Southwestern Industries TRAK TRM, DPM, DPM5, DPMS3, DPMS5, DPME2, SPORT B3, B5 Bed Mill Manual
TRAK TRM, TRAK DPM, TRAK DPM5, SPORT B3, SPORT B5, TRAK DPMS3, TRAK DPMS5, TRAK DPME2, ProtoTRAK MX2, ProtoTRAK MX3, TRAK AGE2, TRAK AGE3, ProtoTRAK M3, ProtoTRAK SM, ProtoTRAK EDGE 3. The TRAK & Sport Bed Mills are designed for versatility, accuracy, and efficiency. These machines are ideal for a variety of tasks, including milling, drilling, and tapping. The manual provides detailed instructions on how to install, maintain, troubleshoot and service your machine.
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TRAK & Sport Bed Mills
Safety, Installation, Maintenance, Service & Parts List Manual
Covering Machine Models:
• TRAK TRM
• TRAK DPM
• TRAK DPM5
• SPORT B3
• SPORT B5
• TRAK DPMS3
• TRAK DPMS5
• TRAK DPME2
Covering Non-current Control Models:
• ProtoTRAK MX2 & MX3
• TRAK AGE2 & AGE3
• ProtoTRAK M3
• ProtoTRAK SM
• ProtoTRAK EDGE 3
Southwestern Industries, Inc.
2615 Homestead Place
Rancho Dominguez, CA 90220 USA
T | 310.608.4422 | F | 310. 764.2668
Service Department: 800.367.3165
e-mail: [email protected] | [email protected] | web: southwesternindustries.com
Document: P/N 24941
Version: 012512
Safety, Installation, Maintenance, Service & Parts List Manual
Covering Machine Models:
• TRAK TRM
• TRAK DPM
• TRAK DPM5
• SPORT B3
• SPORT B5
• TRAK DPMS3
• TRAK DPMS5
• TRAK DPME2
Covering Non-current Control Models:
• ProtoTRAK MX2 & MX3
• TRAK AGE2 & AGE3
• ProtoTRAK M3
• ProtoTRAK SM
• ProtoTRAK EDGE 3
Southwestern Industries, Inc.
2615 Homestead Place
Rancho Dominguez, CA 90220 USA
T | 310.608.4422 | F | 310. 764.2668
Service Department: 800.367.3165
e-mail: [email protected] | [email protected] | web: southwesternindustries.com
Document: P/N 24941
Version: 012512
Copyright © 2011, 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
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
i
Southwestern Industries, Inc.
TRAK & Sport Bed Mills Safety, Installation, Maintenance, Service & Parts List Manual
Table of Contents
1.0 Safety
1.1 Safety Publications 1
1.2 Danger, Warning, Caution, Note Labels &
Notices as Used in this Manual
1.3 Safety Precautions
2.0 Installation
2.1 Floor Plan, Layout & Space Requirements 7
2.2 Uncrating
2.3 Shortages: Inventory Checklist
2.4 Installation Instructions & Checklist
2.5 Machine Specifications
2.6 Maximum Work Capacities
2.7 Control Hardware
2.7.1 TRAK AGE & ProtoTRAK MX
Controls
2.7.2 ProtoTRAK M3 Controls –
Sport B3 & B5
2.7.3 ProtoTRAK SM Control –
DPMS3 & DPMS5
2.7.4 ProtoTRAK Edge 3 Control –
DPME2
2.8 Lifting and/or Moving the Machine
2.9 Releasing the Head Counterweight Supports
2.10 Cleaning
2.11 Leveling: Tolerance for DPMS is .0005”/10”
2.12 Electrical Connection
2.12.1 Pendant and Wiring Diagrams
for TRM, DPM & DPM5
2.12.2 Pendant and Wiring Diagrams
for Sport B3 & B5
2.12.3 Pendant and Wiring Diagrams
for DPMS3 & DPMS5
2.12.4 Pendant and Wiring Diagrams
for DPME2 – EDGE
2.12.5 Phase Converters
2.13 Air Connection - Optional
2.14 Mounting the Display Pendant
2.15 Cable Interconnections
2.16 Lubrication
2.16.1 Way Lubrication
2.16.2 Head Lubrication TRAK Bed Mills
2.17 ProtoTRAK SMX Euclid Block Procedure
3.0 Troubleshooting by Symptom
3.1 Problems Relating to Machining Results 51
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
3.2 Problems Regarding Motion of 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
3.3 Problems Relating to Operation of Control
3.3.1 Display Blanks
3.3.2 Bad Picture on Display
3.3.3 Keyboard Lockup
3.3.4 Fault X, Y or Z
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
3.3.11 E-Stop Error
3.3.12 Limit Switch Error
3.4 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
3.5 Problems with the Machine Tool
3.5.1 Z-Axis Noisy
3.5.2 Spindle Stalls or Turns Off During
Machining
3.5.3 Spindle Motor Hums or Will
Not Run
3.5.4 Spindle Runs Backwards
3.5.5 Spindle Motor Intermittently Stops
and Starts or Does Not Operate
3.5.6 Head Noise
4.0 Diagnostics
4.1 The Machine Tool & Set-Up 69
4.1.1 The Milling Machine Checklist
4.1.2 A Special Word About X/Y/Z Gibs
4.1.3 Lubrication
4.1.4 Machining Set-Up
4.2 The Mechanical Drive Train (X, Y)
4.2.1 Ballscrew Alignment
4.3 Computer/Pendant Diagnostics
4.3.1 Diagnostic for Computer Modules
Contained in Pendant
4.3.2 Diagnostics for Computer Modules
Separate from Pendants
4.3.2 Checking Floppy Drive by
Southwestern Industries, Inc.
TRAK & Sport Bed Mills Safety, Installation, Maintenance, Service & Parts List Manual
Table of Contents
1.0 Safety
1.1 Safety Publications 1
1.2 Danger, Warning, Caution, Note Labels &
Notices as Used in this Manual
1.3 Safety Precautions
2.0 Installation
2.1 Floor Plan, Layout & Space Requirements 7
2.2 Uncrating
2.3 Shortages: Inventory Checklist
2.4 Installation Instructions & Checklist
2.5 Machine Specifications
2.6 Maximum Work Capacities
2.7 Control Hardware
2.7.1 TRAK AGE & ProtoTRAK MX
Controls
2.7.2 ProtoTRAK M3 Controls –
Sport B3 & B5
2.7.3 ProtoTRAK SM Control –
DPMS3 & DPMS5
2.7.4 ProtoTRAK Edge 3 Control –
DPME2
2.8 Lifting and/or Moving the Machine
2.9 Releasing the Head Counterweight Supports
2.10 Cleaning
2.11 Leveling: Tolerance for DPMS is .0005”/10”
2.12 Electrical Connection
2.12.1 Pendant and Wiring Diagrams
for TRM, DPM & DPM5
2.12.2 Pendant and Wiring Diagrams
for Sport B3 & B5
2.12.3 Pendant and Wiring Diagrams
for DPMS3 & DPMS5
2.12.4 Pendant and Wiring Diagrams
for DPME2 – EDGE
2.12.5 Phase Converters
2.13 Air Connection - Optional
2.14 Mounting the Display Pendant
2.15 Cable Interconnections
2.16 Lubrication
2.16.1 Way Lubrication
2.16.2 Head Lubrication TRAK Bed Mills
2.17 ProtoTRAK SMX Euclid Block Procedure
3.0 Troubleshooting by Symptom
3.1 Problems Relating to Machining Results 51
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
3.2 Problems Regarding Motion of 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
3.3 Problems Relating to Operation of Control
3.3.1 Display Blanks
3.3.2 Bad Picture on Display
3.3.3 Keyboard Lockup
3.3.4 Fault X, Y or Z
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
3.3.11 E-Stop Error
3.3.12 Limit Switch Error
3.4 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
3.5 Problems with the Machine Tool
3.5.1 Z-Axis Noisy
3.5.2 Spindle Stalls or Turns Off During
Machining
3.5.3 Spindle Motor Hums or Will
Not Run
3.5.4 Spindle Runs Backwards
3.5.5 Spindle Motor Intermittently Stops
and Starts or Does Not Operate
3.5.6 Head Noise
4.0 Diagnostics
4.1 The Machine Tool & Set-Up 69
4.1.1 The Milling Machine Checklist
4.1.2 A Special Word About X/Y/Z Gibs
4.1.3 Lubrication
4.1.4 Machining Set-Up
4.2 The Mechanical Drive Train (X, Y)
4.2.1 Ballscrew Alignment
4.3 Computer/Pendant Diagnostics
4.3.1 Diagnostic for Computer Modules
Contained in Pendant
4.3.2 Diagnostics for Computer Modules
Separate from Pendants
4.3.2 Checking Floppy Drive by
ii
Southwestern Industries, Inc.
TRAK & Sport Bed Mills Safety, Installation, Maintenance, Service & Parts List Manual
Formatting a Disk
4.4 Motor Diagnostics
4.4.1 Cable Connections
4.4.2 To Check the Motor Encoders
4.4.3 Encoder Counts to Pendant
4.4.4 Moving Problem From One Axis
to Another
4.5 Servo Drivers
4.6 Glass Scales
4.6.1 Alignment of Scales
4.6.2 Measurements Do Not Repeat
4.7 TRAK Sensors
4.7.1 Faulting Axis
4.7.2 Measurements Do Not Repeat
4.8 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
4.9 External Connector Box
4.10 Red LED Diagnostic Status Indicators
4.11 Service Codes
4.11.1 CODE 11: Hysteresis
4.11.2 Code 12: Feed Forward Constant
4.11.3 Code 33: Software ID
4.11.4 Code 97: System Axis
Configuration
4.11.5 Code 100: Axis Open Loop Test
4.11.6 Code 101: X-Axis Motor Encoder
Test
4.11.7 Code 102: Y-Axis Motor Encoder
Test
4.11.8 Code 103: Z-Axis Motor Encoder
Test
4.11.9 Code 123: Calibration
4.11.10 Code 127 - Set X or Y Backlash
Constant
4.11.11 Code 128: Input Backlash
Constant
4.11.12 Code 129: Arc Accuracy
4.11.13 Code 314: Toggle Test Lights
‘On’ in Status Line SM only
4.11.14 Code 319: Error Log – SM only
5.0 Procedures for Replacements
& Maintenance
5.1 Replacements 96
5.1.1 Servo Motor Replacement
5.1.2 Servo Driver Replacement
5.1.3 Computer Module
5.1.4 System Flash Disk Replacement
5.1.5 Cable Routing on Machine
5.1.6 TRAK Sensor Replacement
5.1.7 Glass Scale Replacement
5.1.8 Power Drawbar
5.1.9 Ball Screw Replacement, X-Axis
(Table), DPMSX2
5.1.10 Ball Screw Replacement, Y-Axis
(Saddle), DPMSX2
5.1.11 Z-Axis Screw Removal &
Replacement
5.1.12 Air Solenoid Replacement for Power
Drawbar – DPMS3/DPMS5 only
5.1.13 Spindle Motor Wiring
5.1.14 Electric Box Service
5.1.15 Auxiliary Function Interface
5.1.16 Feed Trip Adjustmemt
5.1.17 Quill Clock Spring Replacement &
Adjustment
5.1.18 Spindle Motor Removal &
Replacement
5.1.19 Drive Belt Replacement
5.1.20 Timing Belt Replacement
5.1.21 Brake Shoe Replacement
5.1.22 Spindle Replacement
5.2 Maintenance
5.2.1 Gib Adjustments
5.2.2 Calibration & Backlash Constants
5.2.3 Head Rotation and Tramming
5.2.4 Limit Switch Option
5.2.5 Accuracy and Repeatability
Measurements
6.0 Figures & Parts List
2-1 Machine Footprints
2-2 Overall Dimensions
2-3 TRAK & Sport Bed Mills Component
Identification
2-4 TRAK & Sport Bed Mill Rear View
2-5 Lifting the Machine, Method 1
2-6 Lifting the Machine, Method 2
2-7 Placement of Levels
2-8 Leveling Screws
2-9 Pendant Drawer – AGE2/3 & MX2/3
2-10 Computer Cabinet – AGE3 & MX3
Connections – DMP & DPM5
2-11 AGE2 / MX2 Computer Cabinet
-- TRM
2-12 TRM Wiring (P/N 16042) for 1995
and Earlier
2-13 Electrical Box Connections – DPM
& DPM5
2-14 Wiring Diagram – DPM & DPM5
2-14 (continued)
2-15 M3 Pendant Display Basic
Configuration – Sport B3 & B5
2-16 Wiring the Sport B3 & B5
2-17 Sport B3 & B5 – Electric Box
Connections
2-18 Schematic Standard Electric Box –
Sport B3 & B5
2-19 Pendant Cable Connections – SM
2-20 Pendant – SM
2-21 Wiring the DPMS3 & DPMS5
2-22 Edge 3 Pendant Rear – DPME2
2-23 Electrical Box without Transformer –
DPME2
2-24 Electrical Schematic – DPEM2
Southwestern Industries, Inc.
TRAK & Sport Bed Mills Safety, Installation, Maintenance, Service & Parts List Manual
Formatting a Disk
4.4 Motor Diagnostics
4.4.1 Cable Connections
4.4.2 To Check the Motor Encoders
4.4.3 Encoder Counts to Pendant
4.4.4 Moving Problem From One Axis
to Another
4.5 Servo Drivers
4.6 Glass Scales
4.6.1 Alignment of Scales
4.6.2 Measurements Do Not Repeat
4.7 TRAK Sensors
4.7.1 Faulting Axis
4.7.2 Measurements Do Not Repeat
4.8 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
4.9 External Connector Box
4.10 Red LED Diagnostic Status Indicators
4.11 Service Codes
4.11.1 CODE 11: Hysteresis
4.11.2 Code 12: Feed Forward Constant
4.11.3 Code 33: Software ID
4.11.4 Code 97: System Axis
Configuration
4.11.5 Code 100: Axis Open Loop Test
4.11.6 Code 101: X-Axis Motor Encoder
Test
4.11.7 Code 102: Y-Axis Motor Encoder
Test
4.11.8 Code 103: Z-Axis Motor Encoder
Test
4.11.9 Code 123: Calibration
4.11.10 Code 127 - Set X or Y Backlash
Constant
4.11.11 Code 128: Input Backlash
Constant
4.11.12 Code 129: Arc Accuracy
4.11.13 Code 314: Toggle Test Lights
‘On’ in Status Line SM only
4.11.14 Code 319: Error Log – SM only
5.0 Procedures for Replacements
& Maintenance
5.1 Replacements 96
5.1.1 Servo Motor Replacement
5.1.2 Servo Driver Replacement
5.1.3 Computer Module
5.1.4 System Flash Disk Replacement
5.1.5 Cable Routing on Machine
5.1.6 TRAK Sensor Replacement
5.1.7 Glass Scale Replacement
5.1.8 Power Drawbar
5.1.9 Ball Screw Replacement, X-Axis
(Table), DPMSX2
5.1.10 Ball Screw Replacement, Y-Axis
(Saddle), DPMSX2
5.1.11 Z-Axis Screw Removal &
Replacement
5.1.12 Air Solenoid Replacement for Power
Drawbar – DPMS3/DPMS5 only
5.1.13 Spindle Motor Wiring
5.1.14 Electric Box Service
5.1.15 Auxiliary Function Interface
5.1.16 Feed Trip Adjustmemt
5.1.17 Quill Clock Spring Replacement &
Adjustment
5.1.18 Spindle Motor Removal &
Replacement
5.1.19 Drive Belt Replacement
5.1.20 Timing Belt Replacement
5.1.21 Brake Shoe Replacement
5.1.22 Spindle Replacement
5.2 Maintenance
5.2.1 Gib Adjustments
5.2.2 Calibration & Backlash Constants
5.2.3 Head Rotation and Tramming
5.2.4 Limit Switch Option
5.2.5 Accuracy and Repeatability
Measurements
6.0 Figures & Parts List
2-1 Machine Footprints
2-2 Overall Dimensions
2-3 TRAK & Sport Bed Mills Component
Identification
2-4 TRAK & Sport Bed Mill Rear View
2-5 Lifting the Machine, Method 1
2-6 Lifting the Machine, Method 2
2-7 Placement of Levels
2-8 Leveling Screws
2-9 Pendant Drawer – AGE2/3 & MX2/3
2-10 Computer Cabinet – AGE3 & MX3
Connections – DMP & DPM5
2-11 AGE2 / MX2 Computer Cabinet
-- TRM
2-12 TRM Wiring (P/N 16042) for 1995
and Earlier
2-13 Electrical Box Connections – DPM
& DPM5
2-14 Wiring Diagram – DPM & DPM5
2-14 (continued)
2-15 M3 Pendant Display Basic
Configuration – Sport B3 & B5
2-16 Wiring the Sport B3 & B5
2-17 Sport B3 & B5 – Electric Box
Connections
2-18 Schematic Standard Electric Box –
Sport B3 & B5
2-19 Pendant Cable Connections – SM
2-20 Pendant – SM
2-21 Wiring the DPMS3 & DPMS5
2-22 Edge 3 Pendant Rear – DPME2
2-23 Electrical Box without Transformer –
DPME2
2-24 Electrical Schematic – DPEM2
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Key Features
- Versatile
- Accurate
- Efficient
- Milling
- Drilling
- Tapping
- Modular Design
- Closed-loop Feedback
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Frequently Answers and Questions
What is the difference between the TRAK and Sport Bed Mills?
The TRAK and Sport Bed Mills are both designed for versatility, accuracy, and efficiency. The main difference between the two is that the TRAK models are equipped with a closed-loop feedback system, while the Sport models are not. This means that the TRAK models are able to achieve a higher level of accuracy and repeatability. The Sport models are still very capable machines, but they are not as accurate as the TRAK models. The manual provides detailed instructions on how to install, maintain, troubleshoot and service your machine.
What kind of control models are covered in this manual?
This manual covers both current and non-current control models. The current control models include the TRAK TRM, TRAK DPM, TRAK DPM5, SPORT B3, SPORT B5, TRAK DPMS3, TRAK DPMS5, and TRAK DPME2. The non-current control models include the ProtoTRAK MX2 & MX3, TRAK AGE2 & AGE3, ProtoTRAK M3, ProtoTRAK SM, and ProtoTRAK EDGE 3. The manual provides detailed instructions on how to install, maintain, troubleshoot and service your machine.
What are the maximum work capacities of the TRAK & Sport Bed Mills?
The maximum work capacities of the TRAK & Sport Bed Mills are dependent on a lot of variables that cannot be controlled by the machine manufacturer. The manual provides detailed instructions on how to install, maintain, troubleshoot and service your machine.
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