prototrak EMX KNEE Service Manual

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Document: P/N 26109

Version: 100713

Southwestern Industries, Inc.

2615 Homestead Place Rancho Dominguez, CA 90220-5610 USA

T | 800.421.6875 | F | 310. 764.2668

Service Department: 800.367.3165

e-mail: sales@southwesternindustries.com | service@southwesternindustries.com | web: southwesternindustries.com

TRAK® EMX KNEE & BED MILLS

ProtoTRAK® EMX CNC

Service, Safety, Installation, Maintenance, & Parts

Covers Models:

 ProtoTRAK EMX Retrofits  TRAK KEMX Knee Mill  TRAK K3 EMX Knee Mill  TRAK K4 EMX Knee Mill  TRAK DPM EX2 Bed Mill

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Copyright © 2013, 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.

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1.0 Safety

1.1 Safety Publications 1

1.2 Danger, Warning, Caution & Note Labels & Notices as used in this Manual

1.3 Safety Precautions

2.0 Installation

2.1 Floor Plan, Layout & Space Requirements 6

2.2 Uncrating

2.3 Shortages: Inventory Checklist

2.4 Installation Instructions & Checklist

2.5 Machine Specifications

2.6 Maximum Work Capacities

2.7 ProtoTRAK EMX Control Hardware

2.8 Lifting and/or Moving the Machine

2.8.1 Releasing the Head Counterweight Support

2.9 Cleaning

2.10 Leveling: Leveling Tolerance is .0005”/10”

2.11 Pendant Connections

2.12 Electrical Connection

2.13 Air Connection (Optional)

2.14 Lubrication

2.14.1 Manual Lubrication – KEMX

2.14.2 Auto Lubrication – DPMEX2

2.14.3 Head Lubrication

3.0 ProtoTRAK EMX Retrofit Installation

3.1 Recommended Tools 29

3.2 Kit Parts

3.2.1 Ballscews

3.2.2 Pendant Arm Assembly

3.2.3 Motors

3.2.4 Options

3.2.5 Pendant & Pendant Hardware

3.2.6 X Axis Drive Kit

3.2.7 Y Axis Drive Kit

3.2.8 Yoke Kit

3.2.9 Other Parts

3.3 Installation Steps

Step 1: Remove the table and lead screws Step 2: Install the X (Table) Ballscrew Step 3: Install the Y (Saddle) Ballscrew Step 4: Install the Y Axis Drive Train Step 5: Replace the table and install the X Drive Train (Left Side) Motor Step 6: Install the Right Side End Cap and Handwheel

Assembly

Step 7: Install the Display Pendant Step 8: Install the Z Glass Scale Step 9: Connect the Cables and the Power Step 10: Check Out

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ProtoTRAK K EMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

4.0 Troubleshooting by Symptom

4.1 Problems Relating to Machining Results 68

4.1.1 Poor Finish

4.1.2 Circles Out of Round

4.1.3 Taper Cut on a Programmed Straight Line Move

4.1.4 Parts Have Incorrect Dimensions

4.2 Problems Regarding the Motion of the Machine

4.2.1 Run Away Axis

4.2.2 Slow Down Axis

4.2.3 Axis Will Not Jog

4.2.4 Axis Motor Motion is Not Smooth

4.2.5 Searching Axis

4.3 Problems Relation to the Operation of the Control

4.3.1 Display Blanks

4.3.2 Bad Picture on the Display

4.3.3 Keyboard Lockup

4.3.4 Fault X or Y

4.3.5 System Will Not Turn On

4.3.6 System Reboots by Itself

4.3.7 System Shuts Off

4.3.8 Will Not Hold Calibration

4.3.9 E-Stop Error

4.4 Problem with the Measurements

4.4.1 X, Y & Z-Axis Measurements Do

Not Repeat

4.4.2 X, Y & Z-Axis Measurements Are

Not Accurate

4.4.3 The DRO is Not Counting

4.4.4 X, Y, & Z-Axis DRO Counting In

Wrong Direction

4.5 Problems with the Machine Tool

4.5.1 Spindle Stalls or Turns Off

4.5.2 Spindle Motor Hums or Will Not Run

4.5.3 Spindle Runs Backwards

4.5.4 Head Noise

5.0 Diagnostics

5.1 The Machine Tool & Set-Up 80

5.1.1 The Milling Machine Checklist

5.1.2 A Special Word About X & Y Gibs

5.1.3 Lubrication

5.1.4 Machining Set-Up

5.2 The Mechanical Drive Train (X, Y)

5.2.1 Keys to Ballscrew Alignment

5.3 Computer/Pendant Diagnostics

5.4 Motor Diagnostics

5.4.1 Cable Connections

5.4.2 To Check Motor Encoders

5.4.3 Diagnosing a Brush Problem

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5.4.4 Moving Problem from One Axis To Another

5.5 Servo Driver

5.6 Electrical

5.6.1 Checking A/C Voltage

5.6.2 Checking Fuses

5.6.3 Cable Connections

5.7 Service Codes

5.7.1 Software Codes

5.7.2 Machine Set-Up Codes

5.7.3 Diagnostic Codes

5.7.4 Operator Defaults/Options Codes

6.0 Procedures for Replacements & Maintenance

6.1 Replacements 97

6.1.1 Servo Motor Replacement

6.1.2 Motor Brush Replacement

6.1.3 Servo Driver Replacement

6.1.4 Computer Module Replacement

6.1.5 IDE Flash Disk Replacement

6.1.6 Cable Routing on Machine

6.1.7 Replacement Z Axis Scale, Mill Only

6.1.8 Power Drawbar

6.1.9 Ball Screw Replacement, X-Axis

6.1.10 Ball Screw Replacement, Y-Axis

6.1.10.1 Ball Screw Replacement, Z-Axis

6.1.11 Spindle Motor Wiring

6.1.12 Feed Trip Adjustment

6.1.13 Quill Clock Spring Replacement &

Adjustment

6.1.14 Spindle Motor Removal &

Replacement

6.1.15 Drive Belt Replacement

6.1.16 Timing Belt Replacement

6.1.17 Brake Shoe Replacement

6.1.18 Spindle Replacement

6.2 Maintenance

6.2.1 Gib Adjustments

6.2.2 Calibration & Backlash Constants

6.2.3 Head Rotational and Tramming

Figures found in Section 7.0 128 Fig. 100 Top Housing Assembly, K4 Fig. 101 Gear Housing Sub-Assembly, K4 Fig. 102 Hi-Low Slip Clutch Sub-Assembly, K4 Fig. 103 Hi-Low Shift Sub-Assembly, K4 Fig. 104 Pulley Pinion Sub-Assembly, K4 Fig. 105 Lower Vari-Disc Sub-Assembly, K4 Fig. 106 Upper Vari-Disk Sub Assembly, K4 Fig. 107 Speed Change Handwheel Sub-Assembly Fig. 108 Spindle Motor Sub Assembly, K4 Fig. 109 Bottom Housing Assembly, K4 Fig. 110 Worm Gear Cradle Sub-Assembly, K4 Fig. 111 Quill Feed Selector Sub-Assembly, K4 Fig. 112 Quill Pinion Shaft Sub-Assembly, K4 Fig. 113 Overload Clutch Trip Sub-Assembly, K4

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ProtoTRAK K EMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Fig. 114 Feed Reverse Clutch Sub-Assembly, K4 Fig. 115 Spindle Sub-Assembly, K4 Fig. 118 Top Housing Assembly, K2/K3 Fig. 119 Gear Housing Sub-Assembly, K2/K3 Fig. 120 Hi-Low Shift Clutch Sub-Assembly, K2/K3 Fig. 121 Hi-Low Shift Sub-Assembly, K2/K3 Fig. 122 Pulley Pinion Sub-Assembly, K2/K3 Fig. 123 Lower Vari-Disc Drive Sub-Assembly, K2/K3 Fig. 124 Upper Vari-Disc Drive Sub-Assembly, K2/K3 Fig. 125 Speed Change Handwheel Sub-Assembly, K2/K3 Fig. 126 Spindle Motor Sub-Assembly, K2/K3 Fig. 127 Bottom Housing Assembly, K2/K3 Fig. 128 Worm Gear Cradle Sub-Assembly, K2/K3 Fig. 129 Quill Feed Selector Sub-Assembly, K2/K3 Fig. 130 Quill Pinion Shaft Sub-Assembly, K2/K3 Fig. 131 Overload Clutch Trip Sub-Assembly, K2/K3 Fig. 132 Feed Reverse Clutch Sub-Assembly, K2/K3 Fig. 133 Spindle Sub-Assembly, K2/K3 Fig. 134 K2/K3 Base Machine Fig. 135 K4 Base Machine Fig. 136 KE Base Machine

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Southwestern Industries, Inc.

ProtoTRAK K EMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

1.0 Safety

The safe operation of the TRAK Mills and the ProtoTRAK CNC depends on their proper use and the precautions taken by each operator.

 Read and study this manual and the ProtoTRAK EMX Programming, Operating, and Care

Manual. Be certain 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 or 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 OSHA 1910.212 - Milling Machine.

1.1 Safety Publications

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

Safety Requirements for Manual Milling, Drilling and Boring Machines with or without

Automatic Control (ANSI B11.8-2001). Available from The American National Standards

Institute, 1819 L Street N.W., Washington D.C. 20036 Concepts And Techniques Of Machine Safeguarding (OSHA Publication Number 3067).

Available from The Publication Office - O.S.H.A., U.S. Department of Labor, 200 Constitution Avenue, NW, Washington, DC 20210.

1.2 Danger, Warning, Caution, and Note Labels & Notices As Used In This Manual

DANGER - Immediate hazards that will result in severe personal injury or death. Danger labels

on the machine are red in color. WARNING - Hazards or unsafe practices which

damage to the equipment. Warning labels on the machine are orange in color. CAUTION - Hazards or unsafe practices, which

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

before

its use.

could

result in severe personal injury and/or

could

result in minor personal injury or

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ProtoTRAK K EMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Safety & Information Labels Used On The

TRAK Milling Machines

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

of these labels

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ProtoTRAK K EMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Power Requirements at 220 and 440 Volts, 3-phase 60 Hz

KEMX & DPMEX2

Overload Setting 220 V

8.5 A

Overload Setting 440 V

4.25 A

FLA of Largest Motor at 220 V

8.5 A

FLA of Largest Motor at 440 V

4.25 A

FLA of Machine at 220 V

8.5 A

FLA of Machine at 440 V

4.25 A

Safety & Information Labels Used On TRAK Milling Machines

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.

ProtoTRAK K EMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

1.3 Safety Precautions

1. Do not operate this machine before the TRAK Mill Installation, Maintenance, Service and Parts List Manual, and ProtoTRAK EMX Programming, Operating & Care Manual have been studied and understood.

2. Do not run this machine without knowing the function of every control key, button, knob, or handle. Ask your supervisor or a qualified instructor for help when needed.

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

4. Don't get caught in moving parts. Before operating this machine remove all jewelry including watches and rings, neckties, and any loose-fitting clothing.

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

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

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

8. Remove all tools (wrenches, chuck keys, etc.) from the machine before you start. Loose items can become dangerous flying projectiles.

9. Never operate a milling machine after consuming alcoholic beverages, or taking strong medication, or while using non-prescription drugs.

10. Protect your hands. Stop the machine spindle and ensure that the CNC control is in the stop mode:

 Before changing tools  Before changing parts  Before you clear away the chips, oil or coolant. Always use a chip scraper or brush  Before you make an adjustment to the part, fixture, coolant nozzle or take

measurements

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

tool, or fixture around a safeguard.

11. Protect your eyes and the machine as well. Don't use compressed air to remove the chips or clean the machine.

12. Disconnect power to the machine before you change belts, pulley, and gears.

13. Keep work areas well lighted. Ask for additional light if needed.

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

15. Prevent slippage. Keep the work area dry and clean. Remove the chips, oil, coolant and obstacles of any kind around the machine.

16. Avoid getting pinched in places where the table, saddle or spindle head create "pinch points" while in motion.

17. Securely clamp and properly locate the workpiece in the vise, on the table, or in the fixture. Use stop blocks to prevent objects from flying loose. Use proper holding clamping attachments and position them clear of the tool path.

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ProtoTRAK K EMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

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

19. Use proper cutting tools for the job. Pay attention to the rotation of the spindle: Left hand tool for counterclockwise rotation of spindle, and right hand tool for clockwise rotation of spindle.

20. After an emergency stop, always turn the FORWARD/REVERSE switch to "Off" (STOP) before releasing or resetting the E-Stop.

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. Check the direction (+ or -) of movement of the table, saddle and ram when using the jog or power feed.

23. Don't use dull or damaged cutting tools. They break easily and become airborne. Inspect the sharpness of the edges, and the integrity of cutting tools and their holders. Use proper length for the tool.

24. Large overhang on cutting tools when not required result in accidents and damaged parts.

25. Handwheels must have the crank folded inside when using CNC programmed machining or rapid feeds, power feed or jog.

26. Prevent fires. When machining certain materials (magnesium, etc.) the chips and dust are highly flammable. Obtain special instruction from you supervisor before machining these materials. Keep flammable materials and fluids away from the machine and hot, flying chips.

27. Changing the speed of rotation of the spindle must be done while the rotation is on. It is recommended to stop and start the spindle at a low rate of speed.

28. Interlocked table guards may be purchased from Southwestern Industries, Inc., if deemed necessary by the user.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

2.0 Machine Installation

KEMX

Weight (approximate) net

2800 lbs

Weight (approximate) shipping

3100 lbs

Pallet Size

6’ x 6’

A Overall width

103”

B Overall length

70”

C Base width

24.2”

D Width between leveling screws

21.9”

E Distance between leveling screws

29.7”

F Base length

38.8”

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

2.1 Floor Plan, Layout & Space Requirements

Figure 1 - KEMX - Machine Footprints

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Figure 2 - KEMX - Overall Dimensions

KEMX

Table Size

10” x 50”

Dimension G

87”

Dimension G Min

65”

Dimension H Min

64”

Dimension H Max

78”

Dimension I Min

38”

Dimension I Max

49’

Dimension J Max

17”

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Floor Plan, Layout & Space Requirements – DPMEX2

DPMEX2

Footprint of Machine

23.1” x 40.5”

Weight (approximate) net

3200 lbs.

Weight (approximate) shipping

3500 lbs.

Pallet Size

70” x 70”

A Overall width

101”

B Overall length w/ electric box door open

72”

C Bed width

23.125”

D Bed width between leveling screws

20.5”

E Distance between leveling screws

32.5”

F Bed length

40.5”

Figure 2.1 - DPMEX2 - Machine Footprints

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Figure 2.2 - Overall Dimensions

DPMEX2

G Height of table from bottom of bed

34”

H Maximum distance from spindle nose to table

23.5”

I Maximum height of machine from bottom of bed to top of column cover.

78”

J Height of machine from bottom of bed to top of spindle motor

89”

K Width of machine including table

70”

L Length of machine with electric box door closed

64”

2.2 Uncrating

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

Remove the cardboard box containing the TOOL BOX. The leveling pads and screws for the machine can be found in the toolbox. The Y way covers are shipped in a separate tube.

Loosen and remove 4 screws and nuts holding the machine to the wood pallet.

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

2.3 Shortages: Inventory Checklist

_____ Machine (check model and serial number)

______ Manual drawbar with washer ______ Leveling pads (B239) and screws (B240) (4 each) ______ Pendant Display (installed on machine) ______ Pendant Arm assembled to the column ______ Toolbox with various tools ______ ProtoTRAK EMX Safety, Operation & Programming Manual (P/N 26056)

______ TRAK KEMX & Retrofit Safety, Installation, Maintenance, Service & Parts List

Manual (P/N 26109) ______ Way covers – front & rear of saddle ______ Way covers DPMEX2 – front (23676) and rear (23677) of saddle

______ Way covers DPMEX2 - bottom on column (23675), top on column (23675)

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

2.4 Installation Instructions & Checklist



Shut off power to the machine.



Visually inspect the 220 or 440V wiring going into the electrical panel. Visually verify the wiring is correct per our wiring diagram. Make sure a strain relief is being used where the wiring enters the cabinet.



Use a 10mm socket to turn the Z-axis ball screw at the top of the column in order to lower the head until the counterweight is raised off of the counterweight support rods. (DPMEX2 only)



Remove the 2 bottom head supports and also remove the 2 zip ties from the counterweight chain. DPMEX2 only.



Remove the two (2) counterweight support rods.



Clean the machine if needed and remove any remaining grease.



Unlock the table, saddle, knee or column gib locks.



Make and check all the proper electrical connections from the pendant to the electric box. See the pendant and electric box wiring diagrams.



Turn on the power to the machine and to the pendant.



10.

Lubricate all the way surfaces and the ball screws.



11.

Jog the table and saddle or Z axis back and forth until the way surfaces are well lubricated. Oil should be visible on all the way surfaces.



12.

Check the level of the machine. The machine should be level to within 0.0005" front to back and 0.0005" side to side.



13.

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



14.

Perform Service Code 12, Feed Forward Constant.



15.

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



16.

Perform Service Code 127 and 128 to manually calculate the backlash for the X and Y-axis.



17.

Assure the Z-axis quill glass scale is working and the Z axis DRO is functioning. Use Service Code 15 to turn on the Z axis readout. (Z axis quill scale is optional, knee mills only.)



18.

Perform Service Code 123 and press QUILL softkey to calibrate the Z-axis quill using a 75mm standard. For bed mill, calibrate the Z axis with the 75 mm standard.



19.

Perform Service Code 100 in both directions for the X, Y and/or Z-axes, to verify that the feed rate shown on the display is at least 120 ipm.



20.

Run the spindle at various speeds in both high and low gear for 15 minutes. Verify head shifts from high to low gear smoothly. Test quill feed and spindle brake. N/A to retrofits.



21.

Install the Y-axis front and rear way covers.



22.

Install the top and bottom column way covers. Bed mill only.



23.

If the machine has a power drawbar option, check to make sure that the tools load and unload properly. N/A to retrofits.



24.

Wipe down the machine.

Installer: Use this checklist to assure a complete set-up of the KE, DPMEX2 or EMX retrofit.

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

2.5 Machine Specifications

KEMX

DPMEX2

Table size

50” x 10”

49” x 9”

Movement and ranges (X, Y, Z axis)

32” x 16” x 16”

31 x 16 x 23.5”

Quill Travel (maximum)

5”

Quill Diameter

86 mm

Spindle Taper

Speed Range

60-4200 RPM

Spindle to Column

8” to 32”

18”

Quill Feeds Per Revolution of Spindle

.0015/.003/.006”

Head Tilt

+/- 90

Head Swivel

+/- 45

n/a

Spindle Motor Power

3 HP

Voltage

220/440 V

Phase/Cycle

3 phase/60 Hz

Current

8.5/4.3 amps

Maximum Weight of Workpiece

850 lbs

1320 lbs

Drilling Mild Steel (2-axis manual feed)

1 ¼”

Tapping Mild Steel

1”

Milling (metal removal rate/mild steel)

1 ½ inch3/min

2.6 Maximum Work Capacities

Maximum work capacities are dependent on a lot of variables that cannot be controlled by the machine manufacturer. Each one of the following will have an impact on the above numbers: speeds, feeds, cutter, cutter sharpness, material, setup, coolant and machine adjustments. The numbers above assume all conditions are optimal and may be higher or lower depending on material composition.

2.7 ProtoTRAK EMX Control Hardware

 Digital Servo Amplifiers – custom designed for ProtoTRAK operation  D.C. Servo Motors – rated at 280 in-oz. continuous torque are twice that

required

 Precision Ball Screws – in the table and saddle  Modular Design – simplifies service and maximized uptime  115V/60HZ/10 amps  Feedrate Override of programmed feedrate and rapid  Polycarbonate Sealed Membrane Keypad to lock out contamination  7.0” Color LCD  On board IDE flash memory storage for part programs  USB port for interface with a storage device  Rugged Industrial PC  Glass Scale on quill for Z-axis readout (Optional on knee mill)

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Part Number

Description

20819

Spindle Motor

26015-1 26015-7

EMX Pendant

EMX Pendant 3

15616

Y Axis Handwheel (Saddle)

15616

X Axis Handwheel (Table)

20296

X Axis Motor

20296-1

Y Axis Motor

Figure 3 & Parts List Shown - Knee Mill Component Identification

2. OPTIONAL QUILL SCALE SHOWN ABOVE

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Part Number

Description

220V=20676 440V=20676

**Electrical Box – used on knee and bed mills

9001

Lube Pump

Figure 4 & Parts List Shown - Knee Mill Rear View

If the machine was sold with a table guard option, the electrical box part number is 20676-2.

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Item

Part Number

Description

20819-1

Spindle Motor

26015-7

EMX Pendant – 2 ½ axis

15616

Y-Axis Handwheel (Saddle)

15616

X-Axis Handwheel (Table)

21157-1

Lube Pump

20296

X & Z Axis Motor

20296-1

Y Axis Motor

Figure 4.1 & Parts List Shown - DPMEX2 - Component Identification

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

2.8 Lifting and/or Moving the Machine - KEMX

CAUTION!

The K machine weighs approximately 2800 lbs. Proper equipment of

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

(See Figure 5 To Prepare the Mill before Lifting):

1. Using a steel cable with protective sleeving (min 3/4” diameter) or a 3-ton sling, position sling loops on machine as shown in Figure 5.

2. Use cardboard pieces or other suitable protective sheets on both sides of the machine to prevent scratching.

3. Remove the 4 nuts and screws holding the machine to the wood skid.

4. Lift the machine (the machine should lift approximately level).

5. Insert the 4 screws for leveling pads in their place in the bed.

6. Place the machine in its location (see floor plan and bed footprint drawing). Carefully positioning each leveling pad under each leveling screw.

7. Remove the lifting cable or sling and all protective cardboard.

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Figure 5 - Lifting the Machine

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Lifting and/or Moving the Machine – DPMEX2

CAUTION!

The DPMEX2 machines weigh approximately 3200 lbs. Proper equipment of sufficient capacity

must be used when lifting and/or moving the machine.

Method 1

1. Insert a steel bar 1.0" dia x 36" long through the rear side holes of the bed (under column).

2. Use a steel cable (with protective sleeving) min. 3/4" dia. or a 3 ton sling.

3. Use cardboard pieces or other suitable protective sheets on both sides of the machine to prevent scratching.

4. Remove the 4 nuts and screws holding the machine to the wood skid.

5. Lift the machine (the front side of the machine should be lower than the back side).

6. Insert the 6 screws for leveling pads in their place in the bed. 4 screws for DPMEX2.

7. Place the machine in its location (see floor plan and bed footprint drawing) carefully positioning each leveling pad under each leveling screw.

8. Remove the lifting cable or sling, the steel bar and all protective cardboard.

(see Figure 5.1)

Figure 5.1 - Lifting the Machine - Method 1

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Method 2

WARNING!

The lift truck must have sufficient lifting capacity (3 tons) and be equipped with suitably

long forks.

1. Insert 2 steel bars 1" dia x 36" long through both sides in the existing holes in the machine base (front and back).

2. Position 4 (two each side) wood vee blocks under the steel bars and over a suitable lift truck.

3. Lift the machine up (somewhat tilted towards the front) 4-6" from the ground and move it to its floor plan position.

4. Insert the 6 screws for the leveling pads in their place in the bed.

5. Place the machine in its location (see floor plan bed/footprint) carefully positioning each leveling pad under each leveling screw.

(see Figure 5.2)

Figure 5.2 - Lifting the Machine - Method 2

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

2.8.1 Releasing the Head Counterweight Supports – DPMEX2

CAUTION!

Do not remove the steel rods unless they are loose.

only

In order to move (raise or lower) the spindle head/ram it is first necessary to remove the 2 steel rods (with flanges) inserted through the holes in the column. These rods support the counterweight during shipping to prevent damage to the counterweight chains and sprockets.

1. Release ram gib locks.

2. DPMEX2 – Lower the head slowly with a 10mm socket on the top end of the Z-axis ball screw until the chain between the ram and the counterweight is tight.

3. Lower a little further until the 2 support steel rods are loose. Remove the 2 steel rods and store them for future machine moves or transportation.

4. Do not continue to move the ram until all ways have been cleaned.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

2.9 Cleaning

WARNING!

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

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.

1. Remove rust protective coating from the machine before moving any slideways (table, saddle, knee, column, etc.).

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

3. It may be necessary to move back and forward, left and right, and up and down the table, saddle and the ram. Always release the clamp levers (two in front of the table, one underneath the saddle on each side, and two ram lockbolts on the right side of the column) before attempting to move the above parts.

4. Be certain the table, saddle and spindle move freely and smoothly over their entire length.

2.10 Leveling: Leveling Tolerance is .0005”/10”

1. Set the machine on its 4 leveling pads on a solid, level floor prepared in accordance with the state and local rules for machine tool installation.

2. Put one or two precision Spirit Levels or Electronic Levels in the center of the table in the positions illustrated in Figure 6.

3. Adjust the 4 corner leveling screws on their pads until the machine is level to .0005 in/10 in.

4. If the machine must be anchored to the floor, follow the general instruction for installing machine tools and use for leveling any well-known methods: shims, etc.).

5. If the machine must be installed on vibration mounts/pads (rubber, commercially available leveling and vibration mounts, etc.) follow the instructions delivered with the mounts/pads, ordering them to satisfy the load of the machine and the maximum weight of the workpiece.

6. When machine is correctly level, lock the adjusting screws in place with their hex nuts.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

I00138

Figure 6 - Placement of Levels

Figure 7 - Leveling Screws

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

2.11 Pendant Connections

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. Be certain that 400-volt electricity (typical range 415 - 460V) is used only

with a machine labeled 440 volts at the motor and at the electrics box on the back of

the column.

DANGER!

The 220 or 440-volt line must originate from a dedicated and independent fused box

with a manual shut-off lever. It is the responsibility of the purchaser to supply a

wired box that meets all local codes and regulations.

The follow diagram shows the cable connections to the pendant. The Z motor port refers to DPMEX2 machines only. This connector is not found on 2 axis EMX controls. See section 3 for more information on routing cables. See steps 7 and 9.

Figure 7-1 - Pendant Connections

2.12 Electrical Connection

The TRAK Mills can be configured for 220 or 440 volt 3 phase electricity. These machines also require a 110V power source to power the control.

Incoming 220 or 440-volt power connects to the machine through the electrical box located on the back of the column. The power cable enters the black box through a hole on the top of the box.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

DANGER!

Only a qualified electrician should wire the 220 or 440-volt 3-phase electricity.

To convert a machine from 220 to 440 volt power or vice versa 3 things must happen: spindle motor must be rewired, overload relay must be set to 8.5 amps for 220 V and

4.25 for 440 volts and the voltage stickers on the electric’s box must be replaced.

See Section 6.1.11 for a diagram of how to rewire the spindle motor. Southwestern Industries recommends the machine be earth grounded by driving a

copper rod into the ground. It is the responsibility of the customer to install this rod.

Figure 8 - Wiring - Not for retrofit

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Part Number

Description

220V = 20676 440V = 20676

Electrical Box

220V = 23438-3 440V = 23438-3

Overload

23436

Contactor (Qty = 2) (Reverse or Forward)

20676-2

Electrical Box Replacement if machine has table guard option.

CAUTION!

Failure to properly lubricate the mill will result in the premature failure of bearings,

sliding surfaces & ball screws.

CAUTION!

Failure to manually activate the pump at the beginning of each day and allowing the

pump to run dry may cause severe damage to the TRAK mill way surfaces and ball

screws.

2.13 Air Connection - Optional

The machine has an air hookup in the rear of the machine if the machine has a power drawbar

If the machine has a power drawbar option then the machine will include an air

regulator, air manifold and an oiler. The air fitting is ¼” NPT. Within the manifold there

is an additional air line port in case the user wants to hook up an air line to clean chips. Remove the plug to gain access to this port

2.14 Lubrication

2.14.1 Manual Lubrication - KEMX

The TRAK EMX mill X & Y way surfaces and ball screws need to be manually lubricated. The Manual Lube automatically discharges about 4ml of oil every plunge.

1. At the beginning of each day, manually pull the pump handle.

Note: If the machine has been sitting for a long while, run the machine through the full length of its travel to ensure lubrication reaches all surfaces.

2. At the beginning of each day, check the oil level in the system. If low, fill

with Mobil Vactra Oil No. 2 or equivalent.

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Figure 17 - Knee Mill Lubrication

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Parts List - Knee Mill Lubrication (Figure 17)

Item

P/N

Description

Qty

9001

FRU-K3-HAND OILER

1 2 9002

FRU-K3-ALUMINUM PIPE

6 3 9003

FRU-K3-ELBOW

6 4 9004

FRU-K3-T-JOINT - 4 HOLES- M8 X 1.0

1 5 9005

FRU-K3-CONNECTOR

3 6 9006

FRU-K3-REGULATING DISTRIBUTOR

1 7 9007

FRU-K3-FLEXIBLE TUBE

1 8 9008

FRU-K3-SCREW NUT - M8 X 1.0 MALE

15 9 9009

FRU-K3-SCREW NUT - PD 1/8- 19MM

9010

FRU-K3-SCREW - M5 X 20 mm LG

9011

FRU-K3-SCREW NUT - M8 X 1.0 FEMALE

9012

FRU-K3-ADAPTER

9013

FRU-K3-SLEEVE - 4.1 mm I.D.

i00889

2.14.2 Way Lubrication – DPMEX2

The auto lube system provides centralized automatic lubrication for the ways and ballscrews. The lube pumps 2-liter reservoir is serviced with Mobil Vactra Oil No. 2 or equivalent. The pump is factory set to pump oil for 15 seconds for every 60 minutes of spindle time. There is an internal memory on the pump so that the pump will not reset every time the spindle is turned off.

The pumping output can be regulated electronically to control the pause time between pumping cycles, and the duration of the pumping cycle. The following describes the buttons used to program the lube pump. In order to modify any of the settings the spindle must be on.

The pump has an alarm that will sound if any of the following problems arise:

 Oil line breakage  Oil filter blockage  Bad motor  Low oil pressure  No oil in tank

INT (Interval) - this button programs the interval between pumping cycles. Each press of the button increases the interval by one minute.

DIS (Discharge) - this button programs the amount of time the pump will discharge each pumping cycle. Each press of the button increases the discharge time by one minute.

FEED - this button is used to manually feed the ways and ballscrews.

RST - this button tells the pump to discharge for the time programmed. Factory Default Values

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

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

To adjust the amount of Discharge Pressure displayed on the lube pump gauge, loosen

CAUTION!

Failure to manually activate the pump at the beginning of each day, or allowing the

Auto Lube to run dry may cause severe damage to the TRAK DPMEX2 way surfaces

and ballscrews.

the jam nut and turn the adjustment screw located on the top right side of the lube pump while the lube pump is activated.

At the beginning of each day, check the oil level in the Auto Lube system. If low, fill with Mobil Vactra Oil No. 2 or equivalent (SAE 30 or ISO 68).

2.14.3 Head Lubrication – TRAK Mills

Once Each Week:

1. Fill the oil cup on the front of the head with SAE 30 or 30 W oil. This oil lubricates the Hi/Lo range shifter.

2. Fill the ball oiler located in the front lower right corner of the speed changer housing. This oil lubricates the speed changer shaft.

3. Extend the quill fully and apply a coating of SAE 30 or 30W oil to the outside diameter of the quill.

Every Four Months:

Apply a good grade of general-purpose grease through the grease fittings on the back of the head and on the left side of the head. This grease lubricates the Low range gear set and the feed change gears respectively. Also lubricate vari-disk on spindle motor by means of grease fitting on motor shaft.

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

3.0 ProtoTRAK EMX Retrofit Installation

3.1 Recommended Tools

 Allen wrenches, set, inch and metric  Drill motor  Drills, set  Taps, set, and tap handle  Machinist square  Bubble level  Crescent wrench, 10”  Torque wrench, up to 60 ft/lbs. - Optional, better if you have it  Crowfoot wrench, 1 1/4” open end to fit torque wrench  Socket set with 3” and 6” extension and ratchet wrench  Dial calipers  Flat blade screwdriver set  Phillips screwdriver set  Gauge block, 6” or 150mm - Calibrate X, Y  Gauge block, 3” or 75mm - Calibrate optional Z scale  .0001” dial indicator and magnetic base  Center punch  Hammer, small  Combination wrenches, set, 3/8” to 15/16”  Counterbores or step drills set  Combination wrench, 10mm  Transfer punch set  Transfer screw set  Feeler gage - Z glass scales option  Pliers set  File set  Xacto knife with flat blade  3/4” 2 flute end mill - For machining test  Safety glasses

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

3.2 Kit parts

1 - BALLSCREW-XAXIS

(P/N 26031-42), (P/N 26031-48), (P/N 15608-36) or (P/N 15608-54)

This item will have one of these part numbers based on the kit that is shipped.

1 - BALLSCREW-YAXIS

(P/N 26032-12), (P/N 26032-16) or (P/N 15609-19)

This item will have one of these part numbers based on the kit that is shipped.

1 ea - PENDANT ARM (P/N 26037)

1 ea - NAMEPLATE-

SYSTEM S/N (P/N 21934)

3.2.1 Ballscrews

Warning: never unscrew a ballscrew from its ball nut. This will destroy the ballscrew. This is especially important with the Y-axis ballscrew. Before installing, be sure that the ballscrew is long enough for the saddle travel of your machine.

3.2.2 Pendant Arm Assembly – P/N 26034-2, -3 or –4 This assembly will vary depending on the machine it is installed on.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

1 ea. – PLATE-

LEVELING

(P/N 16919)

4 ea - TIE WRAP-4 IN-PLASTIC

(P/N 22475)

1 ea - CAP PLUG

(P/N 26038)

2 ea – SCREW-

DRIVE-4-SS

(P/N 4X3/8 34J)

4 ea – BHCS

(P/N 1/4-20 X 1/2 27B)

4 ea – SCREW-SOC

SET-STL-BO-CUP

(P/N 1/4-20X3/4 40B)

4 ea– CABLE MOUNT

(P/N 26050)

1 ea – BUSHING-

THREADED

M-20X2.5 METRIC

(P/N 26016-2)

1 ea – BUSHING-

THREADED

3/4-10 STANDARD

(P/N 26016-1)

1 ea – NUT-HEX-STL-

(P/N 3/8-16 50B)

1 ea – SCREW-SHCS-

STL-BO

(P/N 3/8-16X2 3/4 25B)

1 ea – WASHER-EXT

TOOTH-STL-ZINC

(P/N 1/2 75Z)

1 ea – WASHER –

BELLEVILLE SPRING

LOCK

(P/N 24009-2)

1 ea – SCREW-SHCS-STL-BO

(P/N 1/2-13X3 1/2 25B) (P/N 5/8-11X3 1/2 25B)

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

3.2.3 Motors

X & Z MOTOR ASSY ENCODER/DRIVER 4020 (P/N 20296 Qty 2)

Y MOTOR ASSY ENCODER/DRIVER 4020 (P/N 20296)

1 – Z GLASS SCALE

(P/N 22800-4)

1 – REMOTE STOP/GO SWITCH

(P/N P-TRAK RSG)

1 – USB-FLASH DRIVE-512MB

(P/N 24671-512)

3.2.4 Options

Z Glass scale and glass scale mounting bracket

The Z Glass Scale and hardware are packaged in two separate boxes. One box contains the scale and the other contains all hardware. See the instructions that came with your glass scale kit for the listing of parts.

Remote Stop-Go switch Option

USB Thumb Drive Option

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

3.2.5 Pendant and pendant hardware

1 ea - PENDANT ASSY – PROTOTRAK EMX

(P/N 26015-2)

2 ea – CABLE ASSY – AC

POWER

(P/N 22608)

4 ea – SCREW-SHCS-

STL-BO

(P/N 1/4-20X3/4

25B)

4 ea – WASHER-1/4

HARD BLK OX 1/8

THK

(P/N 15759)

4 ea – CLAMP-

CABLE (4160)

(P/N 21967)

NO PHOTO

55 ea – CABLE TIE-PLASTIC 8 IN LONG (TCA1)

(P/N 21968)

1 ea – MANUAL-

EMX SERVICE AND

INSTALLATION

(P/N 26109)

1 ea – MANUAL-

EMX

PROGRAMMING

(P/N 26056)

1 ea – DRIVE HOUSING

(P/N 15621)

1 ea – FRONT COVER

(P/N 15624)

1 ea – BACK COVER

(P/N 15622)

1 ea – HOUSING-

BEARING

(P/N 15612-1)

(Sold as set with

15885 under 15612)

ProtoTRAK EMX Pendant Hardware – P/N 26035-2

3.2.6 X-Axis Drive Kit – P/N 20255-1,-2,-3,-5 or –6

This assembly will vary depending on the machine it is installed on.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

1 ea – RING-BEARING

HOUSING

(P/N 15885)

1 ea – BELT-TIMING

5MM POWERGRIP

(P/N 400-5M-15)

2 ea – WASHER-FLAT

SAE-STL-ZINC

(P/N 1/2 71Z)

2 ea – NUT-HEX JAM-

STL-ZINC

(P/N 1/2-20 51Z)

2 ea – WASHER-EXT

TOOTH-STL-ZINC

(P/N 1/2 75Z)

2 ea – SPACER – .020”

THICK

(P/N 14772-2)

4 ea – WASHER-FLAT

USS-STL-BO

(P/N 3/8 70P)

7 ea – WASHER-1/4

HARD BLK OX 1/8

THK

(P/N 15759)

1 ea – SPACER- .100”

THICK

(P/N 14772)

1 ea – STOP – X-AXIS

(P/N 15638)

Use if needed. Mount

on saddle to prevent X

motor bracket from

pinching the oil

manifold.

1 ea – FERRULE-

SPROCKET

(P/N 16350)

1 ea – SEAL-

BEARING HOUSING

(P/N 15626)

1 ea – NUT CLAMP-X,Y,

& Z AXIS

(P/N 16452)

1 ea – KEY WOODRUFF

#404-1/8 X 1/2

(P/N 98481A090)

1 Set – BEARING-

ANGULAR CONTACT

(P/N 23930)

2 ea – SPACER -

.050” THICK

(P/N 14772-5)

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

4 ea – SCREW-SHCS-STL-BO

(P/N 3/8-16X2 1/2 25B), (P/N M8-1.25X65 25B)

or (P/N M10-1.5X65 25B)

Kits may contain one or all of these parts.

3 ea – SCREW-RH-

PHIL-STL-BO

(P/N 8-32X3/8 20B)

1 ea – PULLEY-SOLID

44 TEETH W/O

GUIDES

(P/N 16983-1)

7 ea – SCREW-HEX ND-STL-

(P/N 1/4-20X1 24B)

1 ea – HANDWHEEL ASSY-MX

(P/N 15616)

1 ea – SCREW-SHCS-STL-BO

(P/N 8-32X3/8 25B)

1 ea – SCREW-SHCS-STL-BO

(P/N 5/16-18X1 25B)

1 ea – SCREW-SHCS-STL-BO

(P/N 10-32X3/4 25B)

3 ea – SCREW-SHCS-STL-BO

(P/N 10-32X1 25B)

1 ea – MOTOR BRACKET-KNEE MILLS-40 DEGR

(P/N 20623)

1 ea – COVER-SPORT 40 DEGREE

(P/N 20621)

3.2.7 Y-Axis Drive Kit – P/N 23083-1,-2,-3 or -4

This assembly will vary depending on the machine it is installed on.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

1 ea – HANDWHEEL ASSY-MX

(P/N 15616)

1 ea – BELT-TIMING

5MM POWERGRIP (Y

AXIS)

(P/N 890-5M-15)

1 ea – PULLEY-SOLID 44

TEETH W/O GUIDES

(P/N 16983-1)

1 ea – BEARING

HOUSING

(P/N 15980-1)

(Sold as set with 15885

under 15980)

1 ea – RING-BEARING

HOUSING

(P/N 15885)

1 – ea NUT CLAMP-X,Y,

& Z AXIS

(P/N 16452)

1 Set – BEARING-

ANGULAR CONTACT

(P/N 23930)

1 ea – SEAL-BEARING

HOUSING

(P/N 15626)

1 ea – FERRULE-

SPROCKET

(P/N 16350)

1 ea – DIAL NUT

(P/N 15836)

1ea – WASHER-FLAT

SAE-STL-ZINC

(P/N 1/2 71Z)

1 ea – WASHER-EXT

TOOTH-STL-ZINC

(P/N 1/2 75Z)

1 ea – NUT-HEX JAM-

STL-ZINC

(P/N 1/2-20 51Z)

4 ea – SCREW-SHCS-STL-BO

(P/N 3/8-16X2 1/2 25B), (P/N M8-1.25X65 25B)

or (P/N M10-1.5X65 25B)

Kits may contain one or all of these parts.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

4 ea – SCREW-HEX ND-

STL-BO

(P/N 1/4-20X1 24B)

4 ea – WASHER-1/4

HARD BLK OX 1/8 THK

(P/N 15759)

1 ea – SHEET METAL-

PT4-COOLANT MOTOR

COVER ASSY

(P/N 23141)

This item is found in the

Misc. Parts box.

1 ea – KEY WOODRUFF

#404-1/8 X 1/2

(P/N 98481A090)

1 ea – SPACER – .020”

THICK

(P/N 14772-2)

3 ea – WASHER-FLAT

USS-STL-BO

(P/N 3/8 70P)

1 ea – TAB WASHER

(P/N 15614)

1 ea – DIAL HOLDER

(P/N 15627-2)

8 ea – SCREW-PH-PHIL-

STL-BO

(P/N 6-32X3/8 10B)

3 ea – SCREW-SHCS-STL-

(P/N 10-32X3/8 10B)

2 ea – SCREW-PH-PHIL-

STL-BO

(P/N 1/4-20X3/8 10B)

3 ea – WASHER-SPLIT

LOCK-STL-BO

(P/N 10 73B)

4 ea – WASHER-

.75X.394X.10-STL

(P/N 23082)

4 ea – SCREW-SHCS-STL-

(P/N 10-32X3/4 25B)

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

1 ea – YOKE-MACHINED

(P/N 15546-x)

Needed when the original machine yoke is not usable. This part may not be in every kit. It will be included in kit P/N 15844-2

1 ea – TUBING-

TYGOTHANE 1/4 OD.

1/8 ID 2FT

(P/N 5549K11)

1 ea – FITTING (P/N P2 TUB-2)

Needed when knee mill

contains only 1 oil line

that supplies both the X

and Y ballscrews.

2 ea – ELBOW-

RIGHT ANGLE-

THREADED

LEADLOY A

(P/N 15187)

2 ea – SCREW-SCO SET-

STL-BO-CUP

(P/N 10-32X3/8 40B)

2 ea – SCREW-SHCS-

STL-BO

(P/N 5/16-18X1 1/4

25B)

2 ea – PIN-ROLLED-

STL-PLAIN

(P/N 3/16X1 1/4 81P)

2 ea – WASHER –

BELLEVILLE SPRING

LOCK

(P/N 24009-1)

2 ea – oil line restrictor

(P/N 15782)

3.2.8 Yoke Kit – P/N 15844-1,-2,-3,-5,-6 or -13

This assembly will vary depending on the machine it is installed on.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

3.2.9 Other parts

1 – YOKE SHIM

(P/N 16568) Needed if the ballscrew bore is too small relative to the yoke bore.

1 – END CAP

(P/N 22007)

Needed when the original end cap

is not usable.

1 – BACKING PLATE

(P/N 16029)

Needed to support the Y-axis

bearing assembly when the hole in

the machine casting is too large.

1 – BEARING

(P/N 22008)

Needed when the original

floating bearing is not

usable.

1 – BALLSCREW EXTENSION

ASSEMBLY

(P/N 15181)

Needed for the X-axis ballscrew for

tables that are 49” long.

1 – BALLSCREW EXTENSIVE SUB

ASSEMBLY

(P/N 14975)

Needed the X-axis ballscrew for

tables that are 50” long.

The parts in this section are not needed for all machine models and do not appear in some kits. Even if they are in your kit, you may not need to use them. See the instructions.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

3.3 Installation Steps

The following steps suggest the best way to install the ProtoTRAK EMX retrofit. We recommend you proceed with the installation by doing the following.

- Follow the order of the steps.

- Read the Warnings and Cautions to avoid injury and damage.

- Refer to the drawings for the order of assembly of parts.

- Use the photos and tips to save yourself some time.

Step 1. Remove the table and lead screws.

DANGER!

Crushing, slicing and pinching hazards are present with this step. Use extreme caution

when removing the table. Ensure you have adequate working area and support before

you remove the table. Don’t work alone.

We suggest you remove the items in the following order:

1. Left and right hand wheel and bearing assemblies from the table

2. Table gib (easiest with table centered)

3. Table

4. Saddle hand wheel and bearing assembly (with saddle cranked all the way forward)

5. Table and saddle lead screws

6. Yoke, or lead screw nut retainer

7. Nut, bushing, key and pins from the yoke (if a new yoke came with the kit, you don’t have to do this)

Tips:

 Keep the original machine hardware organized as you remove it. You will need some of it

later.

 Before removing any of the hardware from the machine, crank the table all the way to the

right or left in order to be able to position the lift table next to the machine.

 With the machine disassembled, do a good job of cleaning the gibs, oil grooves and

slideways. This will help ensure smooth operation of your ProtoTRAK.

 Assure that the lubrication system is working properly.

Caution!

When removing the table, make sure it does not cock or it may break the dovetails as it

slides out.

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

WARNING! Use proper support for the table

Ready for Step 2

This step is completed when: the table is removed, the casting is cleaned and the parts are

organized for later.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Step 2. Install the X (table) ballscrew.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Caution: Never unscrew the ballscrew from the nut. This will destroy the ballscrew.

Tips:  Install the elbow oil fitting and 10-32 set screws on the ball nut. The set screw goes in flush to

the surface to prevent oil from draining out of the hole. Don’t tighten too much or it will damage the ballnut.

 First position the yoke in the saddle without the casting screws, then slide the ballscrew into the

yoke. Once the ballscrew is in you can screw in the screws that go through the yoke and into the saddle casting, although you should not tighten them until the ballscrew is aligned.

 If you are using the original machine yoke and it was pinned to the casting, simply replace the

pins. If not, it will be necessary to align the ballscrew.

 Align the X ballscrew either to the back of the saddle or to a piece of round stock you clamp into

the back dovetail. The ballscrew should be aligned within +/- 0.005” end-to-end.

 Trim excess oil line tubing to get it out of your way.  T-fittings are provided in case they are needed. Use provided restrictors in the oil lines to

both the x and y ball nuts so that there will be enough pressure to force oil to the ways.

Caution!

Ballscrews must be aligned. Damage to the ballscrew and drive assemblies will occur if

the ballscrews are not aligned properly.

Caution!

Assure that the oil line will provide for proper oil flow to the ball nut. The ballscrew must

have oil.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Position ballscrew with yoke still loose

Install set screw flush, not tight

Elbow fitting

Oil line installed with restrictor

Tighten ball nut retaining screw

Install casting screws snugly, not tight yet

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Align to back of the saddle…

…within  0.005”

Now tighten. Check alignment again.

This step is completed when: the X ballscrew is tightly attached to the saddle casting and is

aligned within +/- 0.005” from end-to-end.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Step 3. Install the Y Axis (Saddle) Ballscrew.

Caution: never unscrew the ballscrew from its ball nut. This will destroy the ballscrew.

Tips:

 Note that the oil fitting and set screw for the Y-axis ballscrew are in different positions than

for the X ballscrew.

 Make sure the oil fitting clears the machine casting at the front. If it doesn’t, you will have

to grind away some of the casting for it to clear.

 Pull the saddle all the way forward to make it easier to slide the ballscrew into the yoke.  The flat of the ball nut should match the flat of the yoke. These flats are there in order to

clear the beveled gear of the knee crank.

 If you are using a yoke provided in the kit (and not the original yoke), make sure the flat of

the new yoke clears the beveled gear. If it does not, you will have to grind some of the yoke away.

 Run the oil line for the ballscrew to the right and rear of the yoke. Don’t trim it too short –

having it longer will make maintenance easier in the future. Make sure to install an oil line restrictor.

 Leave the oil line to the ballscrew long – for easier maintenance access

Caution!

Make sure the sliding way covers will not shear the oil line when the saddle moves.

The ballscrew must have oil.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Note the flat on the yoke

Align ball nut flat with yoke flat

Attach oil line and routed

Ball nut and yoke must clear the bevel gear

Oil lines routed

This step is completed when: The Y-axis ballscrew is installed and it clears the bevel gear

inside the saddle casting when the saddle is pushed back. Both oil lines are attached to both ball nuts and oil is flowing to the ball nuts and all the ways.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Step 4. Install the Y Axis Drive Train.

Tips:

 Assemble bearing housing assembly on a flat surface before you assemble it onto the

ballscrew.

 There are two sets of bearing housings and bearing rings (one for Y and one for X); they

are matched sets, don’t mix them.

 The bearing seal should fit flush into the bearing housing with the groove side out. Press

or gently tap it in with a hammer.

 The angular contact bearings must be oriented properly. The thick part of the inner races

should face away from each other and be separated by the bearing ring.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Figure 18 - Y - Axis Drive Assembly - P/N: 23083-3

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Parts List - Y-Axis Drive Assembly - P/N: 23083-3

Item

P/N

Title

Qty

15626

SEAL-BEARING HOUSING

23930

BEARING SET (2)-ANGULAR CONTACT- 7204 BECBP

1 Set 4 15980

BEARING HOUSING ASSY-LARGE FLANGE-Y AXIS

1 5 16452

NUT CLAMP-X ,Y, & Z AXIS

1 6 20623

MOTOR BRACKET-KNEE MILLS-40 DEGR

1 7 16983-1

PULLEY-SOLID 44 TEETH W/O GUIDES

1 8 16350

FERRULE-SPROCKET

890-5M-15

BELT - TIMING 5MM POWERGRIP (Y AXIS)

20621

COVER-SPORT 40 DEGREE

15627-2

DIAL HOLDER

15836

DIAL NUT

15614

TAB WASHER

15616

HANDWHEEL ASSY-MX

1/2 71Z

WASHER-FLAT SAE-STL-ZINC

1/2 75Z

WASHER-EXT TOOTH-STL-ZINC

1/2-20 51Z

NUT-HEX JAM-STL-ZINC

10-32X3/4 25B

SCREW-SHCS-STL-BO

M10-1.5X60 25B

SCREW-SHCS-STL-BO

23082

WASHER-.75X.394X.10-STL

1/4-20X1 24B

SCREW-HEX HD-STL-BO

15759

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

6-32X3/8 10B

SCREW-PH-PHIL-STL-BO

23141

SHEET METAL-PT4-COOLANT MOTOR COVER ASSY

10-32X1 25B

SCREW-SHCS-STL-BO

10 73B

WASHER-SPLIT LOCK-STL-BO

98481A090

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

14772-2

SPACER - .020" THICK

20322

SPACER Y-AXIS- BALLSCREW

1/4-20X3/8 10B

SCREW-PH-PHIL-STL-BO

2 20296

MOTOR/ENCODER/SERVO ASSY-DRIVER

1 26032-12

BALLSCREW - Y AXIS

26032-16

BALLSCREW - Y AXIS

i23083-3

(Figure 18)

The clamp nut is designed to trap the bearing against the ballscrew journal with the correct preload:

- Thread the clamp nut onto the ball screw and tighten the #10-32 clamp screw until you feel the clamp nut contact the ball screw threads. It should drag as you tighten the clamp nut.

- Tighten the clamp nut to 50 ft/lb.

- Tighten the 10-32 clamp screw.

The bearing housing is designed to float to find its own center. If it does not contact the saddle casting (because the hole is too large) use the backing plate (PN 16029) that is provided for the machine models that need them.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Once the clamp nut is installed, turn it until the bearing housing contacts the knee casting (or

Bearing letters face in

Bearing ring

Facing in

Groove side out

backing plate) and the saddle begins to move forward. Then install the motor mounting casting. Bring the saddle forward until it is about an inch away from the front of its travel. Having the

ball nut retainer (yoke) close to the mounting bracket will help to align it properly. Put the Y axis drive belt on the pulley before installing the vernier dial. Install the motor next.

Position the motor so the cable can be routed to the left and around the machine. Use the machine’s original vernier dial. Install the top cover of the motor mounting bracket and check for clearance between the vernier

dial and cover. Add shims to the vernier dial holder if needed. Tighten the 1/2-20 hex head nut to 50 ft/lb.

Warning!

Don’t push down on the ballscrew as you are tightening – this may bend the

ballscrew.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Bearing housing complete assembly

Bearing housing assembly next

Clamp nut pins bearings

10-32 socket head cap screw, but not tight yet

Torque clamp nut to 50 ft/lb.

Now tighten socket head cap screw

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Woodruff key

Brass ferrule

Flat against casting

Motor bracket

Pulley

Belt

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Motor

Proper tightness

Motor, proper orientation

Vernier and spacer

Dial nut, tab washer and handwheel

Tighten, don’t push down

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Y-axis drive completed

This step is completed when: The drive train feels smooth as you crank the Y-axis hand

wheel through the entire travel. You will feel the belt cogs engage and the balls move through the ball nut, but it should be consistent and smooth.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Figure 18.1 - X-Axis Drive Assembly - P/N: 20255-2

Step 5. Replace the table & install the X drive train (left side) & motor.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Parts List - X-Axis Drive Assembly (Figure 18.1)

Item

P/N

Title

Qty 1 15621

DRIVE HOUSING

1 4 15624

COVER - X-AXIS - DRIVE - HOUSING-MX

1 5 15622

BACK COVER

1 6 15616

HANDWHEEL ASSY-MX

1 8 15612

BEARING HOUSING ASSY-X AXIS

15638

STOP - X-AXIS

15626

SEAL-BEARING HOUSING

16983-1

PULLEY-SOLID 44 TEETH W/O GUIDES

16452

NUT CLAMP-X ,Y, & Z AXIS

16350

FERRULE-SPROCKET

98481A090

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

14772

SPACER - .100" THICK

400-5M-15

BELT - TIMING 5MM POWERGRIP

23930

BEARING SET (2)-ANGULAR CONTACT-7204 BECBP

1Set

14772-2

SPACER - .020" THICK

14772-5

SPACER - .050" THICK

8-32X3/8 25B

SCREW-SHCS-STL-BO

5/16-18X1 25B

SCREW-SHCS-STL-BO

M10-1.5X65 25B

SCREW-SHCS-STL-BO

1/4-20X1 24B

SCREW-HEX HD-STL-BO

8-32X3/8 20B

SCREW-RH-PHIL-STL-BO

10-32X3/4 25B

SCREW-SHCS-STL-BO

1/2-20 51Z

NUT-HEX JAM-STL-ZINC

15759

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

M10 70P

WASHER-FLAT USS-STL-PLAIN

1/2 75Z

WASHER-EXT TOOTH-STL-ZINC

1/2 71Z

WASHER-FLAT SAE-STL-ZINC

22008

BEARING-204KTT

1 26031-42

BALLSCREW - X AXIS

26031-48

BALLSCREW - X AXIS

i20255-2

Danger!

Crushing, slicing and pinching hazard. Use extreme caution when replacing the table.

Don’t work alone.

Tips:

 Screw the X ballscrew to the opposite side to make it easier to slide the table back on.  Temporarily install the 1/2-20 hex head nut on the ballscrew and use a wrench to turn it.  Before you slide the table back on attach the oil lines and test the oil flow. Liberally

lubricate the ways.

 Make sure the gib locks have not fallen out of their holes and into the saddle.  Reinstall the table gib after the table is back on the machine.  Unlike the Y-axis drive, the X-axis bearing housing attaches to the drive housing.  See Step 4 for tips about the assembly of bearing housing and the clamp nut.  Position the left end of the table almost flush with the left side of the saddle to install the

left side drive train and motor.

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

 Make sure the belt is tight on the pulleys.  Position the motor so the cable can be routed to the left (your left, facing the machine) and

around the machine.

 When more than one fastener is called out in the drawing, use the ones that work for your

machine.

 Item 10 in the list above may be installed on the saddle if needed to prevent the X motor

casting from damaging the oil manifold. Use the 5/16-18 X 1 SHCS to fasten the stop.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Table back on

X gib back in

Bearing housing assembly

Tighten, don’t push down, to 50 ft-lbs

Ready for drive housing

Drive housing installed on table

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Securing the bearing housing assembly

Key, ferrule, pulley

Washer, star washer, ½ hex nut

Tighten to 50 ft-lbs

Belt

Front cover

Motor

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Complete. Note motor orientation.

This step is completed when: The motor is installed with the cable pointing down and toward

the rear of the machine.

Step 6. Install the right side end cap and hand wheel assembly.

See the figure from Step 5 above.

Tips:

 Use the original right or left side hardware from the machine.  Position the table (by screwing the ballscrew) so that the right end is almost flush with the

right side of the saddle to install the hardware.

 Some installations require a ballscrew extension (included in the kit). If you use the

ballscrew extension, note that there is a setscrew inside the extension. First install the extension; use two wrenches to tighten it securely. Then install and tighten the setscrew (lock tight is recommended). Use the bushing to seat the floating bearing (that came with the machine.

 Once the handwheels are installed on both sides, crank the table back and forth. It should

move smoothly throughout the entire travel with no binding.

 Adjust the table and saddle gibs to be snug but allow smooth motion.

Warning!

Don’t push down on the ballscrew as you are tightening – this may bend the

ballscrew.

This step is completed when: The drive train feels smooth as you crank the X-axis hand

wheel through the entire travel. You will feel the belt cogs engage and the balls move through the ball nut, but it should be consistent and smooth.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Extension, only if needed

Tighten extension

Set screw to tighten extension

Bushing

Original bearing in original housing

Housing on table

 Use cable ties to secure the cables to the pendant-mounting arm. You may want to do this

after the system check out in step 10. Just don’t forget to come back to it because the

machine will look a lot nicer with the cables all tied up.

 Note: The tableguard port is not used for retrofits.

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Spacers as needed

Vernier dial, lock nut, spacers as needed

Handwheel, washer, star washer, nut

Tighten, don’t push down, to 50 ft-lbs

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Step 7. Install the display pendant.

Item

P/N

Title

UseAs

Qty

26037

PENDANT ARM

16919

PLATE-LEVELING

26038

CAP PLUG

26016-1 26026-2

BUSHING - THREADED - 3/4-10 BUSHING - THREADED - M20X2.5

1/2-13X3 1/2 25B

SCREW-SHCS-STL-BO

1/2 75Z

WASHER-EXT TOOTH-STL-ZINC

3/8-16 50B

NUT-HEX-STL-BO

24009-2

WASHER - BELLEVILLE SPRING LOCK

1/4-20X3/4 40B

SCREW-SOC SET-STL-BO-CUP

26050

CABLE MOUNT

22475

TIE WRAP – 4 IN. PLASTIC

3/8-16X2 3/4 25B

SCREW-SHCS-STL-BO

1/4-20 X 1/2 27B

SCREW-BHCS-STL-BO

21934

NAME PLATE - SYSTEM S/N

4X3/8 34J

SCREW - DRIVE 4SS

1/2-13 50Z

NUT - HEX - STL - ZINC

26066

BRACKET - PENDANT ARM

5/16-18X1 25B

SCREW-SHCS-STL-BO

5/8-11X3 1/2 25B

SCREW-SHCS-STL-BO

i01274

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Southwestern Industries, Inc.

ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

The drawing illustrates the two ways of mounting the pendant arm to the machine. Your kit will include one of the two sets of hardware depending on the model of your machine. For Bridgeport models, if it is necessary to use the 5/8" bolt supplied, you will have to open up the through-hole in the pendant arm.

Attach the nameplate serial number plate (21934) on the pendant arm. This serial number plate is the serial number that you will need to reference for service parts and other support in the future. The Service Department will not be able to help you efficiently without the serial number.

This step is completed when: The display pendant is mounted securely to the machine ram and the serial number name plate is attached to the pendant arm.

Step 8. Install the Z glass Scale

There are several different brackets that come with the Z-axis glass scale kit, depending on the machine model. Illustrated instructions will come with the scale kit.

This step is completed when: the glass scale is mounted securely to the machine quill and moves smoothly with quill travel.

Step 9. Connect the cables and the power.

Caution: do not turn the power on to the pendant until all cables are plugged in properly. Plugging or unplugging with power on will destroy the computer.

Tips:

 Loosely route the cables and check that there will be enough slack to accommodate full

table and saddle traverse.

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

 Use cable ties to secure the cables to the pendant-mounting arm. You may want to do this

Pendant arm and cables

Z cables – plug in all cables with system off

after the system check out in step 10. Just don’t forget to come back to it because the machine will look a lot nicer with the cables all tied up.

 Note: The tableguard port is not used for retrofits.

This step is completed when: The cables are plugged into the display.

Step 10. Check out.

Do the following:

1. Plug the ProtoTRAK EMX into a 110 volt outlet.

2. Turn the ProtoTRAK EMX on.

3. Go into DRO mode, press Jog.

4. Push the X, the table should move under power. Press the +/- key and press the X again. It should move the opposite direction.

5. Note: The table should move to the left for positive X counting and the saddle should move towards the operator for positive Y counting. Moving the quill up should result in positive Z counting. Use Service Code 97 to change if needed.

6. Do the same with the Y key and observe the saddle.

7. Press Return to get out of Jog.

8. Move the quill handle. There should be a readout on the Z. If the Z isn’t activated, see section 5.9 for instructions on how to do service code 15.

If the system is jogging we recommend that you calibrate and set backlash constants now. See section 6.2.2. Also run service code 12, see Section 5.7.2.1.

If you have any problems, see the troubleshooting section in this manual for what to do. Don’t worry, there isn’t anything too tough. You may just have to reinstall something.

Congratulations! See your ProtoTRAK EMX Safety, Programming, Operating and Care Manual for instructions for using the ProtoTRAK EMX, a tutorial and some sample programs.

Now you can machine!

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

4.0 Troubleshooting by Symptom

Possible Cause

Check This

Too much backlash entered for code 128

Verify nothing is mechanically loose and the backlash values are not higher than what physically is in the system.

Machine Tool & Setup problem

Check for any looseness in the setup (Tool, Tool holder, Part, Vise, or Fixture). Check the condition and type of cutter being used, type of material, RPM and Feedrate, etc. See Machine Tool & Setup Section 5.1

Table, Saddle, or Knee Locks are locked

Make sure the Table and Saddle Locks are unlocked. Never use gib locks with a CNC machine.

Inadequate or no Lubrication 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 5.1.3

X, Y, Z and knee Gibs are not adjusted properly

Check the adjustment of the X, Y and Z gibs. See Gib Adjustments in Section 6.2.1.

X, Y & Z-axis Drive Trains are loose

Check Repeatability using the Repeatability and Positional Accuracy procedure. Step by step, carefully inspect the Drive Train for any looseness. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 5.2

Way surfaces are pocked, scarred, or excessively worn

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.

Use this section to begin the process of resolving a service problem. Each symptom 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

4.1 Problems Relating to Machining Results

4.1.1 Poor Finish

The part finish is marred with scallops or is very rough.

Do the following Service Codes and document values:

 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

4.1.2 Circles Out of Round

Circles are not round within 0.002” TIR over 3.0” DIA. This is best measured by placing a dial indicator in the quill and sweeping around the part.

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

Note: The typical slideway-milling machine is not capable of achieving more precise

Possible Cause

Check This

Torque values on X and Y-axis are too high.

Make sure torque is lower than 20 in-lbs. Normal values for a machine that is aligned and adjusted properly should be between 10 and 15 in-lbs. Make sure torque is consistent across axis travel.

Machine Tool and Setup problem

Check for any looseness in the setup (Tool, Tool holder, Part, Vise, or Fixture). See Machine Tool & Setup - Section 5.1

Machine not level

Verify that the machine is level to specification.

Head is not Trammed

Verify that the Head is Trammed to specification. See Tramming the Head Sec 6.2.3

X and Y Gibs are not adjusted properly

Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures.

Calibration or Backlash problem

Recalibrate the machine. Reset the Backlash. Check Repeatability and Positional Accuracy. See Calibration & Backlash Constants Section 6.2.2

X & Y-axis Drive Trains are loose

Head Bolts are loose

Verify that all the head bolts are tight.

results although careful adjustments to a new milling machine may produce better results. If more precise circles are required, then it is recommended to use a precision boring head/boring bar.

Do the following Service Codes and document values:

 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.

4.1.3 Taper Cut on a Programmed Straight Line Move

An unwanted tapered cut occurs, when the machine is programmed to move in a straight line along either the X or Y-axis. The DRO shows motion of a few thousandths of an inch in the axis that is not supposed to be moving.

Explanation: For straight line cuts along the X or Y-axis, the control is designed to lock the motor of the axis that is not moving. A taper is created when there is play in the system. The force of the tool shoves the table or saddle out of position.

The system will respond to being pushed out of position by making an adjustment at the end of the move.

An unwanted tapered cut is the result of looseness in the system.

Do the following Service Codes and document values:

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

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ProtoTRAK KEMX, DPMEX2 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

 Code 12 Feed Forward Constant.

Possible Cause

Check This

Machine Tool & Setup problem

Check for any looseness in the setup (Tool, Tool holder, Part, Vise, or Fixture). See Machine Tool & Setup Section 5.1

X and Y Gibs are loose

Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures. See Section 6.2.1

X and Y-axis Drive Trains are loose

Possible Cause

Check This

Machine Tool & Setup problem

See Machine Tool & Setup Section 5.1

Programming Error

In the program, look for common errors in programming such as transposing numbers, tool diameters, and pressing INC SET when ABS SET is meant. This is especially suspected if the dimensional errors are larger than a few thousandths. See the Controls Programming, Operations and Care manual.

 Code 127 Measures the backlash in the system.  Code 128 Enter backlash compensation.

4.1.4 Parts Have Incorrect Dimensions

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

 Circles: 0.002” TIR over 3.00” DIA  Positional Accuracy: +/- 0.0005"  Repeatability: 0.0005"

Note: The typical slideway-milling machine is not capable of achieving more precise results. Although careful adjustments to a new milling machine have produced better results, you should not expect the same level of accuracy from an older or worn machine.

Furthermore, the system should be expected to repeat within the resolution of the displayed DRO numbers of 0.0005”. Do the following Service Code:

 Code 33 Software Identification. This is needed if you call SWI Customer Service.  Code 123 Calibration using a measurement standard, or  Code 122 Calibration using work piece measurements.  Code 12 Feed Forward Constant.  Code 127 Measures the backlash in the system.  Code 128 Enter backlash compensation.

4.1.4.1 Every Part Has the Same Error

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Calibration or Backlash problem

Recalibrate the machine. Reset the Backlash. Check Repeatability and Positional Accuracy. See Calibration & Backlash Constants

4.1.4.2 The Dimensional Errors Are Random or Accumulate in Size

Possible Cause

Check This

Machine Tool & Setup problem

See Machine Tool & Setup Section 5.1

X and Y-axis Drive Trains are loose

Possible Cause

Check This

The home positions or tools are not set correctly

See the Controls Programming, Operations and Care manual.

Bad Motor Encoder

See Motor diagnostics Section 5.4

Over the Part Program Run

4.2 Problems Regarding the Motion of the Machine

4.2.1 Run Away Axis

The axis makes an unwanted move at rapid speed in one direction and faults out. This is usually caused by an encoder signal being interrupted.

Do the following Service Codes:

 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 properly.

 Code 131 Motor encoder operation test.

4.2.2 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 Sets the maximum allowable arc accuracy error. This applies to arcs only.

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Possible Cause

Check This

The maximum allowable Arc Accuracy is set too low.

This value will only slow down the machine during arc moves. The factory default is set at 0.001". Perform Code 129 to check or change this value. See Service Codes section

Incoming AC voltage is inadequate

Perform Code 100. See Service Codes - Section 5.9 and Electrical Section 5.8

Table and Saddle Locks are locked

Make sure the Table and Saddle Locks are unlocked.

Inadequate or no Lubrication to Ballscrews and Way surfaces

X and Y Gibs are not adjusted properly

Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures.

Binding in the Drive Train

Check Repeatability using the Repeatability and Positional Accuracy procedure. Check the torque reading of the Drive Train. Step by step, carefully inspect the Drive Train for any binding. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 5.2

Servo Drive failure

See Servo Drive Section 5.5

Motor failure

See Motor Section 5.4

4.2.3 Axis Will Not Jog

Possible Cause

Check This

Improper Boot-up

Shut down the system and wait 10 seconds before rebooting

E-Stop is pressed in

Check E-Stop. Especially if both axes will not jog

Servo Drive failure

Especially, if only one axis will not jog; See Servo Driver Section 5.5

Shorted motor

See Motor Section 5.4

Poor cable or wiring connections

See Electrical Connection Section 5.8

Computer/Pendant failed

See Computer/Pendant diagnostics Section 5.3

The system powers up but will not respond to the jog command.

Do the following Service Codes and procedures:

 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.

4.2.4 Axis Motor Motion Is Not Smooth

While under motor power, the motion is not smooth. The motion appears to be "rough" or jerky”.

Do the following Service Codes and procedures:

 Code 33 Software Identification. This is needed if you call SWI Customer Service.  Code 12 Feed Forward Constant. High feed forward constants will cause an

unstable servo system.

 Code 127 Measures 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.

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Possible Cause

Check This

X and Y Gibs are not adjusted properly

Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures.

Calibration or Backlash problem

Recalibrate the machine. Reset the Backlash. Check Repeatability and Positional Accuracy. See Calibration & Backlash Constants section.

Binding in the Drive Train

Possible Cause

Check This

Most often causes by excess backlash compensation

Use code 127. Check physical backlash in system and re-enter in code 128.

High feed forward values

Check ball screw torque. Typical values should be between 10 to 15 in-lbs.

Excessive friction in the sliding ways

Lubrication, gib adjustments, gib locks. See Machine Tool & Setup - Section 5.1

Looseness in the drive train

Especially the tightness of the drive assembly. See Mechanical Drive Train (X, Y) - Section 5.2

Possible Cause

Check This

Screen saver has been activated

Press any key to turn back on.

The system has shut down

Turn the power switch off, check the computer/ pendant fuses and cable connections. See Electrical Section 5.8

Poor cable connection from Computer Module to LCD (Liquid Crystal Display)

Double-check the connection from the computer module to the LCD.

Computer/Pendant failed

See Computer/Pendant Section 5.3

4.2.5 Searching Axis

The handwheels are slowly turning back and forth when the servos are engaged. Several thousandths of motion are observed on the vernier dial and the frequency is one cycle every couple of seconds.

Do the following Service Code and procedures:

 Code 12 Sets a feed forward power constant to drive axis motors.  Code 128 Backlash compensation.

4.3 Problems Relating to the Operation of the Control

4.3.1 Display Blanks

The display is completely blank.

4.3.2 Bad Picture on the Display

The display has strange characters, horizontal bars or other unfamiliar images, or the display continually rolls.

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Possible Cause

Check This

Computer/Pendant failed

See Computer/Pendant Section 5.3

Poor cable connection from Computer Module to LCD (Liquid Crystal Display)

Double-check the connection from the computer module to the LCD.

Possible Cause

Check This

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)

Remove the RSG. Turn 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.

Computer/Pendant failed

See Computer/Pendant Section 5.3

Possible Cause

Check This

Table and Saddle Locks are locked

Make sure the Table and Saddle Locks are unlocked. High torque on any axis may cause faulting problems during alignment routine.

X and Y Gibs are adjusted extremely tight

Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures. See X and Y Gib Adjustments Section 6.2.1

Excessive friction in the slideways

See Machine Tool & Setup Section 5.1

Binding or looseness in the Drive Train

See Mechanical Drive Train (X, Y) Section 5.2

Incoming electrical power

Incoming voltage. See Electrical Section 5.8

Servo Drive failure

See Servo Driver - Section 5.5

Motor failure

See Motor diagnostics, Section 5.4

Computer/Pendant failure

See Computer/Pendant diagnostics, Section 5.3

4.3.3 Keyboard Lockup

The screen display is normal, but the system will not respond to key presses.

Do the following Service Codes and procedures:

 Code 81 To check if the pendant keys are working properly, press each key. If a

key is working properly, the corresponding key on the screen will light. The pendant will also beep.

4.3.4 Fault X or Y

The program run or jogging operation is interrupted with a Fault Message on the display.

Do the following Service Codes and procedures:

 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.

4.3.5 System Will Not Turn On

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

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Possible Cause

Check This

110 V line is not plugged in

Check incoming 110 V power source to black electrical cabinet

Pendant On/Off switch is Off.

Check the Pendant On/Off switch

Fuse blown in pendant or electrical cabinet

Remove fuses and check continuity.

IDE Flash Drive

If Boot Failure message appears, then check that the IDE Flash is properly installed. See section 5.3.

Computer/Pendant has failed

See Computer/Pendant diagnostics Section 5.3

4.3.6 System Reboots by Itself

Possible Cause

Check This

Interruption of 110 V power to pendant

Using a Voltmeter, check the incoming 110VAC to the pendant.

Poor wiring and cable connections

Check for any loose wiring or cables

Computer/Pendant failed

See Computer/Pendant diagnostics Section 5.3

Possible Cause

Check This

Fuse blown in pendant

Remove fuse and check continuity

Poor wiring and cable connections

Check for any loose wiring. Also, check the 110VAC Power Cable connection from the electrical box to the Pendant. See Electrical Section 5.8

Computer/Pendant has failed

See Computer/Pendant diagnostics Section 5.3

Possible Cause

Check This

Configuration file corrupt

Load default configuration by going to code 313

Not saving Calibration values

Replace Computer/Pendant module. See Computer/Pendant

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

4.3.7 System Shuts Off

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

4.3.8 Will Not Hold Calibration

The control will not hold calibration. Go to the "Configuration Values" screen and write down the calibration values for the motor encoders (Encoder) 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 Software Identification. This is needed if you call SWI Customer Service.  Code 313 Configuration Values  Code 123 Calibration using a measurement standard, or  Code 122 Calibration using work piece measurements.

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If calibration factors are being saved,

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

Does 110 V power come out of the pendant through the e-stop connector? If yes, and the screen has an E-stop message, replace the computer module.

Possible Cause

Check This

Machine Tool & Setup problem

Check for any looseness in the setup (Tool, Tool holder, Part, Vise, or Fixture). Make sure there is sufficient contact between the tool holder and the spindle. See Machine Tool & Setup Section 5.1

X and Y Gibs are loose

Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures.

but the measurements are not repeating or are not accurate:

 See Measurements Are Not Repeating  See Measurements Are Not Accurate

4.3.9 E-Stop Error

For TRAK Knee mills, the E-Stop turns the power off to the axis and spindle motors (for retrofits, the e-stop does not cut power to the spindle motor). For the machine this is done by stopping 110V power from reaching the electrical box through the use of a relay in the pendant.

110V Power reaches the electrical box through the AC E-stop cable. It is used to energize the spindle motor contactor. If this contactor is not energized the spindle will not turn on. See Figure 19.

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.

4.4 Problem with the Measurements

4.4.1 X, Y and Z-Axis Measurements Do Not Repeat

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

Test for accumulative error by moving the axis a number of times to see if the error gradually grows by a small amount or if the error abruptly changes by a large amount, it may be caused by a bad encoder.

Expected repeatability numbers should be 0.0005” or less

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Possible Cause

Check This

X and Y-axis Drive Trains are loose

5.2

Spindle and/or Quill are loose

Use a Dial Indicator and check for side-to-side movement between the Spindle and the Head. Next, check for side-to-side movement between the Quill and the Head. There should be no more than 0.0003" of side-to-side movement. Make sure that there is a few thousandths gap between the Spindle Collar and the Quill after tightening.

Head bolts are loose

Tighten Ram bolts

4.4.2 X, Y, and Z-Axis Measurements Are Not Accurate

Possible Cause

Do This

The Calibration is incorrect

Recalibrate the machine. See Calibration & Backlash Constants

Incorrect backlash values

If the machine does not repeat bi-directionally check the backlash on the axis in question. See Section 5.2.2.

Possible Cause

Check This

Motor Encoder not counting

See Motor diagnostics section 5.4

Computer/Pendant failure

See Computer/Pendant diagnostics 5.3

Measurements repeat, but with a dial indicator mounted to the bottom the spindle, traversing the length of a gage block or some other measurement standard, the measurement is not accurate.

4.4.3 The DRO Is Not Counting

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

Do the following Service Codes:

 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 131 Motor encoder operation test.

4.4.4 X, Y, and Z-Axis DRO Counting in Wrong Direction

The DRO is counting in the wrong direction.

The positive directions for each axis are:

 X-axis – Table moves to the left.  Y-axis – Saddle moves toward the front of the machine.  Z-axis – Quill moves up.

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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 not dull. See Machine Tool & Setup Section 5.1

Drive Belt in the head is slipping

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

Cut more than the machine is capable

Check width and depth of cut

Insufficient voltage, excessive amp load

Check incoming power. Check overload setting.

Possible Cause

Check This

Wrong voltage

Check the 220V/440V voltage to the machine

Poor wiring connections

Check all the wiring connections to the electric’s box.

Defective cables or poor cable connections

Check all cable connections

Spindle Motor is bad

Check the resistance of the Spindle Motor windings on the Spindle Motor between L1 & L2, L2 & L3, and L1 & L3, using an Ohmmeter. The resistance should range from ".7 to 1.2 Ohm". If the Ohmmeter reads "0 Ohms" or "OL", then replace Spindle Motor. Next, check the resistance between L1 & Ground, L2 & Ground, and L3 & Ground, using an Ohmmeter. The resistance should read "OL". If not then replace Spindle Motor.

Spindle will not run because 110 V power is not reaching the spindle contactor

Check 110 V coming out of the AC e-stop port on the pendant. If no voltage replace or repair the pendant.

Do the following service code and procedures:

 Code 33 Software Identification. This is needed if you call SWI Customer Service.  Code 97 set positive motor encoder direction.  Code 313 Check the line that specifies the product.

4.5 Problems with the Machine Tool

4.5.1 Spindle Stalls or Turns Off During Machining

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

4.5.2 Spindle Motor Hums or Will Not Run

If the spindle will not run, you must ensure that 110V power is reaching the spindle

motor contactors in the electrics box. Check your 110V power across terminals wire 3 and ground. If power has reached the electrical box, use the schematic in Section

5.8 to see how the power is routed.

If the spindle motor makes a constant humming noise during operation, check the 3-phase power to the machine by checking line to line.

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4.5.3 Spindle Runs Backwards

Possible Cause

Check This

3-Phase wires backwards

Need to switch any 2 of the 3 wires either coming into the machine or motor. Warning: Be sure to shut off all power to the machine before attempting to switch any wires.

Possible Cause

Check This

Machine setup or tooling problem

If the noise is most evident under load (cutting situations) then it is important to look at setup and tooling being used. Ask the following questions. Is the cutter dull? Is the tool loose in the holder? Am I taking a bigger cut then is possible on the machine? Is the part moving in the vice? Am I using realistic speeds and feeds? Any one of these can have a significant impact.

Upper spindle bearing is worn out.

Remove the upper bearing plate above the spindle. This will unload the bearing. If the noise goes away then this bearing should be replaced.

Verify nosepiece is tight on bottom of spindle.

To check if the nosepiece is bottomed out try to insert a piece of paper in between the nosepiece and the quill. If a piece of paper does fit then this may be the problem. Before tightening or loosening the nosepiece make sure to loosen the setscrew that holds it in place.

Spindle bearings are worn out

This is categorized by a high pitch sound and is most evident

at high RPM’s. It should also cause chatter under load.

Replace the spindle if this is the case. See spindle replacement in Section 5.

The spindle motor runs in the opposite direction. The spindle will run in opposite directions from high to low gear.

4.5.4 Head Noise

Head noise pertains to any unusual noises coming from the head under load and no load situations. Most often head noise will only be noticeable under load situations. It is important to try to distinguish between problems with components in the head versus problems caused by the setup or tooling being used on a particular job. Use the table below to try to pinpoint the possible cause. Also try to pinpoint the noise by seeing if it exists in high, low or neutral. For example, if the noise is evident in neutral then this eliminates the spindle bearings.

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Problems With:

Can Contribute To:

Most Suspect When (and why):

Spindle bearings See Spindle Replacement

Noisy head Parts incorrect Circles out of round

Older machines, machines that are pushed hard

Lubrication system

Premature wear of ball screws, wear surfaces. Faulting Poor finish

New installations (may not be hooked up or line sheared)

Inadequate lubrication habits

Premature wear of ball screws, wear surfaces Poor finish Faulting

New installations (more motion than the machinist is used to with a manual mill) Lubricate machine every morning before use.

Gib locks - on X, Y and Z axis

If locked can lead to axis faults.

Note: when using the CNC to machine, never tighten the gib locks!

X and Y gibs loose See Gib Adjustment - Section 5.2.1

Taper on straight Y moves Poor finish Circle out of round

When machine hasn’t been serviced

in a long while.

Gibs too tight

Not getting to position, does not repeat, axis faults Poor finish

N/A

Gibs floating

Not getting to position, does not repeat, axis faults Poor finish

Contact area of gibs. May need to be scraped. Very old machines may not have any more adjustments on gib. A new gib will need to be fit on the machine.

Gibs defective - bowed, scarred

Excess play when gib is checked side to side

Inadequate gib contact

Way surfaces pocked, scarred, or excessively worn

Poor finish Out of round circles Faulting

Inadequate lubrication

Machine not level Weight not distributed evenly on all four screws See Leveling procedures

Parts incorrect Machine geometry off, i.e. tram.

New installation or heavy crash. Relocation of mill. Head out of tram See Tramming Head - Section 5.2.3

Leaves uneven surfaces on bottom of pockets.

Machine not level

5.0 Diagnostics

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

5.1 The Machine Tool & Set-Up

5.1.1 The Milling Machine Checklist

The following is a quick reference for the types of problems that may arise if problems are noticed in these areas.

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Problems With

Can Contribute To:

Feed and Speeds (spindle rpm) See below

Poor finish Machine chatter Excessive speeds and feeds can break cutting tools or wear tools prematurely.

Tooling Using the wrong cutter for an application Entering the wrong size diameter and programming with tool compensation.

Poor finish Parts incorrect size

Cutting too deep

Part dimensions incorrect Driving and cutting forces cause deflections, since no material is totally rigid Machine chatter

No coolant

Poor finish, decrease the life of the cutter

5.1.2 A Special Word About X, Y & Z Gibs

The slideway surfaces are vital to the performance of the bed mill. Gibs should be:

 flat  free of twist  free of burrs

 free of blockages in the oil passages and channels

Defective or scarred gibs must be replaced. Shimming of gibs may not yield acceptable results.

It is good machining practice to avoid the use of shop air to clean the chips off a machine. This risks blowing chips into the sliding way surfaces and compromising the performance of the machine.

Gibs that are not adjusted correctly will affect the performance of the machine. It will lead to positioning and repeatability problems. The gibs should be adjusted at least twice a year.

See Gib Adjustments Section 5.2.1.

5.1.3 Lubrication

Lubrication is one of the single, most important maintenance issues and plays a key role in assuring the performance and durability of the Knee mill. At the beginning of each day manually supply oil to the way surfaces.

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

5.1.4 Machining Set-Up

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

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5.1.4.1 Spindle Speeds

Spindle speeds are influenced by a number of variables:

 Material  Rigidity of the Machine Setup  Coolant  Cutter type, material and diameter  Cutting Depth

As a general rule:  Lower spindle speeds are used to machine hard or tough material or where heavy cuts

are taken.

 Higher spindle speeds are used to machine softer materials in order to achieve better

surface finishes. Higher speeds also apply when using small diameter cutters for light cuts on frail work pieces and delicate setups.

Note: Cutter diameter greatly affects spindle speeds. The larger the diameter, the lower the spindle speed.

5.1.4.2 Feedrates

Factors that affect feedrates:

 Depth and width of cut  Design or type of cutter  Sharpness of the cutter  Workpiece material  Type of finish or accuracy required  Climb or conventional milling

If a fine finish is required, reduce the feed rather than increase the spindle speed. Cutters are dulled by higher spindle speeds rather than high feedrates.

5.2 The Mechanical Drive Train (X, Y)

Indications:  Troubleshooting instructions indicate that the drive train is potentially the problem and

other (more easily checked variables) have been exhausted.

 Roughness, looseness, tightness or jamming movement in the table or saddle.

1. Check for machine considerations, especially gib locks and gib adjustments.

See Gib Adjustments section

2. Check the torque of the axis in three places (both ends and center of ball screw) along

the length of the ball screw. The torque should be within 2 or 3 in-lbs across the length of the ball screw. If it is not, chances are the ball screw is misaligned. A misaligned ball screw can lead to parts being out of round and servo problems at low feedrates. A bad ball screw can also cause high torque, although this is highly unlikely. See Sections 5.2.1 and 5.2.2 for more information.

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CAUTION!

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

ball screw!

Potential Problem:

Check By:

Bad ball screw

 Visually inspecting the ball nut - if the nylon seal is broken or deformed,

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

 Cranking the ball screw through a significant part of its travel. If it

jams, feels loose or has rough spots, replace the ball screw.

 Using the dial indicator on a vertical flat of the ball screw to check for

backlash between the ball screw and ball nut.

The following steps take you in logical sequence through the assemblies for the knee mills. For drawings of these assemblies see figures. These instructions break the machine down from fully assembled and point out the areas to look at specifically.

3. Check that the belt is properly tightened. A loose belt can lead to excessive backlash

compensation values on motor encoder only machines.

4. Check that the nut that tightens up against the ball screw pulley is tight. If this is loose

the pulley may not run true on the ball screw.

5. Check that the tapered sleeve that seats the pulley has not clamped to the ball screw

prematurely. It should be seated firmly against the pulley. Tightening the nut may not have ensured this. Also make sure the pulley is keyed to the ball screw.

6. Ensure that the screws that hold the bearing housing in place to the bracket are not

loose.

7. Ensure that the Clamp Nut is secured. The following applies to the clamp nut:

 When loosening, make sure to back out the 10-32 screw from the clamp nut.  When tightening, snug the 10-32 screw so the clamp goes onto the ball screw thread

with some drag. Thread it onto the ball screw and torque the clamp nut to 50 ft/lbs and then tighten the screw down.

8. Take out the angular contact bearings and inspect them. They should roll smoothly and

be lightly greased. If not, replace them. When putting the bearings back into the housing make sure to put them in correctly. Failure to do this will cause problems. The thin race of each bearing should be facing inward toward the spacer ring.

Note: the bearing housing and spacer ring are matched sets - keep them together.

9. Check the ball screw mounting to the yoke. Make sure the SHCS are tight.

10. Inspect the ball screw, ball nut and yoke for the potential problems shown in the chart on

the next page.

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Potential Problem:

Check By:

Ball nut not tightened to the yoke

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

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

Yoke loose in the saddle

 Inspection for any motion of the yoke or looseness in the Yoke

mounting screws.

Oil lines sheared

 Visual inspection.

Oil line blockage

 Pump the oil and ensure that it flows evenly to the ways and ball

screw.

Ball screws not aligned properly

 Measure from the ball screw to the back of the saddle on both sides of

the yoke (the table must be removed). The measurements must be within ±.005” end to end. See above explanations.

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

5.2.1 Keys to Ball Screw Alignment

 X-axis – there are 3 components that can cause misalignment: the yoke, the left side

bearing housing bracket, and the right side bearing housing.

 Yoke – the yoke is aligned at the factory and pinned in place. It is aligned to within

+/-0.0005” with a precise alignment tool. The yoke most likely is not causing the problem. If this were the problem you would need to remove the pins and align the X ball screw with the back of the saddle. Drill new holes and pin the yoke in place. The Yaxis ball screw bore is machined perpendicular to the X bore. If the X-axis is aligned the Y-axis will also be aligned.

 Left side table bearing housing – this is most likely the cause of the misalignment.

To align the bracket and bearing housing, move them as close to the yoke as possible. Loosen the bracket bolts and bearing housing bolts and then retighten. This should allow the bearing housing to align itself up with the yoke.

 Right side table bearing housing – once again move the bearing housing as close to

the yoke as possible. Loosen the bearing housing and retighten. This should allow the bracket to align itself. If you do not move the table toward the yoke the ball screw will tend to bend down slightly and cause misalignment.

 Y-axis – the only component that can cause a misalignment problem is the motor

mounting bracket. To align this bracket, move the saddle as close to the front of the machine as possible. Loosen the bracket and then retighten it. Once again moving the saddle forward allows the yoke to be as close to the bearing housing as possible.

5.3 Computer/Pendant Diagnostics

The pendant consists of 2 separate modules: the computer module, and LCD screen/enclosure.

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

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Possible problems

Can lead to

Poor cable connections

There are 4 or 5 cable connections to the rear of the pendant. Make sure all cables are properly fastened.

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

Pendant locks up

Press the E-stop button and see if lock up clears if not then do the following: Turn the pendant off, wait at least 30 seconds, and turn it back on and check to see if the malfunction has been reset.

No voltage to RSG port

RSG will not work – should be 5 DC volts present Check with a voltmeter.

IDE flash drive failure

If the IDE flash drive fails, the system will not boot up or operate. It will need to be replaced. All programs and machine configurations will be lost. Make sure to back up your flash disk from time to time.

LCD backlight burns out

Check all cable connections to LCD, distribution board and computer module. Make sure the power is turned off before doing so.

Faulty E-stop switch

It can be stuck open or closed (pressed). If it is stuck closed the pendant will need to be replaced because the user will have no way to get rid of the message. If it is open it will allow the machine to still operate but it will be unsafe for the user. The pendant will still need to be replaced.

Overlay failure (keys on pendant)

Certain buttons on overlay do not work. Do code 81 to verify each key beeps.

Low voltage to pendant or current spikes

10 or 8 amp fuse in pendant blows. Pendant will not turn on if the 10 amp fuse in the on/off switch is blown.

The following is the list of diagnostic LED’s found on the back of the applications board.

Remove the black cover on the rear of the pendant to access them. See figure 23. LED lights – the applications board has 10 LED lights with LED 1 found on the left of the

LED segment.

1. 5 volt power LED – signifies that 5 volts is present on the applications board which is being supplied from the power supply.

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

3. Watchdog timer – not used

4. Not used

5. Z absolute zero LED – this LED will be lit when the Z axis counter is set to zero. This light should come on when you are + or – 0.001” from your zero.

6. Not used - will be used on future products with more axes.

7. Y absolute zero LED - this LED will be lit when the Y axis counter is set to zero. This light should come on when you are + or – 0.001” from your zero.

8. X absolute zero LED - this LED will be lit when the X axis counter is set to zero. This light should come on when you are + or – 0.001” from your zero.

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WARNING!

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

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

9. 110 volt power LED – this light will be on when the applications board is seeing 110 volts. Check the 8 amp fuse on the applications board if this light is not on.

10. Not used.

5.4 Motor Diagnostics

The Motor subsystem is comprised of 3 parts: The Motor Encoder and the Motor and Servo Driver. The motors are powered by 110 VAC voltage. The servo driver is also an integral part of servo system, which is discussed in detail in the next section.

Rarely do both the X and Y motor/servo systems fail at the same time and in the same way. So, if your problem is occurring on both axes, its source is probably somewhere else.

5.4.1 Cable Connections

Check the motor cable connections on the cable breakout box. Verify there are no pushed in pins on the connector.

5.4.2 To Check the Motor Encoders

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

Run Service Codes 100 or 131. This will display on the DRO if the motor encoder is counting. If the axis does not count, the encoder is not counting. This means either the encoder or the cable is the problem. Visually check the cable for any problems. If the encoder has failed the motor must be replaced.

5.4.3 Diagnosing a Brush Problem

Each of the axis motors on the machine contains 4 brushes. These are a wear item and may need to be replaced during the life of the control system. When the brushes begin to wear out, you may start to see intermittent faulting of an axis. Please note your brushes will last for a number of years before they need replacement so if you are seeing this symptom in the 1st year of 2 of your product, this is probably not the cause.

Motor Identification

Before ordering your brush replacement kit, you 1st will need to identify the type of motor you have on your machine. This can be done by identifying the diameter of the cap that

holds the brushes in place. Each motor has 4 caps spaced 90˚ apart. They are found at the

end of the motor furthest away from the motor pulley. If the diameter of the cap holding the brush in place is ¾” in diameter then the motor is a Hathaway motor. If the diameter of the

cap is ½” in diameter then the motor is an AO Smith motor. You can also identify the type of

motor by removing the brush and measuring its cross sectional size. If the brush measures 3/8” x 1/8” then it is a Hathaway motor and if it measures 3/8” x ¼” it is an AO Smith motor. On Hathaway motors it will be time to replace the brushes when the brush reaches a length of approximately ¼”. On AO Smith motors it will be time to replace the brushes when the brush reaches a length of approximately 3/16”.

See Section 6.1.2 for the procedure for replacing motor brushes.

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Swap these components

Results

Physically switch the X and Y motors

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

Has problem moved to Y-axis? If yes, replace motor. If no, the motor is not the problem.

WARNING!

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

machine. There is possibility of death by electrocution!

5.4.4 Moving Problem from One Axis to Another

Another way to troubleshoot a problem with a particular axis is to swap parts from 1 axis to another to see if the problem moves. If the problem moves then that component is faulty. See the example below.

Symptom – X Axis will not move and faults

This particular problem can happen because of any of following reasons: bad motor, servo driver, or computer module. In some cases it is not 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.

5.5 Servo Driver

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

Indications:

 Problems moving just one axis, including hard turning in one or both directions.

Servo Types:

 X and Y servos are identical

Objective:

 Isolate the problem to the particular Servo Driver

Steps:

1. Turn off and unplug the system.

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

Note: To avoid pulling the wires out of the connector, use the loop to pull the connector from the Servo Driver.

If the problem moves to the other axis and clears up from the original axis, replace the Servo Driver.

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Problems Here:

May Indicate:

1. The wall outlet.

 Fuse blown in the shop electrical panel.  Incoming service from local utility is bad.

Call the electric company.

2. The control power cord from the wall. For TRAK mills, check the end that goes to the electrics box.

 Power cord defective.

3. Check the top fuse on the electrical cabinet. It should be a 10-amp fuse.

 If this is blown then power will not reach

the 4 outlets on the electrical box.

4. Check the 110-power cord to the pendant.

 Power cord defective

CAUTION!

Turn off power before removing and replacing

5.6 Electrical

5.6.1 Checking A/C Voltage

This procedure tests for the 110V power for the control.

 Use a Voltmeter, reading A/C volts.  Acceptable range is 100V to 130V.

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

Test the following in the order presented:

5.6.2 Checking Fuses

There are 4 fuses to check in the system. There are 2 in the pendant and, for TRAK mills, 2 in the electrical cabinet. The top fuse in the electrical cabinet is 10 amps and fuses power to the pendant. The bottom fuse is 5 amps and fuses power to the lube pump outlets. The 2 fuses in the pendant are 10 amp and 8 amps. The 10-amp fuse in the pendant is found in the on/off switch. The 8-amp fuse is found on the applications board inside the pendant.

To check fuses:

1. Use a Volt/Ohmmeter; select “OHM”.

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

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

 A good fuse reads 0 (zero) or close to it.  A bad fuse reads Open or Infinity.

5.6.3 Cable Connections

The TRAK knee mill machines use 5+ 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.

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CAUTION!

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

damage to the connector board and harm to the technician.

Explanation:

1. Turn off and

unplug

the system from the wall.

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.

5. Make sure to tighten up the screws on each of the connectors.

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Figure 19 - Electrical Box Schematic

5.7 Service Codes

Service codes are broken down into the 4 following categories: software, machine setup, diagnostics and user options/defaults.

All Service Codes are accessed in the DRO Mode by pressing the soft key for “SERV CODES”. The service codes can be found under one of the headings listed on the main screen. Press the heading you want to access the code in question. Press CODE #, enter the number you want, press SET.

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5.7.1 Software Codes

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

Note: If you are working with the SWI Customer Service Group, write the values down for Code 33 or Code 313. These values will be valuable for troubleshooting.

5.7.1.1 CODE 33: Software ID

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

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

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

5.7.1.2 CODE 141: Load Configuration file from USB thumb drive

This code allows you to load your configuration file from the USB thumb drive to the

ProtoTRAK’s internal IDE Flash drive. The configuration file consists of items such as

calibration and backlash constants. This code is used when a computer module or IDE Flash Drive has been replaced and you already loaded the information on the thumb drive using code 142.

5.7.1.3 CODE 142: Save Configuration file to USB thumb drive

This code allows you to save your configuration file to a USB thumb drive. The configuration file consists of items such as calibration and backlash constants. Use this process before a computer module or IDE Flash Drive needs to be replaced. It stores the configuration file from the ProtoTRAK’s internal IDE Flash Drive to the USB thumb drive. It is a good idea to do this code after the machine is initially setup so these values can be saved and used in the future. If the computer or IDE flash drive fails, then you will not have the ability to save the configuration file and the machine will need to be re-setup when the computer or IDE flash drive is replaced.

5.7.1.4 CODE 313: Display Configuration File

This code displays the configuration file. This file contains pertinent information about the machine. Some of the common service code values are displayed on this page as well, such as code 12, 100, 128, and 129. Press the Load Default if you wish to load factory defaults for all of the control’s settings and configurations.

5.7.1.5 CODE 316: Update Software

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

5.7.1.6 CODE 340: copy part programs to USB Thumb drive

Load in USB thumb drive and enter this service code. All the part programs that are stored in

the ProtoTRAK’s internal storage will be copied to the USB Thumb Drive.

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5.7.1.7 CODE 341: copy part programs from the USB Thumb drive

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

5.7.2 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.

5.7.2.1 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 particular machine.

The Code 12 is used for diagnosing and resolving:

 Problems with machine motion.  Machined parts come out bad – especially poor finish.

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

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

Note: You will lose your DRO

position reference.

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

3. Press Auto

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

Explanation

Typical values should be between 4.04 and 11.11 are considered normal for each axis. Higher values indicate excessive friction in the system. Lower values indicate a loose system and may mean a gib adjustment is necessary. Value 4.04 means the friction is a factor of 4 in one direction, and 4 in the other direction. The values should be within 3 or 4 of each other in both directions. A value of 6.08 would still be considered normal.

The feed forward gain can be adjusted manually by pressing the manual button. Choose the axis you would like to change and then enter values in the positive and negative direction to adjust. Adjusting the gain can help solve circularity problems. Default values can be set by pressing the Reset button. The manual feature should only be used in extreme cases where the AUTO routine did not solve the problem. Manual adjusts above 12 may lead to servo related problems.

5.7.2.2 Code 97 set positive motor encoder direction.

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

new Computer Module.

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STEPS:

1. Center the table and saddle and position the quill about halfway down.

2. Go into Service Codes and input Code 97.

3. Very carefully, move the table, the saddle and the quill in the positive direction, less than 2 inches for each axis. Positive motion is:

 X - table moves to the left (so the tool moves to the right relative to the

workpiece)

 Y - saddle moves toward the front (so the tool moves up relative to the

workpiece).

 Z - the quill moves up.

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

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

5.7.2.3 CODE 100: Axis Open Loop Test

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

CAUTION!

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

speed for 1 second in the direction you choose. Avoid crashes by making sure the 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 Pendant 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 Y.

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. The table below assumes machine has secondary feedback. Machines with motor encoders only will display the reading next to the axis in question.

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Your input

Display

Data displayed.

X +

Motor encoder reading

nothing (should be 0 )

Feedrate

the maximum feedrate attained

Your input

Motor encoder reading

X -

nothing (should be 0 )

Feedrate

the maximum feedrate attained

Your input

nothing (should be 0 )

Y +

Motor encoder reading

nothing (should be 0 )

Feedrate

the maximum feedrate attained

Your input

nothing (should be 0 )

Y -

Motor encoder reading

nothing (should be 0 )

Feedrate

the maximum feedrate attained

Your input

nothing (should be 0 )

Z +

nothing (should be 0 )

Motor encoder reading

Feedrate

the maximum feedrate attained

Your input

nothing (should be 0 )

Z -

nothing (should be 0 )

Motor encoder reading

Feedrate

the maximum feedrate attained

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

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

be the problem.

 The feedrate should be a minimum of 120 ipm.  If the feedrate is less than 120 ipm and inconsistent in both directions, check the

incoming AC voltage and mechanics of the drive train.

5.7.2.4 Code 122: Calibration using part measurements

See Section 6.2.2.2 for a further explanation of this code.

5.7.2.5 CODE 123: Calibration

See Section 6.2.2.1 for a further explanation of this code.

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5.7.2.6 CODE 127 - Set X or Y Backlash Constant

See Section 6.2.2.3 for a further explanation of this code.

5.7.2.7 CODE 128: Input Backlash Constant

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

5.7.3 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.

5.7.3.1 Code 54: Program Continuous Run

This Code runs a program continuously without stopping for SET Z or CHECK Z commands. It is helpful in running a long period to identify an intermittent problem.

1. Prepare a program as you normally would.

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

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

5.7.3.2 Code 81: Keyboard Test

This code is used to check if the keyboard is functioning correctly. It allows you to test each key on the pendant individually. When you press the keys, the corresponding box for that key will highlight on the screen. The pendant will also beep, indicating that the key is working correctly. If one of the keys does not work the pendant assembly may need to be replaced. If none of the keys are working chances are that the computer module will need to be replaced.

5.7.3.3 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.

5.7.3.4 Code 319: Error Log

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

5.7.3.5 CODE 320: History Log

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

5.7.3.6 CODE 327: Check Available Memory

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

5.7.3.7 CODE 342: Toggle test lights on or off

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

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5.7.4 Operator Defaults/Options Codes

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

To get to any of these codes go to Service Codes, press “D” and press the code you wish to

view.

5.7.4.1 CODE 22: Turn on Simulation Mode

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

5.7.4.2 Code 66: Metric Mode

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

67.

5.7.4.3 Code 67: English Mode

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

5.7.4.4 Code 79: Beeper On

This turns on the beeper to the control keys.

5.7.4.5 Code 80: Beeper Off

This turns off the beeper to the control keys.

5.7.4.6 Code 89: Turn off Simulation Mode

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

5.7.4.7 Code 129: Arc Accuracy

When the EMX control operates at high feedrates it may create small part machining errors

as it goes around sharp corners. This exists on all CNC’s and is commonly called a “following error.” The control is factory preset to allow a maximum following error of 0.001 inch. The

feedrate will automatically be adjusted around sharp corners so as to not violate this limit. This code only applies to arcs that are programmed and ones that are created in the tool path to generate the shape you want. This code will not make a difference on mill moves.

You may adjust the maximum following error to a value as small as .0001 inch. However, the smaller the value, the slower the feedrate around corners.

To input a new Following Error use the following procedure:

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

.0100) and press INC SET.

5.7.4.8 Code 130: Toggle between 2 and 3 axis

Allows the user to switch between 2 and 3 axis mode.

prototrak EMX KNEE Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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