prototrak 1840V Maintenance Manual

Document: P/N 24970

Service Department: 800.367.3165

TRAK® TRL 1540V, 1840V,

& 2460V Lathes

Safety, Installation, Maintenance Service & Parts List Manual

Service Manual for Non-Current Lathe Products

Version: 062211

Covering Machine Models:

• TRAK TRL 1540V

• TRAK TRL 1840V

• TRAK TRL 2460V

Covering Non-current Control Models:

• ProtoTRAK VL

Southweste rn Industries, Inc.

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

e-mail: [e-mail] | [e-mail] | web: southwesternindustries.co m

Copyright © 2007, Southwestern Industries, Inc. All rights are reserved. No part of this
publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by
any means, mechanical, photocopying, recording or otherwise, without the prior written
permission of Southwestern Industries, Inc.

While every effort has been made to include all the information required for the purposes of this
guide, Southwestern Industries, Inc. assumes no responsibility for inaccuracies or omission and
accepts no liability for damages resulting from the use of the information contained in this guide.

All brand names and products are trademarks or registered trademarks of their respective
holders.

Southwestern Industries, Inc.
2615 Homestead Place
Rancho Dominguez, CA 90220-5610
Phn 310/608-4422
Service Department
Phn 800/367-3165

 Fax [phone]
 Fax [phone]

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

Table of Contents

1.0 Safety Specifications

1.1 Safety Publication s 1

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

1.3 Safety Precautions

2.0 Installation

2.1 Floor Plan, Layout & Space Requirements

- 1540V, 1840V, & 2460V 6

2.2 Lathe Specifications

2.3 Uncrating

2.4 Shortages: Inventory Checklist

2.5 Installation Instructions & Checklist

2.6 ProtoTRAK VL Control Hardware

2.7 Lifting and/or Moving the Machine

2.8 Cleaning

2.9 Leveling

2.10 Electrical Connection

2.10.1 Phase Converters

2.11 Air Connection

2.12 Mounting the Display Pendant

2.13 Cable Interconnections

2.14 Lubrication

2.14.1 Lube Pump Operation

2.14.2 Factory Default Values

2.14.3 1840V & 2460V Headstock Oil

Reservoir

2.15 Cutting the Test Part

2.16 Measurement of the Test Part

2.17 Mounting the A2-5 Chuck

3.0 Troubleshooting by Symptom

3.1 Problems Relating to Machining Results 23

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 Moti on i s not Smoot 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 B

3.3.3 Keyboard Lockup

3.3.4 Fault X or Z

3.3.5 Problems Reading the Floppy Disk;

3.3.6 System Will Not Turn On or

3.3.7 System Reboots by Itself

3.3.8 System Shuts Off

3.3.9 Will Not Hold Calibration

ad Picture on the Display

Programs not Saved Properly
Boot-Up

3.3.10 E-Stop Error

3.3.11 Motor Alignment Routine Does Not
Work Properly

3.3.12 Limit Switch 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-2460V Only

3.5.5 Headstock is Leaking Oil

-2460V Only

3.5.6 Tailstock Barrel is Stiff

4.0 Diagnostics

4.1 The Machine Tool & Set Up 39

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 Motor Alignment Routine

4.4.2 Cable Connections

4.4.3 To Check the Motor Encoders

4.4.4 E

4.4.5 Moving Problem from One Axis

4.5 Servo Drivers

4.5.1 Cap Block

4.5.2 Servo Driver Cooling Fan

4.5.3 Servo Driver Fault Codes

4.6 Electrical

4.6.1 Power Module

4.6.2 Drive Module

4.6.3 Spindle Auxiliary Module

4.6.4 Encoder Module

4.6.5 Cable Connections

4.6.6 Checking A/C Voltage

4.7 Door & Gear Switch

4.8 Service Codes

4.8.1 Software Codes

4.8.2 Machine Set-Up Codes

4.8.3 Diagnostic Codes

ncoder Counts to Pendant

to Another

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

4.8.4 Operator Defaults/Options Codes

4.8.5 Lube Pump Cod es

5.0 Procedures for Replacements &
Maintenance

5.1 Replacements 62

5.1.1 Servo Motor Replacement

5.1.2 Servo Drive Replacement

5.1.3 AC Spindle Drive Replacement

5.1.4 Computer Module Replacement

5.1.5 Hard Drive Replacement

5.1.6 Electronic Handwheels & Jogstick

5.1.7 Cable Routing in Electrics Box

5.1.8 Spindle Encoder Replacement

5.1.9 Spindle Drive Belt Tightening/

Replacement

5.1.10 Spindle Motor Removal

5.1.11 X-Axis Ball Screw Removal

5.1.12 Installing Angular Contact Bearings

5.1.13 Z-Axis Ball Screw Removal

5.1.14 Align Z-Axis Ball Screw Assembly

5.1.15 1840V & 2460V Headstock Taper

Adjustment

5.1.16 1540V Headstock Taper Adjustment

5.1.17 Aligning Tailstock to Spindle

5.1.18 Spindle Motor Wiring

5.1.19 Spindle Cartridge Replacement-

1540V Only

5.2 Maintenance

5.2.1 Gib Adjustments

5.2.2 Calibration & Backlash Constants

5.2.3 Lubrication

5.2.4 X & Z Limit Switch Adjustments

6

.0 Indexer Options

6.1 Dorian Indexer Option 100

6.1.1 Field Installation Instructions

6.1.2 Removing the Indexer from

the Lathe

6.1.3 Troubleshooting the Indexer

6.1.4 Troubleshooting from LED’s

in Black Box

6.1.5 Indexer Encoder Re-Alignment

6.1.6 Indexer Maintenance

6.1.7 Warranty Issues

6.2 4 Tool Indexer Option

6.2.1 Field Installation Instructions

6.2.2 Removing the Indexer from

th

e Lathe

6.2.3 Troubleshooting the Indexer

6.2.4 Troubleshooting the Cable

Breakout Box

Figure List

Fig. 2-1 2460V Lathe
Fig. 2-2 1540V Lathe
Fig. 2-3 1840V Lathe
Fig. 2-4 Lifting the Lathe-1540V & 2640V
Fig. 2-5 Leveling
Fig. 2-6 Wiring the 1540V & 2640V
Fig. 2-7 Pendant Cable Connection –Left Side

Fig. 2-8 Pendant – Right Side
Fig. 4-1 Electrical Cabinet
Fig. 5-1 Motor Assembly
Fig. 5-2 Drive Module
Fig. 5-3 A/C Spindle Drive
Fig. 5-4 Computer Module & Hard Drive

Replacement
Fig. 5-5 Spindle Motor Belt Replacement
Fig. 5-6 X-Axis Drive Train – 1540V
Fig. 5-7 X-Axis Drive Train – 2460V
Fig. 5-8 Angular Contact Bearing
Fig. 5-9 Z-Axis Drive Train – 1540V & 1840V
Fig. 5-10 Z-Axis Drive Train – 2460V
Fig. 5-11 1840V & 2460V Headstock Taper
Adjustment
Fig. 5-12 1540V Headstock Taper Adjustment
Fig. 5-13 Tailstock Adjustment
Fig. 5-14 Spindle Motor Wiring
Fig. 5-15 1540V Headstock Cartridge Removal
Fig. 5-16 X-Axis Gib
Fig. 5-17 Z-Axis Gib
Fig. 5-18 Calibration Set-Up
Fig. 5-19 Headstock Oil Removal
Fig. 5-20 1540V & 2460V
Fig. 5-21 Tailstock Lubrication
Fig. 6-1 Indexer Mounting
Fig. 6-2 Indexer Cable Routing
Fig. 6-3 Motor Drive Adjustments &

PLC Inputs & Outputs
Fig. 6-4 Indexer Mounting – 1540V & 2460V
Fig. 6-5 4 – Tool Indexer Cable Routing

7.0 Drawings & Parts Lists

Fig. 7-1 2460V Overall Machine Drawing 114
Fig. 7-2 2460V Overall Machine Drawing
Fig. 7-3 2460V Overall Machine Drawing
Fig. 7-4 2460V Overall Machine Drawing
Fig. 7-5 2460V Headstock Drawing
Fig. 7-6 2460V Headstock Drawing
Fig. 7-7 2460V Carriage Side View
Fig. 7-8 2460V Tailstock Assembly
Fig. 7-9 2460V Tailstock Assembly
Fig. 7-10 2460V Tailstock Assembly
Fig. 7-12 1840V Bed and Chip Pan page
Fig. 7-13 1840V Splash Guard & Cover
Fig. 7-14 1840V Headstock Assembly
Fig. 7-15 1840V Headstock Assembly
Fig. 7-16 1840V Tailstock Assembly
Fig. 7-17 1540V Spindle Encoder Drive Assembly
Fig. 7-18 1540V Steady Rest
Fig. 7-19 1540V Overall Machine
Fig. 7-20 1540V Overall Machine
Fig. 7-21 1540V Overall Machine
Fig. 7-22 1540V Overall Machine
Fig. 7-23 1540V Overall Machine
Fig. 7-24 1540V Tailstock Assembly
Fig. 7-25 1540V Tailstock Assembly
Fig. 7-26 1540V Tailstock Assembly
Fig. 7-27 1540V Bed & Carriage
Fig. 7-28 1540V Bed & Carriage
Fig. 7-29 1540V Bed & Carriage
Fig. 7-30 1540V B

ed & Carriage

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

Fig. 7-31 Lathe Apron Assembly
Fig. 7-32 Pendant Bracket Kit
Fig. 7-33 Auxiliary Module Diagram
Fig. 7-34 Power Diagram
Fig. 7-35 Encoder Diagram
Fig. 7-36 Spindle Drive System
Fig. 7-37 Servo Drive System
Fig. 7-38 Servo Drive Output
Fig. 7-39 Cable Set

1

Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoT RAK VL C NC Safet y, Installation, M aintenance, Serv ice & Parts List M anual

1.0 Safety Specifications

The safe operation of the TRAK TRL 1540V, 1840V, and 2460V lathe depends on proper use and
the precautions taken b y each operator.

• Read and study the machine’s corresponding 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 1540V, 1840V, 2460V 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

1.1 Safety Publications

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

its use.

before

servicing.

Safety Requirements for Manual Turning Machines with or without Automatic
Control (ANSI B11.6-2001). Available from the Ame r i ca n N ational Standards
Institute, 1819 L Street N. W . , Washington, D.C. 20036.

Concepts And Techniques Of Machine Safeguarding (OSHA Publication Number

3067). Available from The Publication Office - O.S.H.A., U.S. Department of
Labor, 200 Constitution Av e n u e, NW, Washington, DC 20210.

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

1.2 Danger, Warning, Cau tion, and Note Labels 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 o n 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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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoT RAK VL C NC Safet y, Installation, M aintenance, Serv ice & Parts List M anual

220 Volts

Safety & Information Labels Used On The

TRAK TRL 1540V, 1840V & 2460V Lathe

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

remove any of these labels

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoT RAK VL C NC Safet y, Installation, M aintenance, Service & P arts List M anual

Power Requirements at 220 Volts, 3-phase 60 HZ

Model

Full-load Amp of Machine

Full-load Amp of Largest Motor

Safety & Information Labels Used On The

TRAK TRL 1540V, 1840V, & 2460V Lathe

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

remove any of these labels

1540V 47 33
1840V 36 33
2460V 59 45

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoT RAK VL C NC Safet y, Installation, M aintenance, Serv ice & Parts List M anual

1.3 Safety Precautions

WARNING!

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

1. Do not operate this machine before the machines’ corresponding Programming, Operating
and Care Manuals have been studied and understood.

2. Read and study this TRAK TRL V 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 the machine without knowing the function of every control key, button, knob, or
handle. Ask your supervisor or a qualified instructor for help w hen 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 the 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.

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

before

servicing.

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.

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.

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoT RAK VL C NC Safet y, Installation, M aintenance, Service & P arts List M anual

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 machining 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.

6

Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoT RAK VL C NC Safet y, Installation, M aintenance, Serv ice & Parts List M anual

2.0 Installation

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

2.1 Floor Plan, Layout & Space Requirements

– 1540V, 1840V, & 2460V

Figure 2-1
2460 V Lathe

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRA K VL CN C Safety , Installation, M aintenance, Serv ice & Parts List M anual

Figure 2-2
1540V Lathe

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoT RAK VL C NC Safet y, Installation, M aintenance, Serv ice & Parts List M anual

Height of Centers

8”

9”

11.5”

Swing Over Cross Slide

6 5/8”

9”

14.5”

Coolant

12 gal.

13 gal.

15 gal.

Width

12 5/8”

14 ½”

15.75”

Figure 2-3
1840V Lathe

2.2 Lathe Specifica tions

Capacity 1540V 1840V 2460V

Distance Between Centers 40” 40 ¼” 60”
Swing Over Bed 15” 18 ½” 24”
Swing Over Saddle Wings 15” 17” 24”

Cross Slide Travel 11 ½” 13” 12.5”
Tool Section Max. ¾” 1” 1 ¼”

Oil Pump – Way Lubrication 2 liter 2 liter 2 liter
Oil Reservoir – Headstock None 3.5 gal. 3 gal.
Bed

Height 12 5/8” 13 3/8” 12 5/8”
Headstock

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRA K VL CN C Safety , Installation, M aintenance, Serv ice & Parts List M anual

Spindle Nose A2-5 D1-6 D1-8

Spindle Taper

MT #6

MT #6

MT #8

Number of Spindle Speed

1 2 2

Quill Travel

6 ½”

6 ¼”

12” 2 speed

Spindle Motor

H.P.

10

10

15

Phase, Hz

3/60

3/60

3/60

Dimensions

Other

Way Surface Hardness

400 – 450 HB

Chuck

6”, A2-5

8”, D1-6

12”, D1-8

Spindle Through Hole 2 1/8” 2.36” 4.09”

Taper in Reduction Sleeve MT #4 MT #4 MT #5
Spindle Diameter Front
Bearing
Number of Bearings 5 3 2
Bearing Class (Radial Runout) P2 (ABEC 9) P5 P5

Ranges
Spindle Speed Range (RPM) 150–4000 80–850, 250-2500 40-670, 100-1800
ID Thread on End of Spindle N/A M62 X 2MM Pitch M106.5 X 1.5MM Pitch
Tailstock

Quill Diameter 2 3/8” 2.95” 3.5”
Quill Taper Hole MT #4 MT #5 MT #5

Voltage 220 220 220
Amps, Full Load 47 36 59

Net Inches L x W x H lbs. 89 x 53 x 70, 4100 91 x 53 x 70, 4500 113 x 58 x 74, 7300
Ship Inches L x W x H lbs. 90 x 55 x 73, 4650 97 x 58 x 72, 5170 117 x 59 x 77, 8000

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

3.15” 3.35” 5.51”

Headstock Lubrication *Grease Oil Bath Oil Bath
Options
Tooling Kit ¾” ¾” ¾” or 1”

5C Collet Closer A2-5 D Camlock n/a
Indexer Option ¾”, 8 Position

¾”, 4 position

Gang Tooling ¾” ¾” n/a

¾”, 8 Position
¾”, 4 Position

1”, 8 position
1”, 4 position

* No maintenance grease cartridge

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoT RAK VL C NC Safet y, Installation, M aintenance, Serv ice & Parts List M anual

ATTENTION!

2.3 Uncrating

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

Remove the cardboard boxes with the PENDANT DISPLAY (handle carefully). The
leveling pads and screws for the machine can be found in the toolbox.

Loosen and remove 4 screws for the 1540, 6 screws for the 1840V, and 8 screws for the
2460V and the 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 m achine.

2.4 Shortages: Inventory Checklist

______Machine (check model and serial number)

______ Leveling pads and screws (4 each for 1540V, 6 each for the 1840V, and 8 each

for 2460V)
______ Pendant Display – 22328-2
______ Pendant Cable Cover (22401)
______ Toolbox wi th various tools
______ 1540V, 1840V, & 2460V Safety, Operation & Programm ing Manual (P/N 24492)

______ 1540V, 1840V, & 2460V Safety, Installation, Maintenance, Service & Parts List Manual (P/N

24970)

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

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRA K VL CN C Safety , Installation, M aintenance, Serv ice & Parts List M anual

2.5 Installation Instructions & Checklist

3.

Clean the machine if needed and remove any remaining grease.

6.

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

10.

On the 2460 verify oil is reaching the site glass. Oil is only flowing when the spindle is on. Also

13.

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



14.

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

17.

Open and close the door and verify the door switch is functional. The control should display a

20.

Perform Service Code 12, Feed Forward Constant.



21.

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

Installer: Use this checklist to assure a complete set-up of the 1540V, 1840V or 2460V.



1.

Shut off power to the machine.



2. Visually inspect the 220-wiring going into the electrical panel. Visually verify the wiring is correct
per our wiring diagram. Make sure a strain relief is being used where the wiring enters the
cabinet. Have the customer repair any wiring discrepancies.




4.

Mount the pendant on top of the sliding door. Make sure the pendant swivels and slides easily.



5. Make and check all the proper electrical connections from the pendant to the electric box. See
the pendant and electric box wiring diagrams. Be sure to mount the cable cover to the left side
of the pendant along with the servo cable bracket to ensure the cables stay in place. Note: the
servo drive cables plug into the top and bottom connector, the middle connector is not used on
the lathe 1540V, 1840V, & 2460V




7.

Remove the protective plastic covers from the headstock and the windows on the sliding doors.



8. Turn on the power to the machi ne and to the pendant. Make sure that the 220V line is plugged
in. Check the voltage coming out of the transformer across the 115V and 0V taps. The
acceptable range is between 110V and 130V. Adjust taps as necessary. See section 4.6.6 for
instructions.



9. Perform motor alignment routine. Press Check System key on boot up screen. It can also be
accessed through Se rvice Code 203 for the 1540V and 1840V and code 204 for the 2460. This
must be done initially before the machine can be moved. Use the handwheels first to move the
carriage away from any obstructions. Total movement will be approximately 1” in all directions.
See Section 4.4.1.



make sure the coolant pump is rotating in the correct direction.



11. Lubricate all the way surfaces and the ball screws. Under service codes press code 300 to operate
the lube pump.



12. 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.



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



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



16. 1840V & 2460V only – shift the headstock in low and high gear and veri fy the control recognizes
each gear. To run the spindle a maximum RPM must be set in SETUP mode.



message of “DOOR OP EN” in DRO mode when the door is open and it should disappear when the
door is closed.



18. Make sure the X and Z electronic handwheels and jogstick are funct ional.



19. Check to make sure that the E-Stop buttons on the pendant and door for the 1540V and 1840V
and pendant and apron for the 2460V are functioning correctly.





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



23. Check for positional accuracy and repeatability on the X and Z-axis using programs X LATHE
REPEAT.PT4 and Z LATHE REPEAT.PT4 respectively. Positioning and repeat ability values should
be less than or = to 0.0005”. Programs can be found on hard drive under the PT4 folder followed
by the SWI TEST PROGRAMS folder. Note: the door must be closed to run these programs.

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoT RAK VL C NC Safet y, Installation, M aintenance, Serv ice & Parts List M anual

26.

Use accessory key on pendant and make sure the coolant pump turns on. The accessory key

29.

Wipe down the machine prior to leaving.



24. 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 300 ipm.



25. On the 2460V and 1840V, run the spindle throughout each gear range at various speeds. On the
1540V, run the spindle at various speeds throughout the 150 to 4000 RPM range.



should be in the ON position in DRO to test.



27. Check to make sure the limit switches are functioning properly.



28. 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.



CAUTION!

If the TRAK TRL 1540V has a chuck mounted to the spindle, make sure t he 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 TRAK TRL 1840V & 2460V has a chuck mounted to the spindle, make sure the cam locks are tight, and

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 unknow n, do not run the chuck over 1000 rpm.

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

2.6 ProtoTRAK VL Control Hardware

• 2-axis CNC, 2-axis DRO

• 266 PC-based processor

• 64 MB of RAM

• A.C. Servo Motors rated at 704 in-oz continuous torque for X and Z-axes

• Precision ground ballscrews in the carriage and cross slide to ensure smooth accurate

contours without backlash

• Feedrate override of programmed feedrate and rapid

• Programmable Spindle Speed

• Speed override of programmed spindle speed

• Polycarbonate sealed membrane and gasket sealed control enclosure to lock out contamination

• 10 ½" color LCD for clear presentation of prompts, status information and part graphics

• RS232 port for interface to comput ers

• Modular design simplifies service and maximizes uptime

• 10 GB minimum hard drive

• Single floppy disk drive for additional part program storage

• Limit switches for the X and Z-axes that are installed to prevent crashes.

• Electronic handwheels on the X and Z-axes.

2.7 Lifting and/or Moving the Machine

CAUTION!

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRA K VL CN C Safety , Installation, M aintenance, Serv ice & Parts List M anual

The 1540V, 1840V, and 2460V machines weigh approximately 4100, 4500, and 7300 lbs. re spectively.

Proper equipment of sufficient capacity must be used when lifting and/or moving the machine.

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

Figure 2-4
Lifting the Lathe – 1540V, 1840V, & 2460V

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TRAK TRL 1540V, 1840V, 2460V & ProtoT RAK VL C NC Safet y, Installation, M aintenance, Serv ice & Parts List M anual

WARNING!

Do not attempt to lift this machine with a forklift having less than 10000 lb capacity for
the 1540V and 1840V and 15000 lb for the 2460V. The shipping weight of the machine
including electronics is 4650, 5170, and 8000 lbs respectively for the 1540V, 1840V, and
2460V.

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 four (4) for
rest pads for the 1540V, six (6) rest pads for the 1840V, and eight (8) rest pads for the
2460V.

For proper operation, the machine should be set on a substantial floor capable of
supporting the weight safely. For the location of the bolt holes, size, and recommended
mounting, see Figures 2-1, 2-2, & 2-3.

2.8 Cleaning

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

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

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.

CAUTION!

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

to the TURCITE surface of slideways can occur.

4. Be certain the carriag e, cross slide and spindle move freely and smoothly over their
entire length.

2.9 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 8/6/4 rest pads, it must be leveled by the
use of the 8/6/4 leveling bolts. It is important that the lathe be level in order to produce
accurate work. It may be necessary to l ag bolt the machine in order to eliminate a small
amount of twist.

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 of the bedways (Figure 2-5,
Positions B & C). To take a reading off the level transversely, place it on top of .7500"
parallels at each end of the bedways (Figure 2-5, Positions A & D).

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WARNING!

Figure 2-5
Leveling

I00193

Using the four (4) interior leveling screws (see Figure 2-5) on the lathe base, level the
bedways longitud inally within .0008" over the total length and transversely within .0005"
inches. After leveling with the four (4) interior leveling screws, bring the two (2) exterior
leveling screws (see Figures 2-1, 2-2, & 2-3) into contact with the leveling pads using
care not to disturb the level. The 1540V lathe only has 4 leveling screws.

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

2.10 Electrical Connecti on

The 1540V, 1840V, & 2460V Lathes can only be configured for 208-240 volt 3-phase
electricity. To run at 440V, you will need a step down transformer from 440V to 220V
and rated at a minimum of 20 KVA for the 1540V and 1840V and 23 KVA for the 2460V.

DANGER!

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

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

440 Volts will damage expensive electrical components if machine is wired by mistake as 440

volts. These components are not covered under warranty. The circuit breaker for the machine

should be a minimum of 60 amps for the 1540V and 60 amps for the 1840V and the 2460V.

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DANGER!

DANGER!

The 208-240 volt line must originate from a dedicated and ind ependent fused box with a m anual

shut-off lever. It is the responsibility of the purchaser to supply a wired box that meets all local

codes and regulations.

The

208-240 volts wires to the machine through the electrical box located on the back of

the column. The wire enters the main on/off switch through a hole on the top of the
box. The ground wire should be connected at the top or bottom of the breaker bracket.

Only a qualified electrician should wire the 208-240 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.

2.10.1 Phase Converters

For those machines that will be run with a phase conver ter 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-var ying load. The phase
converter for the 1540V should be rated for 25 to 30 K VA, the 1840V machines sho uld be
rated for 20 to 25 KVA , and the 2460V machines should be rated for 30 to 35 KVA.
Please contact your local phase converter distributor for precise sizing.

Machine Type
220V
1540V ~25-30 47
1840V ~20-25 35
2460V ~30-35 59

Phase Converter Size
Recommended Range

Site Prep FLA

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Southwestern Industries, Inc.

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Figure 2-6
Wiring the 1540V, 1840V, & 2460V

2.11 Air Connection

The 1540V, 1840V, & 2460V machines have an air hookup in the rear of the machine only
if they come with a Dorian ind exer option.

The air regulator is set to 90 psi at the factory for the indexer unit.

2.12 Mounting the Display Pendant

The ProtoTRAK VL display pendant mounts to the top of the sliding doors and is held to
an L bracket with 4 soc ket head cap screws.

Make sure the pendant rotates freely from side to side.
Make all of the cable connections to the left side of the pendant and cover these cables

with the cable cover provided with the machine. Also make sure to fasten the servo
cables with the bracket provided.

2.13 Cable Interconnections

All cable interconnections are made at the factory except for those connecting to the
pendant display. There are a total of 8 cables that need to be connected to the pendant.
See Section 7 for a complete illustration of cable interconnections for all components.

With the main power to the machine turned off plug in the connectors that are bundled
on the pendant arm. Each cable mates to only one connector on the pendant display
back panel. Each cable is labeled with a sticker. Use the key on the pendant to match up

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the connectors with the correct port. The parallel port will have a key plugged into this
port. The monitor port, RS232 and network ports will be left empty during installation.

Make sure there is sufficient slack in the cables for when the pendant is rotated a bout the
pendant arm. The following drawing describes all of the cable conne ctions to the
pendant. Make sure to plug the servo cables into the X and Z ports on the pendant. The
Y-axis port is left empty. These cables also have a bracket that is used to fasten the
cable securely to the pendant. Failure to install this bracket could cause intermittent
problems.

Make sure there is a hardware (option) key plugged into the parallel port of the pendant.
This key activates any converters or options ordered. The part number for this key is

22648. The key must be programmed according to the type of machine it is on and the

options ordered.

CAUTION!

Make sure the main power switch is turned off on the back of the electrical cabinet before

plugging in the cables.

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRA K VL CN C Safety , Installation, M aintenance, Serv ice & Parts List M anual

Figure 2-7
Pendant Cable Connections
Left Side

Figure 2-8
Pendant
Right Side

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CAUTION!

CAUTION!

CAUTION!

2.14 Lubrication

The 1540V, 1840V, and 2460V auto lube system provides centralized automatic
lubrication for the carriage, cross slide and ballscrews. The lube pump has a 2-liter
reservoir filled with Mobil Vactra Oil No. 2.

Oil that is too heavy and viscous such as 50W or 90W oil can clog oil line tubing. Do not mix detergent

type automotive or multi-purpose oils with the Mobil Vactra Oil No.2 used in this application.

The lube pump has electronic memory, which acts as an internal clock to keep track of
the running time of the axis motor. Even when the spindle i s turned off, the lube pumps
internal clock will not reset. The interval between pump cycles is based on axis motor
movement time.

2.14.1 Lube Pump Operation

The pumping output can be regulated electronically to control the Interval Time between
pumping cycles, and the Discharge Time of each pumping cycle. The pump can also be
run manually through a key found under service codes. The following describes the steps
used to program the lube pumps Interval and Discharge times.

• Setting Interval Time: Service Cod e 301

Press "Mode", "Set up", "Service Codes", "C" (Machine Setup), Code 301, and then
enter the desired Interval time in minutes.

• Setting Discharge Time: Service Code 302

Press "Mode", "Set up", "Service Codes", "C" (Machine Setup), Code 302, and then
enter the desired Discharge time in seconds.

• To manually Pump Oil: Service Co de 300

Press "Mode", "Set up", "Service Codes", press "E", and then press Code 300
(Lubrication Pump Switch). The pump will pump oil for the amount of time
programmed in Code 302. The spindle does not need to be turned on.

2.14.2 Factory Default Values

Interval Time - 60 min
Discharge Time - 15 sec
Discharge Pressure - Approximately 100 - 150psi

To adjust the amount of Discharge Pressure displayed on t he lube pump gauge, loosen
the jam nut and turn the adjustment screw located on the top right side of the lube
pump while the lube pump is activated. To activate the lube pump use Service Code 300.

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

and sliding surfaces.

Failure to manually activate the pump at the beginning of each day, or allowing the Auto Lube to run dry

may cause severe damage to the 1540V, 1840V, or 2460V lathe way surfaces and ballscrews.

The settings for the lube pump can be viewed by doing the following: press Service
Codes, press “A” (software), press Code 313. This screen lists the values programmed
for the cycle time and discharge time.

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2.14.3 1840V & 2460V Headstock Oil Rese rvoirs

Before turning on the spindle, check to make sure the headstock oil reservoir is full. A
site glass is located under the spindle cover. The reservoir holds approximately 3 gallons.
If low, fill the site level with Mobil DTE 24 or equivalent oil through the plug located on
the headstock cover .

2.15 Cutting the Test Part (See Figure 2-9)

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 t he 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 500 RPM.

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
650 to 950 RPM is recommended.

2.16 Measurement of the Test Part

Tools Required:

• O.D. Micrometers with .0001" gra duations

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.

i00196

Figure 2-9 – Test Part

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2.17 Mounting of A2-5 Chuck

The 1540V lathe has an A2-5 spindle and requires a chuck of this type. Use the following
procedure to mount this s tyle chuck.

Bolt the chuck adapter plate to the spindle with (4) M10 X 50 SHCS. The adaptor is
orientated by the key on the spindle.

Then bolt the chuck to the adaptor plate with (3) M8 x 70 SHCS. The chucks SWI
provides are self-aligning and need no adjustment.

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3.0 Troubleshooting by Symptom

Use this section to begin the process of resolving a service problem. Each problem type is
described in a few words and then more fully described in an explanatory paragraph. Following
this is a chart that directs in the most logical steps.

3.1 Problems Relating to Machining Results

3.1.1 Poor Finish

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

Do the following Service Codes:

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

• Code 12 Feed Forward Constant.

• Code 127 Measures backlash in the system.

• Code 128 Enter backlash compensation.

Possible Cause Check This

Inadequate or no Lubr ication to
Ballscrews and Way surfaces

X & Z-axis Drive Trains are loose Check Repeatability using the Repeatability and Positional

Way surfaces are pocked, scarred, or
excessively wo rn

Machine set-up problem Machine’s fee t are 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
Loose bearing problem Looseness in the spindle bearings. Adjust spindle preload.

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.

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
Visually check the condition of all the Way surfaces. For
machines that may have excessively worn Way surfaces
you may need to adjust the Gibs in this area. This will
affect performance when using the machine outside of
this area. Check lubrication to affected areas.

,

Leveling

speeds too fast, Feeds too slow.
See Machine Tool & Set up , Sect ion 4. 1

Ball screw misalignment,
See Mechanical Drive Train (X,Z), Section 4.2. See Spind le
Bearing Preload
Section 5.1.19 for 1540V.

Section 2.9

,

Section 5.1.16 (1840V & 2460). See

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

3.1.2 Turning Diameters Out of Round

Loose bearing problem

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

Possible Cause

Check This

Headstock and/or tailstock

See Adjust Headstock for Taper - Section 5.1.15

Parts are not round within .0004” TIR for 1840V & 2460V and 0.0002” for the 1540V.
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: 2460V - The typical geared head engine lathe is not capable of more precise
diameters. Careful adjustments to this turning machine will insure to maintain this
accuracy. Better accuracy should not be expected from a lathe of this class.

Do the following service code and procedures:

Possible Cause Check This

Tooling problem Improper tooling, workpiec e 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 5.1.16 (1840V &
2460V only)

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.

Do the following se rvice code and procedure:

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

Machine set-up problem Machine not leveled properly

See Leveling - Section 2.9

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

follow rest, reduce overhang from chuck headstock or tailstock.
Looseness in the gib or
misalignment of ball screw

Loose bearing problem Looseness in the spindle bearings.

not aligned

Gib adjustment.

See Gib Adjustment - Section 5.2.1

See Z Ball screw Alignment - Section 5.1.14

See Mechanical Drive Train (X,Z) - 4.2

See Spindle Bearing Preload - Section 5.1.16 (1840V & 2460V only)

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

5.1.17

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 on 1840V & 2460V and 0. 0002” on 1540V.

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

.0008” over 6 inches.

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

3.1.4.1 Every Part Has the Same Error

Possible Cause

Check This

Machining Setup

See Machine Tool & Setup - 4.1

Looseness in the Drive Train, ball nut loose in

See Mechanical Drive Train (X,Z) - 4.2

Possible Cause

Check This

Failure of the spi ndle encoder

Replace spindle encoder
Broken or slipping encoder coupling

Check and replace as necessary

Broken or loose belt on 1540V lathe only

Check belt tension

Programming Error Programmed dimensions not correct. Check

absolute and incremental values.

Machine & Setup Related See Machine Tool & Setup - 4.1

3.1.4.2 Errors are Random 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 a nd up to 10 leads.
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 retracts. 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.

Do 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.

Looseness in the Gib Gib adjustment

See Gib Adjustment - Section 5.2.1

Looseness in the drive train The drive train Diagnostics

See Mechanical Drive Train (X,Z) - Section 4.2
Failure of the spi ndle encoder
Run service code 133 to check if the encoder
counts.

Replace spindle encoder

See Spindle Encoder replacement - Section

5.1.8

3.1.5.2 Not Threading

The machine will not cut a thread at al l.

Possible Cause Check T his

Spindle speed too fast Slow down spindle speed.

Run service code 133 to check if the encoder
counts.

See Spindle Encoder replacement - Section

5.1.8

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3.2 Problems Regard ing the Motion of the Machine

The home positions or tools a re not set

See the Controls Programming, Operations, 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 4.9 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-axis Gibs using the X

Binding in the Drive Train

Check Repeatability using the Repeatability and Positional

Servo Drive failure

See Servo Drive Se ction 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 bei ng interrupted.

Do the following Service Codes:

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

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

if the encoders are counting.

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.

Do the following Service Codes:

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

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

if the encoders are counting.

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

Possible Cause 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 section.
Values lower than 0.005” may reduce the feedrate.

Electrical Section 4.6

If not, check to make sure that the lube pump is functioni ng
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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TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

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

X Gib not making good contact.

Pull gibs out and mark with a blue die to check where

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 mot i on is not smooth. The motion appears to be "rough" or jerky”.
Do the following Service Codes and procedures:

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

• Code 12 Feed Forward Constant.

• 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.

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.
Do 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

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

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

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 Mechani cal Drive Train (X, Z) Section 4.2

Misalignment of ball screw 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

Computer/Pendant failed

See Computer/Pend ant Section 4.3

3.3.1 Display Blanks

The display is completely blank.

Screen saver has been activated Press any key to turn back on. All LED keys on

pendant will blink when the screen saver is on. Pre ss
any key to deactivate. Hitting this key will not
activate any feature on the control.

The system has shut down Turn the power switch off, check the computer/

pendant fuses and cable connections. See Electrical

Section 4.8
Poor cable connection from Com puter
Module to LCD (Liquid Crystal Display)
Fuse blown in pendant Remove fuse and check continuity

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 Computer
Module to LCD (Liquid Crystal Display)
Computer/Pendant failed See Computer/Pendant Section 4.3

Double-check the connection from t he 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.
Do the following Service Codes 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.

Possible Cause Che ck T his

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)

Poor cable connections from the
Computer Module to the Distribution
Board and from the Distribution Board
to the Keyboard
Computer/Pendant failed See Computer/Pendant Section 4.3
Electromagnetic interference has
entered through the RS232 cable (if
connected); especially if intermittent

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.

Re-seat cable connecto rs by pulling out and pushing

back in.

Especially suspected if the RS232 cable is run near

any electrical conduit. If the problem is chronic,

remove the cable for a while to see if there is a

difference.

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3.3.4 Fault X or Z

Possible Cause

Check This

Binding or looseness in the Drive Train

See Mechanical Drive Train (X, Z) Section 4.2

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

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

• 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.

Servo cables at pendant switched around. Make sur e during an installation the X, Y and Z servo

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 Gibs using

the X and Z-axis Gib adjustment procedures. See X
and Z-axis Gib Adjustments Section 5.2.1

Excessive friction in the slideways See Machine Tool & Setup Sectio n 4.1

Incoming electrical power Incoming voltage. See Electrical Section 4.6
Servo Drive failure See Servo Driver - Se ction 4.5
Motor failure See Motor diagnostics, Section 4.4
Computer/Pendant failure See Computer/Pendant diagnostics, Section 4.3

3.3.5 Problems Reading the Floppy Disk; Programs Not Saved Properly

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

Possible Cause Check This

Improper Boot-up Shut down the system and wait 10 second s before

rebooting

Floppy Disk failure The Floppy Disk may be bad. See if the Floppy Disk

can be read by a Personal Computer. Does the green
light on the floppy drive come on when you access the
disk? If so, power is getting to the floppy drive. If
not check connections of floppy drive inside the
computer module. See Computer/Pendant Section 4.3
for more information.

Floppy Disk full Put the Floppy Disk into a Personal Computer to see

how many bytes remain. A floppy holds 1.44 MB.

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3.3.6 System Will Not Turn On or Boot-Up

Bad Fuses in electrics box

Check the 2-Transformer fuses, 1-Power Strip fuse. See Electrical

Out coming 110VAC from Transformer is

Using a Voltmeter, check the out coming 110VAC from the

Out coming 110VAC from Power Strip is

Using a Voltmeter, check the out coming 110VAC from the Power
Computer/Pendant has failed

See Computer/Pendant diagnostics Section 4.3

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

Possible Cause Check This

Main Disconnect switch is off Check the Main Disconnect swi tch.
Pendant On/Off switch is Off. Check the Pendant On/Off switch
Fuse blown in pendant or the 2
transformer fuses.
Incoming 220VAC is too high, too low or
not present

Remove fuse and check continuity. Is the power strip light on?

Using a Voltmeter, check the incoming 220VAC to the machine.
See Electrical Section 4.6

Section 4.6

too high, too low or not present

too high, too low or not present
Poor wiring and cab le connections Check for any loose wiring. Also, check the 110VAC Power Cable

Bad cable from the 110VAC Power Strip
to the Pendant.
Hard Drive failure When the Computer Module starts the boot-up process, look at

Transformer. See Electrical Section 4.6

Strip. See Electrical Section 4.6

connection from t he 110VAC Power Strip to the Pendant. See
Electrical Section 4.6
Using a Voltmeter, check the out coming voltage from the
110VAC Power Cable to the Pendant. See Electrical Section 4.6

th

line on the Display Screen. If the Mother Board of the

the 8
Computer Module is communicating w ith the Hard Drive you will
see "Detecting IDE Primary Master … Toshiba MK6014MAP". If
the Mother Board of the Computer Module is not communicating
with the Hard Drive you will see "Detecting IDE Primary Master …
None".
Also, check the wir ing connection between the Hard Drive and
the Mother Board. See Computer/Pendant diagnostics Section 4.3

3.3.7 System Reboots by Itself

During operation, the screen suddenly blanks and then shows that the system has begun
the boot-up sequence.

Possible Cause Check This

Incoming 220VAC is too high, too low
or not present
Out coming 110VAC from Transformer
is too high, too low or not pres ent
Out coming 110VAC from Power Strip is
too high, too low or not present
Bad cable from the 110VAC Power Strip
to the Pendant.
Poor wiring and cab le connections Check for any loose wiring. Also, check the 110VAC Power Cable

Computer/Pendant failed See Computer/Pendant diagnostics Section 4.3

Using a Voltmeter, check the incoming 220VAC to the machine.
See Electrical Section 4.6
Using a Voltmeter, check the out coming 110VAC from the
Transformer. See Electrical Section 4.6
Using a Voltmeter, check the out coming 110VAC from the
Power Strip. See Electrical Section 4.6
Using a Voltmeter, check the out coming voltage from the
110VAC Power Cable to the Pendant. See Electrical Section 4.6

connection from t he 110VAC Power Strip to the Pendant. See
Electrical Section 4.6

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3.3.8 System Shuts Off

Poor wiring and cable connections

Check for any loose wiring. Also, check the 110VAC Power
Bad cable from the 110VAC Power Strip to

Using a Voltmeter, check the out coming voltage from the
Hard drive failure

Check the hard drive connections in the computer module.

Possible Cause

Check This

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

Possible Cause Check This

Fuse blown in pendant Remove fuse and check continuity
Incoming 220VAC is too high, too low or not
present
Bad fuses in electrics box Check the 2-Transformer fuses, 1-Power Strip fuse. See

Out coming 110VAC from Transformer is too
high, too low or not present
Out coming 110VAC from Power Strip is too
high, too low or not present

Using a Voltmeter, check the incoming 220VAC to the machine.
See Electrical Section 4.6

Electrical Section 4.6
Using a Voltmeter, check the o ut coming 110VAC from the
Transformer. See Electrical Section 4.6
Using a Voltmeter, check the out coming 110VAC from the
Power Strip. See Electrical Section 4.6

Cable connection fr om the 110VAC Power Strip to the Pendant.
See Electrical Section 4.6

the Pendant.

Computer/Pendant has failed See Computer/Pendant diagnostics Section 4.3

110VAC Power Cable to the Pendant. See Electrical Section 4.6

3.3.9 Will Not Hold Calibration

The control will not hold calibration. Go to the "Configuration Values" screen and write
down the calibration values for the motor encoders. T he calibration values are written in
Hexadecimal. Recalibrate the system and see if the values change. Turn the system off
and on and see if the values are held.

Do the following service codes and procedures:

• Code 33

• Code 313 Configuration Values.

• Code 123 Calibration Mode.

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 (Section 3.4.1)

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

See Computer/Pendant

• See Measurements Are Not Accurate (Section 3.4.2)

3.3.10 E-Stop Error

The E-Stop cuts power to the Coolant pump and Lube pump by de-energizing a relay,
which is internally hard-wired inside the Auxiliary Module. The signal that is responsible
for de-energizing the relay comes down from the Computer Module to the Auxiliary
Module through the Spindle Control cable. Furthermore, the Auxiliary Module sends a
signal to the Spindle Drive causing the Spindle Drive to command a "Servo to Stop",

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which cuts power to the Spindle Motor. This signal is sent from the Auxiliary Module to

Loose connectio ns

Check servo drive cables at pendant and servo drives.

the Spindle Drive through the Spindle Drive cable.
In Addition, when the E-Stop is activat ed, the Computer Module sends a "Servo to Stop"

command to each of the X and Z-Drive Modules. This cuts the power to the X and Z-axis
Servomotors. These signals are fed down from the Computer Module to the X and Z­Drive Modules thro ugh the X and Z-Drive Module cables. C heck the X and Z-axis Drive
Modules for fault messages.

If the E-Stop button is depressed, and no message is displayed on the screen, then
either the E-Stop button or the Computer Module is at fault. Check the E-Stop button and
the cable connection from the E-Stop button to the Computer Module.

Possible Cause Check This

Faulty E-Stop switch Check the cable connections from the computer module to the E-

Stop switch. Check the E-Stop switch for functionality.

Bad Computer Module Assuming that the E-Stop S witch and cable to the Computer Module

are good, if the E-Stop but ton is depressed, and no message is

displayed on the screen, then replace the pendant.
Bad spindle auxiliary module Replace module
Bad spindle control cable This cable runs from the computer module to the auxiliary module.

3.3.11 Motor Alignment Routine Does Not Work Properly

The Motor Alignment Routine Code 203 (1540V & 1840V only) calculates the relative
position between the motor poles on the stator and the magnets on the rotor through
the use of the motor encoder. Once the stator and rotor are aligned, the encoder’s
absolute zero is set. The routine also distinguishes which type of motor is being used on
the machine. The ro utine can last up to 30 seconds. After 30 seconds, the routine will
under go a Time-out. If the motor alignment routine fails to work properly, a message
should appear on the display prompting the user that the motor alignment routine has
failed. Each axis moves less than 1” during routi ne. The 2460V uses service code 204 to
align the servo motors. This routine looks for the index pulse on the motor encoder and
aligns the motor to this location.

Possible Cause Check Thi s

Gib locks are on or
mechanically one axis has very
high torque.
Servo driver failure See servo driver diagnostics Section 4.5
Motor failure. See motor diagnostics Section 4.4

Unlock gib locks and measure the torque on each axis. I t should
be less than 20 in-lbs.

3.3.12 Limit Switch Error

Limit switches are installed on the carriage and cross slide to prevent serious damage to
the machine in the event of a crash. Each individual limit switch has two separate
plungers. One plunger is responsible for triggering in the positive direction, while the
other plunger is responsible for triggering in the negative direction. The limit switch will
trigger when carriage or cross slide moves past the available travel. In the event a limit
switch is triggered, the following error message will be displayed.

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Limit Switches are triggered

Reset the Limit Switches using the procedures described above.

Poor Limit Switch Cable connection

Check for any pins that are loose, pus hed in, or bent. Verify that

Limit Switch failure

auxiliary module in the electrics box.

Turn off all power to the machine. For the positive direction,

module. See below.

Critical Error 5252: Limit Switch Active

Switch.

When this happens , the control will not allow the operator to continue to manually move
the carriage or cross slide in the same direction.

To return the machine to its normal state of operation, perform the following procedure:

1. Use the electronic hand wheel to move the carriage or cross slide off the limit switch.

2. Press the "Mode" or "Return" key to reset the control.

3. Press the "DRO" key to enable the machine to once again jog.
Do the following service code and procedures:

• Code 312 Toggles limit switches on/off – this will turn the limit switches on or off.
This is a temporary fix for the problem and allows the user to run the machine until
replacement part can be installed. If the limit switches are turned off and a problem
occurs because of a crash, this will not be covered under warranty.

Possible Cause Check This

The X-axis Limit Switch is activated.

Use the Hand Wheels to Move off the

a

there is a good connection between the cable and the Auxiliary
Module.

Try this
Switch 2 limit switch cables on the

Auxiliary or Computer Module failure Turn off a ll power to the machine. Use two paper clips to jumper

check for continuity between pins 1 and 6 on the Limit Switch
cable connector. You should hear a continuous beep from your
Multi-meter. By hand, manually depress the plunger on the limit
switch responsible for when the table, saddle, or ram is moving
in the positive direction. The beep from your Multi-meter should
stop beeping. This means the Limit Switch is triggering properly
for the positive direction. For the negative direction, repeat the
same procedure as described above using pins 5 and 9 on the
Limit Switch cable connector.
Does the limit switch problem move to the other axis? If it does
then the switch is most likely the problem. If it stays with the
original axis then it could be the auxiliary module or computer

connector pins 1 & 6 t ogether and 5 & 9 together on the
Auxiliary module for the limit switch port in question. Next, turn
on all power to the machine. This will verify whether or not the
Auxiliary Module and the Computer Module are working properly.
If there is still a failure, look at the "Product # " list ed under
"Configuration Values" (Mode, Setup, Service Codes, A-Software
Version, More). This "Product # " represents the type of
configuration for the machine type. The "Product # " should
read 1540 or 2460. The Machine I.D. Key (located on the
Auxiliary Module) configures the system according to machine

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type. If the Computer Module reads the correct "Product # ",
then the Computer M odule is good and the Auxiliary Module is
bad. However, if the Computer Module reads the incorrect
"Product # ", then the Computer Module is bad and the Auxiliary
Module is good. Of course this is all under the assumption that
the Auxiliary Module has the correct Machine I.D. Key.

3.4 Problem with the Measurements

3.4.1 X & Z-Axis Measurements Do Not Repeat

With a dial indicator mounted to the spindle, touch off a fixed surface either in t he 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 Positiona l

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 Hea d on
motor are loose

Swap the motor in question with a known good motor.

For example, swap the X-axis motor with the Z-axis

motor. If the symptom stays with the motor in question,

then replace the motor. If not, then the motor is not at

fault and something else is causing the problem.

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.

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Possible Cause Do This

The Calibration is incorrect

Recalibrate the machine.

Incorrect backlash values

If the machine does not repeat bi-directionally check the

Electronic handwheel fa ilur e

Each handwheel should count 0.100” & 0.020” respectively for Z

Servo driver failure

Check the LED status on the axis in quest ion. See Servo driver

See Calibration & Backlash Constants

backlash on the axis in question. See Section 5.2.2.

3.4.3 The DRO Is Not Counting

The DRO for one axis i s not counting when an axis is moved. Often times if this is the
case the axis will fault. See Section 4.4.3.

Do the following Service Codes:

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

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

if the encoders are counting.

• Code 132 Electronic handwheel test.

• Code 131 Manual DRO test.

Possible Cause Che ck T his

and X in fine mode; and 0.400” & 0.100” in course mode.

Section 4.5
Motor Encoder not counting See Motor diagnostics
Computer/Pendant failure See Computer/Pendant diagnostics

3.4.4 X & Z-Axis DRO Counting in Wrong Direction

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

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

• Z-axis – carriage moves toward tailstock.

Do the following se rvice code and procedures:

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

• Code 313 Check the line that specifies the product.

If the product does not match the machi ne then the machine ID key will need to be replaced.

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

The Electric Handwheels count in the wrong direction.
The positive directions for each Electric Handwhee l are:

• X-axis - Electric Handwheel turns counterclockwise

• Z-axis - Electric Handwheel turns clockwise

Do the following service code 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

Possible Cause

Check This

Wrong voltage

Check the voltage to the machine before and after the Spindle Drive
1 of the 3 fuses for the Spindle Drive

Check each of the 3 fuses in the Spindle Drive Fuse Block (F2) for

Poor wiring connections

Check all the wiring connections to the Main Disconnect Switch,

Defective cables or poor cable

Check the Spindle Control cable and cable connection between the
Improper wiring/jumper configuration

Check to make sure that the Spindle Motor has the correct

Spindle Drive may be in "Local Mode"

On the Spindle Drive, push the "DSPL" button until "LO/RE" lights up.
Spindle Drive contains incorrect

Contact customer service.

3.5.1 Spindle Stalls or Turns-Off During Machining

During machining, the spindle turns off and loses p ower. First check incoming voltage
and connections.

Possible Cause Check This

Machine Tool and Setup problem Check the type of material being cut, type and size of cutting tool,

RPM, and Feed rate. Also check the condition of the cutter to verify

that the cutter is no t dull. See Machine Tool & Setup Section 4.1
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 Thermal Overload Relay
has tripped

Spindle Drive parameters are not
correct

3.5.2 Spindle Motor Hums or Will Not Run

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

IOUT - Current O ut (located on the Sp indle Drive). When the Overload

Relay is enabled, an "oL1" error occurs shutting off the Sp indle Drive.

The harder the Spindle Motor works trying to make heavy cuts, the

more current the Spindle Motor utilizes. This can be caused by a cut so

large that it exceeds the machine capability, or a problem with the

spindle motor or AC drive.

May need to re-download the Spindle Drive para meters. Contact

Customer Service for assistance.

Note: machines can only be wired for 220 volts. 4 40 volts will ruin electrical components
in the machine. These components will not be covered under warranty.

is blown

connections

on the Spindle Moto r

and can not be run from the Pendant

parameters and is not programmed
correctly

Fuse Block (F2) with a Voltmeter. Also, check the voltage to the
Spindle Drive (L1, L2, and L3).

continuity with Ohmmeter. See Electrical Connection

Spindle Drive Fuse B lock, Spindle Drive, and Spindle Motor. See
Electrical Connection

Auxiliary Module and the Spindle Drive. Check the Spindle Control
cable and cable connection betwee n the Pendant and the Auxiliary
Module. See Electrical Connection

wiring/jumper configuration for 220VAC. See Electrica l wiring section.

Use the "Up" and "Down" arrow keys to choose between "Lo"- Local
(Run Spindle Motor from Spindle Drive) or "rE" - Remote
Motor from the Pendant).

(Run Spindle

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3.5.3 Spindle Runs Backwards

Spindle preload loose

Tighten spindle preload on bearing. The spindle
Leaking from behind belt drive pulley

Replace shaft seal - o-rings or gaskets.

Oil leaking from behind the spindle

Remove spindle encoder and check seal.

Make sure the rear backing plate is mounted correctly.

Possible Cause

Check This

Oil leaking from seal between lid and

Remove gearbox lid and reseal. Thoroughly clean lid

The spindle motor runs in the opposite direction. The spindle should always spin in the
clockwise direction when the forward key on the pendant is pressed.

Possible Cause Check This

3-Phase wires backwards Need to switch any 2 of the 3 wires either coming out of the

Spindle Drive (T1, T2, and T3) or going into the Spindle Motor (U,
V, and W). Caution: Be sure to shut off all power to the ma chine
before attempting to switch any wires.

3.5.4 Excess Gearbox Noise – 1840V & 2460V Only

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

Possible Cause Che ck T his

Headstock manual oil pump failure Make sure oil is flowing in the site glass. The oil

pump is run off a gear in the headstock.
Shift level out of position. Gears are not
mating properly.

Lack of lubrication to gear tra in Check level of oil in gearbox
Spindle bearing not being lubricated
properly, worn bearing

Move the shift lever in and out. Turn off spindle and

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

bearings.

3.5.5 Headstock is Leaking Oil – 1840V & 2460V Only

A Form-A-Gasket sealant should be use to seal any leaking areas. Make sure the sealant
fills the leaking area thoroughly. Sealant must cure for 24 hours for best results.

3.5.5.1 Leaking Oil from Rear of Gearbox

Possible Cause Che ck T his

encoder.
Oil leaking from the rear bearing
assembly.

3.5.5.2 Leaking Oil From Front of Gearbox

gearbox

preload should be approximately 10-15 in/lbs.

There should be a tapped hole located at the 12

o’clock position. If the tapped hole is located at the 6

o’clock position the seal will leak.

before resealing. Make sure the front backing plate

matches up with the seal behind the cover.

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3.5.6 Tailstock Barrel is Stiff

The tailstock barrel is stiff or not smooth moving through its travel. The ta ilstock 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” transversely. See
Leveling Procedures, Section 2.9.

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. At the beginning of each day
manually supply oil to the way surfaces by doing Service Code 300.

Lack of lubrication can lead to a variety of problems with your machine motion due to
increased friction in the sliding ways. This increased friction may lead to part inaccuracies
and decreased life expectancies of your ball screws and way surfaces.

2460 only - Make sure the oil pump 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
under the spindle cover. Lack of lubrication in the headstock can lead to increased wear
of the gear train as well as premature wearing or failure of the spindle bearings. Oil
flows to the site glass only when the spindle is on.

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Problems With

Can Contribute To:

No coolant

Poor finish, decrease the life of the cutter

Poor surface finish

Dull tool

Long workpieces out of round

Use a follow or steady rest

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.

Feed and Speeds (spindle rpm)
See below

Tooling
Using the wrong cutter for an application
Cutting too deep Part dimensions incorrect

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

Problem

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
Parts incorrect

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
Work improperly supported
Machine tool out of level - See

Section 2.9.

Gib Adjustment,

Section 5.2.1.

Leveling Procedures,

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 ball screw 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. Write 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 torque required to manual turn the 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 ball screws.

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 5-4 and 5-6 in Section 5.0.

1. Ens ure that the screws that hold the bearing housing in place are not loose.

2. Ens ure that the Clamp Nut is secured. The following applies t o the clamp nut: When

loosening, make sure to back out the 10-32 screw from the cl amp nut.

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

4. Take out the angular contact bearings in the X & Z-axis and inspe ct them. They
should roll smoothly and be lightly greased. If not, replace them. The Z-axis has 2
bearing housings.

NOTE: The bearing housing and spacer rings are matched sets - keep them
together.

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

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

CAUTION!

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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, ball screws and cross-slide.

Z Ball screws not

• Manually turn the ball screw t hrough the length of its travel. P ay particular attention

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

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

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

• Dial indicator on a vertical flat of the ball screw indicates backlash between the ball
screw 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: Ball screws are inspecte d throughout their entire travel for backlash and consistent
torque. A ball screw should be good for millions of inches of travel if installed properly. Do not
be too quick to replace a ball screw if there is insufficient indication that it is bad; this will just be
a costly delay to resolving the real problem.

See:

Z Ball Screw Removal,
X Ball Screw Removal,
Aligning Z Ball Screw,

Section 5.1.13
Section 5.1.11

Section 5.1.14

4.3 Computer/Pendant Diagnostics

The pendant consists of 3 separate modules: the computer module, hard-drive module,
and the sheet metal and LCD screen.

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

Poor cable connections There are 9 cable connections to the left side of the

pendant. Make sure all cables are properly fastened.

Pendant locks up Press the E-stop button and see if lock up clears if not

then do the following:
Turn the pendant off, wait at least 30 seconds, and
turn it back on and check to see if the malfunction has
been reset.

No voltage to RSG port RSG will not work – should be 5 volts present

Check with a voltmeter.

Low voltage to hard drive or slave board. Can cause the system to lock up and the hard drive to

act abnormally. Check voltage to power cable at hard
drive module with voltmeter. It should be 4.8 volts
and above. Lower values than this can cause
problems.

Possible problems Can lead to

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Hard drive failure If the hard drive fails, the system will not boot up or

WARNING!

operate. It will need to be replaced. All programs and
machine configurations will be lost. Make sure to back
up your hard drive from time to time. Only the hard
drive module will need to be replaced.

Floppy disk failure Will not allow user to save or pull up programs from a

floppy disk. Can the floppy drive format a disk? See
instructions below.

LCD backlight burns out Check all cable connections to LCD, distribution board

and computer module. Make sure the power is turned
off before doing so.

Faulty E-stop switch It can be stuck open or closed (pressed). If it is stuck

closed the pendant will need to be replaced because
the user will have no wa y 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.

Axis faults on screen Servo driver cables at pendant are loose. Make sure

cable connection bracket is fastened down. Make sure
cable clips into female portion on the top and bottom.
Sometimes the clips tend to stick.

Overlay failure ( keys on pendant) Certain buttons on overlay do not work. Do code 81 to

verify each key beeps.
Low voltage to pendant or current spikes 1 amp fuse in pendant b lows. Pendant will not turn on.
Slave board not functioning Machine will not run. If under Code 33 it says

“Firmware Edge or Demo,” it means the slave board is

not functioning.

4.3.1 Checking Floppy Dr ive by Formatting a Disk

1. Find a new disk and install in floppy drive.

2. Install keyboard into middle port.

3. Press CTRL ESC to get to start menu.

4. Press R for run.

5. Type Format a: - press enter.

6. If the format works your disk drive is working. If format does not work, reboot
control and see if it now works. If it does not work replace the computer module.

7. Press ALT ESC to get back to PT4 software.

4.4 Motor Diagnostics

The Motor subsystem is comprised of 2 parts: The Motor Encoder and the Motor. The
motors are powered by 3-phase AC voltage. The servo driver is also an integral part of
servo system, which is discussed in detail in the next section.

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

are run by 220 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.

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WARNING!

4.4.1 Motor Alignment Routine

This service code needs to be performed each time the ProtoTRAK is turned on, new software
is installed or motors have been replaced. The control will boot up automatically to this
screen. Press the Check System key and follow instructions on screen.

It is important that there are no obstructions on any axis before running this code. If there is an

obstruction, then use the el ectronic handwheels to slowly move the machine away from the

obstruction.

Each axis will move approximately 1” during this routine. The handwheels will not move
at the normal feedrates during this routine. Failure to move each axis away from an
obstruction will cause a crash.

Code 203 (1540V & 1840V only) ca lculates the relative position between the motor poles
on the stator and the magnets on the rotor through the use of the motor encoder. Code
204 is used on the 2460V. The alignment is set by reading the index off of the motor
encoder.

4.4.2 Cable Connections

Check the motor cable connections on the motor side as well as the servo side. Make sure the
threaded connectors on the motor side are fully threaded in place. The connectors should
thread down about 7 to 8 turns for both the motor power cable and motor encoder cable. On
the servo side make sure the 3 phase wires are plugged properly into the servo driver. The
wires should be placed into the servo driver from left to right with the red wire on the left and
the black wire on the right. Failure to put the correct color wire into the correct port may
cause the motor to run in the wrong direction. Make sure none of the wires are crimped on
the insulation instead of the fork connector. Also verify each motor cable ground wire is
fastened to the side o f the aluminum heat sink which the servos are mounted on. Check the
connection of the motor encoder cable on the encoder module.

4.4.3 To Check the Motor Encoders

If the motor encoder inside the motor has failed or is not reading the machine will fault out on
that axis. Do the following to verify this problem:

Run Service Code 131. This will display on the DRO if the motor encoder is counting. If this
number does not move then the encoder is not counting. This means either the encoder or
the cable is the problem. Visually check the cable for any problems. If the encoder has failed
the motor must be replaced.

4.4.4 Encoder Counts to Pendant

Before replacing the motor due to a bad motor encoder it is a good idea to check the cables
that take those signals back to the pendant. If these signals are not getting back to the
pendant then the axis will fault. Check the following cab le connections.

• Umbilical #1 and #2 at the encoder module

• Umbilical #1 and #2 at the pendant

• Check the servo driver connections at the pendant and also at the servo driver

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4.4.5 Moving Problem from One Axis to Another

Swap these components

Results

Physically switch the X and Z

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

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.
This particular example was done on a machine with motor encoders only.

motors
Switch X and Z encoder cables
on encoder module and X and Z
servo driver cables at the
computer module.

This runs the Z motor with the
X port on the computer. Jog
the X and the Z-axis should
move.
Switch X and Z motor power
cables at the servo driver,
switch X and Z motor encoder
cables on encoder module.

Jog the Z-axis key and t he X­axis will move. Jog the X-axis
key and the Z will move.

4.5 Servo Drivers

The servo drivers are located in the electrics box on the lower right side. They are
positioned from top to bottom as X and Z.

Indications:

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

Servo Types:

• X and Z servos are identical.

Objective:

• Isolate the problem to the particular Servo Driver

The input signal to each servo driver is 220 VAC 3 phase power. Inside the servo driver
this input signal is transformed into a direct current output signal and reconfigured to
simulate a 220 VAC signal with varying frequency. The servo driver takes the commands
from the computer module and varies the frequency of the 220 VAC output signal, thus
the speed of the motor.
SWI uses two different brands of servo drive modules. One servo drive module is
manufactured by Semipower Systems and the other i s manufactured by MTS Systems.

the motor is not the problem.
Has the problem moved to the Y-axis?
If yes, the X port on the computer is the problem, replace the
pendant. The signal is not getting from the computer to the
servo driver and on to the motor.
If no, the X servo driver is most likely the problem. It could
also be a problem with the servo driver cable that runs from
the pendant to the servo driver or the power cable from the
servo driver to the X motor.

This allows the X motor to be run with the Z servo driver and Z
port on the computer modul e and the Z motor to be run with
the X servo driver and X port on the computer.
Has the problem moved to the Z-axis?
If yes, then it is the X servo driver, replace this component.
This also proves that there are no problems with any of the
cables.

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WARNING!

Although both brands of servo modules are almost identical, there are some subtle
differences with the LED codes that are displayed.

4.5.1 Cap Block

Above the Z axis servo driver is a component called a cap block. The cap block serves 2
purposes: it filters the input signal voltages to the servo drivers and it is a current reserve
for the servos. In other words it acts like a battery and stores energy for the servo
system. When the motors are commanded to move, initially they will draw power from
the cap block. If this component fails the servo system will not work. Most likely the
fuses labeled under F3 (T1, T2 and T3) will be blown or there will be visible damage to
the cap block itself.

If one suspects a CapBlok failure, use a voltmeter (DC mode) to verify that the voltage
between the terminals, "+B" and "-B" is approximately 300VDC. Terminals "+B" and "-B"
are located at the top left corner of each of servo drive module. Next check for any loose
wiring connections to the servo drive modules and to the CapBlok.

Make sure to first turn the power off and unplug the machine. Wait about 10 minutes or so for

the CapBlok to discharge. Use a voltmeter to verify the voltage between terminals, "+B" and "-B"

are safe before handling.

4.5.2 Servo Driver Cooling Fan

The PowerBlok drive modules in the electric box are temperature dependent (See Fault
Code 5 - Substrate over-temperature). Therefore, SWI has mounted the servo drive
modules to a heat sink to help transfer heat away by means of convection. On the
bottom of the aluminum extrusion that the servos mount to sits a 12 VDC fan that cools
the servo system. The temperature of the system must be above 131° F for the fan to
turn on. The 12-volt signal will only be present when the temperature reaches 131° F.
The fan will turn off when the temperature reaches 122° F. If you see a Code 5 on one
of the servos check to see that this fan is operational. The Z servo driver powers the fan.
If the fan is not working check to see that 12 VDC is coming out of the Z servo driver by
checking across the 2 pins on the servo driver. If there is 12 volts, then the fan is bad,
otherwise the servo driver is bad. An alternative solution may be to swap the X and Z
servo drivers.

WARNING!

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

servo drivers are run by 220 VAC. There is possibility of death by electrocution!

4.5.3 Servo Driver Fault Codes

Each servo driver has an LED display that indicates fault and status conditions. On power
up, before communication with the servo drivers is established, any fault code may be
present. Once communication is established the LED should read 0. In addition, cycling
the power clears the fault if the condition is no longer true.

The "decimal point" of the Seven-Segment LED display for the Semipower and MTS servo
drive modules will turn on when the servomotor is active. Also, the Seven-Segment LED
display for both the Semipower and MTS servo drive modules will display a "0" when the
servomotor is active providing there are no errors. Therefore, when the Seven-Segment
LED display shows a zero, the decimal point is on, no error conditions exist, the servo
drive module is enabled, then the motor will be energized and servoing.

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However, when the servomotors are not active, the Semipower servo drive module will
display a "0" with no "decimal point" and the MTS servo drive module will display a "2"
with no "decimal point". When the servomotors are not active, the "2" displayed on the
MTS servo drive module does not mean that there is a "Watchdog timer timeout" fault.
This is just the way SWI has configured the MTS servo drive module for this particular
application. It is completely normal to see a "2" with no "decimal point" displayed on the
MTS servo drive module when the servomotors are not active.

Note: always check for errors when the servo drivers are active. This takes place in DRO
and RUN mode.

The codes are as follows:

Code 0 - No Fault
Code 1 - Over-current: This over-current error is due to current conditions that exceed

the thermal rating o f the internal components inside the power drive module. This
feature does not protect the motor. Sudden faults are high feedrates may cause this
condition.

Code 2 - Watchdog timer timeout: This timeout error can primarily be attributed to
electrical noise or mechanical disconnection, w hich interrupts the timing of the motor
current data whi c h is sent back to the contr oller every 4-times per PWM cycle. Check all
cable connections from pendant to servo driver.

Code 3 - Motor Short/Ground Short: The power drive module is protected from
short circuit and ground fault conditions by automatically shutting down without damage
to any internal components. The power drive module shal l stop operating when either the
ground or phase current reaches approximately 5 -t imes the current rating of the inverter
or brake IGBT. However, an over-current fault may be reported instead of a short circuit
/ ground fault in the case that the short circuit trip point is not reached within a certain
time frame. A shorted motor may cause this. Install a known good motor on this servo
drive and see if the problem still exists.

Code 4 - IGBT Saturation Fault: Normally a fault code of 4 is a symptom of poor
system grounding. If the fault can not be cleared by turning the power off and then back
on to the power drive module, the fault may indicate a hardware failure with the power
drive module. This means the power drive module will need to be replaced providing that
the system grounding checks out to be good.

Code 5 - Substrate over-temperature: The substrate temperature is monitored by
the hardware of the power drive module. If the temperature exceeds 92 degrees Celsius
or 197.6 degrees Fahrenheit, the power drive module will stop operating and report fault
condition "5". The power of the 12VDC fan is controlled internally by the power drive
module. The power to the fan is cycled on and off automatically based on the
measurement of the substrate temperature.

Code 6 - PWM frequency fault: If the PWM frequency exceeds 10.5kHz, the power
drive module will display an error code of "6". This means that the parameter associated
with the power output of the power drive module may have to be set correctly within the
servo control. In addition, a "6" fault can also be a symptom of poor grounding or PWM
command signal shielding. Make sure that the motor and the AC power ground are both
tied to the Power d rive module heat sink. Also check t he routing and shielding of the
servo driver cable that runs from the pendant to the servo driver. This problem should
never be evident on the machine.

Code 7 - Substrate temp sensor fault: If the substrate temperature sensor fails, the
power drive module will display an error code of "7". This is a hardware failure. The servo
drive module must be replaced.

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Code 8 - Control Mode fault: If the servo controller is not properly configured to
control a power drive module in PWM mode, or there is a cabling error, the module will
display an error code of "8". This problem should never be evident on the machine.

Code 9 - DC link under voltage: The power drive module will report under voltage
conditions. If an under voltage condition exists, the power drive module will shut down
the output and report fault condition "9". The under voltage tr ip point is 170VDC for
230VAC power drive modules. These voltages are set in the hardware. Check the DC
voltage across the terminals labeled B- and B+. At 230 volts the DC voltage should be
approximately 300 VDC.

Code A - DC link over voltage: The power drive module will report over voltage
conditions. If an over voltage condition exists, the power drive module will shut down the
output and report fault condition "A". The over voltage trip point is 450VDC for 230VAC
power drive modules. These voltages are set in the hardware. This code may only be
present if the machine was mistakenly wired for 440 volts.

Code B - DC logic power supply fault: This error code "b" can be attributed to poor
grounding practices. Assuming that there is not a hardware failure in the pow er drive
module, look at the ground connection between the motor frame and the power drive
module. A poor connection here can generate enough noise t o cause this power supply to
droop.

Codes C, D, E and F – not used
As stated above in the motor section, one way to troubleshoot a faulty servo driver is to swap

components with a problem free axis and see if the problem moves. Switching the power
cable and encoder cable for the faulty axis with a good axis can do this. If the problem moves
to the other axis and clears up from the original axis, replace the Ser vo Driver.

WARNING!

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

servo drivers are run by 220 VAC. There is possibility of death by electrocution!

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4.6 Electrical

Figure 4-1

The electrical box is broken down into 4 different modules: power module, drive module, auxiliary
module and encoder module. See Figure 4-1 for an illustration of the box layout. See figures 7­33 through 7-37 for cable diagrams.

Electrical Cabinet

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Item

P/N

Title

Use As

Qty

2

22287-1540V

AC DRIVE-10 HP VECTOR

EA

1

5

22149

FAN-PT4-12V-DRIVE MODULE

EA

1

9

22164

FAN-PT4-ENCLOSURE

EA

1

12

22552

FILTER-PT4 ELE CTRICS BOX

EA 1 13

22553

HANDLE-PT4-ELECTRICS BOX

EA

1

16

21893-6

FUSE- 500 VOLT- SLO-BLO TYPE

EA

2

19

22288

MODULE ASSY- PT4- POWER PANEL POWER STRIP

EA 1 20

21824-8

FUSE-3AG-SLOW BLOW

EA

1

23

21824-1.6

FUSE-3AG-SLOW BLOW

EA

1

30

22758-2460V

KEY-PT4-MACHINE ID (2460V)

EA

1

Electrical Cabinet, Parts List

1 22157-32 RESISTOR- 750 W 32 OHM EA 2 or 3

24084-2460V
3 22027-220 SERVO- POWERBLOK- 220V EA 2
4 22028-220 CAPBLOK MODULE-PT4 220V EA 1

6 22068-2 MODULE ASSY-VL- ENCODER INTERFACE EA 1
7 22065-2 MODULE ASSY-PT4-EB-SPIN/AUX I/F-LATHE EA 1
8 21893-25 FUSE- 500 VOLT- SLO-BLO TYPE EA 3

10 22656 GUARD- FAN EA 1
11 22653 HANDLE OPERATING MECHANISM EA 1

14 22554 WASHER- SEALING EA 1
15 21753 GROUND BAR-PT4 EA 1

17 21258 TRANSFORMER -1000VA EI EA 1
18 22654

22654-1

21 21824-3 FUSE-3AG-SLOW BLOW EA 1
22 21824-1 FUSE-3AG-SLOW BLOW EA 1

AC DRIVE 15 HP VECTOR

BREAKER-220 VOLT- 60 AMP – 2460
BREAKER-220 VOLT- 50 AMP - 1540

EA 1

24 22552-1 FILTER-PT4 COOLING FAN EA 1
27 21893-2 FUSE- 500 VOLT- SLO-BLO TYPE – not used on 1540 or

2460

28 22026-40

22026-60

33 22758-1540V KEY-PT4-MACHINE ID (1540V) EA 1

i00980-1

FUSE- CLASS J TIME DELAY-AJT-40 AMP-1540
FUSE- CLASS J TIME DELAY-AJT-40 AMP-2460

EA 3

EA 3

4.6.1 Power Module

The purpose of the power module is to fuse and distribute 220 V 3 phase power to the
drive module assembly. Also, 220 V single-phase power is input into the transformer to
produce 110 V single-phase power to the power strip. The power strip has (6) 110 V
outlets that supply power to the pendant, spindle auxiliary module, spindle motor fan,
electrical box fans and a work light. One outlet is used as a spare. There is a LED light
on the power strip that indicates it is getting 110V power. If this is out check its fuse
followed by the fuses for the transformer.

The power module has (3) 40 amp fuses (1540V & 1840V ) or (3) 60 amp fuses (2460V) to
protect the spindle AC drive and (3) 25 amp fuses to protect the X and Z servo drivers. It also
has (2) 6 amp fuses for the transformer. The power module also has a ground bar where all
of the panels are grounded. The 1840V has an additional 2 fuses r ated at 2 amps to protect
the headstock oil pump.

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4000 – 200 Hz

Low Gear 850 High 2500

Low Gear 670 High 1800

4.6.2 Drive Module

The drive module consists of 2 servo drivers for X and Z, an AC drive to control the
spindle, and a fan to cool the servo drivers. An explanation for the servo drivers can be
found in the servo driver sec tion.

4.6.2.1 AC Spindle Motor Drive

The AC drive varies the frequency of the power to change the speed of the motor. The
lower the frequency the lower the spindle RPM and the higher the frequency the highe r
the RPM. The frequency range for the 1540V, 1840V, & 2460V machines are shown
below. The corresponding RPM’s for each machine are listed in the table below. Note
that the 1840V & 2460V have a low and high gear while the 1540V has only 1 speed
range.

1540V – Spindle RPM -

Frequency

150 – 7.5 Hz Low Gear 80 High 250

1840V – Spindle RPM –

Frequency

10.5 Hz

2460V – Spindle RPM -

Frequency

Low Gear 40 High 100 –

8 Hz

106 Hz

– 145 Hz

4.6.2.2 Braking Resistors

The braking mechanism for the spindle motor is non-mechanical. The braking effect is
caused by the AC drive sending a current that produces a set magnetic field. This set
field will oppose the motion of the motor and bring the motor to a stop. The energy
generated through braking is dissipated by 2 (1540V & 1840V) or 3 (2460V) brake
resistors and mounted to the top of the electrical cabinet. The motor is set to brake in 3­4 seconds for the 1540 & 1840 and 6 seconds for the 2460. Chucks larger than 12” may
require the braking parameter N22 to be adjusted to a higher value.

WARNING!

The resistor becomes very hot during braking. Before working around this area, be sure braking

has not occurred in the last 10 minutes.

Note: the values in the AC drive are programmed at the factory and should never be
adjusted without approval.

If there is a problem with the braking of the system the resistor can be checked with an
ohmmeter. Remove the cover of the AC spindle drive and locate terminals B1 and B2.
The reading across these terminals should be approximately 16 ohms for the 1540V &
1840V and 11 ohms for the 2460V. If the ohmmeter displays an overload then the
resistor is bad or there is a bad connection. Each individual resistor should measure
32/33 ohms.

4.6.3 Spindle Auxiliary Module

This module is located on the lower left side of the electrical cabinet above the encoder
module. See Figure 4-1. This list below describes what takes place through each
connection.

• LPT Parallel Port (From Pendant) - Controls the Auxiliary Module from the
Pendant. Its primary function is to control the limit switches, coolant pump, lube
pump, and spindle signals.

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• Machine I.D. Key Port - Configures the slave s oftware according to the machine
type. This key tells the control what type of machine it is. If this key is not present
the machine will not boot up correctly.

• Spindle Control Port (From Pendant) - Interfaces signals such as Run, Off, Stop,
FWD/REV, and E-Stop fr om the Pendant to the spind le auxiliary module.

• Spindle Control Port (To PC7 Spindle Drive) - Interfaces signals such as Run, Stop,
FWD/REV, Overload, and E-Stop from the spindle auxiliary module to the Spindle Drive.

• Euro Relay Port – not used on lathes

• Indexer Port - An auxiliary function that uses Logic signals to operate the indexer.

• XZ-Limit Switch Ports - Logic signals from limit switches. These signals are a lso

direction specific.

• Door Guard Port – feeds signal back to control from door switch.

• Coolant Pump Outlet - An auxiliary function that uses a 110V signal to power the

coolant pump. This outlet uses a 3A fuse for circuit protection and an Indicating
Lamp, which signifies that the outlet is powered up. The fuse and the Indicating
Lamp are located next to the outlet.

• Lube Pump Outlet - An auxiliary function that uses a 110V signal to power the lube
pump. This outlet uses a 3A fuse for circuit protection and an Indicating Lamp, which
signifies that the outlet is powered up. The fuse and the Indicating Lamp are located
next to the outlet.

• Auxiliary Module Power In -110V signal from the power strip to power the
auxiliary module. This uses a 3A fuse for circuit protection and an Indicating Lamp,
which signifies that the Auxiliary Module is powered up. The fuse and the Indicating
Lamp are located next to the incoming power cord.

4.6.4 Encoder Module

This module is located on the lower left side of the electrical cabinet below the spindle
auxiliary module. See Figure 4-1. This list below describes what takes place through
each connection. There are 2 LED’s that signify that power is reaching this module.
Power reaches the encoder module through umbilical cables 1 and 2 and also the
electronic hand wheel cable. If these lights are off and all the cables are plugged in then
the computer module is probably the problem.

• Umbilical #1 & Umbilical #2 Ports (To Pendant) - The lathes have (2) motor
encoder signals which are communicated between the Encoder module and the
Pendant by use of (2) Umbilical cables. The X signal is communicated through
umbilical #1 and the Z motor signal is transferred through umbilical #2.

• Electric Hand Wheel Port (To Pendant) - Communicatio n for X & Z-Hand Wheel
and jogstick logic signals between the Pendant and the Encoder module.

• X & Z-Electric Hand Wheel & Jogstick Ports - This port is used to receive logic
signals from of the X and Z-Electric Hand Wheels and jogstick.

• X & Z-Motor Encoder Ports - These ports are used to receive logic signals from
each of the XYZ-Motor Encoders.

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4.6.5 Cable Connections

WARNING!

possibly cause death by electrocution!

The lathe machines use 15+ 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

unplug

the system from the wall.

connector board and harm to the technician.

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

3. Carefully clean any chips away from the connectors.

4. One-by-one, take out each connector and then plug them back in. Do the same at
the computer/display.

5. Make sure the screws are tightened on each of the connectors.

4.6.6 Checking A/C Voltage

This procedure tests for the 115V power for the control.

• Use a Voltmeter, reading A/C volts.

• Acceptable ra nge is 110V 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.

Our system is shipped out assuming the customers shop has 220 V power. The transformer
secondary tap is set on 115 volts. Measure the voltage coming out of the transformer by
placing the voltmeter across the 115 V and 0 V taps. If this measurement is above 120 volts
then move the tap from 115 V to 110 V. If the reading is low, 110 V or below, then change the
tap from 115 V to 124 V. Input power to the machine that is 230 V or above will cause the 110
voltage to be high and voltage that is 208 V or below typically causes 110 voltage to be low.

WARNING!

Turn the main power off before changing the taps on the transformer. Failure to do this can

4.6.6.1 Checking Fuses

There are 15 fuses that make up the system on these lathes. There is (1) 1-amp fuse in
the pendant, 13 fuses in the electrical cabinet and 1 fuse in t he lube pump.

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To check fuses:

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

2. Remove the fuse completely from the pendant display or computer module.

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

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

• A bad fuse reads Open or Infinity or OL (overload).

4.6.6.2 Fuse Indicator Lights

The power strip and spindle auxiliary module have LED lights on them to signify that 110
V power is reaching the components. If these lights are off, check up stream to see if
some other fuses are blown.

Within the spindle auxiliary module there are also 3 LED’s that come on when the lube
pump, indexer and coolant pump outlets are activated. The indexer light should always
be on unless there is an E-stop pressed. The lube and coolant pumps lights are on only
when these devices are programmed to run. If they do not come on when they should
check the fuse next to the light .

4.7 Door & Gear Switch

The 1540V, 1840V and 2460V machines 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.

Gear Switch – 1840V & 2460V only
On the 1840V & 2460V, the gearbox has 2 gear ranges. See the table in section 4.6.2.

on page 53. A switch is mounted under the sheet metal cover on the left side of the
headstock. The switch closest to the headstock casting controls high gear and the other
one controls low gear. If the gear shifter is in the middle of both gears, neither switch
will be engage and the spindle will be in neutral. Both switches are wired normally
closed. This means the switch is open when the switch is triggered. There should be no
continuity between pins 1 and 6 when the high gear switch is forced closed and
continuity when the switch is in the open position. There should be no continuity between
pins 2 and 7 when the low gear switch is forced closed and cont inuity when the switch is
in the open position.

4.8 Service Codes

Service codes are broken down into the 5 following categories: software, machine setup,
diagnostics, user options/defaults and lubrication pump control.

All Service Codes are accessed in the SET-UP Mode by pressing the soft key for “SERV
CODES”. The service codes can be found under one of the headings list ed on the main
screen. Press the heading you want to access the code in question. If you know code #
you want press the CODE # softkey and it will take you directly to the code in question.
Press CODE #, enter the number you want, press SET.

4.8.1 Software Codes

The following codes pertain to software functions in the control. To get to any of these
codes go to Service Codes, press “A” and press the code you wish to view.

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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: Software ID

The Code 33 is the software identification procedure. The two types of software in the
control include:

• Software Version - the version of the system you have installed

• Firmware Version - the version of firmware software that is responsible for control

to servo interface.

• Converter Version – the version of software that is responsible for converters and
options.

4.8.1.2 CODE 37: RS232 Baud Rate

This code sets the baud rate for RS232 applications. The recommended baud rate is 9600.
The following baud ra tes can be chosen: 4800, 9600, 19200, 38400, 57600, 115200.

4.8.1.3 CODE 141: Load Configuration File From Flop p y “A” Drive

This code allows you to load your configuration file from the floppy disk to your hard
drive. The configuration file consists of items such as calibration and backlash constants.
This code is used when a computer module or hard drive has been replaced.

4.8.1.4 CODE 142: Save Configuration File to Floppy “ A ” Dri v e

This code allows you to save your configuration file to a floppy disk. The configuration
file consists of items such as calibration and backlash constants. This code is used when
a computer module or hard drive needs to be replaced. This stores the configuration file
from the hard drive to the floppy disk. It is a good idea to do this code after the machine
is initially setup so these values can be saved and used in the future. If the computer or
hard drive fails, then you will not have the ability to save the configuration file and the
machine will need to be re-setup when the computer or hard drive is replaced.

Note: All machines will have a copy of the configuration file in the back of the electric’s
cabinet.

4.8.1.5 CODE 313: Display Configuration File

This code displays the configuration file. This file contains pertinent information about
the machine. The file will look similar to the following. If the file becomes corrupt you
can load default values by pressing the F4 softkey.

Product = 1540V (displays machine ID key of machine )
Lube pump cycle time – 60 minutes
Lube pump discharge time – 15 seconds
Motor encoder calibration constants X=242.0411 Z=242.0342
(These numbers above are typical numbers for the calibration constants)
Arc accuracy – 0.005”
Limit switches – on or off
Spindle on or off during run – On or Off
Code 128 X=0.001” Z=0.0016”
Code 12 (+) X=000005 Z=000006
(-) X=000005 Z=000006
Code 100 (+) X=352.7 Z=325.2
(-) X=350.1 Z=333.1

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4.8.1.6 CODE 316: Update Master Software

Load upgrade disk in floppy drive and press this service code. New software will
automatically download and control will reboot. Please perform alignment routine
afterwards.

4.8.1.7 CODE 317: Update Slave Software

Load upgrade disk in floppy drive and press this service code. New software will
automatically download and control will reboot. Please perform alignment routine
afterwards.

4.8.1.8 CODE 318: Activate Conv er ters or Options

See programming and o perating manual.

4.8.2 Machine Set-Up Codes

The following codes are used primarily when setting up a new machine. To get to any of
these codes go to Service Codes, press “B” and press the code you wish to view.

4.8.2.1 CODE 12: Feed Forward Constant

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

Steps:

1. Position the table and addle in the center of travel.

Note: You will lose your DRO

position reference.

2. Go into the Service Codes and input the Code 12.

3. Press Auto

4. The system will run the routine automatically and then display values on the position
readout.

Explanation

Typical values should be between 2.02 and 8.08 are considered normal for the Z axis and
10 to 18 for the X axis. Higher values indicate excessive friction in the system. Lower
values indicate a loose system and may mean a gib adjustment is necessary. The value

2.02 means the friction is a factor of 2 in one direction, and 2 in the other direction. The

values should be within 3 of each other in both directions. A value of 6.08 would still be
considered normal.

Machines with axis torques from 8 to 12 in-lbs can expect values in the 4 to 6 range.
Machines with torques from 13 to 17 in-lbs can expect values from 5 to 7 and machines
with a torque range from 18 to 22 in-lbs can expect values from 7 to 9. Typical torque
values on machines that ha ve the ball screw aligned and the gibs adjusted to

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specification should be between 10 to 15 in-lbs. Divide the X-axis values by 2 and apply

Your input

Display

Data displayed.

Feedrate

the maximum feedrate attained

Your input

X -

Z

the torque values from above.
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
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
9 may lead to servo related problems.

4.8.2.2 CODE 100: Axis Open Loop Test

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

IMPORTANT -- SAFETY NOTICE

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

for 1 second in the direction you choose. Avoid crashes by making sure the quill is out of the

way and by starting with the table and saddle centered. MAKE SURE THAT NO ONE IS

STANDING IN THE WAY OF THE TABLE OR SADDLE!

Note: You will lose the DRO reference position.

This procedure is to be run for each axis that is servo-driven, and for both the plus and
minus direction for each axis.

1. Center the table and saddle and raise the head. Make sure the gib locks are released.

2. On the P endant display, go into the Service Codes and input the Code 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 direction, press +/-, then INC SET.

5. In the conversation line it will say “PRESS GO”. Press Go after you are sure that the
machine will not crash in the direction and axis that you have specified.

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

X + X motor encoder reading

Z

X motor encoder reading

Feedrate the maximum feedrate attained

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Your input

X

nothing (should be 0 )

Feedrate

the maximum feedrate attained

Your input

Z

motor encoder reading

WARNING!

Z +

Z motor encoder reading

X nothing (should be 0 )

Z -

Feedrate the maximum feedrate attained

Interpretation of the resulting values displayed:
The values for the encoder displays should be i n the range of 4.0000” to 6.5000”.
The feedrate should be a minimum of 300 ipm. Shops with higher voltages will see higher

values. Values for voltages in the 208 V range will see values somewhere around 325 to 350
ipm. Shops with voltages around 240 V may see values in the 400+ ipm range.

• If the feedrate is very different on the same axis for + and -, then the torque on the
axis that is tested is may be higher than 15 in-lbs. Typical torque values on
machines that have the ball screw aligned and the gibs adjusted to specification
should be between 10 to 15 in-lbs. This will produce code 100 values within 50 ipm
in the positive and negative directions. Machines that have an axis torque of 20 in­lbs may see a deviation of 75 ipm. If the code 100 values exceed this deviation then
the axis torque is too high. Align the ball screw or adjust the gibs.

• If the feedrate is less than 300 ipm and consistent in both directions, check the
incoming AC voltage.

4.8.2.3 CODE 123: Calibration

See Section 5.22 for a further explanation of this code.

4.8.2.4 CODE 127 - Set X or Z Backlash Constant

See Section 5.22 for a further explanation of this code.

4.8.2.5 CODE 128: Input Backlash Constant

Code 128 allows you to enter the backlash values for each axis. It displays the value
after it enters. This code is only used on machines with mot or encoders only.

4.8.2.6 CODE 203 or 204: Brushless Motor Alignment

This service code needs to be performed each time the ProtoTRAK is turned on, new
software is installed or axis motors have been replaced. The control will boot up
automatically to this screen. Press the Check System key and follow instructions on screen.

It is important that there are no obstructions on any axis before running this code. If there is an

obstruction, then use the el ectronic handwheels to slowly move the machine away from the obstruction.

Each axis will move approximately 1” during this routine. The handwheels will not move
at the normal feedrates during this routine. Failure to move each axis away from an
obstruction will cause a crash.

1840V & 1540V Only: The Motor Alignment Routine Code 203 calculates the relative
position between the motor poles on the stator and the magnets on the rotor through the
use of the motor encoder. Once the stator and rotor are aligned the encoder’s absolute
zero is set. The routine also distinguishes which type of motor is being used on the
machine. The routine can last up to 30 seconds. After 30 seconds, the routine will under

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go a Time-out. If the motor alignment routine fails to work properly, a message should
appear on the display prompting the user that the motor alignment routine has failed. or
glass scale on or off.

The 2460V Lathe uses Code 204 to align the motors .

4.8.2.7 Code 308: Reverse X Hand Wheel Direction

This service code reverses the direction of the X hand wheel.

4.8.2.8 Code 310: Reverse Z Hand Wheel Direction

This service code reverses the direction of the Z hand wheel.

4.8.2.9 Code 311: Run Machine with Spindle Off

This service code toggles this function on or off. It defaults to off from the factory, which
means the spindle must be on for a program to run. If it is on and you forget to turn the
spindle on, the tool will move to Z rapid and wait for the spindle to come on. This
function will be needed if you are running a repeatability program with an indicator in the
spindle. Make sure this feature is on when cutting parts.

4.8.2.10 Code 312: Toggle Li mi t Switches On/Off

This service code toggles the limit switches on or off. Code 313 also displays which state
the limit switches are in.

4.8.3 Diagnostic Codes

The following codes are used primarily when diagnosing a problem with the machine. To get
to any of these codes go to Service Codes, press “C” and press the code you wish to view.

4.8.3.1 Code 54: Program Continuous Run

This Code runs a program continuously without stopping for tool change 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: Keyboard Test

This code is used to check if the keyboard is functioning correctly. It allows you to test
each key on the pendant individually. When you press the keys, the corresponding box
for that key will highlight on the screen. The pendant will also beep, indicating that the
key is working correctly. If one of the keys does not work the pendant ass embly 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 before the calibratio n and backlash factors have been factors
into the counts.

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4.8.3.4 Code 132 - Electronic Hand Wheel Tes t

Turn the X or Z-axis electronic hand wheel. The display should show movement as the
hand wheel is being turned. There should be no skipping and it sho uld count smoothly
while the hand wheel is being turned. One revolution of hand wheel should read 0.4000”
for Z and 0.1000” for X in course, and 0.100” & 0.020” for fine mode.

4.8.3.5 Code 133 – Spindle Encoder Test

Turn the spindle or run the spindle at low RPM’s. The display should show the counts
from the spindle encoder. I t should count to 360 on the Z display and then r eset. Each
time it resets it displays the number in the X display area.

4.8.3.6 Code 314: Toggle Test Lights ‘On’ in Stat us Line

This code toggles on and off 2 test lights that appear in status line. The top light
signifies if the master software is working. If functioning it should flash a green light.
The bottom light signifies if the slave firmware is functioning. It will appear orange in run
mode when it is processing information. Pressing the mode key will change this orange
box to black. The orange box will also change to black when the program you a re
running reaches the 3
no keys will work. This code is useful for diagnosing intermittent problems with the
control locking up.

rd

event from the end of the program. If the firmware is locked up

4.8.3.7 Code 319: Error Log

This code when turned on captures the commands that were sent to the servo system.
It includes items such as positioning commands, errors, stop and go commands, etc. It
may be helpful for identifying problems between programmed commands and executed
commands. To turn on the error log press the F6 softkey. The page forward and
backward keys allow you to scroll through the file one page at a time. The data forward
and data backward keys allow you to scroll through the file one line at a time. The data
bottom key takes you to the bottom of the file and then changes to data top which will
take you back to the top. The file will capture data until the file reaches a size of
approximately 600 Kb. At this time the file is saved to a backup file and the original file
is cleared and data is once again captured. Once again as the file reaches a size of 600
Kb it copies over the previous backup file. From here the user can save the file to the
floppy drive by pressing the F8 softkey. Once this in done it prompts you for which file
you want to save to disk. The F1 key saves the current file to disk and the F2 key saves
the backup file to disk. To clear the files press the F7 softkey.

4.8.3.8 Code 324: Toggle Simulation Mode

Simulation Mode allow s the control to run a program without actually moving the table.
It is helpful in diagnosing Computer/display problems.

4.8.4 Operator Defau l ts/Options Codes

The following codes allow the user to set programming defaults or turn features on or
off. To get to any of these codes go to Service Codes, press “D” and press the code you
wish to view.

4.8.4.1 Code 66: Default Metric

This code causes the control to turn on in the metric mode.

4.8.4.2 Code 67: Default English

This code causes the control to turn on in the English mode.

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4.8.4.3 Code 79: Beeper On

This turns on the beeper to t he control keys.

4.10.4.4 Code 80: Beep e r O f f

This turns off the beeper to the control keys.

4.8.4.5 Code 129: Arc Accuracy

When the VL 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

0.005 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 lathe 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 instructions on the screen and input the Following Error value (from .0001 to

.0100) and press INC SET.

4.8.4.6 Code 323: RS232 Com Port

This code switches between COM ports for RS232 applications.

4.8.4.7 Code 143: Toggle Tool Change Spindle Mode

This code allows the spindle to stay on at tool changes when turned to the ON position.

4.10.4.8 Code 147: Initialize Index er

This code is to be used on machines with indexers only. It will reinitialize (reset) the
indexer if the unit is in the wrong position. This type of situation may occur if the E-stop
is pressed while the unit is rotating to a new tool position. This code will also need to be
run, for example, if the indexer is in tool position 4 and the control thinks it is in some
other tool position.

4.8.5 Lube Pump Codes

The following codes are used for programming and operating the lube pump. To get to
any of these codes go to Service Codes, press “E” and press the code you wish to view.

4.8.5.1 Code 300: Lube Pump Switch

This code acts as a switch to turn the lube pump on for the programmed time set in Code 302.

4.8.5.2 Code 301: Set Lube Pump cycle time

This code sets the interval time between lube cycles.

4.8.5.3 Code 302: Set Lube Pump discharge time

This code sets the lube pumps discharge time.

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5.0 Procedures for Replacements & Maintenance

WARNING!

Replacement motors will not come with adapter plates.

Figure 5-1

5.1 Replacements

5.1.1 Servo Motor Replacement

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

servomotors are run by 220 VAC. There is possibility of death by electrocution!

1. Turn off power to the machine.

2. Remove the necessary sheet metal covers to get access to the motor.

3. Remove the power and encoder cable from the motor.

4. The motor is bolted in place with (4) M6 SHCS.

5. The motor is bol ted to an adapter plate. Remove the motor from the adapter plate
before sending back to SWI. Use the adapter plate on the replacement motor.

CAUTION!

See Figure 10 for an illustration of the motor and adapter plate.

Motor Assembly

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5.1.2 Servo Driver Replacement

WARNING!

Do not work with the Servo Drivers unle ss the power is disconnected from the machine. The

servo drivers are run by 220 VAC. There is possibility of death by electrocution!

1. Turn off power to the machine.

2. Open up the electrical cabinet.

3. Remove the bracket that holds the cable in place. Remove the servo driver cable
from the front of the servo driver.

4. Remove the power cable that runs to the servomotor. This includes the (3) 3 phase
wires and a ground wire on the side of the aluminum extrusion. In order for the
servomotor to move in the same direction as it did before you replaced it you must
put the wires back in the same terminals. T1 uses the red wire, T2 uses the white
wire and T3 uses the black wire.

5. Remove the black wires from servo driver labeled L1, L2 and L3. These wires feed
power into the servo drivers.

6. Remove the wires that run between each servo driver. They are labeled B-, B+ and
IR. Once again, make sure to put them back into their proper terminals.

7. On the Z drive remove the small red cable that runs to the fan at the bottom of the
extrusion. This cable provides p ower to the fan.

8. On the Z servo drive make sure to unplug the capacitor from the servo drive. The
capacitor mounts to the top of the drive. Use this capacitor with the replacement
servo driver.

9. The servo driver then mounts to the aluminum extrusion with 4 screws.

CRITICAL!

After replacing a servo driver, make sure to secure the bottom right hand screw of the drive that
includes a ground cable to the heat sink, and the grou nd cable to the side of the heat sink. Also

make sure that the heat sink is grounded to the ground bar on the power panel. Failure to do

this may cause a good servo dri ver to not work properly.

See Figure 5-2 for an illustration of the wiring of the servo drive.

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

Figure 5-2

Drive Module

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

5.1.3 AC Spindle Drive Replacement

WARNING!

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

is run by 220 VAC. There is possibility of death by electrocution!

1. Turn power off to the machine.

2. Before working on this unit make sure all lights on the display are off. These units have a
capacitor internally that keep them powered up for a minute or so after the power is
turned off.

3. Remove the display unit on the front face of the unit. Also remove the lower cover
on the unit to gain access to the wires.

4. Disconnect the 3 wires on the lower left side of the unit. These wires bring power into
the unit.

5. Remove the 2 wires labeled B1 and B2. These wires run up to the resistor.

6. Remove the 3 wires labeled T1, T2 and T3. These wires take power to the spindle
motor. Make sure to put these wires in the same position on the new unit. T1 uses
the red wire, T2 uses the white wire and T3 uses the black wire.

7. Remove the ground wires from the bottom of the unit.

8. The unit bolts in place with 4 screws.

9. Follow the instru ctions in reverse order when reinstalling.

Note – the replacement AC drive will have the AC drive cable (#22443 or 22443-1)
already wired to the drive.

See Figure 5-3 for an illustration of the wiring of the AC drive.

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Figure 5-3

ITEM 17

SPINDLE

SPINDLE

PIN #

FUNCTION

PIN – 1540/1840

PIN - 2460

1

SPD FWD

S1

S1

2

SPD REV

S2

S2

3

SPD E-STOP

S3

S3

4

TAP MODE

S5

S5

5

SPD RESET

S4

S4

6

SPD GND

SC

SN

7

A GND

FC

AC

8

DAC OUT

FR

A1

9

GND

MC

MC

10

GND

PC

M2

11

FAULT FDB

MA

MA

12

RUN FDB EN

P1

M1

13 - 14

-

i00989

15 A GND FC AC

A/C Spindle Drive

Note – 2460 AC drive looks slightly different

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5.1.4 Computer Module Replacement

1. Turn power off to the machine and control.

2. Unplug all the connectors on the pendant arm side of the pendant.

3. Remove 4 screws on the right side of the unit and 2 screws on the left side of the
unit. The module is now free to slide toward the right side of the pendant.

4. Slide the computer module a few inches and stop. Pulling the computer module too
far will damage the LCD cable.

5. Now reach from the pendant arm side of the unit inside and remove the 37-pin LCD
cable.

6. Now slide the module about ½ way out of the pendant sheet metal.

7. Remove the ground stud from the side of the computer module.

8. Next remove the 37 and 9 pin connectors from the top of the computer module.

9. Lastly slide the unit completely out of the sheet metal.

10. Follow the instructions in reverse order when reinstalling the new computer module.

11. Make sure the connectors are fully seated before bolting the unit back in place.

Note: if the hard drive is functional, you may want to remove the hard drive and install it
in the new computer module. See the instructions in Section 5.1.5.

See figure 5-4

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

Part #

Description

24200-2

VL Pendant W/Out Computer

Figure 5-4

Computer Module &
Hard Drive Replacement

22328-2 Pendant Assembly

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

5.1.5 Hard Drive Replacement

CAUTION!

The hard drive is located inside of the computer module. It has been designed so it can
be easily replaced in the field without replacing the entire computer module. Follow the
instructions below. See figure 5-4.

1. Turn off power to the machine.

2. On the right side of the pendant above the floppy drive remove the 2 screws holding
the hard drive in place.

3. Slide the unit towa r d you. Be careful not to pull it too far since a cable will restrict its
travel.

4. Unplug the 40-pin hard drive cable and 4-pin power cable from the connector board.
Lastly remove the hard drive assembly. The entire assembly will be replaced which
includes the hard drive, connector board and associated sheet metal.

5. When reinstalling the 40-pin cable make sure you plug it in correctly. The tab on the
cable should match the opening cut out in the male connector.

6. Slide the unit back into place and fasten the 2 screws.

Note: the new hard drive will have all of the necessary software installed already.

It is a good idea to back up your hard drive from time to time via a network or floppy disk. If

your hard drive needs to be replaced you will loose all of your programs. See your programming

manual for instruct i on on how to do this.

5.1.6 Electronic Handwheels & Jogstick

There are 2 electronic handwheels on the lathes and 1 jogstick to move the carriage
quickly into position. Each unit is replaced as an assembly. Disconnect the handwheels
and jogstick from the apron cable.

5.1.7 Cable Routing in Electrics Box

Each cable on this machine is labeled to help identify where it is used. The lower section
of the electrics box has an area where the extra slack in the cables can be stored. There
is a cover that covers up all of the cables. Whenever you replace a cable or reroute a
cable it is very important to keep the power cables and logic cables separated from each
other. The power cables consist of the (3) 220-volt servo motor cables and (6) 110-volt
power cables for the pendant, spindle motor fan, wor k light, coolant pump , lube pump
and spindle auxiliary module. The logic cables are used to carry signals between
modules, handwheels, encoders, etc. The power cables have been placed on the right
side of the electrics box when facing from the back of the machine and the logic cable s
have been routed to the left side of the box. Mixing of the power and logic cables may
cause noise from the power cables to interrupt the signals in the logic cables. This can
lead to intermittent axis faults or repeatability problems.

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5.1.8 Spindle Encoder Replacement

i00491

1. Unplug or remove all power from the lathe.

2. Remove the spindle cover to gain access to the encoder.

3. Loosen setscrews on flexible coupling and the bolts that hold the en coder on.

4. Slide the encoder off.

5. The spindle encoder assembly is only available as a complete unit. Do not
disassemble.

Note: on the 1540 make sure the belt between the spindle and encoder bracket is
properly fastened.

5.1.9 Spindle Drive Belt Tightening/Replacement

The spindle drive motor is located inside the base pedestal, underneath the headstock.
Access is gained by opening the upper cover on the headstock and removing the lower
access panel on the pedestal.

When removing the belt, loosen the top nut and raise motor with the bottom nut until
the belt is loose.

To tighten the spindle belt, loosen the bottom nut “A” under the motor bracket and use
the top nut “B” to tighten the belt. See t he figure below. Make sure the tension on the
belt is such that there is no slippage when the lathe is started at its maximum speed.
The belt tension can be checked by pulling on one of the belts in the center of its travel
with a scale until you reach 15 lbs. on the scale. At this point the deflection of the belt
relative to the other belt should be no more than 1/2”. If the deflection is more than
1/2” tighten the belt.

Belt tension shoul d be checked frequently during the fir st days of operation, and
periodically thereafter. Keep the pulleys and belt clean and free of any foreign material
to ensure long life and maximum traction.

Figure 5-5
Spindle Motor B elt Adjustme nt

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

5.1.10 Spindle Motor Rem ov al

1. Unplug or remove all power from the lathe.

2. Mark and remove motor electrical leads.

3. Because of the weight and size of the spindle motor, and the restricted working
space, extreme caution should be used in slidi ng the motor from its mounting plate.

4. Loosen the belt tension. See section above.

5. The motor is sec ure d with four screws to a flange plate. See the figure above.

5.1.11 X-Axis Ball Screw Removal

1. Unplug or remove all power from the lathe.

2. Access to the X-axis ball screw is gained by removing the back cover in the chip
guard and removing the X-axis motor cover.

3. Remove the motor.

4. Remove all items on the right e nd of the ball screw. See Figure 5-6 & 5-7.

5. Unbolt the ballscrew nut from the yoke.

6. The X ball screw is removed through the exposed hole when the cross slide is
removed.

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

Figure 5-6
X Axis Drive Train – 1540V & 1840V

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

X Axis Drive Train Parts List – 1540V & 1840V

Item

P/N

Title

UseAs

Qty

1

20982

SADDLE-TRL 1840 CSS

EA 1 2

20996

COVER PLATE-TRL 1840 X AXIS

EA 1 3

M6-1.0X12 27B

SCREW-BHCS-STL-BO

EA 2 4

20981

CROSS SLIDE-TRL 1840 CSS X AXIS

EA

1

21

21978

BRACKET-PT4- X-AXIS DRIVE

EA

1

22

M10-1.5X80 25B

SCREW-SHCS-STL-BO-FULLY THD

EA 4 23

21979

BRACKET-MOUNTING MOTOR-PT4- X AXIS DRIVE

EA

1

25

M8-1.25X30 25B

SCREW-SHCS-STL-BO

EA

4

29

M5-0.8X10 27B

SCREW-BHCS-STL-BO

EA

13

30

20980

BED-TRL 1840 CSS

EA

1

34

20988

CABLE WAY

EA 1 35

M6-1.0X14 25B

SCREW-SHCS-STL-BO

EA

2

36

20987

CONNECTOR-CABLE WAY

EA

1

37

M6-1.0X20 25B

SCREW-SHCS-STL-BO

EA 8 39

M6 70B

WASHER-FLAT USS-STL-BO

EA

8

40

22521

FITTING - LIQUID TIGHT 3/8 NPT

EA

1

Item

P/N

Title

UseAs

Qty

7

20984

BALLSCREW - X AXIS

1

1

8

5/16-18X1 25B

SCREW-SHCS-STL-BO

EA 4 9

16300

BEARING HOUSING

EA

1

10

23930

BEARING-ANGULAR CONTACT- 7204 BECBP

SET

1

12

M6-1.0X25 25B

SCREW-SHCS-STL-BO

EA

4

13

16314

NUT CLAMP-X AXIS

EA

1

14

10-32X3/4 25B

SCREW-SHCS-STL-BO

EA 1 15

16350

FERRULE-SPROCKET

EA

1

16

16983-1

PULLEY-SOLID 44 TEETH W/O GUIDES

EA

1

17

W02

LOCKWASHER

EA 1 18

NT02

NUT-LOCK

EA

1

20

500-5M-15

TIMING BELT

EA

1

24

M8 70B

WASHER-FLAT USS-STL-BO

EA 4 25

M8-1.25X30 25B

SCREW-SHCS-STL-BO

EA

4

27

M8-1.25X25 25B

SCREW-SHCS-STL-BO

EA

4

31

98481A090

KEY WOODRUFF #404-1/8 X 1/2

EA 1 32

7204-AVH

NILOS RING-7204

EA

1

33

1/4 73B

WASHER-SPLIT LOCK-STL-BO

EA

4

40

M8-1.25X20 25B

SCREW-SHCS-STL-BO

EA

1

i00977

5 20960 YOKE-TRL 1840 X AXIS EA 1

28 21996 COVER ASSY-PT4- X AXIS DRIVE EA 1

11 15885 RING-BEARING HOUSING EA 1

38 93501A030 WASHER SERRATED EA 4

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

Figure 5-7 - X Axis Drive Train – 2460V

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

X Axis Drive Train Parts List – 2460V

10

87-0228

Rear Cover Plate

SS41

1

 19x16UNF

W02 ( 15)

N02 ( 15x32UNF)

34 Socket Head Cap Screw

M8x16L

2

Item Parts No. Description Material Specifications Q'ty

1 Socket Head Cap Screw M8x30L 6
2 25200-1 Wiper - Bedway (Front) Rubber 87-0244 1
3 Hexagon Socket Screw M6x16L 4
4 77USA-0213 Nut Seat FC25 1
5 Socket Head Cap Screw M8x30L 4
6 O-Ring P7 1
7 20984 X-Axis Ballscrew SCM415 24-0211 1
8 25200-2 Wiper - Bedway (Rear) Rubber 87-0245 1
9 Hexagon Socket Screw M6x20L 4

11 24-0728 X-Axis Motor Cover Plate SS41 1
12 21994 Motor - X Axis 1
13 Socket Head Cap Screw M8x25L 4
14 Spring Washer M8 4
15 24-0208 Motor Plate S20C 1
16 Symchronous Pulley Aluminum 1
17 500-5M-15 Belt - X Axis 1
18 Socket Head Cap Screw M8x25L 8
19 77A-0202 Lock Block FC25 1
20 50-0325 Adjusting Screw S30C 4
21 21050-3F Gib - Z Axis FC25 77A-0218 1
22 77A-0216 Lock Block FC25 1
23 7204-AVH Ring - Nilos 1
24 23930 Bearing Set - Angular Cont ac t 7204BECBP 2
25 15885 Spacer S45C 1
26 16300 Bearing Housing S45C 1
27 16314 Nut - Clamp S45C
28 16350 Ferrule Brass 1
29 98481A090 Key - Woodruff #3 (1/8"x1/2") 1
30 16983-1 Pulley - Ballscrew 1
31 W02 Lock Washer
32 NT02 Lock Nut
33 Socket Head Cap Screw 10-32x3/4" 1

1

1

1

35 Flat Washer M8 2
36 Spring Washer M8 2
37 87-0738 Clamping Block SS41 1
38 Socket Head Cap Screw M10x90L 4
39 Socket Head Cap Screw M6x10L 2
40 Flat Washer M6 2
41 Spring Washer M6 2
42 77USA-0698 Cam SS41 1
43 Socket Head Cap Screw M8x30L 4
44 Flat Washer M8 4
45 Spring Washer M8 4
46 Socket Head Cap Screw M6x20L 4
47 Flat Washer M6 2
48 Spring Washer M6 4
49 87-0730 Bracket FC20 1
50 Wire Protector 88x45ax1850L 1

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

51 Hexagon Socket Screw M5x10L 11

84

24-0723

Operation Box

SS41

1

 30

N04( 20x16UNF)

52 24-0729 End Cover SS41 1
53 Socket Head Cap Screw M8x20L 2
54 Flat Washer M8 2
55 Spring Washer M8 2
56 77USA-0307 Switch Seat SS41 1
57 Socket Head Cap Screw M6x20L 2

NBNS543-BO2D12-

58 22551-1 Switch - Limit
59 Socket Head Cap Screw M6x16L 2
60 Flat Washer M6 2
61 Spring Washer M6 2
62 77USA-0698 Cam SS41 2
63 24-0207 X Axis Transmission Box FC30 1
64 Cross Recessed Head Screw M6x16L 6
65 25200-6 Wiper - Bedway (Right, Rear) Rubber 63-0362 1
66 25200-7 Wiper - Bedway (Left, Rear) Rubber 63-0363 1
67 Socket Head Cap Screw M6x25L 2
68 Spring Washer M6 2

69 Micro Switch
70 Socket Head Cap Screw M6x16L 2
71 Flat Washer M6 2
72 Spring Washer M6 2
73 87-0714 Cam SS41 1
74 25200-4 Wiper - Bedway (Left, Front) Rubber 63-0360 1
75 25200-5 Wiper - Bedway (Right, Front) Rubber 63-0361 1
76 Cross Recessed Head Screw M6x16L 6
77 87-0715 Cam SS41 2
78 Socket Head Cap Screw M5x16L 4
79 Flat Washer M6 4
80 Spring Washer M6 4
81 Socket Head Cap Screw M6x16L 4
82 Flat Washer M6 4
83 Spring Washer M6 4

61-12-10 1

BNS543-BO2D12­61-12-10 1

85 24-0724 Operation Box Cover SS41 1
86 Hexagon Socket Screw M5x6L 8
87 77USA-0311 Apron FC25 1
88 77USA-0605 Ballscrew Cover SS41 1
89 Cover - Round Hole
90 N04 Lock Nut S45C
91 W04 Lock Washer W04 1

Bearing - Ball - Double Row

92 22446
93 77USA-0307 Nut Seat FC20 1
94 Socket Head Cap Screw M12x50L 4
95 Spring Washer M12 4
96 77USA-0316 Bedway - Wiper (Right) Rubber 1
97 Cross Recessed Head Screw M6x16L 3
98 Rod S45C 1
99 87-0727 Support Bracket SS41 1

100 97-0716 Cross Slide Cover SS41 1

Angular Contact 2204E-2RSITN9 1

1

1

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

101

Hexagon Socket Screw

M6x10L

5

102 25200-3 Gib - X Axis FC30 87-2017 1

 19x16UNF

W01 (12)

N01 ( 12x32UNF)

103 17-0321 Adjusting Screw S30C 2
104 Socket Head Cap Screw M8x25L 4
105 87-0215 Cross Slide FC25 1
106 87-0201 Saddle FC25 1
107 Socket Head Cap Screw M12x90L 4
108 Cross Recessed Head Screw M6x16L 3
109 77A-0317 Bedway Wiper (Left) Rubber 1
110 23983 Ballscrew - Z Axis SCM415 77A-0310A 1
111 7205-AVH Ring - Nilos AVH7205 1
112 23940 Bearing Set - Angular Contact 7205 BECBP 2
113 Spacer S45C 1
114 16295-1 Housing - Bearing S45C 1
115 Socket Head Cap Screw M8x25L 4
116 16314 Nut - Clamp S45C
117 16350 Ferrule Brass 1
118 16983-1 Pulley - Ballscrew 1
119 98481A090 Woodruff Key #3 (1/8"x1/2") 1
120 W01 Lock Wsaher
121 N01 Lock Nut
122 Socket Head Cap Screw M8x25L 4
123 Spring Washer M8 4
124 Socket Head Cap Screw 10-32x3/4" 1
125 Socket Head Cap Screw M12x35L 4
126 Spring Washer M12 4
127 400-5M-15 Belt - Z Axis 1
128 24-0304 Z Axis Motor Seat FC30 1
129 Pulley 1
130 Socket Head Cap Screw M6x25L 4
131 Flat Washer M6 4
132 Spring Washer M6 4
133 24-0306 Z Axis Motor Plate S20C 1
134 21994 Motor - Z Axis 1
135 87-0229 Front Cover Plate SS41 1

i01177

1

1

1

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

Figure 5-8
Angular Contact Bearings

5.1.12 Installing Angular Contact Bearings

1. On the inner race of the an gular contact bearings, the thin walls face each other.

2. 50 ft/lb. torque is needed to tighten the clamp nut. See the figure above.

5.1.13 Z-Axis Ball Screw Removal

1. Unplug or remove all power from the lathe.

2. The Z-axis ball screw is attached to the lathe in three places:
a. The left end where the Z-axis motor, the pulley, the clamp and the pair of

angular contact be arings are mounted.

b. Behind the apron assembly where the ball nut is attached to the yoke and the oil

line is located.

c. The right end where the floating bearing is located.

3. Access to the left end is gained by removing the sheet metal panel below the
headstock nameplate.

4. Access to the ball nut and the yoke is gained by removing the apron assem b ly.

5. For easy asses s to the ball screw, remove the ball screw cover.

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

Figure 5-9
Z Axis Drive Train – 1540V & 1840V

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

20

20995

YOKE-Z AXIS

EA 1 26

M12-1.75X45 25B

SCREW-SHCS-STL-BO

EA

4

39

22062

SPACER-PT4-Z-AXIS DRIVE

EA 1 5

N01

LOCKNUT

EA

1

10

16452

NUT CLAMP-X ,Y, & Z AXIS

EA

1

15

7205-AVH

NILOS RING-7205

EA 1 18

15759

WASHER-1/4 HARD BLK OX 1/8 THK

EA

8

19

23054

STUD-M6-1.0X40-FULLY THREADED-

EA

4

29

98481A090

KEY WOODRUFF #404-1/8 X 1/2

EA 1 32

21155

PLUG-Z AXIS COVER

EA

1

40

M6-1.0 52P

NUT-HEX-STL-PLAIN

EA 4 41

M8-1.25X20 25B

SCREW-SHCS-STL-BO

EA

4

Z-Axis Drive Train Parts List – 1540V & 1840V

Item P/N Title Use As Qty

1 21997 BRACKET-PT4-Z AXIS DRIVE EA 1
2 M12-1.75X35 25B SCREW-SHCS-STL-BO EA 4

27 20962 HOUSING-TAILSTOCK BEARING EA 1
30 20999 COVER-TRL 2460 Z AXIS EA 1
31 20980 BED-TRL 2460 CSS EA 1
33 M12 73B WASHER-SPLIT LOCK-STL-BO EA 5

6 W01 LOCKWASHER EA 1
7 16983-1 PULLEY-SOLID 44 TEETH W/O

GUIDES
8 16350 FERRULE-SPROCKET EA 1
9 400-5M-15 BELT - TIMING 5MM POWERGRIP EA 1

11 10-32X3/4 25B SCREW-SHCS-STL-BO EA 1
12 M8-1.25X35 25B SCREW-SHCS-STL-BO EA 4
13 16295-1 HOUSING- BEARING Z-AXIS EA 1
14 23940 BEARING SET-ANGULAR CONTACT-

7205 BECBP

EA 1

SET 1

CLASS 4.6

21 M8-1.25X30 25B SCREW-SHCS-STL-BO EA 7
23 22446 BEARING-SELF ALIGNING-2204 E-

2RS1TN9

24 W04 LOCKWASHER EA 1
25 N04 LOCKNUT EA 1

34 185210 C ONTROL UNI T CSA-5 EA 1
35 186251 COMPRESSION NUT EA 1
36 106254 CO MPR E SSION SLE EV E EA 1

42 1/4 73B WASHER-SPLIT LOCK-STL-BO EA 4

i00978

EA 1

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

Figure 5-10 -- Z Axis Drive Train – 2460V

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Southwestern Industries, Inc.

TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

Z Axis Drive Train Parts List – 2460V

10

87-0228

Rear Cover Plate

SS41

1

 19x16UNF

W02 ( 15)

N02 ( 15x32UNF)

34

Socket Head Cap Screw

M8x16L

2

Item Parts No. Description Material Specifications Q'ty

1 Socket Head Cap Screw M8x30L 6
2 25200-1 Wiper - Bedway (Front) Rubber 87-0244 1
3 Hexagon Socket Screw M6x16L 4
4 77USA-0213 Nut Seat FC25 1
5 Socket Head Cap Screw M8x30L 4
6 O-Ring P7 1
7 20984 X-Axis Ballscrew SCM415 24-0211 1
8 25200-2 Wiper - Bedway (Rear) Rubber 87-0245 1
9 Hexagon Socket Screw M6x20L 4

11 24-0728 X-Axis Motor Cover Plate SS41 1
12 21994 Motor - X Axis 1
13 Socket Head Cap Screw M8x25L 4
14 Spring Washer M8 4
15 24-0208 Motor Plate S20C 1
16 Symchronous Pulley Aluminum 1
17 500-5M-15 Belt - X Axis 1
18 Socket Head Cap Screw M8x25L 8
19 77A-0202 Lock Block FC25 1
20 50-0325 Adjusting Screw S30C 4
21 21050-3F Gib - Z Axis FC25 77A-0218 1
22 77A-0216 Lock Block FC25 1
23 7204-AVH Ring - Nilos 1
24 23930 Bearing Set - Angular Contact 7204BECBP 2
25 15885 Spacer S45C 1
26 16300 Bearing Housing S45C 1
27 16314 Nut - Clamp S45C
28 16350 Ferrule Brass 1
29 98481A090 Key - Woodruff #3 (1/8"x1/2") 1
30 16983-1 Pulley - Ballscrew 1
31 W02 Lock Washer
32 NT02 Lock Nut
33 Socket Head Cap Screw 10-32x3/4" 1

1

1

1

35 Flat Washer M8 2
36 Spring Washer M8 2
37 87-0738 Clamping Block SS41 1
38 Socket Head Cap Screw M10x90L 4
39 Socket Head Cap Screw M6x10L 2
40 Flat Washer M6 2
41 Spring Washer M6 2
42 77USA-0698 Cam SS41 1
43 Socket Head Cap Screw M8x30L 4
44 Flat Washer M8 4
45 Spring Washer M8 4
46 Socket Head Cap Screw M6x20L 4
47 Flat Washer M6 2
48 Spring Washer M6 4
49 87-0730 Bracket FC20 1
50 Wire Protector 88x45ax1850L 1

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51

Hexagon Socket Screw

M5x10L

11

52 24-0729 End Cover SS41 1

75

25200-5

Wiper - Bedway (Right, Front)

Rubber

63-0361

1

 30

N04( 20x16UNF)

53 Socket Head Cap Screw M8x20L 2
54 Flat Washer M8 2
55 Spring Washer M8 2
56 77USA-0307 Switch Seat SS41 1
57 Socket Head Cap Screw M6x20L 2

NBNS543-BO2D12-

58 22551-1 Switch - Limit
59 Socket Head Cap Screw M6x16L 2
60 Flat Washer M6 2
61 Spring Washer M6 2
62 77USA-0698 Cam SS41 2
63 24-0207 X Axis Transmission Box FC30 1
64 Cross Recessed Head Screw M6x16L 6
65 25200-6 Wiper - Bedway (Right, Rear) Rubber 63-0362 1
66 25200-7 Wiper - Bedway (Left, Rear) Rubber 63-0363 1
67 Socket Head Cap Screw M6x25L 2
68 Spring Washer M6 2

69 Micro Switch
70 Socket Head Cap Screw M6x16L 2
71 Flat Washer M6 2
72 Spring Washer M6 2
73 87-0714 Cam SS41 1
74 25200-4 Wiper - Bedway (Left, Front) Rubber 63-0360 1

61-12-10 1

BNS543-BO2D12­61-12-10 1

76 Cross Recessed Head Screw M6x16L 6
77 87-0715 Cam SS41 2
78 Socket Head Cap Screw M5x16L 4
79 Flat Washer M6 4
80 Spring Washer M6 4
81 Socket Head Cap Screw M6x16L 4
82 Flat Washer M6 4
83 Spring Washer M6 4
84 24-0723 Operation Box SS41 1
85 24-0724 Operation Box Cover SS41 1
86 Hexagon Socket Screw M5x6L 8
87 77USA-0311 Apron FC25 1
88 77USA-0605 Ballscrew Cover SS41 1
89 Cover - Round Hole
90 N04 Lock Nut S45C
91 W04 Lock Washer W04 1

Bearing - Ball - Double Row

92 22446
93 77USA-0307 Nut Seat FC20 1
94 Socket Head Cap Screw M12x50L 4
95 Spring Washer M12 4
96 77USA-0316 Bedway - Wiper (Right) Rubber 1
97 Cross Recessed Head Screw M6x16L 3
98 Rod S45C 1
99 87-0727 Support Bracket SS41 1

100 97-0716 Cross Slide Cover SS41 1

Angular Contact 2204E-2RSITN9 1

1

1

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101

Hexagon Socket Screw

M6x10L

5

102 25200-3 Gib - X Axis FC30 87-2017 1

 19x16UNF

W01 (12)

N01 ( 12x32UNF)

103 17-0321 Adjusting Screw S30C 2
104 Socket Head Cap Screw M8x25L 4
105 87-0215 Cross Slide FC25 1
106 87-0201 Saddle FC25 1
107 Socket Head Cap Screw M12x90L 4
108 Cross Recessed Head Screw M6x16L 3
109 77A-0317 Bedway Wiper (Left) Rubber 1
110 23983 Ballscrew - Z Axis SCM415 77A-0310A 1
111 7205-AVH Ring - Nilos AVH7205 1
112 23940 Bearing Set - An gu lar Co n t ac t 7205 BECBP 2
113 Spacer S45C 1
114 16295-1 Housing - Bearing S45C 1
115 Socket Head Cap Screw M8x25L 4
116 16314 Nut - Clamp S45C
117 16350 Ferrule Brass 1
118 16983-1 Pulley - Ballscrew 1
119 98481A090 Woodruff Key #3 (1/8"x1/2") 1
120 W01 Lock Wsaher
121 N01 Lock Nut
122 Socket Head Cap Screw M8x25L 4
123 Spring Washer M8 4
124 Socket Head Cap Screw 10-32x3/4" 1
125 Socket Head Cap Screw M12x35L 4
126 Spring Washer M12 4
127 400-5M-15 Belt - Z Axis 1
128 24-0304 Z Axis Motor Seat FC30 1
129 Pulley 1
130 Socket Head Cap Screw M6x25L 4
131 Flat Washer M6 4
132 Spring Washer M6 4
133 24-0306 Z Axis Motor Plate S20C 1
134 21994 Motor - Z Axis 1
135 87-0229 Front Cover Plate SS41 1

i01177

1

1

1

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5.1.14 Align Z-Axis Ball Screw Assembly

See Figure 5-9 or 5-10.

1. Recheck machine level. Adjust as necessary.

2. Move carriage to middle of travel.

3. Loosen headstock bearing housing and mounting bracket and loosen tailstock
bearing housing.

4. Snug but do not tighten the yoke mounting bolts.

5. Move the ball screw manually and move the carriage to the tail stock end.

6. Tighten the yoke, this will align it vertically.

7. Tighten the tailstock bearing housing.

8. Loosen the yoke and retighten to realign ball horizontally.

9. Using a 3/8” socket extension, move the carriage to the headstock.

10. Tighten the Z-axis housing.

11. Tighten the bearing housing.

12. Turn the ball screw manually with the 3/8” socket extension and move the carriage
to the middle of the travel.

13. Loosen the yoke mounting bolts to readjust the apron plate after the bearings have
been tightened.

14. Retighten the yoke.

15. Move the ball screw manually and move the carriage through the entire length of
the Z-axis. Pay special attention to the areas near the headstock, tailstock, and in
the middle of the travel. If there is any binding or rough spots, the ali gnment
procedure must be repeated. The axis should feel equally free throughout the entire
range.

16. Using a torque wrench, measure the torque to move the z-axis at each end, and in
the middle of the a xis travel. The torque reading should be a maximum of 10-15 in­lb.

5.1.15 Headstock Taper Adjustment

The headstock may be adjusted to remove turning a taper if the taper is caused by a lack
of parallelism of the spindle to the bed ways. Ensure that the level of the bed is correct
prior to any headstock adjustments.

1840V & 2460 Machine

To adjust the headstock alignment, loo sen the four socket head cap screws that attach
the headstock housing to the bed. Using the adjusting screw located at the rear of the
headstock, (see figure 5-11) adjust the headstock position in the direction necessary t o
remove the taper. Note that the headstock will pivot about a pin located between the
two front attaching screws. Tighten the attaching screws and test for taper.

To access the front two cap screws the front cover guard will have to be removed.

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i00488

Figure 5-11
1840V & 2460V Headstock Taper Adjustment

1540 Machine

1. Remove the headstock sheet metal cover.

2. Loosen the bolts holding the headstock splash guard. This should be fine if the
adjustments are minor.

3. Loosen the 4 bolts that hold the headstock down to the lathe bed.

4. Use the adjusting screws to pivot the headsto ck in or out. When facing the encoder
side of the headsto ck the right screw on the adjusting bracket will push the
headstock away from you while the left screw will pull the headstock toward you.

5. After the necessary adjustments are made, tighten the 4 bolts that hold the
headstock in place. Be careful when t ightening these bol ts that the headstock does
not move.

6. Replace the sheet metal cover.

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Figure 5-12
1540 Headstock Taper Adjustment

5.1.16 Spindle Bearing Preload – 1840V & 2460V Only

1. Run the lathe for 10 minutes to insure the bearings are lubricated and slightly
warmed. Run the lathe at 500 RPM.

2. Stop lathe and set the gearbox in neutral between low and high gears. Using the
torque wrench, measure the spindle rolling torque. The acceptable range of rolling
torque is around 10 - 15 in-lb. Note that the torque required to start (“breaking
away torque”) the spindles rotation will be higher.

3. If torque is out of tolerance. Remove the spindle belt cover. You will then need to
remove a bearing cover to gain access to the spindle adjusting nut. Loosen the
three setscrews on the spindle-adjusting nut before tightening or loosening (Figure

34).

4. Torque too low: Lock the spindle in low gear. With a spanner wrench tighten the
adjusting nut. Return the speed selection lever to the neutral position. Measure the
rolling torque and repeat until 10 – 15 in -lb. of rolling torque is achieved. Tighten
the three setscrews to retain the adjustment.

5. Torque too high: Lock the spindle in gear. With a spanner wrench loosen the
adjusting nut two full turns. Place an aluminum block over the end of the spindle and
with a hammer drive the spindle forward until it is loose. (Near zero rolling torque)
With a spanner wrench tighten the adjusting nut. Return t he speed selection lever to
the neutral position. Measure the rolling torque and repeat until 10 - 15 in -lb. of
rolling torque is achieved. Tighten the three setscrews to retain the adjustment.

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5.1.17 Aligning Tailstock to Spindle

If there is taper ap pearing on the wor kpiece while machining by using the tailstock, the
tailstock will need to be realigned to the spindle. Follow the steps below.

1. Insert a gage bar between the spindle and tailstock, attach a base of a dial indicator
to the saddle, apply the needle of the indicator to the surface of the bar, then move
the saddle through the longitudinal travel. Take the measurement of its maximum
difference from end to end for later adjustment.

2. Release the 4 bolts labeled “A” in the drawing.

3. Release the screw labeled “B”.

4. Adjust screw “C” until the tailstock is aligned with the spindle.

5. Tighten up the locking nuts “A”.

i00515

Figure 5-13 – Tailstock Adjustment

5.1.18 Spindle Motor Wiring

The 1540V, 1840V, & 2460V spindl e motors are wired for 220 volts (low voltage
configuration). The wiring consists of 3 phase power for the motor and 110 V power for
the spindle motor fan. Please see the motor junction box diagram for wiring information.

Each junction box contains 6 terminals. M ake sure to hook up t he wires in the same
terminals after the replacement motor is installed. Failure to do so may run the motor in
the wrong direction.

The spindle motor fan wires are also found in the junction box. There is 1 hot wire, 1
neutral wire and 1 ground wire. It does not matter which wires are connected to the hot
and neutral wires. All grounds from each cable are connected to either of the screws in
the junction box.

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Figure 5-14

Spindle Motor
Wiring

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TRAK TRL 1540V, 1840V, 2460V & ProtoTRAK VL CNC Safety, Installation, Maintenance, Service & Parts List Manual

5.1.19 Spindle Cartridge Replacement – 1540V Only (see Figure 5-15)

The spindle and bearings on the 1540 lathe are to be replaced as an assembly. The
spindle and bearings are encased within a cartridge that bolts to the headstock.
Problems with the spindle or bearings are to be solved by replacing the entire cartridge.

1. Remove the headstock sheet metal cover.

2. Remove the spindle encoder belt.

3. Remove the chuck guard from the headstock splash shield.

4. Loosen the spindle motor and remove belt from spindle to headstock pulley.

5. Remove headstock splash shield for easier access to the ca r tridge.

6. Remove the rear clamping plate from the headstock casting. (Item 3) This can be
done by removing 8 (M6) SHCS and 6 (M8) SHCS. This will allow the spindle
assembly to easily slide through the opening of the casting. This plate may be left
on but it makes it more difficult to remove the cartridge. If it is left on the M6 SHCS
will still need to be removed.

7. Rem ove the 6 (M12) SHCS that hold the front of the cartridge to the headstock.
Once these are remove the cartridge should slide out of the headstock. This
assembly weighs over 100 lbs please get additional help to remove the cartridge.

8. Slide the new cartridge into the casting. Make sure to place the drain holes pointed
down towards the floor when mounting. This will allo w any coolant that makes it in
between the spindle and cartridge to drain out.

9. Reverse the steps to install the new cartridge.

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Figure 5-15
1540 Headstock Cartridge Removal

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1540 Headstock Cartridge P arts List

Item

P/N

Title

Use As

Qty

2

22170

SPINDLE ASSY - 1540V LATHE -PT4

EA 1 3

22183

24-0113-00

EA

1

8

23359

BELT - HEADSTOCK ASSY - 1540V

EA 1 9

16873

SPINDLE ENCODER ASSY

EA

1

1 22171 24-0101-00 EA 1

4 M6-1.0X20 25B SCREW-SHCS-STL-BO EA 8
5 M8-1.25X35 25B SCREW-SHCS-STL-BO EA 6
6 M12-1.75X35 25B SCREW-SHCS-STL-BO EA 6
7 22206 ENCODER DRIVE A SSY - LATHE EA 1

i00983

5.2 Maintenance

5.2.1 Gib Adjustments

The objective of adjusting the gibs is to eliminate as much play in the table, saddle and
ram sliding surfaces as possible without having t he tightness of the gib interfere with
their free movement and cause a decrease in the accuracy and/or performance of the
machine due to excessive friction.

5.2.1.1 Cross Slide Gib Adjustment

1. Remove the yoke bolt s from the top of the cross slide and slide it back a nd forth and
feel for any looseness in the system. If it is loose tighten up the adjusting screws.

NOTE: Adjustments should be made where the gibs are worn the worst.

2. Turn the X-axis ball screw with a torque wrench and measure the torque. The
torque should be less than 15 in/lb. and consistent over the travel of the X-axis. If
the measurement is higher than this then loosen the gib. Make sure the cross slide
is aligned properly. One easy way to check for this is to remove the yoke bolts and
see if the yoke springs back into position. Misalignment is also evident if the torque
is higher when the yoke is up against the rear bearing housing.

Figure 5-16
X Axis Gib

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5.2.1.2 Z-Axis Gib Adjustment

1. Mount a dial indicator on the Z-axis ways and locate on top of the carriage.

2. Lift the carriage up to measure the amount of play. The dial indicator should not
move more than 0.001”. If it moves more tighten the gibs. Make sure not to over
tighten the gibs.

3. This pr ocedure with the dial indicator will need to be done in the front and rear of
the saddle.

Figure 5-17
Z-Axis Gib

5.2.2 Calibration & Backlash Constants

Calibration and backlash constants were set as part of the installation and set-up of your
system. They should be re-set when indicated in the Troubleshooting section or after
the replacement of the computer module, or any parts of the drive train.

Calibration is used teach the machine a known distance. We typically calibrate our
machines over a 150 mm distance. There is no limit to how far you can calibrate the
machine.

5.2.2.1 Calibration

NOTE: Calibration usually is only done after replacing a computer module or adjusting the drive
train.

1. Recheck machine level and adjust as necessary.

2. Press the “SERV CODE” soft key.

3. Input 123 on the keyboard, then press the “INC SET” key.

4. Input the “X” key to tell the control the x-axis is being calibrated.

5. Place the .0001 indicator in the spindle and set up the metric standard on the

cross slide. Make sure the standard is parallel t o t he cross slide by using a
combination square. Ensure that the standard is set up so that the readings will

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be taken with the cross slide extended towards the operator and moving in
towards the motor end of the X-axis.

6. When the indicator is zeroed at the beginning of the standard press the “INC SET”

key.

7. Move the cross slide towards the motor side of the x-axis until the indicator zeros

on the end of the standard. Input 300 on the keyboard.

8. If the calibration was successful the screen will return to the set up screen.

9. Press the “SERV CODE” soft key.

10. Input 123 on the keyboard , then press the “INC SET” key.

11. Press the “Z” key to tell the control that the z-axis is being calibrated.

12. Set up the metric standard on the Z-axis ways.

13. Set up the magnetic base and .0001 indicator on the cross slide.

14. When the indicator is zeroed at the beginning of the standard press the “INC SET”

key.

15. Move the saddle towards the chuck until the indicator zeros o n the end of the

standard, then press the “INC SET” key.

16. Input 150 on the keyboard .

17. If the calibration is successful the screen will change to the set up screen.

Figure 5-18
Calibration Set-Up

5.2.2.2 Backlash Compensation

Code 127: Calculate X or Z Backlash Constant

Every mechanical system has at least a little backlash or lost motion. It is produced by
the small amount of p lay between the gibs and ways, and mostly by the accumulative
bending or elasticity of all the parts of the drive train under load. The backlash constant
is factory set, but may need to be adjusted periodically.

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1. Set a .0001 inch dial indicator in the spindle, and touch off on a block or the vise

Conversation Says

You Do

c. Select

c. Press SERV CODES

along the directio n (X or Z) you wish to check, or set the backlash constant.

2. Turn on the ProtoTRAK and at the Main Men u, follow the procedure below precisely:

a. --- a. Press MODE
b. Select Mode b. Press SET UP

d. Select d. Press “B”
e. Select Code 127 e. Press X or Z
f. Backlash Value = _ _ _ _ f. What is shown is the current value.

Follow the instruction on the screen
and press the appropriate soft keys.
Wait a few seconds between each
INCR VALUE or DECR VALUE

press.
g. The following is an example of what you
might see when running this code.

For example, if the up and down "Oscill ation

Value" shown in the conversation line is .00278

inch, and the dial indicator is moving back and

forth .0012, then the true backlash value is

.00278 -.0012 = .00158 inch. Input this by

pressing MODE, SET UP, SERV CODE, 128, SET

and then .00158, SET, RETURN.

3. The X backlash identified and stored in Step 2 should be less than 0.003” on a new
machine. If it is appreciably larger, inspect the drive train for loose bolts, brackets,
bearings, etc.

The backlash can also be found manuall y with a 0.0001” indicator with the following
method.

• Load the indicator to zero from one direction and zero out the DRO.

• Move the indicator to 0.002” and then back to zero. Do not over shoot 0,

otherwise start over.

• Whatever number appears on the screen is the backlash value.

• Enter this value into service code 128.

• After entering this number redo the process. The DRO and indicator should

now both read 0.

CODE 128: Input Backlash Constant

Code 128 allows you to enter the backlash values for each axis. It displays the value
after it enters.
Be sure not to enter too much backlash on any given axis. Too much backlash in the
system may cause bi-directional repeatability problems or axis motor searching.

5.2.3 Lubrication

5.2.3.1 1840V & 2460V Headstock Lubrication

An oil pump provides lubrication for an even distribution of oil to all the gears and
bearings in the headstock. One of the oil lines pumps oil to a site glass located on the