILL PINION SHAFT
BUSHING KIT-PINION SHAFT-R8
WASHER
OVERLOAD CLUTCH WORM GEAR
OVERLOAD CLUTCH RING
SCREW SOC HD CAP M4-P0.7x15L
SNAP RING 95 DOWEL PIN Ø 14
SCREW PIN
i20779-3
Figure 130
Quill Pinion Shaft
P/N: 20779-3
206
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Qty
1
1
1
1
1
3
1
(1)
Item
1
2
3
4
5
6
7
8
9
10
11
12
P/N
K-B81
K-B81-1
K-B80
K-B79
K-B78
K-B76
K-B75
K-B97
K-B98
K-B96
K-B74
K-B77
Title
OVERLOAD CLUTCH SLEEVE
KEY 5x8x13L
OVERLOAD CLUTCH
SAFETY CLUTCH SPRING
OVERLOAD CLUTCH LOCKNUT
SOCKET SET SCREW M6-P1.0x8L
CLUTCH RING
OVERLOAD CLUTCH WASHER
SNAP RING Ø 10
OVERLOAD CLUTCH TRIP LEVER
CLUTCH RING PIN (2REQ.)
BRASS PLUG
i00703-K2-K3
Qty
1
1
1
1
1
1
1
1
1
1
2
1
Figure 131
Overload Clutch Trip
P/N: 20779-4
207
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
P/N
K-B57
K-B47
K-B44
K-B43
K-B59
K-B49
K-B48
K-B62
K-B50
K-B56
K-B51
K-B52
K-B55
Title
FEED WORM SHAFT
FEED WORM SHAFT THRUST WASHER
FEED WORM SHAFT BUSHING
WORM
PIN Ø 3x12L
FEED REVERSE BEVEL GEAR
BUSHING
KEY 3x3x15L
FEED REVERSE CLUTCH
PIN Ø 3x19L
FEED REVERSE BEVEL GEAR
BUSHING
REVERSE CLUTCH ROD
i00704-K2-K3
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
Figure 132
Feed Reverse Clutch
P/N: 20779-5
208
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
P/N
K-B127
K-B134
20838
K-B136
K-B137
K-B133
K-B132
K-B131
K-B130
K-B129
K-B150-1
K-B151
K-B150-2
K-B139
20840
DESCRIPTION
SPINDLE R8
SPINDLE DIRT SHIELD
BEARING 7207CTYNSULP4
BEARING SPACER-SMALL
BEARING SPACER-LARGE
NOSE-PIECE
SLEEVE
BEARING-6206ZZ
BEARING LOCKWASHERØ 30
SPINDLE BEARING LOCK NUT- Ø30-20N
STRAIGHT LOWER CLAMP
FELT OIL STRAINER
STRAINER UPPER CLAMP
SCREW-PH-HD-M5-0.8X8L
BEARING SPACER SET
Figure 133
Spindle Assembly
P/N: 20836
i00705-K2-K3
Qty
1
1
1 SET
1
1
1
1
1
1
1
1
1
1
2
1
209
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 134
K2/K3 Base Machine P/N 20785
Parts List – K2 & K3 Base Machine (reference only)
210
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
P/N
C01
C02
C04
C06
C07
C08
C09
C10
C13
C14
C15
C16
C17
C18
C19
C23
C31
C32
C33
C37
C38
C39
C40
C41
C42
26
C43-K2
C43-K3
C44
C46
C47
C48
C49-K2
C49-K3
27
28
29
30
31
32
33
34
35
36
C50
C51
C53-1
C52
C54-1
37
C55-K2
C55-K3
C56
C57-1
C58-1
C59
C60
C61
C62
C64
38
39
40
41
42
43
44
45
Title
QUILL HOUSING ADJ.GEAR
RAM ADAPTER
NUT
VERTICAL ADJUSTING WORM
WORM THRUST WASHER(2REQ.)
VERTICAL ADJUSTING WORM SHAFT
WORM KEY
RAM
SOCKET CAP SCREW(2REQ.)
ROLL DOWEL PIN
ANGLE PLATE
ROUND HD DRIVE SCREW(5REQ.)
ADAPTER PIVOT PIN
CHAMFERED & HARDENED WASHER(7REQ.)
ADAPTER LOCKING BOLT(3REQ.)
TABLE 42" OR 48"
STOP PIECE T-BOLT(3REQ.)
TABLE STOP PIECE(2REQ.)
HEX NUT(3REQ.)
TABLE LOCK BOLT HANDLE
SADDLE LOCK BOLT
SADDLE LOCK PLUNGER
SOCKET HD CAP SCREW(2REQ.)
GIB ADJUSTING SCREW(3REQ.)
TABLE STOP BRACKET (not shown on drawing)
Comments
Available only in 20851
Available only in 20851
Available only in 20851
Available only in 20852
Available only in 20852
SADDLE/TABLE GIB
FELT WIPERS(4REQ.)
TABLE LOCK PLUNGER
TABLE LOCK BOLT
TABLE LOCK BOLT HANDLE
SADDLE/KNEE GIB
SADDLE KNEE WIPER PLATE(4REQ.)
OVAL HEAD SCREW(8REQ.)
LEFT HAND COLUMN WIPER HOLDER
SADDLE
KNEE WIPER FELT
KNEE/COLUMN GIB
ALLEN CAP SCREW(2REQ.)
RIGHT HAND COLUMN WIPER HOLDER
KNEE WIPER FELT
CHIP GUARDS-UPPER
CHIP GUARDS-MIDDLE
CHIP GUARDS-LOWER
KNEE
STOP SCREW
Available only in 20873
Available only in 20873
Available only in 20873
211
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
C65
C69
C71
C72
C73
C74
C75
C76
C77
C79
C80
C81
C82
C83
C84
C85
C86
C87
C88
C89
C90
C91
C92
C93
C94
C95
C96
C97
C98
C99
C102
C103
C104
C105
C118
C119
C120
C121
C122
C123
C124
C125
C126
C127
C128
C129
C130
C131-K2
C131-K3
KNEE LOCK SHAFT ASSEMBLY
KNEE LOCK PLUNGER
KNEE BINDER PLUG(PLASTIC)
DOG POINT SET SCREW
SET SCREW
JAM NUT
KEY
WASHER
BEVEL GEAR
SEALED BALL BEARING
BEARING RETAINER RING
SOCKET HEAD CAP SCREW
ELEVATING SCREW ASSEMBLY
HANDLE
ELEVATING CRANK
GEARSHAFT CLUTCH INSERT
DIAL LOCK NUT
DIAL WITH 100 GRADUATIONS
DIAL HOLDER
SOCKET HEAD CAP SCREW
BEARING RETAINING RING
GREASE SEALED BEARING
BEARING CAP
KEY
ELEVATING SHAFT FOR 12" KNEE
GREASE SEALED BEARING
BEVEL PINION
SET SCREW
COLUMN
WASHER
SOCKET HEAD CAP SCREW
PEDESTAL
ELEVATING SCREW NUT
SOCKET HEAD CAP SCREW
SPIDER
RAM LOCK STUD
RAM PINION
RAM PINION HANDLE
PLASTIC BALL
CHAMFERED HARDENED WASHER
TURRET
GIB SCREW NUT
GIB SCREW
LOCK BAR
SCREW
LOCKING BOLT
RAM PINION SCREW
Available only in 20854
Available only in 20854
RAM/TURRET GIB
212
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
94
95
96
97
98
99
100
101
20851
20852
20853
20854
20873
FC112
FC113
FC114
STOP PIECE T-BOLT ASSY
TABLE LOCK HANDLE
KNEE LOCK HANDLE & SHAFT
KNEE CRANK HANDLE ASSY
CHIP GUARD SET K2/K3
LEVELING SCREW
LEVELING NUT
LEVELING PAD
i20785
213
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 135
K4 Base Machine P/N 26900
214
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Parts List - K4 Base Machine
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
P/N
FC1
FC10
FC11
FC23
FC24
FC25
FC26
FC27
FC28
FC29
FC31
FC32
FC33
FC37
FC39
FC42
FC43
FC44
FC45
FC46
FC48
FC49
FC51
FC52
FC53
FC54
FC55
FC56
FC57
FC58
FC59
FC60
FC61
FC62
FC65
FC66
FC67
FC68
FC69
FC70
FC71
FC72
FC73
FC74
FC75
FC76
FC77
Title
QUILL HOUSING GEAR
RAM
LIFTING EYE BOLT
TABLE 50"
SADDLE BOTTOM GIB
GIB BLOCK
GIB
GIB BLOCK
SET SCREW
SET SCREW
STOP PIECE T-BOLT
TABLE STOP PIECE
HEX NUT
TABLE LOCK HANDLE
SADDLE LOCK PLUNGER
TABLE STOP BRACKET (not shown on dwg)
SADDLE/TABLE GIB
SADDLE CHIP WIPER
SADDLE CHIP WIPER PLATE
TABLE LOCK PLUNGER
TABLE LOCK BOLT HANDLE
SADDLE GIB
CAP SCREW
SADDLE
LEFT HAND COLUMN WIPER HOLDER
KNEE WIPER FELT
KNEE/COLUMN GIB
ALLEN CAP SCREW
RIGHT HAN COLUMN WIPER HOLDER
KNEE WIPER FELT
CHIP GUARDS - UPPER
CHIP GUARDS - MIDDLE
CHIP GUARD LOWER
KNEE
KNEE PLATE
CAP SCREW
GIB BLOCK
KNEE GIB
GIB BLOCK
CAP SCREW
CAP SCREW
CAP SCREW
CAP SCREW
JAM NUT
KEY
WASHER
BEVEL GEAR
215
Southwestern Industries, Inc.
Comments
Available only in 20869
Available only in 20869
Available only in 20869
Available only in 20868
Available only in 20868
Available only in 20867
Available only in 20867
Available only in 20867
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
FC78
FC79
FC80
FC82
FC83
FC85
FC86
FC87
FC88
FC89
FC90
FC91
FC92
FC93
FC94
FC95
FC96
FC97
FC98
FC102
FC103
FC104
FC105
FC112
FC113
FC114
FC115
FC118
FC119
FC120
FC121
FC122
FC123
FC124
FC125
FC126
FC127
FC128
FC129
FC130
FC131
20855
20867
20868
20869
SCREW
SEALED BALL BEARING
BEARING RETAINER RING
ELEVATING SCREW ASSY
HANDLE
GEARSHAFT CLUTCH INSERT
DIAL LOCK NUT
DIAL WITH GRADUATIONS
DIAL HOLDER
SOCKET HEAD CAP SCREW
BEARING RETAINING RING
GREASE SEALED BEARING
BEARING CAP
KEY
ELAVATING SHAFT
GREASE SEALED BEARING
BEVEL PINION
SET SCREW
COLUMN & BASE- K4
SOCKET HEAD CAP SCREW
PEDESTAL
ELEVATING SCREW NUT
SOCKET HEAD CAP SCREW
CAP SCREW
NUT
MACHINE MAT
OIL FILTER
SPIDER
RAM LOCK STUD
RAM PINION
RAM PINION HANDLE
PLASTIC BALL
CHABERED HARDENED WASHER
TURRET
GIB SCREW NUT
GIB SCREW
LOCK BAR
SCREW
LOCKING BOLT
RAM PINION SCREW
RAM/TURRET GIB
FRU-SK4-KNEE CRANK HANDLE ASSY
FRU-SK4-CHIP COVER ASSY
FRU-SK4-HANDLE & BAR LOCK ASSY
FRU-SK4 FC31,FC32,FC333
Available only in 20855
i20699
216
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 136
Transformer Option 220V &440V
P/N: 23470-220 or 23470-440
217
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Figure 137
Transformer Options 220V & 440V
P/N 23470-220 or 23470-440
218
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Transformer Options Part List
P/N 23470-220 & 23470-440
Item
3
5
5
7
12
12
13
13
-
P/N
23430-M0D
23440-220
23440-440
23454-3
24927-10
24927-5
24910-15
24910-10
Title
SAFETY SWITCH - 30A - 600VAC - MODIFIED
ENCLOSURE ASSY-TRANSFORMER OPTION-220V
ENCLOSURE ASSY-TRANSFORMER OPTION-440V
CABLE ASSY-SAFETY SWITCH/XFMR MODULE-DPM
LABEL-FUSE CHART REPLACEMENT-220V
LABEL-FUSE CHART REPLACEMENT-440V
FUSE-TIME DELAY-15 AMPS-220V
FUSE-TIME DELAY-10 AMPS-440V
i23470-220
219
Southwestern Industries, Inc.
TRAK K2, K3, K4 Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Southwestern Industries, Inc
TRAK Warranty Policy
Warranty
TRAK products are warranted to the original purchaser to be free from defects in work-manship and
materials for the following periods:
Product
New TRAK
Any EXCHANGE Unit
Warranty Period
Materials
Factory Labor
1 Year
1 Year
90 Days
90 Days
The warranty period starts on the date of the invoice to the original purchaser from Southwestern Industries,
Inc. (SWI) or their authorized distributor.
If a unit under warranty fails, it will be repaired or exchanged at our option for a properly functioning unit in
similar or better condition. Such repairs or exchanges will be made FOB Factory/Los Angeles or the location
of our nearest factory representative or authorized distributor.
Disclaimers of Warranties
•
This warranty is expressly in lieu of any other warranties, express or implied, including any implied
warranty of merchantability or fitness for a particular purpose, and of any other obligations or
liability on the part of SWI (or any producing entity, if different).
•
Warranty repairs/exchanges do not cover incidental costs such as installation, labor, freight, etc.
•
SWI is not responsible for consequential damages from use or misuse of any of its products.
•
TRAK products are precision mechanical/electromechanical measurement systems and must be
given the reasonable care that these types of instruments require:
•
Replacement of chip scrapers and wipers is the responsibility of the customer. Consequently, the
warranty does not apply if chips have been allowed to enter the mechanism.
•
Accidental damage, beyond the control of SWI, is not covered by the warranty. Thus, the warranty
does not apply if an instrument has been abused, dropped, hit, disassembled or opened.
•
Improper installation by or at the direction of the customer in such a way that the product
consequently fails, is considered to be beyond the control of the manufacturer and outside the
scope of the warranty.