prototrak 1440EX Maintenance Manual

Southwestern Industries, Inc.

Service Department: 800.367.3165

TRAK

ProtoTRAK

® TRL 1440EX Lathe

® ELX CNC

Safety, Installation, Maintenance, Service & Parts Li sts Manual

Document: P/N 26008
Version: 061411

2615 Homestead Place
Rancho Dominguez, CA 90220-5610 USA
T | 310.608.4422 | F | 310. 764.2668

e-mail: sales@southwe sterni ndustrie s.com | service@southw e sterni ndustrie s.com | web:
southwesternindustries.com

Copyright © 2008, 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 Industrie s, 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
Phn 310/608-4422

 Fax [phone]

Service Department
Phn 800/367-3165

 Fax [phone]

Southwestern Industries, Inc.

TRAK TRL Lathe, ProtoTRAK ELX CNC Safety, Installation, Maintenance, Service & Parts List

Table of Contents

1.0 Safety

1.1 Safety Publication s 1

1.2 Danger, Warning, Caution and Note
Labels and Notices Used in this Manual

1.3 Safety Precautions

2.0 Installation

2.1 Floor Plan, Layout & Space Requirements 5

2.2 Lathe Specifications

2.3 Uncrating

2.4 Shortages: Inventory Checklist

2.5 Installation Instructions & Checklist

2.6 Lifting and/or Moving the Machine

2.7 Cleaning

2.8 Leveling

2.9 Electrical Connection

2.9.1 Phase Converters

2.10 Mounting the Display Pendant

2.11 Cable Interconnections

2.12 Lubrication

2.12.1 Headstock Oil Reservoir

2.13 Cutting the Test Part

2.14 Measurement of the Test Part

3.0 Troubleshooting by Symptom

3.1 Problems Relating to Machining Results 18

3.1.1 Poor Finish

3.1.2 Turning Diameters Out of Round

3.1.3 Cutting Taper

3.1.4 Parts Have Incorrect Dimensions

3.1.5 Threading Problems

3.2 Problems Regarding the Motion of the
Machine

3.2.1 Run Away Axis

3.2.2 Slow Down Axis

3.2.3 Axis Motor Mot i on i s not Sm oot h

3.2.4 Vibration in Motion

3.3 Problems Relating to the Operation
of the Control

3.3.1 Display Blanks

3.3.2 Bad Picture on the Display

3.3.3 Keyboard Lockup

3.3.4 Fault X or Z

3.3.5 Problems Reading the Floppy Disk;

Programs not Saved Properly

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 E-Stop Error

3.4 Problem with the Measurements

3.4.1 X & Z Axis Measurements Do Not

Repeat

3.4.2 X & Z Axis Measurements Are Not

Accurate

3.4.3 The DRO is not Counting

3.4.4 X & Z Axis DRO Counting in Wrong
Direction

3.4.5 X & Z Axis Electric Handwheels
Count in Wrong Direction

3.5 Problems with the Machine Tool

3.5.1 Spindle Stalls or Turns-Off
During Machining

3.5.2 Spindle Motor Hums or Will
Not Run

3.5.3 Spindle Runs Backwards

3.5.4 Excess Gearbox Noise

3.5.5 Tailstock Barrel is Stiff

4.0 Diagnostics

4.1 The Machine Tool & Set Up 30

4.1.1 Leveling

4.1.2 A Special Word About the
X & Z Gib

4.1.3 Lubrication

4.1.4 Machining Set-Up

4.2 The Mechanical Drive Train (X, Z)

4.3 Computer/Pendant Diagnostics

4.4 Motor Diagnostics

4.4.1 Cable Connections

4.4.2 To Check the Motor Encoders

4.4.3 Diagnosing a Brush Problem

4.4.4 Moving Problem from One Axis
to Another

4.5 Servo Drivers

4.6 Electrical

4.6.1 Checking A/C Voltage

4.6.2 Checking Fuses

4.6.3 Cable Connections

4.7 Door & Gear Switch

4.8 Service Codes

4.8.1 Software Codes

4.8.2 Machine Set-Up Codes

4.8.3 D

4.8.4 Operator Defaults/Options Codes

iagnostic Codes

5.0 Procedures for Replacements &
Maintenance

5.1 Replacements 48

5.1.1 Servo Motor Replacement

5.1.2 Motor Brush Replacement

5.1.3 Servo Driver Replacement

5.1.4 Computer Module Replacement

5.1.5 IDE Flash Disk Replacement

5.1.6 Electronic Handwheels

5.1.7 Spindle Proximity Sensor

Replacement

5.1.8 Spindle Drive Belt Tightening /

Replacement

5.1.9 Spindle Motor Removal

5.1.10 X-Axis Ballscrew Removal

5.1.11 Z-Axis Ballscrew Removal

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TRAK TRL Lathe, ProtoTRAK ELX CNC Safety, Installation, Maintenance, Service & Parts List

5.1.12 Z-Axis Ballscrew Alignment

5.1.13 Headstock Taper Adjustment

5.1.14 Spindle Bearing Preload

5.1.15 Aligning Tailstock to Spindle

5.1.16 Spindle Motor Wiring

5.1.17 Spindle Removal

5.1.18 Gear Shifting Lever Removal

5.1.19 Shift Lever Detent Adjustment

5.2 Maintenance

5.2.1 Gib Adjustments

5.2.2 Calibration & Backlash Constants

5.2.3 Lubrication

6.0 Drawings & Parts Lists

(See List of Figures for details) 73

List of Figures

2-1 Floor Plan, Layout, and Space Requirements
2-2 Lifting the Lathe
2-3 Leveling
2-4 Wiring the 1440EX Lathe
2-5 Pendant Rear View
2-6 Pendant Cable Connections
2-7 Test Part
4-1 Electrical Cabinet
4-2 Electrical Cabinet Schematic
5-1 Computer Module and LCD/Enclosure

Replacement

5-2 1440EX Proximity Sensor
5-3 Spindle Motor Belt Adjustment
5-4 X-Axis Drive Train
5-5 Z-A
5-6 Headstock Taper Adjustment
5-7 Tailstock Adjustment
5-8 Gear Shifting Lever Removal
5-9 Shift Lever Detent Adjustment
5-10 X-Axis Gib
5-11 Z-Axis Gib
5-12 Calibration Set-Up
5-13 Headstock Oil Fill and Removal
5-14 Way Lubrication
5-15 Tailstock Lubrication
6-1 Over a ll Machine Dra wing (F ront View)
6-2 Overall Machine Drawing (Rear View)
6-3 Overall Machine Drawing (Top View)
6-4 Overall Machine Drawing (Left Side View)
6-5 Overall Machine Drawing (Right Side View)
6-6 Headstock Drawing (Controller Box)
6-7 Headstock Components (Spindle Assembly)
6-8 Headstock Components (Pulley Shaft)
6-9 Headstock Components (Intermediate B

6-10 Headstock Components (Intermediate C
6-11 Gear Mesh Matrix

6-12 Tailstock Assembly
6-13 Apron Assembly/Forward/Reverse/

xis Drive Train

Shaft)
Shaft)

Coolant Switches

ii

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TRAK TRL Lathe, ProtoTRAK ELX CNC Safety, I nstallation, M aintenance, Service & P arts List

1.0 Safety Specifications

The safe operation of the TRAK TRL Lathe & ProtoTRAK ELX CNC depends on its proper use and
the precautions taken b y each operator.

• Read and study the TRAK TRL Lathe & ProtoTRAK ELX CNC Safety, Programming,
Operating, and Care Manual. Be certain that every operator understands the operation
and safety requirements of this machine

• Read and study the TRAK TRL Lathe Safety, Installation, Maintenance, Service & Parts
List Manual. Be certain that every operator understands the operation and safety
requirements of this machine

• Always wear safety glasses and safety shoes.

• Always stop the spindle and check to ensure the CNC control is in the stop mode before

changing or adjusting the tool o r workpiece.

• Never wear gloves, rings, watches, long sleeves, neckties, jewelry, or other loose items
when operating, or around the machine.

• Use adequate point of operation safeguarding. It is the responsibility of the employer to
provide and ensure point of operation safeguarding per ANSI B11.6-2001.

before

before

servicing.

1.1 Safety Publications

Refer to and study the following publications for assistance in enhancing the safe use of
this machine:

its use.

Safety Requirements for Manual Turning Machines with or without Automatic
Control (ANSI B11.6-2001). Available from the American National St a n dards
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 Av e n u e, NW, Washington, DC 20210.

All other regulations are specific to the State in which the machine is installed.

1.2 Danger, Warning, Caution, and Note La bels and Notices
as Used In This Manual

DANGER - Immediate hazards that

Danger labels on the machine are red in color.
WARNING - Hazards or unsafe practices that

and/or damage to the equipment. Warning labels on the machine are gold in color.
CAUTION - Hazards or unsafe practices that

equipment/product damage. Caution labels on the machine are gold in color.
NOTE - Call attention to specific issues requiring special attention or understanding.

will

result in severe personal injury or death.

could

result in severe personal injury

could

result in minor personal injury or

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Safety & Information Labels Used On The

It is forbidden by OSHA regulations and by law to deface, destroy or remove any

TRAK TRL Lathe

of these labels

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TRAK TRL Lathe, ProtoT RAK E LX C NC Safety , Installation, M aintenance, Serv ice & Parts List

1.3 Safety Precautions

WARNING!

Use only chucks which are rated to the maximum RPM of the lathe.

1. Do not operate this machine before the TRAK TRL Lathe and ProtoTRAK ELX CNC

Programming, Operating and Care Manual has been studied and understood.

2. Rea d and study this TRAK TRL Lathe Safety, Installation, Maintenance, Service & Parts List

Manual. Be certain that every operator understands the operation and safety requirements
of this machine

3. Do not run t his machine without knowing the function of every control key, button, knob, or

handle. Ask your supervisor or a qualified instructor for help when needed.

4. Protect your eyes. Wear approved safety glasses (with side shields) at all times.

5. Don't get caught in moving parts. Before operating this machine, remove all jewelry,

including watches and rings, neckties, and any loose-fitting clothing.

6. Keep your hair away from moving parts. Wear adequate safety headgear.

before

servicing.

7. Protect your feet. Wear safety shoes with oil-resistant, anti-skid soles, and steel toes.

8. Take off gloves before you start the machine. Gloves are easily caught in moving parts.

9. Remove all tools (wrenches, chuck keys, etc.) from the machine before you start. Loose

items can become dangerous flying projectiles.

10. Never operate any machine tool after consuming alcoholic beverages, or taking strong

medications, or while using non-prescription drugs.

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TRAK TRL Lathe, ProtoT RAK ELX CN C Safety , Installation, M aintenance, Serv ice & Parts List

11. Protect your hands. Stop the machine spindle and ensure that the CNC control is in the STOP

mode:

• Before changing tools

• Before changing parts

• Before you clear away the chips, oil or coolant. Always use a chip scraper or brush

• Before you make an adjustment to the part, chuck, coolant nozzle or take measurements

• Before you open safeguards (protective shields, etc.). Never reach for the part, tool, or

fixture around a safegua rd.

12. Protect your eyes and the machine as well. Don't use a compressed air hose to remove the

chips or clean the machine (oil, coolant, etc.).

13. Stop and disconnect the power to the machine before you change belts, pulley, gears, etc.

14. Keep work area well lighted. Ask for additional light if needed.

15. Do not lean on the machine while it is running.

16. Prevent slippage. Keep the work area dry and clean. Remove the chips, oil, coolant and

obstacles of any kind around the machine.

17. Avoid getting pinched in places where the spindle, carriage, cross slide or sliding door create

"pinch points" while in motion.

18. Securely clamp and properly locate the workpiece in the chuck or in the fixture. Use proper

tool holding equipment.

19. Use correct cutting parameters (speed, feed, and depth of cut) in order to prevent tool

breakage.

20. Use proper cutting tools for the job.

21. Prevent damage to the workpiece or the cutting tool. Never start the machine (including the

rotation of the spindle) if the tool is in contact with the part.

22. Don't use dull or damaged cutting tools. They break easily and may become airborne.

Inspect the sharpness of the edges, and the integrity of cutting tools and their holders.

23. Large overhangs on cutting tools when not required result in accidents and damaged parts.

24. Prevent fires. When m achining certain materials (magnesium, etc.) the chips and dust are

highly flammable. Obtain special instruction from your supervisor before machining these
materials.

25. Prevent fires. Keep flammable materials and fluids away from the machine and hot, flying

chips.

26. Never change gears when the spindle is rotating.

27. Do not rotate the spindle by hand unless the Red Emergency Stop button is pressed.

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TRAK TRL Lathe, ProtoT RAK E LX C NC Safety , Installation, M aintenance, Serv ice & Parts List

2.0 Installation

Read and understand this entire installation section before beginning the installation procedure.

2.1 Floor Plan, Layout & Space Requirements

Figure 2-1
1440EX Dimensions and Layout Requirements

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TRAK TRL Lathe, ProtoT RAK E LX C NC Safety , Installation, M aintenance, Service & Par ts List

Height of Centers

7”

Swing Over Saddle Wings

14”

Coolant Tank Capacity

3 gal

Bed

Spindle Nose

D1-4

Taper in Reduction Sleeve

3

Spindle Diameter Front Bearing

2.36”

Spindle Speed Range (RPM)

60-2400

Tailstock

Quill Taper Hole

MT#3

Spindle Motor

Voltage

220V / 440V

Net Inches L x W x H lbs.

73 x 44 x

Ship Inches L x W x H lbs.

78 x 49 x

Other

Way Surface Hardness

400-450HB

Tooling Kit

¾”

Gang Tooling

None

2.2 Lathe Specificati ons

1440EX

Distance Between Centers 40”
Swing Over Bed 14”

Swing Over Cross Slide 7”
Cross Slide Travel 8”
Tool Section Max. ¾”

Oil Pump – Way Lubrication .5 quart
Oil Reservoir – Headstock 2 gal

Width 8.1”
Height 10.6”

Headstock

Spindle Through Hole 1.56”
Spindle Taper MT#5

Number of Bearings 2
Number of Spindle Speed Ranges 12

Quill Travel 5”
Quill Diameter 1.575”

H.P. 5

Amps, Full Load 14 / 7
Phase, Hz 3P, 60Hz

Dimensions

57; 1800
67; 2200

Coolant Pump Motor, H.P. 1/8
Spindle Motor Brake Magnetic

Headstock Lubrication Splash Lube

Options

Chuck 6”, D1-4
5C Collet Closer D1-4
Indexer Option None

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TRAK TRL Lathe, ProtoT RAK E LX C NC Safety , Installation, M aintenance, Serv ice & Parts List

2.3 Uncrating

ATTENTION!

Carefully remove the wood crate and protective packaging, paying attention not to
scratch, damage, or mar any parts of the machine.

The leveling pads and screws for the machine can be found in the t ool box.
Loosen and remove the screws and nuts holding the machine to the wood pallet.

Immediately report, in writing, any damages observed at this time that can be attributed to the

transportation or im proper handling/moving of the ma chine.

2.4 Shortages: Inventory Checklist

______Machine (check model and serial number)

______ Leveling pads and screws (6 each) – (P/N 26331)

______ Pendant Display (P/N 26015-4)
______ Toolbox with various tools
______ TRAK Lathe Safety, Operation & Programming Manual (P/N 26010)

______ TRAK Lathe Safety, Installation, Maintenance, Service & Parts List Manual (P/N 26008)

In case of shortages, contact the representative from whom you purchased the machine.

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TRAK TRL Lathe, ProtoT RAK E LX C NC Safety , Installation, M aintenance, Service & Par ts List

3.

Clean the machine if needed and remove any remaining grease.

6.

Slide the door back and forth to make sure it slides smoothly.

10.

Lubricate all the way surfaces and the ballscrews by manually operating the lubrication pump

13.

Check the level of the machine. The machine should be level to within 0.0008" longitudinally and



14.

Check the tailstock and the tailstock barrel locks by locking and unlocking. Run the tailstock
barrel in and out to ensure proper function.

17.

Check to make sure that the E-Stop button is functioning correctly.

20.

Perform Service Co de 127 and 128 to manually calculate the backlash for the X and Z-axis.



21.

Check for positional accuracy and repeatability on the X and Z-axis using programs 1.LX2 for the

24.

Flip the coolant switch on and off to make sure coolant is working properly – optional.

2.5 Installation Instructions & Checklist

Installer: Use this checklist to assure a complete set-up of the lathe.



1.

Shut off power to the machine.



2. Visually inspect the 220/440 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.




4.

Ensure the pendant is securely mounted to the mounting ar m.



5. Check all the electrical connections from the pendant to the electric box. See the pendant and
electric box wiring diagrams.




7.

Remove the protective plastic covers from the headstock and the window on the sliding door.



8. Turn on the power to the machi ne and to the pendant. Ensure that the 220/440V and 110V lines
are plugged in.



9. Check the oil level on the sight glass on the headstock. Fill if low. Ensure that the coolant pump
is rotating in the correct dir ection.




11. Jog the saddle and cross slide back and forth until the way surfaces are well lubricated. Oil
should be visible on all the way surfaces.



12. Position the saddle and tailstock to the center of the bed for leveling.



0.0005" transversely. Even though it is the responsibility of the customer, make any adjustments
if necessary.



15. Open and close the door and verify the door switch is functional. The control should display a
message of “DOOR OP EN” in DRO mode when the door is open and it should disappear w hen the
door is closed.



16. Make sure the X and Z electronic handwheels are functional.




18. Perform Service Code 12, Feed Forward Constant.



19. Perform Service Code 123 to calibrate the X and Z-axis using a 150mm standard.



X-axis and 2.LX2 for the Z-axis. Positioning and repeatability values should be less than or equal
to 0.0005”. Programs can be found on the hard drive. Not e: the door must be closed to run
these programs.



22. Perform Service Code 100 in both directions for the X and Z-axis to verify that the feed rate
shown on the display is at least 120 ipm.



23. Run the spindle throughout each gear at each speed.




25. Cut the test part to check for taper. Measure the test bar and make any machine adjustments.
If unacceptable taper is found, re-check the level before attempting to adjust the headstock.



26. Wipe down the machine prior to leaving.

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TRAK TRL Lathe, ProtoT RAK E LX C NC Safety , Installation, M aintenance, Serv ice & Parts List

CAUTION!

CAUTION!

If the TRAK Lathe has a chuck mount ed to the spindle, make sure the chuck is mounted properly to

the spindle and also make sure the chuck jaws are engaged onto themselves or a piece of material

before running the machine.

If the chuck was not purchased from SWI, check to make sure the chuck is rated for the maximum

rpm of the machine. If it is not, do not run the machine above the chuck’s maximum rated rpm.

If the chuck’s rpm rate is unknown, do not run the chuck over 1200 rpm.

The chucks purchased from SWI are rated for the machine's maximum rpm.

2.6 Lifting and/or Moving the Machine

Proper equipment of sufficient capacity must be used when l ifting and/or moving the ma chine.

To lift the machine, remove the chip pan. Place the forks of the forklift at least 32” apart as
shown in figure 2-2. Be certain to lift the lathe toward the headstock.

Figure 2-2
Lifting the Lathe

Machine Weight Approximate Machine Shipping

Weight

1,800 lbs 2,200 lbs 6,000 lbs

Minimum Forklift Capacity

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CAUTION!

Do not remove the skid from the machine until it is brought to its final position, especially
if the machine is to be moved on rollers.

Once the skid has been removed, place the machine in position on top of the six (6) rest
pads.

For proper operation, the machine should be set on a substantial floor capable of
supporting the weight safely.

2.7 Cleaning

1. Remove rust protective coating from the machine before moving any slideways.

2. The coating is best removed wit h clea n, dry rags. Do not use a cleaning solution that
may damage the rubber way scrapers, plastic parts, or paint.

WARNING!

Do not use gasoline or other flammable cleaning agents for cleaning the machine.

3. It may be necessary to move back and forward and left and right the carriage
and cross slide.

Never move any of the above parts over ways that were not previously cleaned. Serious damage

to the TURCITE surface or slideways can occur.

4. Be certain the carriage, cross slide and tailstock move freely and smoothly over their
entire length.

2.8 Leveling

The precision and durability of the lathe depends on it being leveled properly. Final
inspection can be done only when the machine has been correctly leveled.

After the machine is in position on top of the 6 rest pads, it must be leveled by the use of
the 6 leveling bolts. It is important that the lathe be level in order to produce accurate
work. It may be necessary to lag bolt the machine in order to eliminate a small amount
of twist.

NOTE: Next to each leveling screw is another hole used to bolt the machine to the floor.
Southwestern Industries recommends that the TRAK 1440EX be bolted to the floor.

NOTE: The use of a precision level having a minimum accuracy of .0005" over 10.0" will
be required.

Move the saddle and tailstock to the center of the bed. To take a reading off the level
longitudinally, place the level at each of the four (4) corners o f the bedways (Figure 2-3,
Positions B & C). To take a reading off the level tr ansversely, place it on top of .7500"
parallels at each end of the bedways (Figure 2-3 Positions A & D).

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220 volts at the motor and at the electrics box on the back of the column.

WARNING!

Figure 2-3

Leveling

I00193

Using the four (4) interior leveling screws on the lathe base, level the bedways
longitudinally within .0008" over the total length and transversely withi n . 0005" . After
leveling with the four (4) interior leveling screws, bring the exterior leveling screws on
the lathe (see Figure 2-1) into contact with the leveling pads using care not to disturb the
level.

For a newly installed machine, check the level once every week. Once the foundation is
rigid enough, then check it once pe r month.

Note: Each 1/2” leveling screw hole is accompanied by a 5/8” bolt hole to fasten the
lathe to the ground.

2.9 Electrical Connection

The TRAK Lathe can be configured for 208-240 volt or 416-480 volt 3 phase electricity.
To run at 440V, you will need to order the 440V option. The control system also needs a
dedicated 110 volt l ine with a minimum capacity of 10 amps.

DANGER!

Be certain that 200-volt electricity (typical range 208 – 240V) is used only with a machine labeled

Running at a voltage other than what the machine is w ired for will damage expensive electrical

components. These components are not covered under warranty.

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DANGER!

DANGER!

The 208-240/416-480 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

208-240/416-480 volts wires to the machine through the electrical box located on

the back of the headstock. The wire passes through a hole on the top of the box. The
ground wire should be connected at the top or bottom of the breaker bracket.

Only a qualified electrician should wire the 208-240/416-480 volt 3-phase electricity.

Southwestern Industrie s recommends the machine be earth grounded by driving a
copper rod into the ground. It is the responsibility of the customer to install this rod.

2.9.1 Phase Converters

For those machines that will be run with a phase converter it must be a CNC rated rotary
type rather than a static phase converters. CNC rated rotary phase converters allow for
varying loads in the system. A CNC rated phase converter also regulates the new leg
created so it does not end up being too high or low of a voltage. The electrical load on
the machine will vary based on the type of cut taken and the speed of the motor. Static
phase converters can only be used on machines with a non-varying load. Please conta c t
your local phase converter distributor for precise sizing.

Model Recommended Size of Phase

Full-load Amp of Machine

Converter

1440EX 7-10 KVA 15 FLA

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TRAK TRL Lathe, ProtoT RAK E LX C NC Safety , Installation, M aintenance, Serv ice & Parts List

Figure 2-4
Wiring the 1440EX Lathe

NOTE: Please connect the incoming ground wire t o either the green terminal block as
shown in Figure 2-4 or the ground screws below the terminal blo ck s where other green
wires are attached.

2.10 Mounting the Di s pl a y Pendant

The ProtoTRAK ELX display pendant mounts to the mounting arm attached to the
electrical cabinet.

The machine will arrive with the pendant already installed.

2.11 Cable Interconnections

All cable interconnections are made at the facto ry including those connecting to the
pendant display.

With the main power to the machine turned off, verify all cab le connections to the
pendant. Each cable m ates to only one connector on the pendant display back panel.
Each cable is labeled with a sticker. Use the key on the pendant to verify the connectors
with the correct port.

The following drawing describes all of the cable connections to the pendant.

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TRAK TRL Lathe, ProtoT RAK E LX C NC Safety , Installation, M aintenance, Service & Par ts List

CAUTION!

Make sure the main power is disconnected before plugging in the cables.

Figure 2-5
Pendant Rear View

Figure 2-5
Pendant Rear View

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TRAK TRL Lathe, ProtoT RAK E LX C NC Safety , Installation, M aintenance, Serv ice & Parts List

Figure 2-6
Pendant Cable Connections

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TRAK TRL Lathe, ProtoT RAK E LX C NC Safety , Installation, M aintenance, Service & Par ts List

Item

P/N

Title

Qty

1

20082-3

ELECTRONIC HANDWHEEL ASSY-Z-AXIS TRL

1 2 20082-2

ELECTRONIC HANDWHEEL-X-AXIS TRL

1 3 20296

MOTOR ASSY ENCODER/DRIVER 4020

1 4 20296-1

MOTOR ASSY ENCODER/DRIVER

1 5 26015-4

PENDANT ASSY - PROTOTRAK ELX

1 6 26159

SWITCH ASSEMBLY - FWD/REV

1 7 26155

SWITCH ASSEMBLY - COOLANT

1 8 26071

SENSOR - PROXIMITY

1 9 23265

PUMP COOLANT 1/8 HP

1

10

26180

BRAKE - MAGNETIC

1

11

26329

MOTOR - SPINDLE

1

i26009-2

CAUTION!

2.12 Lubrication

The TRAK Lathe lube system provides centralized lubrication for the carriage, cross slide
and ballscrews. The lube pump has a ½ quart reservoir filled with Mobil Vactra Oil No. 2
or non-detergent 30 weight.

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.

We recommend that you manually pump the oil 5-10 times at the start of every day and
every hour during the day.

Failure to properly lubricate the lathe will result in the premature failure of ballscrews

and sliding surfaces.

2.12.1 Headstock Oil Reservoir

Before turning on the spindle, check to make sure the headstock oil reservoir is full. A
site glass is located on the headstock. The reservoir holds approximately 2 gallons. If
low, fill with SAE 30 weight oil or equivalent oil through the plug located on the
headstock cover.

2.13 Cutting the Test Part (See Figure 2-7)

Tools Required

• Chuck

• Tool Post

• Tool Block

• Tool Holder, right-hand face and turn type

In order to accurately m achine the test part, the gears and bearings in the headstock
must be properly warmed and preloaded. This is accomplished by running the spindle
for 15 to 25 minutes prior to cutting the test bar at 450 RPM.

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Load an approximately 2” dia. aluminum bar into the spindle chuck. Load a standard
right hand face and turning to ol into a tool block. Align and lock the tool block onto the
tool post. Set the depth of cut to a maximum of .002.

Set the spindle to an acceptable speed for turning the test piece. A speed range from
640 to 830 RPM is recommended.

2.14 Measurement of the Test Part

Tools Required:

• O.D. Micrometers with .0001" graduations

Using a calibrated O.D. micrometer with .0001" graduations, measure and record the
generated dimension at a 6.00 spacing. The acceptable measurement of parallelism of
spindle axis to carriage movement (taper of test piece) is .0008" in 6". If the taper
measured is not acceptable, re-machine the test part and/or check and adjust the level
of the machine, or adjust the headstock.

Figure 2-7 – Test Part i00196

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3.0 Troubleshooting by Symptom

Inadequate or no Lubr ication to

Make sure all the Way surfaces are getting proper

X & Z-axis Drive Trains are loose

Check Repeatability using the Repeata b ility and Positional

Way surfaces are pocked, scarred, or

Visually check the condition of all the Way surfaces. For

Machine set-up problem

Machine’s feet a re not equally supporting weight. See

Tooling problem

Improper tooling, Work piece not properly supported
X gib too tight or loose

See Gib Adjustment, Section 5.2.1

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

Poor finish can be caused by a number of variables including: speeds, feeds,
tooling, machine setup and chatter.

Perform the following Service Codes:

• Code 33 Software Identification. This is needed if you call SWI Customer Service.

• Code 12 Feed Forward C onstant.

• Code 127 Measures backlash in the system.

• Code 128 Enter backlash compensation.

Possible Cause Check This

Ballscrews and Way surfaces

excessively wo rn

Loose bearing problem Looseness in the spindle bearings. Adjust spindle preload.

lubrication. If not, check to make sure that the lube pump
is functioning properly. Also check for any pinched or
blocked oil lines.

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, Z), Section 4.2

machines that may have excessively worn Way surfa c es
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.

Leveling, Section 2.8.

speeds too fast, Feeds too slow.
See Machine Tool & Setup, Section 4.1

Ball screw misalignment,
See Mechanical Drive Train (X, Z), Section 4.2. See

,

Spindle Bearing Preload

Section 5.1.14

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3.1.2 Turning Diameters Out of Round

Loose bearing problem

Looseness in the spindle bearings. See Mechanical Drive Train (X, Z),

Looseness in the gib or

Gib adjustment.

Loose bearing problem

Looseness in the spindle bearings.

Headstock and/or tailstock

See Adjust Headstock for Taper, Section 5.1.12.

Parts are not round within .0004” TIR. Runout for the spindle is best measured by using
a .0001” dial indicator and mounting to the inside taper of the spindle. Rotate the
spindle and measure the indicator movement.

NOTE: The typical geared head engine lathe is not capable of more precise diameters.
Careful adjustments to this turning machine will ensure to maintain this accuracy. Better
accuracy should not be expected from a lathe of this class.

Perform the following service code and procedures:

Possible Cause Check This

Tooling problem Improper tooling, workpiece not properly supported.

See Machine Tool & Setup, Section 4.1

Section 4.2. Spindle bearing not preloaded correctly. Reseat bearing and
preload. See Adjust Spindle Bearing Preload, Section 5.1.14

3.1.3 Cutting Taper

Parts are considered to be cutting on a taper if there is a difference in diameter of more
than .0008” over 6 inches. This is best measured by using a .0001” micrometer.

Perform the following service code and procedure:

• Code 12 Determines the feed forward constant for the axis motors.

Possible Cause Check This

Machine set-up problem Machine not leveled properly

See Leveling, Section 2.8.

Tooling problem Improper tooling; Work piece not properly supported. Use steady rest or

follow rest, reduce overhang from chuck headstock or tailstock.

misalignment of ball screw

not aligned

See Gib Adjustment, Section 5.2.1.
See Z Ballscrew Alignment, Section 5.1.12.

See Mechanical Drive Train (X, Z), 4.2.
See Spindle Bearing Preload, Section 5.1.13.

To adjust tailstock from side to side, adjust grub screw. See Section

5.1.15.

3.1.4 Parts Have Incorrect Dimensions

Parts are being machined with dimensions that are different than those programmed.
Typical accuracy expectations should be:

• Parts should be round within .0004” TIR.

• The acceptable measurement of parallelism of spindle axis to carriage movement is

.0008” over 6 inches.

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3.1.4.1 Every Part Has the Same Error

Possible Cause

Check This

Machining Setup

See Machine Tool & Setup, Section 4.1.

Looseness in the Drive Train, ball nut loose in

See Mechanical Drive Train (X, Z), Section 4.2.

Looseness in the Gib

Gib adjustment

Looseness in the drive train

The drive train Diagnostics

Possible Cause

Check This

Programming Error Programmed dimensions not correct. Check

absolute and incremental values.

Machine & Setup Related See Machine Tool & Setup, Section 4.1.

3.1.4.2 Erro r s are Rand o m or Accumulate in Size over the Part Run

Possible Cause Check This

yoke, split nut loose, yoke loos e

3.1.5 Threading Problems

Threads can be cut with and an unlimited number of pitches.
To reduce the relief area when threading up to a shoulder the spindle speed should be

reduced as much as possible. The slower the speed of the spindle, the closer the cutting tool
can come to the end of the programmed thread before it pulls out and r etracts. If a nut must
be turned all the way up to a shoulder, machine a relief area behind the last thread.

NOTE: No machine can thread up to a shoulder and instantaneously pull out.

Perform the following service codes and procedures:

• Code 12 Determines the feed forward constant for the axis motors.

• Code 133 Spindle encoder test

3.1.5.1 Cross Threading

Threaded parts are cross-threaded after completion of the threading event.

Possible Cause Check T his

See Gib Adjustment, Section 5.2.1.

See Mechanical Drive Train (X, Z), Section 4.2.
Failure of the spindle proximity sensor
Run service code 133 to check if t he sensor
counts.

Replace spindle proximity sensor

See Spindle Encoder replacement, Section

5.1.7.

3.1.5.2 Not T hread i ng

The machine will not cut a thread at all.

Spindle speed too fast Slow down spindle speed.
Failure of the spindle proximity sensor
Run service code 133 to check if t he sensor
counts.

Replace spindle proximity sensor

See Spindle Encoder replacement, Section

5.1.7.

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3.2 Problems Regarding the Motion of the Machine

The home position or tools are not set

See the Controls Programming, Operat ions and Care

The maximum allowable Arc Accuracy is

This value will only slow down the machine during arc moves.
Incoming AC voltage is inadequate

Perform Code 100. See Service Codes - Section 4.8 and

Inadequate or no Lubr ication to

Make sure all the Way surfaces are getting prope r lubrication.
X and Z-axis Gibs are not adjusted

Check the adjustment of the X and Z-a xis Gibs using the X

Binding in the Drive Train

Check Repeatability using the Repeatability and Positional

Servo Drive failure

See Servo Drive, Section 4.5.

Motor failure

See Motor, Section 4.4.

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 a n encoder signal being interrupted.

Perform the following Service Codes:

• Code 33 Software Identification. This is needed if you call SWI Customer Service.

• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and

if the encoders are counting.

Possible Cause Che ck T his

correctly
Bad Motor Encoder See Motor Diagnostics, Section 4.4.

manual.

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.

Perform the following Service Codes:

• Code 33 Software Identification. This is needed if you call SWI Customer Service.

• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and

if the encoders are counting.

• Code 129 Set's the maximum allowable arc accuracy error. This applies to arcs only.

Possible Cause Check This

set too low.

Ballscrews and Way surfaces

The factory default is set at 0.005". Perform Code 129 to
check or change this value. See Service Codes, Se c tion 4.8.
Values lower than 0.005” may reduce the feedrate.

Electrical Section 4.6.

If not, check to make sure that the lube pump is functioning
properly. Also check for an y pinched or blocked oil lines. See
Lubrication Section 4.1.3.

properly

and Z-axis Gib adjustment procedures.

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,
Z), Section 4.2.

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3.2.3 Axis Motor Motion Is Not Smooth

Possible Cause

Check This

Binding in the Drive Train

Check Repeatability using the Repeatability and Positional

Possible Cause

Check This

Binding or looseness in the Drive Train

Check Repeatability using the Repeatability and

Axis Motor belt too tight.

Loosen belt.

While under motor power, the m otion is not smooth. The motion appears to be "rough" or jerky”.
Perform the following Service Codes and procedures:

• Code 33 Software Identification. This is needed if you call SWI Customer Service.

• Code 12 Feed Forward C onstant.

• Code 127 Measure's the backlash in the system.

• Code 128 Enter backlash compensation.

• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and

if the encoders are counting.

X and Z-axis Gibs are not adjusted
properly
Calibration or Backlash problem Recalibrate the machine. Reset the Backlash. Check

Check the adjustment of the X and Z-axis Gibs using the
X and Z-axis Gib adjustment procedures.

Repeatability and Positional Accuracy. See Calibration &
Backlash Constants, Section 5.2.2.

Accuracy procedure. Check the torque reading of the
Drive Train. Step b y s tep, carefully inspect the Drive
Train for any bind ing. It may be necessary to
disassemble and then reassemble the Drive Train. See
Mechanical Drive Train (X, Z), Section 4.2.

3.2.4 Vibration in Motion

While axis is moving there is vibration or noise coming from the X or Z-axis.
Perform the following Service Codes and procedures:

• Code 12 Feed Forward Constant.

• Code 127 Measure's the backlash in the system.

• Code 128 Enter backlash compensation.

Too much backlash entered in Code 128. Recheck the machines backlash.
Inadequate or no Lubr ication to
Ballscrews and Way surfaces

X Gib is not making good contact. Pull gibs out and mark with a blue die to check where

Make sure all the Way surfaces are getting proper
lubrication. If not, check to make sure that the lube
pump is functioning properly. Also check for any
pinched or blocked oil lines. See Lubrication, Section

2.12.

the gibs are making contact. It is recommended that
the gibs uniformly contact at least 80% of the surface.

Misalignment of ball screw See Mechanical Drive Train (X, Z), Section 4.2.

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, Z), Section 4.2.

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3.3 Problems Relating to the Operation of the Control

Possible Cause

Check This

Fuse blown in pendant

Remove fuse and check continuity

Computer/Pendant failed

See Computer/Pendant , Se ct ion 4.3 .

Possible Cause

Check This

3.3.1 Display Blanks

The display is completely blank.

Screen saver has been activated Press any key to turn back on. Hitting this key will not

activate any feature on the control.

The system has shut down Turn off the power switch off; check the

computer/pendant fuses and cable connections.

See Electrical, Section 4.6.
Poor cable connection from Com puter
Module to LCD (Liquid Crystal Display)

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 Che ck T his

Poor cable connection from Com puter
Module to LCD (Liquid Crystal Display)
Computer/Pendant failed See Computer/Pendant , Se ct ion 4.3 .

Double-check the connection from the computer

module to the LCD.

Check connections on computer module.

3.3.3 Keyboard Lockup

The screen display is normal, but the system w ill not respond to key presses.
Perform the following Service Code and procedures:

• 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.

Voltage drop/spike has occurred Shut down the system and wait 10 seconds to reboot

the system.
Remote Stop-Go (RSG) switch has a
short (if connected)

Computer/Pendant failed See Compute r/P end ant , Se cti on 4.3 .

Remove the RSG. T urn the system off and then on

again. If the problem goes away and then re-appears

when the RSG is plugged-in, replace the RSG.

3.3.4 Fault X or Z

The program run or jogging operation is interrupted with a Fault Message on the display.
Perform the following Service Codes and procedures:

• Code 33 Software Identification. This is needed if you call SWI Customer Service.

• Code 12 Feed Forward Constant

• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and

if the encoders are counting.

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Possible Cause Check T his

Motor cables at pendant switched around.

Make sure during an installation the X and Z motor
Motor failure

See Motor diagnostics, Section 4.4.

Computer/Pendant failure

See Computer/Pendant diagnostics, Section 4.3.

Improper Boot-up

Shut down the system and wait 10 seconds before

110 V line is not plugged in

Check incoming 110 V power source to black electrical

Interruption of 110 V power to pendant

Using a Voltmeter, check the incoming 110VAC to the

cables at the pendant are in the correct ports.

X and Z-axis Gibs are adjuste d extremely tight Check the adjustment of the X and Z-axis Gi b s using

the X and Z-axis Gib adjustment procedures. See X

and Z-axis Gib Adjustme nts, Section 5.2.1.
Excessive friction in the slideways See Machine Tool & Setup, Section 4.1.
Binding or looseness in the Drive Train See Mechanical Drive Train (X, Z), Section 4.2.
Incoming electrical power Incoming voltage. See Electrical, Section 4.6.
Servo Drive failure See Servo Driver, Section 4.5.

3.3.5 Problems Reading the USB Drive; Programs Not Saved
Properly

The USB drive will not read or write programs from a disk.

Possible Cause Check This

rebooting.

USB thumb drive failure The USB thumb drive may be bad. See if the USB

drive can be read by a Personal Computer.

USB thumb drive is full Put the USB drive into a Personal Computer to see

how many bytes remain. The size varies.

USB thumb drive is incompatible with the
ProtoTRAK ELX

See the programming manual (P/N 26010) for the
brands compatible with the ProtoTRAK ELX.

3.3.6 System Will Not Turn On

Nothing happens when the switch is turned on or the system does not boot-up.

Possible Cause Che ck T his

cabinet.
Pendant On/Off switch is Off. Check the Pendant On/Off switch.
Fuse blown in pendant or electrical
cabinet
IDE Flash Drive If Boot Failure message appears, then check that the

Computer/Pendant has failed See Computer/Pendant Diagnostics, Section 4.3.

Remove fuses and check continuity.

IDE Flash is properly installed. See Section 5.1.5.

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 Che ck T his

pendant.
Poor wiring and cab le connections Check for any loose wiring or cables.
Computer/Pendant failed See Computer/Pendant Diagnostics, Section 4.3.

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3.3.8 System Shuts Off

Faulty E-Stop switch

Check the cable connections from the computer

Bad Computer Module

Does 110 V power come out of the pendant through

During operation, the system shuts off a nd will not turn back on.

Possible Cause Che ck T his

Fuse blown in pendant Remove fuse and check continuity
Poor wiring and cab le connections Check for any loose wiring. Also, check the 110VAC

Power Cable connection from the electrical box to the

Pendant. See Electrical, Section 4.6.
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" scree n and write
down the calibration values for the motor encoders (Encoder) 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:

• Code 33

• Code 313 Configuration Values

• Code 123 Calibration using a measurem ent standard, or

Possible Cause Che ck T his

Configuration file corrupt Load default configuration by going to code 313.
Not saving Calibration values Replace Computer/Pendant module.

If calibration factors are being saved, but the measurements are not repeating or are not accurate:

• See Measurements Are Not Repeating – see section 3.4.1

• See Measurements Are Not Accurate – see section 3.4.2

Software Identification. This is needed if you call SWI Custome r Service.

See Computer/Pendant.

3.3.10 E-Stop Error

The E-Stop turns the power off to the axis and spindle motors. This is done by stopping
110V power from reaching the electrical box through the use of a relay in the pendant.

110V Power reaches the electrical box through the AC E-stop cable. It is used to
energize the spindle motor contactor. If this contactor is not energized the spindle will
not turn on. See Figure 2-6 and 4-2.

If the E-Stop button is depressed, and no message is displayed on the scree n, then
either the E-Stop button or the Computer Module is at faul t.

Possible Cause Che ck T his

module to the E-Stop switch. Check the E-Stop switch

for functionality.

the E-stop connector? If yes, and the screen has an

E-stop message, replace the computer module.

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3.4 Problem with the Measurements

The Calibration is incorrect

Recalibrate the machine.

3.4.1 X & Z-Axis Measurements Do Not Repeat

With a dial indicator mounted to the spindle, touch off a fixed surfa ce either in the X or
Z-axis direction a nd then set the DRO equal to 0. Crank away several inches and then
touch off again at the same place. If the reading has not returned to 0 on the DRO, zero
the display and repeat the procedure. If the measurement does not repeat, you have a
repeatability problem that must be resolved.

Expected repeatability numbers should be 0.0005” or less.

Possible Cause Che ck T his

Machine Tool & Setup problem Check for any looseness in the setup. See Machine Tool

& Setup, Section 4.1.

X and Z-axis Gibs are loose Check the adjustment of the X and Z-axis Gibs using the

X and Z-axis Gib adjustment procedures.

X and Z-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, Z), Section 4.2.
Encoder Disk or Reader Head on
motor are loose

Swap the motor in question with a known good 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.

3.4.2 X & Z-Axis Measurements Are Not Accurate

Measurements repeat, but with a dial indicator mounted to 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 indicator touch off a fixed
surface either in the X 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

See Calibration & Backlash Constants
Incorrect backlash values If the machine does not repeat bi-directionally check the

backlash on the axis in question. See Section 5.2.2.

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3.4.3 The DRO Is Not Counting

Possible Cause

Check This

The DRO for one axis is not counting when an axis is moved. Often times if this is the
case the axis will fault.

Perform the following Service Codes:

• Code 33 Software Identification. This is needed if you call SWI Customer Service.

• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and

if the encoders are counting.

• Code 132 Electronic handwheel test.

• Code 131 Manual DRO test.

Electronic handwheel fa ilur e Each handwheel should count 0.100" for Z and X in fine mode,

and count 0.400" in course mode.
Motor Encoder not counting See Motor diagnostics.
Computer/Pendant failure See Computer/ Pendant diagnostic s.

3.4.4 X & Z-Axis DRO Counting in Wrong Dir ection

The DRO is counting in the wrong direction.
The positive directions for each axis are:

• X-axis – cross slide moves toward the operator.

• Z-axis – carriage moves toward tailstock.

Perform the following service codes and procedures:

• Code 33 Software Identification. This is needed if you call SWI Customer Service.

• Code 97 Sets positive motor encoder direction.

• Code 313 Check the line that specifies the product.

3.4.5 X & Z-Axis Electronic Handwheels Count in Wrong Direction

The Electronic Handwheels count in the wrong direction.
The positive directions for each Electronic Handwheel are:

• X-axis - Electronic Handwheel turns counterclockwise

• Z-axis - Electronic Handwheel turns clockwise

Perform the following service codes and procedures:

• Code 308 Reverse X-axis Handwheel Direction

• Code 310 Reverse Z-axis Handwheel Direction

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3.5 Problems with the Machine Tool

Machine Tool and Setup problem

Check the type of material being cut, type and size of cutting tool,
Motor drive Belt is slipping

Check the alignment, condition, and tension of the Drive Belt.

Cut more than the machine is capable

Check speeds, feeds, and depth of cut.

Spindle Drive parameters are not

May need to re-download the Spindle Drive parameters. Contact

Possible Cause

Check This

Poor wiring connectio ns

Check all the wiring connections to the electrics box. Make sure the
Defective cable connections

Check all cable connections.

3.5.1 Spindle Stalls or Turns-Off During Machining

During machining, the spindle turns off and loses power. First check incoming volt a g e
and connections.

Possible Cause Check This

RPM, and Feed rate. Also check the condition of the cutter t o verify
that the cutter is not dull. See Machine Tool & Setup, Section 4.1.

Overload has tripped or is not set
correctly

correct

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. The overload is set to 14 amps for 220V and to 7 amps
for 440V. See figure 4-1.

Customer Service for assistance at 800.367.316 5.

3.5.2 Spindle Motor Hums or Will Not Run

The spindle motor makes a constant humming noise during operation or will not turn on.

Wrong voltage

Missing a phase Check each phase to make sure you have the correct voltage.

Spindle Motor is faulty Check the resistance of the spindle motor windings on the spindle

Check the 220V or 440V voltage t o the machine.

motor is wired for the correct volta ge.

motor between L1 (U) and L2 (V), L2 (V) and L3 (W), then L1 (U) and

L3 (W) using a digital ohmmeter. If the ohmmeter reads more than

one (1) ohm difference or “OL” (infinite) between any pair, replace the

motor. The next check is for resistance to ground using a digital

ohmmeter. Check L1 (U) to ground, L2 (V) to ground, and L3 (W) to

ground. The meter reading in the display window should be “OL”

(infinite) with reference to ground. Any other reading indicates a

problem, and the motor should be replaced.

3.5.3 Spindle Runs Backwards

The spindle motor runs in the opposite direction. The spindle should always spin in the
counterclockwise direction when the spindle on/ off switch is turned to forward.

Possible Cause Check This

3-Phase wires backwards Need to switch any 2 of the 3 wires coming into the machine (T1,

T2, and T3).

3.5.4 Excess Gearbox Noise

Gearbox noise is louder than normal. Take note of t he gear where the noise is most
noticeable. Remove the gearbox lid and try to isolate where the noise is coming from.

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See figure 6-11 to troubleshoot gear noise.

Headstock manual oil pump failure

Make sure oil is flowing in the site glass. The oil

Shift level out of position. Gears are not

Move the shift levers in and out. Turn off spindle and
Lack of lubrication to gear train

Check level of oil in gearbox

properly, worn bearing

bearings.

Possible Cause Che ck T his

pump is run off a gear in the headstock.

mating properly.

Spindle bearing not being lubricated

Spindle preload loose Tighten spindle preload on bearing. The spindle

put back in gear. Adjust the gear cluster in question
to make sure it is mating properly.

Check to make sure oil is finding its way to the

preload should be approximately 10-15 in/lbs.

3.5.5 Tailstock Barrel is Stiff

The tailstock barrel is stiff or not smooth moving through its travel. The tailstock barrel
subassembly jams inside the tailstock

Possible Cause Che ck T his

Misalignment of tailstock housing Realign bearing housing and tailstock screw. Loosen

screw support and realign.
Too much grease. Disassemble and remove excess grease.
Vernier Dial is binding or rubbing on
screw support.

Remove dial and machine off a couple of thousandths

or shim.

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4.0 Diagnostics

This section explains the diagnostic procedures used to isolate service problems.

4.1 The Machine Tool & Set-Up

4.1.1 Leveling

Leveling is one of the most important aspects of setting up the machine properly.
Improper leveling can lead to a variety of machining problems.

The machine should be level to within .0008” longitudinally and .0005” transversel y. See
Leveling Procedures, Section 2.8.

4.1.2 A Special Word About the X & Z Gib

The X gib is vital to the performance of your lathe.
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.

The Z gib is used to keep the carriage firmly planted down to the ways. There are two Z
gibs, one located on each way.

See Gib Adjustments, Sect ion 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 performa nce and durability of the lathe. A t the beginning of each day
manually supply oil to the way surfaces by pumping the lube pump 5-10 times.

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 ballscrews and way surfaces.

Make sure the oil splash system for the headstock is working properly at the start of each
day. Check periodically the site glass for the headstock oil. The site glass is located on
the headstock. Lack of lubrication in the headstock can lead to increased wear o f the
gear train as well as premature wearing or failure of the spindle bearings.

4.1.4 Machining Set-Up

The machining set-up itself is always something that can greatly influence the
performance of the lathe. The following are some things to keep in mind.

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Problems With

Can Contribute To:

Cutting too deep

Part dimensions incorrect
No coolant

Poor finish, decrease the life of the cutter

Poor surface finish

Dull tool

Feed and Speeds (spindle rpm)
See below

Tooling
Using the wrong cutter for an application

The following is a list of common machining problems and some possible solutions.

Problem

Long workpieces out of round Use a follow or steady rest
Excessive chatter Tool bit improperly ground or not on center

Poor finish
Excessive speeds and feeds can break cutting tools or
wear out too fast.
Poor finish

Driving and cutting forces cause deflections, since no
material is totally rigid

Check or Try This

Reduce feedrate
Increase spindle speed
Use a higher rake angle tool
Make sure tool is not dull or chipped
Use proper grade of cutting tool
Use coolant
Check to see if tools are on the centerline

Avoid extreme negative rake inserts
Tool overhang too great, tool deflection
Improper feeds and speeds
X gib loose. See Gib Adjustment, Section 5.2.1.
Work improperly supported
Machine tool out of level - See Leveling Procedures,
Section 2.8.

4.1.4.1 Spindle Speeds

Spindle speeds are influenced by a number of variables:

• Material

• Rigidity of the Machine Setup

• Coolant

• Insert, geometry and material of insert

• Depth of cut

4.1.4.2 Feedrates

Factors that affect feedrates:

• Depth of cut

• Design or type of insert

• Sharpness of the insert

• Workpiece material

• Type of finish or accuracy required

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4.2 The Mechanical Drive Train (X,Z)

Indications:

• Troubleshooting instructions indicate that the drive train is potentially the problem and
other, more easily checked variables, have been exhausted.

• Roughness, looseness, tightness or jamming movement in the carriage or cross slide.

• Carriage walk-up due to Z ballscrew misalignment.

1. Check for machine considerations, especially X gib adjustments and leveling. See Gib
Adjustments, Section 5.2.1.

2. Do the following special service codes:

• Code 12 - this is a procedure that helps the control adjust to the friction characteristics

unique to the machine. Writ e down the resulting values from the display. If your
problem is control related, check to see if this procedure has resolved the problem.

3. The tor que required to manually turn t he X and Z-axis ballscrews should be between 10 to 15
in-lbs. These values should be consistent in both directions and along all areas of the axis
travel. Values that differ from that of above may correspond to misaligned ballscrews.

The following steps take you in logical sequence through the assemblies. If the step doesn’t
isolate or resolve the problem, it will be necessary to disassemble the indicated item and move to
the next step.

See Figures 5-2 through 5-3 in Sectio n 5. 0.

1. Ensure that the screws that hold the bearing housing in place are tight.

2. Ensure that the clamp nut is secured to 50 ft-lb. The following applies to the clamp nut:
When loosening, make sure to back out the 10-32 screw from the clamp nut.

3. When tightening, snug the 10-32 screw to ke ep the clamp nut from spreading, tighten it
again after the clamp nut is tight.

4. Take out the angular contact beari ngs in the X & Z-axis and inspect them. They should roll
smoothly and be lightly greased. If not, replace them.

NOTE: The bearing housing and spacer rings a r e matched sets - keep them together.

5. With the motor and drives removed, inspect the ballscrew, ball nut and yoke for the potential
problems shown in the chart below.

CAUTION!

Unlike a leadscrew, do not unscrew the ballscrew from its nut. This will destroy the ballscrew!

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Potential Problem:

Check By:

Ball nut not

Inspection for space between the head of the bolt and the ball nut i.e. the retaining

Oil line blockage

Pump the oil and ensure that it flows evenly to the ways, ballscrews and cross-slide.

Z Ballscrews not

• Manually turn the ballscrew through the length of its travel. Pay particular attention

Poor cable connections

There are several cable connections on the rear of the
No voltage to RSG port

RSG will not work – should be 5 DC volts present

LCD backlight burns out

Check all cable connections to LCD, distribution board

Bad ballscrew • Visual inspection of the ball nut - if the nylon seal is broken or deformed, if

contamination has visibly entered the ball nut or if balls are out of the ball nut,
replace the ballscrew.

• Cranking the ballscrew through a significant part of its travel. If it jams, feel loose or
has rough spots, replace the ballscrew.

• Dial indicator on a vertical flat of the ballscrew indicates backlash between the
ballscrew and ball nut.

•

tightened to the
yoke
Yoke loose in the
carriage
Oil lines sheared • Visual inspection.

bolt has bottomed out in its thread and is not securing the ball nut to the yoke
properly.

• Inspection for any motion of the yoke or looseness in the Yoke mounting screws.

•

aligned properly

to the movement near the headstock, the middle and the tailstock.

NOTE: Ballscrews are inspected throughout their entire travel for backlash and consistent torque.
A ballscrew should be good for millions of inches of travel if installed properly. Do not be too
quick to replace a ballscrew if there is insufficient indication that it is bad; this will just be a costly
delay to resolving the real problem.

See:

Z Ballscrew Removal,
X Ballscrew Removal,
Aligning Z Ballscrew,

Section 5.1.14
Section 5.1.12

Section 5.1.15

4.3 Computer/Pendant Diagnostics

In general, the pendant/computer module is best diagnosed by eliminating all other possible
alternatives. The following table lists some problems and what these problems can lead to.

Possible problems Can lead to

pendant. Make sure all cables are properly fastened.

Warning: do not unplug and plug cables with
the control on. This will destroy the computer.

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.

Check with a voltmeter.

IDE flash drive failure If the IDE flash drive 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.

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

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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.

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 10 or 8 amp fuse in pendant blow s. Pendant will not

turn on if the 10 amp fuse in the on/off switch is
blown.

The following is the list of diagnosti c LEDs found on the back of the applications board.
Remove the black cover on the rear of the pendant to access them.

LED lights – the applications board has 10 LED light s with LED 1 found on the left of the
LED segment.

1. 5 volt power LED – signifies that 5 volts are p res ent o n t he ap p l ications board
which is being supplied from the power supply.

2. Overlay Key LED – this LED will flash each time a key is pressed on our overlay.

3. Not used

4. Spi ndle Encoder Zero LED – When a spindle encoder is used no t a proximity
switch

5. Z El ectronic Handwheel Zero LED.

6. X El ectronic Handwheel Zero LED.

7. Z Motor Encoder Zero LED.

8. X Motor Encoder Zero LED.

9. 110 volt po wer LED – this light will be on when the applications board is s eeing
110 volts. Check the 8 amp fuse on the applications board if this light is not on.

10. Spindle Enable Output LED – This LED will indicate when the spindle enable
function is activated.

4.4 Motor Diagnostics

The Motor subsystem is comprised of 2 parts: The motor and the servo driver. The motors are
powered by 110 VAC vo ltage.

WARNING!

Do not work with the motors unless the power is disconnected from the machine. The motors

are run by 110 VAC. There is possibility of death by electrocution!

Rarely do both the X and Z 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 back of the ELX pendant. Verify there are no
pushed in pins on the connector.

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4.4.2 To Check the Motor Encoders

Physically switch the X and Z

Has problem moved to Z-axis? If yes, replace motor. If no,

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:

Run Service Code 100 or 131. This will display on the DRO if the motor encoder is counting.
If this number does not count approximately the same amount as physical movement, the
motor assembly needs to be replaced. If the encoder has failed the motor must be replaced.

4.4.3 Diagnosing a Brush Problem

Each of the axis motors on t he machine contains 4 brushes. These ar e a wear item and
may need to be replaced during the life of the control system. When the brushes begi n
to wear out, you may start to see intermittent faulting of an axis. Please note your
brushes will last for a number of years before they need replacement so if you are seeing
this symptom in the 1

See Section 5.1.2 for the procedure for replacing motor brushes.

st

year or 2 of your product, this is probably not the cause.

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. In 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.

Swap these components Results

motors

Warning – turn off the
power before plugging or
unplugging motors, or you
will destroy the computer

the motor is not the problem.

4.5 Servo Drivers

Note: the Servo Driver is located in the black box on the side of each motor.

Indications:

• Problems moving just one axis. The axis faults out on the screen.
Servo Types:

• X is a light duty driver

• Z is a heavy duty driver

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WARNING!

CAUTION!

Objective:

• Isolate the problem to the particular Servo Driver
Steps:

1. Turn off and unplug the system.

2. Physically swap the servo module from the axis that is not working to one that is.

WARNING!

Do not work with the Servo Driver unless the power is disconnected from the machine. There is

possibility of death by electrocution!

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.

Do not run each axis very long when swapping servos. They are not rated to run each other’s

motor for long periods of time.

4.6 Electrical

4.6.1 Checking A/C Voltage

This procedure tests for the 110V power for the control. Check the 110 VAC at the e­stop AC out connector on the pendant.

• Use a Voltmeter, reading A/C volts

• Acceptable range is 100V to 130V

Note: systems running consistently close to the high or low values may have problems
when normal voltage fluctuations push the voltage out of the acceptable range.

4.6.2 Checking Fuses

Turn off power before removing and replacing fuses

There are 5 fuses to check in the system. There are 2 in the pendant and 3 in the
electrical cabinet. The bottom fuse in the electrical cabinet on the power strip is 10 amps
and fuses power to the pendant. The top fuse is 5 amps and fuses power to the coolant
pump, worklamp, and spare. The third fuse in the electrical cabinet is item 8 on figure 4-

1. The 2 fuses in the pendant are 10 amp and 8 amps. The 10-amp fuse in the pendant
is found in the on/off switch. The 8-amp fuse is found on the applications board inside
the pendant.

To check fuses:

1. Use a Volt/Ohmmeter; select “OHM” or “

2. Remove the fuses completely from the pendant or electrics box for TRAK Knee mills.

3. Place a lead of the meter on each end of the fuse.

Ω”.

• A good fuse reads 0 (zero) or close to it.

A bad fuse reads Open or Infinity.

•

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4.6.3 Cable Connections

CAUTION!

The TRAK lathe uses several cables to communicate between systems. It is often the
case that what appears to be the failure of an electrical component is actually
attributable to a poor connection.

Indications:

• Control problems, chronic or intermittent.

• Motor problems

• Measurement problems.

Explanation:

1. Turn off and

Do not plug and unplug connectors with the system power on. This may cause damage to the

2. Visually inspect the connections for excessive debris, moisture, or obvious damage.

3. Ca refully clean any chips away from the connectors.

unplug

the system from the wall.

connector board and harm to the technician.

4. One-by-one, take out each connector and then plug them back in.

5. Make sure to tighten up the screws o r locking ring on each of the connectors.

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Figure 4-1
Electrical Cabinet

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Item

P/N

Title

Qty

1

26088

TRANSFORMER-100VA

1 2 26091

POWER STRIP ASSY

1 3 23037

DIODE-BRIDGE RECTIFIER-HIGH CURRENT-25
WATT 1 4

24483-1

RELAY- TIMER, OFF DELAY (brake timer)

1 5 26092

CONTACTOR- 3 PHASE REVERSING CONTACTOR

1 6 23821

OVERLOAD RELAY - 220 volt

1 6 23821-4

OVERLOAD RELAY - 440 volt

1 7 23435

RELAY-POWER-100-120 VAC-DPDT

1

8

24126-004

FUSE-5x20mm SERIES 195 - 4 amp

1 9 21824-5

FUSE-3AG-SLOW BLOW, 5 AMP

1

10

21824-10

FUSE-3AG-SLOW BLOW, 10 AMP

1

i01409

Electrical Cabinet Parts List

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Figure 4-2 – Electrical Cabinet

Schematic

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4.7 Door Switch

All TRAK lathes use a door interlock switch to verify to the control that the door is closed in various
modes of operation. This switch is wired normally open but is forced closed when the door is
closed during CNC run mode. There should be continuity between pins 1 and 6 when the switch is
forced closed and no continuity when the switch is in the open position.

4.8 Service Codes

Service codes are broken down into 4 categories: Software, Machine Se tup, Diagnostic, Operator
Defaults/Options.

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 and enter the code number.

4.8.1 Software Codes

The following codes pertain to software functions in the control.

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.

4.8. 1.1 CODE 33: S o ftware ID

The Code 33 is the software identification procedure. The software ID will display the
various software modules. The two that are important for resolving problems are:

• User Interface/Tool Path – write down the numbers if service support is needed.

• Motion Control – write down the numbers if service support is needed.

Other software information displayed on this screen is rarely needed. You should provide
it on request of a service technician.

4.8. 1.2 CODE 141: Load C o n figura t i o n f i le fro m US B t hu mb d r i v e

This code allows you to load your configuration file from the USB thumb drive to the
ProtoTRAK’s internal IDE Flash drive. The configuration file consists of items such as
calibration and backlash constants. This code is used when a computer module or IDE
Flash Drive has been repl aced and you already loaded the information on the thumb
drive using code 142.

4.8. 1.3 CODE 142: S a v e Confi g u r a t i o n file t o USB thumb dri v e

This code allows you to save your configuration file to a USB thumb drive. The
configuration file consists of items such as calibration and backlash constants. Use this
process before a computer module or IDE Flash Drive needs to be replaced. It stores the
configuration file from the ProtoTRAK’s internal IDE Flash Drive to the USB thumb drive.
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 . I f the computer or IDE flash 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 IDE flash drive is replaced.

4.8. 1.4 CODE 313: Displ a y Confi g ur a t i o n File

This code displays the configuration file. This file contains pertinent information about
the machine. Some of the common service code values are displayed on this page as

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well, such as code 12, 100, 128, and 129. Press the Load Default if you wish to load
factory defaults for all of the control’s settings and configurations.

4.8. 1.5 CODE 316: Update Software

Load in USB thumb drive and enter this service code. New software will automatically
download and control will reboot.

4.8. 1.6 CODE 340: copy part programs to USB Thumb drive

Load in USB thumb drive and enter this service code. All the part programs that are
stored in the ProtoTRAK’s internal storage will be copied to the USB Thumb Drive.

4.8. 1.7 CODE 341: copy part programs from the USB T humb drive

Load in USB thumb drive and ent er this service code. All the part programs that are
stored on the USB Thumb Drive will be copied to the ProtoTRAK’s internal storage.

4.8.2 Machine Set-up Codes

The following codes are used primarily when setting up a new machine.

4.8. 2.1 CODE 12: Feed Forward Constant

The Code 12 procedure helps the control “learn” the friction characteris tics of the
machine by sending a graduated series of motor signals and observing the results. The
process takes less than 30 seconds to run. It is both a diagnostic routine that displays
values, and a routine that sets the parameters of the control for the particular machine.

The Code 12 is used for diagnosing and resolving:

• Problems with machine motion.

• Machined parts come out bad – especially poor finish.

Note: Code 12 routine will set the parameters for the particular machine and its
particular situation. If the machine changes its friction characteristic, the Feed Forward
Constant should change too, or the system will not servo properly. Whenever gibs are
adjusted or a heavy workpiece has been added to the table, you should run a Code 12.
When the heavy workpiece is removed, Code 12 should be run again.

1. Position the table and 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 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 e ach 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.

The feed forward gain can b e 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

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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.

4.8.2.2 CODE 97 set positive motor encoder direction.

This procedure sets the Plus and Minus motion for the Motor encoders.
It may be necessary to perform this procedure after a new installation or after installing a

new Computer Module.

STEPS:

1. Center the table and saddle and position the quill about ha lfway down.

2. Go into Service Codes and input Code 97.

3. Very carefully, move the table, the saddle and the quill in the positive direction, less

than 2 inches for each axis. Positive motion is:

• X – cross slide moves toward the operator

• Z – saddle moves along the bed ways away from the spindle.

If you do not move correctly from the beginning, repeat the procedure.

4. Press INC SET to signal the procedure is complete.

4.8.2.3 CODE 100: Axis Op e n L o o p Test

Code 100 procedure is used to diagnose problems with the configuration of the system,
the encoders and incoming A/C voltage.

CAUTION!

During this procedure, the designated axis will be given a command to move at maximum speed

for 1 second in the direction you choose. Avoid crashes by making sure the table and saddle are

centered. MAKE SURE THAT NO ONE IS STANDING IN THE WAY OF THE 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 cross slide and saddle. Make sure the gib locks are released.

2. On the Pendant display, go into the Service Codes and input the Co de 100.

3. The conversation line will say: “SELECT AXIS”. Input the axis. Either X or Z.

4. In the conversation line it will say “WHICH DIRECTION? PLUS”.

• If you want to run in the plus direction, press INC SET.

• If you want to run in the minus dir ection, press +/-, then INC SET

5. In the conversation line it will say “PRESS GO”. Press Go after you are sure that the

machine will not crash in the direction and axis that you have specified.

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X +

X

Motor encoder reading

Your input

X

Motor encoder reading

Your input

X

nothing (should be 0 )

Your input

Z -

Z

Motor encoder reading

Feedrate

the maximum feedrate attained

6. Afterward the screen will display values next to the DRO position axes. The DRO

value should match actual travel distance.

Your input Display Data displayed.

Z nothing (should be 0 )
Feedrate the maximum feedrate attained

X - Z nothing (should be 0 )

Feedrate the maximum feedrate attained

Z + Z Motor encoder reading

Feedrate the maximum feedrate attained

X nothing (should be 0 )

Interpretation of the resulting values displayed:
The values for the encoder displays should be in the range of 3.0000” to 5.0000”.

• If the motor encoder is not within this value, then the one that is out of specification

may be the problem.

• The feedrate should be a minimum of 120 ipm.

• If the feedrate is less than 120 ipm and inconsistent in both directions, check the

incoming AC voltage and m echanics of the drive train.

4.8.2.4 CODE 123: Calibration

See Section 5.2.2.1 for a further explanation of this code.

4.8. 2.5 CODE 127 - Set X or Y Backlash Constant

See Section 5.2.2.2 for a further explanation of this code.

4.8.2.6 CODE 128: Input Bac klas h C on s tant

Code 128 allows you to enter the backlash values for each axis. It displays the value
after it enters.

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4.8.2.7 CODE 308: Reverse X Hand Wheel Direction

This code reverses the direction of the X-axis hand wheel

4.8.2.8 CODE 310: Reverse Z Hand Wheel Direction

This code reverses t h e direction of the Z-axis hand wheel

4.8.3 Diagnostic Codes

The following codes are used primarily when diagnosing a problem with the machine.

4.8.3.1 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.

1. Prepare a program as you normally would.

2. Press MODE, SET UP, “C”, Code 54, INC SET. The program run will start automatically.

3. Press STOP to stop, and GO to continue.

4.8. 3.2 CODE 81: Keyboar d 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 wo rk 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.

4.8.3.3 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.

4.8.3.4 CODE 132: Electronic Hand Wheel Test

Turn the X or Z-axis electronic hand whee l. The display should show movement as the
Handwheel is being tur ned. There should be no skipping and is should co unt smoothly
while the hand wheel is being turned. One revolution of the hand wheel should read

0.4000” for X and Z in course, and 0.100” in fine mode.

4.8.3.5 CODE 133: Spindle Encoder Test

This code ensures that the proximity sensor on the spindle is counting correctly. After
entering this code, the spindle can either be turned on or can be turned manually. Every
full revolution of the spindle will cause the X value on screen to increase by one. If the
spindle is turned on, then the Z value on screen will calculate the actual RPM by the
proximity sensor count.

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4.8.3.6 CODE 319: E rror Log

This service code keeps track of all commands being sent to the servo system. This may
be asked for when troubleshooting a problem specific to motion of the ProtoTRAK.

4.8.3.7 CODE 320: Histo r y L o g

This code keeps track of incidents such as servo faults and software updates, and allows
for it to be saved onto a USB drive. This is useful for keeping track how often an error
occurs. You may be asked by a customer service representative to send in for
evaluation.

4.8.3.8 CODE 326: Error Message Display

This code describes the various error messages.

4.8.3.9 CODE 327: Check Available Memory

This code monitors how much memory (RAM) is available within the system, as well as
much space is available within our internal storage device.

4.8.3.10 CODE 329: Tes t Front Pa n e l Ba c kl i g h t

This code tests the backlight on/off function. After entering this code, the backlight will
turn off for three seconds and then turn back on.

4.8.3.11 CODE 332: Load/Save Tool T able

This code allows the user to save a tool table from the control onto a USB drive, or load a
tool table from a USB drive to the control.

4.8. 3.12 CODE 342: To g g l e t e st lig ht s on or o ff

Use this service code to toggle a set of test lights visible on screen. The top green light
will blink indicating that our operating system and User Interface software is responding
properly. The middle orange light is to indicate that commands are being sent to our
servo system. The bottom turns red when our servos are in position, and green when
they are not.

4.8.4 Operator Defaults/Op ti on s Codes

The following codes allow the user to set programming defaults or turn features on or
off.

4.8. 4.1 CODE 22: Tur n o n S imulatio n Mod e

This code allows the ProtoTRAK to emulate RUN, POWER FEED, and JOG modes without
having to move the servos.

4.8.4.2 C O D E 66: Met r i c Mod e

This code gives you the choice of switching to Metric Measurements for temporary use or
setting Metric as the default, which means it will not change unless you change it with
code 67.

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4.8.4.3 CODE 67: English Mode

This code gives you the choice of switching to English (inch) Measurements for temporary
use or setting English as the default, which means it will not change unless you change it
with code 66.

4.8.4.4 CODE 79: Beepe r On

This turns on the beeper to t he control keys.

4.8.4.5 CODE 80: Beepe r Off

This turns off the beeper to the control keys.

4.8.4.6 CODE 89: Turn o f f S imulation Mode

Use this code to turn off the simulation mode and return to normal operation.

4.8.4.7 CODE 129: Arc Accuracy

When the ELX 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 Err or use the following procedure:

Follow the inst ructions on the screen and input the Following Error value (from .0001 to

.0100) and press INC SET.

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5.0 Procedures for Replacements & Maintenance

WARNING!

5.1 Replacements

5.1.1 Servo Motor Replacement

1. Turn off power to the machine.

2. Each motor is mounted by the use of (4) ¼-20 screws. Be careful not to over

tighten these bolts and strip the threads.

Do not work with the Servo Motors unless the power is disconnected from the machine. The

servo motors are run by 110 VAC. There is possibility of death by electrocution!

5.1.2 Motor brush replacement

1. This procedure assumes the motor assembly has either been removed from the
machine and/or no power is applied to the machine.

2. When the motor is mounted to the casting that holds t he Servo Driver, it is
necessary to remove the four Phillips head bolts at the shaft end of the motor,
which hold the motor to the housing to access all four brush assemblies. DO NOT
Remove/Disconnect any wires, it is not necessary.

3. Before removing caps, please note they are made of plastic and care must be
taken when removing them to not damage the screw slots. To this end, apply
firm downward force while gently turning the caps counter clockwise.

4. Note there are four (4) caps to be removed to access and replace all of the brush
assemblies. When the caps are loose and before removing it, hold your finger
over the top of the cap/ ho le to contain the parts

5. Remove the O-ring, Keeper and brush assembly.

6. Insert new brush assembly, re-insert keeper (Note: No Keeper is used on the
Hathaway/EmoteQ Motor) and install new O-Ring taking care to use the edge of
a small screw driver to gently force the O-Ring into the hole down onto the
Washer/Keeper. If the O-ring is installed properly, it will hold the brush assembly
in place while you install the cap.

7. Install Cap to complete installation and repeat this process for the remaining
three (3) brush assemblies.

8. Re-assemble motor to housing while p ushing wiring back into housing taking
care to not pinch it.

9. Re-install the assembly to the machine.

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5.1.3 Servo Driver Replacement

WARNING!

DANGER!

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.

Always engage (push in) the Emergency Stop switch, turn the ProtoTRAK ELX Control

off, and disconnect the servo driver cable at the cable breakout box.

1. Press in the Emergency Stop.

2. Remove the servo motor/driver assembly from its mounting bracket.

3. Remove the 10 cap screws that hold the servo driver and its heat sink plate to the motor
casting.

4. Disconnect the cable connector. Do not pull on the wires.

5. Reinstall the new servo driver with its heat sink plate. Be certain the gasket
properly seals the assembly.

6. Reinstall the motor/driver assembly. Make certain the belt is tight so that there
is little play if pinched in the middle.

5.1.4 Computer Module and LCD Enclosure Replacement (figure
5-1)

If it is determined that these components are faulty, it will be necessary to exchange the
entire pendant.

1. Turn off power to the machine and control.

2. Unplug all the connectors from the rear of the pendant.

3. Remove the pendant from the pendant arm by removing the 3/8 – 16 bolt and
nut that secures it in place.

4. Place the pendant assembly on a clean and secured table with the display
pointing away from you.

5. Remove the (6) 8-32 x 3/8" Pan Phillips head screws securing the computer
module to the LCD/enclosure.

6. Pull the computer module a few inches and stop. Pull ing the computer module
too far will damage the ribbon cables.

7. Reach from the top and remove the overlay cable and LCD cable from the
computer module. The LCD cable will have some RTV holding it in place.

8. Remove the two E-stop wires, LCD inverter cable, and the ground wire from the
LCD/ enclosure side.

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9. Replace the computer module or LCD/enclosure.

10. Follow the instructions in reverse order when reinstalling the new computer
module or LCD/enclosure. Make sure that all connectors are properly seated
before fastening the unit back in place.

Figure 5-1

Computer Module and LCD/Enclosure Replacement

Item P/N Title Use Qty

1 21824-8 Fuse – 8 Amp Slow Blow EA 1
2 21824-10 Fuse – 10 Amp Slow Blow EA 1
3 26027-32 Memory – IDE Flash EA 1

5.1.5 IDE Flash Disk Replacement

1. From the control, go the SETUP, SERV CODES, SECTION A, and then code 142,
and save your Configuration file (calibration values, e tc.) to a USB thumb drive.
Run code 340 to save your parts programs.

2. Turn off the power to the machine and control.

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3. Unplug all the connectors from the rear of the pendant.

4. Remove the pendant from the pendant arm by removing the 3/8 – 16 bolt and
nut that secures it in place.

5. Place the pendant assembly on a clean and secured table with the disp lay facing
away from you.

6. Remove the (6) 8-32 x 3/8" Pan Phillips head screws securing the computer
module to the LCD/enclosure.

7. Pull the computer module a few inches and stop. Pull ing the computer module
too far will damage the ribbon cables.

8. Reach from the top and remove the overlay cable.

9. Remove the IDE flash drive from the motherboard. Remove the extra adhesive
from the motherboard.

10. Firmly insert the replacement IDE flash drive into the motherboard. While
pressing in the replacement, be sure the pins line up correctly. Secure the
connector with RTV adhesive such as REP Fast Gasket adhesive, P/N 1430.

11. Secure the computer module back to the LCD/enclosure by following the
instructions in reverse order.

12. Make sure that the overlay cable is properly seated before fastening the unit
back in place.

13. Turn on the power to the machine and control.

14. Update the system software by inserting a thumb drive that contains updated
system software from our website (
service code 316 found in section A to update the software.

15. Use service code 141 to restore the configuration file saved on your USB thumb
drive if you were able to save it using code 142. Otherwise, do the calibration
and backlash procedures described in 5.2.2

www.southwesternindustries.com). Use

5.1.6 Electronic Handwheels

There are 2 electronic handwheels. Each unit is replaced as an assembly. Disconnect
the handwheels from the apron cable. (See figure 6-1)