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Service Manual - FH5 & FH7 - Southwestern Industries, Inc.

1. Title Qty 1 21552 3 SPINDLE HEAD 5 H P 1 2 21553 4 COVER SPINDLE ALUMINUM CASTING 1 3 22279 COVER SPINDLE HEAD AIR VENT 2 4 4 0 7 6 10B SCREW PH PHIL STL BO 4 5 23320 SPINDLE FLANGE QUILL ASSY 1 6 5 16 18X3 4 25BISCREW SHCS STL BO 6 7 K050360 BELT POLY V MICRO V K PROFILE 5 RIBS GATES CORP 2 8 1 4 20X1 4 40B SCREW SOC SET STL BO CUP 2 9 23326 MOTOR GFVF SPINDLE INVERTER DUTY FUKUTA 4P 5 HP 1 11 10 1 5 40 25B SCREW SHCS STL BO 4 12 M10 70P WASHER FLAT USS STL PLAIN 4 14 23171 NMTB DRAWBAR DPMV 3 5 HP 1 15 21661 SPACER DRAWBAR 3 5 HP 1 16 23284 DRAWBAR MANUAL 1 PIECE HEAD 1 17 22116 SPACER DRAWBAR 1 PIECE HEAD 1 18 23121 LOCK ASSY 1 19 22679 COVER 1 20 8 1 25 40 24Z SCREW HEX HEAD ZINC 1 21 23310 PULLEY MOTOR SHAFT DPMV5 1 22 M6 1 0X15 20Z SCREW RH PHIL STL ZINC 4 23 23327 RETAINER PULLEY MOTOR 1 24 M6 1 0X25 258 SCREW SHCS STL BO 3 25 Mb5 0 8X25 25B SCREW SHCS STL BO 5 26 23324 COVER UPPER SPINDLE 1 27 21729 3 KEY MOTOR SHAFT 8x10x50mm 1 28 M10 73B WASHER SPLIT LOCK STL BO 4 29 10 1 5 45 24 5 HD STL BO 4 30 8 1 25 502 NUT HEX ZINC 1 122500 1 5 1 18 Spindle Motor Replacement FHM7 see Figure 31 1 2 Bo 91 cB Turn machine off Disconnect power from machine Remove the spindle head cover to gain access to the spindle motor Open motor junction box and disconnect all wires and conduit from motor Take note how t
2. 02 e FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 24291 Figure 27 FHM7 X Drive Train P N Parts List FHM7 X Drive Train P N 24291 Figure 27 Item P N Title Qty 1 24518 SCREW GIB ADJUSTING 3 2 24549 SCREW GIB X AXIS 2 3 24507 L GIB X AXIS LEFT 1 4 24521 WIPER WAY Y AXIS FHM7 V7 4 5 24507 R GIB X AXIS RIGHT 1 6 H 034 14B SADDLE 1 7 25209 COVER BALLSCREW CHIP GUARD Y AXIS 1 10 H 067 9C BASE MACHINE 1 11 H 106 8 SEAT GIB LEFT 1 12 H 107 8 SEAT GIB RIGHT 1 13 24509 GIB Y AXIS BOTTOM 2 14 H 120 6 COVER 1 15 H 122 6 STOP 2 16 24514 SWITCH LIMIT 2 17 H 124 7A COVER 1 18 24505 COVER WAY TABLE 2 19 HT 011 8B BRACKET RIGHT BEARING 1 20 HT 012 8B BRACKET LEFT BEARING 1 21 24500 BALLSCREW X AXIS 1 22 HT 022 8 BRACKET FEED NUT 1 23 HT 022 8B BRACKET CROSS SCREW 1 24 HT 029 14 TABLE 1 25 HT 032 PLUNGER RUBBER 8 26 HT 040 7 COVER BEARING 1 27 HT 041 6 SLEEVE LOCKING 1 28 24545 PULLEY X AXIS BALLSCREW 1 29 HT 090 8B COVER 1 30 HT 098 8 COVER 1 31 HT 157 8 BRACKET HANDWHEEL 1 32 HT 166 8 BUSHING 1 33 HT 167 SEAL OIL 1 34 HT 181 SEAL OIL 1 35 HX 002 BUSHING 1 39 23940 BEARING ANGULAR CONTACT U SET 2 7205 1 40 24512 BEARING DEEP 630577 1 42 24546 KEY 5x 5x 20L 1 FHM5
3. TRAK FHM5 8 FHW Safety Installation Maintenance Service amp Parts List Item P N Title Qty 1 760 5A COVER FIXED 1 2 24525 MOTOR ASSY SPINDLE DPMV7 1 3 24518 SCREW GIB ADJUSTING 3 4 H 026 B SCREW 1 5 H 035 8 PLATE ALUMINUM 4 6 24510 GIB Z AXIS SIDE 1 7 H 045 14C KNEE 1 8 H 067 8 BODY MACHINE 1 9 H 077 3 SCREW 1 10 24502 BALLSCREW Z AXIS 1 11 H 109 12 SEAT GIB 1 12 H 110 12 SEAT GIB 1 13 24511 GIB Z AXIS REAR 2 14 H 124 5 HOLDER MICRO SWITCH 1 15 H 139 8 BRACKET R ROLLER S 1 16 H 139 8A BRACKET R ROLLER S 1 17 H 140 10 HOLDER FIXED MOTOR 1 18 H 140 10B HOLDER FIXED 1 19 24542 PULLEY Z AXIS BALLSCREW 1 20 H 145 8 ROLLER 4 21 H 146 8 SPACER 4 22 H 147 8 SHAFT DRIVE 4 23 H 148 8 SCREW 4 24 H 149 8A WEIGHT BALANCE 1 25 H 160 9 BRACKET BEARING 1 26 H 165 8 PIPE CONNECTION 2 27 H 167 10B COVER TOP 1 28 H 168 8 HOLDER BALANCE WEIGHT 1 29 H 170 8 WASHER 1 30 H 171 8 HOLDER MICRO SWITCH 1 31 24550 VALVE 1 32 24551 NOZZLE COOLANT 1 33 H 310 8 COVER 1 34 H 331 8 BRACKET ARM 1 35 H 332 14 COVER ARM 1 36 HB 127 B BRACKET 1 39 HB 134 10 BRACKET BUSHING BEARING 1 42 24532 CARTRIDGE HOUSING 1 43 24529 PULLEY SPINDLE 1 44 24527 PULLEY MOTOR 1 45 HB 199 10 CLAMPING RING 1 46 HB 200 10 DUST COVER 1 47 HB 201 13 SPACER 1 48 HT 067 14A CABINET ELECTRICAL CONTROL 1 49 HX 002 10 BUSHING BEARING 3 50 HX 007 COVER BEARING 1 144 Southwestem Industries Inc Parts List FHM7 Column amp Z Axis Dri
4. 5X 3X i01092 136 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 101093 Figures 48 amp 49 FHM7 Bed 137 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Parts List FHM7 Bed Figures 48 amp 49 Item P N Title Qty 2 H 026 B SCREW 3 3 H 029 8A PLATE ALUMINUM 4 5 H 034 14B SADDLE 1 7 H 060 COVER BEARING 1 8 H 067 8 BODY MACHINE 1 9 H 067 9C BASE MACHINE 1 10 H 075 HOLDER COOLANT NOZZLE 1 11 24524 SCREW LEVELING 6 12 H 103 BLOCK ADJ USTING 6 13 H 106 8 SEAT GIB LEFT 1 14 H 107 8 SEAT GIB RIGHT 1 15 24509 GIB Y AXIS BOTTOM 2 16 H 124 7B BOX LIMIT SWITCH 1 17 H 165 8 PIPE CONNECTION 1 18 H 166 8C 2 19 H 166 14B COVER FRONT 1 20 H 170 8 WASHER 6 21 H 172 9 COVER 1 22 H 173 8B COVER 1 23 H 237 8 COVER 1 24 H 237 9 COVER 1 25 H 239 10 NETWORK OIL 2 26 H 254 NETWORK OIL 5 27 23265 PUMP COOLANT 1 8 HP 1 28 H 259 PLUG COOLANT 1 29 24506 COVER WAY Y AXIS REAR 1 30 H 263 10 BRACKET UP DOWN CHIP GUARD 1 3l 22291 1 LUBRICATION PUMP 1 32 H 267 10 TEFLON L 1 33 H 268 10 TEFLON R 1 34 H 279 8 GUARD 1 35 H 280 8 PLATE L FI
5. 7 The FHM5 amp FHM7 Bed Mills can only be configured for 208 240 volt 3 phase electricity To run at 440V you will need a step down transformer from 440V to 220V These machines also require a 110v power source to power the control DANGER Be certain that 200 volt electricity typical range 208 240V is used only with a machine labeled 220 volts at the motor and at the electrics box on the back of the column WARNING 440 Volts will damage expensive electrical components if machine is wired by mistake as 440 volts These components are not covered under warranty The circuit breaker for the machine should be a minimum of 17 5 amps FHM5 and 37 5 amps FHM7 DANGER The 208 240 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 The 208 240 volts wired to the machine through the electrical box located on the back of the column The wire enters the main on off switch through a hole on the top of the box on the left side 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 19 Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Manual 2 12 1 Phase Converters For those machines that will be run with a
6. 27 87 39 76 26 57 26 57 63 Figure 2 Overall Dimensions FHM5 6 Southwestem Industries Inc 5 8 FHM Safety Installation Maintenance Service 8 Parts List Figure 2A 7 Overall Dimensions Height of table from bottom of bed Maximum distance from spindle nose to table Height of machine from bottom of bed to top of column cover NOTE Top of Z axis motor for FHM7 Height of machine from bottom of bed to top of spindle motor Width of machine including table Length of machine with electric box door closed 2 2 Uncrating FHM5 41 24 85 5 99 HH 94 80 FHM7 38 25 24 91 75 92 5 110 5 93 75 Carefully remove the wood crate and protective packaging paying attention not to scratch damage or mar any parts of the machine FHM5 Remove the cardboard boxes with the PENDANT DISPLAY handle carefully the box containing the TOOL BOX and Z crank The leveling pads and screws for the machine can be found in the toolbox The Y axis way covers are shipped in a separate tube The lower Z way cover can be found in a box as well Remove two steel bars 1 0 inch in diameter These items are necessary for lifting and moving the machine Loosen and remove 4 screws and nuts holding the machine to the wood pallet Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance S
7. Axis faults on screen Servo driver cables at pendant are loose Make sure cable connection bracket is fastened down Make sure cable clips into female portion on the top and bottom Sometimes the clips tend to stick Overlay failure keys on pendant Certain buttons on overlay do not work Do code 81 to verify each key beeps Low voltage to pendant or current spikes 1 amp fuse in pendant blows Pendant will not turn on Slave board not functioning Machine will not run If you run Code 33 and no slave software version is shown the slave board is not functioning 51 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 4 4 4 3 1 Checking Floppy Drive by Formatting a Disk Find a new disk and install in floppy drive Install keyboard into middle port Press CTRL ESC to get to start menu Press R for run Type Format a press enter If the format works your disk drive is working If format does not work reboot control and see if it now works If it does not work replace the computer module 7 Press ALT ESC to get back to PT4 software CMT SUIS PES 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 WARNING Do not work with the mot
8. X Y and Z axis Gibs are adjusted Check the adjustment of the X Y and Z axis Gibs extremely tight using the X Y and Z axis Gib adjustment procedures See X Y and Z axis 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 proper 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 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 may be bad See if the Floppy Disk can be read by a Personal Computer Does the green light on the floppy drive come on when you access the disk If so power is getting to the floppy drive If not check connections of floppy drive inside the computer module See Computer Pendant Section 4 3 for more information Floppy Disk full Put the Floppy Disk into a Personal Computer to see how many bytes remain 3 3 6 System Will Not Turn On or Boot Up Nothing happens when the switch is turned on or the syste
9. ZATOZ AXIS LUBRICATION SYSTEM PLACE ITEMS 5 6 20 19 amp 24 IN PLASTIC BAG THEN PLACE IN SADDLE PULL EXCESS Y AXIS OIL LINE UP THROUGH SADDLE BEFORE TIGHTING COMPRESSION NUT DO NOT KINK OR ALLOW LINE TO RUB BALLSCREW TWIST TIE EXCESS OIL LINE TO SADDLE RIBS 130 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 6 3 Bed Parts List B230 VENT LEFT SLIDE B246 VENT LEFT FRONT 6 4 Table Saddle Spare Parts List FHM5 GIB LOCK HANDLE amp PLUNGER 6 4 1 Table Saddle Spare Parts List FHM7 Tr AMEGIBIOWCHANDIERRIUNGER 00 BADDEGIBIOCKHANDIESPLUNGER 131 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 6 5 Manual Ram Elevation Drawing 16793 ASSY Figure 45 FHM5 Manual Ram Elevation 132 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 6 6 Coolant Pump Mounting SECTION 100788 Figure 46 Coolant Pump Mounting 133 m Industries Inc TRAK FHM5 8 FHM7 Safety Installation Maintenance Service amp Parts List Figure 47 FHM7 Table amp Saddle 134 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Parts List FHM7 Table amp
10. Specifications FHM5 FHM7 Table Size 50 x 12 76 x 14 T Slots number x width 3 x 16mm 4 x 16mm Travel X Y Z axis 40 x 20 x 20 60 x 23 x 20 5 Spindle Taper 40 taper 40 taper Spindle Speed Range 160 4000 RPM 200 5000 RPM Spindle Nose to Table max part height 0 20 5 0 23 Spindle Center to Column Face 20 1 23 34 Spindle Motor Power 5 HP 7 5 HP Voltage 220 V 220 V Phase Cyde 3 phase 60 Hz 3 phase 60 Hz Current Full load amps 17 5 FLA 37 5 FLA Machine Net Weight 4400 Ibs 7650 Ibs Maximum Weight of Workpiece 1760 Ibs 2200 Ibs Power control 110v 1 phase 15 amp 110v 1 phase 15 amp 10 Southwestem Industries Inc 5 8 FHM Safety Installation Maintenance Service 8 Parts List 2 6 Maximum Work Capacities FHM5 Drilling Mild Steel 1 dia Tapping Mild Steel 5 8 Milling metal removal rate mild steel 5 inch min FHM7 Drilling Mild Steel 1 Tapping Mild Steel 5 8 Milling metal removal rate mild steel 7 inch min Maximum work capacities are dependent on a lot of variables that cannot be controlled by the machine manufacturer Each one of the following will have an impact on the above numbers speeds feeds cutter cutter sharpness material setup coolant and machine adjustments The numbers above assume all conditions are optimal and may be higher or lower depending on material composition 2 7 ProtoTRAK SMX Control Hardware 3 axis CNC 3 axis DRO 40
11. press Code 313 This screen lists the values programmed for the cycle time and discharge time See Section 6 for diagrams of how the oil lines are routed on the FHM 25 Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Manual 2 17 ProtoTRAK SMX Euclid Block Procedure The test part should be machined at the completion of the installation The material for the Euclid block test part is found in the toolbox 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 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 SMX hard drive it is part number euclid 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 and set Z reference positions in the SET UP mode Set Z retract a few inches above the part 6 Begin to run the program The part will be machined in the following sequence Event s Description Depth of Cut 1 circle
12. 0 ABS 3 Using the DRO display back the saddle off 1 2 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 250 ipm 4 Loosen the 2 setscrews on the cam so that the cam can slide back and forth freely within its cam holder 5 Loosely mount the limit switch assembly 6 Slide the cam up next to the plunger located on the limit switch assembly 7 Mount the limit switch assembly to its bracket such that the cam will initially make contact near the bottom but not past the tapered portion of the plunger 13 Slide the cam up against the plunger until the limit switch is triggered Note The moment when the limit switch is triggered can be seen on the DRO display 14 Mount the cam in this position 15 Loosen the 2 set screws on the other cam located near the back of the bed so that the cam can slide back and forth freely within its cam holder 16 Slowly move the saddle to the rear of the bed by hand until the end of the travel is reached In DRO mode set X 0 ABS 17 Using the DRO display back the saddle off 1 2 18 Slide the cam up against the plunger until the limit switch is triggered Note The moment when the limit switch is triggered can be seen on the DRO display 19 Mount the cam in this position 20 Jog the saddle at 250ipm to
13. 101257 POWER CONNECTION FOR MISTER FROM ELECTRICS BOX ON VM amp CABLE BREAKOUT BOX ON SM Figure 11 amp Parts List Shown FHM5 amp FHM7 Air Regulator Solenoid Assembly P N 22380 1 Item P N Title Qty 2 22378 MANIFOLD PT4 AIR 1 3 22607 FILTER REGULATOR PT4 1 8 22644 4 PLUG 1 4 NPT HEX SOCKET 3 9 22645 4 NIPPLE 1 4 NPT x 1 37 LG 1 11 22646 4 ADAPTOR ELBOW MALE 1 4 x 1 8 NPT 1 12 22647 2 NIPPLE 1 8 NPT x 0 750 LG 1 18 4 40 3 8 31 JSCREW PH PHIL EXT SEMS STL BO 2 19 10 32X3 8 10B SCREW PH PHIL STL BO 2 20 M6 1 0X25 25B SCREW SHCS STL BO 2 24 22772 SOLENOID ASSY AIR REGULATOR 1 25 22773 OILER 1 i22380 1 21 Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service 8 Parts List Manual 2 14 Mounting the Display Pendant The ProtoTRAK SMX display pendant mounts to the pendant arm with four 1 4 20 x 3 4 SHCS that are shipped screwed into the left side of the display There is a locating screw on the pendant arm to help align the pendant with the mounting holes CAUTION The locating screw in the arm is used for positioning Keep a hold of the pendant until the screws are fastened If the pendant arm rotates too freely remove the painted cap on the bracket attached to the column and tighten the hex nut to adjust it Replace the cap 2 15 Cable Interconnections All cable interconnections are made at the factory except for
14. 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 adequate 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 check keys 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 e Before changing tools 3 Southwestem Industries Inc 5 8 FHM7 Safety Installation Maintenance Service amp Parts List 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 e Before changing parts e Before you clear away the chips oil or coolant Always use a chip scraper or brush e 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 hose to remove the chips or clean the machine oil c
15. FHM7 1 4 22773 OILER 1 6 1 4 20X125B SCREW SHCS STL BO 3 7 24009 3 WASHER BELLEVILLE SPRING LOCK 3 8 1 4 71B WASHER FLAT SAE STL BO 3 10 22581 2 SWITCH CONTROL HEAD TORQUE RITE 1 11 22581 4 NOSEPIECE TORQUE RITE 1 i22580 5 84 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 5 1 11 Ball Screw Replacement X Axis Table FHM5 1 Remove table trays from each side of the table 2 Remove bearing housing from right side of table 3 Remove the sheet metal covers from the motor mounting brackets 4 Remove the X axis motor and belt from the left side of the table 5 Remove the pulley and ferrule from the ball screw 6 Remove the motor mounting bracket 7 Loosen and remove the clamp nut Loosen the setscrew on the clamp nut before loosening the clamp nut 8 Push the table to the left so the bearing housing moves away from the saddle 9 Remove the bearing housing Note which way the bearings are in the bearing housing 10 Slide the table to the right and remove the oil line and the 4 screws holding the ball nut to the yoke 11 Pull the ball screw out Reassemble 12 Install the new ball screw into the yoke 13 Slide table back to the left and assemble the left side of the X axis 14 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 Slid
16. amp FHM7 Safety Installation Maintenance Service amp Parts List 4 1 2 Special Word About X Y Z Gibs The slideway surfaces are vital to the performance of the bed mill Gibs should be flat free of twist free of burrs free of blockages in the oil passages and channels Defective or scarred gibs must be replaced Shimming of gibs will not yield acceptable results It is good machining practice to avoid the use of shop air to clean the chips off a machine This risks blowing chips into the sliding way surfaces and compromising the performance of the machine Gibs that are not adjusted correctly will affect the performance of the machine It will lead to positioning and repeatability problems The gibs should be adjusted at least twice a year See Gib Adjustments Section 5 2 1 4 1 3 Lubrication Lubrication is one of the single most important maintenance issues and plays a key role in assuring the performance and durability of the bed mill At the beginning of each day manually supply oil to the way surfaces by doing Service Code 300 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 foll
17. during shipment 3 Remove the 3 socket head cap screws that secure the counterweight retaining plug to the column 4 Using an M14 Allen wrench remove the bolt that secures the retaining plug to the counterweight 5 Lower the spindle head ram slowly until the chain between the ram and the counterweight is tight 6 Lower the spindle head ram a little further until the retaining plug is loose Remove retaining plug and store them for future use 7 Do not continue to move the spindle head ram until all ways have been cleaned 17 Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Manual 2 10 Cleaning 1 Remove rust protective coating from the machine before moving any slideways table saddle ram spindle head etc 2 The coating is best removed with clean dry rags Do not use a cleaning solution that may damage the rubber way scrapers plastic parts or paint WARNING asoline or other flammable cleaning agents for cleaning the machine 3 It may be necessary to move back and forward left and right and up and down the table saddle and the ram Always release the clamp levers two in front of the table one underneath the saddle on each side and two on the ram on the right side of the column before attempting to move the above parts CAUTION Never move any of the above parts over ways that were not previously cleaned Serious damage to the TURCITE su
18. 2X Njaa ONES OS 8 sao 8 8 L dH CE d NEE 8 N OL ASE 9 OE T N Ns KO 8 5 aA S N N N d E RI 2 Si ds 7 7 lt e SSS lt S H 7 s8 i e e g i i L a a FHM7 Z Axis Drive Train Figure 31 101 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List e 8 99 C MADA a Q 101097 Parts List FHM7 Z Axis Drive Train Figure 31 amp 32 Item P N Title Qty 1 760 5A COVER FIXED 1 2 24525 MOTOR ASSY SPINDLE DPMV7 1 3 24518 SCREW GIB ADJUSTING 3 4 H 026 B SCREW 1 5 H 035 8 PLATE ALUMINUM 4 6 24510 GIB Z AXIS SIDE 1 7 H 045 14C KNEE 1 8 H 067 8 BODY MACHINE 1 9 H 077 3 SCREW 1 10 24502 BALLSCREW Z AXIS 1 11 H 109 12 SEAT GIB 1 12 H 110 12 SEAT GIB 1 13 24511 GIB Z AXIS REAR 2 14 H 124 5 HOLDER MICRO SWITCH 1 15 H 139 8 BRACKET R ROLLER S 1 16 H 139 8A BRACKET
19. 9 5 3 Code 302 Set Lube Pump discharge time This code sets the lube pumps discharge time 70 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 5 0 Procedures for Replacements amp Maintenance 5 1 Replacements 5 1 1 Servo Motor Replacement WARNING Do not work with the Servo Motors unless the power is disconnected from the machine The servomotors are run by 110 VAC There is possibility of death by electrocution 1 Turn off power to the machine 2 Each motor is mounted by the use of 4 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 l Press in the Emergency Stop 2 Remove the servo motor driver assembly from its mounting bracket the Y axis assembly is located inside the front of the bed 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 Reinstal
20. 91 Fig 31 FHM7 Z Axis Drive Train 101 5 1 14 Ball Screw Replacement Y Axis Fig 31 1 FHM5 Head 106 Saddle FHM7 93 Fig 32 FHM7 Head 110 5 1 15 Z Axis Ball Screw Removal amp Fig 33 Spindle Motor Wiring 111 Replacement 98 Fig 34 Table Gib amp Saddle Bottom Gib Adjustment 113 5 1 16 Air Solenoid Replacement 104 Fig 35 Saddle Side Gib Adjustment 114 5 1 17 Spindle Motor Replacement Fig 36 Ram Back Gib Adjustment 116 FHM5 104 Fig 37 Ram Side Gib Adjustment 118 5 1 18 Spindle Motor Replacement Fig 38 Calibration Set Up 119 FHM7 107 Fig 39 Tramming the Head 121 5 1 19 Spindle Assembly Replacement Fig 40 Limit Switch Installation 122 FHM5 108 Fig 41 Limit Switches FHM5 125 5 1 20 Spindle Assembly Replacement Fig 42 Counter Balance System Drawing FHM5 126 FHM7 109 Fig 43 FHM Lubrication Drawing Pump amp Ram 127 5 1 21 Spindle Motor Wiring 111 Fig 44 FHM5 amp 7 Lubrication Drawing 129 5 2 Maintenance 112 Fig 45 Manual Ram Elevation Drawing FHM5 132 5 2 1 Gib Adjustments 112 Fig 46 Coolant Pump Mounting 133 5 2 2 Calibration amp Backlash Constants 118 Fig 47 FHM7 Table 8 Saddle 134 5 2 3 Tramming the Head 120 Fig 48 FHM7 Bed 136 5 24 X Y amp Z Limit Switch Adjustments 121 Fig 49 FHM7 Bed 137 Fig 50 FHM7 Column Parts 140 6 0 Parts Lists amp Drawings Fig 51 FHM7 Column Parts 141 6 1 Counter Balance System Drawing 126 Fig 52 FHM7 Column Parts 142 6 2 Lubrication System Drawings 127 Fig 53 FHM7 Column Parts 143 6
21. FHM5 amp 7 Safety Installation Maintenance Service amp Parts List EH TIME LATA LM f T LA SN ANARD AN ion N B N NN 5 4 INTI Ree SI N E MINN lt N ON s e BESI Figure 32 FHM7 Head Z Axis Spindle Refer to Figure 31 Parts List in Section 5 1 15 110 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 5 1 21 Spindle Motor Wiring The 5 spindle motors are wired for 220 volts low voltage in the Y configuration The FHM7 spindle motors are wired in low voltage in the A configuration Each junction box contains 6 terminals The 3 upper terminals should be jumpered together and have wires labeled U2 V2 and W2 as shown in the figure The bottom 3 terminals should have 3 wires on each terminal as shown It is important to hook up the incoming 3 phase wires in the same order as what is shown in the figure Failure to do this will run the spindle motor backwards on the control The spindle motor fan wires are also found in the junction box There is 1 hot wire 1 neutral wire and 1 ground wire The hot and neutral wires are connected to 2 wires coming out of the spindle fan by the use of wire nuts It does not matter which wires are connected to the hot and neutral wires There are also 3 ground wires inside the junction box 2 gr
22. Installation Maintenance Service amp Parts List 3 Check that the belt is properly tightened A loose belt can lead to excessive backlash compensation values on motor encoder only machines To adjust belt tension loosen the 4 screws that secure the motor to the bracket Adjust motor for proper belt tension as necessary See the drawings for illustrations 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 FHM5 X axis only 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 5 X axis amp Y axis bearing housings Ensure that the bearing housing is clamped in place by the bracket This design uses the bracket to secure the bearing housing in place It should not allow the bearing housing to float between the bracket and machine For the FHM7 verify the bearing housing cover is properly fastened 7 FHM5 X axis amp y axis 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
23. Loosen the 4 screws that fasten the spindle motor down Release the belt tension by sliding the motor forward Remove the spindle motor belt Remove the locknut that fastens the upper spindle pulley and key Remove the dust cover that covers the top of the upper spindle bearings Remove the upper bearing cap Remove the locknut that fastens the upper spindle bearings NOTE the upper bearings will not come out with the spindle assembly They are removed from the top of the quill Remove the screws that hold the lower spindle collar to the bottom of the quill housing To remove the spindle assembly tap the top of the spindle shaft to push the spindle down Install the new upper spindle bearings and the bearing cap Make sure to put the upper spindle bearings on correctly The thicker outer race of each bearing should be facing each other The spacers should be in between the bearings Now go ahead and install the new spindle assembly back up into the quill The upper shaft of the spindle must go through the upper spindle bearings Once the spindle assembly is all the way up tighten the spindle collar back to the quill Now remove the upper bearing cap and fasten the locknut back down to load the upper bearings Re install the bearing cap and dust shield Install the spindle pulley and key and locknut Install the spindle belt and re tension the belt Install the power drawbar and head cover 109 Southwesiem Industries Inc
24. N Title Qty 2 H 026 B SCREW 3 3 H 029 8A PLATE ALUMINUM 4 5 H 034 14B SADDLE 1 7 H 060 COVER BEARING 1 8 H 067 8 BODY MACHINE 1 9 H 067 9C BASE MACHINE 1 10 H 075 HOLDER COOLANT NOZZLE 1 11 24524 SCREW LEVELING 6 12 H 103 BLOCK ADJUSTING 6 13 H 106 8 SEAT GIB LEFT 1 14 H 107 8 SEAT GIB RIGHT 1 15 24509 GIB Y AXIS BOTTOM 2 16 H 124 7B BOX LIMIT SWITCH 1 17 H 165 8 PIPE CONNECTION 1 18 H 166 8C COVER 2 19 H 166 14B COVER FRONT 1 20 H 170 8 WASHER 6 21 H 172 9 COVER 1 22 H 173 8B COVER 1 23 H 237 8 COVER 1 24 H 237 9 COVER 1 25 H 239 10 NETWORK OIL 2 26 H 254 NETWORK OIL 5 27 23265 COOLANT PUMP 1 8 HP 1 28 H 259 PLUG COOLANT 1 29 24506 COVER WAY Y AXIS REAR 1 30 H 263 10 BRACKET UP DOWN CHIP GUARD 1 31 22291 1 LUBRICATION PUMP 1 32 H 267 10 TEFLON L 1 33 H 268 10 TEFLON R 1 34 H 279 8 GUARD 1 35 H 280 8 PLATE L FIXED 1 36 H 281 8 PLATE R FIXED 1 41 HT 022 8 BRACKET FEED NUT 1 42 HT 022 8B BRACKET CROSS SCREW 1 43 24501 BALLSCREW Y AXIS 1 44 HT 028 7A BRACKET BEARING CROSS FEED 1 45 HT 028 8B BRACKET BEARING CROSS FEED 1 46 HT 029 14 TABLE 1 47 HT 041 8 BUSHING 1 48 24544 PULLEY Y AXIS BALLSCREW 1 96 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List Parts List FHM7 Y Axis Drive Train P N 24292 Figure 29 49 24372 HOU
25. Saddle Figure 47 Item P N Title Qty 1 24518 SCREW GIB ADJUSTING 3 2 24549 SCREW GIB X AXIS 2 3 24507 L GIB X AXIS LEFT 1 4 24521 WIPER WAY Y AXIS FHM7 V7 4 5 24507 R GIB X AXIS RIGHT 1 6 H 034 14B SADDLE 1 7 25209 COVER BALLSCREW CHIP GUARD Y AXIS 1 10 H 067 9C BASE MACHINE 1 11 H 106 8 SEAT GIB LEFT 1 12 H 107 8 SEAT GIB RIGHT 1 13 24509 GIB Y AXIS BOTTOM 2 14 H 120 6 COVER 1 15 H 122 6 STOP 2 16 24514 SWITCH LIMIT 2 17 H 124 7A COVER 1 18 24505 COVER WAY TABLE 2 19 HT 011 8B BRACKET RIGHT BEARING 1 20 HT 012 8B BRACKET LEFT BEARING 1 21 24500 BALLSCREW X AXIS 1 22 HT 022 8 BRACKET FEED NUT 1 23 HT 022 8B BRACKET CROSS SCREW 1 24 HT 029 14 TABLE 1 25 HT 032 PLUNGER RUBBER 8 26 HT 040 7 COVER BEARING 1 27 HT 041 6 SLEEVE LOCKING 1 28 24545 PULLEY X AXIS BALLSCREW 1 29 HT 090 8B COVER 1 30 HT 098 8 COVER 1 31 HT 157 8 BRACKET HANDWHEEL 1 32 HT 166 8 BUSHING 1 33 HT 167 SEAL OIL 1 34 HT 181 SEAL OIL 1 35 HX 002 BUSHING 1 39 23940 BEARING ANGULAR CONTACT U SET 2 7205 1 40 24512 BEARING DEEP GROOVE 6305Z7Z 1 42 24546 KEY 5x 5x 20L 1 i24291 135 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Figure 48 FHM7 Bed
26. Secure the computer module back to the LCD enclosure by following the instructions in reverse order Make sure that all connectors are properly seated before fastening the unit back in place Turn power on to the machine and control When the system boots you may get a message stating that the system cannot find your configuration file Press NO if asked to load defaults Update the System Software by inserting the PT4 update disk into the floppy drive Go to service codes 316 and 317 found in section A Update the master and slave software Restore the Configuration file saved on your backup configuration disk with service code 141 found in section A of the service code section CAUTION It is a good idea to back up your flash disk from time to time via a network or floppy disk If your flash disk needs to be replaced you will loose all of your programs See your programming manual for instruction on how to do this 5 1 5 AC Drive Replacement 76 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 7 8 9 Turn power off to the machine Before working on this unit make sure all lights on the display are off These units have a capacitor internally that keep them powered up for a minute or so after the power is turned off Remove the display unit on the front face of the unit Also remove the lower cover on the unit to gain access to the wires Disconnect
27. This Wrong voltage Check the 220v voltage to the machine Poor wiring connections Check all the wiring connections to the electrics box Defective cables or poor cable Check all cable connections connections Improper wiring jumper configuration on the Spindle Motor Spindle Drive may be in Local Mode and can not be run from the Pendant Spindle Motor is bad Spindle Drive contains incorrect parameters and is not programmed correctly Check to make sure that the Spindle Motor has the correct wiring jumper configuration for 220VAC See Electrical wiring section On the Spindle Drive push the DSPL button until LO RE lights up Use the Up and Down arrow keys to choose between Lo Local Run Spindle Motor from Spindle Drive or rE Remote Run Spindle Motor from the Pendant Check the resistance of the Spindle Motor windings on the Spindle Motor between L1 amp L2 L2 amp L3 and L1 amp L3 using an Ohmmeter The resistance should range from 0 5 Ohms to 2 Ohms 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 Contact customer service 3 5 4 Spindle Runs Backwards The spindle motor runs in the opposite direction The spindle should always spin in the clockwise direction when the forward key on the pendant is p
28. WASHER FLAT USS STL BO 6 98 5 8 70B WASHER FLAT USS STL BO 1 99 24566 SPINDLE CARTRIDGE ASSY 1 124293 5 1 16 Air Solenoid Replacement 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 assembly in hand unthread the solenoid from the rear of the air regulator The solenoid and cable will be replaced as a unit See Figure 11 in Section 2 for an illustration of this assembly 5 1 17 Spindle Motor Replacement FHM5 1 2 3 Turn machine off Disconnect power to machine from the shop feeder box Open the motor junction box to gain access to the wiring Disconnect all the wires and conduit going to the motor Take note of how the motor is wired The spindle motors must be wired for low voltage in the Y configuration Remove the 4 screws that fasten the ventilation plate on the right side of the spindle head and remove vent plate Release the belt tension by adjusting the belt tension mechanism which is integrated to the upper spindle plate cover Disengage the 2 belts from the motor pulley thru the vent access hole 104 Southwestem Industries Inc FHM5
29. XED 1 36 H 281 8 PLATE R FI XED 1 41 HT 022 8 BRACKET FEED NUT 1 42 HT 022 8B JBRACKET CROSS SCREW 1 43 24501 BALLSCREW Y AXIS 1 44 HT 028 7A X BRACKET BEARING CROSS FEED 1 45 HT 028 8B BRACKET BEARING CROSS FEED 1 46 HT 029 14 TABLE 1 47 HT 041 8 BUSHING 1 48 24544 PULLEY Y AXIS BALLSCREW 1 49 24372 HOUSING BEARING 2 50 24373 COVER BEARING 1 51 HT 096 8A COVER 1 138 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Parts List FHM7 Bed Fiqures 48 amp 49 52 HT 142 8A COVER 1 53 24519 NUT LOCK 2 54 HX 046 STOP LIMIT SWITCH 2 55 24504 COVER WAY Y AXIS FRONT 1 56 HY 066 8 REST FOOT 1 57 HY 066 8A__ REST FOOT 1 58 HY 073 8 BRACKET BEARING BALL SCREW 1 59 HY 083 9 BUSHING 2 60 24508 GIB Y AXIS SIDE 1 61 24514 SWITCH LIMIT 1 62 24428 MOTOR DRIVER ASSY 40 55 1 64 670 5M 15 BELT TIMING 5MM POWERGRIP 1 65 620477 BEARING 3 66 24513 BEARING SET ANGULAR CONTACT 1 68 24546 KEY 5x 5 x 20L 2 69 AK0505022 5 5 22 1 70 AKP138 PIPE 3 8 2 71 AKP212 PIPE 1 2 2 72 24515 NUT LOCK 2 73 24547 NUT 3 4 10 NC 6 74 5 0 8 10 258 JSCREW SHCS STL BO 5 75 13 16 24X3 8 10B ISCREW PAN HEAD PHILLI PS STL BO 26 76 1 4 20X5 8 258 SCREW SHCS STL BO 29 77 1 4 20 3 4 258 SCREW SHCS STL BO 10 78 1 4 20X1 5 8 25BISCREW SHCS STL BO 2 79 1 4 20 1 3 4 25BISCR
30. amp 7 Safety Installation Maintenance Service amp Parts List i24291 90 Southwestern Industries Inc 5 1 13 Ball Screw Replacement Y Axis Saddle FHM5 1 Remove the sheet metal from the front of the machine and from the motor mounting bracket 2 Move the saddle toward the front of the machine and remove the electronic hand wheel 3 Remove the Y axis motor and belt 4 Remove the pulley and ferrule from the ball screw 5 Remove the motor mounting bracket 6 Loosen and remove the clamp nut Loosen the setscrew on the clamp nut before loosening the clamp nut 7 Remove the bearing housing Note which way the bearings are in the bearing housing 8 Remove the oil line and the 4 screws holding the ball nut to the yoke 9 Pull the ball screw out Reassemble 10 Install Y ball screw to yoke and install oil line to ball nut 11 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 Slide spacer onto ball screw Slide top bearing onto ball screw and seat with clamp nut Slide top bearing onto ball screw and seat with clamp nut Be sure to clamp nut to at least 50 ft lbs Don t forget to tighten setscrew after clamp nut is tight 12 Install motor mounting bracket woodruff key ferrule pulley star washer and nut Before tightening down the motor mounting bracket move the saddle to the front of the machine 13 Ass
31. amp FHM Safety Installation Maintenance Service amp Parts List 10 11 12 13 14 Remove the 4 M10 hex head screws that hold the motor Remove the motor Be careful the motor weighs approximately 70 Ibs for the FHM5 and over 100 Ibs for the FHM7 Install new motor pulley assembly and secure loosely with the 4 M10 hex head screw Engage the belt to motor and spindle pulley Make sure that the belt is 10096 engaged to both pulleys Adjust belt tension mechanism until proper belt tension is reach Belt is visible thru the vent hole Tighten the 4 M10 hex head screws that secure the motor to the casting Connect all the wires that go to the motor See the motor wiring section for further explanation Install remaining components in reverse order Turn on all the power to the machine Run the head at low and high rpm Listen for any obvious unusual noises 105 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 122500 1 SS SSS SSN 9 SECTION N N N SN NN NS A kt SON XN 5 DWE N Figure 31 1 FHM5 Head 106 Southwesiem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List Parts List FHM5 Head Figure 31 1
32. amp Table 21774 Z Axis Handwheel Ram 22291 1 Lube Pump 24428 X Y or Z Motor 12 Southwestem Industries Inc 5 8 FHM Safety Installation Maintenance Service 8 Parts List MACHINE A OFF ON ELECTRICAL CABINET AIR FILTER REGULATOR ASSY i00756 V3 1 Figure 4 FHM Rear View 13 Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Manual 2 8 Lifting and or Moving the Machine FHM5 Method 1 see Figure 5 1 Insert a steel bar 1 0 dia x 36 long through the rear side holes of the bed under column 2 Use steel cable with protective sleeving min 3 4 dia or a 3 ton sling 3 Use cardboard pieces or other suitable protective sheets on both sides of the machine to prevent scratching Remove the 4 nuts and screws holding the machine to the wood skid Lift the machine the front side of the machine should be lower than the back side Insert the 6 screws for leveling pads in their place in the bed B Place the machine in its location see floor plan and bed footprint drawing carefully positioning each leveling pad under each leveling screw 8 Remove the lifting cable or sling the steel bar and all protective cardboard STEEL CABLE 3 4 DIA OR 3 TON SLING Figure 5 5 Lifting the Machine POLESFOR Method 1 14 Southwestem Industries Inc FHM5 8 FHM7 Safety Installation Maintenan
33. attached to a cam holder Each limit switch stop cam must be set to a specific distance from the end of the bed in order to maximize travel and simultaneously prevent serious damage to the machine in the event of a crash Also the 122 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List limit switch assembly must be set to a specific distance from the cam in order for the limit switch to trigger properly The limit switch bracket contains slotted holes which allow for in and out positioning adjustments of the limit switch assembly 5 2 4 3 1 and cam holder The cam holder is mounted to the side of the bed by use of a couple of screws However the cam is mounted to the cam holder by a special means Each of the two set screws on the cam itself push against the top side of two ball bearings located inside the cam forcing them out of the side of the cam and up against the inner walls of the cam holder This action clamps the cam to the cam holder Also the cam holder is longer than the cam which allows for side to side positional adjustment of the cam within the cam holder 5 2 4 3 2 Procedure for setting Y limit switch 1 Remove the limit switch assembly from its bracket to prevent any interference between the limit switch assembly and the cam assembly in Step 2 2 Slowly move the saddle to the front of the bed by hand until the end of the travel is reached In DRO mode set X
34. by making sure the quill is out of the way and by starting with the table and saddle centered MAKE SURE THAT NO ONE IS STANDING IN THE WAY OF THE TABLE OR SADDLE Note You will lose the DRO reference position This procedure is to be run for each axis that is servo driven and for both the plus and minus direction for each axis 1 Center the table and saddle and raise the head Make sure the gib locks are released 2 Onthe Pendant display go into the Service Codes and input the Code 100 3 The conversation line will say SELECT AXIS Inputthe axis Either X Y or Z 4 Inthe conversation line it will say WHICH DIRECTION PLUS 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 65 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 5 In the conversation line it will say PRESS GO Press Go after you are sure that the machine will not crash in the direction and axis that you have specified 6 Afterward the screen will display values next to the DRO position axes The table below assumes machine has secondary feedback Machines with motor encoders only will display the reading next to the axis in question Your input X Your input X Vour input Y Your input Your input Z Your input 2 Interpretation of the resulting values displayed The values for the e
35. first close the adjustment screw CW on top of the oiler completely making sure to not over tighten Then open the screw CCW between 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 of the spindle This device allows the tool to easily be aligned with the dogs when loading a tool CAUTION Some tools may not work with this device and the original spindle dogs will need to be used The original spindle dogs are shipped with each machine in the toolbox Some boring bar holders may not work with this device 83 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List Figure 25 amp Parts List Shown FHM5 amp FHM7 Drawbar Option P N 22580 XX i22580 XX Item P N Title Qty 1 22581 POWER DRAW BAR TORQUE RITE 1 21660 DRAWBAR DPMV NMTB 2 PC HEAD 5 1 21660 CAT DRAWBAR DPMV CAT 2 PC HEAD FHM5 1 23284 DRAWBAR MANUAL FHM5 1 2 24165 NMTB DRAWBAR DPMV7 FHM7 1 24165 CAT DRAWBAR DPMV7 7 1 23171 NMTB DRAWBAR NMTB 1 PC HEAD FHM5 1 23171 CAT DRAWBAR CAT 1 PC HEAD 5 1 21661 SPACER DRAWBAR 3 5 HP FHM5 1 3 22116 SPACER DRAWBAR MANUAL FHM5 1 24166 SPACER DRAWBAR DPMV7
36. phase converter it must be a CNC rated 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 and the speed of the motor CUSTOMER POWER CUSTOMER TO PROVIDE STRAIN RELIEF Figure 10 FHM5 amp x amp FHM7 Wiring 2 13 Air Connection The FHM machines have an air hookup in the rear of the machine It includes an air regulator air manifold air solenoid and an oiler for a power drawbar if the machine was ordered with this option The air fitting is 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 The air regulator is set to 90 psi at the factory for the power drawbar unit See Section 5 for more information on the power drawbar unit The air comes in through the manifold and then into the air regulator that tees off into an oiler for the power drawbar unit and into an air solenoid The solenoid is used for a misting system the user may install later on this machine There is a 1 4 quick disconnect air fitting on the solenoid where the mister air hose can be plugged into See the figure below for an illustration 20 Southwestem Industries Inc 5 8 FHM Safety Installation Maintenance Service amp Parts List AIR IN DA NPT HOOK AIR HERE FOR MISTER
37. 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 scale If the error abruptly changes by a large amount it may be caused by a bad encoder Expected repeatability numbers should be 0 0005 or less Do the following service codes and procedures e Code 304 Toggle X sensor glass scale on off e Code 305 Toggle Y sensor glass scale on off Possible Cause Check This Machine Tool amp 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 amp Setup Section 4 1 X Y and Z axis Gibs are loose Check the adjustment of the X Y and Z axis Gibs using the X Y and Z axis Gib adjustment procedures Section 5 2 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 Use service codes 304 for X and 305 for Y to turn off the suspect encoder Does problem still exist after turning it off Section 4 6 amp 4 7 X and Y axis Drive Trains are loose Check Repeatability using the Repeatability and Positional Accura
38. the 3 wires on the lower left side of the unit These wires bring power into the unit Remove the 2 wires labeled B1 and B2 These wires run up to the resistor Remove the 3 wires labeled T1 T2 and T3 These wires take power to the spindle motor Make sure to put these wires in the same position on the new unit T1 uses the red wire T2 uses the white wire and T3 uses the black wire Remove the ground wires from the bottom of the unit The unit bolts in place with 4 screws Follow the instructions in reverse order when reinstalling Note the replacement AC drive will have the AC drive cable 22443 already wired to the drive 5 1 6 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 power cables consist of the 3 110 volt motor cables and 2 110 volt power cables for the pendant and a coolant pump or solenoid power cable The logic cables are used to carry encoder signals between the cable breakout box and computer module Mixing of the power and logic cables may cause noise from the power cables to interrupt the signals in the logic cables This can lead to intermittent axis faults or repeatability problems 77 Southwesiem Industnes Inc FHM5 amp 7 Safety Installation Maintenance Service 8 Parts List 5 1 7 Electronic Handwheels There are 3 electronic handwheels on the FHM machines The X and Y hand
39. the code you wish to view 4 9 3 1 Code 54 Program Continuous Run This Code runs a program continuously without stopping for SET Z or CHECK Z commands It is helpful in running a long period to identify an intermittent problem l Prepare a program as you normally would 2 Press MODE SET UP C Code 54 INC SET The program run will start automatically 3 Press STOP to stop and GO to continue 4 9 3 2 Code 81 Keyboard Test This code is used to check if the keyboard is functioning correctly It allows you to test each key on the pendant individually When you press the keys the corresponding box for that key will highlight on the screen The pendant will also beep indicating that the key is working correctly If one of the keys does not work the pendant assembly may need to be replaced If none of the keys are working chances are that the computer module will need to be replaced 4 9 3 3 Code 131 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 132 Electronic Hand wheel Test Turn the X Y or Z axis electronic hand wheel The display should show movement as the hand wheel is being turned There should be no skipping and it should count smoothly 68 Southwestem Industri
40. then tighten the screw down For the FHM7 verify the nut on the X axis and double nut on the Y axis is tight 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 FHM5 the bearing housing and spacer ring are matched sets keep them together 9 Check the ball screw mounting to the yoke Make sure the SHCS are tight 10 Inspect the ball screw ball nut and yoke for the potential problems shown in the chart on the next page CAUTION Unlike a lead screw do not unscrew the ball screw from its nut This will destroy the ball screw Potential Problem Check By Bad ball screw e Visually inspecting the ball nut if the nylon seal is broken or deformed if contamination has visibly entered the ball nut or if balls are out of the ball nut replace the ball screw e Cranking the ball screw through a significant part of its travel If it jams feels loose or has rough spots replace the ball screw e Using the dial indicator on a vertical flat of the ball screw to check for backlash between the ball screw and ball nut 49 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List e Inspection for s
41. unit remove power drawbar unit rod and spacer Remove the 4 SHCS securing the upper spindle plate cover Use 2 M8 x 30 SHCS to jack the upper spindle plate cover off from the spindle shaft Using a bearing puller remove the upper bearing from the spindle shaft Remove the 2 spindle belt Loosen the 3 setscrew securing the upper lock nut on the spindle shaft Remove the lock nut using a spanner wrench Remove pulley and key from the spindle shaft Loosen the setscrew that holds the nosepiece to the quill Tap the spindle quill assembly down with a rubber mallet Using an adjustable spanner wrench loosen the nosepiece by turning it counter clockwise The spindle collar will start to tighten up as you continue to loosen it Use a dead blow hammer to hit the top of the spindle shaft little by little while simultaneously loosening the spindle collar Eventually the spindle shaft and bearings will drop out through the bottom of the spindle quill Replace components in reverse order See Figure 32 for an illustration 108 Southwesiem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List 5 1 20 Spindle Assembly Replacement FHM7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Turn off power to the machine Remove the spindle head cover to gain access to the spindle Remove the power drawbar if one is installed
42. will run the routine automatically and then display values on the position readout Explanation Typical values should be between 4 04 and 11 11 are considered normal for each axis Higher values indicate excessive friction in the system Lower values indicate a loose system and may mean a gib adjustment is necessary Value 4 04 means the friction is a factor of 4 in one direction and 4 in the other direction The values should be within 3 or 4 of each other in both directions A value of 6 08 would still be considered normal On S products do not equate Code 12 values to torque on ball screw Measure friction in system with an in Ib 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
43. 0 mhz PC based processor 256 MB of RAM D C Servo Motors rated at 560 in oz continuous torque for X Y and Z axes Precision ground ballscrews in the table saddle and ram to ensure smooth accurate contours without backlash Feedrate override of programmed feedrate and rapid Programmable Spindle Speed Speed override of programmed spindle speed Polycarbonate sealed membrane and gasket sealed control enclosure to lock out contamination 10 1 2 color LCD for clear presentation of prompts status information and part graphics Modular design simplifies service and maximizes uptime 256 mb compact flash drive Single floppy disk drive for additional part program storage Auxiliary function box for control of spray mist coolant spindle off a 110 AC outlet coolant pump and a programmable rotary table or indexer Limit switches for the X Y and Z axes that are installed on the table saddle and ram to prevent crashes Electronic handwheels on the X Y and Z axes 2 USB ports 11 Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Manual SPINDLE MOTOR POWER DRAW BAR OPTIONAL ELECTRONIC HANDWHEEL SADDLE ELECTRONIC HANDWHEEL TABLE i01199 Figure 3 amp Parts List Shown FHM Component Identification Part Number Description FHM5 FHM7 23326 24525 Spindle Motor 24000 1 SMX Pendant 21946 X amp Y Axis Handwheels Saddle
44. 1 s ________ CENTERING BAR PJ swoost i0 BUDE ASSY UPPER CWEIGHTASSY 1 13 50068 CHAN A A dO 4 7 4 21765 SPROCKETIS THEE J 100789 127 Southwestern Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 6 2 Lubrication System Drawings Figure 43 amp Parts List Shown FHM Lubrication System 8200 wounsrusia 10 654 zo 2 uo 9 J anw 18 s 1 1 wvBdWWt3Aaxi 9 mu 38N1 ieee 1 Swa NOILYOINSNT SIXVA 4 AA mame td YO 24 e 39871 WNNINNTIV 33v SIBNL TV 8 W31SAS NOILWOINSNT A 9 X OL N 3ovdsns 9NIans 3015 1431 NWn09 OL 9 BOIS 1331 NWN109 3H1 JO 3OVSYNS ONIGIIS HOVE OL Ns MIYOS NYI SIXV Z OL 7 JOVAYNS ONIONS 3015 LH IY OL 7 3dis LHOIH NWN109 3H1 30 30V4UNS SNIGI1S MOVE OL ZOVSYNS 9NIans 3015 LHOIY SIXv Z OL N G3I3IO3dS 3SIMYSHLO SS3INA S31ON 128 Southwestem Industries Inc TRAK FHM5 amp FHW Safety Installation Maintenance Service amp Parts List i21688 2 Figure 44 FHM5 amp 7 Lubrication Kit P N 21688 2 129 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Install
45. 14 Southwesiem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List 7 Attach a 0001 dial indicator with a magnetic base to the right front of the saddle Place the indicator stylus on the edge of the large box way Move the right end of the table back and forth and note the amount of movement on the dial indicator Adjust the Y axis gib until the registered movement is 0010 0015 e adjust the gib for excessive clearance Loosen the gib lock screw on the right backside of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the right front side of the saddle Tighten the gib lock screw on the back end of the saddle to lock the gib in place and recheck Repeat as necessary e adjust the gib for too small of a clearance Loosen the gib lock screw on the front right side of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the right backside of the saddle Tighten the gib lock screw on the front right side of the saddle to lock the gib in place and recheck Repeat as necessary Replace the front and rear chip wiper and wiper guard 5 2 1 5 Saddle Bottom Gib Adjustment Y Axis see Figure 34 1 2 3 Clean all chips dirt and excess oil from the table and saddle Center the saddle on the bed ways Mount your indicator on the left side of the saddle Point C with the table in t
46. 15 BELT TIMING 5MM POWERGRIP 63 24558 ELBOW 90 64 24555 BEARING TA3025 65 24513 BEARING SET ANGULAR CONTACT 67 24512 BEARING BALL 69 24543 KEY 5 x 5 x 25L 70 24530 KEY 8 X 7 X 60L 71 24528 KEY 10 X8 X 35 72 24520 NUT LOCK M25X 1 5 73 24515 NUT LOCK 74 24533 NUT LOCK M35 X 1 5 75 24534 NUT LOCK M40 X 1 5 77 1 4 20 50B NUT HEX STL BO 78 5 8 18 50B NUT HEX STL BO 79 3 4 10 50B NUT HEX STL BO 80 AOS255211 JSEAL OIL 25x52x11 81 AOS385216 JSEAL OIL 38x52x16 82 3 16 24X1 2 10B SCREW PAN HEAD PHILLIPS STL BO 83 3 16 24 5 8 10B SCREW PAN HEAD PHILLIPS STL BO 103 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List Parts List FHM7 Z Axis Drive Train Figure 31 amp 32 85 1 4 20 1 2 258 JSCREW SHCS STL BO 4 85 1 4 20X5 8 25B SCREW SHCS STL BO 7 86 1 4 20X3 4 258 SCREW SHCS STL BO 6 87 1 4 20 1 258 SCREW SHCS STL BO 1 88 5 16 18 7 8 258 ISCREW SHCS STL BO 4 89 5 16 18X1 258 SCREW SHCS STL BO 6 90 3 8 16X125B SCREW SHCS STL BO 20 91 3 8 16 1 1 2 25BISCREW SHCS STL BO 9 92 11 2 12 1 1 4 25BSCREW SHCS STL BO FULL THREAD 4 93 3 4 10 5 24B SCREW HEX HD STL BO 1 94 M5 0 8X12 10B SCREW PH PHIL STL BO 8 95 M6 1 0X12 25B SCREW SHCS STL BO 15 96 6 1 0 20 258 SCREW SHCS STL BO 3 97 3 8 70P
47. 2 Safety Publications Refer to and study the following publications for assistance in enhancing the safe use of this machine Safety Requirements for Manual Milling Drilling and Boring Machines with or without Automatic Control ANSI B11 8 2001 Available from The American National Standards Institute 1819 L Street N W Washington D C 20036 Concepts And Techniques Of Machine Safeguarding OSHA Publication Number 3067 Available from The Publication Office O S H A U S Department of Labor 200 Constitution Avenue NW Washington DC 20210 Danger Warning Caution 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 that could result in severe personal injury and or damage to the equipment Warning labels on the machine are orange in color CAUTION Hazards or unsafe practices that cou d result in minor personal injury or equipment product damage Caution labels on the machine are yellow in color 1 Southwestem Industries Inc 5 8 FHM7 Safety Installation Maintenance Service amp Parts List NOTE Calls attention to specific issues requiring special attention or understanding NOTICE The manufacture is not liable responsible for any damages or injury of any kind to persons or property caused by or resulting from the improp
48. 3 Bed Parts List 131 6 4 Table Saddle Spare Parts List 131 6 4 1 Table Saddle Spare Parts List 131 6 5 Manual Ram Elevation Drawing 132 6 6 Coolant Pump Mounting 133 List of Figures Fig 1 Machine Footprints 5 Fig 2 Overall Dimensions FHM5 6 Fig 2A Overall Dimensions FHM7 7 Fig FHMV Component Identification 12 Fig 4 FHMV Rear View 13 Fig 5 Lifting the Machine Method 1 14 Fig 6 Lifting the Machine Method 2 15 Fig 7 Lifting the Machine FHM7 16 Fig 8 Placement of Levels 19 Fig 9 Leveling Screws 19 Southwestern Industries Inc TRAK 5 amp FHM7 Safety Installation Maintenance Service amp Parts List 1 0 Safety The safe operation of the FHM Bed Mill depends on its proper use and the precautions taken by each operator Read and study this manual and the FHM Safety Operation amp Programming Manual Be certain every operator understands the operation and safety 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 workpiece 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 1
49. 4 20X1 2 25B SCREW SHCS STL BO 4 45 21946 ELEC HANDWHEEL X amp Y AXIS 1 43 M6 1 0X30 25B SCREW SHCS STL BO 4 4 15967 COVER UPPER 1 5 15968 COVER LOWER 1 21585 1 COVER BALLSCREW END 1 10 21584 1 END PLATE COVER 1 11 6 32X3 8 10B SCREW PH PHIL STL BO 5 25 8 1 25 25 258 SCREW SHCS STL BO 4 13 98481A090 KEY WOODRUFF 404 1 8 X 1 2 1 15 16066 NUT CLAMP X amp Y AXIS 1 16 565 5M 15 BELT TIMING 1 17 21662 BEARING HOUSING ASSY 1 18 20374 BEARING ANGULAR CONTACT 7205 2 20 16078 BEARING SEAL 1 21 24009 2 WASHER BELLEVILLE SPRING LOCK 5 24 M10 1 5X12 25B SCREW SHCS STL BO 1 26 24009 1 WASHER BELLEVILLE LOCK 4 27 1 4 20X1 24B SCREW HEX HD STL BO 4 28 15759 WASHER 1 4 HARD BLK OX 1 8 THK 4 29 24009 3 WASHER BELLEVILLE SPRING LOCK 4 33 10 32X3 4 25B SCREW SHCS STL BO 1 36 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 1 37 16350 FERRULE SPROCKET Z AXIS DRIVE TRL 1440 1 38 1 2 71Z WASHER FLAT SAE STL ZINC 1 39 1 2 20 51Z NUT HEX JAM STL ZINC 1 40 1 2 75Z WASHER EXT TOOTH STL ZINC 1 41 M10 1 5X80 25B SCREW SHCS STL BO FULLY THD 4 42 21985 SPACER ANGLED 30 DEGREE Y AXIS 1 i24462 Ball Screw Replacement X Axis Table FHM7 1 2 Remove table way covers from each side of the table Remove the left bearing housing cover by removing the 8 10 24 truss head screw that secures it to the left bearing bracket Remove the motor cover housing by removing the 4 10 24 truss head screw secures it to the left bearing housin
50. Are Not Repeating e See Measurements Are Not Accurate 3 3 10 Auxiliary Functions Not Working 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 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 All of the auxiliary function signals are carried down to the cable breakout box through umbilical 2 Each function then has its own relay inside this box If one of these relays fail then these features will not work Do the following service code and procedures 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 Verify that the fuses are good or bad by 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 output of the Haas Indexer connector is activated Check 110 V
51. BS 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 250 ipm 5 Using the DRO display back the table off 1 2 6 Loosely mount the cam and the spacer on the same side of the table that the end of travel was reached 7 Slide the cam and the spacer up next to the plunger which is located on the limit switch assembly 8 Setthe height of the cam such that the cam initially makes contact near the bottom but not past the tapered portion of the plunger as shown below in Figure 44 9 Slide the cam along with the spacer up against the plunger until the limit switch is triggered Note The moment when the limit switch is triggered can be seen on the DRO display 10 Mount the cam and the spacer in this position 11 Repeat Steps 2 6 for setting the position of the cam and the spacer for the other side of the table 12 Jog the table at 250ipm to each side and verify that the limit switches are working properly Also make sure that the table does not exceed its travel and crash Ca 000 Tapered portion of Plunger Limit Switch Figure 40 Limit Switch Installation 5 2 4 3 Y axis Limit Switch Stop Installation and Adjustment The limit switch stops for the Y axis are mounted on the side of the bed The limit switch stop consists of a cam
52. Codes 4 9 3 Diagnostic Codes 4 9 4 Operator Defaults Options Codes 4 9 5 Lube Pump Codes 39 40 40 41 41 42 Southwestern Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 5 0 Procedures for Replacements Fig 10 Wiring the FHM5 amp FHM7 20 amp Maintenance Fig 11 Air Regulator Solenoid Assembly 21 5 1 Replacements 7 Fig 12 Pendant Cable Connections Left Side 23 5 1 1 Servo Motor Replacement 71 Fig 13 Pendant Right Side 24 5 1 2 Servo Driver Replacement 71 Fig 14 Euclid Block 27 5 1 3 Computer Module amp LCD Enclosure Fig 15 Electrical Cabinet 59 Replacement 72 Fig 16 Servo Driver Replacement 72 5 1 4 System Flash Disk Replacement 76 Fig 17 Computer Module and LED Enclosure 74 5 1 5 AC Drive Replacement 77 Fig 18 Flash Disk Replacement 75 5 1 6 Cable Routing in on Machine 77 Fig 20 5 Base Mounting 78 5 1 7 Electronic Handwheels 78 Fig 21 TRAK Sensor Mounting 79 5 1 8 Sensor FHM5 Only 78 Fig 22 FHM5 Sensor Assembly 80 5 1 9 Glass Scale Replacement 81 Fig 23 Glass Scale Alignment 82 5 L10 Power Drawbar 83 Fig 25 Power Drawbar Assembly 84 5 1 11 Ball Screw Replacement X Axis Fig 26 FHM5 X Drive Train 86 Table FHM5 85 Fig 27 FHM7 X Drive Train 89 5 1 12 Ball Screw Replacement X Axis Fig 28 FHMS Y Drive Train 92 Table FHM7 87 Fig 29 FHM7 Y Drive Train 95 5 1 13 Ball Screw Replacement Y Axis Fig 30 5 Z Axis Drive Train 99 FHM5
53. 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 Accumulating error will add roughly the same amount to the reading after each traverse See Step 3 For random error look for problems in the set up of the glass scale that have resulted in a loss of rigidity Common sources of random error include e Loose scale mounting hardware e Loose reader head 54 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 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 glass 55 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 4 7 TRAK Sensors FHM5 only TRAK Sensors are used on the X and Y axis for secondary feedback They are optional on the FHM5 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 e determine if the TRAK Sensor is bad and needs to be replaced e To determine if there is a pro
54. EW SHCS STL BO 2 80 5 16 18 1 2 25B SCREW SHCS STL BO 4 81 5 16 18 3 4 258 SCREW SHCS STL BO 14 82 5 16 18 1 258 SCREW SHCS STL BO 6 83 7 8 9X3 1 2 258 SCREW SHCS STL BO 6 84 1 4 70 WASHER FLAT USS STL BO 1 85 5 16 70B FLAT WASHER 5 16 18 i24292 139 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Figure 50 FHM7 Column Parts Refer to Figure 53 Parts List o ON IN ON 9 2 d i01098 140 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 101099 Figure 51 FHM7 Column Parts 141 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Figure 52 t Ss 142 i01100 28 12 Qe 6 8 Southwesiem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 101101 Figure 53 FHM7 143 Southwesiem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Parts List FHM7 Column amp Z Axis Drive Train Figure 50 51 52 53
55. Enter backlash compensation 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 X Y and Z axis Gibs are not adjusted Check the adjustment of the X Y and Z axis Gibs using properly the X Y and Z axis Gib adjustment procedures Section 5 2 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 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 5 2 2 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 33 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service 8 Parts List 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 C
56. Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Parts List FHM5 amp FHM7 Electrical Cabinet Figure 15 7 22283 1 3 15 WIREWAY G LIGHT GRAY 12 1 4 20X3 8 317 SCREW PH PHIL EXT SEMS STL ZINC Item P N Title Qty 1 25063 SHEET METAL AUX PANEL 0 2 24042 1 MODULE SPINDLE CONTROL MILLS 1 3 24999 1 ENCLOSURE ASSY CABLE BREAKOUT BOX 1 4 24184 3 AC DRIVE ASSY 15 HP 1 24184 4 AC DRIVE ASSY 5 HP FHM5 1 6 22283 2 3 30 WIREWAY TYPE G LIGHT GRAY 1 1 7 13 10 32 3 8 312 SCREW PH PHIL EXT SEMS STL ZINC 10 21 22392 1 15 COVER WIREWAY TYPEG 1 22 22392 2 30 COVER WIREWAY TYPE G 1 25 25064 SHEET METAL DRIVE PANEL 15 HP 0 25065 SHEET METAL DRIVE PANEL 5 HP 5 0 26 24930 CABLE POWER EXTENSION 1 27 M8 1 25X20 25B SCREW SHCS STL BO 8 28 8 70B WASHER FLAT USS STL BO 8 i24459 2 4 8 2 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 in 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 electr
57. K 4 23 1 2 20 51Z NUT HEX JAM STL ZINC 1 24 1 2 71Z WASHER FLAT SAE STL ZINC 1 25 1 2 75Z WASHER EXT TOOTH STL ZINC 1 26 21985 SPACER 30 DEGREE Y AXIS DRIVE ASSY 1 27 6 1 0 25 258 SCREW SHCS STL BO 4 28 3 16X1 1 481P PIN ROLLED STL PLAIN 2 29 21984 BRACKET WAY COVER FRONT Y AXIS DRIVE 1 31 6 32X3 8 10B JSCREW PH PHIL STL BO 4 32 98481 A090 KEY WOODRUFF 404 1 8 X 1 2 1 33 1 4 20X5 8 26B SCREW FHCS STL BO 4 36 5 0 8 10 108 SCREW PH PHIL STL BO 2 37 21946 ELECTRONIC HANDWHEEL X 8 Y AXIS 1 38 6 1 0 75 258 SCREW SHCS STL BO 4 39 22768 37 LABEL TEXT 1 i24461 5 1 14 Ball Screw Replacement Y Axis FHM7 1 Gr eU GID Move the y axis to the front of the machine Remove the electronic handwheel and axis motor cover Remove the front ballscrew bearing and housing Remove the Y axis motor and belt Remove the double nut that holds the pulley and slide the ballscrew pulley from the ballscrew along with the key Remove the bearing cover locking nut axis bearings and bearing housing block When removing the bearings take note to how they are mounted 93 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 7 Now go to the bottom of the column and rear of bed and remove the access cover to the rear bearing on the Y axis 8 Remove the nut bearing and bushing that is found at the end of the ballscrew 9 Now go the front of the machine a
58. K REPLACEMENT KIT FOR SX PENDANT REV D AND ABOVE 25078 1 FLASH DISK REPLACEMENT KIT FOR SX PENDANT REV A B ORC i25078 amp 1 75 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 5 1 4 System Flash Disk Replacement 10 11 12 13 14 15 16 From the control go to SETUP SERV CODES SECTION A and then code 142 and save your Configuration file calibration values etc on a floppy disk There is a disk in the electric s cabinet for this purpose Label this disk as Backup Configuration and store it for later use Turn power off to the machine and control Unplug all the connectors on the pendant arm side of the pendant Remove the pendant from the pendant arm by removing the 4 14 20 x 3 4 SCHS that secure it in place Place the pendant assembly on a clean and secured table with the display pointing away from you Remove the 6 10 32 x 3 8 Pan Phillips Head Screws and 4 10 32 x 3 8 FHCS securing the computer module to the LCD enclosure Pull the computer module a few inches and stop Pulling the computer module too far will damage the ribbon cables Remove the defective System Flash Disk located on the back side of the mother board by pushing the eject button on the flash drive Firmly insert the replacement System Flash Disk into the drive making sure that the label with the serial number is pointing towards the motherboard
59. ProtoTRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Manual Document P N 25083 Version 081513 Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 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 2012 Southwestern Industries Inc All rights are reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical photocopying recording or otherwise without the prior written permission of Southwestern Industries Inc While every effort has been made to include all the information required for the purposes of this guide Southwestern Industries Inc assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from the use of the information contained in this guide All brand names and products are trademarks or registered trademarks of their respective holders Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 5610 Phn 310 608 4422 Fax 310 764 2668 Service Department Phn 800 367 3165 Fax 310 886 8029 Table of Contents 1 0 1 1 1 2 1 3 2 9 2 10 2 11 2 12 2 13 2 14 2 15 2 16 2 17 3 0 3 1 3 2 3 3 Safety Safety Publications Danger Warni
60. R ROLLER S 1 17 H 140 10 HOLDER FIXED MOTOR 1 18 H 140 10B HOLDER FIXED 1 19 24542 PULLEY Z AXIS BALLSCREW 1 20 H 145 8 ROLLER 4 21 H 146 8 SPACER 4 22 H 147 8 SHAFT DRIVE 4 23 H 148 8 SCREW 4 24 H 149 8A WEIGHT BALANCE 1 25 H 160 9 BRACKET BEARING 1 26 H 165 8 PIPE CONNECTION 2 27 H 167 10B JCOVER TOP 1 102 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List Parts List FHM7 Z Axis Drive Train Figure 31 amp 32 28 H 168 8 HOLDER BALANCE WEIGHT 29 H 170 8 WASHER 30 H 171 8 HOLDER MICRO SWITCH 31 24550 VALVE 32 24551 NOZZLE COOLANT 33 H 310 8 COVER 34 H 331 8 BRACKET ARM 35 H 332 14 COVER ARM 36 HB 127 B BRACKET 39 HB 134 10 BRACKET BUSHING BEARING 42 24532 CARTRIDGE HOUSING 43 24529 PULLEY SPINDLE 44 24527 PULLEY MOTOR 45 HB 199 10 CLAMPING RING 46 HB 200 10 DUST COVER 47 HB 201 13 SPACER 48 HT 067 14A CABINET ELECTRICAL CONTROL 49 HX 002 10 JBUSHING BEARING 50 HX 007 COVER BEARING 51 HX 007 9 COVER BEARING 52 HX 028 10 JSUPPORT DUST HELMET 53 HX 030 10 JSUPPORT DUST HELMET 54 24523 COVER Z BALLSCREW 55 HX 046 STOP LIMIT SWITCH 56 043 14 ARM 57 24556 SPACER BEARING INNER 58 24557 SPACER BEARING OUTER 60 24427 SPROCKET ASSY 26 TEETH 40 55 61 24553 BELT SET SPINDLE 62 425 5
61. SING BEARING 2 50 24373 COVER BEARING 1 51 HT 096 8A COVER 1 52 HT 142 8A COVER 1 53 24519 NUT LOCK 2 54 HX 046 STOP LIMIT SWITCH 2 55 24504 COVER WAY Y AXIS FRONT 1 56 HY 066 8 REST FOOT 1 57 HY 066 8A REST FOOT 1 58 HY 073 8 BRACKET BEARING BALL SCREW 1 59 HY 083 9 BUSHING 2 60 24508 GIB Y AXIS SIDE 1 61 24514 SWITCH LIMIT 1 62 24428 MOTOR ENCODER SERVO ASSY DRIVER 4055 1 64 670 5M 15 BELT TIMING 5MM POWERGRIP 1 65 26198 1 BEARING DEEP GROOVE 62047Z 2 66 23940 BEARING ANGULAR CONTACT U SET 2 7205 1 68 24546 KEY 5x 5x 20L 2 69 AK0505022 KEY 5x5x22 1 70 AKP138 PIPE 3 8 2 71 AKP212 PIPE 1 2 2 72 24515 NUT LOCK 2 73 24547 NUT 3 4 10 NC 6 74 M5 0 8X10 25B SCREW SHCS STL BO 5 75 3 16 24X3 8 10B SCREW PAN HEAD PHILLIPS STL BO 26 76 1 4 20X5 8 25B SCREW SHCS STL BO 29 77 1 4 20X3 4 25B SCREW SHCS STL BO 10 78 1 4 20X1 5 8 25B SCREW SHCS STL BO 2 79 1 4 20X1 3 4 25B SCREW SHCS STL BO 2 80 5 16 18X1 2 25B SCREW SHCS STL BO 4 81 5 16 18X3 4 25B SCREW SHCS STL BO 14 82 5 16 18X1 25B SCREW SHCS STL BO 6 83 7 8 9X3 1 2 25B SCREW SHCS STL BO 6 84 1 4 70B WASHER FLAT USS STL BO 1 85 5 16 70B FLAT WASHER 5 16 18 i24292 97 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 4 NO UM opus OUS o 12 13 14 15 16 17 18 19 5 1 15 Z Axis Ball Screw Removal amp Replacement FHM5 amp FHM7 CAUTION Never screw a
62. X5 24B SCREW HEX HD STL BO 1 94 M5 0 8X12 10B SCREW PH PHIL STL BO 8 95 M6 1 0X12 25B SCREW SHCS STL BO 15 96 M6 1 0X20 25B SCREW SHCS STL BO 3 97 3 8 70P WASHER FLAT USS STL BO 6 98 5 8 70B WASHER FLAT USS STL BO 1 99 24537 SPINDLE ASSEMBLY 1 i24293 145 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Southwestern Industries Inc TRAK Warranty Policy Warranty TRAK products are warranted to the original purchaser to be free from defects in work manship and materials for the following periods Warranty Period produer Materials Factory Labor New TRAK 1 Year 1 Year Any EXCHANGE 90 Days 90 Days Unit The warranty period starts on the date of the invoice to the original purchaser from Southwestern Industries Inc SWI or their authorized distributor If a unit under warranty fails it will be repaired or exchanged at our option for a properly functioning unit in similar or better condition Such repairs or exchanges will be made FOB Factory Los Angeles or the location of our nearest factory representative or authorized distributor Disclaimers of Warranties 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 repa
63. ack 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 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 Verify configuration file Code 313 does not read calibration file and backlash constants default values Load save configuration file from has been erased or corrupted floppy disk in 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 Section 5 2 2 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 misalign
64. 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 Verify that the Head is Trammed to specification See Tramming the Head X Y and Z axis Gibs are not adjusted Check the adjustment of the X Y and Z axis Gibs properly using the X Y and Z axis Gib adjustment procedures Section 5 2 1 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 TRAK Sensors or Glass Scales 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 Spindle Shaft is loose Verify using a dial indic
65. am bracket assembly to the column such that the cam will initially make contact near the bottom but not past the tapered portion of the plunger 20 Slide the cam up against the plunger until the limit switch is triggered Note The moment when the limit switch is triggered can be seen on the DRO display 21 Mount the cam in this position 124 Southwesiem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List SA Z8100 SAHILIMS X SAHOLIMS JINTIZSA 125 143 714 55 HOLMS 215525 vi 15526 t Sixvz W3ovds rorizz ZL ma lVdS WvO O pec OL WVOJ 6 XU s39vdS 201160 1 H3T1OHWvo 1330vNS 60 22 9 HOLMS SIXV 1404408 66022 S D elec v HOLMS LIMIT WWo 80 22 SIXV Z 9 X rld H3d1OH Wvo 2752 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List Limit Switches Figure 41 6 0 Parts Lists amp Drawings 6 1 Counter Balance System Drawing Figure 42 amp Parts List Shown FHM Counter Balance System DETAIL A FOR TRANSPORT ONLY DETAIL B mm PN 7 O moss NUFHEXSTLBO 1140 4 MASTERLNK x 4 21717 6 BAR CWEIGHT TRANSPORT 2193712 SUPPORT BAR 600 LOWER CWEIGHT PJ Swoom
66. amp Parts List Part List FHM5 Z Axis Drive Train P N 16790 1 Figure 30 Item P N Title Qty 1 16806 M BALLSCREW ASSY Z AXIS 1 2 PJ540015 BRACKET LOWER ELEVATING BALL SCREW 1 3 2205E 2RS1TN9 BEARING SELF ALIGNMENT SKF 1 4 16774 COVER BEARING 1 5 16795 MODIFIED BEVEL GEAR BS1236 2A 1 6 M10 1 5X10 40B SCREW SOC SET STL BO CUP 1 7 16770 MODIFICATION OF 3 HP RAM PING JENG PART 1 8 M6 73B WASHER SPLIT LOCK STL BO 6 9 M6 1 0X25 25B SCREW SHCS STL BO 6 10 7205 AVH NILOS RING 7205 1 11 16295 1 BEARING HOUSING ASSY 1 13 20374 BEARING ANGULAR CONTACT 2 14 16773 NUT CLAMP Z AXIS 1 15 10 32X3 4 25B SCREW SHCS STL BO 1 16 16350 FERRULE SPROCKET 1 17 16983 PULLEY SOLID 44 TEETH Z AXIS 1 18 NO1 LOCKNUT 1 19 W01 LOCKWASHER 1 20 M8 73B WASHER SPLIT LOCK STL BO 4 21 98481A090 KEY WOODRUFF 404 1 8 X 1 2 1 22 M8 1 25X20 25B SCREW SHCS STL BO 4 23 710 5M 15 BELT TIMING 1 24 21944 PLATE BALLSCREW SUPPORT Z AXIS 1 25 1 4 20X1 1 4 258 SCREW SHCS STL BO 4 26 15759 WASHER 1 4 HARD BLK OX 1 8 THK 4 27 23197 BRACKET Z AXIS MOTOR DPMS 1 28 23198 MOTOR DRIVER ASSY 4050 1 31 M10 73B WASHER SPLIT LOCK STL BO 8 32 17030 LOUVRE SPACER 1 34 M10 1 5X45 25B SCREW SHCS STL BO 8 35 M10 71B WASHER FLAT SAE STL BO 4 i16790 XX 100 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List
67. arts List 4 9 4 5 Code 129 Arc Accuracy When the SMX control operates at high feedrates it may create small part machining errors as it goes around sharp corners This exists on all CNC s and is commonly called a following error The control is factory preset to allow a maximum following error of 0 001 inch The feedrate will automatically be adjusted around sharp corners so as to not violate this limit This code only applies to arcs that are programmed and ones that are created in the tool path to generate the shape you want This code will not make a difference on mill moves You may adjust the maximum following error to a value as small as 0001 inch However the smaller the value the slower the feedrate around corners To input a new Following Error use the following procedure Follow the instructions on the screen and input the Following Error value from 0001 to 0100 and press INC SET 4 9 4 6 Code 335 Leave Spindle On During Pause Toggles the spindle to stay on or to turn off at a programmed Pause event 4 9 5 Lube Pump Codes The following codes are used for programming and operating the lube pump To get to any of these codes go to Service Codes press E and press the code you wish to view 4 9 5 1 Code 300 Lube Pump Switch This code acts as a switch to turn the lube pump on for the programmed time set in Code 302 4 9 5 2 Code 301 Set Lube Pump cycle time This code sets the interval time between lube cycles 4
68. as occurred Shut down the system 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 ed 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 run 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 if there is a difference 3 3 4 Fault X Y or Z 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 backlash 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 35 Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service 8 Parts List Make sure the Table Saddle and Ram Locks are unlocked High torque on any axis may cause faulting problems during alignment routine
69. ation Maintenance Service amp Parts List Parts List FHM 5 amp 7 Lubrication Kit P N 21688 Figure 44 Item P N Title Qty 1 P8011010 CHAIN 10MMX10MMX34 UNITS 1 2 P8621010 CABLE CARRIER 10MMX10MMX42 UNITS 1 5 PA4 NUT COMPRESSION 4mm 22 6 PB4 SLEEVE COMPRESSION 4mm 36 8 PAN4 NUT 14 10 JD 4 2 WAY JUNCTION 12 DB8 DISTRIBUTOR 13 PSSA OIL DISTRIBUTOR 14 14 4 TUBING 4MM ALUM 144 15 P04 TUBING 4MM PLASTIC 108 16 23254 BRACKET X amp Y AXIS LUBRICATION 1 17 22346 BRACKET LUBE X AXIS BALLSCREW 1 18 21737 BRACKET X amp Y AXIS LUBRICATION 1 19 PD408 ADAPTER 2 20 PH408 ADAPTER RIGHT ANGLE 13 22 PZ0104 CLAMP 1 23 M5 0 8X10 10B SCREW PH PHIL STL BO 1 24 PH4 8 CONNECTOR 1 25 M8 1 25X25 25B SCREW SHCS STL BO 2 26 M6 1 0X16 20B SCREW RH PHIL STL BO 2 i21688 2 G NOTES UNLESS OTHERWISE SPECIFIED 1 ALL TUBES ARE 4mm ALUMINUM TUBE 2 ALLTUBES ARE 4mm NYLON J NTOX AXIS LEFT GIB ANTO X AXIS FRONT WAY SURFACE S TOY AXIS LEFT BOTTOM GIB V AXIS LEFT WAY SURFACE ANTOY AXIS LEFT SIDE GIB 8NTO X AXIS REAR WAY SURFACE 9 X AXIS LEFT REAR DOVE TAIL CONTACT SURFACE ATO X AXIS RIGHT GIB ANTO Y AXIS BALLSCREW Y AXIS RIGHT BOTTOM GIB ANTO Y AXIS RIGHT WAY SURFACE ATO Y AXIS RIGHT SIDE CONTACT SURFACE X AXIS BALLSCREW ATO X AXIS RIGHT REAR DOVE TAIL CONTACT SURFACE
70. ator whether or not the Spindle Shaft is loose If so it could possibly be either bad spindle bearings or loose quill etc 29 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List 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 The system will respond to being pushed out of position by making an adjustment at the end of the move An unwanted tapered cut is the result of looseness in the system Do the following Service Codes 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 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 e Code 128 Enter backlash compensation Possible Cause Check This Machine Tool amp Setup problem Check for any looseness in the setup Tool Tool holder Part Vise or Fixture See Ma
71. ball screw is raised Angle the ball screw out and away from the head Lower the ball screw on the right side of the machine until the top of the ball screw clears the support plate Reassemble all components in reverse order as shown above except leave off the pulley locknut and lock washer until ball screw is realigned Torque clamp nut to 50 ft Ib for the FHM5 and lock nut for the FHM7 With the ball screw assembly installed loosen four 5 16 18 cap screws from bearing housing raise head to the uppermost position and re tighten 5 16 18 cap screws Note that there is 060 clearance between the bearing housing outside diameter and the inside diameter of the support plate to allow for realignment Traverse the head to the extreme of the up and down travel manually to check for freedom of movement Use torque wrench to make sure torque is consistent along length of screw Use torque wrench to make sure torque is consistent along length of screw See Figure 30 for the FHM5 and Figure 31 for the FHM7 for an illustration of the Z axis drive train See Section 5 2 2 to properly measure amp set the Z Backlash Compensation amp calibration 98 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List LL x o 4 Figure 30 1 FHM5 Z Axis Drive Train P N 16790 99 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service
72. ball screw partially or totally out of its nut They cannot be reassembled Ensure that there is sufficient vertical clearance above the top of the machine to remove the ball screw Minimum clearance required is 32 inches Remove vertical column top cover Remove servomotor belt and Z motor mounting bracket Remove upper and lower Z axis way covers Lower head to table Place 1 or 2 inch wood board between spindle nose and table to protect Lower head until weight of head is supported by the table Tighten both ram locks on the right side of ram Remove locknut and lock washer from the top of the Z ball screw Remove pulley and key For the FHM5 loosen 10 32 socket screw on clamp nut For the FHM5 using wrench flats on clamp nut and wrench flats on ball screw remove clamp nut Remove the four cap screws from bearing housing flange For the FHM5 remove the clamp nut remove the locknut on the FHM7 Remove bearing nilos ring and bearing housing with matched spacer from ball screw Remove the cap screws and lock washers from ball nut flange Loosen setscrew from bevel gear FHM5 only Rotate ball screw by hand if necessary to access set screw Extract ball screw assembly from machine until ball nut flange is above the top of the ram Support ball screw amp remove lubrication line from ball nut flange Raise the ball screw until the bottom end of the ball screw is above the ram Be careful to remove bevel gear as the
73. blem with the sensor set up 4 7 1 Faulting Axis If a sensor has stop reading and you try to move an axis the axis will run away and fault Our control uses the counts from the sensor and motor when reading position If either one of these signals is not working our system will fault 1 The first thing that can be done to see if it is the sensor is to turn off the sensor on the axis in question This will allow the system to run only on the motor encoders If the fault continues then the sensor was not the problem Turn the sensor back on See the service code section for a codes needed to turn the sensors on and off 2 The next thing to do is to visually inspect the sensor and base to determine if there has been a crash A damaged base will usually have crinkles in the small triangular plates on the front and back 3 Next make sure the sensor is preloaded correctly against the running surface There is a setscrew on the base that allows for adjustment 4 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 Ifthe 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 w
74. ce Service amp Parts List Method 2 see Figure 6 1 Insert 2 steel bars 1 dia x 36 long through both sides in the existing holes in the machine base front and back 2 Position 4 two each side wood vee blocks under the steel bars and over a suitable lift truck 3 Lift the machine up somewhat tilted towards the front 4 6 from the ground and move it to its floor plan position WARNING The lift truck must have sufficient lifting capacity 5 tons and be equipped with suitably long forks When lifting the machine on the pallet the center of gravity of the machine while on the pallet is 36 from the edge of the pallet 4 Insert the 6 screws for the leveling pads in their place in the bed 5 Place the machine in its location see floor plan bed footprint carefully positioning each leveling pad under each leveling screw 4 x 4 x 8 WOOD BLOCKS VEE GROVED i00758 Figure 6 FHM5 Lifting the Machine Method 2 15 Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Manual 2 8 1 Lifting the machine FHM7 see Figure 7 CAUTION The FHM7 machines weigh approximately 7650 Ibs Proper equipment of sufficient capacity OND must be used when lifting and or moving the machine Using the recommended size forklift lift the pallet with the machine on thru the fork pocket Note The center of gravity CG of the machine while on the pa
75. ce and recheck Repeat as necessary e adjust the gib for too small of a clearance Loosen the gib lock screw on the top of the ram Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the bottom of the ram Tighten the gib lock screw on the bottom of the ram Tighten the gib lock screw on the top of the ram to lock the gib in place and recheck Repeat as necessary 7 Repeat the procedure for the back gib on the right side of the machine CAUTION Be careful not to over tighten the ram gibs Over tightening may lead to faulting and repeatability problems Double check the gib adjustment by checking the torque on the Z axis Use an in Ib torque wrench on top of the ball screw and typical readings should be from 12 to 17 in Ibs and consistent across the Z travel 5 2 1 7 Ram Side Gib Adjustment Z Axis see Figure 37 l Clean all chips dirt and excess oil from the column ways 2 Attach a 0001 dial indicator with a magnetic base towards the rear of the table on the right side of the ram Place the indicator stylus on the ram in line and below the lower mounting bolt for the coolant hose connector block 3 Lock and unlock the lower ram side gib lock and note the amount of movement on the dial indicator Adjust the ram side gib until the registered movement is 0005 0010 adjust the gib for excessive clearance Loosen the gib lock screw on the bottom of the ram Estimate the amo
76. chine Tool amp Setup Section 4 1 X Y and Z axis Gibs are loose Check the adjustment of the X Y and Z axis Gibs using the X Y and Z axis 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 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 30 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service 8 Parts List 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 Feedb
77. ctions in reverse order when reinstalling the new computer module or LCD enclosure Make sure that all connectors are properly seated before fastening the unit back in place 72 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List xu 1 06092 ASSV 31nqON 3i31ndWOO XS SMIUIS 26 01 6 ONNOHD 000 2 Le Vd ASSY LNVON3d XIS 000 2 LH Vd ASSY LNVON3d XWS mavoqo1 3 anayo NOILNEIYLSIG SMA349S 1913 25 01 318v 0193 800VZ UILNAWOD LNOHLIM A SSV LNVON3d XIS 1 800vZ H31ndWOO LNOHLIM ASSY LNVON3d XWS Computer Module amp LCD Enclosure Replacement Figure 17a 73 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 10 32 x 1 2 FHMS i24000 7 A 10 32 x 3 8 PHMS GRN WIRE Figure 17b Computer Module USB amp LCD Enclosure Replacement 74 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List MOTHER BOARD FLASH DISK INSERT AS FOLLOWS NOTE THE WHITE LABEL CONTAINING THE PART NUMBER OF THE FLASH DISK MUST FACE THE BACK OF THE MOTHERBOARD 101119 Figure 18 amp Parts List Shown Flash Disk Replacement Item P N Description 1 24008 1 JPENDANT SMX WITHOUT COMPUTER MODULE 2 24000 1 or 7 PENDANT SMX USA 3 25078 FLASH DIS
78. cy 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 Encoder Disk or Reader Head on motor Swap the motor in question with a known good motor are loose 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 40 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List Possible Cause Check This Spindle and or Quill are loose Use a Dial Indicator and check for side to side movement between the Spindle and the Head Next check for side to side movement between the Quill and the Head There should be no more than 0 0003 of side to side movement Make sure that there is a few thousandths gap between the Spindle Collar and the Quill after tightening Ram 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 Note First check for repeatability of the DRO With a dial
79. d continue To return the machine to its normal state of operation perform the following procedure 1 Use the electronic hand wheel to move the table saddle or ram off the limit switch 2 Press the Mode or Return key to reset the control 3 Press the DRO key to enable the machine to once again jog Possible Cause Check This Limit Switches are triggered Reset the Limit Switches using the procedures 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 cables 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 stays with the original axis then it could be the Switch 2 limit switch cables on the cable cable breakout box breakout box 39 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List 3 4 Problem with the Measurements 3 4 1 X Y and Z axis Measurements Do Not Repeat With a dial indicator mounted to the bottom of the spindle touch off a fixed surface either in the X or Y axis direction and then set the DRO equal to 0 Crank away several inches and then touch off again at the same place If the reading has not returned to 0 on the DRO zero the display and repeat the procedure If the measurement does not repeat you have a repeatability
80. dwheel Direction e Code 310 Reverse Z axis Handwheel Direction Problems with the Machine Tool 3 5 1 Z axis Noisy While jogging or cutting in the Z axis direction the axis makes unusual noises See below for head noise 42 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service 8 Parts List Possible Cause Check This Machine Tool and Setup problem Check for any looseness in the setup Tool Tool holder Part Vise or Fixture See Machine amp Setup Section 4 1 Inadequate or no Lubrication to the Make sure all the Way surfaces are getting proper Ballscrew 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 Z axis Gibs are not adjusted properly Check the adjustment of the Z axis Gibs using the Z axis Gib adjustment procedure See Z axis Gib Adjustments Section 5 2 1 Mechanical Drive Train Misalign ballscrew or top and lower bearing failure Z axis motor failure Replace Z axis motor See Motor Diagnostics Section 4 4 3 5 2 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 type of material being cut type and size of cutting tool RPM and Feed rate Also check the condition of t
81. e counterweight during shipping to prevent damage to the counterweight chains and sprockets 1 Release the spindle head ram gib locks 2 Using the ram crank slowly raise the spindle head ram and remove the wood block that supports the spindle head ram during shipping 3 Lower the head slowly with the ram crank until the chain between the ram and counterweight is tight 4 Lower a little further until the 2 support steel rods are loose Remove the 2 steel rods and store them for future machine moves or transportation 5 Remove the panel on the bottom rear of the bed Verify that the lower end of the counterbalance rod guide at the bottom of the column is attached using the 2 socket head cap screws supplied Replace the panel 6 Do not continue to move the head ram until all ways have been cleaned CAUTION Do not remove the steel rods unless they are loose 2 9 1 Releasing the Head Counterweight Supports FHM7 In order to move raise or lower the spindle head ram it is first necessary to remove the retaining plug that supports the counterweight located on the right side of the machine The retaining plug support the counterweight during shipping to prevent damage to the counterweights chains and sprocket 1 Release the spindle head ram gib lock 2 Using an M8 Allen wrench turn the Z axis ballscrew at the top of the column to slowly raise the spindle head ram Remove the wood block that supports the spindle head ram
82. e 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 Goto setup mode select Service Codes go to section B and press CODE 123 5 Select the axis you want to calibrate 6 Follow the instructions on the screen to complete calibration 118 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List SPINDLE USE SHORTEST POSSIBLE DIAL ROD Figure 38 Calibration Set up 7 GAGE BLOCK MACHINE FRAME i00022 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 need to be adjusted periodically 1 Seta 0001 inch dial indicator in the spindle and t
83. e running this direction 7 LED labeled Z LIMIT PLUS this light will be on only when the Z axis plus limit switch is triggered This only applies to a 3 axis product 8 LED labeled Z LIMIT MINUS this light will be on only when the Z axis minus limit switch is triggered This only applies to a 3 axis product d Service Codes Service codes are broken down into the 5 following categories software machine setup diagnostics user options defaults and lubrication pump control All Service Codes are accessed in the SET UP Mode by pressing the soft key for SERV CODES The service codes can be found under one of the headings listed on the main Screen Press the heading you want to access the code in question If you know code you want press the CODE softkey and it will take you directly to the code in question Press CODE enter the number you want press SET 4 9 1 Software Codes The following codes pertain to software functions in the control To get to any of these codes go to Service Codes press A and press the code you wish to view Note If you are working with the SWI Customer Service Group write the values down for code 33 or code 313 These values will be valuable for troubleshooting 4 9 1 1 Code 33 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
84. e spacer onto ball screw Slide top bearing onto ball screw and seat with clamp nut Be sure to clamp nut to at least 50 ft lbs Don t forget to tighten setscrew after clamp nut is tight 15 Install motor mounting bracket motor spacer bracket woodruff key ferrule pulley star washer and nut Before tightening down the motor mounting bracket move the table all the way to the left 16 Move table to the right and assemble right side bearing housing 17 Assemble motor to bracket The servo should be facing toward the rear of the machine 18 Install belt Tighten lower 2 bolts followed by the top 2 bolts to properly tension belt 19 Install electronic hand wheel 20 Attach the sheet metal to the motor mounting bracket 21 Install the table trays See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw See Figure 26 for an illustration of the X axis drive train 85 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service 8 Parts List Figure 26 FHMS X Drive Train 86 Southwesiem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List Parts List FHM5 X Drive Train Figure 26 Item P N Title Qty 3 15966 BRACKET Y AXIS MOTOR MOUNT 1 47 22768 36 LABEL TEXT 1 46 M6 1 0X75 25B SCREW SHCS STL BO 4 44 1
85. ed 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 28 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List 3 1 2 Circles Out of Round Circles are not round within 0 002 TIR over 3 0 DIA This is best measured by placing a dial indicator in the quill and sweeping around the part Note The typical slideway milling machine is not capable of achieving more precise results Although careful adjustments to a new milling machine have produced better results you should not expect the same level of accuracy from a machine of this Class f more precise circles are required then it is recommended to use a precision boring head boring bar Do the following Service Code 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 high values for a machine that is aligned and
86. efore use Gib locks on X and Y axis If locked can lead to axis faults Note when using the CNC to 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 Poor finish in a long while Section 5 2 1 Circle out of round Gibs too tight Not getting to position does not repeat N A axis faults Poor finish Gibs floating Not getting to position does not repeat Contact area of gibs May need to be axis faults scraped Very old machines may not Poor finish have any more adjustments on gib A new gib will need to be fit on the machine Gibs defective bowed Excess play when gib is checked side to Inadequate gib contact scarred side Way surfaces pocked Poor finish Inadequate lubrication scarred or excessively worn Out of round circles Faulting Ram gibs loose Parts incorrect dimensions Vibration or jerky motion in Z axis Head out of tram in Y direction Machine not level Parts incorrect New installation or heavy crash Weight not distributed Machine geometry off i e tram evenly on all 6 screws See Leveling procedures Head out of tram Leaves uneven surfaces on bottom of Machine not level ram gibs loose See Tramming Head pockets Section 5 2 3 Spindle belt loose Machine stalls during a heavy cut Make sure belt tensioning device in locked in place Belt is worn after many years of use 46 Southwestem Industries Inc TRAK FHM5
87. emble motor to bracket The servo should be facing the right of the machine 14 Install belt Tighten lower 2 bolts followed by the top 2 bolts to properly tension belt 15 Install electronic hand wheel 16 Install all sheet metal See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw See Figure 28 for an illustration of the Y axis drive train 91 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List Figure 28 FHMS Y Drive Train P N 24461 92 Southwesiem Industnes Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List Parts List FHM5 Y Drive Train P N 24461 Figure 28 Item P N Title Qty 1 15966 BRACKET Y AXIS MOTOR MOUNT 1 3 21982 SHEET METAL PT4 LOWER Y AXIS DRIVE ASSY COVER 1 4 21662 BEARING HUSING ASSY 1 6 16078 SEAL BEARING HOUSING 1 7 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 1 8 16066 NUT CLAMP X amp Y AXIS 1 9 16350 FERRULE SPROCKET 1 13 M8 1 25X25 258 SCREW SHCS STL BO 4 14 565 5M 15 BELT TIMING 1 15 20374 BEARING ANGULAR CONTACT 2 16 24009 1 WASHER BELLEVILLE LOCK 4 17 10 1 5 65 258 SCREW SHCS STL BO 4 18 10 32 3 4 25B SCREW SHCS STL BO 1 19 1 4 20 1 24B SCREW HEX HD STL BO 4 20 15759 WASHER 1 4 HARD BLK OX 1 8 THK 4 21 24009 3 WASHER BELLEVILLE SPRING LOC
88. equired result in accidents and damaged parts 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 Interlocked table guards Interlocked table guards may be purchased from Southwestern Industries Inc if deemed necessary by the user 4 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service 8 Parts List 2 0 Installation Read and understand this entire installation section before beginning the installation procedure 2 1 Floor Plan Layout amp Space Requirements FHM5 amp FHM7 117 QU GONG SS 1 5 Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Manual Footprint of Machine Weight approximate net Weight approximate shipping Pallet Size A Overall width B Overall length C Bed width D Bed width between leveling screws D1 Bed width between leveling screws E Distance between leveling screws E1 Distance between leveling screws F Bedlength FHM5 24 x 48 4 4400 Ibs 4700 Ibs 6 x 6 136 105 24 21 7 N A 20 5 N A 48 4 FHM7 42 52 x 63 7650 Ibs 7975 16 90 5 x 84 171 65 119 5 42 52
89. er or unauthorized use H IG H operation maintenance alteration modification change in configuration of this machine or any of its VO LTAG E component parts or the use of this unit with any third party accessories or parts 400775 115 Volts 208 240 Volts Safety amp Information Labels Used On The FHM Bed Mill It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels 2 Southwestem Industries Inc 5 amp FHM7 Safety Installation Maintenance Service 8 Parts List 9 SOUTH WESTERN INDUSTRIES um PLACE RANCHO DOMI ELECTRICAL RATINGS Es LL PHASE FLA OF LARGEST MOTOR AMPS SHORT CIRCUIT INTERRUI AMPS ELECTRICAL DRAWING CNC CONTROL ELECTRICAL RATINGS IF APPLICABLE VOLTS 8 JAMPS T PHASE o 60 MACHINE ONLY MADE IN i00774 Power Requirements at 220 Volts 3 phase 60 HZ Model Full load Amp of Machine Full load Amp of Largest Motor FHM5 17 5 17 5 FHM7 37 5 37 5 1 3 Safety Precautions 1 gt 10 Do not operate this machine before the FHM Safety Operation 8 Programming Manual has been studied and understood Do not run this machine without knowing the function of every control key button knob or handle Ask your supervisor or a qualified instructor for help when needed Protect your eyes Wear approved safety glasses with side shields at all times
90. ere are 8 cable connections to the left side of the pendant 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 Low voltage to flash drive or slave board Can cause the system to lock up and the flash drive to act abnormally Check voltage to power cable at flash drive module with voltmeter It should be 4 8 volts and above Lower values than this can cause problems Flash Disk failure If the flash disk fails the system will not boot up or operate It will need to be replaced All programs and machine configurations will be lost Make sure to back up your flash disk from time to time 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 instructions below LCD backlight burns out 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
91. eresis 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 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 64 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 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 Steps 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 the Code 12 3 Press Auto 4 The system
92. ervice amp Parts List Manual Remove the cardboard boxes with PENDANT DISPLAY handle carefully the box containing the TOOL BOX The leveling pads and the screw for the machine can be found in the toolbox The table steel way covers Y axis front steel way cover retractable rear saddle ram bottom cover and top column covers are shipped separate with the machine See Section 2 8 for details on lifting moving the machine 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 5 Manual drawbar P N 23284 with washer P N 22116 FHM7 Manual drawbar P N 24538 with washer P N 24539 _ Leveling pads B239 and screws B240 6 each Pendant Display with four 1 4 20 screws for mounting Pendant Arm assembled to the column Toolbox with various tools FHM5 P N 24965 or FHM7 P N 24503 FHM5 amp FHM7 Safety Operation amp Programming Manual P N 25083 77 FHM5 8 FHM7 Safety Installation Maintenance Service amp Parts List Manual P N 25083 Table trays FHM5 _ _ Manual Z axis crank P N 16526 Table way covers FHM7 P N 24505 2 each _ _ Way covers FHM5 front B268 and rear B267 1 of saddle _ _Way covers FHM7 front P N 24504 and rear P N 24506 of saddle Column cover
93. es Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List while the hand wheel is being turned One revolution of hand wheel should read 0 2000 4 9 3 5 Code 314 Toggle test lights on in status line This code toggles on and off 2 test lights that appear in status line The top light signifies if the master software is working If functioning it should flash a green light The bottom light signifies if the slave firmware is functioning It will appear orange in run mode when it is processing information Pressing the mode key will change this orange box to black The orange box will also change to black when the program you are running reaches the 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 6 Code 319 Error Log This code when turned on captures the commands that were sent to the servo system It includes items such as positioning commands errors stop and go commands etc It may be helpful for identifying problems between programmed commands and executed commands To turn on the error log press the F6 softkey The page forward and backward keys allow you to scroll through the file one page at a time The data forward and data backward keys allow you to scroll through the file one line at a time The data bottom key takes you to the bottom of the file and then changes to data t
94. et 4 9 1 4 Code 313 Display Configuration File This code displays the configuration file This file contains pertinent information about the machine The file will look similar to the following If the file becomes corrupt you can load default values by pressing the F4 softkey Product FHM displays machine ID key of machine Lube pump cycle time 60 minutes Lube pump discharge time 15 seconds Motor encoder calibration constants X242 0462 X242 0267 Z242 0312 Secondary feedback calibration constants X3302 6107 3302 5345 Z3302 6433 These numbers above are typical numbers for the calibration constants the numbers for secondary feedback are default numbers which means no calibration has been done or the machine does not have secondary feedback Arc accuracy 0 001 Secondary feedback 0 1 2 or 3 0 off 1 X on only 2 Y on only 3 XY both on Limit switches on or off Spindle on or off during run On or Off Code 11 values X 0 002 Y 0 001 Code 128 0 001 0 0014 Z 0 0016 Code 12 4 000005 000006 Z 000006 X 000005 000005 Z 000006 Accessory Key Mist or Coolant Code 100 352 7 Y 367 2 Z 325 2 3501 Y 356 7 Z 333 1 4 9 1 5 Code 316 Update Master Software Load upgrade disk in floppy drive and press this service code New software will automatically download and control will reboot 63 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installa
95. g Remove the X axis motor and belt from the left side of the table 87 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 5 Using a 8 Allen hex key at the end of the ballscrew to hold it remove the hex nut and lock washer securing the ballscrew pulley 6 Remove pulley key and locking sleeve on the ballscrew 7 Remove the 4 3 8 16 SHCS securing the left bearing housing to the saddle 8 Remove left bearing housing and ballscrew bushing 9 Remove the 3 20 SHCS securing the right bearing housing cover 10 Remove the housing cover 11 Disengage the lock washer tab from the two lock nuts 12 Loosen and remove the 2 lock nut 13 Remove the 4 3 8 16 SHCS securing the right bearing housing 14 Remove the right bearing housing and bushing 15 Slide the table to the right remove the oil line and the 3 5 16 18 SHCS that secures the ball nut to the yoke 16 Pull the ball screw out Reassemble 17 Install the new ball screw into the yoke 18 Reconnect oil line and fasten ball nut into yoke 19 Slide table back to the center and assemble the left side of the X axis 20 Slide the left bearing housing bushing onto the ball screw 21 Slide left bearing housing with bearing onto ball screw 22 Mount bearing housing to saddle with the 4 3 8 16 SHCS 23 Slide locking sleeve onto ball screw with the short side out 24 Install key and slide pulley ont
96. g diagrams DAE plugged in bl a nsn sj switch button to operate the lube pump MI or s should be visible on all the way surfaces Service Code 300 17 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 18 Make sure all 3 electronic handwheels are functional Use Service Code 132totest 19 Check to make sure that the E Stop button is functioning correctly 20 Perform Service Code 12 Feed Forward Constan II 4 4 4 8 21 Perform Service Code 123 to calibrate the X and Y axis using a 150mm standard oT n 5 9 dual feedback machines i e TRAK sensor or glass scale with a motor encoder re single feedback machines i e motor encoder only 24 Check for positional accuracy and repeatability on the X and Y axis using programs XREPEAT PT4 and YREPEAT PT4 respectively Positioning and repeatability values should be less than or to 0 0005 Programs can be found on hard drive under the PT4 folder followed by the SWI TEST PROGRAMS folder O 25 Perform Service Code 123 to calibrate the Z axis ram using a 75mm standard O 26 Perform Service Code 127 and 128 to manually calculate the backlash for the Z axis ram 27 Check for positional accuracy and repeatability on the Z axis using program ZREPEAT PT4 P
97. gn 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 9 2 Install the Replacement Scale CAUTION If the scale is not long enough for the table it will break when the machine is traversed past the scale travel 1 Mount the scale to the back of the table or Y axis mounting spar 2 Align the sale so that it is within 0 005 end to end Notes For the Y axis the mounting spar should already be aligned It must be parallel to the Y axis travel within 005 end to end both horizontally and vertically The mounting spar can be aligned in and out by the use of the adjustment screw 3 Line the reader head up with the mounting holes on the back of the saddle for the 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 7 Tightening the reader head mounting screws This ensures the reader head is aligned within a few thousandths 8 Remove the shipping brac
98. he center of its travel and zero out your indicator Then move the table all the way to the right side When the gibs are adjusted properly you should see no more than 0 0003 movement on the indicator Do the same thing on the right side of the saddle Point B this time moving the table all the way to the left The reading should be positive on the indicator because the saddle should rise where you are indicating Note You can get better readings than 0 0003 but the torque on the Y ball screw may exceed our recommended levels Remove the ball screw cover and check the torque with an in Ib torque wrench Normally the torque should be around 15 n Ibs Do not exceed 20 in Ibs Values higher than this may cause circularity problems To adjust the gib for excessive clearance Loosen the gib lock screw on the back of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the front of the saddle Tighten the gib lock screw on the back end of the saddle to lock the gib in place and recheck Repeat as necessary To adjust the gib for too small of a clearance Loosen the gib lock screw on the front of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the back of the saddle Tighten the gib lock screw on the front of the saddle to lock the gib in place and recheck Repeat as necessary 115 Southwestem Industries Inc FHM5 amp 7 Safe
99. he cutter to verify 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 Auxiliary Function Spindle Off is being Check how the program is written Also check the used in the program program for any programming errors regarding the Auxiliary Functions See the Controls Programming Operations and Care manual Spindle Drive Thermal Overload Relay OUT Current Out located on the Spindle Drive has tripped The current has exceeded the limit of the drive When the Overload Relay is enabled an oL1 error occurs shutting off the Spindle Drive The harder the Spindle Motor works trying to make heavy cuts the more current the Spindle Motor utilizes This can be caused by a cut so large that it exceeds the machine capability or a problem with the spindle motor or AC drive Spindle Drive parameters are not May need to re download the Spindle Drive correct parameters Contact Customer Service for assistance 3 5 3 Spindle Motor Hums or Will Not Run The spindle motor makes a constant humming noise during operation or will not turn on Note machines can only be wired for 220 volts 440 volts will ruin electrical components in the machine These components will not be covered under warranty 43 Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service 8 Parts List Possible Cause Check
100. he motor is wired and re wire in the low voltage configuration Release the belt tensioning device that is used to tight the belt Remove the 4 screws that hold the motor down in place Slide the motor forward to remove the belt from the motor pulley Remove the motor Be careful the motor weights over 100 lbs Use a lift to remove the motor and to put the new motor in place Slid the belt over the motor pulley and snug the 4 bolts that fastens the motor down FHM5 amp 107 Southwestem Industries Inc FHM Safety Installation Maintenance Service amp Parts List 10 11 12 Tension the belt by use the belt tensioning device in front of the motor Be careful not to over tighten the belt The belt should deflect about 1 4 in the center of the belt when applying force in this spot Tighten the 4 bolts that hold the motor down Connect all wires and the conduit back to the motor junction box Install the head cover plate and turn power back on to the machine 5 1 19 Spindle Assembly Replacement FHM5 Note The quill should never have to be disassembled from the spindle head The spindle will be replaced as an assembly 1 2 16 Turn off and unplug all the power to the machine Loosen the 4 M8 hex nut securing the spindle motor Release the belt tension by adjusting the belt tension mechanism which is integrated to the upper spindle plate cover For machine fitted with the optional Power Drawbar
101. heel 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 56 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 4 7 2 Measurements Do Not Repeat Determine if the error in repeatability is random or accumulating 1 Mount a dial indicator in the quill Touch off a fixed point on the table and set the DRO to 0 Traverse away approximately 6 inches Return and touch off again Write down the reading on the DRO Do not re zero the DRO traverse away and return several times Write down the DRO readings Random error will be unpredictable and give scattered readings adding and or subtracting the error after each traverse with no pattern See Step 2 Accumulating error will add roughly the same amount to the reading after each traverse See Step 3 For random error look for problems in the set up of the TRAK Sensor that have resulted in a loss of rigidity Common sources of random error include broken base broken bracket loose puller screws loose run bar very loose motion of the table or saddle loose clamp screw 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 Ins
102. hich includes an E stop message from the pendant LED labeled SPD RUN this light should be on whenever the spindle is on 4 LED labeled SPD ENABLE this light should be on whenever you are in DRO tool setup and RUN mode 2 10 LED Segment 1 LED labeled E STOP OUT this light should be on whenever the E stop is in the out position When the E stop is pressed this light should go off 2 LED labeled LATCH RELAY this light should be on when the spindle is running or if the spindle is not running and the fwd rev switch is in the off position when in DRO tool setup or RUN mode Note if spindle won t turn on and the spindle is enabled and the e stop is out then either the fwd rev switch is bad or the spindle control board is bad 3 LED labeled TAP MODE light should be on whenever you are not tapping Light will be off when in the tap event Not applicable to knee mills or retrofits 4 LED labeled TAP REVERSE this light will be on when the spindle changes direction at the bottom of a tap event and back off after the spindle changes direction once outside of the tap event Not applicable to knee mills or retrofits 5 LED labeled REV RELAY when fwd rev switch is in reverse this light will be on Note this does not mean necessarily that the spindle will be running this direction 6 LED labeled FWD RELAY when fwd rev switch is in forward this light will be on Note this does not mean necessarily that the spindle will b
103. ic company 2 The control power cord from the wall e Power cord defective Check the end that goes to the electrics box e 3 Check the top fuse on the electrical cabinet If this is blown then power will not reach It should be an 8 amp fuse the 4 outlets on the electrical box 3 Check the 110 power cord to the pendant Power cord defective 4 8 3 Checking Fuses There are 6 fuses to check in the system There are 2 in the pendant and 4 in the electrical cabinet There are three fuses in the spindle control module a5a 3a 8a and one 5a fuse inn the cable breakout box The 2 fuses in the pendant are 1 amp and 12 amps The 12 amp fuses the cable breakout box and the 1 amp the pendant 60 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List With the auxiliary function option there is 1 more fuse to check on the cable breakout box for the coolant or mister option To check fuses 1 Use a Volt Ohmmeter select OHM 2 Remove the fuse completely from the pendant electrics box or cable breakout box 3 Place a lead of the meter on each end of the fuse e A good fuse reads 0 zero or close to it e Abad fuse reads Open or Infinity 4 8 4 Cable Breakout Box Connections This module is located in the electrical cabinet of the machine It consists of 3 motor connections 3 limit switch connections 3 encoder connections and an E stop connection Machines with a
104. ignals 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 amp Y axis signals Umbilical 2 carries the z signals e Check the servo driver connections at the pendant and also at the servo driver 52 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 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 power cable or computer module n some cases it is 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 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 i
105. il the movement is between 0005 001 4 Move the table to the right and mount the indicator at Point A and move the table back and forth perpendicular to the length of the table Note the amount of movement of the dial indicator Adjust gib until the movement is between 0005 001 e To adjust the gib for excess clearance Loosen the nut closest to the table and tighten the nut furthest from the table Once the clearance has been taken up tighten each nut against the gib bracket Do this for each end of the table e To adjust the gib for too small of a clearance Loosen the nut furthest from the table and tighten the inside nut up against the bracket to pull the gib away from the machine Once the clearance has been taken up tighten each nut against the gib bracket Do this for each end of the table 5 Replace table trays See Figure 34 112 Southwesiem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List Figure 34 Table Gib amp Saddle Bottom Gib Adjustment i00777 V5 5 2 1 3 Saddle Side Gib Adjustment Y Axis FHM5 See Figure 35 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 pus SOS Remove the chip wiper guard and chip wiper from the front and rear of the left side box way 113 Southwestern Industries Inc FHM5 amp 7 Safety Installation Main
106. 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 display 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 Section 5 2 2 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 132 Electronic handwheel test e Code 304 amp 305 Turns off X and Y sensor or scale Possible Cause Check This Electronic handwheel failure Each handwheel should count 0 200 per revolution in both directions in fine mode and 0 800 per revolution in course mode 41 So
107. ing the load screw The white lines on the side of the M5 base tell you when it is loaded correctly Note You want to load the gage wheel against the running surface using the flat spring of the M5 base Do not tighten the clamp screw fully until after loading the sensor Figure 21 TRAK Sensor Mounting 79 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List SA 98200 1 3Sv8 SW SIN Lh O8 lLS SOHS M3HOS 462 8 SXOC F L SLANQOHA TIY HOSNIS 208201 SL SXYX HOSH3S H3AO9 1VL3IAL33HS SIXV X H3OVdS HOSNIS SWAQ ILVId 4 L HOSN3S 1350 v8 62991 Figure 22 amp Parts List Shown FHM5 Sensor Kit P N 22564 80 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List 5 1 9 Glass Scale Replacement 5 1 9 1 Remove the Glass Scale 1 Unplug the glass scale connector from the encoder module inside the electrics 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 ali
108. irs exchanges do not cover incidental costs such as installation labor freight etc e SWI is not responsible for consequential damages from use or misuse of any of its products e products are precision mechanical electromechanical measurement systems and must be given the reasonable care that these types of instruments require e Replacement of chip scrapers and wipers is the responsibility of the customer Consequently the warranty does not apply if chips have been allowed to enter the mechanism e Accidental damage beyond the control of SWI is not covered by the warranty Thus the warranty does not apply if an instrument has been abused dropped hit disassembled or opened 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
109. ket that fixes the reader head to the scale for shipping WARNING After the reader head is attached to the reader head mounting bracket do not move the machine axis until the shipping bracket is removed This will break the reader head This is not covered under warranty See Figure 23 for an illustration of how to align glass scales 81 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List xz 61 25 8 avos xz 01 021 lt 23 amp Parts List Shown Figure Glass Scale Alignment 82 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 5 1 10 Power Drawbar A power drawbar is an optional item on the FHM machine It is bolted to the top of the head by the use of 3 SHCS Some machines may require a washer to space the unit up to the proper height to allow the drawbar to engage properly Air Regulator and Oiler This unit requires between 80 and 100 psi to operate properly Some units work fine at 80 psi while others may need 90 or 100 psi It is also important to make sure the oiler for this unit is kept filled with oil Fill the reservoir about 2 3 full using AIR TOOL OIL ONLY Failure to do this will not allow oil to lubricate the internal components of the unit and it may wear out prematurely It is also important to make sure the oiler is set properly To set the oiler
110. l the new servo driver with its heat sink plate Be certain the gasket properly seals the assembly 6 Reinstall the motor driver assembly Make certain the belt is tight so that there is little play if pinched in the middle 71 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 124101 5 Figure 16 FHM5 amp FHM7 Servo Drive Replacement P N 24101 7R 5 1 3 Computer Module and LCD Enclosure Replacement 10 11 12 13 Turn power off to the machine and control Unplug all the connectors on the pendant arm side of the pendant Remove the pendant from the pendant arm by removing the 4 1 4 20 x 3 4 SCHS that secure it in place Place the pendant assembly on a clean and secured table with the display pointing away from you Remove the 6 10 32 x 3 8 Pan Phillips Head Screws and 4 10 32 x 3 8 FHCS securing the computer module to the LCD enclosure Pull the computer module a few inches and stop Pulling the computer module too far will damage the ribbon cables Now reach from the top and remove the 37 pin LCD cable 37 pin distribution cable and the 9 pin E Stop cables The cables are to stay with the computer module Now slide the module about way out of the LCD enclosure Remove the ground wire from the LCD enclosure side Lastly slide the unit completely out of the LCD enclosure Replace computer module or LCD enclosure Follow the instru
111. llet is 42 from the edge of the pallet Using 4 pieces of 4 x 4 x 6 high steel block Equally position the steel blocks to the front back and side of the machine base Gradually lower the lift and let the machine base rest on the 4 steel blocks Note Machine weight must be equally distributed and well supported by the 4 steel blocks also make sure that the position of the blocks does not obstruct the skid Remove forklift from steel pallet Remove the 4 bolts securing the machine base to the pallet and let the steel pallet rest on the floor Carefully lift the machine thru the fork access cut out on the side of the machine Remove steel pallet under the machine Insert the 6 leveling screws into place Position and lower the machine to its location see floor plan bed footprint Note Make sure to position each leveling pads under each leveling screws WARNING The lift truck must have sufficient lifting capacity 15000 Ibs with a 24 load center or Figure 7 FHM7 Lifting the Machine equivalent and be equipped with 6 ft extension forks LIFTING BARS 16 Southwestem Industries Inc FHM5 8 FHM Safety Installation Maintenance Service 8 Parts List 2 9 Releasing the Head Counterweight Supports FHM5 In order to move raise or lower the spindle head ram it is first necessary to remove the 2 steel rods with flanges inserted through the holes in the column These rods support th
112. m does not boot up Possible Cause Check This Main Disconnect switch is off Check the Main Disconnect switch Pendant On Off switch is Off Check the Pendant On Off switch Fuse blown in pendant or the electrical Remove fuses and check continuity cabinet 110V line is not plugged in Check incoming 110v power source to electrical cabinet 36 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List Possible Cause Check This Flash Drive failure 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 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 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 110v power to pendant Using a voltmeter check the incoming 100 AC to the pendant Poor wiring and cable connections Check for any loose wiring Computer Pendant failed See Computer Pendant diagno
113. ment etc Also check to make sure the Sensor or Glass Scale assemblies are functioning correctly See TRAK Sensors or Glass Scales 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 31 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List 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 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 Possible Cause Check This The home positions or tools are not set See the Controls Programming Operations and Care correctl manual The Sensor or Glass Scale is not See TRAK Sensors or Glass Scales diagnostic Section 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 follo
114. ments 5 2 4 1 Limit Switch Assembly Configurations There are two different types of limit switch assembly configurations One type has the cable exiting from the right and the other type has the cable exiting from the left The following table lists which machines get what type of limit switch assembly configurations for each axis 5 2 4 2 X axis 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 cam and spacer 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 travel and simultaneously prevent serious damage to the machine in the event of a crash Also the cam must be set to a specific distance from 121 Southwesiem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List the limit switch assembly in order for the limit switch to trigger properly The cam contains slotted holes which allows for up and down adjustment All limit switches are set at the factory for maximum travel 5 2 4 2 1 Procedure for setting X limit switch l Loosen the X axis cams and spacers on each side of the table 2 Slide each X axis cam and spacer within the T slot to the end of the table 3 Slowly move the table to one side by hand until the end of the travel is reached 4 n DRO mode set X 0 A
115. mer 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 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 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 unlocked 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 Check the adjustment of the X Y and Z axis Gibs See X properly Y and Z axis 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 pock
116. n 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 5 Cable Connections The FHM machines use 8 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 8 6 Spindle Control Module LED Segments 1 t 10 LED Segment 61 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 4 9 1 LED labeled Gear 1 this light should be on whenever the machine is in low gear LEDs labeled Gear 2 thru Gear 4 are not used 2 LED labeled SPD FAULT this light will be on whenever the AC drive is in a fault condition w
117. ncoder displays should be in the range of 4 0000 to 6 5000 e fthe 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 feedrate should be a minimum of 300 ipm e If the feedrate is less than 300 ipm and inconsistent in both directions check the incoming AC voltage and mechanics of the drive train 4 9 2 4 Code 123 Calibration See Section 5 2 2 for a further explanation of this code 66 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 4 9 2 5 Code 127 Set X or Y Backlash Constant See Section 5 2 2 for a further explanation of this code 4 9 2 6 Code 128 Input Backlash Constant Code 128 allows you to enter the backlash values for each axis It displays the value after it enters This code is only used on machines with motor encoders only 4 9 2 7 Code 304 Toggles X sensor or glass scale on off This service code toggles the X sensor or glass scale on or off It is used to configure the machine and also is a useful tool for troubleshooting Code 313 configuration file displays whether the sensors have been turned on or off The line labeled secondary feedback explains which sensors or glass scales are turned on This line can read any one of the following 0 sensors or glass scales turned off 1 X senso
118. nd remove the ballnut from the yoke Slide the ballscrew toward you to remove Make sure to disconnect the oil line Reassemble 10 Install the Y ballscrew to the yoke and install the oil line 11 Install the axis bearings in the housing and into the ballscrew in the same manner as you removed them Tighten the lock nut and install the bearing cover 12 Install the ballscrew pulley and key Lock the pulley with the double nut 13 Install the axis motor and belt 14 Install the front bearing and housing 15 Install the motor bracket cover and electronic handwheel Note See the diagnostic section under mechanical drive train for an explanation on how to align the ballscrew 94 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 990888 0080 108 CO 9 8 5 9 o Figure 29 FHM7 Y Axis Drive Train P N 24292 A MIX EJJA ZZ m 22 222 2 a Ai y 22220900 _ 2 fp tls 88 2 00 GO G2 9 go 95 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List Parts List FHM7 Y Axis Drive Train P N 24292 Figure 29 Item P
119. ng Caution Note Labels amp Notices as Used in this Manual Safety Precautions Installation Floor Plan Layout amp Space Requirements Uncrating Shortages Inventory Checklist Installation Instructions amp Checklist Machine Specifications Maximum Work Capacities ProtoTRAK SMX Control Hardware Lifting and or Moving the Machine 2 8 1 Lifting the Machine Releasing the Head Counterweight Supports 2 9 1 Cleaning Leveling Tolerance for FHMV is 0005 10 Electrical Connection 2 12 1 Phase Converters Air Connection Mounting the Display Pendant Cable Interconnections Lubrication 2 16 1 Lube Pump Operation 2 16 2 Factory Default Values ProtoTRAK SMX Euclid Block Procedure Releasing Supports Troubleshooting by Symptom 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 Motion of Machine 3 2 1 Run Away Axis 3 2 2 Slow Down Axis 3 2 3 Axis Will Not J og 3 2 4 Axis Motor Motion Is Not Smooth 3 2 5 Vibration in Motion Problems Relating to Operation of Control 3 3 1 Display Blanks 3 3 2 Bad Picture on Display 3 3 3 Keyboard Lockup 3 3 4 Fault X Y or Z 3 3 5 Problems Reading Floppy Disk 3 3 6 System Will Not Turn on or Boot Up 3 3 7 System Reboots by Itself 3 3 8 System Shuts Off 3 3 9 Will Not Hold Calibration 3 3 10 Auxiliary Functions Not Wo
120. o ball screw 25 Secure pulley with the lock washer and hex nut Note Use a 8 Allen hex key to hold ball screw 26 Install motor mounting bracket motor spacer bracket woodruff key ferrule pulley star washer and nut Before tightening down the motor mounting bracket move the table all the way to the left 27 Move table to the right and assemble right side bearing housing 28 Assemble motor to bracket The servo should be facing toward the rear of the machine 29 Install belt Tighten lower 2 bolts followed by the top 2 bolts to properly tension belt 30 Attach the sheet metal to the motor mounting bracket 31 Install the table trays See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw See Figure 27 for an illustration of the X axis drive train 88 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 2160 7 g 8zppz 1010W sp 5 2 4 Le 8 Q 9 me AN 146 G nr QZ 88 5 ol 22241 Z 7 vare M z 222222 2278 ore um ZA LLL K 11 7777727 CNL A DAZ 8 K i 31 i ft NU l t 7 JJ LJ J IL IC IC IC IC Ji X KAT NX EAT SSS 19 Lr ILL A oe vo eee hore e H TN x
121. odes and procedures 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 e Code 128 Enter backlash compensation 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 Y and Z axis Gibs are not adjusted Check the adjustment of the X Y and Z axis Gibs using properly the X Y and Z axis Gib adjustment procedures Section 5 2 1 Gibs not making good contact Pull gibs out and mark with a blue die to check where the gibs are making contact It is recommended that the gibs uniformly contact at least 80 of the surface 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 scre
122. oolant etc Stop and disconnect the machine before you change belts or pulleys Keep work area 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 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 Prevent damage to the workpiece or the cutting tool Never start the machine including the rotation of the spindle if the tool is in contact with the part Check the direction or of movement of the table 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 and the integrity of cutting tools and their holders Use proper length for the tool Large overhang on cutting tools when not r
123. op 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 F1 key saves the current file to disk and the F2 key saves the backup file to disk To clear the files press the F7 softkey 4 9 3 7 Code 324 Toggle Simulation Mode Simulation Mode allows the control to run a program without actually moving the table It is helpful in diagnosing Computer display problems 4 9 4 Operator Defaults Options Codes The following codes allow the user to set programming defaults or turn features on or off To get to any of these codes go to Service Codes press D and press the code you wish to view 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 69 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp P
124. orkpiece material Type of finish or accuracy required Climb or conventional milling If a fine finish is required reduce the feed rather than increase the spindle speed Cutters are dulled by higher spindle speeds rather than high feedrates The Mechanical Drive Train X Y Indications e Troubleshooting instructions indicate that the drive train is potentially the problem and other more easily checked variables have been exhausted e Roughness looseness tightness or jamming movement in the table or saddle 1 Check for machine considerations especially gib locks and gib adjustments See Gib Adjustments section 2 Check the torque of the axis in three places both ends and center of ball screw along the length of the ball screw The torque should be within 2 or 3 in lbs across the length of the ball screw If it is not chances are the ball screw is misaligned A misaligned ball screw can lead to parts being out of round and servo problems at low feedrates A bad ball screw can also cause high torque although this is highly unlikely See Sections 4 2 1 and 4 2 2 for more information The following steps take you in logical sequence through the assemblies for both the FHM5 FHM7 For drawings of these assemblies see Figures 26 27 28 and 29 in Section 5 These instructions break the machine down from fully assembled and point out the areas to look at specifically 48 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety
125. ors unless the power is disconnected from the machine The motors are run by 110 VAC There is possibility of death by electrocution Rarely do both the X and Y motor servo systems fail at the same time and in the same way So if your problem is occurring on both axes its source is probably somewhere else 4 4 1 Cable Connections Check the motor cable connections on the cable breakout box Verify there are no pushed in pins on the connector 4 4 2 To Check the Motor Encoders If the motor encoder inside the motor has failed or is not reading the machine will fault out on that axis Do the following to verify this problem Motor encoder only machines run Service Code 100 or 131 This will display on the DRO if the motor encoder is counting If this number does not move then 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 Code 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 what axis you are doing 4 4 3 Encoder Counts to Pendant Before replacing the motor due to a bad motor encoder it is a good idea to check the cables that take those signals back to the pendant If these s
126. ositioning and repeatability values should be less than or to 0 0005 eee ai aii min rate shown on the display is at least 300 ipm 29 Run the spindle at 1000 rpm for 5 minutes and then at 5000 rpm for 5 minutes 30 Install the Y axis front and rear way covers FHM5 only O 31 Install the Y axis front steel way cover FHM7 only 32 Install the retractable rear saddle ram bottom cover FHM7 only 9 Southwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Manual 33 Install the Z axis upper way cover and Z axis lower cover and bracket 5 only 34 Install the Z axis upper column cover FHM7 only 35 Use accessory key on pendant and make sure solenoid fires The accessory key should be in the ON position to test solenoid Make sure air is hooked up to the machine during the test Make sure the solenoid is plugged in If the machine has a power drawbar option check to make sure that the tools load unload properly 37 Cut a Euclid block The total run out of the circle frame on the Euclid block must be within 0 002 Visually inspect the finish on the Euclid block and make any necessary adjustments to the machine See the Euclid block instructions 38 Wipe down the machine prior to leaving 2 5 Machine Specifications
127. ouch off on a block or the vise along the direction X Y or Z you wish to check or set the backlash constant 2 Turn on the ProtoTRAK and at the Main Menu follow the procedure below precisely Press MODE 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 119 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 3 The X backlash identified and stored in Step 2 should be less than 0 003 on a new machine If it is appreciably larger inspect the drive train for loose bolts brackets bearings etc The backlash can also be found manually with a 0 0001 indicator with the following method Load the indicator to zero from one direction and zero out the DRO Move the indicator to 0 002 and then back to zero Do not over shoot 0 otherwise start over Whatever number appears on the screen is the backlash value En
128. ound wires from the incoming 3 phase cable and 1 ground wire from the spindle motor fan cable Please refer to Figure 33 for an illustration of how to wire the spindle motor for the FHM5 Y configuration See motor junction box diagram for FHM7 A configuration DPMV FUKUTA FROM SPINDLE FAN SPINDLE MOTOR Y CONNECTION BLK BLK MOTOR JUNCTION BOX WIRE NUTS BRN HOT REMOVE PAINT FOR BLUE GROUND NEUT GROUND SCREW 100776 Figure 33 Spindle Motor Wiring 111 Southwesiem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service 8 Parts List 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 2 Gib Adjustment X Axis The X axis has 2 gibs for the table because of the length of the saddle Each gib is adjusted from each end of the table There are not 2 adjustment screws at either end of the gib like the Y axis and Z axis 1 Clean all chips dirt and excess oil from the table 2 Remove the table trays 3 Move the table to the left and mount the indicator at Point D and move the table back and forth perpendicular to the length of the table Note the amount of movement of the dial indicator Adjust gib unt
129. out in this area Also make sure the mounting hardware for the reader head is tight Loose hardware can cause excess backlash when reversing direction To align the scale place a 0 001 indicator on the bed ways and on top of the scale extrusion Move the table along its full travel from one end to another to verify it is aligned If the scale is misaligned loosen the 2 screws at either end to shift the scale up or down as needed You will also need to loosen the center support bracket to allow the scale to pivot Y Axis The Y axis must be aligned in the up and down direction and must be parallel to the Y axis way surface Both surfaces must be aligned to within 0 005 Failure to align the scale properly could cause the same problems as mentioned above Mount your 0 001 indicator on the saddle and move the Y axis back and forth along its travel Note In order to run the machine with the electronic handwheels and align the scale you will need to turn the scale system off with a service code See service code section See Figure 23 in Section 5 for an illustration of how to align the glass scales 4 6 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 the touch off again e Write down the reading on the DRO e Do not Re zero the
130. owing are some things to keep in mind Problems With Can Contribute To Feed and Speeds spindle rpm Poor finish See below Machine chatter Excessive speeds and feeds can break cutting tools or wear tools prematurely Tooling Poor finish Using the wrong cutter for an application 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 Poor finish decrease the life of the cutter 47 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 4 2 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 e Lower spindle speeds are used to machine hard or tough material or where heavy cuts are taken e 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 W
131. pace between the head of the bolt and the ball nut i e the yoke the retaining bolt has bottomed out in its thread and is not securing the ball nut to the yoke properly screws 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 005 end to end See above explanations Note Ball screws are inspected throughout their entire travel for backlash and consistent torque A ball screw should be good for millions of inches of travel if installed properly Do not be too quick to replace a ball screw if there is insufficient indication that it is bad this will just be a costly delay to resolving the real problem 4 2 1 Ball Screw Alignment e X axis there are 3 components that can cause misalignment the yoke the left side bearing housing bracket and the right side bearing housing This machine has 2 separate yokes for the X and Y axis The yoke is bolted to the table on the X axis e FHM5 X Axis Yoke the yoke is aligned at the factory If you suspect the yoke is misaligned the bolts for the yoke can be accessed from an opening on the bottom left side of the saddle Break these bolts free and move the table back and forth along its travel and then retighten the bolts e Left side table bearing housing To align the bracket move the yoke table left as close to the bracket as possible Loosen the bracket bol
132. pect the base to determine if it has been damaged A damaged base will usually have crinkles in the small triangle shaped plates on the front and back Use a bubble level or an indicator to adjust the puller screws so that the base is parallel to the running surface Inspect that the sensor is not cocked so that the case contacts the running surface Inspect the wheel for chips that are adhered or for gouges 57 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 4 8 Electrical 48 1 Main Electrical Box The electrical box is made up of the following main components 1 2 AC drive used to control the spindle motor Braking resistors used to break the spindle motor There are three resistors on the FHM7 and one on the FHM5 To verify the resistors are good measure the resistance across B1 and B2 of the AC drive For the FHM7 it should read 10 ohms when all three resistors are good For the FHM5 it should read 32 ohms when the resistor is good Spindle Control Module used to control spindle related functions gear switch input remote e stop and 110 volt power source for various items Cable breakout box see section 4 8 4 58 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Figure 15 Electrical Cabinet P N 24459 1 FHM5 P N 24459 2 FHM7 Shown i24459 2 59 Southwestem
133. 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 0 250 on Euclid block 4 12 cuts triangle on Euclid block 0 500 13 rectangular frame cuts outer 2 750 rectangle 0 750 14 21 finish cut for triangle section tool 2 0 500 7 After the program runs the program will locate to the following position e X 1 318 e Y 1 318 8 Mount a dial indicator in the quill and check the circles 9 Checkthe runout of the sides of the square frame 10 Inspect the machined surfaces for smoothness 26 Southwestem Industries Inc 5 8 FHM Safety Installation Maintenance Service 8 Parts List i00763 Figure 14 Euclid Block 27 Southwestem Industries Inc FHM5 amp FHM7 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 problem type is described in a few words and then more fully described in an explanatory paragraph Following this is a chart that directs in the most logical steps 3 1 Problems Relating to Machining Results 3 1 1 Poor Finish The part finish is marred with scallops or is very rough It should be determined whether the cut is straight along the X or Y axis or at a diagonal Do the following Service Codes e Code 33 Software Identification This is needed if you call SWI Custo
134. 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 This is done by stopping 110V power from reaching the cable breakout box through the use of a relay in the pendant 38 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service 8 Parts List Once power reaches the cable breakout box it distributes power to the axis motors auxiliary functions and 110V power to the spindle contactor A 5 volt signal is sent to the spindle control board which energizes a relay which then enables the AC drive 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 replace the pendant 3 3 12 Limit Switch Error 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 64 Servo Error X axis Limit Switch Correct the fault condition an
135. program the lube pumps Interval and Discharge times e Setting Interval time Service Code 301 Press Mode Set up Service Codes C Machine Setup Code 301 and then enter the desired Interval time in minutes e Setting Discharge time Service Code 302 Press Mode Set up Service Codes C Machine Setup Code 302 and then enter the desired Discharge time in seconds e To manually pump oil Service Code 300 Press Mode Set up Service Codes press E and then press Code 300 Lubrication Pump Switch The pump will pump oil for the amount of time programmed in Code 302 The spindle does not need to be turned on 2 16 2 Factory Default Values Interval Time 60 min Discharge Time 15 sec Discharge Pressure Approximately 100 150psi To adjust the amount of Discharge Pressure displayed on the lube pump gauge loosen the jam nut and turn the adjustment screw located on the top right side of the lube pump while the lube pump is activated To activate the lube pump use Service Code 300 CAUTION Failure to properly lubricate the mill will result in the premature failure of ball screws and sliding surfaces CAUTION Failure to manually activate the pump at the beginning of each day or allowing the Auto Lube to run dry may cause severe damage to the FHM5 or FHM7 mill way surfaces and ballscrews The settings for the lube pump can be viewed by doing the following press Service Codes press A software
136. r 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 This service code toggles the Y sensor or glass scale on or off See Code 304 for further explanation 4 9 2 9 Code 312 Toggle Limit Switches On Off Use this service code to enable or disable the use of limit switches Remember to check which type of limit switches are active in code 338 This code is default to off 4 9 2 10 Code 308 Reverse X hand wheel direction This service code reverses the direction of the X hand wheel 4 9 2 11 Code 309 Reverse Y hand wheel direction This service code reverses the direction of the Y hand wheel 4 9 2 12 Code 310 Reverse Z hand wheel direction This service code reverses the direction of the Z hand wheel 4 9 2 13 Code 311 Set no move if spindle off on off This service code toggles this function on or off It defaults to on from the factory which means the spindle must be on for a program to run If it is on and you forget to turn the spindle on the tool will move to Z rapid and wait for the spindle to come on This function will be needed if you are running a repeatability program with an indicator in the spindle Make sure this feature is on when cutting parts 4 9 2 14 Code 312 Toggle limit switches on off This service code toggles the limit switches on or off Code 313 also displays which state the limit s
137. ressed Possible Cause Check This 3 Phase wires backwards Need to switch any 2 of the 3 wires either coming out of the Spindle Drive T1 T2 and T3 or going into the Spindle Motor U V and W Caution Be sure to shut off all power to the machine before attempting to switch any wires 3 5 5 Head Noise Head noise pertains to any unusual noises coming from the head under load and no load situations Most often head noise will only be noticeable under load situations It is important to try to distinguish between problems with components in the head versus problems caused by the setup or tooling being used on a particular job Use the table below to try to pinpoint the possible cause 44 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service 8 Parts List 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 questions 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 of these can have a significant impact Belt is loose Check to make sure the tensioning device is properly fastened Make sure the lock nut is tight that holds this device in place The belt is not lined up with the groove
138. rface of slideways can occur 4 certain the table saddle head ram and spindle move freely and smoothly over their entire length 2 11 Leveling Leveling Tolerance for FHM is 0005 10 1 Set the machine on its 6 leveling pads on a solid level floor prepared in accordance with the state and local rules for machine tool installation 2 Putone or two precision Spirit Levels or Electronic Levels in the center of the table in the positions illustrated in A1 and B1 3 Adjustthe 4 corner leveling screws on their pads until the machine is level to 0005 in 10 in Snug the 2 middle leveling screws being careful to not affect the level 4 Ifthe machine must be anchored to the floor follow the general instruction for installing machine tools and use for leveling any well known methods shims etc 5 If the machine must be installed on vibration mounts pads rubber commercially available leveling and vibration mounts etc follow the instructions delivered with the mounts pads ordering them to satisfy the load of the machine and the maximum weight of the workpiece 6 When machine is correctly level lock the adjusting screws in place with their hex nuts 18 Southwestem Industries Inc 5 8 FHM Safety Installation Maintenance Service amp Parts List LEVEL SCREW LOCK HEX NUT MACHINE BED LEVEL PAD Figure 8 Figure 9 Placement of Levels Leveling Screws 2 12 Electrical Connection 5 8
139. rive failure See Servo Drive Section 4 5 Motor failure See Motor Section 4 4 32 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service 8 Parts List 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 Possible Cause Check This Shut down the system and wait 10 seconds before rebooting E Stop is pressed in Check E Stop Especially if both axes will not jog Servo Drive failure Especially if only one axis will not jog See Servo Driver Section 4 5 Shorted motor See Motor Section 4 4 Poor cable or wiring connections See Electrical Connection Section 2 12 Computer Pendant failed See Computer Pendant diagnostics Section 4 3 3 2 4 Axis Motor Motion Is Not Smooth While under motor power the motion is not smooth The motion appears to be rough or jerky Do the following Service Codes and procedures 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 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 e Code 128
140. rking 3 3 11 E Stop Error 4 0 4 1 4 5 4 6 3 3 12 Limit Switch Error 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 DRO Is Not Counting 3 4 4 X amp Z Axis DRO Counting in Wrong Direction 3 4 5 X Y and Z Axis Electric Hand wheels Turn in Wrong Direction Problems with the Machine Tool 3 5 1 Z Axis Noisy 3 5 2 Spindle Stalls or Turns Off During Machining 3 5 3 Spindle Motor Hums or Will Not Run 3 5 4 Spindle Runs Backwards 3 5 5 Head Noise Diagnostics The Machine Tool amp Set Up 4 1 1 The Milling Machine Checklist 4 1 2 A Special Word About X Y Z Gibs 4 1 3 Lubrication 4 1 4 Machining Set Up The Mechanical Drive Train X Y 4 2 1 Keys to Ball Screw Alignment Computer Pendant Diagnostics 4 3 1 Checking Floppy Drive Motor Diagnostics 4 4 1 Cable Connections 4 4 2 To Check the Motor Encoders 4 4 3 Encoder Counts to Pendant 4 4 4 Moving Problem From One Axis to Another Servo Drivers Glass Scales 4 6 1 Alignment of Scales 4 6 2 Measurements Do Not Repeat TRAK Sensors FHM5 Only 4 7 1 Faulting Axis 4 7 2 Measurements Do Not Repeat Electrical 4 8 1 Main Electrical Box 4 8 2 Checking AC Voltage 4 8 3 Checking Fuses 4 8 4 Cable Breakout Box Connections 4 8 5 Cable Connections 4 8 6 Spindle Control Module LEDs Service Codes 4 9 1 Software Codes 4 9 2 Machine Set up
141. s on the pulleys Make sure the 8 grooves on the belt are lined up with the 8 grooves on the 2 pulleys Remove the upper spindle cover to verify If the belt is frayed then replace the belt Verify nosepiece is tight on bottom of spindle FHM5 Only To check if the nosepiece is bottomed out try to insert a piece of paper in between the nosepiece and the quill If a piece of paper does fit then this may be the problem Before tightening or loosening the nosepiece make sure to loosen the setscrew that holds it in place Spindle bearings are worn out This is categorized by a high pitch sound and is most evident at high RPM s Tt should also cause chatter under load Replace the spindle if this is the case See spindle replacement in Section 5 45 Southwestem Industries Inc FHM5 amp FHM 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 See Spindle Replacement round pushed hard surfaces poor finish up or line sheared Inadequate lubrication Premature wear of ball screws wear New installations more motion than habits surfaces the machinist is used to with a Poor finish manual mill Lubricate machine every morning b
142. s FHM5 bottom on column B202 top on column B201 Column covers FHM7 top on column P N 24522 In case of shortages contact the representative from whom you purchased the machine 8 Southwestem Industries Inc 5 8 FHM7 Safety Installation Maintenance Service amp Parts List 2 4 Installation Instructions amp Checklist Installer Use this checklist to assure a complete set up of the FHM5 or FHM7 O 1 Shutoff power to the machine gt S Visually inspect the 220 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 3 Clean the machine if needed and remove any remaining grease 4 Unlock the table saddle and ram gib locks 5 Install the manual Z axis hand crank 5 only Use a M8 Allen wrench on the Z axis ball screw end at the top of the column to manually lower or raise the spindle head ram FHM7 only 9 Remove the M8 Allen wrench on the Z axis ball screw end Release the counterweight support See Section 2 9 and 2 9 1 for details 8 Install the table way covers to both ends of table FHM7 only Remove the manual Z axis hand crank FHM5 only Mount the pendant to the pendant arm using 4 1 4 20 x 3 4 socket head cap screws See the pendant and electric box wirin
143. s 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 X Y and Z servos are identical Objective e Isolate the problem to the particular Servo Driver Steps l Turn off and unplug the system WARNING Do not work with the Servo Driver unless the power is disconnected from the machine There is possibility of death by electrocution 2 Physically swap the servo module from the axis that is not working to one that is Note To avoid pulling the wires out of the connector use the loop to pull the connector from the Servo Driver If the problem moves to the other axis and clears up from the original axis replace the Servo Driver 53 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 4 6 Glass Scales Glass scales are used on the X and Y axis for secondary feedback They are optional on the FHM machines 4 6 1 Alignment of scales X Axis The X axis scale must be aligned within 0 005 in the up and down direction over the length of the scale for proper operation Misalignment can cause the scale to not read in the certain areas of the scale that are not aligned with the reader head If this happens the axis will mostly likely fault
144. stics Section 4 3 3 3 8 System Shuts Off During operation the system 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 drive failure Check the flash drive connections in the computer module Computer Pendant has failed See Computer Pendant diagnostics Section 4 3 3 3 9 Will Not Hold Calibration The control will not hold calibration Go to the Configuration Values screen and write down the calibration values for the motor encoders Encoder and the position feedback encoders Scales The calibration values are written in Hexadecimal Recalibrate the system and see if the values change Turn the system off and on and see if the values are held Do the following service codes and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 313 Configuration Values e Code 123 Calibration Mode 37 Southwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service 8 Parts List Possible Cause Check This 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
145. ten the cam bracket screws to hold in place 6 By hand slowly move the head down to approximately 1 1 2 above the top of the table Note Use a tape measure to measure the distance between the spindle and the table 7 Slide the cam up next to the plunger located on the limit switch assembly 8 Mount the cam bracket assembly to the column such that the cam will initially make contact near the bottom but not past the tapered portion of the plunger 9 Slide the cam up against the plunger until the limit switch is triggered Note The moment when the limit switch is triggered can be seen on the DRO display 10 Mount the cam in this position 11 On the upper cam assembly loosen the 2 setscrews on the cam 12 Slide the cam to the top of its cam holder 13 Tighten the 2 setscrews on the cam to hold it in place 14 Loosen the two screws that mount the cam bracket assembly to the column of the machine 15 The cam bracket assembly contains slotted holes to allow for in and out positioning adjustments of the cam assembly Move the cam bracket assembly away from the limit switch assembly and then tighten the cam bracket screws to hold in place 16 By hand slowly move the head up toward the top of the column until just before the Z axis upper way cover begins to squish together 17 Back the head off 1 2 in the downward direction 18 Slide the cam up next to the plunger located on the limit switch assembly 19 Mount the c
146. tenance Service amp Parts List 100024 Figure 35 Saddle Side Gib Adjustment 5 Attach a 0001 dial indicator with a magnetic base to the left front of the saddle Place the indicator stylus on the edge of the large box way 6 Move the left end of the table back and forth and note the amount of movement on the dial indicator Adjust the Y axis side gib until the registered movement is 0010 0015 e adjust the gib for excessive clearance Loosen the gib lock screw on the back of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the front of the saddle Tighten the gib lock screw on the back end of the saddle to lock the gib in place and recheck Repeat as necessary 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 necessary 7 Replace the front and rear chip wiper and chip wiper guard 5 2 1 4 Saddle Side Gib Adjustment Y Axis FHM7 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 right side of the saddle 4 Remove the chip wiper guard and chip wiper from the front and rear of the left side box way 1
147. ter this value into service code 128 After entering this number redo the process The DRO and indicator should now both read 0 CODE 128 Input Backlash Constant Code 128 allows you to enter the backlash values for each axis It displays the value after it enters This code is only used on machines with motor encoders only 5 2 3 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 120 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List Figure 39 Tramming of Head 5 2 3 2 Back to Front amp Side to Side Adjustment Note The head of the FHM machine is adjusted at the factory This procedure should only be needed for a head replacement It is placed in this section for continuity with the tramming discussion With the dial indicator sweep the table from 6 o clock to 12 o clock The head should be trammed within 0 0008 from front to back and side to side and overall tram TIR should be 0 0008 or less Note Minor adjustments can be made with the back ram gibs Tightening the gibs will tend to tilt the head up from the table Loosening the gibs tends to allow the head to droop down toward the table Over tightening or loosening can lead to other problems with the machine Typical adjustments with the gibs is 0 0005 or less 5 2 4 X Y and Z Limit Switch Adjust
148. the front and then to the back to verify that the limit switches are working properly Also make sure that the table does not exceed its travel and crash 123 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 5 2 4 4 Z axis Limit Switch Stop Installation and Adjustment The limit switch stops for the Z axis are mounted on the side of the column The limit switch stop consists of a cam cam holder bracket and spacer Each limit switch stop cam must be set to a specific distance from each end of the column in order to maximize travel and simultaneously prevent serious damage to the machine in the event of a crash Also the cam assembly must be set to a specific distance from the limit switch assembly in order for the limit switch to trigger properly The cam bracket assembly contains slotted holes which allow for in and out positioning adjustments of the cam assembly 5 2 4 4 1 Procedure for setting Z limit switch 1 On the lower cam assembly loosen the 2 setscrews on the cam Slide the cam to the bottom of its cam holder Tighten the 2 setscrews on the cam to hold it in place Loosen the two screws that mount the cam bracket assembly to the column of the machine se The cam bracket assembly contains slotted holes to allow for in and out positioning adjustments of the cam assembly Move the cam bracket assembly away from the limit switch assembly and then tigh
149. those connecting to the pendant display There are a total of 8 cables that need to be connected to the pendant 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 Each cable is labeled with a sticker Use the key on the pendant to match up the connectors with the correct port The parallel port will have a key plugged into this port The monitor port RS232 and network ports will be left empty during installation Make sure there is sufficient slack in the cables for when the pendant is rotated about the pendant arm The worst case is when the pendant is all the way forward toward the operator The following drawing describes all of the cable connections to the pendant Make sure there is a hardware option key plugged into the parallel port of the pendant This key activates any converters or options ordered The part for this key is 22648 The key must be programmed according to the type of machine it is on and the options ordered CAUTION Make sure the main power switch is turned off on the back of the electrical cabinet before plugging in the cables 22 Southwestem Industries Inc 5 8 FHM Safety Installation Maintenance Service 8 Parts List E EE a o 29 SPINDLE CONTROL i2400 7 Lf Figure 12 Pendant Cable Connections Left Side P N 24000 1 or 7 23 Sou
150. thwestem Industries Inc FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List Manual KEYBOARD USB PORTS 1 AMP FUSE 12 AMP FUSE i01186 Figure 13a Pendant Cable Connections Right Side w Floppy Drive P N 24000 1 Figure 13b Pendant Cable Connections Right Side w USB Ports P N 24000 7 24 Southwestem Industries Inc 5 8 FHM Safety Installation Maintenance Service 8 Parts List 2 16 Lubrication The FHM5 and FHM7 auto lube system provides centralized automatic lubrication for the table saddle and ballscrews The lube pump has a 2 liter reservoir filled with Mobil Vactra Oil No 2 or equivalent CAUTION Oil that is too heavy and viscous such as 50W or 90W oil can clog oil line tubing Do not mix detergent type automotive or multi purpose oils with the Mobil Vactra Oil No 2 used in this application The lube pump has electronic memory which acts as an internal clock to keep track of the running time of the axis motors Even when the spindle is turned off the lube pumps internal clock will not reset The interval between pump cycles is based on axis movement motor time 2 16 1 Lube Pump Operation The pumping output can be regulated electronically to control the Interval Time between pumping cycles and the Discharge Time of each pumping cycle The pump can also be run manually through a key found under service codes The following describes the steps used to
151. tion Maintenance Service amp Parts List 4 9 1 6 Code 317 Update Slave Software Load upgrade disk in floppy drive and press this service code New software will automatically download 4 9 1 7 Code 318 Activate Converters or Options See programming and operating manual 4 9 2 Machine Set up Codes The following codes are used primarily when setting up a new machine To get to any of these codes go to Service Codes press B and press the code you wish to view 4 9 2 1 Code 11 Hysteresis Note This code is use only for systems with Sensors or Glass Scales on the table and saddle The Code 11 service routine checks the readings of the motor encoder against the sensor encoder It is a measurement of how much motor motion is necessary to create table or saddle motion This test helps us to look at two things 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 Wote 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 hyst
152. ts 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 yoke as close to the bearing housing as possible table right Loosen the bearing housing and retighten This should allow the bracket to align itself If you do not move the table toward the yoke the ball screw will tend to bend down slightly and cause misalignment 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 The yoke is pinned at SWI should not become misaligned unless the machine has been repeatedly crashed 50 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 4 3 Computer Pendant Diagnostics The pendant consists of 2 separate modules the computer module and LCD screen enclosure In general the pendant computer module is best diagnosed by eliminating all other possible alternatives The following table lists some problems and what these problems can lead to Unplug accessories such as the keyboard Remote Stop Go and mouse Check to see if the problem is resolved Possible Problems Can lead to Poor cable connections Th
153. ty Installation Maintenance Service amp Parts List 5 2 1 6 Ram Back Gib Adjustment Z Axis see Figure 36 Clean all chips dirt and excess oil from the table and saddle Remove the lower wav cover on the ram to gain access to Z crank Disconnect the upper wav cover to expose the back ram gibs Remove drawbar nosepiece if present Place a piece of wood on the table underneath the quill n wo Position the milling head so that the table can be reached by cranking the Z axis down with the hand crank 7 Attach a 0001 dial indicator with a magnetic base to the column near the base of the ram on the left side of the machine Place the indicator stylus on the rear surface of the ram near the bottom Figure 36 Ram Back Gib Adjustment 116 Southwesiem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service amp Parts List 6 Crank the Z axis until it touches the wood block Place a moderate amount of force on the crank FHM5 only and note the indicator reading For the FHM7 use the Z electronic handwheel to move the head down on the wood block Adjust the left side gib until the registered movement is 001 0015 e adjust the gib for excessive clearance Loosen the gib lock screw on the bottom of the ram Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the top of the ram Tighten the gib lock screw on the bottom of the ram to lock the gib in pla
154. unt of gib lock screw adjustment required and tighten the gib lock screw on the top of the ram Tighten the gib lock screw on the bottom of the ram to lock the gib in place and recheck Repeat as necessary e adjust the gib for too small of a clearance Loosen the gib lock screw on the top of the ram Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the bottom of the ram Tighten the gib lock screw on the top of the ram to lock the gib in place and recheck Repeat as necessary 4 Reattach the upper and lower way cover to the ram 117 Southwestem Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List Figure 37 Ram Side Gib Adjustment 5 2 2 Calibration amp BacklashConstants Calibration and backlash constants were set as part of the installation and set up of your system They should be re set when indicated in the Troubleshooting section or after the replacement of the Computer module or any parts of the drive train 5 2 2 1 X Y and Z Calibration Calibration is used teach the machine a known distance We typically calibrate our machines over a 150 mm distance There is no limit to how far you can calibrate the machine 1 If you have installed TRAK Sensors move each axis through its travel 4 6 times in order to allow the gage wheel to establish its track 2 Set up a gauge block or standard and indicate it parallel to th
155. uthwestem Industries Inc FHM5 amp FHM Safety Installation Maintenance Service 8 Parts List 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 Section 4 4 Glass Scale or Sensor Failure Does axis now count If so replace scale Computer Pendant failure See Computer Pendant diagnostics 3 5 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 X axis Table moves to the left e Y axis Saddle moves toward the front of the machine e Z axis Ram 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 313 Check the line that specifies the product Product 2 is a FHM5 Product 35 is a FHM7 If the product does not match the machine then the machine ID key will need to be replaced 3 4 5 X Y and Z axis Electric Handwheels Turn in Wrong Direction The Electric Handwheels turn in the wrong direction The positive directions for each Electric Handwheel are e X axis Electric Handwheel turns clockwise e Y axis Electric Handwheel turns counterclockwise e Z axis Electric Handwheel turns clockwise Do the following service code and procedures e Code 308 Reverse X axis Handwheel Direction e Code 309 Reverse Y axis Han
156. ve Train Figure 50 51 52 53 52 HX 028 10 SUPPORT DUST HELMET 2 53 HX 030 10 SUPPORT DUST HELMET 2 54 24523 COVER Z BALLSCREW 1 55 HX 046 STOP LIMIT SWITCH 2 56 HY 043 14 ARM 1 57 24556 SPACER BEARING INNER 1 58 24557 SPACER BEARING OUTER 1 60 24427 SPROCKET ASSY 26 TEETH 40 55 1 61 24553 BELT SET SPINDLE 2 62 425 5M 15 BELT TIMING 5MM POWERGRIP 1 63 24558 ELBOW 90 1 64 24555 BEARING TA3025 4 65 24513 BEARING SET ANGULAR CONTACT 1 67 24512 BEARING BALL 1 69 24543 KEY 5 x5 x 251 1 70 24530 KEY 8 X 7 X 60L 1 71 24528 KEY 10 X8 X 35 1 72 24520 NUT LOCK M25X 1 5 1 73 24515 NUT LOCK 1 74 24533 NUT LOCK M35 X 1 5 1 75 24534 NUT LOCK M40 X 1 5 1 77 1 4 20 50B NUT HEX STL BO 1 78 5 8 18 50B NUT HEX STL BO 1 79 3 4 10 50B NUT HEX STL BO 4 80 AOS255211 SEAL OIL 25x52x11 1 81 AOS385216 SEAL OIL 38x52x16 1 82 3 16 24X1 2 10B SCREW PAN HEAD PHILLIPS STL BO 24 83 3 16 24X5 8 10B SCREW PAN HEAD PHILLIPS STL BO 6 85 1 4 20X1 2 25B SCREW SHCS STL BO 4 85 1 4 20X5 8 25B SCREW SHCS STL BO 7 86 1 4 20X3 4 25B SCREW SHCS STL BO 6 87 1 4 20X1 25B SCREW SHCS STL BO 1 88 5 16 18X7 8 25B SCREW SHCS STL BO 4 89 5 16 18 1 258 SCREW SHCS STL BO 6 90 3 8 16X1 25B SCREW SHCS STL BO 20 91 3 8 16X1 1 2 25B SCREW SHCS STL BO 9 92 1 2 12X1 1 4 25B SCREW SHCS STL BO FULL THREAD 4 93 3 4 10
157. version of firmware software that is responsible for control to servo interface 62 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List e Converter Version the version of software that is responsible for converters and options e Operating System Version shows the version of the XP operating system 4 9 1 2 Code 141 Load Configuration file from floppy A drive This code allows you to load your configuration file from the floppy disk to your hard drive The configuration file consists of items such as calibration and backlash constants This code is used when a computer module or hard drive has been replaced 4 9 1 3 Code 142 Save Configuration file to 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 electric s cabin
158. w See Mechanical Drive Train X Y Section 4 2 3 3 Problems Relating to the Operation of the Control 3 3 1 Display Blanks The display is completely blank Possible Cause Check This 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 The system has shut down Turn the power switch off check the computer nn pendant fuses and cable connections See Electrical Section 4 8 Poor cable connection from Computer Module to LCD Liguid Crystal Display module to the LCD 34 Southwestem Industries Inc FHM5 8 FHM7 Safety Installation Maintenance Service 8 Parts List 3 3 2 Bad Picture on the Display The display has strange characters horizontal bars or other unfamiliar images or the display continually rolls Possible Cause Check This Poor cable connection from Computer Check connections on computer module Module to LCD Liquid Crystal Display Computer Pendant failed See Computer Pendant Section 4 3 3 3 3 Keyboard Lockup The screen display is normal but the system will not respond to key presses Do the following Service Codes and procedures e Code 81 press each key on the pendant The screen will display a keypad that signifies if a key is working The pendant will also beep Possible Cause Check This Voltage drop spike h
159. wheel are interchangeable All 3 handwheels are mounted on the machine by the use of 4 SHCS The X and Y hand wheel have a hole in the hand wheel so the mounting bolts can be accessed easily with a 5 mm Allen wrench or ball end screwdriver The handwheels are plugged into the encoder module located in the lower left side of the electrical cabinet See the Section 6 for how to route the cables in the electrics box 5 1 8 TRAK Sensor FHM5 only 5 1 8 1 Replacing the M5 Base See Figures 20 and 21 1 Remove the sensor by removing the clamp screw and then backing the load screw out a few turns The sensor should lift off the base easily 2 Remove the old M5 Base by removing the two 1 4 20 hex head screws that are threaded into the base 3 Assemble the new base as per Figure 20 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 20 M5 Base Mounting 78 Southwestern Industries Inc FHM5 amp 7 Safety Installation Maintenance Service amp Parts List 5 1 8 2 Replacing the TRAK Sensor 1 Remove the old sensor by removing the clamp screw and then backing the load screw out a few turns The sensor should lift off the base easily 2 Install the new sensor on the M5 base using the clamp screw 3 Load the sensor against the running surface table or run bar us
160. wing 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 Possible Cause Check This 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 Table Saddle or Ram Locks are locked Make sure the Table Saddle and Ram Locks are unlocked Inadequate or no Lubrication to Make sure all the Way surfaces are getting proper lubrication Ballscrews and Way surfaces 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 Z axis Gibs are not adjusted Check the adjustment of the X Y and Z axis Gibs using the properly X Y and Z axis Gib adjustment procedures Section 5 2 1 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 D
161. witches are in 67 Southwestem Industries Inc TRAK FHM5 amp FHM7 Safety Installation Maintenance Service amp Parts List 4 9 2 15 Code 321 Reverse Y position sensor direction This service code reverses the direction of the encoder It may be needed if sensors or glass scales are mounted on different sides of the machine 4 9 2 16 Code 322 Reverse X position sensor direction This service code reverses the direction of the encoder It may be needed if sensors or glass scales are mounted on different sides of the machine 4 9 2 17 Code 337 Spindle RPM Calibration This service code is for manually calibrating the spindle using a tachometer simply follow the on screen instructions Please note that when installing a new machine or replacing computer module that if no configuration is present spindle may not run properly Press the F4 button to load spindle calibration defaults if needed This has no effect on other settings such as calibration backlash etc 4 9 2 18 Code 338 Toggle Limit Switches 1 or 2 input This is used to toggle the type of limit switch hardware installed on your machine All newer style machines will have the 2 input style Select 1 if you are using the older style single input limit switches The default for this code is 2 input 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

Service Manual - FH5 & FH7 - Southwestern Industries, Inc.

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Service Manual - FH5 &amp; FH7 - Southwestern Industries, Inc.

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Service Manual - FH5 & FH7 - Southwestern Industries, Inc.