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Service Manual for Non-Current Knee Mill Products

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1. 12 13 i23470 220 242 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Southwestern Industries Inc TRAK Warrantv Policv Warrantv TRAK products are warranted to the original purchaser to be free from defects in work manship and materials for the following periods Product Warranty Period Materials Factory Labor E New 1 Year 1 Year TRAK ProtoTRAK Any EXCHANGE Unit 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 product subsystem or component 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 e 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 e Warranty repairs exchanges do not cover incidental costs such as installation labor freight etc e SWlis not responsible for consequential damages from use or misus
2. Item P N Title Qty 1 FB57 FEED WORM SHAFT 1 2 FB44 FEED WORM SHAFT BUSHING 1 3 FB47 FEED WORM SHAFT THRUST WASHER 1 4 FB43 WORM 1 5 FB59 PIN 3x12L 1 6 FB49 FEED REVERSE BEVEL GEAR 1 7 FB48 BUSHING 1 8 FB62 KEY 3x3x15L 1 9 FB50 FEED REVERSE CLUTCH 1 10 FB50 1 PIN 3x19L 1 11 FB55 REVERSE CLUTCH ROD 1 12 FB52 BUSHING 1 13 FB51 FEED REVERSE BEVEL GEAR 1 120698 5 208 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual i20698 5 Figure 115 8 Parts List Shown Spindle Assembly K4 P N 20836 1 Mme 7 I Item P N Title Qty 1 FB127 SPINDLE BT 40 1 2 FB133 NOSE PIECE 1 3 FB134 SPINDLE DIRT SHIELD 1 4 20839 BEARING ANGULAR CONTACT U SET 2 7010 P4 1 5 FB136 BEARING SPACER LARGE 1 6 FB137 BEARING SPACER SMALL 1 7 FB139 SPINDLE BEARING KNOCK NUT 1 8 FB139 1 SET SCREW M8 P1 25x6L 2 10 26392 BEARING DEEP GROOVE 6008ZZ 1 11 FB143 LOCK RING 40 1 12 FB140 SPINDLE FIXED NUT 2 13 FB141 COLLET ALIGNMENT SCREW M8 P1 25x20L 2 14 20841 BEARING SPACER SET 1 120836 1 209 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 118 Upper Head Assy K2 K3 P N 24679 210 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts Lis
3. 2 Washer Bellville 1 Note 1 Four different hex head bolts are provided to match the 1 15896 PendantCap 11 machine 1 2 13x6 5 8 11x6 3 4 10x6 M20 2 5x150 1 16738 JPendatam 12 Note 2 Four different washers are provided to match the bolt 1 16920 CableCiamp 13 used 3 1 10 32x1 1 2 SHCS o 14 Figure 2 27 amp Parts List Shown Pendant Arm Assembly 45 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual L PN DESCRIPTIO PIN 21842 PENDANT ARM PTA li 158966 JPENDANTCUP 100 16919 PLATELEVELING fi 1 4 20X3 4 258 SCREW SET CUP PT SIL 80 f 218477 PLATE CABLE CLAMP Ji 10 12 13X6 24P SCREW HEX HD STL PLAIN 1 12 13 4 10X6 24P SCREW HEX HO STL PLAIN 13 M20 25 150 24P PLA WASHER FLAT USS _15 570P J WASHER FLATUSS 3 47 a470P TWASHER FLAT USS 18 21965 WASHER BELLVILLE 9712K93 18 J3 16x180P PIN DOWEL STL BO SCREW HEX HD SIL BO NUT JAM NYLON LOCK NAMEPLATE EDGE SERIAL NUMBER SCREW DRIVE SS A Se B I 2000 z U e LE tu Note 1 Four different hex head bolts are provided to match the machine 1 2 13x6 5 8 1 1x6 3 4 10x6 M20 2 5x150 Note 2 Four different washers are provided to match the boll used Figure 2 28 amp Parts List Shown Pendant Arm Installation 2 22 Cable Interconnections SM All cable i
4. 71 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service 8 Parts List Do the following service codes and procedures e Code 304 Toggle X sensor glass scale on off SM CNC only e Code 305 Toggle Y sensor glass scale on off SM CNC only Possible Cause Check This Machine Tool 8 Setup problem 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 8 Setup Section 4 1 X and Y Gibs are loose Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures TRAK Sensor or Glass Scale problem Make sure that the Sensor or Glass Scale is installed correctiv 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 correctiv Use service codes 304 for X and 305 for Y to turn off the suspect encoder Does problem still exist after turning it off Possible Cause Check This Check Repeatability using the Repeatability and X and Y axis Drive Trains are loose Encoder Disk or Reader Head on motor are loose Spindle and or Ouill are loose 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 Mech
5. L R E zx n T mi mi t ay 53 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 2 25 Lubrication CAUTIONI Failure to properlv lubricate the mill will result in the premature failure of bearings and sliding surfaces 2 25 1 Manual Lubrication The TRAK mill X amp Y way surfaces and ball screws need to be manually lubricated The Manual Lube automatically discharges about 4ml of oil every plunge 1 Atthe 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 SAE 30 or 30W oil or eguivalent way lube oil 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 54 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Figure 2 36 K2 K3 K4 Knee Mill Lubrication ay 4 F l E 8X3 2 LEFT KNEE SQUARE WAY N CEN 8 CE i Bi 2 E Q T dpi Lk oO e e O o BED NO HE 5 Ti o GI o 6 b ELEVATING SCREWNUT a AQ LEFT COLUMN SL
6. Saddle moves toward the front of the machine e Zaxis Quill moves up Do the following service code and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 97 Move each axis in positive direction MX and AGE e Code 313 Check the line that specifies the product e Code 321 322 325 Reverse position of sensor of X Y or Z axis SM Model If the product does not match the machine then the machine ID key will need to be replaced 73 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List 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 Check This Machine Tool and Setup problem Check the tvpe of material being cut tvpe and size of cutting tool RPM and Feed rate Also check the condition of the cutter to verifv that the cutter is not dull See Machine Tool amp Setup Section 4 1 Drive Belt in the head is slipping Check the alignment condition and tension of the Drive Belt Cut more than the machine is capable Check width and depth of cut 3 5 2 Spindle Motor Hums or Will Not Run The spindle motor makes a constant humming noise during operation or will not turn on If the spindle will not run you must make sure 110 V power is reaching the spindle motor c
7. lt va 100432 18 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2 9 AGE2 AGE3 Pendant Back Panel ON OFF 8 Amp Slo Blo Fuse Logic Cable to 115V AC Power In Computer Cabinet Ground Stud 19 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Figure 2 10 AGE2 AGE3 Computer Cabinet Right Side Program Storage Floppy Disk Drive Cable Logic to Pendant Auxiliary Function Connection A G E 3 Only Parallel Port osition Encoders TRAK Sensors Limit Switches Motor Connectors 115V AC Power From Pendant E Stop 2 13 ProtoTRAK M2 and M3 Control Hardware e Digital Servo Amplifiers custom designed for ProtoTRAK operation e D C Servo Motors for the X and Y axes rated at 280 in oz e Ball screws in the table saddle and column ensure smooth accurate contours without backlash e Closed loop Feedback utilizing 000036 resolution motor encoders e Modular Design simplified service and maximizes uptime 20 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual e Feedrate Override of programmed feedrate and rapid e Polycarbonate Sealed Membrane Keypad and Gasket Sealed Control e Enclosures to lock out contamination e 9 CRT for clear presentation of prompts stat
8. 156 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 20 amp Parts List Shown Edge Retrofit Pendant Arm Installation NO pm DESGRIPTION jar 21842 PENDANT ARM PT4 1588622 JPENDANT CUF 4 21 56 18 572 NUTJAMNVLON TOC 22 21934 __ NAMEPLATE EDGE SERIAL NUMBER 23 4x35344 SCREW DRIVE 157 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Note 1 Four different hex head bolts are provided to match th machine 1 2 13x6 5 8 11x6 3 4 10x6 M20 2 5x150 Note 2 Four different washers are provided to match the boll used ENE Prepare the assembly as shown in Figure 7 13 Insert the two bellville washers Item 16 opposing each other Thev should create a hollow portion between the washers Tighten the nut to set tension on the arm The arm should rotate freelv with some resistance 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 Install the cap Install the cable clamp and cable cover 7 3 2 Installation of the Pendant Displav 1 2 3 Fasten the pendant onto the pendant arm using 4 14 20 x1 SHCS
9. 225 Southwestern Industries Inc TRAK K2 K3 K4 SMX Retrofit Safety nstallation Maintenance Service amp Parts List Manual Parts List K2 K3 Lower Head Housing Assv Figure 127 87 20779 3 SUB ASSV QUILL PINION SHAFT R8 1 88 K B167 FRU K3 KEY 5x5x25L 1 89 K B27 1 FRU K3 SET SCREW M6 P1 0x8L 1 90 K B41 FRU K3 NEEDLE BEARING BA66 BEARING SIZE KO BA66Z 1 91 K B192 FRU K3 QUILL HOUSING 1 92 K B104 FRU K3 TRIP HANDLE 1 93 K B105 FRU K3 BLACK PLASTIC BALL 2 94 K B125 1 FRU K3 HANDWHEEL SPRING PIN 3x3x10L 1 95 K B125 FRU K3 HANDWHEEL 1 96 K B111 FRU K3 REVERSE KNOB 1 97 K B100 FRU K3 CAP SET SCREW M5 PO 8x35L 1 98 25042 SCALE HEAD ROTATION R8 1 99 25043 POINTER SCALE 1 100 25044 DRIVE SCREW SCALE 4 101 20835 FRU SK2 SK3 HANDWHEEL ASSY 1 102 20834 FRU SK2 SK3 FEED REVERSE KNOB ASSY 1 103 24052 TRIP HANDLE ASSEMBLY INCLUDES PLASTIC BALL 1 104 20832 FRU SK2 SK3 FEED TRIP ASSY 1 105 20847 QUILL MICRO NUT 8 SCREW ASSY 1 106 24051 CLOCK SPRING ASSEMBLY SPRING 8 COVER 1 107 20849 FRU SK2 SK3 FEED HANDLE ASSY QUILL HANDLE 1 108 20843 FRU SK2 SK3 QUILL LOCK SLEVE ASSY 1 109 K B142 FRU K3 QUILL 1 110 K B150 1 STRAIGHT LOWER CLAMP 1 111 K B151 FELT OIL STRAINER 1 112 K B150 2 STRAINER UPPER CLAMP 1 113 K B139 SCREW PH HD M5 0 8X8L 2 114 M5 0 8X5 40B SCREW SOC SET STL BO CUP 1 120779 226 Southwestern Industries
10. Step 3 Check for repeatability of measurement by setting zero on both indicator and display traversing away and then returning to the zero point on the indicator If the measurement on the display does not return to 0 repeat the process a few times e If the measurement error accumulates in a regular predictable way the M5 mounting base is not parallel to the travel of the axis e fthe error is not regular i e random then there is something wrong with the set up Step 4 If the measurement repeats touch off one end of the gage block and set zero on the indicator and at the display Note the axis being calibrated should read Absolute measurement Step 5 Go into the special code for calibration e MODE SET UP e SPECIAL CODE 123 Follow the instructions in the conversation line of the display for each sensor 184 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 8 6 All Machines Retrofits System Calibration SPINDLE USE SHONTEST POSSIBLE DIAL ROD DIAL INDICATOR ZERO REFERENCE MACHINE TABLE MACHINE FRAME 100022 185 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 9 0 Introduction to Self Service The objective of this section of the manual is to allow the user of the ProtoTRAK SM to resolve
11. o NOTE The customer is responsible for hooking up the 220 440V to the mill Air No air is required BED FOOT PRINT Space amp Weight e Floor area 101 x 66 e Height 84 e Footprint 24 x 38 29 1 37 4 e Net Weight 2200 lb Shipping Weight 2500 Ib The floor area encompasses the space required for the table to move full travel in both directions plus a 22 clearance 21 9 from the rear ofthe bed This space at 224 2 the rear will be required in case it is necessary to make repairs to the electrical cabinet o A solid and level foundation to maintain approximately 2200 Ib plus the weight of Figure 2 3 the workpiece maximum total 2950 Ib TRAK K2 is required Four leveling screws are provided 10 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 2 5 Site Preparation Trak K3 Electrical e 115 VAC 60 Hz 8 AMP 1 Phase e 220 VAC 60 Hz 8 5 AMP 3 Phase OR e 440 VAC 60 Hz 4 25AMP 3 Phase A separate 115 VAC circuit with a 15 AMP breaker originating at the main power panel for shop electrical service and dedicated to the sole use of the K3 is required to maintain proper operation Machine tool must be earth grounded Standard 3 prong 115V wall socket is required in addition to the 220 440 VAC line o m NOTE The customer is responsible for hooking up u_u the 220 440V to the mill Ai
12. 38 VS56 FRU K3 BRAKE LOCK HANDLE 1 39 VS57 FRU K3 BAKELITE BALL HANDLE 1 40 OIL 1 FRU K3 OIL CUP 1 42 VS52 1 FRU K3 NUT 1 43 20819 SPINDLE MOTOR ASSV K2 8 K3 3HP 1 44 VS130 FRU K3 WASHER FLAT 10 2 4 45 VS111 FRU K3 SOC HD SCREW 3 8 16NCx32L 4 211 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 119 8 Parts List Shown K2 K3 Gear Housing Assy P N 20778 1 FRU K3 GEAR HOUSING FRU K3 GUIDE SPRING FRU K3 SPRING GUIDE PIN 212 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 120 K2 K3 Hi Low Shift Clutch Assy P N 20778 2 i20778 2 213 Southwestern Industries Inc TRAK K2 K3 K4 SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 High Low Shift Clutch Assy P N 20778 2 Figure 120 Item P N Title Qty 1 VS75 FRU K3 BEARING SLEEVE 1 2 VS77 FRU K3 BALL BEARING 2 REQ 6908ZZ 2 3 VS78 FRU K3 BEARING SPACER 1 4 VS79 FRU K3 BEARING SPACER 1 5 VS80 FRU K3 SNAP RING R 65 1 6 VS73 FRU K3 SPLINED GEAR HUB 1 7 VS72 FRU K3 KEY 8x7x10L 1 8 VS74 FRU K3 SPINDLE BULL GEAR 1 9 VS114 FRU K3 WASHER 1 10 VS115 FRU K3 EXTERNAL TOOTH WASHER 40 1 11 VS81 FRU K3 LOCK WASHER 9 16 18NC 1 12 VS76 FRU K3 RING 1 13 20817 BEARING SPA
13. Install the cable cover to the pendant arm as shown in Figure 7 13 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 2 27 for a description of cable routing Install the machine ID key to the LPT port on the pendant The key can be found in the hardware kit see Figure 2 27 7 4 Cable Breakout Box Mounting SM model 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 2 16 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 7 14 1 Check the tram of the head in the X direction If it is within a few thousandths then continue on If not tram Mount the upper mounting bracket looselv to the upper mounting surface of the head with a 10 32 cap screw Mount the lower mounting bracket looselv to the lower mounting surface of the head with a 10 32 cap screw Caution Do not dri
14. K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 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 e Problems with machine motion e 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 A value of 6 08 would still be considered normal
15. KEY 46 FC76 WASHER 47 FC77 BEVEL GEAR 238 Southwestern Industries Inc TRAK K2 K3 K4 SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K4 Base Machine Assy Figure 135 48 FC78 SCREW 49 FC79 SEALED BALL BEARING 50 FC80 BEARING RETAINER RING 51 FC82 ELEVATING SCREW ASSY 52 FC83 HANDLE Available only in 20855 53 FC85 GEARSHAFT CLUTCH INSERT 54 FC86 DIAL LOCK NUT 55 FC87 DIAL WITH GRADUATIONS 56 FC88 DIAL HOLDER 57 FC89 SOCKET HEAD CAP SCREW 58 FC90 BEARING RETAINING RING 59 FC91 GREASE SEALED BEARING 60 FC92 BEARING CAP 61 FC93 KEY 62 FC94 ELAVATING SHAFT 63 FC95 GREASE SEALED BEARING 64 FC96 JBEVEL PINION 65 FC97 SET SCREW 66 FC98 COLUMN 8 BASE K4 67 FC102 JSOCKET HEAD CAP SCREW 68 FC103 JPEDESTAL 69 FC104 ELEVATING SCREW NUT 70 FC105 JSOCKET HEAD CAP SCREW 71 FC112 JCAP SCREW 72 FC113 JNUT 73 FC114 MACHINE MAT 74 FC115 OIL FILTER 75 FC118 SPIDER 76 FC119 JRAM LOCK STUD 77 FC120 JRAM PINION 78 FC121 JRAM PINION HANDLE 79 FC122 JPLASTIC BALL 80 FC123 JCHABERED HARDENED WASHER 81 FC124 TURRET 82 FC125 JGIB SCREW NUT 83 FC126 JGIB SCREW 84 FC127 JLOCK BAR 85 FC128 JSCREW 86 FC129 JLOCKING BOLT 87 FC130 RAM PINION SCREW 88 FC131 RAM TURRET GIB 89 20855 FRU SK4 KNEE C
16. Maintenance 10X 24 Service amp Parts List Manual 100912 Parts List EDGE M2 M3 amp SM Retrofits V Drive Train Figure 5 13 Title EAL BEARING HOUSING 6983 1 90 5M 15 10 m 12 156272 13 l l UJ 7 COR IRIN Rll N a eoo Ww oO UT NU e WIN m 14 17 18 19 20 23 WASHER 1 4 HARD BLK OX 1 8 THK 24 16 32X3 6 108 10 1 l 6 25 SHEET METAL PT4 COOLANT MOTOR COVER ASSY 1 i 9 15 16 21 22 26 27 1073B 30 31 147722 SPACER 020 THICK Item 3 E E NNI L5 1 E 9 10 Hoy 12 13 14 15 16 EE 18 19 20 21 22 23 24 25 26 27 30 100912 117 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 1 11 Air Solenoid Replacement Auxiliary Function Machines Only 1 2 3 4 Unhook the air from the machine Unplug the power cable that connects to the right side of the air regulator bracket Remove the 2 screws that hold the connector to the bracket Undo the airline that runs from the oiler to the power drawbar if that option is installed on the machine Remove the 2 screws on the left side of the bracket that holds the air manifold to the U shaped bracket With the assembiv in hand unthread the solenoid from the rear of the air regulator The solenoid and cable will be replaced as a unit See F
17. OSHA Publication Number 3067 Available from The Publication Office O S H A U S Department of Labor 200 Constitution Avenue NW Washington DC 20210 1 2 Danger Warning Caution and Note Labels amp 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 cou d 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 that cou d 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 TRAK Knee Mill amp Sport Knee Mill Safety Installation Maintenance Service amp Parts List Manual NOTICE The manufacture is not liable responsible for anv damages or injurv of anv kind to persons or property caused by or resulting from the improper or unauthorized use operation maintenance alteration modification change in configuration of this machine or anv of its component parts or the use of this unit with anv third partv accessories or parts 100775 Safety amp 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 the
18. TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Parts List Enclosure Assv Transformer Option 23440 220 amp 23440 440 Figure 2 22 Item P N Title Qty 1 21258 TRANSFORMER 1000VA El ak 4 23434 SOCKET RELAY 1 5 23435 RELAY POWER 100 120 VAC DPDT 1 6 23436 CONTACTOR 4 POLE 2 7 23437 MECHANICAL INTERLOCK 1 8 23438 3 RELAY OVERLOAD 220V TO 440V CONVERSION 1 11 22199 1 RECEPTACLE PANEL MOUNT NEMA STD 15A 125V 4 13 21871 CONNECTOR 4 POSITION SIZE 11 1 14 23297 1 CONNECTOR RECEPTACLE 7 POSITION SHELL SIZE 13 1 16 21820 FUSE HOLDER 2 17 21824 5 FUSE 3AG SLOW BLOW 1 18 21830 12 FUSE TYPE 3AB 12A SLO BLO 1 19 22868 TERMINAL BLOCK 4 20 22869 END PLATE al 22 21753 3 GROUND BAR 6 HOLE 1 23 21901 150 MOV V150LA20B 5 24 23036 FUSE HOLDER 32 AMP 690V 2 25 23153 6 FUSE 600 VAC TIME DELAV CLASS CC 6A 220V 5 23153 3 FUSE 600 VAC TIME DELAY CLASS CC 3A 440V 26 22303 16G WIRE BUSS 16 GA AWG 12 STRAIGHT 12 25 39 23440 1 220 SCH ENCLOSURE ASSY TRANSFORMER OPTION SCH 1 40 22557 1 TERMINAL BLOCK 6mm BLOCK 3 41 24299 3 TERMINAL BLOCK RAIL END STOP GROUND 2 42 22571 8 125 RAIL DIN 8 13 45 23429 nde EE TRANSFORMER 1 92 22016 TERMI NAL MALE FEMALE 1 i23440 1 220 C amp 23440 440 F 38 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2
19. Tooling Using the wrong cutter for an application Excessive speeds and feeds can break cutting tools or wear tools prematurely Poor finish Entering the wrong size diameter and Parts incorrect size programming with tool compensation Cutting too deep Part dimensions incorrect Driving and cutting forces cause deflections since no material is totally rigid Machine chatter No coolant Poor finish decrease the life of the cutter 71 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 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
20. 1 51 VS109 DRAWBAR R8 MANUAL 1 52 VS109 1 FRU K3 SPACER 1 53 K B191 FRU K3 BLACK PLASTIC BALL HANDLES 1 54 K B190 FRU K3 PINION SHAFT HUB HANDLE 1 55 K B148 FRU K3 QUILL LOCK SLEEVE 1 56 K B148 1 FRU K3 COMPRESSION SPRING 1 57 K B153 FRU K3 QUILL LOCK SLEEVE TAPPED 1 58 KB 201 FRU K3 INDICATOR ROD SCREW 1 59 K B149 FRU K3 LOCK HANDLE 1 60 KB 202 FRU K3 INDICATOR ROD 1 61 K B164 FRU K3 QUILL STOP MICRO SCREW 1 62 K B160 FRU K3 SNAP RING 16 1 63 K B124 2 FRU K3 FEED TRIP PLUNGER NUT M40 P0 7 2 64 K B124 1 FRU K3 FEED TRIP PLUNGER SOC SET SCREW M4 P0 7x20L 1 65 K B145 FRU K3 FEED TRIP LEVER 1 66 K B124 FRU K3 FEED TRIP PLUNGER 1 67 K B185 FRU K3 REVERSE TRIP BALL LEVER SCREW 1 68 K B144 FRU K3 SOCKET SET SCREW 1 69 K B183 FRU K3 REVERSE TRIP BALL LEVER 1 70 K B161 FRU K3 QUILL MICRO STOP NUT 1 71 K B162 FRU K3 MICROMETER NUT 1 72 K B123 FRU K3 TRIP PLUNGER BUSHING 1 73 K B184 FRU K3 FEED REVERSE TRIP PLUNGER 1 74 K B121 FRU K3 TRIP PLUNGER 1 75 K B120 FRU K3 COMPRESSION SPRING 1 76 K B158 FRU K3 CHEM BLACKED RD HD SCREWS 2 REQ M5 P0 8x8L 2 77 K B118 FRU K3 CAM ROD SLEEVE ASSY 1 78 K B159 FRU K3 MICROMETER SCALE 1 79 KB 200 FRU K3 SCREW SOC HD 3 8 24NFx15L 1 80 K B163 FRU K3 QUILL STOP KNOB 1 81 20779 5 FEED REVERSE CLUTCH ASSY 1 82 OIL 1 FRU K3 OIL CUP 1 83 K B109 FRU K3 KEY 3x3x20L 1 84 K B17 1 FRU K3 WORM GEAR SET SCREW M6 P1 0x8L 1 85 K B88 1 FRU K3 COMPRESSION SPRING 1 86 K B89 FRU K3 OVERLOAD CLUTCH LEVER SPRING PLUNGER 1
21. 23 Transformer Option Schematic AC NEUTRAL 9 919 9 0 9 iD visa wa 1 41 HH G Ut Vi WA m o 0 0 Dia GA 101128 REAR VIEW OF SWITCH CONTACTS 39 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 2 21 Mounting the Displav Pendant The ProtoTRAK SM display pendant mounts to the pendant arm with four 1 4 20 x 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 40 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Figure 2 24 SM Control Pendant Arm Assembly 41 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Parts List SM Control Pendant Arm Assembly Figure 2 24 Item P N Title Qty 2 15896 PENDANT CUP 1 3 16797 RAM SUPPORT MACHINED 1 4 16738 PENDANT ARM MACHINED M2 B5 SK2 1 5 20695 PLUG SPORT E STOP 1 6 16919 PLATE LEVELING 1 4
22. 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 Note The Euclid block program is available for all controllers Figure 2 37 K2 K3 K4 Euclid Block 250 250 250 100763 57 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual 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 fullv described in an explanatorv 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 verv rough Do the following Service Codes and document values e Code 33 Software Identification This is needed if you call SWI Customer Service e Code11 Measures backlash in the system Only used on Dual Feedback systems e Code 12 Feed Forward Constant e Code 127 Measures backlash in the system not used on Dual Feedback systems e Code 128 Enter backlash compensation Possible Cause Check This Too much backlash entered for code Verify nothing is mechanically loose and the backlash 128 or calculated with code 11 values are not higher than what physically is in the system Machine Tool amp Setup problem Check for any looseness in
23. CHANGE HOUSING 1 2 FVS20 BUSHING SELF LUBRICATING 1 3 FVS22 SPEED CHANGER GEAR 1 4 FVS31 SPEED CHANGE CHAIN DRUM 1 5 FVS21 WORM 1 7 FVS25 SPEED CHANGE SHAFT 1 8 FVS40 ROLL PIN 3x15L 2 9 FVS24 COPPER BUSHING 2 10 FVS32 CHAIN 3109 525 1 11 FVS31 1 DOWEL PIN 3x25L 1 12 FVS30 SPEED CHANGE STUD 1 13 FVS27 SPEED CHANGE HANDWHEEL 1 14 FVS18 FULL DOG SOCKET SET SCREW M6 P1 0x10L 1 15 FVS28 HANDLE 3 8 16NC 1 16 VS24 1 FRU K3 WASHER WAVE 1 17 FVS16 1 VARI SPEED DIAL 1 18 FVS16 2 NAME PLATE 1 19 FVS95 NUT ACORN 5 16 18NC 1 20 FVS19 DRIVE SCREW 4 21 M5 0 8X14 40B SCREW SOC SET STL BO CUP 1 22 M5 0 8X5 40B SCREW SOC SET STL BO CUP 1 i20697 7 198 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 108 8 Parts List Shown K4 Spindle Motor Assy P N 20820 120820 Item P N Title Qtv 1 FVS110 MOTOR 5 HP 1 2 FVS3 1 KEY 6x6x45L 1 3 FVS2 STATIONARY MOTOR VARIDISC 1 4 FVS6 BUSHING l 5 FVS5 ADJUSTABLE MOTOR VARIDISC 1 6 FVS6 1 KEY 7x7x50L 1 7 FVS8 SPRING FOR VARIDISC MOTOR SHAFT 1 8 FVS9 ADJUSTABLE VARIDISC SPRING COLLAR 1 9 FVS10 SCREW SOC HD CAP M8 P1 25x30L 1 10 24054 ADJUSTABLE MOTOR VARIDISC ASSY 1 120820 199 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 109 K4 Lower Head Housing Assy P
24. 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 Doaseries 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 0000 7 Loosen the three bolts and adjust the tram with the bolt mounted on the top of the ram 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 table must droop down rather than up because tool pressure will take care of the extra 0 0005 130 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 5 2 4 Limit Switch Option 5 2 4 1 Xaxis Limit Switch Stop Installation and Adjustment The limit switch stops for the X axis are mounted to the front side of the table The limit switch stop consists of a square bracket which is fastened to the T slot on the front side of the table Each limit switch stop must be set to a specific distance from the end of the table in order to maximize
25. Ib e 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 5 12 for an illustration of the Y axis drive train 113 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 5 12 MX2 MX3 AGE2 AGE3 Retrofits Y Drive Train L 114 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List MX2 MX3 AGE2 AGE3 Retrofits Y Drive Train Figure 5 12 ITEM Q 1 1 11 15617 1 14 1 17 1 18 1 19 2 S 1 EB 0 20195 2 LIP CLUTCH 125 IN LBS 1 5613 NUT CLAMP 23 15836 DIAL NUT 1 24 15616 1 HANDWHEEL 1 1 l 1 2 27 32 35 41 Bii X2 1 2 SCREW SOC HD CAP BLK OX 4 44 10 32 x 3 4 SCREW SOC HD CAP BLK OX 4 45 1 4 20x1 SCREW HEXHED 4 49 91079A033 NUT JAM ZINC PLATE 1 2 20 1 51 1 4 DIA 15759 WASHER FLAT 4 53 3 8 DIA WASHER FLAT 4 80 24X6X6 CARTON CARDBOARD 11 NIN ui B amp B Wire 115 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 5 13 EDGE M2 M3 amp SM Retrofits Y Drive Train 116 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation
26. Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 128 8 Parts List Shown K2 K3 Worm Gear Cradle Assy P N 20779 1 3 K808 FRU K3 FEEDDRIVEWORMGEAR 1 4 K B05 FRU K3 WORMCRADLEBUSHING 1 5 K BOA FRU K3 FEEDWORMGEARSHAFTSLEEVE 1 6 K 809 FRU K3 FEED DRIVEWORMGEARSHAFT 1 7 Keit FRUKS KEY3XSOSL 1 8 KBIO FRU K3 WORMSHAFTKEY3x3x8 1 9 803 FRU KS FEEDBEVELPINION 1 10 K B02 FRU K3 BEVELPINIONWASHERG5 1 11 K BOL FRU K3 SOCHD SCREW M5 PO Sx10L 1 12 K B36 FRU K3 FEEDDRIVINGGEAR 1 13 K B361 FRU K3 KEY3x3x8L 1 14 K B15 FRU K3 FEEDREVERSEBEVELGEAR 1 15 KBI3 FRUKSWASHER G22OD 1 16 K B14 FRU K3 SOCHDSCREWM6 P1 0x15L_ 1 17 K B37 FRU K3 KEY3x3x10L 1 18 K B40 FRU K3 FEEDDRIVEGEAR 1 19 K B16 FRUK3 EEDENGAGEPIN 1 20 k B06 FRUKS SETSCREWM PLOxXGL 1 i20779 1 rlrlIrjrjrlrjriribjbjrjrljrjrIjrjrIE H 227 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 129 8 Parts List Shown K2 K3 Quill Feed Selector Assy P N 20779 2 NL 207793 1 k B66 FRU K3 CLUSTERGEARCOVER 2 K B64 FRU K3 CLUSTERGEARSHAFTCRANK 3 I B70 JI FRU K3 SHIFTCRANK 4 Kk B69 FRU K
27. Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service 8 Parts List 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 Possible Cause Check This 3 Phase wires backwards Need to switch anv 2 of the 3 wires either coming into the machine or motor Caution Be sure to shut off all power to the machine before attempting to switch anv wires 3 5 4 Head Noise Head noise pertains to anv 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 Possible Cause Check This Machine setup or tooling problem 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 guestions Is the cutter dull Is the tool loose in the holder Am taking a bigger cut then is possible on the machine Is the part moving in the vice Am using realistic speeds and feeds Any one ofthese can have a
28. N 20698 200 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 120698 Parts List K4 Lower Head Housing Assv Figure 109 Item P N Title Qtv 1 FB192 QUILL HOUSING 1 2 FB31 CLUSTER GEAR SHAFT 1 3 FB33 BEVEL GEAR BEARING 1 4 FB94 SNAP RING 95 DOWEL PIN 14 1 5 FB29 CLUSTER GEAR KEY 3x3x45L 1 6 FB28 CLUSTER GEARS ASSEMBLY 1 7 FB41 NEEDLE BEARING KO BA66Z 1 8 FB27 CLUSTER GEAR SHAFT UPPER BEARING 1 9 20698 1 FRU SK4 4VK H1 WORM GEAR CRADLE SUB ASSY 1 10 FB19 SHIFT SLEEVE 1 11 FB18 WORM GEAR CRADLE THROW OUT 1 12 FB20 CAP SCREW M5 P0 8x12L 3 13 FB24 STEEL BALL 1 14 FB25 A SPRING 1 15 FB23 SHIFT CRANK 1 16 FB68 SET SCREW M6 P1 0x8L 1 17 20698 2 QUILL FEED SELECTOR ASSY 1 18 FB67 CAP SCREW M6 P1 0x18L 4 19 FB186 WORM GEAR 1 20 FB189 ADJ WORM SHAFT 1 21 FB187 KEY 4x4x18L 1 22 20698 3 QUILL PINION SHAFT ASSY 40 TAPER 1 23 FB178 CLOCK SPRING CLOCK SPRING ASSY 1 24 FB177 SPRING COVER 1 25 M8 1 25X20 25B SCREW SHCS STL BO 2 26 FB176 PINION SHAFT HUB SLEEVE 1 27 FB171 KEY 3x3x20L 1 28 FB89 OVERLOAD CLUTCH LEVER SPRING PLUNGER 1 29 FB88 COMPRESSION SPRING 1 30 FB88 1 INTERNAL COMPRESSION SPRING 1 31 20698 4 OVERLOAD CLUTCH TRIP ASSY 1 32 FB99 CLUTCH ARM COVER 1 33 FB73 CAP SCREW M5 P0 8x40L 2 34 FB100 SOCKET SET SCREW M6 P1 0
29. On SMproducts do not equate Code 12 values to torque on ball screw 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 Axis Open Loop Test Code 100 procedure is used to diagnose problems with the configuration of the system the encoders and incoming A C voltage IMPORTANT SAFETY NOTICE 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 guill 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 90 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual Center the table and saddle and raise the head Make sure the gib loc
30. Parts List Do the following service code and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service Possible Cause Check This Bad 110VAC Coolant or solenoid Check if the fuse light indicator next to the plug is lit receptacle fuse Verifv that the fuses are good or bad bv checking the resistance of the fuses using an Ohmmeter Poor cable connections 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 Faulty Indexer connector Check for continuity between pins 3 and 4 when the output of the Haas Indexer connector is activated Bad cable breakout box 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 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 If power does not reach the cable breakout box then none of these functions will work 110V Power reaches the electrical box through the AC E stop cable It is used to energize the spindle motor contactor If this contac
31. SPACER 1 4 FVS79 BEARING SPACER 1 5 FVS80 SNAP RING R 75 1 6 FVS73 SPLINED GEAR HUB 1 7 FVS72 KEY 8x7x10L 1 8 FVS74 SPINDLE BULL GEAR 1 9 FVS114 WASHER 1 10 FVS115 EXTERNAL TOOTH WASHER 50 1 11 FVS81 LOCK WASHER 50 18NC 1 12 FVS76 RING 1 13 20818 BEARING SPACER 1 120697 2 191 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 103 8 Parts List K4 Hi Low Shift Assy P N 20697 3 Item P N Title Qtv 1 FVS89 HI LOW DETENT PLATE 1 2 FVS87 CLUTCH GEAR SHAFT 1 3 FVS92 HI LOW PINION BLOCK 1 4 FVS91 SPRING 1 5 FVS90 HI LOW DETENT PLUNGER 1 6 FVS94 HI LOW SHAFT CRANK 1 7 FVS57 BAKELITE BALL HANDLE 1 8 FVS88 PIN 319 9 FVS92 1 SET SCREW M5 PO 8x6L 1 10 FVS93 SCREW SOC HD M5 PO 8x15L 2 11 FVS116 WASHER FLAT 6 1 12 FVS12 SOCKET CAP SCREW M6 P1 0x15L 1 13 24083 HI LOW SHAFT ASSEMBLY 1 120697 3 192 Southwestern Industries Inc TRAK K2 K3 K4 SMX Retrofit Safety nstallation Maintenance Service amp Parts List Manual i20697 3 Figure 104 8 Parts List Shown K4 Pulley Pinion Assy P N 20697 4 i20697 4 Item P N Title Qty 1 FVS67 BULL GEAR PINION COUNTER SHAFT 1 2 FVS69 KEY 5518L 1 3 FVS66 BULL GEAR PINION 1 4 AK118 BEARING DEEP GROOVE 6203ZZ 2 5 FVS3 SOCKET SET SCREW M6 P1 0x6L 1 6 23954 BEARING DEE
32. Service amp Parts List Manual Machine Shipping Specifications K2 K3 K4 Weight approximate net 2200 Ibs 2800 Ibs 3600 Ibs Weight approximate shipping 2500 Ibs 3100 Ibs 3900 Ibs Pallet Size 6 x 6 6 x 6 6 x 6 A Overall width 101 101 101 B Overall length 66 70 72 C Base width 24 2 24 2 24 D Width between leveling screws 219 21 97 22 8 E Distance between leveling screws 29 1 29 7 33 1 F Base length 37 4 38 8 42 5 See site preparation guide Southwestern Industries Inc 7 TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Figure 2 2 K2 K3 K4 Overall Dimensions 8 Side to Side Head Rotation RNA A jie ANSA T G A OK Si Ni 4 i Y Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Overall Dimensions Table Size 10 x 50 10 x 50 T Slots number x width x depth 5 8 x 3 x 2 1 2 5 8 x 3 x 2 1 2 5 8 x 3 x 2 1 2 Dimension A 85 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 tool
33. System Reboots by Itself During operation the screen suddenly blanks and then shows that the system has begun the boot up sequence Possible Cause Check This Interruption of 110 V power to pendant Using a Voltmeter check the incoming 110VAC to the pendant Poor wiring and cable connections Check for any loose wiring or cables Computer Pendant failed See Computer Pendant diagnostics Section 4 3 68 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service 8 Parts List 3 3 8 Svstem Shuts Off During operation the svstem shuts off and will not turn back on Possible Cause Check This Fuse blown in pendant Remove fuse and check continuit Poor wiring and cable connections 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 Flash disk failure Remove and reseat the flash disk Computer Pendant has failed See Computer Pendant diagnostics Section 4 3 3 3 9 Will Not Hold Calibration SM Oniv 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 The calibration values are written in Hexadecimal Recalibrate the svstem and see if the values change Turn the svstem off and on and see if the values are held Do the following service codes and procedures
34. VS39 FRU K3 SPEED CHANGE PLATE PIVOT STUD 1 9 VS41 FRU K3 WASHER Q 8 2 1 10 VS40 FRU K3 ROLL PIN 3x15L 2 11 VS35 FRU K3 ADJUSTMENT NUT 1 12 VS34 FRU K3 CHAIN END STUD 1 13 VS33 FRU K3 CHAIN FRONT SCREW M4 P0 7x5L 1 14 VS7 FRU K3 SNAP RING 35 1 15 FVS96 JAM NUT 3 8 16NC 1 16 24564 BEARING HOUSING ASS Y K2 K3 1 17 24631 VARIDISC ASSY ADJUSTABLE 1 i20778 6 220 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 125 8 Parts List Shown K2 K3 Speed Change Handwheel P N 20778 7 WORM 09 8 vso JROLPNOSdS 2 9 vem COPPERBUSHING 2 10 vsert WASHERWAVE 1 ti ve SPEEDCHANGEHANDWHEEL 7 SPEED DIAL lt NIN M5 0 8X5 40B SCREW SOC SET STL BO CUP 120778 7 221 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 126 8 Parts List Shown K2 K3 Spindle Motor P N 20819 o i20819 Item P N Title Qty 1 VS110 FRU K3 MOTOR 3 HP 1 2 VS3 1 FRU K3 KEV 6x6x45L 1 3 VS2 FRU K3 STATIONARY MOTOR VARIDISC 1 4 VS6 FRU K3 BUSHING 1 5 VS5 FRU K3 ADJUSTABLE MOTOR VARIDISC ASSY 1 6 VS6 1 FRU K3 KEY 7x7x50L 1 7 VS8 FRU K3 SPRING FOR VARIDISC MOTOR SHAFT 1 8 VS9 FRU K3 ADJUSTABLE VARIDISC SPRING COLLAR 1 9 VS10 FRU K3 SCREW SOC HD CA
35. complete listing of the cable connections to the back of the pendant enclosure Figure 7 38 Edge Pendant Display Back View Configuration 1 AMP FUSE 8 AMP FUSE X AXIS MOTOR ENCODER COMPUTER SERVO MOTORS CONNECTOR SYSTEM OPTIONAL REMOTE STOP GO E SWITCH POWERIN CONNECTOR GROUND STUD BEEPER BOLTS TO FLOPPY 8 PENDANT ARM DRIVE d DISPLAV WILL DOOR 5 SWIVEL TO i CHANGE VIEWING ANGLE OPTIONAL Z SCALE CONNECTOR E STOP FACTORY OPTIONAL II RA EURO MODEL ONLY TESTPORT EN SE PENDANT DISPLAY BACK 100664 177 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 8 0 Z Motor Ball Screw Assembly Note This section is for the installation of ProtoTRAK SM 3 axis controls only Note Tram the head before beginning this procedure 8 1 Installation of the Base Plate Figure 8 1 SM3 Retrofit Base Plate Installation 100920 For the microfeed assembly remove in this order 1 D E 2 F G H 3 J 4 KL 1 Removethe mill head assemblies indicated in Figure 5 9 Caution After the quill stop knob is removed take care that the quill is not allowed to Kit Variation For Lagun mills substantial modification of the mill is required See Appendix 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 178 Southwestern In
36. e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 313 Configuration Values e Code 123 Calibration Mode Possible Cause Check This Configuration file corrupt Load default configuration by going to code 313 Not saving Calibration values Replace Computer Pendant module See Computer Pendant If calibration factors are being saved but the measurements are not repeating or are not accurate e See Measurements Are Not Repeating e 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 On the SM CNC 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 69 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp
37. 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 atthe 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 power connects to the machine through the electrical box located on the back ofthe column The power cable enters the black box through a hole on the top of the box 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 See Section 5 1 12 Figure 5 14 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 2 19 1 Phase Converters For those machines that will be run wit
38. 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 e When loosening make sure to back out the 10 32 screw from the clamp nut e 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 Ibs 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 t
39. following Service Codes and procedures e Code 81 SM only press each key on the pendant The screen will display a keypad that signifies if a key is working The pendant will also beep e Logic Cable Test MX2 3 and AGE2 3 models only The Logic Cable Test is used for the diagnosis of problems with the pendant and or computer module Follow these steps then call back to the Service Department with the results of the following steps if your problem is not solved 7 Adjust the brightness knob on the back of the pendant making sure it is not turned all the way down 8 Check both fuses on the pendant and in the computer module making sure they are not blown 9 If there is a remote stop go switch RSG attached to the system remove it Then reboot the system by turning it off waiting 30 45 seconds then turning it back on This step may correct your problem If your problem persists after completing step 3 continue to step 4 10 Locate the cable on the back of the display pendant labeled Cable Logic it is a 32 pin computer cable held in by two thumbscrews 11 With the power to the system turned on remove this cable and you should see nine 9 clearly defined evenly spaced amber horizontal bars on a black background Also every key should beep as you press it 12 If vou do not get the nine 9 horizontal bars and the kevs do not beep then turn the svstem off leaving the cable removed from the svstem after 30 45 secon
40. in contact with the part Check the direction or of movement of the table saddle and quill when using the jog or power feed Don t use dull or damaged cutting tools They break easily and become airborne Inspect the sharpness of the edges the integrity of cutting tools and their holders Use proper length for the tool Large overhang on cutting tools when not reguired result in accidents and damaged parts Handwheels must have the crank folded inside when using CNC programmed machining or rapid feeds power feed or jog 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 Prevent fires Keep flammable materials and fluids away from the machine and hot flying chips 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 5 Southwestern Industries Inc TRAK Knee Mill amp Sport Knee Mill Safety Installation Maintenance Service amp Parts List Manual 2 0 Installation Read and understand this entire installation section before beginning the installation procedure 2 1 Floor Plan Layout amp Space requirements Figure 2 1 K2 K3 K4 Machine Footprints BED FOOTPRINT san JIT Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance
41. installations may not be wear surfaces hooked up or line sheared Poor finish Inadequate lubrication habits Premature wear of ball screws New installations more motion than wear surfaces the machinist is used to with a Poor finish manual mill Lubricate machine every before use machine never tighten the gib locks X and Y gibs loose Taper on straight Y moves When machine hasn t been serviced See Gib Adjustment Section 5 2 1 Poor finish in a long while Circle out of round repeat axis faults Poor finish Gibs floating Not getting to position does not Contact area of gibs May need to repeat axis faults be scraped Very old machines may Poor finish not have any more adjustments on gib A new gib will need to be fit on the machine Gibs defective bowed scarred Excess play when gib is checked Inadequate gib contact side to side Way surfaces pocked scarred or Poor finish Inadequate lubrication excessively worn Out of round circles Faulting Machine not level Parts incorrect New installation or heavy crash Weight not distributed evenly on all Machine geometry off i e tram six screws See Leveling procedures Head out of tram Leaves uneven surfaces on Machine not level See Tramming Head Section 5 2 3 bottom of pockets 76 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 4 1 2 A Special Word About X amp V Gibs The slidewav
42. it in place 2 Remove the quill handle hub bv removing Screw A and kev 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 kev 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 6 Tilt the motor forward and remove the belt from the motor pullev Remove the 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 5 17 K2 K3 K4 Spindle Motor 100155 120 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 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
43. machine Within Sections 6 0 7 0 and 8 0 it mav 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 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 sguare Bubble level Crescent wrench 10 Torque wrench up to 60 ft Ibs 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 X Acto knife with flat blade 3 4 2 flute end mill Safety glasses 132 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 6 3 Suggested Fastener Stock It is suggested that the ProtoTRAK installer have on hand the following fasteners in th
44. 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 mav not work with this device 105 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 5 8 K2 K3 K4 Power Drawbar Assembly 106 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual Parts List K2 K3 k4 Power Drawbar Assembly Figure 5 8 2 22380 1 or AIR REGULATOR ASSY 2 with solenoid 23888 SPACER DRAWBAR 40 TAPER SPINDLE 22581 2 SWITCH CONTROL HEAD TORQUE RITE 22581 4 NOSEPIECE FOR SPINDLE 40 taper heads only t 4 NPT AIR FITTING 90 8 80 D TUBING 132 LG 3 80 D TUBING 27 LG E cH DRAWBAR NMTB 40 TAPER 22641 CAT DRAWBAR CAT 40 TAPER SOCKET AIR GUN REPLACEMENT TR220 not shown on drawing i00875 1 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 Position the table in the center of travel Remove the left side table tray by pulling it up and remove the X motor Remove the motor mounting bracket and bearing housing Remove the right side bearing housing aa etd GHA Loosen the table gibs Slide the table to the right and
45. not always 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 This particular example was done on a machine with motor encoders only 82 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Swap these components Results Physically switch the X and Y Has problem moved to Y axis If yes replace motor If no motors the motor is not the problem Note motors are always replaced with the servo driver 4 5 Servo Driver Note the Servo Driver is located in the black box on the side of each motor Indications e Problems moving just one axis including hard turning in one direction Servo Types e Xand Y servos are identical Objective e 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 probl
46. properlv could cause the same problems as mentioned above Mount vour 0 001 indicator on the saddle and move the V axis back and forth along its travel e 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 5 6 in Section 5 for an illustration of the Z glass scales 4 6 2 Measurements Do Not Repeat 1 Determine if the error in repeatabilitv 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 awav approximatelv 6 inches Return the touch off again Write down the reading on the DRO Do not Re zero the DRO traverse awav 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 roughiv 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 rigiditv Common sources of random error include e Loose scale mounting hardware e Loose reader head e Very loose motion of the table or saddle 3 Accumulating error is commonly the result of e Scale out of parallel to the axis travel e Dirt or chip on the glass scale e Broken gla
47. reference point 100010 Figure 7 6 Knee Mill Retrofits X Axis Ballscrew 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 reguired e Yoke kit already opened e V Axis drive assembly 23083 xx e Y Axis ball screw Figure 7 7 Knee Mill Retrofits Y Axis Ballscrew Overall Length Maximum Y Travel ELBOW OIL 24 00 FITTING 3900 o ro e DERE 29 00 17 10 32 SET SCREW HERE Wa FLAT TO CLEAR KNEE BEVEL GEAR 100673 CAUTION Unlike a leadscrew never unscrew a ball screw from its nut This will destroy the ball screw 138 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 16 18
48. significant impact Possible Cause Check This Upper spindle bearing is worn out Remove the upper bearing plate above the spindle This will unload the bearing If the noise goes away then this bearing should be replaced Verify nosepiece is tight on bottom To check ifthe nosepiece is bottomed out try to insert a piece of spindle 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 Spindle bearings are worn out 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 75 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service 8 Parts List 4 0 Diagnostics This section explains the diagnostic procedures used to isolate service problems 4 1 The Machine Tool amp 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 Can Contribute To Most Suspect When and why Spindle bearings Noisy head Older machines machines that are See Spindle Replacement Parts incorrect pushed hard Circles out of round Lubrication system Premature wear of ball screws New
49. speed steel sharp e Coolant Flood coolant Cool Tool or Kerosene 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 SM flash drive it 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 5 Load the 750 end mill and set Z Absolute 0 at the top of the part 56 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 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 seguence 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 e X 1 318 e Y 1 318
50. 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 95 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual Figure 5 1 Servo Driver 124101 5 5 1 3 Computer Module Replacement SM Model Sov o Ce en Turn power off to the machine and control Unplug all the connectors on the pendant arm side of the pendant Remove 4 screws on the right side of the unit and 2 screws on the left side of the unit The module is now free to slide toward the right side of the pendant Slide the computer module a few inches and stop Pulling the computer module too far will damage the LCD cable Now reach from the pendant arm side of the unit inside and remove the 37 pin LCD cable Now slide the module about way out of the pendant sheet metal Remove the ground stud from the side of the computer module Next remove the 37 and 9 pin connectors from the top of the computer module Lastly slide the unit completely out of the sheet metal 10 Follow the instructions in reverse order when reinstalling the new computer module 11 Make sure the connectors are fully seated before bolting the unit back in place Note if the flash drive is functional you may want to remove the flash disk and install it in the new flash drive 96 Southwestern Industries Inc TR
51. the majority of potential service problems This manual assumes that the user is not experienced with CNC troubleshooting and repairs Special tools are not reguired 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 There are 3 forms at the back of the manual that are to be used to order parts or reguest service The 3 forms are labeled as follows e F10210 1 Parts Order Form this form is to be used for parts not requiring an exchange part e F10210 5 Service Parts Order Form this form is to be used to order parts that are to be returned Please fill out the entire sheet we need this information to fix the problem when the part arrives back e F10210 4 Service Request Form this form is to be used when service is being requested Please contact Southwestern Industries if you need additional copies of these forms Be sure to request the form by number Your next step is to contact the SWI Customer Service Group for assistance 9 1 1 Communication with the SWI Customer Service Group e SWI Service Department Direct Line 800 367 3165 e Web Address www southwesternindustries com This phone line ring
52. 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 SM Model 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 e Umbilical 1 and 2 at the cable breakout box e Umbilical 1 and 2 at the pendant e 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
53. 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 amp Setup Section 4 1 Never use gib locks with a CNC machine Inadequate or no Lubrication to Make sure all the Way surfaces are getting proper Ballscrews and Way surfaces 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 X Y and knee Gibs are not adjusted Check the adjustment of the X and Y gibs See X and Y properl Gib Adjustments in Section 5 2 1 X amp Y axis Drive Trains are loose 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 Way surfaces are pocked scarred or Visually check the condition of all the Way surfaces For excessively worn 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 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 58 Southwestern In
54. toward table using 10 32 x 34 shcs washer and acorn nut 4 Slide t nuts to hold stops into front t slots on the table 5 Mount stops to t nuts using 5 16 18 x shcs and washers 6 Route the cable to the right to allow full forward travel of saddle and full travel of knee Attach to machine with 3 8 jiffy clamp 7 8 3 Limit Switch Cable Connections l 2 3 Use the clamps in the kit to tie the X and Y cables to the machine Before mounting make sure all the cables can reach their destinations Plug the limit switch cables into the cable breakout box 167 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual Figure 7 28 X and Y Axis Limit Switch Machine Mounting CONNECTION BOX X AXIS TO Y AXIS PENDANT Z AXIS ROUTE CABLE TO BACK OF COLUMN TO JUNCTION BOX USE CABLE CLAMPS TO FASTEN TO MACHINE USE T SLOT IN TABLE TO MOUNT STOP 100677 Figure 7 29 X amp Y Axis Limit Switch Assemblies 10 32X3 4 SHCS 10 32X3 4 SHCS 10 32X1 2 SHCS 10 FLAT WASHER 10 FLAT WASHER 10 FLAT WASHER 10 ACORN NUT 10 LOCK WASHER X AXIS LIMIT SWITCH COVER BRKT SADDLE 10 32X3 4 SHCS 10 FLAT WASHER 10 ACORN NUT XAXIS NE XK LIMIT LR 5 16 18X3 4 SHCS SWITCH 5 16 FLAT WASHER x 5 16 LOCK WASHER 10 32X3 4 SHCS FRONT se N MOUNTING SADDLE BRACKET X AXIS SIDE VIEW Y AXIS SIDE VIEW 168
55. 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 limit switch 1 Loosen the X axis square bracket on each side of the table Slide each X axis square bracket within the T slot to the end of the table 2 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 1 2 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 100 ipm 5 Using the DRO display back the table off 1 2 6 Lock thelimit switch bracket in place 7 Jog the table at 100ipm to each side and verify that the limit switch is working properlv Also make sure that the table does not exceed its travel and crash 5 2 4 2 Y axis Limit Switch 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 The cam is placed to ensure maximum travel 131 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 6 0 Retrofit Installation This section of the manual is intended to provide step bv step instructions for installing a ProtoTRAK 2 or 3 axis control on a vertical knee milling
56. x 1 34 screws The flat of the ballnut flange should match up with the flat on the voke These flats are there so that the voke and ballnut will clear the bevel gear Check that these clear now bv pushing the saddle back If the voke provided in the kit does not clear the bevel gear it will be necessarv 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 voke trim it appropriatelv 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 CAUTIONI 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 voke use the supplied brass fitting and the original restrictor 139 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual Figure 7 8 SM AGE2 3 Edge M2 M3 Retrofits Y Axis Drive Train 140 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List SM AGE2 AGE
57. 0 115200 4 9 1 3 CODE 141 Load Configuration file from floppv A drive This code allows vou to load vour configuration file from the floppv disk to vour 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 4 CODE 142 Save Configuration file to floppy A drive This code allows you to save your configuration file to a floppy disk 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 electrics cabinet 4 9 1 5 CODE 313 Display Configuration File SM Model 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 enc
58. 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 Z axis 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 Z only applies to 3 axis retrofits 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 13 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 26 3 axis machines only If machine has an auxiliary function option use the accessory key on pendant and make sure the coolant pump or solenoid for the mister fires The accessorv kev 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 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 prope
59. 16 HANDWHEELASSYMX Oo 1 8 612 HOUSING BEARING 120 1585 RING BEANNGHOUSNG 10 SPACER 100 THICK l 832x3 8258 SCREWSHCSSTLOO 60 45 M10 1 5X6525B SCREW SHCS STLBO 1 1 1 1 1 4 as W 20Xl248 SCREWHEXHD SILBO O O 7 48 10 32233 4258 SCREW SHCSSTLBO 120 a9 w 20517 NULHEXJAMSTLZNC O 2 54 MI070p WASHER FLAT USS STLPLAIN 4 100911 Install the left end assembly items as shown in Figure 7 11 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 V socket head cap screws Slide the table to the right and secure the drive housing bracket to the bearing housing per Figure 7 11 Install the rest of the items of Figure 7 11 and tighten 32 20 nut to 50 ft Ib 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 33 20 nut on the right of the ball screw and use this to turn the ball screw 146 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 38 Install the original machine right side assembly and the SWI provided handwheel as per Figure 7 11 Tighten 32 20 nut to 50 ft Ib If the machine had a power feed use the hardware from the left side Note if the ball screw reguir
60. 16920 CLAMP CABLE 1 9 1 4 20X3 4 40B SCREW SOC SET STL BO CUP 4 10 10 32X1 1 4 25B JSCREW SHCS STL BO 1 11 1 2 13X6 24P SCREW HEX HD STL PLAIN 1 16 9712K93 WASHER BELLEVILLE 2 17 3 16X3 4 80P__ PIN DOWEL STL PLAIN 4 18 5 8 71P WASHER FLAT SAE STL PLAIN 2 19 1 4 20X3 4 25B__ SCREW SHCS STL BO 3 22 5 8 18 57Z NUT NYLON LOCK J AM STL ZINC 1 27 1 4 20X5 8 25B SCREW SHCS STL BO 1 28 23139 SHEETMETAL COVER PENDANT ARM 1 29 10 32X3 8 31B SCREW PH PHIL EXT SEMS STL BO 2 30 21934 NAMEPLATE EDGE S N 1 31 4 x 3 8 34 SCREW DRIVE 2 i00893 42 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Figure 2 25 amp Parts List Shown MX2 MX3 AGE2 AGE3 Rear View of Pendant Display Pendant Arm Assembly 43 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Figure 2 26 8 Parts List Shown MX 2 3 AGE2 AGE3 Pendant Arm Assembly Rounded Ram e g Bridgeport Series Mill 44 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Part No Description tem _1_ seenotebelow Bolt Hex Head 1 1 see note below Washer Flat aa 1 Ram Support 3 Bracket 1 4 20x3 4 Screw Set Cup 4 Pendant Arm Leveling Plate 5 Assembly 11 5 8 18x8 172 2 58 Washer 4
61. 2 e Footprint 24 x 43 e Net Weight 3630 Ib 33 1 42 5 Shipping Weight 3950 Ib The floor area encompasses the space required for the table to move full travel in both directions plus a 22 clearance from the rear of the bed This space at 22 8 24 the rear will be required in case it is necessary to make repairs to the electrical cabinet A solid and level foundation to maintain approximately 3630 Ib plus the weight of the workpiece maximum total 4480 Ib is reguired Four leveling screws are provided Figure 2 5 TRAK K4 12 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual 2 7 Installation Instructions amp Checklist Installer Use this checklist to assure a complete set up of the K2 K3 K4 or 2 or 3 axis retrofit 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 6 Make and check all the proper electrical connections from the pendant to the electric box See the pendant and electric box wiring 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 nea
62. 2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Accumulating error will add roughiv the same amount to the reading after each traverse See Step 3 2 Forrandom error look for problems in the set up of the TRAK Sensor that have resulted in a loss of rigiditv Common sources of random error include e broken base e broken bracket e loose puller screws e loose run bar e very loose motion of the table or saddle e loose clamp screw 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 e 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 e Use a bubble level or an indicator to adjust the puller screws so that the base is parallel to the running surface e Inspect that the sensor is not cocked so that the case contacts the running surface e 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 e Use a Voltmeter reading A C volts e 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 i
63. 3 Edge M2 M3 Retrofits V Axis Drive Train Figure 7 8 item P N we aw 4 15980 BEARING HOUSING Jf 6 20623 MOTOR BRACKET KNEE MILLS 40 DEGR 1 8 i6350 JFERRULESPROCKETU 1 9 890 5M I5 BELT TIMING 5MM POWERGRIP Y AXIS 1 19 10 32X3 4 258 SCREW SHCS STL BO 4 M10 1 5X65 SCREW SHCS STL BO E 25B 21 23082 WASHER 7SX39AXi10STL 4 22 M 20X1248 SCREW HEXHD STLBO 4 23 15759 WASHER IAHARDBLKOXi BTHK 4 SPACER 020 THICK 100912 21 Place the bearing housing on a flat surface and install the following as shown below Figure 7 9 Knee Mill Retrofits Bearing Housing Figure 7 10 Y Axis Drive Train Models MX2 3 AGE2 3 Retrofits Bearing E mu contact bearing item E item 16 inner race thick side facing up 100674 141 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 10 MX2 3 AGE2 AGE3 Retrofits Y Axis Drive Train VERNIER DIAL 25 6 142 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service 8 Parts List Manual 12025 4 XX Parts List MX2 MX3 AGE2 AGE3 Retrofits Y Axis Drive Train Figure 7 10 ITEM P N DESCRIPTION QTY 18 49 i56 sa BEARING II 20 20195 2 SLIP CLUTCH 125 IN LBS 1 35 prn 4772 5 SPACER 16 X2 SCREW SOC HD C
64. 3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual e Enter this value into service code 128 e 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 motor encoders only 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 rotate the head side to side 1 Loosen the four locknuts 2 Rotate the head with the adjusting worm shaft 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 figure 5 25 and a parallel bar to square the head to the table 5 2 3 2 Tramming 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 Alignment 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 Adjust the Y axis so that the spindle is in the center of the table Adjust the Z r
65. 3 SPRING 3X20 NG 6 IN 1 2 3 5 K B68 FRU K3 GEAR SHIFT PLUNGER 7 8 K B63 FRU K3 FEEDGEARSHIFTFORK 9 kees FRU KS SHAFT DRIVE SCREW SCALE K B72 FRU K3 SHIFT KNOB 5 16 18NC i20779 2 228 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 130 8 Parts List Shown K2 K3 Ouill Pinion Shaft Assy P N 20779 3 Item P N Title UseAs Qtv 1 K B166 QUILL PINION SHAFT EA 1 2 25706 BUSHING KIT PINION SHAFT R8 EA 1 3 K B91 WASHER EA 1 4 K B92 OVERLOAD CLUTCH WORM GEAR EA 1 5 K B93 OVERLOAD CLUTCH RING EA 1 6 K B92 1 SCREW SOC HD CAP M4 P0 7x15L EA 3 7 K B94 SNAP RING 95 DOWEL PIN 14 EA 1 8 K B168 JSCREW PIN EA 1 TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 229 Southwestern Industries I nc i20779 3 Figure 131 8 Parts List Shown K2 K3 Overload Clutch Trip Assy P N 20779 4 20779 4 Title Qtv 3 K B80 FRU K3 OVERLOADCLUTCH 1 4 k B79 FRU KS SAFETVCLUTCHSPRING 1 5 K B78 FRU K3 OVERLOADCLUTCHLOCKNUT 1 ejeje 6 K B76 FRU K3 SOCKET SET SCREW M6 P1 0x8L 1 l K B75 FRU K3 CLUTCH RING pa n 8 K B97 FRU K3 OVERLOAD CLUTCH WASHER 9 K B9 FRUKSSNAPRINGO10 FRU K3 BRASS PLUG i20779 4 230 Southwestern Industries Inc TRAK K2 K3 KA S
66. 5 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 e Xaxis there are 3 components that can cause misalignment the yoke the left side bearing housing bracket and the right side bearing housing e 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 Y axis ball screw bore is machined perpendicular to the X bore If the X axis is aligned the Y axis will also be aligned e Leftside 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 e Right side table bearing housing once again move the bearing housing as close to the yoke as possible Loosen the be
67. 59 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List The svstem will respond to being pushed out of position bv making an adjustment at the end of the move An unwanted tapered cut is the result of looseness in the svstem Do the following Service Codes and document values e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 11 Measure s the backlash in the system Only used on machines with Dual Feedback svstems e Code12 Feed Forward Constant e Code 127 Measure s the backlash in the system Only used on machines with no Dual Feedback e Code 128 Enter backlash compensation Check for any looseness in the setup Tool Tool holder Part Vise or Fixture See Machine Tool amp 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 X and Y axis Drive Trains are loose 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 e Circles 0 002 TIR over 3 00 DIA e Positional Accuracy 0 0005
68. 9 SHIFT KNOB 1 5 FB71 SPRING 1 6 FB70 STEEL BALL 1 7 FB68 SET SCREW M6 P1 0x8L 1 8 FB63 FEED GEAR SHIFT FORK 1 9 FB60 FEED SHIFT ROD 1 10 FB61 KP SET SCREW M5 P0 8x6L 1 120698 2 205 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 112 8 Parts List Shown K4 Ouill Pinion Shaft Assy P N 20698 3 Item P N Title Qtv 1 FB166 SHAFT QUILL PINION 40 TAPER 1 3 FB92 OVERLOAD CLUTCH WORM GEAR 1 4 FB93 OVERLOAD CLUTCH RING 1 5 B92 1 SCREW SOC HD CAP M4 P0 7x15L 3 6 FB94 SNAP RING 95 DOWEL PIN 14 1 7 FB168 SCREW PIN 1 8 25707 BUSHING KIT PINION SHAFT 40 TAPER 1 120698 3 206 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 113 8 Parts List Shown K4 Overload Clutch Trip Assy P N 20698 4 Qty 1 1 4 FB79 SAFETYCLUTCHSPRING 6 FB76 SOCKET SET SCREW M6 P1 0x8L 8 FB97 OVERLOAD CLUTCH WASHER 9 FB98 SNAPRING 10 10 FB96 OVERLOAD CLUTCH TRIP LEVER 1 0 FB74 CLUTCH RING PIN 2REQ FB77 BRASS PLUG i 20698 4 207 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 114 8 Parts List Shown K4 Feed Reverse Clutch Assy P N 20698 5
69. AD CAP SCREW 66 C90 BEARING RETAINING RING 67 C91 GREASE SEALED BEARING 68 C92 BEARING CAP 69 C93 KEY 70 C94 ELEVATING SHAFT FOR 12 KNEE 71 C95 GREASE SEALED BEARING 72 C96 BEVEL PINION 73 C97 SET SCREW 74 C98 COLUMN 75 C99 WASHER 76 C102 SOCKET HEAD CAP SCREW 77 C103 PEDESTAL 78 C104 ELEVATING SCREW NUT 79 C105 SOCKET HEAD CAP SCREW 80 C118 SPIDER 81 C119 RAM LOCK STUD 82 C120 RAM PINION 83 C121 RAM PINION HANDLE 84 C122 PLASTIC BALL 85 C123 CHAMFERED HARDENED WASHER 86 C124 TURRET 87 C125 GIB SCREW NUT 88 C126 GIB SCREW 89 C127 LOCK BAR 90 C128 SCREW 91 C129 LOCKING BOLT 92 C130 RAM PINION SCREW C131 K2 93 C131 K3 RAM TURRET GIB 94 20851 STOP PIECE T BOLT ASSY 95 20852 TABLE LOCK HANDLE 96 20853 KNEE LOCK HANDLE amp SHAFT 235 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 Base Machine Assv Figure 134 97 20854 KNEE CRANK HANDLE ASSY 98 20873 CHIP GUARD SET K2 K3 99 FC112 LEVELING SCREW 100 FC113 LEVELING NUT 101 FC114 LEVELING PAD 120785 236 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 135 K4 Base Machine Assv P N 20699 237 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manua
70. AK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual COMPUTER MODULE TOADAPTER CABLE 22754 DISTRUBUTION BOARD TO E STOP CABLE 21794 1 COMPUTER MODULE TO DISTRUBUTION BOARD CABLE 21795 HARD DRIVE CABLE 22572 4 21824 1 COMPUTER MODULE BUSS SV 100884 CABLE 22427 DRIVE MODULE 22960 Figure 5 2 SM Computer Module 8 Flash Drive Replacement 5 1 4 System Flash Disk Replacement SM Model The system software for the SM control is contained on a 64 MB flash disk that is located under the door on the right side of the pendant in the upper flash drive slot If this needs to be replaced push the bottom to eject the disk and reload the new disk Turn power off to the machine before doing this replacement CAUTION It is a good idea to back up your flash drive from time to time via a network or floppy disk If your flash drive needs to be replaced you will lose all of your programs See your programming manual for instruction on how to do this 5 1 5 Cable Routing on Machine 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 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 faul
71. AP BLK OX er eee E aa rr ENDE TAM ZINC PLATE Y 20 51 DIA 15759 WASHER FLAT 14 53 3 8DA WASHER FLAT 4 80 24X6X6 CARTON CARDBOARD 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 143 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 11 Knee Mill Retrofits Backing Plate P N 16029 SPINO O O 23 Install the bearing housing A on the ballscrews as shown in Figure 7 8 The angular contact bearing should have the inner race thick side outward 100675 24 Install the clamp nut and torque to 50 ft Ib Tighten the 10 32 x 34 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 set screw 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
72. BEARING SPACER SET 1 120836 232 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 134 K2 K3 Base Machine Assy 20785 233 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 Base Machine Assy Figure 134 Item P N Title Comments 1 C01 QUILL HOUSING ADJ GEAR 2 C02 RAM ADAPTER 3 C04 NUT 4 C06 VERTICAL ADJUSTING WORM 5 C07 WORM THRUST WASHER 2REQ 6 C08 VERTICAL ADJUSTING WORM SHAFT 7 C09 WORM KEY 8 C10 RAM 9 C13 SOCKET CAP SCREW 2REQ 10 C14 ROLL DOWEL PIN 11 C15 ANGLE PLATE 12 C16 ROUND HD DRIVE SCREW 5REQ 13 C17 ADAPTER PIVOT PIN 14 C18 CHAMFERED amp HARDENED WASHER 7REQ 15 C19 ADAPTER LOCKING BOLT SREQ 16 C23 TABLE 42 OR 48 17 C31 STOP PIECE T BOLT 3REQ Available only in 20851 18 C32 TABLE STOP PIECE 2REQ Available only in 20851 19 C33 HEX NUT 3REQ Available only in 20851 20 C37 TABLE LOCK BOLT HANDLE Available only in 20852 21 C38 SADDLE LOCK BOLT 22 C39 SADDLE LOCK PLUNGER Available only in 20852 23 C40 SOCKET HD CAP SCREW 2REQ 24 C41 GIB ADJUSTING SCREW 3REQ 25 C42 TABLE STOP BRACKET not shown on drawing C43 K2 26 C43 K3 SADDLE TABLE GIB 27 C44 FELT WIPERS 4REQ 28 C46 TABL
73. CER ASSY 1 120778 2 214 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 121 8 Parts List Shown K2 K3 Hi Low Shift Assy P N 20778 3 Item P N Title Qty 1 VS89 FRU K3 HI LOW DETENT PLATE 1 2 VS87 FRU K3 CLUTCH GEAR SHAFT 1 3 VS92 FRU K3 HI LOW PINION BLOCK 1 4 VS91 FRU K3 SPRING 1 5 VS90 FRU K3 HI LOW DETENT PLUNGER 1 6 VS94 FRU K3 HI LOW SHAFT CRANK 1 7 VS88 FRU K3 PIN 3X19L 1 8 VS93 FRU K3 SCREW M5 PO 8x15L 3 9 VS92 1 FRU K3 SET SCREW M5 PO 8x5L 1 10 VS92 2 FRU K3 WASHER FLAT 11 1 11 VS57 FRU K3 BAKELITE BALL HANDLE 1 12 VS116 FRU K3 WASHER FLAT M5 1 13 24083 HI LOW SHAFT ASSY 1 120778 3 215 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 122 8 Parts List Shown K2 K3 Pulley Pinion Assy P N 20697 4 Item P N Title Qty 1 FVS67 BULL GEAR PINION COUNTER SHAFT 1 2 FVS69 KEY 5518L 1 3 FVS66 BULL GEAR PINION 1 4 AK118 BEARING DEEP GROOVE 6203ZZ 2 5 FVS3 SOCKET SET SCREW M6 P1 0x6L 1 6 23954 BEARING DEEP GROOVE SET 2 6203ZZ 1 i20697 4 216 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 123 K2 K3 Lower Vari Disc Drive P N 20778 5 as
74. Do not tighten the clamp screw fully until after loading the sensor Figure 5 4 TRAK Sensor Mounting i00019 99 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual ndustries Inc Southwestern l TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manua Parts List K2 K3 K4 Sensor Assembly Fig 5 5 Item PIN Title 6 M250 SENSOR ALL TRAK PRODUCTS i00890 5 1 7 Glass Scale Replacement 5 1 7 1 Remove 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 1 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 Replacement Scale CAUTION If the scale is not long enough for the table it will break when the mach
75. E LOCK PLUNGER 29 C47 TABLE LOCK BOLT 30 C48 TABLE LOCK BOLT HANDLE C49 K2 31 C49 K3 SADDLE KNEE GIB 32 C50 SADDLE KNEE WIPER PLATE 4REQ 33 C51 OVAL HEAD SCREW 8REQ 34 C53 1 LEFT HAND COLUMN WIPER HOLDER 35 C52 SADDLE 36 C54 1 KNEE WIPER FELT C55 K2 37 C55 K3 KNEE COLUMN GIB 38 C56 ALLEN CAP SCREW 2REQ 39 C57 1 RIGHT HAND COLUMN WIPER HOLDER 40 C58 1 KNEE WIPER FELT 41 C59 CHIP GUARDS UPPER Available only in 20873 42 C60 CHIP GUARDS MIDDLE Available only in 20873 43 C61 CHIP GUARDS LOWER Available only in 20873 44 C62 KNEE 45 C64 STOP SCREW 46 C65 KNEE LOCK SHAFT ASSEMBLV 234 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 Base Machine Assv Figure 134 47 C69 KNEE LOCK PLUNGER 48 C71 KNEE BINDER PLUG PLASTIC 49 C72 DOG POINT SET SCREW 50 C73 SET SCREW 51 C74 JAM NUT 52 C75 KEY 53 C76 WASHER 54 C77 BEVEL GEAR 55 C79 SEALED BALL BEARING 56 C80 BEARING RETAINER RING 57 C81 SOCKET HEAD CAP SCREW 58 C82 ELEVATING SCREW ASSEMBLY Available only in 20854 59 C83 HANDLE Available only in 20854 60 C84 ELEVATING CRANK 61 C85 GEARSHAFT CLUTCH INSERT 62 C86 DIAL LOCK NUT 63 C87 DIAL WITH 100 GRADUATIONS 64 C88 DIAL HOLDER 65 C89 SOCKET HE
76. FB164 QUILL STOP MICRO SCREW 1 74 FB160 SNAP RING 16 1 75 FB161 QUILL MICRO STOP NUT 1 76 FB162 MICROMETER NUT 1 77 FB184 FEED REVERSE TRIP PLUNGER 1 78 FB183 REVERSE TRIP BALL LEVER 1 79 FB185 REVERSE TRIP BALL LEVER SCREW 1 80 FB202 INDICATOR ROD 1 81 FB201 INDICATOR ROD SCREW 1 82 FB124 FEED TRIP PLUNGER 1 83 FB145 FEED TRIP LEVER 1 84 FB144 SOCKET SET SCREW 1 85 OIL 1 FRU K3 OIL CUP 1 86 FB125 HANDWHEEL 1 87 FB125 1 HANDWHEEL SPRING PIN 3x3x10L 1 88 FB125 2 HANDWHEEL HANDLE 1 202 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K4 Lower Head Housing Assv Figure 109 89 FB111 REVERSE KNOB 1 90 FB100 SOCKET SET SCREW M6 P1 0x20L 1 91 FB124 1 FEED TRIP PLUNGER SOC SET SCREW M4 P0 7x20L 1 92 FB124 2 FEED TRIP PLUNGER NUT M4 P0 7x20L 2 93 FB128 QUILL SKIRT 1 94 FVS109 DRAWBAR MANUAL K4 DPM3 DPM5 TOP ONE 1 95 FVS109 1 SPACER 1 96 25041 SCALE HEAD ROTATION NT40 1 97 25043 POINTER SCALE 1 98 25044 DRIVE SCREW SCALE 4 99 20834 FRU SK2 SK3 FEED REVERSE KNOB ASSY 1 100 20835 FRU SK2 SK3 HANDWHEEL ASSY 1 101 24099 TRIP HANDLE ASS Y INCLUDES PLASTIC BALL 1 102 20833 FRU K4 FEED TRIP ASSY 1 103 20847 QUILL MICRO NUT amp SCREW ASSY 1 104 20846 FRU SK2 SK3 QUILL LOCK HANDLE ASSY 1 105 20850 FRU SK4 FEED HANDLE ASSY 1 106 24095 CLOCK SPRIN
77. FRU K3 SNAP RING 95 DOWEL PIN 14 1 21 K B32 FRU K3 BEVEL GEAR THRUST SPACER 1 22 K B33 FRU K3 BEVEL GEAR BEARING 1 23 K B31 FRU K3 CLUSTER GEAR SHAFT 6602BB 1 24 20779 1 WORM GEAR CRADLE ASSY 1 25 K B18 FRU K3 WORM GEAR CRADLE THROW OUT 1 26 K B19 FRU K3 SHIFT SLEEVE 1 27 K B25 FRU K3 CAP SCREW 3REQ M5 P0 8x12L 3 28 K B20 FRU K3 GEAR SHIFT PLUNGER 1 29 K B21 FRU K3 COMPRESSION SPRING 1 30 K B22 FRU K3 ROLL PIN 3x20L 1 31 K B23 FRU K3 SHIFT CRANK 1 33 K B186 FRU K3 WORM GEAR 1 34 K B128 FRU K3 QUILL SKIRT 1 35 K B189 1 FRU K3 ADJ WORM SHAFT SET SCREW M6 P1 0x6L 1 36 K B42 FRU K3 BUSHING 1 37 K B187 FRU K3 KEY 4x4x18L 1 38 K B189 FRU K3 ADJ WORM SHAFT 1 39 K B171 FRU K3 KEY 3x3x20L 1 40 K B178 FRU K3 CLOCK SPRING CLOCK SPRING ASSY 1 41 K B177 FRU K3 SPRING COVER 1 42 K B169 FRU K3 RD HEAD SCREW 2REQ M5 P0 8x15L 2 224 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 Lower Head Housing Assy Figure 127 43 K B170 FRU K3 ROLL PIN 1 44 K B175 3 FRU K3 SET SCREW M8 P1 25x6L 2 45 K B175 2 FRU K3 COMPRESSION SPRING 2 46 K B175 1 FRU K3 STEEL BALL 2 47 K B176 FRU K3 PINION SHAFT HUB SLEEVE 1 48 K B175 FRU K3 RACK FEED HANDLE HUB 1 49 K B172 FRU K3 PINION SHAFT HUB SCREW 1 50 20836 SPINDLE ASSY K2 K3
78. FVS135 KEY 8x7x60L 1 15 20697 6 UPPER VARI DISC DRIVE ASSY 40T 1 16 FVS4 BELT 1 17 FVS1 BELT HOUSING 1 18 FVS17 SOCKET CAP SCREW M6 P1 0x35L 6 19 FVS13 TOP BEARING CAP 1 20 FVS15 BALL BEARING 6909VV 1 21 FVS129 SCREW SOC HD CAP M6 P1 0x18L 6 22 20697 7 SPEED CHANGE HANDWHEEL ASSY 40T 1 23 FVS10 SCREW SOC HD CAP M8 P1 25x30L 4 27 FVS11 MOTOR PULLEY COVER 1 28 FVS104 COPPER CHIP 2REQ 2 29 FVS131 SCREW FLAT HD PHILIP M5 P0 8x10L 2 30 FVS132 STUD 7 16 92L 2 31 FVS133 STUD 7 16 56L 1 32 FVS96 JAM NUT 3 8 16NC 1 33 FVS101 VENTILATOR 2REQ 2 34 FVS136 SCREW SOC HD CAP M6 P1 0x10L 12 35 FVS16 1 VARI SPEED DIAL 1 36 FVS95 NUT ACORN 5 16 18NC 1 37 FVS16 2 NAME PLATE 1 38 FVS19 DRIVE SCREW 4 39 OIL 1 FRU K3 OIL CUP 1 40 20820 SPINDLE MOTOR ASSY 5HP GREEN 1 41 FVS130 WASHER FLAT 10 2 4 42 FVS111 SOC HD SCREW 3 8 16NCx32L 4 124688 189 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 101 8 Parts List Shown K4 Gear Housing Assy P N 20697 1 i20697 1 Figure 102 8 Parts List Shown K4 190 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Hi Low Slip Clutch Assy P N 20697 2 Item P N Title Qtv 1 FVS75 BULL GEAR BEARING SPACER 1 2 FVS77 BALL BEARING 2 REQ 6910ZZ 2 3 FVS78 BEARING
79. G ASSEMBLY SPRING amp COVER 1 107 20844 FRU SK2 SK3 QUILL LOCK SLEVE ASSY 1 108 FB142 QUILL 1 109 A071 T BOLT ASSY 1 TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual i20698 203 Southwestern Industries Inc Figure 110 8 Parts List Shown K4 Worm Gear Cradle Assy P N 20698 1 i im ii 4 La P a y g G 5 18 i 120688 1 Item P N Title Qtv 1 FB17 WORM GEAR CRADLE 1 2 FB5 WORM CRADLE BUSHING 1 3 FB6 SETSCREW M6 PP1 0x10L 1 4 FB8 FEED DRIVEWORM GEAR 1 5 FB4 FEED WORM GEAR SHAFT SLEEVE 1 6 FB9 FEED DRIVE WORM GEAR SHAFT 1 7 FB11 KEY 3x3x20L 1 8 FB10 WORM SHAFT KEY 3x3x8L 1 9 FB3 FEED BEVEL PINION 1 10 FB2 BEVEL PINION WASHER 5 1 11 FB1 SOC HD SCREW M5 P0 8x10L 1 12 FB16 FEED ENGAGE PIN 1 13 FB36 FEED DRIVING GEAR 1 14 FB36 1 KEY 3x3x8L 1 15 FB15 FEED REVERSE BEVEL GEAR 1 16 FB13 WASHER 6 22 1 17 FB14 SOC HD SCREW M6 P1 0x15L 1 18 FB37 KEY 3x3x10L 1 19 FB40 FEED DRIVE GEAR 1 i20698 1 204 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 111 8 Parts List Shown K4 Quill Feed Selector Assy P N 20698 2 Item P N Title Qty 1 FB66 CLUSTER GEAR COVER 1 2 FB64 CLUSTER GEAR SHIFT CRANK 1 3 FB69 1 DIAL 1 4 FB6
80. Homestead Place Rancho Dominguez CA 90220 5610 Phone 310 608 4422 4 Fax 310 764 2668 Service Department Phone 800 367 3165 e Fax 310 886 8029 Table of Contents 1 0 1 1 12 1 3 Safetv Safetv Publications Danger Warning Caution amp Note Labels 8 Notices as used in this Manual Safety Precautions Installation Floor Plan Layout amp Space Requirements Uncrating Shortages Inventory Checklist TRAK K2 Site Preparation TRAK K3 Site Preparation TRAK K4 Site Preparation Installation Instructions amp Checklist Machine Specifications Maximum Work Capacities ProtoTRAK SM Control Hardware ProtoTRAK AGE 2 and 3 Control Hardware ProtoTRAK AGE 2 and 3 Software Specifications ProtoTRAK M2 and M3 Control Hardware ProtoTRAK M2 and M3 Software Specifications ProtoTRAK EDGE Control Hardware Lifting and or Moving the Machine Cleaning Leveling Leveling Tolerance is 0005 10 Electrical Connection 2 19 1 Phase Converters Air Connection Optional Mounting the Display Pendant Cable Interconnections SM Cable Interconnections M2 Cable Interconnections M3 Lubrication 2 25 1 Manual Lubrication 2 25 2 Head Lubrication ProtoTRAK SM Euclid Block Procedure Troubleshooting by Symptom 58 Problems Relating to Machining Results 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
81. IDE WAY in CE 55 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 K4 Knee Mill Lubrication Figure 2 36 Item P N oo x a Tie Qty 2 9002 FRU K3 ALUMINUMPIPE 1 6 3 9003 JFRUKSELBOW GN 4 9004 FRU K3 T JOINT 4HOLES M8X1 0 1 5 9005 FRU K3 CONNECTOR 1 3 6 9006 FRU K3 REGULATING DISTRIBUTOR 1 7 9007 FRU K3 FLEXIBLETUBE 8 9008 FRU K3 SCREW NUT M8X1 0MALE 15 9 9009 FRU K3 SCREW NUT PD 1 8 19MM 2 10 9010 FRU K3 SCREW M5X20mmlG 8 100889 2 25 2 Head Lubrication Once Each Week 1 Fillthe 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 fullv and applv a coating of SAE 30 or 30W oil to the outside diameter of the quill Everv Four Months Applv 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 the feed change gears respectivelv 2 26 ProtoTRAK SM 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 tool box e Material Specification Aluminum 6061 T6 or T4 e Blank Size minimum dimensions 3 x 3 x 1 provided in tool box e Tool 750 end mill 2 flute high
82. IN 6x20L 1 27 FVS57 1 BAKELITE BALL HANDLE 3 8 16NC 1 28 24055 BRAKE SHOE ASS Y 1 120697 5 195 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 106 K4 Upper Vari Disc Assy P N 20697 6 196 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K4 Upper Vari Disc Assy P N 20697 6 Figure 106 Item P N Title Qtv 1 FVS44 ADJUSTABLE DRIVEN VARIDISC W KEY 1 2 FVS42 SPINDLE PULLEV BEARING HOUSING 1 3 24641 BEARING DEEP GROVE 6013ZZ 1 4 FVS36 SPEED CHANGE PLATE 1 5 FVS38 PIVOT SLEEVE 5 2 6 FVS37 WASHER M5 P0 8X20L 2 7 FVS123 SOCKET CAP SCREW 2 8 FVS39 SPEED CHANGE PLATE PIVOT STUD 1 9 FVS41 WASHER 8 2 1 10 FVS40 ROLL PIN 3x15L 2 11 FVS35 CHAIN END STUD 1 12 FVS34 ADJUSTMENT NUT 1 13 FVS33 CHAIN FRONT SCREW M4 P0 7x5L 1 14 FVS97 SNAP RING 50 1 15 FVS96 JAM NUT 3 8 16NC 1 16 24599 BEARING HOUSING ASSY K4 1 17 24603 VARIDISC ASSV ADJUSTABLE 1 120697 6 197 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 107 8 Parts List Shown K4 Speed Change Handwheel Assy P N 20697 7 Item P N Title Qtv 1 FVS16 SPEED
83. Industries Inc RAM Figure 7 18 amp Parts List Shown AGE2 AGE3 MX2 MX 3 Pendant Arm Assembly Rounded Ram e g Bridgeport Series Mill BIN gi _QTY PARTNO DESCRIPTION _ ITEM 4 SA eS eee IT ti 2 i 1 115896 PendatGup 11 lt 15618 Siotteg Nut 12 CS 1L96906A106 Cleve Pi La de 4 _2 19712083 Bolvile Washer 1 4 PE Ji LIST 1 PendantArm 1 T d 12 l5eda Fist Washers 7 11 115825 Round Ram Support Brit 8 f Rc ee 111428112 Socket Head Set Sorew 1 9 a TN _4 11 4 20x1 Socket Head Screw 10 b Me 11997 Pvt Pin 11 5 eg Sag i assam l Pir EE E M SE b la E S a x i CO Sr RS Vo Lea 7 dn YS TRON fa A lt B E t ta ki Sa x b S e 3 N N AT BN h te a N 10 ja 155 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 19 amp Parts List Shown M2 M3 Pendant Arm Installation Pendant Arm Assembly Note 1 Four different hex head bolts are provided to match the machine 1 2 13x6 5 8 11x6 3 4 10x6 M20 2 5x150 Note 2 Four different washers are provided to match the bolt used Part No Description tem 1 see note below Bolt Hex Head Washer Flat 2 Ram Support 3 Bracket Screw Set Cup Point Leveling Plate 1 16919 1 1 5 8 18x5 1 2 Bolt Hex Head
84. K SM Control Hardware 233 PC based processor 32 MB of RAM without backlash 2 or 3 axis CNC 3 axis DRO Feedrate override of programmed feedrate and rapid e Polycarbonate sealed membrane and gasket sealed control enclosure to lock out contamination 14 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 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 10 32 color LCD for clear presentation of prompts status information and part graphics RS232 port for interface to computers Modular design simplifies service and maximizes uptime 64 MB flash drive Optional flash expansion slot Single floppv disk drive for additional part program storage Optional auxiliarv function box for control of coolant pump or spray mist coolant spindle off and a programmable rotarv table or indexer 3 axis machines only Figure 2 6 SM Pendant Left Side 100871 15 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2 7 SM Control Right Side BEEPER HARD DRIVE FLOPPY DRIVE MOUSE 1 AMP FUSE BAMPFUSE AC ON OFF 100872 2 11 ProtoTRAK AGE 2 and 3 Control Hardware Machine Tool Error Compensation on all axes by calibrating measu
85. MX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 132 8 Parts List Shown K2 K3 Feed Reverse Clutch Assy P N 20779 5 1 K B57 JI FRU K3 FEEDWORMSHAFT 1 2 K B47 FRU K3 FEED WORM SHAFT THRUST WASHER 3 K B44 FRU K3 FEEDWORMSHAFTBUSHING Pa KB3 JI FRU KS WORM 5 Kess FRU K3 PIN 3x12L 6 K B49 FRU K3 FEEDREVERSEBEVELGEAR 7 Keag FRU KS BUSHING 8 K B62 FRU K3 KEY 3x3x15L 9 K B50 FRU K3 FEEDREVERSECLUTCH 10 i B56 FRU K3 PIN 3x19L 11 K B51 FRU K3 FEEDREVERSEBEVELGEAR 1 12 K B52 7 FRU KS BUSHING 1 i20779 5 1 2 3 5 7 10 11 12 3 231 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 133 8 Parts List Shown K2 K3 Spindle Assy P N 20836 Item P N Title Qtv 1 K B127 SPINDLE R8 1 2 K B134 SPINDLE DIRT SHIELD 1 3 20838 BEARING ANGULAR CONTACT U SET 2 7207 P4 1 4 K B136 BEARING SPACER SMALL 1 5 K B137 BEARING SPACER LARGE 1 7 K B133 NOSE PIECE 1 8 K B132 SLEEVE 1 9 K B131 BEARING DEEP GROVE 6206ZZ 1 10 K B130 BEARING LOCK WASHER 30 1 11 K B129 SPINDLE BEARING LOCK NUT 30 20N 1 12 K B150 1 STRAIGHT LOWER CLAMP 1 13 K B151 FELT OIL STRAINER 1 14 K B150 2 STRAINER UPPER CLAMP 1 15 K B139 SCREW PH HD M5 0 8X8L 2 16 20840
86. P GROOVE SET 2 6203ZZ 1 i20697 4 193 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 105 K4 Lower Vari Disc Assy P N 20697 5 Assembly not available order parts separately 120697 5 194 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K4 Lower Vari Disc Assy P N 20697 5 Figure 105 Assembly not available order parts separately Item P N Title Qtv 1 FVS50 BELT HOUSING BASE 1 2 FVS59 BRAKE BLOCK 2 3 FVS58 TURNING BLOCK SHAFT 1 4 FVS103 RETAINING RING 7 1 5 FVS51 SET SCREW M6 P1 06L 2 6 FVS53 BRAKE LOCK BUSHING 1 7 FVS52 BRAKE LOCK SHAFT 1 8 FSV119 RETAINING RING 11 1 9 FVS47 BRAKE SHOE 2 10 FVS48 BRAKE SHOE PIVOT SLEEVE 1 11 FVS17 SOCKET CAP SCREW M6 P1 0x35L 1 12 FVS49 BRAKE SPRING 2 13 FVS122 WASHER 6 4 14 FVS120 SCREW PHILLIP PAN HD 3 16 24NC6L 4 15 FVS46 BRAKE BEARING CAP 1 16 AK048 BALL BEARING 691272 1 17 FVS14 SOCKET CAP SCREW M 5 PO 8x12L 4 18 FVS45 STATIONARY DRIVEN VARIDISC 1 19 FVS70 SPINDLE PULLY ASSY 1 20 FVS100 SPINDLE PULLY SPACER 1 21 FVS71 KEY 8x8x20L 1 22 FVS97 SNAP RING 50 1 23 FVS52 1 BRAKE LOCK SHAFT SWIVEL 1 24 FVS56 BRAKE LOCK HANDLE 1 25 FVS54 HANDLE FIX BLOCK 3 8 16NC 1 26 FVS55 SPRING P
87. P M8 P1 25x30L 1 10 23953 VARIDISC ASSY ADJUSTABLE MOTOR 1 120819 222 Southwestern Industries Inc TRAK K2 K3 K4 SMX Retrofit Safety nstallation Maintenance Service amp Parts List Manual Figure 127 K2 K3 Lower Head Assy P N 20779 DETAIL A 3 A mV AD A 223 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 Lower Head Housing Assy Figure 127 Item P N Title Qtv 1 K B125 2 FRU K3 HANDWHEEL HANDLE AVAILABLE ONLY IN ASSV 20835 1 2 K B113 FRU K3 HAND WHEEL CLUTCH 1 3 K B117 FRU K3 ROLL PIN 3x15L 1 4 K B103 FRU K3 CAM ROD 1 5 K B108 FRU K3 SOCKET SET SCREW M6 P1 0x8L 1 6 K B119 1 FRU K3 ROLL PIN 3x20L 1 7 K B103 1 FRU K3 CAM ROD PIN 6x15L 1 8 K B107 FRU K3 CAP SCREW M6 P1 0x25L 2 9 K B106 FRU K3 FEED TRIP BRACKET 1 10 20779 4 OVERLOAD CLUTCH TRIP ASSY 1 11 K B73 FRU K3 SOCKET SET SCREW M6 P1 0x20L 1 12 K B101 FRU K3 CHEM BLACKED LOCKNUT M6 P1 0 1 13 K B99 FRU K3 CLUTCH ARM COVER 1 14 M5 0 8X50 25B SCREW SHCS STL BO 2 15 20779 2 QUILL FEED SELECTOR ASSV 1 16 K B67 FRU K3 CAP SCREW M6 P1 0x18L 4 17 K B29 FRU K3 CLUSTER GEAR KEY 3x3x45L 1 18 K B27 FRU K3 CLUSTER GEAR SHAFT UPPER BEARING 1 19 K B28 FRU K3 CLUSTER GEARS ASSEMBLY 1 20 K B94
88. RANK HANDLE ASSY 90 20867 FRU SK4 CHIP COVER ASSY 91 20868 FRU SK4 HANDLE amp BAR LOCK ASSY 92 20869 FRU SK4 FC31 FC32 FC333 239 Southwestern Industries I nc 120699 TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 136 K2 K3 8 K4 Transformer Option 220V and 440V P N 23470 220 or 23470 440 240 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 137 K2 K3 amp K4 Transformer Option Safety Switch 220V amp 440V P N 23470 220 or 23470 440 123470 708 le se o 8 00 00 000 EJ eeoeoecoo Sy 241 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 8 K4 Transformer Option Safety Switch 220V amp 440V P N 23470 220 8 23470 440 Figures 136 137 Item P N Title 3 23430 MOD SAFETY SWITCH 30A 600VAC MODIFIED 5 23440 220 ENCLOSURE ASSY TRANSFORMER OPTION 220V 23440 440 ENCLOSURE ASSY TRANSFORMER OPTION 440V 7 23454 3 CABLE ASSV SAFETV SWITCH XFMR MODULE DPM 24927 10 LABEL FUSE CHART REPLACEMENT 220V 24927 5 LABEL FUSE CHART REPLACEMENT 440V 24910 15 FUSE TIME DELAY 15 AMPS 220V 24910 10 FUSE TIME DELAY 10 AMPS 440V
89. RS232 Com Port SM Model This code switches between COM ports for RS232 applications 94 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 5 0 Procedures for Replacements 8 Maintenance 5 1 Replacements 5 1 1 Servo Motor Replacement WARNINGI Do not work with the Servo Motors unless the power is disconnected from the machine The servomotors are run bv 110 VAC There is possibilitv of death bv electrocution 1 Turn off power to the machine 2 Each motor is mounted by the use of four 14 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 DANGER 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
90. Repeat as necessary e 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 necessarv 7 Replace the front and rear chip wiper and chip wiper guard 5 2 1 4 Saddle Bottom Gib Adjustment Y Axis K3 and K4 Only See Figure 5 23 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 125 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 ofthe 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 Movethe 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 e Toadjustthe gib for excessive clearance Loosen the gib lock screw on the back
91. 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 no Dual Feedback Code 128 Enter backlash compensation Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting Possible Cause Check This X and Y Gibs are not adjusted properly Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures TRAK Sensor or Glass Scale problem 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 amp 4 7 Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants section Binding in the Drive Train Check Repeatability using the Repeatability and Positional Accura
92. Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 7 9 Computer Box Installation Caution Do not mount the computer box on the left side of the machine as the connectors would then be oriented toward the front of the machine and exposed to chips and coolant Do not mount the computer upside down This will damage the floppv drive Step 1 The computer box may be mounted on the right recommended or the back of the machine s column Step 2 Move the saddle full travel toward the column Hold the computer box against the right side of the column or the rear so that the top is 36 from the floor and does not interfere with the machine movement Transfer the center top hole from the upper flange of the computer box to the mill Drill and tap a 5 16 18 hole at least 1 1 4 inch deep Step 3 Screw one 5 16 18 X 2 inch set screw into the hole in the mill so that approximately 3 4 inches remain outside Lock the screw into position with a 5 16 inch washer type nut orienting the washer away from the mill and towards the computer box Step 4 Hang the computer box on this stud Level the computer box and carefully transfer the two slots from the lower edge to the mill Remove the computer box Drill the tap two 2 5 16 18 holes and insert two 2 5 16 18 X 2 inch set screws and lock them in place with washer type nuts as in the previous step Step 5 Install the comput
93. T TO E STOP 115 VAC TO SERVICE 115 VAC TO COOL F R SWITCH PUMP OPTIONAL ELECTRICS BOX 115 VAC TO LUBE FROM SERVICE 220 440 PUMP J IN 115 VAC TO POWER TO SPINDLE MOTOR FEED OPTIONAL 220 440 3 OUT 115 VAC TO WORK LIGHT OPTIONAL 100258 51 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual 2 24 Cable Interconnections M3 All cable interconnections are made at the factory except for those connecting to the display pendant and optional coolant on off switch With the on off switch off down plug in the connectors which are bundled into the pendant arm Each cable mates to only one connector on the display pendant back panel Be certain to attach the braided cable to the ground stud and wing nut See the figure 2 34 for a complete cable interconnection diagram UMBILICAL DB 25 UMBILICAL DB 37 M3 PENDANT 115 VAC TO PENDAN 115 VAC TO SERVICE 15 vac TO OOO FIR SWITCH PUMP OPTIO ELECTRICS BOX 115 VAC TO LUBE FROM SERVICE 220 440 PUMP BIN 115 VAC TO POWER TO SPINDLE MOTOR EED OPTIONA 2201440 32 OUT 115 VAC TO WORK LIGHT OPTIONAL 115 VAC TO ECB TO E STOP 10553 Figure 2 34 M3 Cable Interconnections 32 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Figure 2 35 Schematic Standard Electric Box P N 20676 fre ETE m a
94. TRAK amp SPORT KNEE MILL KNEE MILL RETROFIT Service Manual for Non Current Knee Mill Products Safety Installation Maintenance Service amp Parts List Manual Document 24939 Version 081613 Covering Machine Models e TRAK K2 K3 K4 e SPORT K2 K3 K4 e Knee Mill Retrofits Covering Non Current Control Models e ProtoTRAK M2 and M3 CNC e TRAK AGE2 and AGE3 CNC e ProtoTRAK SM CNC e ProtoTRAK Edge CNC e ProtoTRAK MX2 3 CNC 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 sales southwesternindustries com service southwesternindustries com web southwesternindustries com Copyright O 2013 Southwestern Industries Inc All rights are reserved No part of this publication mav be reproduced stored in a retrieval svstem or transmitted in anv form or bv any means mechanical photocopving recording or otherwise without the prior written permission of Southwestern Industries Inc While everv effort has been made to include all the information required for the purposes of this guide Southwestern Industries Inc assumes no responsibilitv for inaccuracies or omission and accepts no liabilitv 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
95. a press enter If the format works your disk drive is working If format does not work reboot Find a new disk and install in floppy drive Install keyboard into middle port Press CTRL ESC to get to start menu 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 2 parts The Motor Encoder and the Motor 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 81 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual WARNINGI 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 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 This will display on the DRO if
96. a new machine 4 9 2 1 CODE 11 Hysteresis Note This code is use only for systems with Sensors or Glass Scales on the table and sadale 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 e Play How much backlash must be taken up when motion is reversed e 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 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 Forward 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 89 Southwestern Industries Inc TRAK K2
97. am so that the dial indicator will reach the table Move the dial indicator to 6 o clock position and adjust the face so the needle is zero Qu i cem 0 Do a series of sweeps from 3 o clock to 9 o clock and check for the repeatability of the setup The head should be trammed with an 0 001 7 Ifthe head is out of tram from side to side then loosen the 4 head bolts An Allen wrench and breaker bar is provided in the toolbox There are also 2 tram blocks in the toolbox to help with the alignment of the head They are bolted to the side of the head as shown in Figure 5 25 with 2 M8 SHCS Then use 2 M8 SHCS as jackscrews to move the head in the direction it needs to go to align the head and adjust the tram with the bolt mounted on the right side of the head 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 129 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 5 25 K2 K3 K4 Tramming of Head Back to Front Adjustment Note The head ofthe 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 0000 to 0 0005 from front to back Note the table must droop down rather than up because tool pressure will take care of the extra 0 0005 5 2 3 3 Back to
98. ammed federate and rapid Polvcarbonate sealed membrane and gasket sealed control enclosure to lock out contamination 7 4 LCD for clear presentation of prompts and status information Modular design simplifies service and maximizes uptime Single floppv disk drive for additional part program storage The D C Servo Motors for the X and Y axes are rated at 280 in oz maximum continuous torque Figure 2 13 Edge Pendant Display Front RAOTOTAAKENGE 2 x X 24 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2 14 Edge Pendant Display Back 1 AMP FUSE 8 AMP FUSE X AXIS MOTOR ENCODER COMPUTER SERVO MOTORS CONNECTOR REMOTE i STOP GO AIC SWITCH POWER IN CONNECTOR BOLTS TO PENDANT ARM DISPLAY WILL SWIVEL TO CHANGE VIEWING ANGLE OPTIONAL Z SCALE CONNECTOR E STOP FACTORY Y AXIS MOTOR ENCODER EURO MODEL ONLY LIMIT SWITCH TESTPORT CONNECTOR CONNECTOR PENDANT DISPLAY BACK 100664 25 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2 15 K2 K3 K4 Knee Mill Component Identification 20090090 CONTROL RAM QUILL HANDLE ANS AS amni A TULD Dpr SPINDLE BRAKE 100905 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Pa
99. and excess oil from the table and saddle 2 Centerthe 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 5 20 K2 K3 K4 Table Gib Adjustment 100023 123 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 e 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 e 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 require
100. 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 7 165 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 26 Readerhead Mounting For Accu rite Glass Scales 4 M3 leveling screws 0 03 to 0 18 gap 0 8 to 4 6 er either end Reading head cover 1 1 and 4 mounting 1 24 e rmi rer 615 retainer Figure 7 27 Glass Scale Mounting 32 17 53 445 3 Lg den for Me 0021 166 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 7 8 Limit Switch Installation See Figures 7 20 and 7 21 7 8 1 Y Axis 1 Mount right angle limit switch bracket to right side of saddle 2 Mountthe limit switch to the bracket The roller should be facing the knee of the machine 3 Use 2 M10 bolts as stoppers Drill and tap M10 holes in the knee Maximize the travel before drilling holes 4 Use the M10 nut to fasten the bolt in place 5 Position cable to allow full forward travel of saddle and full knee travel 7 8 2 X Axis 1 Attach X Axis bracket to front of saddle with existing shcs 2 Mount switch mounting cover to X Axis bracket with right side flush with mounting bracket with 10 32 x shcs and washer 3 Mount switch with roller
101. and wires so that the mounting holes are accessible 164 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 Attach the readerhead to the readerhead mounting bracket e There are jackscrews on the readerhead to compensate for some gap between the readerhead and the readerhead mounting bracket e Before tightening the readerhead to the bracket there must be a 002 003 gap between the readerhead mounting bracket and the jackscrews This gap will be eliminated by tightening the mounting screws 6 Replace the wires shield and name plate 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 sadale 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
102. anical Drive Train X Y Section 4 2 Swap the motor in guestion 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 Ouill 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 Ouill after tightening Head bolts are loose 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 Note If your part has incorrect dimensions see Parts Have Incorrect Dimensions Section 3 1 4 72 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service 8 Parts List Note First check for repeatabilitv of the DRO With a dial indicator mounted to the bottom of the spindle touch off a fixed surface either in the X Y or Z axis direction and set the DRO equal to 0 Crank away several inches and touch off again at the same place If the reading has not returned to 0 on the DRO zero the disp
103. aring 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 e Y axis the only component that can cause a misalignment problem is the motor mounting bracket To align this bracket move the saddle as far 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 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 80 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Possible problems Can lead to Poor cable connections Make sure all cables are properly fastened Pendant locks up 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 No voltage to RSG port RSG will not work should be 5 DC volts present Check with a voltmeter Low voltage to flash drive or slave board SM Model Can cause the system to lock up and the flash drive to act abnormally Check volta
104. assembiv 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 Please fill out Form No F10139 located in the back of this manual and send it back with your returned unit This form helps us in diagnosing the problem 187 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 10 0 Figures 8 Part Lists Figure 100 K4 Upper Head Assy P N 24688 188 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K4 Upper Head Assembly 40 Taper P N 24688 Figure 100 Item P N Title Qtv 1 20697 1 GEAR HOUSING ASSY 1 2 20697 2 HI LOW SHIFT CLUTCH ASSY 1 3 20697 3 HI LOW SHIFT ASSY 1 4 FVS12 SOCKET CAP SCREW M6 P1 0x15L 6 5 20697 4 PULLEY PINION ASSY 1 6 FVS64 BULL GEAR PINION BEARING CAP 1 7 FVS93 SCREW SOC HD M5 P0 8x15L 3 8 FVS117 KEY 5x520L 1 9 FVS62 TIMING BELT PULLEY 1 10 FVS126 WASHER 5 8 1 11 FVS61 JAM NUT 5 8 11NC 1 12 20697 5 LOWER VARI DISC DRIVE ASSY 1 13 FVS63 BELT 8YU 600L 1 14
105. box 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 and screws Pendant Display with four 1 4 20 screws for mounting Pendant Arm assembled to the column Toolbox with various tools ProtoTRAK Safety Operation amp Programming Manual ila TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Way covers K2 K3 amp K4 front amp rear of saddle In case of shortages contact the representative from whom you purchased the machine 9 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 2 4 Site Preparation Trak K2 Electrical e 115 VAC 60 Hz 8 AMP 1 Phase e 220 VAC 60 Hz 8 5 AMP 3 Phase OR e 440 VAC 60 Hz 4 25 AMP 3 Phase A separate 115 VAC circuit with a 15 AMP breaker originating at the main power panel for shop electrical service and dedicated to the sole use of the K2 is required to maintain proper operation Machine tool must be earth grounded Standard 3 prong 115V wall socket is required in addition to the 220 440 VAC line
106. cy 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 Code 11 Measure s the backlash in the system Only used on machines with Dual Feedback systems 63 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List e Code 12 Feed Forward Constant High feed forward constants will cause an unstable servo system e Code 127 Measure s the backlash in the system Only used on machines with no Dual Feedback e Code 128 Enter backlash compensation e Code 123 Calibrate Possible Cause Check This Too much backlash entered in Code 128 Recheck the machines backlash or Code 11 Inadequate or no Lubrication to Make sure all the Way surfaces are getting proper Ballscrews and Way surfaces 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 X and Y Gibs are not adjusted properly Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures Gibs not making good contact Pull gibs out and mark with a blue die to check wh
107. d 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 5 21 K2 K3 K4 Table Gib Screw TABLE GIB SCREW fi fis TABLE 100151 po 5 2 1 3 Saddle Side Gib Adjustment Y Axis See Figure 5 22 Clean all chips dirt and excess oil from the table and saddle Center the saddle on the bed ways Move the table fully to the left side of the saddle Tec Ud nA dE Remove the chip wiper guard and chip wiper from the front and rear of the left side box way 124 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 5 22 K2 K3 K4 Saddle Side Gib Adjustment DIAL INDICATOR 100024 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 e 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
108. de 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 134 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 2 Knee Mill Retrofits Y Axis Ballscrew Assembly FRONT BEARING HOUSING DIAL BUSHING Y AXIS HAND CRANK 28 CAP VERNIER DIAL SCREWS 4 BEARING RETAINER CUP BEARINGS 100671 Note to remove a ballscrew remove the nut retaining screw and slide the brass acme nut and the Iballscrew out of the yoke together Figure 7 3 Knee Mill Retrofits X Axis Ballscrew Yoke Assembly i00676 135 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 w
109. default tion file and backlash constants has values Load saved configuration file from floppy disk in been erased or corrupted electrics cabinet with Code 141 Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants 3 1 4 2 The Dimensional Errors Are Random or Accumulate in Size Over the Part Program Run Possible Cause Check This Machine Tool amp Setup problem See Machine Tool amp Setup Section 4 1 TRAK Sensor or Glass Scale problem 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 Glass Scales or TRAK Sensors Sections 4 6 amp 4 7 X and Y axis Drive Trains are loose 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 e Code 33 Software Identifica
110. ds turn the svstem back on Check to see if this has caused the bars to appear on the screen If your problem persists after completing steps 1 through 6 note the serial number of the unit and please call the Customer Service Group at 800 367 3165 and report the results of these steps 66 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service 8 Parts List Possible Cause Check This Voltage drop spike has occurred Shut down the svstem and wait 10 seconds to reboot the system Remote Stop Go RSG switch has a Remove the RSG Turn the system off and then on short if connected again If the problem goes away and then re appears when the RSG is plugged in replace the RSG Poor cable connections from the Re seat cable connectors by pulling out and pushing Computer Module to the Distribution back in Board and from the Distribution Board to the Keyboard Electromagnetic interference has Especially suspected if the RS232 cable is ran near entered through the RS232 cable if any electrical conduit If the problem is chronic connected especially if intermittent remove the cable for a while to see ifthere is a difference 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 e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 11 Measure s the backlas
111. dustries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 8 2 8 Parts List Shown SM3 Retrofit Base Plate and Ballscrew Mounting Ballnut Mtg Bolt e EE Washer Bl Er REA Nut Lock 15759 FlatWasher 5 1 4 20x3 8 Socket Head Kl ES EI 1 4 20x1 Socket Head 7 Kai ESI 16180 A G E 3 LIMP Ertsvercene 1 2 13x1 75 Socket Head iii ESE Cap Screw Locator Jackscrew Nut Screw Nut 3 8 3 8 Flat Washer I 3 8 16 Hex Nu Washer 1 2 Cap Screw AE o Note The overall strategy is a The position locator 13 and the hex head screw 15 aligns the baseplate side to side a The leveling nuts 16 align the baseplate front to back 2 Replace the machine s head bolts with the J ackscrew nuts item 14 on the right side Replace the machine s head bolts with the socket head couplers on the left side 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 locktight and the set screws provided 179 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 loca
112. dustries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Note The typical slidewav 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 a machine ofthis class 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 e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 11 Measures backlash in the system Only used on Dual Feedback systems e Code 12 Feed Forward Constant e Code 127 Measures backlash in the system not used on Dual Feedback systems e Code 128 Enter backlash compensation Possible Cause Check This Torque values on X and Y axis are too Make sure torque is lower than 20 in Ibs Normal values for a high machine that is aligned and adjusted properly should be between 10 and 15 in lbs Make sure torque is consistent across axis travel Machine Tool and Setup problem Check for any looseness in the setup Tool Tool holder Part Vise or Fixture See Machine Tool amp Setup Section 4 1 Machine not level Verify that the machine is level to specification Head is not Trammed Verify that the Head is Trammed to specification See Tramming the Head Check the adjustment of the X and Y Gibs using th
113. e 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 a machine of this class Furthermore the system should be expected to repeat within the resolution of the displayed DRO numbers of 0 0005 Do the following Service Code e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 123 Calibration e Code 11 Measure s the backlash in the system Only used on machines with Dual Feedback systems e Code 12 Feed Forward Constant e Code 127 Measure s the backlash in the system Only used on machines with no Dual Feedback 60 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service 8 Parts List e Code 128 Enter backlash compensation 3 1 4 1 Every Part Has the Same Error Possible Cause Check This Machine Tool amp Setup problem See Machine Tool amp Setup Section 4 1 Programming Error 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 Configuration file that contains calibra Verify configuration file Code 313 does not read
114. e X and Y Gib adjustment procedures Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants Section 5 2 2 TRAK Sensor or Glass Scale problem 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 Glass Scales or TRAK Sensors Sections 4 6 amp 4 7 X amp Y axis Drive Trains are loose 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 Head Bolts are loose Verify that all the head bolts are tight 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 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
115. e cable removed from the system after 30 45 seconds turn the system back on Check to see if this has caused the bars to appear on the screen e If your problem persists after completing steps 1 through 6 note the serial number of the unit and please call the Customer Service Group at 800 367 3165 and report the results of these steps Possible Cause Check This System flash drive loose Make sure flash drive is seated properly SM onl Screen saver has been activated 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 SM only Turn the power switch off check the computer pendant fuses and cable connections See Electrical Section 4 8 Poor cable connection from Computer Module to LCD Liquid Crystal Display module to the LCD 65 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service 8 Parts List 3 3 2 Bad Picture on the Displav The displav has strange characters horizontal bars or other unfamiliar images or the displav continuallv rolls Possible Cause Check This Poor cable connection from Computer Check connections on computer module Module to LCD Liquid Crvstal Displav Computer Pendant failed See Computer Pendant Section 4 3 3 3 3 Kevboard Lockup The screen displav is normal but the svstem will not respond to kev presses Do the
116. e event that thev are inadvertentiv left out of the kit or lost during installation Qy Faster 4 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 E51 6 EH EN NE 6 4 Pre Installation Requirements e Power requirements 115V 60Hz 1100VA 10 amp power line dedicated to the ProtoTRAK e Adequate working area around the machine to slide the table completely off the saddle e Availability of a lift table or cart capable of supporting the table once it is removed from the machine 133 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 7 0 Installation Procedures Retrofits 7 1 Xand 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 Left Right Assembly Assembly X AXIS 100670 Figure 7 1 Knee Mill Retrofits X Axis Ballscrew Assembly 2 Center the table and remove the X gib 3 Sli
117. e of any of its products e TRAK products are precision mechanical electromechanical electronic systems and must be given the reasonable care that these types of products require e Accidental damage beyond the control of SWI is not covered by the warranty Thus the warranty does not apply if a product has been abused dropped hit or disassembled e 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 Rev 020713
118. e 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 by pressing the F8 softkey Once this in done it prompts you for which file you want to save to disk The FI 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 6 Code 324 Toggle Simulation Mode SM Model Simulation Mode allows the control to run a program without actuallv moving the table It is helpful in diagnosing Computer displav problems 93 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 4 9 4 Operator Defaults Optio
119. e that the lube pump is functioning properly Also check for any pinched or blocked oil lines See Lubrication Section 4 1 3 X and Y Gibs are not adjusted properly Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures Binding in the Drive Train 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 Servo Drive failure See Servo Drive Section 4 5 Motor failure 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 e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting 62 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Possible Cause Check This Shut down the svstem and wait 10 seconds before rebooting E Stop is pressed in Check E Stop Especiallv if both axes will not jog Especiallv if only one axis will not jog See Servo Driver Section 4 5 Computer Pendant failed See Computer Pendant diagnostics Section 4 3 3 2 4 Axis Motor Motion Is Not
120. eedrate should be a minimum of 120 ipm e Ifthe 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 22 for a further explanation of this code 4 9 2 5 CODE 127 Set X or Y Backlash Constant See Section 5 22 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 SM Model 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 SM Model This service code toggles the Y sensor or glass scale on or off See Code 304 for further explanation 4 9 2 9 Code 321 Reverse Y position sensor direction SM Model This service code rever
121. elt 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 151 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 7 3 Pendant Installation 7 3 1 Pendant Arm Installation Figure 7 16 SM Retrofit Pendant Arm Assembly 152 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List SM Retrofit Pendant Arm Assembly Figure 7 16 IN Title Qty 2 3 5 10 1 1 2 100893 lt 153 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual Figure 7 17 8 Parts List Shown AGE2 AGE3 MX2 MX3 Rear View of Pendant Display Pendant Arm Assembly im H tem P N Description 15857 Cable Clamp 15858 E Stop Assembly Remote Stop Go Connector Brightness Control Beeper On Off Switch 8 Amp Slo Blo Fuse 34 Amp Slo Blo Fuse RS232 Connector rm O oo sijom U K WO IN o 115V AC Power Out to Computer Box 115 V AC Power Into Computer Box 12 Ground Stud 13 Logic Cable to Computer Box TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 154 Southwestern
122. em 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 e 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 83 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 4 7 e 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
123. enance Service 8 Parts List Manual Figure 7 25 amp Parts List Shown AGE2 MX2 Retrofit Z Axis Sensor Mounting Bracket Bridgeport Series 2 Mill P N 16150 Bracket BOTTOM HOLE Item P N Description Qtv 1 Bar Driver 1 2 Square Run Bar 1 3 SW 1021 Bearing ND77R3 1 4 SW 1771 Dowel Pin 3 16 X 1 5 15987 Bearing Retainer Plate 1 6 2 9 9 Body Driver 1 16869 Clamp 1 6 32511 Cap Screw X 5 8long 2 163 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 2 Install the M5 Base on the bracket Parts required e M250C sensor and included hardware See Figure 5 3 in Section 5 a Putin 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 3 Install the sensor on the M5 Base using the clamp screw 4 See Figure 5 4 in Section 5 5 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 vou when it is loaded correctiv Note Y
124. er box on the three 3 studs and secure with 5 16 inch nuts and lockwashers Caution Never hammer studs to straighten them If necessary open the slots on the computer box Step 6 The computer box installation is now complete 169 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual Figure 7 30 AGE2 AGE3 amp MX2 MX3 Retrofits Computer Box Installation MOUNTING AUX FUNCTIONS PARALLEL LOGIS CABLE FROM PENDANT DISPLAY Cr STOP 170 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 31 AGE2 AGE3 amp MX2 MX3 Retrofits Cable Routing 171 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 32 AGE2 3 8 MX2 MX3 Retrofits Computer Cabinet Connectors ij H ae ro Auniiiery Function Cannaction AGE 3 Ord Paralisi Port ODE a O O OQ j r 2 1 Lune Motor Connectors 115V AC Power From Pendant E Stog 172 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 33 AGE2 AGE3 and MX2 Retrofits Pendant Drawer on the Left Side of Pendant Display Logic Cable to Computer Cabinet Note Be sure to connect the enclosed ground straps e From pendant t
125. ere the gibs are making contact It is recommended that the gibs uniformly contact at least 80 of the surface Binding or looseness in the Drive Train 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 Axis Motor belt too tight Loosen belt Misalignment of ball screw 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 e Codeii Measures backlash in system Used only with glass scales and sensors e Codei2_ Sets a feed forward power constant to drive axis motors e Code 128 Backlash compensation on single feedback machines compensation code 128 Run code 11 on dual feedback machines between 10 to 15 in Ibs Excessive friction in the sliding ways Lubrication gib adjustments gib locks See Machine Tool amp Setup Section 4 1 Looseness in the drive train The drive train of the axis that is searching especially the tightness of the drive assembly See Mechanical Drive Train X Y Sectio
126. erstood Do notrun 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 Protect your eyes Wear approved safety glasses with side shields at all times Don t get caught in moving parts Before operating this machine remove all jewelry including watches and rings neckties and any loose fitting clothing Keep your hair away from moving parts Wear adeguate safety headgear Protect your feet Wear safety shoes with oil resistant anti skid soles and steel toes Take off gloves before you start the machine Gloves are easily caught in moving parts Remove all tools wrenches etc from the machine before you start Loose items can become dangerous flying projectiles Never operate a milling machine after consuming alcoholic beverages or taking strong medication or while using non prescription drugs 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 e Before you open safeguards protective shields etc Never reach for the part tool or fixture around a safeguard Protect your eyes and the machine as well Don t use a compressed air to remove the chips or clean t
127. ervice 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 87 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 The list of service codes for the SM Controller can be seen on the pendant 4 9 1 Software Codes The following codes pertain to software functions in the control To get to anv of these codes go to Service Codes press A and press the code vou wish to view Note If vou are working with the SWI Customer Service Group write the values down for Code 33 or Code 313 SM only These values will be valuable for troubleshooting 4 9 1 1 CODE 33 Software ID The Code 33 is the software identification procedure The two types of software in the control include e Software Version the version of the system you have installed e Firmware Version the version of firmware software that is responsible for control to servo interface e Converter Version the version of software that is responsible for converters and options 49 1 2 CODE 37 RS232 Baud Rate This code sets the baud rate for RS232 applications The recommended baud rate is 9600 The following baud rates can be chosen 4800 9600 19200 38400 5760
128. es a ball screw extension see Step 40 Installing ball screw extensions Otherwise go to Step 41 39 Ball screw Extension Installation a b C Slide bushing onto end of ball screw Screw threaded extension snugly onto ball screw Tighten setscrew inside of threaded extension finger tight Back off the threaded extension 1 16 of a turn Tighten setscrew 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 preliminarv 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 awav and the motion is smooth again There is additional information on gib adjustments in Section 5 147 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 13 amp Parts List Shown SM Edge M2 M3 AGE2 AGE3 8 MX2 MX3 Retrofits X Axis Ballscrew Left End 148 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 14 amp Parts List Shown SM Edge M2 M3 AGE2 AGE3 8 MX2 MX3 Retrofits X Axis Ballscrew Right End 149 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Man
129. fting the Machine PROPER LIFTING SLING 4 BOLT TIGHTEN TO 47 FT LBS TORQUE BEFORE LIFTING TIGHTEN RAM LOCKING BOLTS BEFORE LIFTING MOVE TABLE AGAINST COLUMN INSTALLED GROSS WEIGHT OF MACHINE APPROX K2 2200 LBS K3 2800 LBS K4 3600 LBS i00887 30 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 2 17 Cleaning 1 Remove rust protective coating from the machine before moving anv slidewavs table saddle knee etc The coating is best removed with clean drv rags Do not use a cleaning solution that mav damage the rubber wav scrapers plastic parts or paint WARNINGI asoline or other flammable cleaning agents for cleaning the machine It mav be necessarv 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 on the ram on the right side of the column before attempting to move the above parts CAUTIONI Never move anv of the above parts over wavs that were not previousiv cleaned A Serious damage to the TURCITE surface of slidewavs can occur Be certain the table saddle ram and quill move freelv and smoothiv over their entire length 2 18 Leveling Leveling Tolerance is 0005 10 1 Set the machine on its 4 leveling pads on a solid level floor prepared in acc
130. ge 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 Flash disk failure SM Model 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 drive from time to time Only the flash drive module will need to be replaced Floppy disk failure 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 LCD backlight burns out Edge amp SM Model Check all cable connections to LCD distribution board and computer module Make sure the power is turned off before doing so Faulty E stop switch 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 SM and Edge Overlay failure keys on pendant Certain buttons on overlay do not work Do code 81 to verify each key beeps SM and Edge Low voltage to pendant or current spikes 1 amp fuse in pendant blows Pendant will not turn on 4 3 1 Checking Floppy Drive by Formatting a Disk SM Model Press R for run Dr STI pae Type Format
131. h a phase converter it is recommended that itis 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 forthe K2 and K3 and 6 KVA for K4 33 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2 20 K2 K3 K4 Electrical Box P N 20676 or 20676 1 100907 R r hale n a 9 e B E 8 9 8 5 Ey eto 34 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 K4 Electrical Box P N 20676 or 20676 1 Figure 2 20 Part Number Description K2 K3 K4 220V 20676 220V 20676 1 Electrical Box 440V 20676 440V 20676 220V 23438 220V 23438 1 Overload 440V 23438 440V 23438 23436 23436 Contactor Qtv 2 Reverse or Forward 2 20 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 Auxiliarv function options are only found on 3 axis mills If the machine has a power drawbar option then the machine will include a
132. h in the system Only used on machines with Dual Feedback systems e Code 12 Feed Forward Constant e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting Possible Cause Check This Cable connection problems Check all cable connections Make sure the Table and Saddle Locks are unlocked High torgue on any axis may cause faulting problems during alignment routine X and Y Gibs are adjusted extremely Check the adjustment of the X and Y Gibs using the X tight and Y Gib adjustment procedures See X and Y Gib Adjustments Section 5 2 1 Excessive friction in the slideways See Machine Tool amp Setup Section 4 1 Binding or looseness in the Drive Train See Mechanical Drive Train X Y Section 4 2 Incoming electrical power Incoming voltage See Electrical Section 4 8 Measurement system not functioning See Section 4 6 or 4 7 properly Servo Drive failure See Servo Driver Section 4 5 Motor failure See Motor diagnostics Section 4 4 Computer Pendant failure See Computer Pendant diagnostics Section 4 3 67 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service 8 Parts List 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 Check This Improper Boot up Shut down the system and wait 10 seconds before rebooting Floppy Disk failure The Floppy Disk ma
133. he machine oil coolant etc Disconnect power to the machine before you change belts pulley gears Keep work areas well lighted Ask for additional light if needed Do not lean on the machine while it is running Prevent slippage Keep the work area dry and clean Remove the chips oil coolant and obstacles of any kind around the machine Avoid getting pinched in places where the table saddle or spindle head create pinch points while in motion 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 4 Southwestern Industries Inc TRAK Knee Mill amp Sport Knee Mill Safety Installation Maintenance Service amp Parts List Manual 18 19 20 21 22 23 24 25 26 27 28 Use correct cutting parameters speed feed depth and width of cut in order to prevent tool breakage 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 After an emergency stop always turn the FORWARD REVERSE switch to Off STOP before releasing or resetting the E Stop Prevent damage to the workpiece or the cutting tool Never start the machine including the rotation of the spindle if the tool is
134. he 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 Check By Bad ball screw e Visual inspection of 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 e Cranking the ball screw through a significant part of its travel If it jams feel loose or has rough spots replace the ball screw e Dial indicates on a vertical flat of the ball screw to check for backlash between the ball screw and ball nut 79 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Potential Problem Check By Ball nut not tightened to e Inspection for space between the head of the bolt and the ball nut i e the voke the retaining bolt has bottomed out in its thread and is not securing the ball nut to the yoke properly Yoke loose in the saddle e Inspection for any motion of the yoke or looseness in the Yoke mounting screws Oil lines sheared e Visual inspection Oil line blockage e Pump the oil and ensure that it flows evenly to the ways and ball screw Ball screws not aligned e Measure from the ball screw to the back of the saddle on both sides of properly the yoke the table must be removed The measurements must be within 00
135. he 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 nvlon wiper 10 Attach the provided plastic oil line to the elbow oil fitting Slide the ball screw into the voke with the flange of the ballnut to the left Do not install the 5 16 18 x 1 34 screw yet 11 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 12 Secure the ballnut to the yoke with 5 16 18 x 1 34 screws 13 Optional If the yoke was pinned previously replace the pins and then tighten the yoke to the saddle 14 If the yoke was not pinned it will be necessary to align the ball screw 137 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual BALLSCREW Take measurement A on the left and right sides of the saddle casting So that the measurements are comparable BACK measure from the OD of the thread of the ballscrew on saooLe 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
136. her 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 Service Codes TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual 5 0 5 1 5 2 6 0 6 1 6 2 6 3 6 4 7 0 7 1 7 2 7 3 7 4 4 9 1 Software Codes 4 9 2 Machine Set Up Codes 4 9 3 Diagnostic Codes 4 9 4 Operator Defaults Options Codes Procedures for Replacements amp Maintenance Replacements 5 1 1 Servo Motor Replacement 5 1 3 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 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 Spindle Motor Wiring Feed Trip Adjustment Quill Clock Spring Replacement amp Adjustment Spindle Motor Removal amp Replacement Drive Belt Replacement Timing Belt Replacement 5 1 18 Brake Shoe Replacement 5 1 19 Spindle Replacement Maintenance Gib Adjustments Calibration amp Backlash Constants Head Rotational and Tramming Limit Switch Option 95 5 1 12 5 1 13 5 1 14 5 1 15 5 1 16 5 1 17 Re
137. 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 10 In reassembly be certain the fine speed adjustment Screw B goes into the slot of the Speed Change Plate D inthe area in which the screw is not threaded Figure 5 18 K2 K3 K4 Speed Changer Plate SPEED i BELT CHANGER 2 HOUSING C SUBPLATE 100156 5 1 17 Timing Belt Replacement 1 Remove the motor and drive belt 2 Slide the top or adjustable varidisc pulley assembly off the shaft 3 Remove the three M8 screws holding the belt housing base to the gear housing 4 Lowerthe guill about 4 inches 121 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 Remove the belt housing base and lower or stationarv varidisc pullev assembiv 6 Replace the timing belt 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 varidisc pulley This is a slig
138. ht 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 set screw 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 5 19 K2 amp K3 Spindle Quill Assembly QUILL AN NE AX NA AN NN E AN N se 2 3 I SCREW AN DE AN o AS INI zz NOSEPIECE N I LEFT HAND S THREAD HOLE FOR SPANNER 100157 WRENCH 122 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 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 Adjustment X Axis See Figure 5 20 1 Clean all chips dirt
139. igure 2 21 in Section 2 for an illustration of this assembiv 5 1 12 Spindle Motor Wiring Trak K2 K3 K4 The K Mill spindle motors are wired for 220 or 440 volts See Figure 5 14 for how to wire the motor Figure 5 14 K2 K3 K4 MOTOR GROUND SCREW Spindle Motor Wiring 118 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 1 13 Feed Trip Adjustment If the feed trip is adjusted too light it will inadvertentiv trip when drilling If too heavv it will not trip accuratelv and stress the mechanism The correct adjustment depends on the operation to be performed To adjust Release the lock nut Engage the trip handle move it left Adjust the micrometer nut against the quill stop knob Slowly turn the adjusting screw until the handle trips Tighten the lock nut GPS a NA Check the reaction If too sensitive lower the adjusting screw slightly If too heavy raise it Figure 5 15 K2 K3 K4 Feed Trip 100153 5 1 14 Quill Clock Spring Replacement and Adjustment The quill Clock Spring counterbalances the weight of the quill and tool Figure 5 16 K2 K3 K4 Quill Clock Spring QUILL HANDLE p HUB ka lan SPRING HOUSING s B 119 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 1 Move the quill to its top position and lock
140. indle Assembly Fig 134 Base Machine Fig 135 Base Machine Fig 136 Transformer Option 220 440V Fig 137 Transformer Option Safety Switch 200V 440V TRAK K2 K3 8 K4 Safety Installation Maintenance Service 8 Parts List Manual 1 0 Safetv The safe operation of the TRAK K Mills and retrofit mills depends on its proper use and the precautions taken bv each operator e Read and study this manual and the ProtoTRAK Programming Operating and Care Manual Be certain everv operator understands the operation and safetv requirements of this machine before its use e Always wear safety glasses and safety shoes e Always stop the spindle and check to ensure the CNC control is in the stop mode before changing or adjusting the tool or work piece e Never wear gloves rings watches long sleeves neckties jewelry or other loose items when operating or around the machine e 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 The Construction Care And Use of Drilling Milling and Boring Machines ANSI B11 8 1983 Available from The American National Standards Institute 1430 Broadway New York New York 10018 Concepts And Techniques Of Machine Safeguarding
141. ine 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 4 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 4 005 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 X axis or the bracket on the Y axis 4 Install the reader head bolts but leave them loose 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 101 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 WARNINGI After the reader head is attached to the reader head mounting bracket do not move the machine axis until the shipp
142. ing bracket is removed This will break the reader head This is not covered under warrantv See Figure 5 7 for an illustration of how to align glass scales 5 1 7 3 Install the Z Axis Glass Scale See Figure 5 6 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 Tapitems 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 approximatelv 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 glas
143. it e Abad fuse reads Open or Infinity 4 8 3 Cable Breakout Box Connections M amp SM Models 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 e Control problems chronic or intermittent e Motor problems e Measurement problems Explanation l Turn off and unplug the system from the wall WARNING 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 displav 5 Make sure to tighten up the screws on each of the connectors 4 9 Service Codes All Service Codes are accessed in the SET UP Mode by pressing the soft key for SERV CODES The s
144. ith 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 e First part of the X axis ball screw assembly e Second the entire Y axis ball screw assembly e Third the rest of the X axis ball screw assembly Parts required e Yoke kit 15844 xx e X Axis drive kit 20255 xX e X Axis ball screw Figure 7 4 Knee Mill Retrofits X Axis Ballscrew RIGHT LEFT A slet l WRENCH FLAT i RENEE HANDWHEEL 10 32 ui SCREW HERE MOUNTS THIS MOTOR MOUNTS FLANGE SIDE THIS SIDE A Nominal Length Actual RS 4409 3w 48 5609 5r 62 09 SECTION AA ELBOW OIL FITTING HERE 100672 Note There are wrench flats on the X and V ballscrews for convenience CAUTIONI Unlike a leadscrew never unscrew a ball screw from its nut This will destrov the ball screw 8 Position the voke in the saddle with the threaded hole on the left Do not secure the voke to the saddle yet you will need to lift the voke to slide in the ball screw 136 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual Figure 7 5 Knee Mill Retrofits Ball Screw Yoke Assembly 9 In the ballnut flange there are two tapped 10 32 holes One for t
145. ks are released On the Pendant displav go into the Service Codes and input the Code 100 The conversation line will say SELECT AXIS Input the axis Either X Y or Z In the conversation line it will say WHICH DIRECTION PLUS Tu BDS EX e f you want to run in the plus direction press INC SET e f you want to run in the minus direction press then INC SET 5 Inthe 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 Your input X Vour input nothing should be 0 V 4 table encoder reading Motor encoder reading the maximum feedrate attained Vour input ie Your input Z Your input ds Interpretation of the resulting values displayed The values for the encoder displays should be in the range of 3 0000 to 5 0000 91 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual e 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 e The f
146. l Parts List K4 Base Machine Assy Figure 135 Item P N Title Comments 1 FC1 QUILL HOUSING GEAR 2 FC10 RAM 3 FC11 LIFTING EYE BOLT 4 FC23 TABLE 50 5 FC24 SADDLE BOTTOM GIB 6 FC25 JGIB BLOCK 7 FC26 GIB 8 FC27 JGIB BLOCK 9 FC28 JSET SCREW 10 FC29 JSET SCREW 11 FC31 STOP PIECE T BOLT Available oniv in 20869 12 FC32 TABLE STOP PIECE Available oniv in 20869 13 FC33 JHEX NUT Available only in 20869 14 FC37 TABLE LOCK HANDLE Available oniv in 20868 15 FC39 SADDLE LOCK PLUNGER Available oniv in 20868 16 FC42 TABLE STOP BRACKET not shown on dwg 17 FC43 JSADDLE TABLE GIB 18 FC44 SADDLE CHIP WIPER 19 FC45 SADDLE CHIP WIPER PLATE 20 FC46 TABLE LOCK PLUNGER 21 FC48 TABLE LOCK BOLT HANDLE 22 FC49 JSADDLE GIB 23 FC51 JCAP SCREW 24 FC52 JSADDLE 25 FC53 LEFT HAND COLUMN WIPER HOLDER 26 FC54 KNEE WIPER FELT 27 FC55 KNEE COLUMN GIB 28 FC56 JALLEN CAP SCREW 29 FC57 RIGHT HAN COLUMN WIPER HOLDER 30 FC58 KNEE WIPER FELT 31 FC59 CHIP GUARDS UPPER Available only in 20867 32 FC60 CHIP GUARDS MIDDLE Available only in 20867 33 FC61 JCHIP GUARD LOWER Available only in 20867 34 FC62 KNEE 35 FC65 KNEE PLATE 36 FC66 JCAP SCREW 37 FC67 GIB BLOCK 38 FC68 KNEE GIB 39 FC69 GIB BLOCK 40 FC70 CAP SCREW 41 FC71 CAP SCREW 42 FC72 CAP SCREW 43 FC73 JCAP SCREW 44 FC74 JAMNUT 45 FC75
147. lation of the Motor Assembly Lagun Z Axis Cut Out System Checkout and Configuration 8 5 1 Initial System Checkout 8 5 2 Calibration Introduction to Self Service 186 When You Have a Service Problem 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 188 Top Housing Assembly 40 Taper Gear Housing Sub Assembly Hi Low Slip Clutch Sub Assembly Hi Low Shift Sub Assembly Pulley Pinion Sub Assembly Lower Vari Disc Sub Assembly Upper Vari Disk Sub Assembly Speed Change Handwheel Sub Assembly Spindle Motor Sub Assembly Bottom Housing Assembly Worm Gear Cradle Sub Assembly Quill Feed Selector Sub Assembly Quill Pinion Shaft Sub Assembly Overload Clutch Trip Sub Assembly Feed Reverse Clutch Sub Assembly Quill Spindle Sub Assembly Top Housing Assembly R8 Gear Housing Hi Low Shift Clutch Sub Assembly Hi Low Shift Sub Assembly Pulley Pinion Sub Assembly Lower Vari Disc Drive Upper Vari Disc Drive Sub Assy TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Fig 125 Speed Change Handwheel Fig 126 Spindle Motor Fig 127 Lower Head Assembly Fig 128 Worm Gear Cradle Fig 129 Quill Feed Selector Fig 130 Quill Pinion Shaft Fig 131 Overload Clutch Trip Fig 132 Feed Reverse Clutch Fig 133 Sp
148. lav and repeat the procedure If the measurement does not repeat you have a repeatability problem that must be resolved before the accuracy problem can be resolved See Measurements That Do Not Repeat Section 3 4 1 Possible Cause Do This The Calibration is incorrect Recalibrate the machine See Calibration amp 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 e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting e Code 304 amp 305 Turns off X and Y sensor or scale SM CNC only Possible Cause Check This Servo driver failure See Servo driver Section 4 5 Motor Encoder not counting See Motor diagnostics not applicable with Glass Scale option Glass Scale or Sensor Failure Does axis now count If so replace scale Computer Pendant failure See Computer Pendant diagnostics 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 e Xaxis Table moves to the left e Y axis
149. ll break the Sensor or mounting base Install the drain plug provided to discourage the re attachment of the drain tube 160 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 23 V Axis Bracket Installation 18 SPACER PLUS SHIMS AS REQUIRED FRONT VIEW OF MILL 100915 The Run Bar should be e Installed with 2 screws minimum size 20 e Spaced from the knee appropriately to reach the sensor e Free of twist e 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 5 3 and 5 4 show the bracket that comes with the ProtoTRAK SM 2 1 and other kits Examples of other brackets and mountings are 161 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 24 Other X 8 Y Brackets Supplied with Kits JIE X BRACKETS P N BR17MX P N BR 17 Universal P N BR 17C Universal P N 16023 1 Mount to back of Mount to side of Mount to back of saddle saddle saddle X BRACKETS x x SR SS 100913 P N BRASTV P N BR17D 1 dela P N 13384 Mount to front of i saddie Mount to front or back of saddle 162 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maint
150. ll through the threaded quill stop rod Install the 2 each 6 32 leveling screws to each mounting bracket Mount the scale loosely to the mounting brackets with a 1 4 20x 2 bhcs and M6 washer 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 Mount the readerhead bracket to the quill stop knob with the pin and 20x 1 shcs 158 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Remove the readerhead cover plate and position the readerhead bracket so its holes line up with the holes in the readerhead Use shims as necessarv 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 ofthe scale installation is the same as the X axis Steps 5 through 7 Kev 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 a
151. n 4 2 64 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List 3 3 Problems Relating to the Operation of the Control 3 3 1 Displav Blanks The displav is completelv blank Perform the Logic Cable Test Logic Cable Test MX2 3 and AGE2 3 models only Used for the diagnosis of problems with the pendant and or computer module Follow these steps then call back to the Service Department with the results of the following steps if your problem is not solved 1 Adjust the brightness knob on the back of the pendant making sure it is not turned all the way down 2 Check both fuses on the pendant and in the computer module making sure they are not blown 3 If there is a remote stop go switch RSG attached to the system remove it Then reboot the system by turning it off waiting 30 45 seconds then turning it back on This step may correct your problem If your problem persists after completing step 3 continue to step 4 4 Locate the cable on the back of the display pendant labeled Cable Logic itis a 32 pin computer cable held in by two thumbscrews 5 With the power to the system turned on remove this cable and you should see nine 9 clearly defined evenly spaced amber horizontal bars on a black background Also every key should beep as you press it 6 If you do not get the nine 9 horizontal bars and the keys do not beep then turn the system off leaving th
152. n FTV2 reguires the following material to be removed from the box that holds the Lagun nameplate Figure 8 5 Retrofits Going On Lagun Machines Z Axis Cut Out CUT BACK T TMS AREA Pat Se a mt Unfortunately there is not a really good way to do this Your choices are e Have the head machined e Use a hacksaw e 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 183 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 8 5 System Checkout and Configuration 8 5 1 Initial System Checkout Check the following e All cables are plugged in to their proper connectors e All cables are secured and do not restrict the travel of the machine e No high voltage lines are lying next to CNC cables e The CNC is ona dedicated power line Turn on the power e Pendant lights up e Inthe DRO mode each axis counts correctly e Jog at rapid 100 ipm works for each axis in each direction Do the following service routines found in the SET UP mode special codes e Code 11 System hysteresis e Code 12 Feed Forward constant 8 5 2 Calibration Step 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 Step 2 Set up gage block as shown in Figure 8 6
153. n air regulator air manifold and an oiler The air fitting is a NPT Within the manifold there is an additional airline port in case the user wants to hook up an airline 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 factorv 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 svstem the user may install later on this machine There is a quick disconnect air fitting on the solenoid where the mister air hose can be plugged into See Figure 2 21 for an illustration 35 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2 21 Air Regulator Solenoid Assembly juua Kl JR 0 JA ec SN NE AN t SY Sr M l 36 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Figure 2 22 Enclosure Assv Transformer Option 23440 220 8 23440 440 SECTION B B ml iu 89 g B 37 Southwestern Industries Inc
154. n the order presented Problems Here May Indicate 1 The wall outlet e Fuse blown in the shop electrical panel e Incoming service from local utility is bad Call the electric company 2 The control power cord from the wall e Power cord defective Check the end that goes to the electrics box 3 Check the top fuse on the electrical cabinet e If this is blown then power will not reach It should be a 8 amp fuse the 4 outlets on the electrical box 4 Check the 110 power cord to the pendant e Power cord defective 4 8 2 Checking Fuses There are 5 fuses to check in the system There are 2 in the pendant and 2 in the electrical cabinet The top fuse in the electrical cabinet is 8 amp and fuses power to the pendant The bottom fuse is 5 amps and fuses power to the auxiliary 1 auxiliary 2 and 86 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual lube pump outlets The 2 fuses in the pendant are 1 amp and 8 amp The 8 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 Usea 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 e A good fuse reads 0 zero or close to
155. nd 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 f 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 e Broken sensor base e Broken bracket e Sensor tilted too much so that the wheel is not engaging the running surface e Sensor chip scraper has doubled back and is pushing the wheel away from the running surface e 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 e Mount a dial indicator in the quill e Touch off a fixed point on the table and set the DRO to 0 e Traverse away approximately 6 inches e Return and touch off again e Write down the reading on the DRO e Do not re zero the DRO traverse away and return several times e 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 85 Southwestern Industries Inc TRAK K
156. nd down then adjust the angle of the scale to make the gap consistent WARNING The gap must be no larger than 0 060 between the readerhead and glass scale Part No Description I brae 385026 102 Bracket Upper E SCREWS AND WASHERS 1 385026 103 10 32 x 3 8 bhes I2 1 Es SUPPLIED WITH SCALE HARDWARE 100917 385011 153 Pin 385001 372 1 4 20 x 1 shes ZI Figure 7 21 amp Parts List Shown Z Axis Glass Scale 159 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 7 6 TRAK Sensor Installation Optional See Section 5 of this manual for more sensor information Parts required e Sensor M250C e XY 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 anv 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 wav back and the knee is lowered Figure 7 22 X Axis Bracket Installation FRONT VIEW OF MILL Caution For the X axis make sure the drain tube is removed from the path of the TRAK Sensor A crash of the sensor wi
157. need to be adjusted periodically 1 Seta 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 xc o PESIMODE 0 f Backlash Value _ _ _ f 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 g The following is an example of what you For example if the up and down Oscillation might see when running this code 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 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 e Load the indicator to zero from one direction and zero out the DRO e Move the indicator to 0 002 and then back to zero Do not over shoot 0 otherwise start over e Whatever number appears on the screen is the backlash value 128 Southwestern Industries Inc TRAK K2 K
158. ns 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 4 9 4 1 Code 66 Default Metric 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 Accuracv When the SM 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 inputthe Following Error value from 0001 to 0100 and press INC SET 4 9 4 6 Code 323
159. nterconnections 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 See Figures 2 27 through 2 30 for a complete illustration of cable interconnections for all components 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 46 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual kev plugged into it The monitor port RS232 handwheel spindle control and network ports will be left emptv 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 wav forward toward the operator The following drawing describes all of the cable connections to the pendant Make sure there is a hardware option kev plugged into the parallel port of the pendant This key activates any converters or options ordered The part for this key is 22648 The kev must be programmed according to the tvpe of machine it is on and the options ordered The LPTI port must have the machine ID kev plugged in or the machine
160. o computer box e From computer box to an appropriate earth ground or to the machine 173 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 34 M2 M3 SM2 SM3 Retrofits Cable Routing with External Connector Box loop excess cable and secure loops with cable nes 174 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 35 M2 Pendant Display Back View Basic Configuration o FLOPPY DISA DRIVE PARALLEL PORT ari ASC NM VIS V OM or o E Stop CONNECTOR RELAV ASSEMBLY toot ORTON AL Figure 7 36 M2 Pendant with X Y Encoders amp M3 Pendant Uses External Connector Box ta FLOPP bse mmt PARALLEL SORT Li T stor il ge ASC In 115 v Z AWS 1 0 ON DEF ayy AMS 1 0 175 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 7 17 M2 M3 Retrofits External Connector Box AUX I O M ONLY X Y AXIS I O SENSOR LIMIT SWITCH MOTOR AIC POWER IN 120265 176 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 7 10 Svstem Interconnection All connections of motors and the Z axis glass scale are made at the back of the pendant display See Figure 7 38 for a
161. oder calibration constants X 610 0711 Y 610 0812 Z 610 0678 Secondary feedback calibration constants X 3302 6122 Y 3302 5955 Z 3302 5877 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 88 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Secondary feedback 0 1 2 or 3 0 off 1 X on only 2 Y on only 3 XV 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 X22071 Y 208 4 Z 203 6 4 9 1 6 CODE 316 Update Master Software SM Model Load upgrade disk in floppy 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 317 Update Slave Software SM Model Load upgrade disk in floppy drive and press this service code New software will automatically download and control will reboot Please perform alignment routine afterwards 4 9 1 8 CODE 318 Activate Converters or Options SM Model See programming and operating manual 4 9 2 Machine Set up Codes The following codes are used primarily when setting up
162. 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 necessarv e Toadjustthe 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 necessarv Figure 5 23 K3 8 K4 Saddle Bottom Gib Adjustment 100025 126 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 5 2 2 Calibration amp 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 5221 XY 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 indica
163. 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 left to prevent damage or breakage to the dovetails 6 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 7 Tilt the yoke it is pinned to remove the ball screw 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 107 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Important The clamp nut must be reassembled as follows e 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 e 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 e Torque the split nut to 50 ft Ib e 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 5 9 for an illustration of the X axis dri
164. ontactor s in the electrics box Check vour 110V power across terminals wire 3 and ground If power is not reaching the electrical cabinet but is reaching the cable breakout box then most likelv a relav has failed in the cable breakout box The cable breakout box will need to be replaced This relav is in series with the 110 V power in the E stop circuit See Section 3 3 11 If power has reached the electrical box then use the schematic in Section 4 8 for how the power is routed Possible Cause Check This Wrong voltage Check the 220V 440V voltage to the machine Poor wiring connections Check all the wiring connections to the electric s box Defective cables or poor cable Check all cable connections connections Spindle Motor is bad Check the resistance of the Spindle Motor windings on the Spindle Motor between L1 amp L2 L2 amp L3 and L1 amp L3 using an Ohmmeter The resistance should range from 7 to 1 2 Ohm for 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 amp Ground L2 amp Ground and L3 amp Ground using an Ohmmeter The resistance should read OL If not then replace Spindle Motor Spindle will not run because 110 V Check 110 V coming out of the AC e stop port on the cable power is not reaching the spindle breakout box Relay failure in cable breakout box Replace cable contactor breakout box 74 Southwestern
165. ordance with the state and local rules for machine tool installation Put one or two precision Spirit Levels or Electronic Levels in the center of the table in the positions illustrated in Figure 2 18 Adjust the 4 corner leveling screws on their pads until the machine is level to 0005 in 10 in If the machine must be anchored to the floor follow the general instruction for installing machine tools and use for leveling anv well known methods shims etc If the machine must be installed on vibration mounts pads rubber commerciallv available leveling and vibration mounts etc follow the instructions delivered with the mounts pads ordering them to satisfv the load of the machine and the maximum weight of the workpiece When machine is correctiv level lock the adjusting screws in place with their hex nuts 31 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2 18 Placement of Levels 100138 32 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 2 19 Electrical Connection The TRAK K2 K3 amp K4 Knee Mills can be configured for 220 or 440 volt 3 phase electricitv These machines also require a 110V power source to power the control DANGERI Be certain that 200 volt electricity typical range 208 240V is used only with a machine labeled 220 volts at the motor and atthe
166. ou want to load the gage wheel against the running surface using the flexure of the M5 Base Do not tighten the clamp screw fullv until after loading the sensor 7 7 Xand 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 5 7 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 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 name plate shield
167. r No air is required Space amp Weight BED FOOT PRINI e Floor area 101 x 70 e Height 85 e Footprint 24 x 39 e Net Weight 2800 Ib Shipping Weight 3100 Ib 2 A 0 The floor area encompasses the space 29 7 38 8 required for the table to move full travel in both directions plus a 22 clearance from the rear of the bed This space at the rear will be required in case it is necessary to make repairs to the electrical cabinet 21 9 A solid and level foundation to maintain 24 DI approximately 3100 Ib plus the weight of oi the workpiece maximum total 3950 Ib is required Four leveling screws are provided Figure 2 4 TRAK K3 11 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 2 6 Site Preparation Trak K4 Electrical e 115 VAC 60 Hz 8 AMP 1 Phase e 220 VAC 60 Hz 14 AMP 3 Phase OR e 440 VAC 60 Hz 7 AMP 3 Phase A separate 115 VAC circuit with a 15 AMP breaker originating at the main power panel for shop electrical service and dedicated to the sole use of the K4 is required to maintain proper operation Machine tool must be earth grounded Standard 3 prong 115V wall socket is required in addition to the 220 440 VAC line o NOTE The customer is responsible for hooking up the 220 440V to the mill Air No air is required BED FOOT PRIMI Space amp Weight e Floor area 101 x 72 e Height 9
168. r the pivot point of the arm Use a 36 drill bit for drive 9 On retrofits and TRAK knee mills make sure to plug in the machine ID key 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 Model SM CNC only 11 Load master and slave software from software upgrade disk The pendant may or may not have the latest software loaded Retrofits only 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 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
169. ram up or down as necessary 2 Pressthe Mode or Return key to reset the control 3 Press the DRO key to enable the machine to once again jog box is making poor contact described above Poor Limit Switch Cable connection Check for any pins that are loose pushed in or bent Verify that there is a good connection between the cable on the cable breakout box Limit Switch failure Does the limit switch problem move to the other axis If it does then the switch is most likely the problem Try this If it stavs with the original axis then it could be the Switch 2 limit switch cables on the cable cable breakout box 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 egual 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 abruptiv changes by a large amount it may be caused by a bad encoder Expected repeatability numbers should be 0 0005 or less
170. remaining items on Figure 7 8 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 32 20 hex nut to 50 ft Ib Move the saddle back and forth through full travel to inspect for smoothness 7 1 4 X Axis Ball Screw Installation Part 2 CAUTIONI Unlike a leadscrew never unscrew a ball screw from its nut This will destrov the ball screw 31 Attach the X Axis ball screw oil line Liberallv lubricate all wav surfaces 32 Screw the X axis ball screw out of the wav and remount the table Oil and reinstall the X gib CAUTIONI Make sure the gib locks have not fallen into the saddle before vou slide the table back on 144 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 49 0011 1550848 Figure 7 12 SM Edge M2 M3 AGE2 AGE3 amp MX 2 MX3 Retrofit X Axis Drive Train 145 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List SM Edge M2 M3 AGE2 AGE3 8 MX2 MX3 Retrofits X Axis Drive Train Figure 7 12 item PIN me Oy 4 564 JFromcovr 1 6 6
171. rements after installation Digital Servo Amplifiers custom designed fpr TRAK AGE2 operations DC Servo Motors rated at 280 in oz continuous torgue for X and Y Ball Screws in the table and saddle ensure smooth accurate contours without backlash Closed loop Feedback utilizing 000036 resolution motor encoders Modular Design simplifies service and maximizes uptime 115V 60Hz 15 amps Feedrate Override of programmed federate and rapid Polycarbonate Sealed Membrane Keypad and Gasket Sealed Control Enclosures to lock out contamination 9 CRT for clear presentation of prompts status information and part graphics Built in Floppy Disk Storage for program storage RS 232 Port for interface with computers 16 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual 2 sia ProtoTRAK AGE 2 and 3 Software Specifications Auto Geometrv Engine Diameter Cutter Compensation Circular Interpolation Linear Interpolation Conrad Incremental and Absolute Programming Error Messages Fault Messages Program Downloading Teach Mirror Image and Rotation Software Programmable Part Graphics Look Math Help Edit Tool Stepover Scaling For AGE 3 2 Axis Circular Interpolation 3D Graphics Tool Length Offsets 17 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Figure 2 8 AGE2 AGE3 Front Panel N uj lt gt
172. rew assembly 180 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 8 3 Installation of the Motor Assembly Figure 8 3 amp Parts List Shown M3 AGE 3 8 MX3 Retrofit Z Axis Motor Assembly PartNo Description term 20296 Motor Driver Assembly 1 16235 Motor Plate Support 2 E Assemb 16238 Pivoting Shat Eu Head ELA SA Screw 1 4 20x3 8 Socket Set Screw 1 4 20x5 8 Socket Head Cap Screw 10 Assemble the parts shown in Figure 8 3 Note Item 6 is only to keep the pivoting shaft from falling out it should contact the shaft fingertight but do not tighten it against the shatt 181 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service 8 Parts List Manual Figure 8 4 8 Parts List Shown M3 AGE 3 8 MX3 Retrofits Z Axis Baseplate Motor Slide amp Covers Assembly 16237 Belt Guide Roller__ 6 15759 FlatWasher 18 16218 Lateral Cover 9 11 Install the motor slide body assembly Note Put the motor in the locked position and slide the motor slide body to adjust the belt tension 12 Install the covers 182 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 8 4 Lagun Z Axis Cut Out The ProtoTRAK SM3 installation for the Lagu
173. rly N A to retrofits 28 Wipe down the machine prior to leaving 2 8 Machine Specifications K2 K3 K4 Movement and ranges X Y Z axis 33 x 12 x 16 32 x 16 x 16 32 x 1612 x 16 Vo Quill Travel maximum 5 5 5 Quill Diameter 3 3 8 3 3 8 3 15 16 Spindle Taper R8 R8 40 Speed Range 60 4200 RPM 60 4200 RPM 70 3950 RPM Spindle to Column 8 to 20 8 to 23 7 to 26 Quill Feeds Per Revolution of Spindle 0015 003 006 0015 003 006 0015 003 006 Head Swivel L R 90 90 90 Head Tilt 45 45 N A Spindle Motor Power 3HP 3 HP 5 HP Voltage 220 440 V 220 440 V 220 440 V Phase Cycle 3 phase 60 Hz 3 phase 60 Hz 3 phase 60 Hz Current 8 5 4 25 amps 8 5 4 25 amps 14 7 amps Maximum Weight of Workpiece 750 Ibs 850 Ibs 850 Ibs 2 9 Maximum Work Capacities K2 K3 K4 Drilling Mild Steel 1 112 Tapping Mild Steel 1 1 Milling metal removal rate mild steel 1 in min 2 in min Maximum work capacities are dependent on a lot of variables that cannot be controlled by the machine manufacturer Each one ofthe 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 2 10 ProtoTRA
174. rol AGE Edge Edge Control Control Control control Electrical Box 220V 20676 20676 1 20676 20676 1 20676 20676 1 440V 20676 20676 20676 20676 20676 20676 ius aen 20290 20290 n a n a 23050 23050 Cable Breakout Box with Aux 20290 1 20290 1 n a n a 23050 1 23050 1 Functions ano e 9001 9001 9001 9001 9001 9001 Lube Pump 2 16 Lifting and or Moving the Machine The K2 K3 amp K4 machines weighs approximately 2200 2800 amp 3600 Ibs respectively Proper equipment of sufficient capacity must be used when lifting and or moving the machine See Figure 2 17 CAUTION 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 2 17 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 the steel bar and all protective cardboard 29 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2 17 K2 K3 K4 Li
175. rts List Manual Parts List K2 K3 K4 Knee Mill Component Identification Figure 2 15 Item P N Description Model 1 19969 Pendant M2 without sensors k2 k3 k4 Sport mill with M2 2 19969 1 Pendant M2 with sensors k2 k3 k4 Sport mill with M2 3 20180 Pendant AGE2 k2 k3 k4 TRAK Mill with AGE2 4 22328 3 Pendant SM2 k2 k3 k4 TRAK Mill with SM2 5 20347 Pendant M3 without sensors k2 k3 k4 Sport mill with M3 6 20347 1 Pendant M3 with sensors k2 k3 k4 Sport mill with M3 7 20180 1 Pendant AGE3 k2 k3 k4 TRAK Mill with AGE3 8 22328 3 Pendant SM3 k2 k3 k4 TRAK Mill with SM3 9 20819 Spindle Motor k2 k3 10 20820 Spindle Motor k4 11 15616 Y axis Handwheel Saddle k2 k3 k4 12 15616 X axis Handwheel Table k2 k3 k4 13 20296 XYZ Motor k2 k3 k4 27 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2 16 K2 K3 K4 Knee Mill Rear View A A jU SN 7H T zm HE SH ET IL 4 JA L ELECTRICAL BOX le i pm E J Te MANU Jan imi S e COO PUMP 100888 28 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 K4 Knee Mill Rear View Figure 2 16 K2 K3 Aen K2 K3 K4 M K4 AGE K2 K3 SM K4 SM Deserphon M control Cont
176. s 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 e 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 186 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 9 2 Replacements 9 3 1 Exchange Program SWI keeps in stock the major subassemblies required to resolve service problems With verv few exceptions the part needed to resolve anv given service problem is on the shelf and readv to ship A little bit of troubleshooting on vour part means that we can get the right part to vou fast After replacing the failed unit with the replacement unit simplv 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 unigue 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 qualitv replacement units are available at a fraction of the price of a new sub
177. s scale when moving the quill up and down then adjust the angle of the scale to make the gap consistent WARNING The gap must be no larger than 0 060 between the readerhead and glass scale 102 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 5 6 amp Parts List Shown K2 K3 K4 Z Axis Glass Scale Assembly di 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 6 10 32X11 425B SCREW SHCS STL BO WASHER 1 4 HARD BLK OX 1 8 THK 8 116X12818 SPRING PIN 9 1 4 28X3 825B SCREW SHCS STL BO 100891 103 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual ACU RITE GLASS SCALE ACU RITE GLASS SCALE E K2 K3 K4 Y Axis Glass Scale Alignment QTY PARTNUMBER DESCRIPTION _ NO 4 911204130 WASHER EXTERNAL SERRATED LOCK 12 4 911664230 JWASHER FLATM470B 11 4 1 4 20x1 00 25B SCREW SHCS STLBO 10 WASHER SPHERICAL 1 SET 9 2 1 471Z2 WASHER USSFIAT STL BO 8 4 1 473Z WASHER SPLITLOCK STLBO 6 1 20904 MOUNTING BRACKET 4 2 2055 ADJUSTMENT SCREW o 3 1 20546 1 SPACER Y AXIS 2 1 20544 MOUNTING PLATE Y AXIS 1 100894 104 South
178. se labels 2 Southwestern Industries Inc TRAK Knee Mill amp Sport Knee Mill Safety Installation Maintenance Service amp Parts List Manual 100320 SOUTHWESTERN INDUSTRIES owe 2605 HOMESTEAD PLACE RANCHO DOMINGUEZ CA 90220 CV WI TM make M INN AC SPINDLE MOTOR MOSES ISA 60 xz GAPS FULL LOAD CURRENT CNC CONTROL UNIT no NORS EIN 60 fv AMPS FULL LOAD CURRENT OVERLOAD PROTECTION IS NOT PROVIDED AT THE MACHINE MACHINE ONLY MADE IN TAIWAN Safety amp Information Labels Used On The TRAK K2 K3 amp K4 Milling Machines It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels Power Requirements at 220V and 440V 3 Phase 60Hz K2 K3 K4 Overload Setting 220V 8 5A 14A Overload Setting 440V 4 25A TA FLA of Largest Motor and Machine amp 220V 8 5A 14A FLA of Largest Motor and Machine 440V 4 25A JAE Replace the entire electrical enclosure when re wiring spindle motor for different voltage 20676 for 440V 20676 1 for 220V 3 Southwestern Industries Inc TRAK Knee Mill amp Sport Knee Mill Safety Installation Maintenance Service amp Parts List Manual 10 11 12 13 14 15 16 17 Safetv Precautions Do not operate this machine before the TRAK K Mill Installation Maintenance Service and Parts List Manual and ProtoTRAK SM Programming Operating 8 Care Manual have been studied and und
179. sembly not available order parts separately i20778 5 217 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 Lower Vari Disc Drive P N 20778 5 Figure 123 assembly not available order parts separately 3 vs58 FRU K3 TURNINGBIOCKSHAFT 1 4 VS103 FRU K3 RETAININGRINGG7 1 5 vss51 FRU K3 SETSCREWM6 1 0X6 2 V NIP V VS50 2 FRU K3 SCREW FH PH STL BO M6 1 0X6L 24055 BRAKE SHOE ASSY 1 i20778 5 VS46 FRU K3 BRAKE BEARING CAP 1 VS43 1 FRU K3 BALL BEARING 6010ZZ 1 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 218 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 124 K2 K3 Upper Vari Disc Drive Assy P N 20778 6 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 Upper Vari Disc Drive Assy P N 20778 6 Figure 124 Item P N Title Qtv 1 VS42 FRU K3 SPINDLE PULLEV BEARING HOUSING 1 2 24643 BEARING DEEP GROVE 6210ZZ 1 3 VS44 FRU K3 ADJUSTABLE DRIVEN VARIDISC 1 4 VS36 FRU K3 SPEED CHANGE PLATE 1 5 VS38 FRU K3 PIVOT SLEEVE 5 2 6 VS37 FRU K3 WASHER M5 PO 8X20L 2 7 VS123 FRU K3 SCREW SHCS M5 0 8X20L 2 8
180. ses 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 Reverse X position sensor direction SM Model 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 11 Code 325 Reverse Quill Sensor Direction SM Model 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 92 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 4 9 3 1 Code 54 Program Continuous Run This Code runs a program continuousiv 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 SM model 2a Press MODE SET UP Code 54 INC SET The program run will start automatically all other mod 3 Press STOP to stop and GO to continue 4 9 3 2 Code 81 Keyboard Test Edge 8 SM only This code is used to check if the keyboard is functioning correctly It allows you to test each key on the pendant indi
181. ss TRAK Sensors TRAK Sensors are used on the X and Y axis for secondary feedback They are optional on the TRAK 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 e Faulting Axis e The DRO measurements do not repeat e The DRO measurements are not accurate Objectives 84 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual e To determine if the TRAK Sensor is bad and needs to be replaced e To determine if there is a problem with the sensor set up 4 7 1 Faulting Axis If a sensor has stop reading and vou trv to move an axis the axis will run awav 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 svstem will fault 1 SM Only The first thing that can be done to see if it is the sensor is to turn off the sensor on the axis in question This will allow the svstem to run onlv 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 2 Thenext thing to do is to visually inspect the sensor and base to determine if there has been a crash A damaged base will usuallv have crinkles in the small triangular plates on the front a
182. stries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 5 1 10 Ball Screw Replacement Y Axis Saddle CAUTIONI Never screw a ball screw partiallv or totallv out of its nut Thev cannot be reassembled 1 Position the saddle all the wav 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 attaches 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 e 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 e 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 e Torque the split nut to 50 ft
183. 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 will not vield 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 wav 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 repeatabilitv 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 Atthe 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 Can Contribute To Feed and Speeds spindle rpm Poor finish See below Machine chatter
184. t Manual Parts List Upper Head Assembiv K3 K3 Figure 118 Item P N Title Qtv 1 20778 1 GEAR HOUSING ASSY 1 2 20778 2 HI LOW SHIFT CLUTCH ASSY 1 3 20778 3 HI LOW SHIFT ASSY 1 4 VS12 FRU K3 SOCKET CAP SCREW M6 P1 0x15L 2 5 20778 4 PULLY PINION ASSY 1 6 VS64 FRU K3 BULL GEAR PINION BEARING CAP 1 7 VS93 FRU K3 SCREW M5 PO 8x15L 3 8 VS117 FRU K3 KEY 5x525L 1 9 VS62 FRU K3 TIMING BELT PULLEY 1 10 VS126 FRU K3 WASHER 5 8 1 11 VS61 FRU K3 JAM NUT 5 8 11NC 1 12 20778 5 LOWER VARI DISC DRIVE ASSY 1 13 VS63 FRU K3 BELT 3 8 225 1 14 VS14 1 FRU K3 SCREW M8 P1 25x18L 3 15 VS135 FRU K3 KEY 8x7x60L 1 16 VS4 FRU K3 BELT 1 17 20778 6 UPPER VARI ASSV DISC DRIVE R8 1 18 VS1 FRU K3 BELT HOUSING 1 19 VS137 FRU K3 SOCKET CAP SCREW M8 P1 25x25L 6 20 VS13 FRU K3 TOP BEARING CAP 1 21 VS13 1 FRU K3 WAVE WASHER 1 22 VS15 BEARING DEEP GROVE 6007V 1 23 VS129 FRU K3 SCREW SOC HD CAP M6 P1 0x18L 6 24 20778 7 SPEED CHANGE HANDWHEEL ASSV R8 1 25 VS07 FRU K3 SCREW SOC HD CAP M6 P1 0x35L 4 29 VS11 FRU K3 MOTOR PULLEV COVER 1 30 VS104 FRU K3 COPPER CHIP 2REQ 2 31 VS131 FRU K3 SCREW FLAT HD PHILIP M5 PO 8x1OL 2 32 VS132 FRU K3 STUD 7 16 100L 3 33 VS96 FRU K3 JAM NUT 3 8 16NC 1 34 VS101 FRU K3 VENTILATOR 2REQ 2 35 VS136 FRU K3 SCREW SOC HD CAP M6 P1 0x10L 12 36 VS54 FRU K3 HANDLE FIX BLOCK 1 37 VS55 FRU K3 SET SCREW 1
185. te 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 e XandY 150mm or 6 e Z 75mm 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 5 24 Calibration Set Up All Machines Retrofit MACHINE FRAME 100022 127 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 2 2 2 Backlash Compensation 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
186. the Machine 3 2 1 Run Away Axis 3 2 2 Slow Down Axis 3 2 3 Axis Will Not Jog 3 2 4 X Axis Motor Motion is Not Smooth 3 2 5 Vibration in Motion 3 2 6 Searching Axis Problems Relating to the Operation of the Control 4 0 4 5 4 6 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 Svstem 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 optional Problem with the Measurements 3 4 1 X Y amp Z Axis Measurements Do Not Repeat 3 4 2 X Y amp Z Axis Measurements Are Not Accurate 3 4 3 The DRO is Not Counting 3 4 4 X Y amp Z Axis DRO Counting 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 76 The Machine Tool amp Set Up 4 1 1 The Milling Machine Checklist 4 1 2 A Special Work About X amp 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 Anot
187. 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 Check for machine considerations especially gib locks and gib adjustments See Gib Adjustments section 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 78 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual The following steps take you in logical seguence through the assemblies for the knee mills For drawings of these assemblies see Figures 5 9 to 5 13 in Section 5 These instructions break the machine down from fullv assembled and point out the areas to look at specificallv 3 Check that the belt is properly tightened A loose belt can lead to
188. tion This is needed if you call SWI Customer Service e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting properly 61 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Possible Cause Check This Sensors or glass scales are counting in Reverse directions with codes 321 and 322 opposite direction of motor encoder SM Code 97 M2 3 AGE2 3 8 Edge See the Controls Programming Operations and Care correctl manual reading 4 6 or 4 7 Bad Motor Encoder 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 e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting e Code 129 Set s the maximum allowable arc accuracy error This applies to arcs only The maximum allowable Arc Accuracy is This value will only slow down the machine during arc moves set too low The factory default is set at 0 001 Perform Code 129 to check or change this value See Service Codes section Electrical Section 4 8 Inadequate or no Lubrication to Make sure all the Way surfaces are getting proper lubrication Ballscrews and Way surfaces If not check to make sur
189. tor Item 13 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 15 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 Ib 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 20 8 2 Installation of the Ball Screw Install the ball screw assembly as shown in Figure 8 2 Run the quill up and down over its full travel at each step to ensure that there is no binding Adjust as necessary 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 sc
190. tor is not energized the spindle will not turn on See Figure 5 1 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 Check This Faulty E Stop switch Check the cable connections from the computer module to the E Stop switch Check the E Stop switch for functionality Bad pendant 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 then replace the pendant Poor cable connection Check cable breakout box power cable and the AC E stop cable connection on the cable breakout box and electrical cabinet 70 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service 8 Parts List 3 3 12 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 5252 Limit Switch Active The Y axis Limit Switch is activated Use the Hand Wheels to Move off the Switch 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 Forthe Z axis manually lift the arm on the trigger to return the limit switch to its normal position Then jog the
191. trofit Installation Installation Tools amp Hardware Required Tools Hardware Suggested Fastener Stock Pre Installation Requirements 132 Installation Procedures 134 X amp Y Ball Screw Installation 7 1 1 Removing the Table amp Leadscrews 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 amp Servo Driver Installation Pendant Installation 7 3 1 Pendant Arm Installation 7 3 2 Installation of the Pendant Display Cable Breakout Box Mounting 7 5 7 6 7 7 7 8 7 9 7 10 8 0 8 1 8 2 8 3 8 5 9 0 9 1 9 2 9 3 10 Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 0 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 118 119 120 121 122 123 124 Z Axis Glass Scale Installation TRAK Sensor Installation Optional 7 6 01 X amp Y Axis Sensor X amp Y Glass Scale Installation Optional 7 7 1 X Axis Scale Installation 7 7 2 Y Axis Scale Installation Limit Switch Installation 7 8 1 Y Axis 7 8 2 X Axis 7 8 3 Limit Switch Cable Connections Computer Box Installation System Interconnection Z Motor Ball Screw Assembly 178 Installation of the Base Plate Installation of the Ball Screw Instal
192. ts or repeatability problems 97 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 1 6 TRAK Sensor Where Applicable 5 1 6 1 Replacing the M5 Base See Figure 5 3 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 shown in Figure 5 3 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 Adial indicator may be used to align the bumps on the base instead of a bubble level Figure 5 3 M5 Base Mounting Trak Sensor 98 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 1 6 2 Replacing the TRAK Sensor See Figure 5 4 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
193. ual 7 2 Motor Servo Driver Installation Figure 7 15 SM Edge M2 M3 AGE2 AGE3 8 MX2 MX3 Retrofits X Axis Motor Mounting TABLE VIEW A A FRONT peces COVER BACK COVER kesa PLATE M am aa hi v 1 4 20x1 HEX HEAD SCREWS AND 1 4 FLAT WASHERS 4 EACH DRIVE HOUSING BRACKET P N 15621 MOTOR SERVO ORIVER 100001 150 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service 8 Parts List Manual 7 2 1 X Axis Motor Servo Driver Installation Parts required e motor assembly 20296 e Xdrive assembly opened in previous step 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 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 e Motor servo driver 20296 e 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 turn when twisting in the middle of the belt Note The belt should have been installed previously Take extra care that the b
194. us information and part graphics e Built in Floppy Disk Storage for program storage e RS 232 Port for interface with computers 2 14 ProtoTRAK M2 and M3 Software Specifications e Diameter Tool Compensation e Circular Interpolation e Linear Interpolation e Conrad e Incremental and Absolute Programming e Error Messages e Fault Messages e Program Downwloading e Mirror Image and Rotation e Part Graphics e Look Feature e Math Help e Teach e Machine Tool Error Compensation e Backlash Compensation e Scaling of Print Data e M3 Also has e 2 axis Circular and Linear Interpolation e 3D Graphics e Helical Interpolation e Tool Length Offsets 21 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Figure 2 11 M2 M3 Pendant Front Panel a n o m e NN n z a o CO gt NC SC ec Gc 2 Gc Q 22 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual Figure 2 12 M2 M3 Pendant Back Panel gt LO Q LOPPY DISK DRIVE PARALLEL PORT REMOTE STOP GO 23 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 2 15 ProtoTRAK Edge Control Hardware Precision ground ball screws in the table and saddle to ensure smooth accurate contours without backlash Feedrate override of progr
195. ve train 108 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 100911 109 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K2 K3 K4 X Axis Drive Assembly Figure 5 9 P N 1 15621 DRIVE HOUSING 1 15624 FRONT Cover Ti 5 15622 BACKCOER O p 1 15616 HANDWHEELASSYMX O o 1 15614 TABWASHER 120 115612 JHOUSING BEARING 1 15885 RING BEARING HOUSING 1 10 115638 STOP XMIS Pi 156267 SEALBEARINGHOUSING 17 12 169831 1 13 1 14 16350 1 1 14772 5 19 1 2 14772270 SPACER QU THCK OO 2 14772570 sco 2 8 32x3 8258 SCREW SHCS STLEO 6 7 Item EEE r iew 6 me 8 9 10 12 13 14 19 EGA 42 41 42 45 M10 1 5X65 SCREW SHCS STL BO 25B a7 1 2 20 512 52 7 54 M10 70P WASHER FLAT USS STL PLIN Ja 55 56 100911 110 Southwestern Industries Inc TRAK K2 K3 K4 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 5 10 amp Parts List Shown X Axis Ballscrew Left End 111 Southwestern Industries Inc TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 5 11 8 Parts List Shown X Axis Ballscrew Right End E DE uL Ee 5 KI Ea LE 4 LI Ka 112 Southwestern Indu
196. vidually 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 Manual DRO 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 before the calibration and backlash factors have been factors into the counts 4 9 3 4 Code 314 Toggle test lights on in status line SM Model 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 kev will change this orange box to black The orange box will also change to black when the program vou are running reaches the 3 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 5 Code 319 Error Log SM Model This code when turned on captures the commands that were sent to th
197. western Industries Inc Figure 5 7 amp Parts List Shown TRAK K2 K3 K4 amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 bv the use of 3 SHCS Some machines mav 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 reguires between 80 and 100 psi to operate properly Some units work fine at 80 psi while others may need 90 or 100 psi Itis 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 Itis also important to make sure the oiler is set properly To set the oiler first close the adjustment screw CW on top ofthe oiler completely making sure to not over tighten Then open the screw CCW between 32 to 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 ofthe spindle This device allows the tool to easily be aligned with the dogs when loading a tool Note Only used on K4 machines P N 22581 4 CAUTIONI Some tools
198. will not run Figure 2 29 SM Pendant Cable Connections Left Side 47 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2 30 SM Pendant Right Side BEEPER OPTIONAL FLASH DISK DRIVE MOUSE KEYBOARD RSG FLOPPY DRIVE 100903 48 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual Figure 2 31 SM Cable Connection Diagram 49 Southwestern Industries Inc TRAK K2 K3 amp KA Safety Installation Maintenance Service amp Parts List Manual 100883 Figure 2 32 Edge Cable Connection Diagram 101107 FIR SMTCH ESTO N 50 Southwestern Industries Inc TRAK K2 K3 amp K4 Safety Installation Maintenance Service amp Parts List Manual 2 23 Cable Interconnections M2 All cable interconnections are made at the factory except for those connecting to the display pendant and optional coolant on off switch With the on off switch off down plug in the connectors which are bundled into the pendant arm Each cable mates to only one connector on the display pendant back panel Be certain to attach the braided cable to the ground stud and wing nut See the figure below for a complete cable interconnection diagram Figure 2 33 M2 Cable Interconnections X MOTOR n IXMOTOR M2 PENDANT Y MOTOR Z MOTOR AC TO PENDAN
199. x20L 1 35 FB101 CHEM BLACKED LOCKNUT M6 P1 0 1 36 20698 5 FEED REVERSE CLUTCH ASSY 1 37 FB109 KEY 3x3x20L 1 38 FB106 FEED TRIP BRACKET 1 39 FB118 CAM ROD SLEEVE ASSY 1 40 FB120 COMPRESSION SPRING 1 41 FB121 TRIP PLUNGER 1 42 FB123 TRIP PLUNGER BUSHING 1 201 Southwestern Industries Inc TRAK K2 K3 KA SMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K4 Lower Head Housing Assv Figure 109 43 FB103 CAM ROD 1 44 FB117 ROLL PIN 3x15L 1 45 FB104 TRIP HANDLE 1 46 FB105 BLACK PLASTIC BALL 1 47 FB119 1 ROLL PIN 3x20L 1 48 FB107 CAP SCREW M6 P1 0x25L 2 49 FB113 HAND WHEEL CLUTCH 1 51 FB115 COMPRESSION SPRING 1 53 FB108 SET SCREW M6 P1 0x8L 1 54 FB42 BUSHING 1 55 20836 1 SPINDLE ASSY K4 1 56 FB148 QUILL LOCK SLEEVE TAPPED 1 57 FB148 1A COMPRESSION SPRING 1 58 FB153 QUILL LOCK SLEEVE 1 59 FB152 QUILL LOCK BOLT 1 60 FB149 LOCK HANDLE 1 61 FB149 1 CONICAL COMPRESSIONAL SPRING 1 62 FB149 2 SCREW PHILLIP HD 1 63 FB175 RACK FEED HANDLE HUB 1 64 FB114 STEEL BALL 2 65 FB175 2A COMPRESSION SPRING 1 66 FB116 HANDWHEEL CLUTCH SPRING SCREW M8 P1 25x6L 1 67 FB175 3 DOWEL PIN 1 68 FB190 PINION SHAFT HUB HANDLE 1 69 FB191 PLASTIC BALL HANDLES 1 70 FB169 PINION SHAFT HUB SCREW 1 71 FB163 QUILL STOP KNOB 1 72 FB200 SCREW SOC HD 3 8 24NF x 1 1 4 1 73
200. y 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 Floppy Disk full Put the Floppy Disk into a Personal Computer to see how many bytes remain A floppy can typically hold 1 4 MB of information 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 Check This 110 V line is not plugged in Check incoming 110 V power source to black electrical cabinet Pendant On Off switch is Off Check the Pendant On Off switch Fuse blown in pendant or electrical Remove fuses and check continuity cabinet Flash Drive failure SM Only When the Computer Module starts the boot up process look at the 8 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 Computer Pendant has failed See Computer Pendant diagnostics Section 4 3 3 3 7

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