Trak Machine Tools ProtoTRAK SMX K2, ProtoTRAK SMX Retrofit, ProtoTRAK SMX K3, ProtoTRAK SMX K4 Safety, Installation, Maintenance, Service And Parts List

Document: P/N 24319 Version: 082718

ProtoTRAK® SMX

K2, K3, K4 & Retrofit

Safety, Installation, Maintenance, Service & Parts List Manual

Copyright  2018, 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.

Table of Contents

1.0 Safety ................................................................................................................................................................ 1

1.1 Safety Publications .......................................................................................................................................... 1

1.2 Danger, Warning, Caution, and Note Labels & Notices As Used In This Manual ................................................... 1

1.3 Safety Precautions .......................................................................................................................................... 4

2.0 Installation ....................................................................................................................................................... 6

2.1 Floor Plan, Layout & Space Requirements – K2, K3 & K4 ................................................................................... 6

2.2 Uncrating ....................................................................................................................................................... 8

2.3 Shortages: Inventory Checklist ....................................................................................................................... 8

2.4 Installation Instructions & Checklist .................................................................................................................. 9

2.5 Machine Specifications .................................................................................................................................. 10

2.6 Maximum Work Capacities ............................................................................................................................. 10

2.7 ProtoTRAK SMX Control Hardware .................................................................................................................. 11

2.8 Lifting and/or Moving the Machine ................................................................................................................. 14

2.9 Cleaning ....................................................................................................................................................... 16

2.10 Leveling: Leveling Tolerance is .0005”/10” ................................................................................................... 16

2.11 Electrical Connection ................................................................................................................................... 18

2.11.1 Phase Converters .................................................................................................................................. 21

2.11.2 Flange Disconnect/Transformer (Optional) .............................................................................................. 21

2.12 Air Connection - Optional ............................................................................................................................. 25

2.13 Mounting the Display Pendant ..................................................................................................................... 26

2.14 Cable Interconnections ............................................................................................................................... 26

2.15 Lubrication ................................................................................................................................................. 33

2.15.1 Manual Lubrication ............................................................................................................................... 33

2.15.2 Head Lubrication .................................................................................................................................. 35

2.16 ProtoTRAK SMX Euclid Block Procedure ........................................................................................................ 36

3.0 Troubleshooting by Symptom ........................................................................................................................... 38

3.1 Problems Relating to Machining Results ......................................................................................................... 38

3.1.1 Poor Finish.............................................................................................................................................. 38

3.1.2 Circles Out of Round ............................................................................................................................... 38

3.1.3 Taper Cut on a Programmed Straight Line Move ....................................................................................... 39

3.1.4 Parts Have Incorrect Dimensions .............................................................................................................. 40

3.2 Problems Regarding the Motion of the Machine ............................................................................................... 41

3.2.1 Run Away Axis ....................................................................................................................................... 41

3.2.2 Slow Down Axis ..................................................................................................................................... 41

3.2.3 Axis Will Not Jog ..................................................................................................................................... 42

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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

3.2.4 Axis Motor Motion Is Not Smooth ............................................................................................................. 42

3.2.5 Vibration in Motion .................................................................................................................................. 43

3.2.6 Searching Axis ........................................................................................................................................ 43

3.3 Problems Relating to the Operation of the Control .......................................................................................... 44

3.3.1 Display Blanks ........................................................................................................................................ 44

3.3.2 Bad Picture on the Display ...................................................................................................................... 44

3.3.3 Keyboard Lockup ................................................................................................................................... 44

3.3.4 Fault X or Y ........................................................................................................................................... 44

3.3.5 Problems Reading the Floppy Disk; Programs Not Saved Properly .............................................................. 45

3.3.6 System Will Not Turn On or Boot-Up ........................................................................................................ 45

3.3.7 System Reboots by Itself ......................................................................................................................... 46

3.3.8 System Shuts Off .................................................................................................................................... 46

3.3.9 Will Not Hold Calibration ......................................................................................................................... 46

3.3.10 Auxiliary Functions Not Working (Option on 3 Axis Machines Only) .......................................................... 47

3.3.11 E-Stop Error ......................................................................................................................................... 47

3.3.12 Limit Switch Error - Optional .................................................................................................................. 48

3.4 Problem with the Measurements .................................................................................................................... 48

3.4.1 X, Y and Z-Axis Measurements Do Not Repeat .......................................................................................... 48

3.4.2 X, Y, and Z-Axis Measurements Are Not Accurate ...................................................................................... 50

3.4.3 The DRO Is Not Counting ....................................................................................................................... 50

3.4.4 X, Y, and Z-Axis DRO Counting in Wrong Direction .................................................................................... 50

3.4.5 X, Y, & Z-Axis Electric Handwheels Count in Wrong Direction ..................................................................... 50

3.5 Problems with the Machine Tool .................................................................................................................... 51

3.5.1 Spindle Stalls or Turns-Off During Machining ........................................................................................... 51

3.5.2 Spindle Motor Hums or Will Not Run ........................................................................................................ 51

3.5.3 Spindle Runs Backwards ......................................................................................................................... 53

3.5.4 Head Noise ............................................................................................................................................. 53

4.0 Diagnostics ..................................................................................................................................................... 55

4.1 The Machine Tool & Set-Up .......................................................................................................................... 55

4.1.1 The Milling Machine Checklist .................................................................................................................. 55

4.1.2 A Special Word About X & Y Gibs ............................................................................................................ 55

4.1.3 Lubrication............................................................................................................................................. 56

4.1.4 Machining Set-Up ................................................................................................................................... 56

4.2 The Mechanical Drive Train (X, Y) ................................................................................................................. 57

4.2.1 Keys to Ball Screw Alignment ................................................................................................................ 58

4.3 Computer/Pendant Diagnostics ...................................................................................................................... 58

4.4 Motor Diagnostics ......................................................................................................................................... 59

4.4.1 Cable Connections ................................................................................................................................... 60

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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

4.4.2 To Check the Motor Encoders .................................................................................................................. 60

4.4.3 Encoder Counts to Pendant ...................................................................................................................... 60

4.4.4 Moving Problem from One Axis to Another ................................................................................................ 60

4.5 Servo Driver ................................................................................................................................................. 60

4.6 Glass Scales .................................................................................................................................................. 61

4.6.1 Alignment of scales ................................................................................................................................. 61

4.6.2 Measurements Do Not Repeat .................................................................................................................. 61

4.7 TRAK Sensors ............................................................................................................................................... 62

4.7.1 Faulting Axis .......................................................................................................................................... 62

4.7.2 Measurements Do Not Repeat .................................................................................................................. 62

4.8 Electrical ...................................................................................................................................................... 63

4.8.1 Checking A/C Voltage .............................................................................................................................. 63

4.8.2 Checking Fuses ....................................................................................................................................... 63

4.8.3 Cable Breakout Box Connections .............................................................................................................. 64

4.8.4 Cable Connections .................................................................................................................................. 64

4.9 Service Codes ............................................................................................................................................... 68

4.9.1 Software Codes ...................................................................................................................................... 69

4.9.2 Machine Set-up Codes ............................................................................................................................. 70

4.9.3 Diagnostic Codes. ................................................................................................................................... 72

4.9.4 Operator Defaults/Options Codes ............................................................................................................. 73

5.0 Procedures for Replacements & Maintenance ..................................................................................................... 74

5.1 Replacements .............................................................................................................................................. 74

5.1.1 Servo Motor Replacement ........................................................................................................................ 74

5.1.2 Servo Driver Replacement........................................................................................................................ 74

5.1.3 Computer Module and LCD/Enclosure Replacement ................................................................................... 75

5.1.4 System Flash Disk Replacement ............................................................................................................... 77

5.1.5 Cable Routing on Machine ....................................................................................................................... 79

5.1.6 TRAK Sensor .......................................................................................................................................... 79

5.1.7 Glass Scale Replacement ......................................................................................................................... 82

5.1.8 Power Drawbar ....................................................................................................................................... 86

5.1.9 Ball Screw Replacement, X-Axis (Table) ................................................................................................... 88

5.1.10 Ball Screw Replacement, Y-Axis (Saddle) ................................................................................................ 91

5.1.11 Air Solenoid Replacement – Auxiliary Function Machines Only .................................................................. 94

5.1.12 Spindle Motor Wiring ............................................................................................................................. 94

5.1.13 Feed Trip Adjustment (not applicable to 3 axis controls) .......................................................................... 95

5.1.14 Quill Clock Spring Replacement and Adjustment ...................................................................................... 95

5.1.15 Spindle Motor Removal and Replacement ............................................................................................... 96

5.1.16 Drive Belt Replacement ......................................................................................................................... 97

iii

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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

5.1.17 Timing Belt Replacement ....................................................................................................................... 98

5.1.18 Brake Shoe Replacement ....................................................................................................................... 98

5.1.19 Spindle Replacement ............................................................................................................................. 99

5.2 Maintenance ............................................................................................................................................... 100

5.2.1 Gib Adjustments ................................................................................................................................... 100

5.2.2 Calibration & Backlash Constants ........................................................................................................... 103

5.2.3 Head Rotational and Tramming .............................................................................................................. 105

5.2.4 Limit Switch Option ............................................................................................................................... 107

6.0 Retrofit Installation ......................................................................................................................................... 109

6.1 Installation Tools and Hardware ................................................................................................................... 109

6.2 Required Tools/Hardware ........................................................................................................................... 109

6.3 Suggested Fastener Stock ............................................................................................................................ 110

7.0 Installation Procedures ................................................................................................................................... 111

7.1 X and Y Ball Screw Installation ..................................................................................................................... 111

7.1.1 Removing the Table and Leadscrews ...................................................................................................... 111

7.1.2 X-Axis Ball Screw Installation - Part 1 .................................................................................................... 113

7.1.3 Y-Axis Ball Screw Installation ................................................................................................................ 115

7.1.4 X-Axis Ball Screw Installation - Part 2 ..................................................................................................... 120

7.2 Motor/Servo Driver Installation .................................................................................................................... 124

7.2.1 X-Axis Motor/Servo Driver Installation .................................................................................................. 124

7.2.2 Y-Axis Motor and Servo Driver Installation .............................................................................................. 125

7.3 Pendant Installation ..................................................................................................................................... 126

7.3.1 Pendant Arm Installation ....................................................................................................................... 126

7.3.2 Installation of the Pendant Display ......................................................................................................... 127

7.4 Cable Breakout Box Mounting ...................................................................................................................... 128

7.5 Z-Axis Glass Scale Installation ...................................................................................................................... 128

7.6 TRAK Sensor Installation - Optional .............................................................................................................. 130

7.6.1 X and Y Axis Sensor .............................................................................................................................. 130

7.7 X and Y Glass Scale Installation - Optional .................................................................................................... 133

7.7.1 X Axis Scale Installation ......................................................................................................................... 133

7.7.2 Y Axis Scale Installation ......................................................................................................................... 134

7.8 Limit Switch Installation .............................................................................................................................. 136

7.9 System Interconnection ............................................................................................................................... 138

7.9.1 ProtoTRAK SMX Basic System Configuration ............................................................................................ 138

7.9.2 Cable Routing ....................................................................................................................................... 138

8.0 Z Motor/Ball Screw Assembly .......................................................................................................................... 139

8.1 Installation of the Base Plate ....................................................................................................................... 139

8.2 Installation of the Ball Screw ....................................................................................................................... 142

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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

8.3 Installation of the Motor and Remaining Components .................................................................................... 142

8.4 Lagun Z Axis Cutout .................................................................................................................................... 148

9.0 Introduction to Self-Service ............................................................................................................................. 149

9.1 When You Have a Service Problem ............................................................................................................... 149

9.1.1 Communication with the SWI Customer Service Group ............................................................................ 149

9.2 Replacements .......................................................................................................................................... 150

9.2.1 Exchange Program ................................................................................................................................ 150

10.0 Figures and Parts Lists .................................................................................................................................. 151

TRAK Warranty Policy ............................................................................................................................................ 211

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ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual

1.0 Safety

The safe operation of the TRAK K Mills depends on its proper use and the precautions taken by each operator.

 Read and study this manual and the ProtoTRAK SMX Programming, Operating, and Care Manual. Be certain every

operator understands the operation and safety requirements of this machine before its use.

 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 0210.

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 Warning labels on the machine are orange in color.

CAUTION - Hazards or unsafe practices, which Caution labels on the machine are yellow in color.

NOTE - Call attention to specific issues requiring special attention or understanding.

could

result in severe personal injury and/or damage to the equipment.

could

result in minor personal injury or equipment/product damage.

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Safety & Information Labels Used On The

TRAK K Milling Machines

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

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Southwestern Industries, Inc.

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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

SMX K2/K3

SMX K4

Vari-speed Head

Spindle Control

Vari-speed Head

Spindle Control

Overload Setting

220 V

8.5 A

11 A

14 A

17.5 A

Overload Setting

440 V

4.25 A

N/A

7 A

N/A

FLA of Largest Motor

at 220 V

8.5 A

11 A

14 A

17.5 A

FLA of Largest Motor

at 440 V

4.25 A

N/A

7 A

N/A

FLA of Machine at

220 V

8.5 A

11 A

14 A

17.5 A

FLA of Machine at

440 V

4.25 A

N/A

7 A

N/A

Safety & Information Labels Used On The

TRAK K2, K3 & K4 Milling Machines

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

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

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1.3 Safety Precautions

1. Do not operate this machine before the TRAK K Mill Installation, Maintenance, Service and Parts List Manual,

and ProtoTRAK SMX 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.

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.

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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 quill when using the jog or power feed or

ram out.

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. For non-spindle control machines - interlocked table guards. Interlocked table guards may be purchased from

TRAK Machine Tools if deemed necessary by the user.

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Weight (approximate) net

2200 lbs

2800 lbs

3600 lbs

Weight (approximate) shipping

2500 lbs

3100 lbs

3900 lbs

Pallet Size

6’ x 6’

A Overall width

101”

103”

B Overall length

66”

70”

72.5”

C Base width

24.2”

24”

D Width between leveling screws

21.9”

22.8”

E Distance between leveling screws

29.1”

29.7”

33.1”

F Base length

37.4”

38.8”

42.5”

2.0 Installation

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

2.1 Floor Plan, Layout & Space Requirements – K2, K3 & K4

Figure 1 – Machine Footprints

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

Southwestern Industries, Inc.

Table Size

9” x 49”

10” x 50”

T-Slots (number x width)

3” x 5/8”

Dimension G

86”

87”

92”

Dimension G Min

65”

73”

Dimension H Min

56”

64”

Dimension H Max

67”

78”

Dimension I Min

36”

38”

36”

Dimension I Max

49”

49’

54.5

Dimension J Max

18”

17”

23”

Dimension K

69”

77”

Figure 2 – Overall Dimensions

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

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ATTENTION! Immediately report, in writing, any damages observed at this time that can be attributed to the transportation or improper handling/moving of the machine.

2.2 Uncrating

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

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

2.3 Shortages: Inventory Checklist

_____ Machine (check model and serial number) ______ Manual drawbar with washer ______ Leveling pads (FC114), screws (FC112) and leveling nuts (FC113) (4 each) ______ Pendant Display with four 1/4-20 screws for mounting ______ Pendant Arm assembled to the column ______ Toolbox with various tools ______ ProtoTRAK SMX Safety, Operation & Programming Manual (P/N 24493) ______ TRAK K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual (P/N 24319) ______ Way covers K2 – front of saddle - 20875 ______ Way covers K3 & K4 – front of saddle - 20872 ______ Way covers K2 – rear of saddle - 20874 ______ Way covers K3 & K4 – rear of saddle - 20871

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

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

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

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. Have the customer repair any wiring discrepancies. Measure the 220 volt and 110 volt input power to make sure it is within specification. If not, notify customer and report on service report.



Clean the machine if needed and remove any remaining grease.



Unlock the table, saddle, and knee gib locks.



Mount the pendant to the pendant arm using (4) 1/4-20 x 3/4" socket head cap screws.



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



On retrofits, place the nameplate serial # plate (21934) on the pendant arm. This serial # plate is the main system # for that machine. Place the serial # plate using 2 drive screws to the front of the pendant arm near the pivot point of the arm. Use a #36 drill bit for drive screws. See figure 57.



On retrofits and TRAK knee mills make sure to plug in the machine ID key on the top corner of pendant before powering up the pendant. Failure to do so may cause an improper configuration file. If this happens, go to service code 313 and load the defaults. Loading defaults will erase any calibration factors that have been done. See pendant connection – Figure 13.



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



10.

Load master and slave software from software upgrade disk or USB. The pendant may or may not have the latest software loaded. (Retrofits only.)



11.

Lubricate all the way surfaces and the ball screws.



12.

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



13.

Check the level of the machine. The machine should be level to within 0.0005" front to back and 0.0005" side to side. Even though it is the responsibility of the customer, make any adjustments if necessary.



14.

Check tram on head and adjust as necessary.



15.

Check to make sure that the E-Stop button is functioning correctly. N/A to retrofits for spindle.



16.

Perform Service Code 12, Feed Forward Constant.



17.

Perform Service Code 11 to automatically calculate the backlash for the X and Y-axis of glass scale machines



18.

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



19.

Perform Service Code 127 and 128 to manually calculate the backlash for the X and Y-axis of single feedback machines (i.e. motor encoder only).



20.

Check for positional accuracy and repeatability on the X and Y-axis using programs XREPEAT 2 AXIS.PT4 and YREPEAT 2 AXIS.PT4 respectively. Positioning and repeatability values

should be less than or = to 0.0005”. Programs can be found on C drive under the PT4SX

folder followed by the SWI TEST PROGRAMS folder.



21.

For 2 axis machines - perform Service Code 123 and press QUILL softkey to calibrate the Zaxis quill using a 75mm or 3” standard.



22.

For 3 axis machines - perform Service Code 123 and press Z softkey to calibrate the Z-axis ball screw encoder using a 75mm or 3” standard.



23.

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



24.

Run the spindle at various speeds in both high and low gear for 15 minutes. Verify head

2.4 Installation Instructions & Checklist

Installer: Use this checklist to assure a complete set-up of the K2, K3, K4 or SMX 2 or 3-axis retrofit.

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

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shifts from high to low gear smoothly. Test quill feed and spindle brake. N/A to retrofits.



25.

Install the Y-axis front and rear way covers.



26.

Check that all other options that came with machine are installed, functioning or adjusted properly. They included chip pan, table guard, limit switches, EHW’s, RSG, etc



27.

3 axis machines only - If machine has an auxiliary function option, then use accessory key on pendant and make sure the coolant pump or solenoid for the mister fires. The accessory key should be in the ON position to test coolant pump or solenoid. The control should be in DRO mode. Make sure air is hooked up to the machine during the test. If the machine has a separate coolant pump switch mounted on the pendant arm then turn this on and off to test.



28.

If the machine has a power drawbar option, check to make sure that the tools load and unload properly. Verify the drawbar unit is sitting 0.050” to 0.075” above drawbar shoulder.N/A to retrofits.



29.

Wipe down the machine prior to leaving.

Specifications

Movement and ranges (X, Y, Z axis)

33” x 12” x 16”

32” x 16” x 16”

32” x 16 ½” x

16.5”

Quill Travel (maximum)

5”

Quill Diameter

86 mm

100 mm

Spindle Taper

# 40 taper

Speed Range

60-4200 RPM

70-3950 RPM

Optional Spindle Control Speed Range

Low: 40 – 600

High: 300 – 5000

Spindle to Column

8” to 20”

8” to 32”

7” to 31”

Quill Feeds Per Revolution of Spindle (Not applicable on three axis)

.0015/.003/.006”

Head Tilt

+/- 90

Head Swivel

+/- 45

N/A

Spindle Motor Power

3 HP

5 HP

Voltage

220/440 V

Machine with Optional Speed Control

220 V

Phase/Cycle

3 phase/60 Hz

Current- Non Spindle Control

8.5/4.3 amps

14/7 amps

Current – Spindle Control

11 amps

17.5 amps

Maximum Weight of Workpiece

750 lbs

850 lbs

Coolant Capacity

9 gallons

K2/K3

Drilling Mild Steel (2-axis manual feed)

1 ¼”

1 ½”

Tapping Mild Steel

1”

Milling (metal removal rate/mild steel)

1 ½ inch3/min

2 inch3/min

Drilling (3-axis systems)

½”

2.5 Machine Specifications

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.

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2.7 ProtoTRAK SMX Control Hardware

 2 or 3-axis CNC, 3-axis DRO  400 PC-based processor  256 MB of RAM  D.C. Servo Motors rated at 280 in-oz continuous torque for X, Y and Z-axes  Precision ground ballscrews in the table and saddle to ensure smooth accurate contours without backlash  Feedrate override of programmed feedrate and rapid  Polycarbonate sealed membrane and gasket sealed control enclosure to lock out contamination  10 ½" color LCD for clear presentation of prompts, status information and part graphics  Modular design simplifies service and maximizes uptime  256 MB flash drive  Single floppy disk drive for additional part program storage  Optional auxiliary function box for control of coolant pump or spray mist coolant, spindle off and a

programmable rotary table or indexer – 3 axis machines only

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Figure 3 & Parts List Shown Knee Mill Component Identification

Item

Part Number

Description

SMX K2 + K3

SMX K2 + K3 Spindle Control

SMX K4

SMX K4 Spindle Control

20819

24162

20820

24163

Spindle Motor

24000-1

SMX Pendant

15616

Y-Axis Handwheel (Saddle)

15616

X-Axis Handwheel (Table)

20296

X, Y or Z Motor

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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TRAK Machine Tools

Figure 4 & Parts List Shown Knee Mill Rear View

Item

Part Number

Description

SMX K2/K3

SMX K2/K3 Spindle Control

SMX K4

SMX K4 Spindle Control

220V=20676 440V=20676

24060-1 220V only

220V=20676-1 440V=20676

24060-2 220V only

Electrical Box 2

24999

Cable Breakout Box

24999-1

Cable Breakout Box with AUX Functions

9001

Lube Pump

20676-2

N/A

20676-2

N/A

Electrical box (if have tableguard option)

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CAUTION! The K2, K3 & K4 machines weighs approximately 2200, 2800 & 3600 lbs respectively. Proper equipment of sufficient capacity must be used when lifting and/or moving the

machine.

2.8 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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Figure 5 Lifting the Machine

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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.

2.9 Cleaning

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

2. The coating is best removed with clean, dry rags. Do not use a cleaning solution that may damage the rubber

way scrapers, plastic parts, or paint.

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 work piece.

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

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I00138

Item

P/N

Title

FC112

LEVEL SCREW

FC113

LOCK HEX NUT

FC114

LEVELING PAD

i00138

Placement of Levels

Figure 7 & Parts List Shown Leveling Screws

Figure 6

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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.

DANGER!

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

2.11 Electrical Connection

The TRAK K2, K3 & K4 Knee Mills can be configured for 220 or 440 volt 3 phase electricity. These machines also require a 110V power source to power the control. NOTE: Machines with Optional Spindle Control is only available in

220 V configurations.

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.

To convert a K2 or K3 machine from 220 to 440 volt power or vice versa 3 things must happen: spindle motor must be rewired, overload relay must be set to 8.5 amps for 220 V and 4.25 for 440 volts and the voltage stickers on the electric’s box must be replaced.

To convert a K4 machine from 220 to 440 volt power 3 things must happen: spindle motor must be rewired, overload relay must be replaced and set to 14 amps for 220 V and 7 for 440 volts and the voltage stickers on the electric’s box must be replaced.

NOTE: Voltage conversion from 220V to 440V not applicable to machine fitted with the Spindle Control Option.

See Section 5.1.12 for a diagram of how to rewire the spindle motor.

TRAK Machine Tools 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.

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Figure 8 Wiring K2, K3, or K4 – Non Spindle Control – Not for Retrofit

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NOTE: If equipped with Table Guard Option, the Electrical Box the P/N is 20676-2

Part Number

Description

K2/K3/K4

220V & 440V = 20676

Electrical Box

220V & 440V = 23438-3

Overload

23436

Contactor (Qty = 2) (Reverse or Forward)

Item

Part Number

Description K2/K3

K4 1

24060-1

24060-2

Electrical Box

22890-500-120

22890-500-64

Resistor (Qty = 2)

25105K2/K3SX

25106-K4SX

AC Drive - Mini Vector - 220V 12

22961

Relay - Power - 115V DPST

21824-5

Fuse - 3 AG - Slow Blow 5 AMP

21824-8

Fuse - 3 AG - Slow Blow 8 AMP

Figure 9 & Parts List Shown Wiring the K2, K3 or K4 – Spindle Control

See Figure 117 in the rear of the manual for a more detailed breakdown of parts.

TRAK Machine Tools 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.

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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Figure 9-1 Wiring the K2, K3 or K4 – Spindle Control

2.11.1 Phase Converters

For those machines that will be run with a phase converter it is recommended that it is a rotary type rather than a static phase converters. Rotary phase converters allow for varying loads in the system. The electrical load on the machine will vary based on the type of cut taken. Static phase converters can only be used on machines with a nonvarying load. The phase converter for the K mill machines must be rated at a minimum of 5 KVA for the K2 and K3 and 7 KVA for K4.

2.11.2 Flange Disconnect/Transformer (Optional)

The Flange Disconnect Option eliminates the need for the user to provide a power disconnect for the machine on their own, while the Transformer Option allows the user to provide one power source to the machine. Note: This

option is not available to machine fitted with the Spindle Control Option.

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Figure 10 – Flange Disconnect/Transformer Option P/N 23440-220, 23440-1-220, & 23440-440

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Item

P/N

Title

Qty

21258

TRANSFORMER 1000VA EI

1 4 23434

SOCKET-RELAY

23435

RELAY-POWER-100-120 VAC-DPDT

23436

CONTACTOR-4 POLE

2 7 23437

MECHANICAL INTERLOCK

23438

OVERLOAD RELAY-440V

23438-1

OVERLOAD RELAY-220V

22199-1

RECEPTACLE- PANEL MOUNT NEMA STD 15A 125V

21871

CONNECTOR-4 POSITION-SIZE 11

23297-1

CONNECTOR-REVERSE SEX-13-7-CPC

21820

FUSE HOLDER

21824-5

FUSE-3AG-SLOW BLOW

21830-12

FUSE-TYPE 3AB-12A-SLO BLO

22868

TERMINAL BLOCK

22869

END PLATE

21753-3

GROUND BAR- 6 HOLE

21901-150

MOV-V150LA20B

23036

FUSE HOLDER-32 AMP-690V

23153-3

FUSE-600 VAC-TIME DELAY-CLASS CC

22303-16G

WIRE-BUSS-16 GA AWG 12" STRAIGHT

12.25

22557-1

TERMINAL BLOCK - 6mm BLOCK

24299-3

TERMINAL BLOCK-RAIL END STOP/ GROUND

22571-8.125

RAIL-DIN

8.13

23429

SHEETMETAL-COVER PLATE LEFT-PT4-SM TRANSFORMER OPTION

24407

NAMEPLATE - TRANSFORMER

i23440-220

Parts List – Flange Disconnect/Transformer (Figure 10)

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Figure 11 Transformer Option Schematic

2.12 Air Connection - Optional

The K mill machines have an air hookup in the rear of the machine if the machine has a power drawbar or auxiliary function option. Auxiliary function options are only found on 3 axis mills.

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. If the machine has an auxiliary function option then the machine will include an air solenoid as shown below.

The air regulator is set to 90 psi at the factory for the power drawbar unit and solenoid. See Section 5 for more information on the power drawbar unit. The air comes in through the manifold, and then into the air regulator that tees off into an oiler for the power drawbar unit and into an air solenoid. The solenoid is used for a misting system the user may install later on this machine. There is a ¼” quick disconnect air fitting on the solenoid where the mister air hose can be plugged into. See the figure below for an illustration.

Figure 12 Air Regulator/Solenoid Assembly P/N 22380-1

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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CAUTION!

The locating screw in the arm is used for positioning. Keep a hold of the pendant

until the screws are fastened.

Item

P/N

Title

Qty

22378

MANIFOLD-PT4 AIR

1 3 22607

FILTER/REGULATOR-PT4

1 8 22644-4

PLUG-1/4 NPT HEX SOCKET

22645-4

NIPPLE-1/4 NPT x 1.37 LG

22646-4

ADAPTOR-ELBOW MALE 1/4 x 1/8 NPT

22647-2

NIPPLE-1/8 NPT x 0.750" LG

4-40X3/8 31B

SCREW-PH-PHIL-EXT SEMS-STL-BO

10-32X3/8 10B

SCREW-PH-PHIL-STL-BO

M6-1.0X25 25B

SCREW-SHCS-STL-BO

22772

SOLENOID ASSY- AIR REGULATOR

22581-5

OILER

i22380-1

Parts List – Air Regulator/Solenoid (Figure 12)

2.13 Mounting the Display Pendant

The ProtoTRAK SMX display pendant mounts to the pendant arm with four 1/4-20 x ¾ SHCS that are shipped screwed into the left side of the display. There is a locating screw on the pendant arm to help align the pendant with the mounting holes.

If the pendant arm rotates too freely, remove the painted cap on the bracket attached to the column and tighten the hex nut to adjust it. Replace the cap.

2.14 Cable Interconnections

All cable interconnections are made at the factory except for those connecting to the pendant display. There are a total of 4 cables that need to be connected to the pendant for non-spindle control machines. See Figure 15 & 16 for a complete illustration of cable interconnections for all components. There are an additional 2 cables for the electronic handwheel option and 2 more cables for the spindle control option (digital I/O and spindle control ports).

With the main power to the machine turned off, plug in the connectors that are bundled on the pendant arm. Each cable mates to only one connector on the pendant display back panel. Use the key on the pendant to match up the connectors with the correct port. The machine ID port (or called LPT) and parallel port (hardware key) will have a key plugged into it. The monitor port and network ports will be left empty during installation.

Make sure there is sufficient slack in the cables for when the pendant is rotated about the pendant arm. The worst case is when the pendant is all the way forward toward the operator. The following drawing describes all of the cable connections to the pendant.

Make sure there is a hardware (option) key plugged into the parallel port of the pendant. This key activates any converters or options ordered. The part # for this key is 22648. The key must be programmed according to the type of machine it is on and the options ordered.

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CAUTION!

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

plugging in the cables.

Figure 13 Pendant Cable Connections Left Side P/N 24000-1

Make sure the machine ID key is plugged into the machine or it will not run. Note: Spindle control machines use a different machine ID key then non-spindle control machines.

Whenever you replace a cable or reroute a cable it is very important to keep the power cables and logic cables separated from each other. The power cables consist of the (3) 110-volt motor cables and (2) 110-volt power cables for the pendant, and a coolant pump or solenoid power cable. The logic cables are used to carry encoder signals between the cable breakout box and computer module. Mixing of the power and logic cables may cause noise from the power cables to interrupt the signals in the logic cables. This can lead to intermittent axis faults or repeatability problems. See Figure 15 and 16 for a layout of the cable connections.

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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Figure 14a Pendant - Right Side P/N 24000-1 Replaced by 24000-7

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Figure 14b Pendant - Right Side-USB Ports P/N 24000-7

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Figure 15 Cable Connections Diagram Non Spindle Control

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Item

Part Number

Description K2/K3

220V = 20676 440V = 20676

220V = 20676-1 440V = 20676-1

Electrical Box 2

21856

Cable Assembly

24999

Cable Breakout Box (-1 with AUX Functions)

22648-7

Option Key—SMX

22758-SKNEE2X

Key—Machine ID

24000-1

SMX Pendant

Parts List Cable Connection (Figure 15) Non-Spindle Control

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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Figure 16 Cable Connection Diagram with Spindle Control Option

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

CAUTION!

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

sliding surfaces & ballscrews

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.

Item

Part Number

Description

24000-1

SMX Pendant Assembly

24060-1

Enclosure Assembly, SX2

24060-2

Enclosure Assembly, SX3 and SX5

24999

Cable Breakout Box No Aux

24999-1

Cable Breakout Box With Aux

22555-10

Cable Assy - Logic

22555-10

Cable Assy - Logic

22556-10

Cable Assy - Parallel

22556-10

Cable Assy - Parallel

22608

Power Cord

20267

Cable Assy - AC to Computer

i01113

Part List-Cable Connection Diagram with Spindle Control (Figure 16)

2.15 Lubrication

2.15.1 Manual Lubrication

The TRAK 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.

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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Figure 17 Knee Mill Lubrication

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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Item

P/N

Title

Qty 1 9001

HAND OILER

9002

ALUMINUM PIPE

6 3 9003

ELBOW

9004

T-JOINT - 4 HOLES- M8 X 1.0

1 5 9005

CONNECTOR

3 6 9006

REGULATING DISTRIBUTOR

1 7 9007

FLEXIBLE TUBE - 21 inches

9008

SCREW NUT - M8 X 1.0 MALE

15 9 9009

SCREW NUT - PD 1/8- 19MM

9010

SCREW - M5 X 20 mm LG

9011

SCREW NUT - M8 X 1.0 FEMALE

9012

ADAPTER

9013

SLEVE - 4.1 mm I.D.

i00889

WARNING!

Do not overfill this oil cup as excess oil could wash down into the upper spindle

bearings and wash away the grease.

Parts List –Knee Mill Lubrication (Figure 17)

2.15.2 Head Lubrication

Note – the white head represents the K4 40 taper head.

Once Each Week:

1. Add SAE 30 or 30W oil to the side cup on the head. This will provide lubrication to the quill.

Twice a Month:

Apply 2 drops of oil in upper cup on front of head with sae 30 oil. This feed supply’s oil to the feed cradle for the power

quill feed to keep the grease pliable. If oil is not added, the grease on the feed cradle will thicken and this makes it difficult to engage the power quill feed.

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Event #

Description

Depth of Cut

Circle pocket – cuts middle circle

-0.250”

Circle frame – cuts outer 1.830 diameter circle

-0.250”

Circle frame – cuts material from corners remaining on Euclid block

-0.250”

Roughs material in upper right-hand corner

-0.500”

5-12

Cuts triangle on Euclid block with finish cut

-0.500”

Rectangular frame – cuts outer 2.750” rectangle

-0.750”

Every Four Months:

1. Apply a good grade of general-purpose grease through the grease fittings on the back of the head. This grease

lubricates the Low range gear set and the feed change gears respectively.

2. Lubricate vari-disk on spindle motor by means of grease fitting on motor shaft.

2.16 ProtoTRAK SMX Euclid Block Procedure

The test part should be machined at the completion of the installation.

The material for the Euclid block test part is found in the toolbox.

 Material Specification: Aluminum, 6061-T6 or T4  Blank Size: (minimum dimensions) 3 x 3 x 1”, provided in tool box  Tool: .750 end mill, 2 flute, high speed steel,  Coolant: Flood coolant or Cool-Tool

1. Mount vise and indicate the back jaw parallel to the table within .0005”.

2. Clamp material in vice with a minimum of .800” above the vise jaws.

3. Load in the Euclid block program from the ProtoTRAK SMX flash disk, which is Part Number Euclid 2 axis.PT4. It

is found under the PT4 folder followed by the SWI TEST PROGRAMS folder.

4. Use an edge finder to set Absolute 0 on X and Y. Absolute zero is the front left corner of the block as viewed

from in front of the machine.

5. Load the .750 end mill and set Z Absolute 0 at the top of the part.

6. Begin to run the program. Set the spindle to 2000 RPM and follow the instructions on the control for SETTING Z

and CHECKING Z. The part will be machined in the following sequence:

sharp

7. After the program run, the program will locate to the following position.

 X = 1.318  Y = 1.318

8. Mount a dial indicator in the quill and check the circles.

9. Check the runout of the sides of the square frame.

10. Inspect the machined surfaces for smoothness.

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Figure 18 Euclid Test Block P/N 15537-1

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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Possible Cause

Check This

Too much backlash entered for code 128 or calculated with code 11.

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 4.1

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 4.1.3

X, Y, and knee Gibs are not adjusted properly

Check the adjustment of the X and Y gibs. See X and Y Gib Adjustments in Section 5.2.1.

X & Y-axis Drive Trains are loose

Check Repeatability using the Repeatability and Positional Accuracy procedure. Step by step, carefully inspect the Drive Train for any looseness. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 4.2

Way surfaces are pocked, scarred, or 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.

3.0 Troubleshooting by Symptom

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

3.1 Problems Relating to Machining Results

3.1.1 Poor Finish

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

Do the following Service Codes and document values:

 Code 33 Software Identification. This is needed if you call SWI Customer Service.  Code 11 Measures backlash in the system (Only used on Dual Feedback systems)  Code 12 Feed Forward Constant  Code 127 Measures backlash in the system (for Z-axis on three-axis systems; not used on Dual Feedback

systems,)

 Code 128 Enter backlash compensation (for Z-axis on three-axis systems; not used on Dual Feedback systems)

3.1.2 Circles Out of Round

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

Note: The typical slideway-milling machine is not capable of achieving more precise results although careful adjustments to a new milling machine may produce better results. If more precise circles are required, then it is recommended to use a precision boring head/boring bar.

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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TRAK Machine Tools

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 4.1

Machine not level

Verify that the machine is level to specification.

Head is not Trammed

Verify that the Head is Trammed to specification. See Tramming the Head Sec 5.2.3

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 5.2.2

TRAK Sensor or Glass Scale problem

Make sure that the Sensor or Glass Scale is installed correctly according to the Sensor or Glass Scale Installation procedures. Check for any loose brackets or misalignment etc. Also, check to make sure the Sensor or Glass Scale assemblies are functioning correctly. See TRAK Sensors or Glass Scales Sections 4.6 & 4.7.

X & Y-axis Drive Trains are loose

Head Bolts are loose

Verify that all the head bolts are tight. 50 lbs.

Do the following Service Codes and document values:

 Code 33 Software Identification. This is needed if you call SWI Customer Service.  Code 11 Measures backlash in the system (Only used on Dual Feedback systems)  Code 12 Feed Forward Constant.  Code 127 Measures backlash in the system (not used on Dual Feedback systems).  Code 128 Enter backlash compensation.

3.1.3 Taper Cut on a Programmed Straight Line Move

An unwanted tapered cut occurs, when the machine is programmed to move in a straight line along either the X or Yaxis. 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.  Code 11 Measure's the backlash in the system. Only used on machines with Dual Feedback systems.  Code 12 Feed Forward Constant.  Code 127 Measure's the backlash in the system. Only used on machines with single Feedback.  Code 128 Enter backlash compensation.

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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 4.1

X and Y Gibs are loose

Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures. See Section 5.2.1

X and Y-axis Drive Trains are loose

Possible Cause

Check This

Machine Tool & Setup problem

See Machine Tool & Setup Section 4.1

Programming Error

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

Configuration file that contains calibration file and backlash constants has been erased or corrupted.

Verify configuration file (Code 313) does not read default values. Load saved configuration file from floppy disk in electrics cabinet with Code 141.

Calibration or Backlash problem

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

Possible Cause

Check This

Machine Tool & Setup problem

See Machine Tool & Setup Section 4.1

3.1.4 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.  Code 11 Measure's the backlash in the system. Only used on machines with Dual Feedback systems.  Code 12 Feed Forward Constant.  Code 127 Measure's the backlash in the system. Only used on machines with single feedback.  Code 128 Enter backlash compensation.

3.1.4.1 Every Part Has the Same Error

3.1.4.2 The Dimensional Errors Are Random or Accumulate in Size Over the Part Program Run

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TRAK Sensor or Glass Scale problem

X and Y-axis Drive Trains are loose

Possible Cause

Check This

Sensors or glass scales are counting in opposite direction of motor encoder

Reverse directions with codes 321 and 322

The home positions or tools are not set correctly

See the Controls Programming, Operations and Care manual.

The Sensor or Glass Scale is not reading.

See TRAK Sensors or Glass Scales diagnostic Section

4.6 or 4.7

Bad Motor Encoder

See Motor diagnostics Section 4.4

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 4.9 and Electrical Section 4.8

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.

3.2 Problems Regarding the Motion of the Machine

3.2.1 Run Away Axis

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

 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.

3.2.2 Slow Down Axis

The axis slows down and moves at a feedrate that is lower than rapid or than the programmed feedrate. Do the following Service Codes:

 Code 33 Software Identification. This is needed if you call SWI Customer Service.  Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and if the encoders are counting.  Code 129 Set's the maximum allowable arc accuracy error. This applies to arcs only.

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Binding in the Drive Train

Check Repeatability using the Repeatability and Positional Accuracy procedure. Check the torque reading of the Drive Train. Step by step, carefully inspect the Drive Train for any binding. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 4.2

Servo Drive failure

See Servo Drive Section 4.5

Motor failure

See Motor Section 4.4

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 4.5

Shorted motor

See Motor Section 4.4

Poor cable or wiring connections

See Electrical Connection Section 2.12

Computer/Pendant failed

See Computer/Pendant diagnostics Section 4.3

Possible Cause

Check This

X and Y Gibs are not adjusted properly

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

TRAK Sensor or Glass Scale problem

Calibration or Backlash problem

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

3.2.3 Axis Will Not Jog

The system powers up but will not respond to the jog command. Do the following Service Codes and procedures:

 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.

3.2.4 Axis Motor Motion Is Not Smooth

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

 Code 33 Software Identification. This is needed if you call SWI Customer Service.  Code 11 Measure's the backlash in the system. Only used on machines with Dual Feedback systems.  Code 12 Feed Forward Constant. High feed forward constants will cause an unstable servo system.  Code 127 Measure's the backlash in the system. Only used on machines with single feedback. Also used

on SMX3 Z axis.

 Code 128 Enter backlash compensation. Also used on SMX3 Z axis.  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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Binding in the Drive Train

Possible Cause

Check This

Too much backlash entered in Code 128 or Code 11.

Recheck the machines backlash.

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.

Gibs not making good contact.

Pull gibs out and mark with a blue die to check where the gibs are making contact. It is recommended that the gibs uniformly contact at least 80% of the surface.

Binding or looseness in the Drive Train

Check Repeatability using the Repeatability and Positional Accuracy procedure. Check the torque reading of the Drive Train. Step by step, carefully inspect the Drive Train for any binding or looseness. It may be necessary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section 4.2

Axis Motor belt too tight.

Loosen belt.

Misalignment of ball screw

See Mechanical Drive Train (X, Y) Section 4.2

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. Run code 11 on dual feedback machines

High feed forward values

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

3.2.5 Vibration in Motion

While axis is moving there is vibration or noise coming from the X or Y-axis.

Do the following Service Codes and procedures:

 Code 11 Measure's the backlash in the system. Only used on machines with Dual

Feedback systems.

 Code 12 Feed Forward Constant. High feed forward constants will cause an unstable servo system.  Code 127 Measure's the backlash in the system. Only used on machines with no Dual Feedback.  Code 128 Enter backlash compensation.  Code 123 Calibrate.

3.2.6 Searching Axis

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

 Code 11 Measures backlash in system. (Used only with glass scales and sensors.)  Code 12 Sets a feed forward power constant to drive axis motors.  Code 128 Backlash compensation on single feedback machines.

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Excessive friction in the sliding ways

Lubrication, gib adjustments, gib locks. See Machine Tool & Setup - Section 4.1

Looseness in the drive train

Especially the tightness of the drive assembly. See Mechanical Drive Train (X, Y) - Section 4.2

Possible Cause

Check This

Screen saver has been activated

Press any key to turn back on. All LED keys on pendant will blink when the screen saver is on. Press any key to deactivate. Hitting this key will not activate any feature on the control.

The system has shut down

Turn the power switch off, check the computer/ pendant fuses and cable connections. See Electrical Section 4.8

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

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

Fuse blown in pendant

Remove fuse and check continuity

Computer/Pendant failed

See Computer/Pendant Section 4.3

Possible Cause

Check This

Computer/Pendant failed

See Computer/Pendant Section 4.3

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 4.3

3.3 Problems Relating to the Operation of the Control

3.3.1 Display Blanks

The display is completely blank.

3.3.2 Bad Picture on the Display

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

3.3.3 Keyboard Lockup

The screen display is normal, but the system will not respond to key presses. Do the following Service Codes and procedures:

 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 up in yellow. The pendant will also beep.

3.3.4 Fault X or Y

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

Do the following Service Codes and procedures:

 Code 33 Software Identification. This is needed if you call SWI Customer Service.  Code 11 Measure's the backlash in the system. Only used on machines with Dual Feedback systems.  Code 12 Feed Forward Constant.  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

Cable connection problems

Check umbilical 1 and 2. Check #1 for X and Y-axis problems and #2 for the Z-axis.

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 5.2.1

Excessive friction in the slideways

See Machine Tool & Setup Section 4.1

Binding or looseness in the Drive Train

See Mechanical Drive Train (X, Y) Section 4.2

Incoming electrical power

Incoming voltage. See Electrical Section 4.8

Measurement system not functioning properly

See Section 4.6 or 4.7 Servo Drive failure

See Servo Driver - Section 4.5

Motor failure

See Motor diagnostics, Section 4.4

Computer/Pendant failure

See Computer/Pendant diagnostics, Section 4.3

Possible Cause

Check This

Improper Boot-up

Shut down the system and wait 10 seconds before rebooting

Floppy Disk failure

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

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.

Flash Drive failure

When the Computer Module starts the boot-up process, look at the 8th line on the Display Screen. If the Mother Board of the Computer Module is communicating with the Flash Drive you will see "Detecting IDE Primary Master…Scan Disk SDCFB-64". If the Mother Board of the Computer Module is not communicating with the Flash Drive you will see "Detecting IDE Primary Master … None". Also, check the wiring connection between the Flash Drive and the Mother Board. See Computer/Pendant diagnostics Section 4.3

Computer/Pendant has failed

See Computer/Pendant diagnostics Section 4.3

3.3.5 Problems Reading the Floppy Disk; Programs Not Saved Properly; The floppy drive will not read or write programs from a disk.

3.3.6 System Will Not Turn On or Boot-Up

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

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Possible Cause

Check This

Interruption of 110 V power to pendant

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

Poor wiring and cable connections

Check for any loose wiring or cables

Computer/Pendant failed

See Computer/Pendant diagnostics Section 4.3

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 110VAC Power Strip to the Pendant. See Electrical Section 4.8

Computer/Pendant has failed

See Computer/Pendant diagnostics Section 4.3

3.3.7 System Reboots by Itself

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

3.3.8 System Shuts Off

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

3.3.9 Will Not Hold Calibration

The control will not hold calibration. Go to the "Configuration Values" screen and write down the calibration values for

the motor encoders (Encoder) and the position feedback encoders (scales or sensors). The calibration values are written in Hexadecimal. Recalibrate the system and see if the values change. Turn the system off and on and see if the values are held.

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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

Possible Cause

Check This

Bad 110VAC "Coolant or solenoid" receptacle fuse

Check if the fuse light indicator next to the plug is lit. Verify that the fuses are good or bad by checking the resistance of the fuses using an Ohmmeter.

Poor cable connections

Check all the cable connections on the cable breakout box, Coolant Pump, and Air Solenoid (Located on the Air Regulator). In particular, check umbilical # 2 cable, which carries the auxiliary function signals.

Faulty "Indexer" connector

Check for continuity between pins 3 and 4, when the output of the Haas Indexer connector is activated.

Bad cable breakout box

Check 110 V power coming out of the AC E-stop port with the E-stop in the out position. This will cause the spindle to not run.

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 Mode.

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

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

3.3.10 Auxiliary Functions Not Working (Option on 3 Axis Machines Only)

The Auxiliary Functions will not turn on or off at the programmed times. There are 3 Auxiliary Functions:

1. Activates or deactivates a "110VAC Receptacle" typically used for a coolant pump or solenoid for mister.

2. Sends an electrical signal to rotate the turret on a "Haas Indexer".

3. Turns the "Spindle Off" at the end of a programmed event. (Note: This function is not available for retrofits.).

In order to run the above auxiliary functions in run mode, the accessory key on the front of the pendant must be in the AUTO mode. Press and hold to activate AUTO mode.

All of the auxiliary function signals are carried down to the cable breakout box through umbilical #2. Each function then has its own relay inside this box. If one of these relays fail then these features will not work.

Do the following service code and procedures:

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

3.3.11 E-Stop Error

The E-Stop turns the power off to the axis and spindle motors. This is done by stopping 110V power from reaching the cable breakout box through the use of a relay in the pendant. Once power reaches the cable breakout box it distributes power to the axis motors, auxiliary functions and 110V power to the spindle contactor for non-spindle control machines. If power does not reach the cable breakout box then none of these functions will work.

Spindle Control Electrical Box

A 5-volt logic signal is sent to the spindle control board, which energizes a relay that enables the AC drive. Non Spindle Control Electrical Box 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.

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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 cable breakout box power cord on the pendant? If yes, and the screen has an E-stop message, replace the computer module.

Possible Cause

Check This

Limit switch jumpers in cable breakout box are making poor contact.

Remove and reseat jumpers.

Limit Switches are triggered

Reset the Limit Switches using the procedures described above.

Poor Limit Switch Cable connection

Check for any pins that are loose, pushed in, or bent. Verify that there is a good connection between the cables on the cable breakout box.

Limit Switch failure

Try this Switch 2 limit switch cables on the cable breakout box.

Does the limit switch problem move to the other axis? If it does then the switch is most likely the problem. If it stays with the original axis then it could be the cable breakout box.

Critical Error 52: Servo Error X-axis Limit Switch Correct the fault condition and continue.

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.

3.3.12 Limit Switch Error - Optional

Limit switches are installed on the table, saddle, and ram to prevent serious damage to the machine in the event of a

crash. In the event a limit switch is triggered, a limit switch error will appear on the screen.

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

1. Use mechanical handwheels on X and Y to move switch off of trigger. For the Z-axis, manually lift the arm on the

trigger to return the limit switch to its normal position. Then jog the ram up or down as necessary.

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

3. Press the "DRO" key to enable the machine to once again jog.

3.4 Problem with the Measurements

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

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

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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 4.1

X and Y Gibs are loose

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

TRAK Sensor or Glass Scale problem

Make sure that the Sensor or Glass Scale is installed correctly according to the Sensor or Glass Scale Installation procedures. Check for any loose brackets or misalignment etc. Also, check to make sure the Sensor or Glass Scale assemblies are functioning correctly. Use service codes 304 for X and 305 for Y to turn off the suspect encoder. Does problem still exist after turning it off?

Possible Cause

Check This

X and Y-axis Drive Trains are loose

4.2

Encoder Disk or Reader Head on motor are loose

Swap the motor in question with a known good motor. For example, swap the X-axis motor with the Y-axis motor. If the symptom stays with the motor in question, then replace the motor. If not, then the motor is not at fault and something else is causing the problem.

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

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

Expected repeatability numbers should be 0.0005” or less.

Do the following service codes and procedures:

 Code 304 Toggle X sensor/glass scale on/off  Code 305 Toggle Y sensor/glass scale on/off

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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 (not applicable with Glass Scale option). Single feedback only.

Glass Scale or Sensor Failure

Does axis now count? If so, replace scale or sensor.

Computer/Pendant failure

See Computer/Pendant diagnostics

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

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

3.4.3 The DRO Is Not Counting

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

Do the following Service Codes:

 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 304 & 305 Turns off X and Y sensor or scale.

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

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

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

Do the following service code and procedures:

 Code 33 Software Identification. This is needed if you call SWI Customer Service.  Code 313 Check the line that specifies the product.

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

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

The Electric Handwheels count in the wrong direction.

The positive directions for each Electric Handwheel are:

 X-axis - Electric Handwheel turns clockwise.  Y-axis - Electric Handwheel turns counterclockwise.

Do the following service code and procedures:

 Code 308 Reverse X-axis Handwheel Direction.  Code 309 Reverse Y-axis Handwheel Direction.

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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 4.1

Drive Belt in the head is slipping

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

Cut more than the machine is capable

Check width and depth of cut

Insufficient voltage, excessive amp load

Check incoming power. Check overload setting.

Possible Cause

Check This

Machine Tool and Setup problem

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

Spindle Drive Thermal Overload Relay has tripped

IOUT - Current Out (located on the Spindle Drive) cannot exceed 12.75A for K2/K3 and 21A for K4 for more than a few minutes. When the Overload Relay is tripped, an "oL1" error occurs shutting off the Spindle Drive. The harder the Spindle Motor works trying to make heavy cuts, the more current the Spindle Motor utilizes. This can be caused by a cut so large that it exceeds the machine capability, or a problem with the spindle motor or AC drive.

Spindle Drive parameters are not correct

May need to re-download the Spindle Drive parameters. Contact Customer Service for assistance.

Spindle Run Command not reaching AC Drive

Verify Spindle Run LED is on Spindle Control Board.

3.5 Problems with the Machine Tool

3.5.1 Spindle Stalls or Turns-Off During Machining

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

3.5.1.1 Spindle Stalls or Turns-Off During Machining (For Machine with the Optional Spindle Control Drive)

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

3.5.2 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 is not reaching the electrical cabinet but is reaching the cable breakout box, most likely a relay has failed in the cable breakout box. The cable breakout box will need to be replaced. This relay is in series with the 110V power in the E-stop circuit. See Section 3.3.11. If power has reached the electrical box, use the schematic in Section 4.8 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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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" for the K2 and K3, and “.5 to .9 OHM” for the K4. If the Ohmmeter reads "0 Ohms" or "OL", then replace Spindle Motor. Next, check the resistance between L1 & 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 cable breakout box. Relay failure in cable breakout box. Replace cable breakout box.

Possible Cause

Check This

Wrong voltage

Check the voltage to the machine before and after the Spindle Drive with a Voltmeter. Also, check the voltage to the Spindle Drive (L1, L2, and L3).

Poor wiring connections

Check all the wiring connections to the Spindle Drive and Spindle Motor. See Electrical Connection

Improper wiring/jumper configuration on the Spindle Motor

Check to make sure that the Spindle Motor has the correct wiring/jumper configuration for 220VAC. See Electrical wiring section.

Spindle Drive may be in "Local Mode" and cannot be run from the Pendant

On the Spindle Drive, push the "DSPL" button until "LO/RE" lights up. Use the "Up" and "Down" arrow keys to choose between "Lo"- Local (Run Spindle Motor from Spindle Drive) or "rE" - Remote (Run Spindle Motor from the Pendant).

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 "1.0 Ohms" to "1.5 Ohms" for K2/K3 and “.5 Ohms” to “.9 Ohms” for K4. 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 Drive contains incorrect parameters and is not programmed correctly

Contact customer service.

3.5.2.1 Spindle Motor Hums or Will Not Run (for machine with the optional Spindle Control Drive)

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

Note

: machines can only be wired for 220 volts. 440 volts will ruin electrical components in the machine. These

components will not be covered under warranty.

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Spindle Enable Signal not reaching AC Drive

Verify LED on Spindle Control Board is on.

Forward/Reverse Switch is bad or Spindle Control Board

Verify Forward or Reverse LED on Spindle Control Board is lit.

Possible Cause

Check This

3-Phase wires backwards

Need to switch any 2 of the 3 wires either coming into the machine or motor. Note: For machine fitted with the optional Spindle Control, switch any 2 of the 3 wires either coming out of the AC Drive (T1, T2 & T3) or going into the Spindle Motor (U, V & W). 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.

3.5.3 Spindle Runs Backwards

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

3.5.4 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.

Non Spindle Control Drive Machines

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Possible Cause

Check This

Machine setup or tooling problem

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.

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 belt is not lined up with the grooves on the pulleys.

Make sure the 10-ribs on the belt are lined up with the 10grooves on the 2-pulleys. If the belt is frayed then replace the belt.

Machines with spindle control drive

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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 and Y axis

If locked can lead to axis faults.

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

X and Y gibs loose 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

4.0 Diagnostics

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

4.1 The Machine Tool & Set-Up

4.1.1 The Milling Machine Checklist

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

4.1.2 A Special Word About X & Y 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

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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

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.

4.1.3 Lubrication

Lubrication is one of the single, most important maintenance issues and plays a key role in assuring the performance and durability of the Knee mill. 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.

4.1.4 Machining Set-Up

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

4.1.4.1 Spindle Speeds

Spindle speeds are influenced by a number of variables:

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

As a general rule:

 Lower spindle speeds are used to machine hard or tough material or where heavy cuts are taken.  Higher spindle speeds are used to machine softer materials in order to achieve better surface finishes.

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

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

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CAUTION!

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

ball screw!

4.1.4.2 Feedrates

Factors that affect feedrates:

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

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

4.2 The Mechanical Drive Train (X, Y)

Indications:

 Troubleshooting instructions indicate that the drive train is potentially the problem and other (more easily

checked variables) have been exhausted.

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

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

Adjustments section

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

The torque should be within 2 or 3 in-lbs across the length of the ball screw. If it is not, chances are the ball screw is misaligned. A misaligned ball screw can lead to parts being out of round and servo problems at low feedrates. A bad ball screw can also cause high torque, although this is highly unlikely. See Sections 4.2.1 and 4.2.2 for more information.

The following steps take you in logical sequence through the assemblies for the knee mills. For drawings of these assemblies see Figures 31 and 32 in Section 5. 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:

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.

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.

4.2.1 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 Y-axis ball screw bore is machined perpendicular to the X bore. If the X-axis is aligned the Y-axis will also be aligned.

 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.

4.3 Computer/Pendant Diagnostics

The pendant consists of 2 separate modules: the computer module, and LCD screen/enclosure. In general, the pendant/computer module is best diagnosed by eliminating all other possible alternatives. The following table lists some problems and what these problems can lead to.

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Possible problems

Can lead to

Poor cable connections

There are 4 cable connections (6 spindle control) to the left side of the pendant. Make sure all cables are properly fastened.

Pendant locks up

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

No voltage to RSG port

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

Low voltage to flash drive or slave board.

Can cause the system to lock up and the flash drive to act abnormally. Check voltage to power cable at flash drive module with voltmeter. It should be 4.8 DC volts and above. Lower values than this can cause problems.

Flash disk failure

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

Floppy disk failure

Will not allow user to save or pull up programs from a floppy disk. Can the floppy drive format a disk? See Section 4.3.1.

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

1 amp fuse in pendant blows. Pendant will not turn on.

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!

4.3.1 Checking Floppy Drive by Formatting a Disk

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

2. Install keyboard into middle port.

3. Press CTRL ESC to get to start menu.

4. Press R for run.

5. Type Format a: - press enter.

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

does not work replace the computer module.

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

4.4 Motor Diagnostics

The Motor subsystem is comprised of 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.

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Swap these components

Results

Physically switch the X and Y motors

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

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

4.4.1 Cable Connections

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

4.4.2 To Check the Motor Encoders

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

Motor encoder only machines – run Service 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.

Motor encoder and secondary feedback machines – run Service Codes 100 or 131. Both the motor encoder and sensor or glass scale encoder should count on the DRO screen. The motor value should be displayed under the Z-axis and the sensor or glass scale under the X or Y-axis depending on which axis you are doing.

4.4.3 Encoder Counts to Pendant

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

 Umbilical #1 and #2 at the cable breakout box  Umbilical #1 and #2 at the pendant  Umbilical #1 carries the X and Y-axis signals and Umbilical #2 carries the Z signals.

4.4.4 Moving Problem from One Axis to Another

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

Symptom – X Axis will not move and faults This particular problem can happen because of any of following reasons: bad motor, servo driver, or computer module. In some cases it is 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.

4.5 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

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WARNING! Do not work with the Servo Driver unless the power is disconnected from the machine. There is possibility of death by electrocution!

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.

4.6 Glass Scales

Glass scales are used on the X and Y-axis for secondary feedback. They are optional on the TRAK Knee mill machines. The Z glass scale comes standard with the machine.

4.6.1 Alignment of scales



X Axis - The X-axis scale must be aligned within 0.005” in the up and down direction over the length of the scale for proper operation. Misalignment can cause the scale to not read in the certain areas of the scale that are not aligned with the reader head. If this happens, the axis will mostly likely fault out in this area. Also make sure the mounting hardware for the reader head is tight. Loose hardware can cause excess backlash when reversing direction.

To align the scale, place a 0.001” indicator on the bed ways and on top of the scale extrusion. Move the table along its

full travel from one end to another to verify it is aligned. If the scale is misaligned loosen the 2 screws at either end to shift the scale up or down as needed. You will also need to loosen the center support bracket to allow the scale to pivot.



Y Axis - The Y-axis must be aligned in the up and down direction and must be parallel to the Y-axis

way surface. Both surfaces must be aligned to within 0.005”. Failure to align the scale properly could cause the same problems as mentioned above. Mount your 0.001” indicator on the saddle

and move the Y-axis back and forth along its travel.

 Z Axis – The Z scale must be aligned parallel with the quill. Make sure the gap on the readerhead

is consistent along the length of travel. Align the scale within 0.005” up and down.

See Figure 28 in Section 5 for an illustration of the Z glass scales.

4.6.2 Measurements Do Not Repeat

1. Determine if the error in repeatability is random or accumulating:

 Mount a dial indicator in the quill.  Touch off a fixed point on the table and set the DRO to 0.  Traverse away approximately 6 inches.  Return the touch off again.  Write down the reading on the DRO.  Do not Re-zero the DRO, traverse away and return several times.  Write down the DRO readings

Random error will be unpredictable and give scattered readings, adding and/or subtracting the error after each traverse with no pattern. See Step 2.

Accumulating error will add roughly the same amount to the reading after each traverse. See Step 3.

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2. For random error, look for problems in the set-up of the glass scale that have resulted in a loss of rigidity.

Common sources of random error include:

 Loose scale mounting hardware.  Loose reader head.  Very loose motion of the table or saddle.  Loose cable connection

3. Accumulating error is commonly the result of:

 Scale out of parallel to the axis travel.  Dirt or chip on the glass scale.  Broken glass.

4.7 TRAK Sensors

TRAK Sensors are used on the X and Y-axis for secondary feedback. They are optional on the TRAK SMX knee mill machines. The following section talks about some of the common symptoms associated with a problem sensor and how to isolate or fix the problem.

Common symptoms

 Faulting Axis  The DRO measurements do not repeat  The DRO measurements are not accurate

Objectives:

 To determine if the TRAK Sensor is bad and needs to be replaced.  To determine if there is a problem with the sensor set-up

4.7.1 Faulting Axis

If a sensor has stop reading and you try to move an axis, the axis will run away and fault. Our control uses the counts from the sensor and motor when reading position. If either one of these signals is not working our system will fault.

1. The first thing that can be done to see if the sensor is at fault is to turn off the sensor on the axis in

question. This will allow the system to run only on the motor encoders. If the fault continues then the sensor was not the problem. Turn the sensor back on. See the service code section for a codes needed to turn the sensors on and off. Also, run code 100.

2. The next thing to do is to visually inspect the sensor and base to determine if there has been a crash. A

damaged base will usually have crinkles in the small, spring plates on the front and back.

3. Next make sure the sensor is preloaded correctly against the running surface. There is a setscrew on the

base that allows for adjustment.

4. If no outward signs of damage are present, remove the sensor from its base, and inspect the wheel for

damage and wear. If the wheel is worn smooth in the center, replace the sensor. Note: Sensors should not wear smooth for many years of normal operation.

5. If the sensor looks normal, it is probably OK and there is a mechanical obstruction somewhere in the set-up.

Look for the following possible problems:

 Broken sensor base  Broken bracket  Sensor tilted too much (so that the wheel is not engaging the running surface)  Sensor chip scraper has doubled back and is pushing the wheel away from the running surface  Sensor chip scraper is defective or has worn and is pushing the sensor unevenly

4.7.2 Measurements Do Not Repeat

1. Determine if the error in repeatability is random or accumulating:

 Mount a dial indicator in the quill  Touch off a fixed point on the table and set the DRO to 0.  Traverse away approximately 6 inches  Return and touch off again

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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.

Check the end that goes to the electrics box.

 Power cord defective.

3. Check the top fuse on the electrical cabinet. It should be an 8-amp fuse.

 If this is blown then power will not

reach the 4 outlets on the electrical box.

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

 Power cord defective

CAUTION!

Turn off power before removing and replacing fuses.

 Write down the reading on the DRO.  Do not re-zero the DRO, traverse away and return several times  Write down the DRO readings

Random error will be unpredictable and give scattered readings, adding and/or subtracting the error after each traverse with no pattern. See Step 2. Accumulating error will add roughly the same amount to the reading after each traverse. See Step 3.

2. For random error, look for problems in the set-up of the TRAK Sensor that have resulted in a loss of rigidity.

Common sources of random error include:

 broken base  broken bracket  loose puller screws  loose run bar  very loose motion of the table or saddle  loose clamp screw

3. Accumulating error is almost always the result of the wheel not traveling in a path parallel to the motion of

the axis. This causes the wheel to skip at certain regular points in its travel.

 Inspect the base to determine if it has been damaged. A damaged base will usually have crinkles in the

small, triangle-shaped plates on the front and back.

 Use a bubble level or an indicator to adjust the puller screws so that the base is parallel to the running

surface.

 Inspect that the sensor is not cocked so that the case contacts the running surface.  Inspect the wheel for chips that are adhered or for gouges.

4.8 Electrical

4.8.1 Checking A/C Voltage

This procedure tests for the 115V 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:

4.8.2 Checking Fuses

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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.

There are 4 fuses to check in the system. There are 2 in the pendant and 2 in the electrical cabinet, and one on the breakout box. The top fuse in the electrical cabinet is 8 amps and fuses power to the pendant. The bottom fuse is 5 amps and fuses power to the auxiliary 1, auxiliary 2 and lube pump outlets. The 2 fuses in the pendant are 1 amp and 12 amps. The 12-amp fuses the cable breakout box, and the 1 amp the pendant. If you have the auxiliary function option then there is 1 more fuse to check on the cable breakout box for the coolant or mister option. To check fuses:

1. Use a Volt/Ohmmeter; select “OHM”.

2. Remove the fuse completely from the pendant, electrics box or cable breakout box.

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

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

4.8.3 Cable Breakout Box Connections

This module is located on the back side of the machine. It consists of 3 motor connections, 3 limit switch connections, 3 encoder connections and an E-stop connection. Machines with an auxiliary function option have 2 more outlets. A 110 V outlet for a coolant pump or air solenoid and an indexer outlet. The coolant pump signal and indexer signal comes down from umbilical #2.

4.8.4 Cable Connections

The TRAK knee mill machines use 10+ cables to communicate between systems. It is often the case that what appears to be the failure of an electrical component is actually attributable to a poor connection. Indications:

 Control problems, chronic or intermittent.  Motor problems  Measurement problems.

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. Do the same at the computer/display.

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

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Figure 19 Electrical Box Schematic

4.8.5 Spindle Control Electrical Box The

spindle control electrical box is made up of the following main components:

1. AC drive – used to control the spindle motor.

2. 4 output 110 volt outlets – 1 outlet is used to power the pendant, 1 is used to power the lube pump and is turned on

based on the spindle being on, 2 additional outlets.

3. 2 braking resistors – used to brake the spindle motor. The mechanical brake should not be used to brake the

spindle. To verify the resistors are good, measure the resistance across B1 and B2 of the AC drive. For 3 HP

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machines it should read 60 ohms and for 5 HP machines it should read 32 ohms. Values lower or higher than this could be one or both resistors are bad.

4. Relay – used to turn on and off the lube pump and spindle motor fan.

5. Spindle control PCB board - controls the auxiliary signals from the pendant to the AC drive and electrical outlets.

The following explains the LED lights on the spindle control board. There are (2) 10 LED segments on the board. Not all of the LEDs are used. See figure 21 for an illustration.

1st 10 LED Segment

4. LED labeled Gear 1 – this light should be on whenever the machine is in low gear. LEDs labeled Gear 2 thru Gear 4

are not used.

5. LED labeled SPD-FAULT – this light will be on whenever the AC drive is in a fault condition, which includes an E-stop

message from the pendant.

6. LED labeled SPD-RUN – this light should be on whenever the spindle is on.

7. LED labeled SPD-ENABLE – this light should be on whenever you are in DRO, tool setup and RUN mode.

2nd 10 LED Segment

1. LED labeled E-STOP OUT – this light should be on whenever the E-stop is in the out position. When the E-stop is

pressed, this light should go off.

2. LED labeled LATCH RELAY – this light should be on when the spindle is running or if the spindle is not running and

the fwd/rev switch is in the off position when in DRO, tool setup or RUN mode. Note – if spindle won’t turn on and the spindle is enabled and the e-stop is out, then either the fwd/rev switch is bad or the spindle control board is bad.

3. LED labeled TAP MODE – light should be on whenever you are not tapping. Light will be off when in the tap event.

Not applicable to 2-axis knee mills or retrofits.

4. LED labeled TAP REVERSE – this light will be on when the spindle changes direction at the bottom of a tap event

and back off after the spindle changes direction once outside of the tap event. Not applicable to 2-axis knee mills or retrofits.

5. LED labeled REV-RELAY – when fwd/rev switch is in reverse this light will be on. Note – this does not mean

necessarily that the spindle will be running this direction.

6. LED labeled FWD-RELAY – when fwd/rev switch is in forward this light will be on. Note – this does not mean

necessarily that the spindle will be running this direction.

7. LED labeled Z-LIMIT PLUS – this light will be on only when the Z-axis plus limit switch is triggered. This only applies

to a 3rd axis product.

8. LED labeled Z-LIMIT MINUS – this light will be on only when the Z-axis minus limit switch is triggered. This only

applies to a 3rd axis product.

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Figure 21 LEDs on Spindle Control Board

Figure 20 Schematic Diagram of Spindle Control Option

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ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

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

4.9.1 Software Codes

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

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

4.9.1.1 CODE 33: Software ID

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

 Software Version - the version of the system you have installed  Firmware Version - the version of firmware software that is responsible for control to servo interface.  Converter Version – the version of software that is responsible for converters and options.  Operation System Version – shows the version of the XP Operating System.

4.9.1.2 CODE 141: Load Configuration file from external drive

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

4.9.1.3 CODE 142: Save Configuration file to an external drive

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

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

4.9.1.4 CODE 313: Display Configuration File

This code displays the configuration file. This file contains pertinent information about the machine. The file will look similar to the following. If the file becomes corrupt you can load default values by pressing the F4 softkey. Product = KNEE2X (displays machine ID key of machine) Motor encoder calibration constants X=610.0711 Y=610.0812 Z=610.0678 Secondary feedback calibration constants X=3302.6122 Y=3302.5955 Z=3302.5877 (These numbers above are typical numbers for the calibration constants, the numbers for secondary feedback are default numbers, which means no calibration has been done, or the machine does not have secondary feedback) Arc accuracy – 0.001” Secondary feedback – 0, 1, 2 or 3 (0 = off, 1 = X on only, 2 = Y on only, 3 = XY both on) Code 11 values X = 0.002 Y = 0.001” Code 128 X=0.001” Y=0.0014” Z=0.0016” Code 12 (+) X=000005 Y=000006 Z=000006 (-) X=000005 Y=000005 Z=000006 Code 100 (+) X=210.5 Y=208.9 Z=200.1 (-) X=207.1 Y=208.4 Z=203.6

4.9.1.5 CODE 316: Update Master Software

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

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4.9.1.6 CODE 317: Update Slave Software

4.9.1.7 CODE 318: Activate Converters or Options

See programming and operating manual.

4.9.2 Machine Set-up Codes

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

4.9.2.1 CODE 11: Hysteresis

Note: This code is use only for systems with Sensors or Glass Scales on the table and saddle. The Code 11 service routine checks the readings of the motor encoder against the sensor encoder. It is a measurement of how much motor motion is necessary to create table or saddle motion. This test helps us to look at two things:

 Play: How much backlash must be taken up when motion is reversed.  Friction: How much the mechanical components must be "torqued up" in order to break the friction and create

motion.

The Code 11 procedure is very useful and will help in diagnosing all types of motion and performance problems.

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

2. Go into the Service Codes and input Code 11.

3. The system will run the checking routine automatically and then display the values in the position readout.

Explanation: As an overall measure of the system hysteresis, we are looking for the X and Y values to be less than .004". A value greater than this indicates a problem with either excessive friction or play that may affect the finish or accuracy of machined parts.

4.9.2.2 CODE 12: Feed Forward Constant

The Code 12 procedure helps the control “learn” the friction characteristics of the machine by sending a graduated series

of motor signals and observing the results. The 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.

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. On S products, do not equate Code 12 values to torque on ballscrew. Measure friction in system with an in-lb torque wrench. The feed forward gain can be adjusted manually by pressing the manual button. Choose the axis you would like to change and then enter values in the positive and negative direction to adjust. Adjusting the gain can help solve circularity problems. Default values can be set by pressing the Reset button. The manual feature should only be used in extreme cases where the AUTO routine did not solve the problem. Manual adjusts above 12 may lead to servo related problems.

. Note: You will lose your DRO position reference.

Note: You will lose your DRO position reference.

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Your input

Display

Data displayed.

X +

table encoder reading

Y nothing (should be 0 )

Z Motor encoder reading

Feedrate

the maximum feedrate attained

Your input

table encoder reading

X - Y nothing (should be 0 )

Z Motor encoder reading

Feedrate

the maximum feedrate attained

Your input

nothing (should be 0 )

Y + Y table encoder reading

Z Motor encoder reading

Feedrate

the maximum feedrate attained

Your input

nothing (should be 0 )

Y - Y table encoder reading

Z Motor encoder reading

Feedrate

the maximum feedrate attained

Your input

nothing (should be 0 )

Z +

nothing (should be 0 )

Z motor encoder reading

Feedrate

the maximum feedrate attained

Your input

nothing (should be 0 )

Z -

nothing (should be 0 )

Z motor encoder reading

Feedrate

the maximum feedrate attained

4.9.2.3 CODE 100: Axis Open Loop Test

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

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

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

 If you want to run in the minus direction, press +/-, then INC SET

5. In the conversation line it will say “PRESS GO”. Press Go after you are sure that the machine will not crash

in the direction and axis that you have specified.

6. Afterward the screen will display values next to the DRO position axes. 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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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 and sensor or glass scale reading is not within this value, then the one that is out of

specification may be the problem. If one of the encoders is not reading then it will need to be replaced.

 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.

4.9.2.4 CODE 123: Calibration

See Section 5.2.2 for a further explanation of this code.

4.9.2.5 CODE 127 - Set X or Y Backlash Constant See Section 5.2.2 for a further explanation of this code.

4.9.2.6 CODE 128: Input Backlash Constant

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

4.9.2.7 Code 304: Toggles X sensor or glass scale on/off

This service code toggles the X sensor or glass scale on or off. It is used to configure the machine and also is a useful tool for troubleshooting. Code 313 (configuration file) displays whether the sensors have been turned on or off. The line labeled secondary feedback explains which sensors or glass scales are turned on. This line can read any one of the following: 0 = sensors or glass scales turned off 1 = X sensor or glass scale turned on only 2 = Y sensor or glass scale turned on only 3 = both X and Y sensor or glass scale turned on

4.9.2.8 Code 305: Toggles Y sensor or glass scale on/off

This service code toggles the Y sensor or glass scale on or off. See Code 304 for further explanation.

4.9.2.9 Code 321: Reverse Y position sensor direction This service code reverses the direction of the encoder. It may be needed if sensors or glass scales are mounted on different sides of the machine.

4.9.2.10 Code 322: Reverse X position sensor direction This service code reverses the direction of the encoder. It may be needed if sensors or glass scales are mounted on different sides of the machine.

4.9.2.11 Code 325: Reverse Quill Sensor Direction This service code reverses the direction of the encoder.

4.9.3 Diagnostic Codes

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

4.9.3.1 Code 54: Program Continuous Run

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

1. Prepare a program as you normally would.

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

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

4.9.3.2 Code 81: Keyboard Test

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

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4.9.3.3 Code 131: Manual DRO

A manual diagnostic routine to check the motor encoder and table encoders. Turn the X hand wheel to display the encoder readings. This code will display the actual DRO counts and the raw encoder counts.

4.9.3.4 Code 132: Electronic Hand Wheel Test

Turn the X, Y, or Z-axis electronic hand wheel. The display should show movement as the hand wheel is being turned. There should be no skipping and it should count smoothly while the hand wheel is being turned. One revolution of hand wheel should read 0.2000” when in fine mode and 0.800” in course mode

4.9.3.5 Code 314: Toggle test lights ‘on’ in status line

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

4.9.3.6 Code 319: Error Log

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

4.9.3.7 Code 324: Toggle Simulation Mode

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

4.9.4 Operator Defaults/Options Codes

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

4.9.4.1 Code 66: Default Metric

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

4.9.4.2 Code 67: Default English

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

4.9.4.3 Code 79: Beeper On

This turns on the beeper to the control keys.

4.9.4.4 Code 80: Beeper Off

This turns off the beeper to the control keys.

4.9.4.5 Code 129: Arc Accuracy

When the SMX control operates at high feedrates it may create small part machining errors as it goes around sharp

corners. This exists on all CNC’s and is commonly called a “following error.” The control is factory preset to allow a

maximum following error of 0.001 inch. The feedrate will automatically be adjusted around sharp corners so as to not violate this limit. This code only applies to arcs that are programmed and ones that are created in the tool path to generate the shape you want. This code will not make a difference on mill moves. You may adjust the maximum following error to a value as small as .0001 inch. However, the smaller the value, the slower the feedrate around corners. To input a new Following Error use the following procedure: Follow the instructions on the screen and input the Following Error value (from .0001 to .0100) and press INC SET.

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WARNING!

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

machine. The servomotors are run by 110 VAC. There is possibility of death by

electrocution!

WARNING!

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

machine. The servo drivers are run by 110 VAC. There is possibility of death by

electrocution!

WARNING!

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

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

5.0 Procedures for Replacements & Maintenance

5.1 Replacements

5.1.1 Servo Motor Replacement

1. Turn off power to the machine.

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

threads.

5.1.2 Servo Driver Replacement

The Servo Driver for each axis is integrated into the servo motor casting.

1. Press in the Emergency Stop.

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

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

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

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

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

middle.

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Part #

Description

24101-4

X, Y or Z Servo Driver

Figure 22 & Parts List Shown Servo Drive Replacement

5.1.3 Computer Module and LCD/Enclosure Replacement

1. Turn off power to the machine and control.

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

3. Remove the pendant from the pendant arm by removing the (4) ¼ - 20 x 3/4” SCHS that secure it in place.

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

5. Remove the (6) 10-32 x 3/8” Pan Phillips Head Screws and (4) 10-32 x 3/8” FHCS securing the computer module to the LCD/enclosure.

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

7. Now reach from the top and remove the 37-pin LCD cable, 37-pin distribution cable and the 9-pin E/Stop cables. The cables are to stay with the computer module.

8. Now slide the module about ½ way out of the LCD/enclosure.

9. Remove the ground wire from the LCD/enclosure side.

10. Lastly, slide the unit completely out of the LCD/enclosure.

11. Replace computer module or LCD/enclosure.

12. Follow the instructions in reverse order when reinstalling the new computer module or LCD/enclosure.

Make sure that all connectors are properly seated before fastening the unit back in place.

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Figure 23 Computer Module & LCD/Enclosure Replacement

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CAUTION!

It is a good idea to back up your flash disk from time to time via a network, external

drive or floppy disk. If your flash disk needs to be replaced you will lose all of your

programs. See your programming manual for instruction on how to do this.

5.1.4 System Flash Disk Replacement

1. From the control, go to SETUP, SERV CODES, SECTION A, and then code 142 and save your Configuration file

(calibration values, etc.) on a floppy disk or USB drive. Label this disk as “Backup Configuration” and store it for

later use.

2. Turn power off to the machine and control.

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

4. Remove the pendant from the pendant arm by removing the (4) ¼-20 x 3/4” SCHS that secure it in place.

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

6. Remove the (6) 10-32 x 3/8” Pan Phillips Head Screws and (4) 10-32 x 3/8” FHCS securing the computer module

to the LCD/enclosure.

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

cables. If need be, remove 4 cables that connect the computer module to the enclosure. Make sure to reattach them securely before re-assembling the pendant.

8. Remove the defective System Flash Disk (located on the back side of the mother board) by pushing the eject

button on the flash drive.

9. Firmly insert the replacement System Flash Disk into the drive, making sure that the label with the serial number

is pointing towards the motherboard.

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

11. Make sure that all connectors are properly seated before fastening the unit back in place.

12. Turn power on to the machine and control.

13. When the system boots, you may get a message stating that the system cannot find your configuration file.

Clear this message and continue.

14. From the control, go to SETUP, SERV CODES, SECTION A, and then code 33 and verify your software and

firmware versions are current.

15. To verify the current version, go to www.trakmt.com, click on support and then Software for current Prototrak

CNC’s, locate the download for the control.

16. If your software is an older version and does not match the one on the website, follow the instructions for

updating your control using a USB thumb drive.

17. Restore the Configuration file saved on your backup configuration disk with service code 141 found in section A

of the service code section.

18. If your control was networked prior to this change, you will have to reset your network settings.

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Figure 24 and Parts List Flash Disk Replacement

Item

P/N

Description

24008-1

PENDANT WITHOUT COMPUTER MODULE

24030-1

COMPUTER MODULE

3 25078

FLASH DISK (used on Revision D or later pendant)

25078-1

FLASH DISK (used on Revision C or earlier pendant)

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

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Figure 25 M5 Base Mounting

5.1.5 Cable Routing on Machine

Whenever you replace a cable or reroute a cable it is very important to keep the power cables and logic cables

separated from each other. The power cables consist of the (3) 110-volt motor cables and (2) 110-volt power cables for the pendant, and a coolant pump or solenoid power cable. The logic cables are used to carry encoder signals between the cable breakout box and computer module. Mixing of the power and logic cables may cause noise from the power cables to interrupt the signals in the logic cables. This can lead to intermittent axis faults or repeatability problems. See Figure 15 and 16 for a layout of the cable connections.

5.1.6 TRAK Sensor

5.1.6.1 Replacing the M5 Base

See Figures 25 and 26.

1. Remove the sensor by removing the clamp screw and then backing the load screw out a few turns.

The sensor should lift off the base easily.

2. Remove the old M5 Base by removing the two 1/4-20 hex head screws that are threaded into the

base.

3. Assemble the new base as per Figure 25.

4. Use a bubble level to align the raised bumps on the base with the table for X axis or saddle ways for

Y-axis.

5. A dial indicator may be used to align the bumps on the base instead of a bubble level.

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

Southwestern Industries, Inc.

5.1.6.2 Replacing the TRAK Sensor

1. Remove the old sensor by removing the clamp screw and then backing the load screw out a few

turns. The sensor should lift off the base easily.

2. Install the new sensor on the M5 base using the clamp screw.

3. Load the sensor against the running surface (table or run bar) using the load screw. The white lines

on the side of the M5 base tell you when it is loaded correctly.

Note: You want to load the gage wheel against the running surface using the flat spring of the M5 base. Do not tighten the clamp screw fully until after loading the sensor.

Figure 26 TRAK Sensor Mounting

TRAK Machine Tools

Southwestern Industries, Inc.

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Figure 27-K2, K3, K4 K Mill Sensor Assembly

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

Southwestern Industries, Inc.

Item

P/N

DESCRIPTION

M250C

SENSOR - ALL TRAK PRODUCTS

M-5 BASE

LDCEL-C

LOADCELL - M250C

M5 HDWR

HARDWARE - M5 BASE

16023-1

BRACKET-SENSOR X-AXIS (K2)

21511

EXTENSION

14600

BAR-RUN Y-AXIS

13384-4

BRACKET-SENSOR Y-AXIS (K2)

15346

CHIP SCRAPER-M250C

16023-2

BRACKET-SENSOR X-AXIS (K3 & K4)

13777-1

BRACKET UNIVERSAL BR17-RY MODIFIED (K3 & K4)

i01117

CAUTION!

Once the head alignment bracket is installed, do not traverse the axis or the reader

head will break.

CAUTION!

If the scale is not long enough for the table, it will break when the machine is

traversed past the scale travel.

Parts List K Mill Sensor Assembly (Figure 27)

5.1.7 Glass Scale Replacement

5.1.7.1 Remove the X, Y or Z Glass Scale

1. Unplug the glass scale connector from the cable breakout box.

2. Unbolt the reader head of the glass scale from its mounting surface.

3. Unbolt the glass scale enclosure from the table on X or the mounting spar on Y.

4. Install the head alignment bracket that came with the replacement scale to this scale to secure it for shipping

back to SWI. Failure to do this may cause the glass scale to get damaged during shipment. The head alignment bracket secures the reader head so it cannot move and damage the glass in the scale.

Note: 1st align the reader head on the new scale before removing it to fasten the old scale.

5.1.7.2 Install the X or Y Replacement Scale

1. Mount the scale to the back of the table or Y-axis mounting spar.

2. Align the sale so that it is within +/- 0.005" end to end.

Notes: For the Y-axis, the mounting spar should already be aligned. It must be parallel to the Y-axis travel within +/.005" end to end both horizontally and vertically. The mounting spar can be aligned in and out by the use of the adjustment screw.

3. Line the reader head up with the mounting holes on the back of the saddle for the X-axis or the bracket on the

Y-axis.

4. Install the reader head bolts but leave them loose.

5. Use the jackscrews on the reader head to compensate for some gap between the reader head and the reader

head mounting bracket. Leave the alignment brackets attached to the reader head. This bracket assures the reader head is aligned to the glass scale.

6. Tighten each jackscrew until it touches the bracket and then back it off 0.001” or 0.002”. Use a feeler gage to

set the gap.

7. Tightening the reader head mounting screws. This ensures the reader head is aligned within a few thousandths.

8. Remove the shipping bracket that fixes the reader head to the scale for shipping.

TRAK Machine Tools

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Southwestern Industries, Inc.

CAUTION!

After the reader head is attached to the reader head-mounting bracket, do not move

the machine axis until the shipping bracket is removed. This will break the reader

head. This is not covered under warranty.

CAUTION!

The gap must be no larger than 0.060” between the readerhead and glass scale.

See Figure 29 for an illustration of how to align glass scales.

5.1.7.3 Install the Z-Axis Glass Scale

See Figure 28.

1. Check the tram of the head in the X direction. If it is within a few thousands then continue on. If not tram.

2. Assemble Z-axis glass scale mounting bracket and mount to head. Items 1, 2, 3 and 4. Tap items 3 and 4 together

and tap item 3 into the quill stop knob. Leave the bolt loose. Use 2 screws (item 6) and mount item 4 to the side of

item 2 using a spacer between both items to provide a gap of approximately 0.040” between Items 2 and 4. This is

to make sure item 2 does not rub against item 4.

3. Align the glass scale bracket (Item 2) with an indicator and tighten the mounting screws. Leave the quill stop knob

screws loose. Remove the spacer and bolts from Item 4.

4. Unscrew the shipping protection screw from the scale.

5. Mount the glass scale to the mounting bracket and align it with an indicator. It needs to be aligned within 0.008"

with respect to the quill. Tighten the screws down.

6. Fasten the readerhead to the readerhead bracket.

7. Move the readerhead up and down the glass scale and make sure the gap is consistent between the readerhead and

the glass scale. Tighten the screw to the quill stop knob.

8. Remove the red head securing plate.

9. If the gap is not consistent between the readerhead and the glass scale when moving the quill up and down then

adjust the angle of the scale to make the gap consistent.

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

Southwestern Industries, Inc.

Item

P/N

Description

Qty 1 20550

ARM- Z-AXIS MOUNTING PLATE

1 2 20551

MOUNTING PLATE-Z-AXIS GLASS SCALE

20548

ADAPTER-Z-AXIS GLASS SCALE

1 4 20549

ADAPTER PLATE- Z-AXIS GLASS SCALE

10-32X3/4 25B

SCREW-SHCS-STL-BO

10-32X1 1/4 25B

SCREW-SHCS-STL-BO

3 7 15759

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

1 8 1/16X1/2 81B

SPRING PIN

1/4-28X3/8 25B

SCREW-SHCS-STL-BO

i00891

Part #

Description

22800-4

Z Glass Scale

20586

Bracket Assembly

Figure 28 K Mill Z-Axis Glass Scale Assembly & Parts List Shown

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

Southwestern Industries, Inc.

QTY

PART NUMBER

DESCRIPTION

NO.

91120A130

WASHER - EXTERNAL SERRATED LOCK

12 4 91166A230

WASHER - FLAT M4 70B

11 4 1/4-20x1.00 25B

SCREW-SHCS-STL-BO

10 2 1/4 72Z

WASHER-SPHERICAL (1 SET)

1/4 71Z

WASHER-USS FLAT-STL-BO

8 2 1/4x1.00-79Z

WASHER-FENDER 1/4" x1.00 O.D.

1/4 73Z

WASHER-SPLIT LOCK-STL-BO

6 2 1/4-20x2.00 25B

SCREW-SHCS-STL-BO

20904

MOUNTING BRACKET

4 2 20545

ADJUSTMENT SCREW

20546-1

SPACER-Y AXIS

2 1 20544

MOUNTING PLATE, Y AXIS

i00894

Part #

Description

22800-35

X Glass Scale – K2/K3/K4

22800-13

Y Glass Scale – K2

22800-16

Y Glass Scale – K3 & K4

Figure 29 Glass Scale Alignment & Parts List Shown

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

Southwestern Industries, Inc.

CAUTION!

Some tools may not work with this device and the original spindle dogs will need to be used. The

original spindle dogs are shipped with each machine in the toolbox. Some boring bar holders may not

work with this device.

5.1.8 Power Drawbar

A power drawbar is an optional item on a TRAK Knee mill machine. It is bolted to the top of the head by the use of 3 SHCS. Some machines may require a washer to space the unit up to the proper height to allow the drawbar to engage properly.

Air Regulator and Oiler - This unit requires between 80 and 100 psi to operate properly. Some units work fine at 80 psi while others may need 90 or 100 psi. It is also important to make sure the oiler for this unit is kept filled with oil. Fill the reservoir about 2/3 full using AIR TOOL OIL ONLY. Failure to do this will not allow oil to lubricate the internal components of the unit and it may wear out prematurely. It is also important to make sure the oiler is set properly. To set the oiler, first close the adjustment screw (CW) on top of the oiler completely making sure to not over tighten. Then open the screw (CCW) between ½ to ¾ of a turn. Any more than this will cause too much oil to get into the unit and oil may come out of the exhaust port of the unit.

Tool Alignment Device - This unit also comes with a tool alignment device, which attaches to the bottom of the spindle. This device allows the tool to easily be aligned with the dogs when loading a tool.

Note: Only used on K4 machines

TRAK Machine Tools

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Southwestern Industries, Inc.

Item

P/N

Title

22581-1

AIR GUN ASSY ONLY- TORQUE RITE

26987

DRAWBAR-R8 SPINDLE

20893

SPACER - DRAWBAR - R8 SPINDLE

22380-1 or -2

AIR REGULATOR ASSY (-2 with solenoid)

23888

SPACER - DRAWBAR - 40 TAPER SPINDLE

22581-2

SWITCH - CONTROL HEAD - TORQUE RITE

22581-4

NOSEPIECE FOR SPINDLE (40 taper heads only)

8 1/4" NPT AIR FITTING 90°

9 3/8 O.D. TUBING 132" LG.

10 3/8 O.D. TUBING 27" LG.

22641-NMTB

DRAWBAR - NMTB -40 TAPER

22641-CAT

DRAWBAR - CAT - 40 TAPER

TR220

SOCKET - AIR GUN REPLACEMENT (not shown on drawing)

i00875-1

Figure 30 and Parts List Power Drawbar Assembly

For item 4, see section 2.12 for a breakdown of parts.

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

Southwestern Industries, Inc.

CAUTION!

Never screw a ball screw partially or totally out of its nut. They cannot be

reassembled.

CAUTION!

The weight of the table must be supported by the lift to prevent damage or

breakage to the dovetails.

5.1.9 Ball Screw Replacement, X-Axis (Table)

1. Y-axis motor mounting bracket and hardware must be removed to remove X yoke.

2. Position the table in the center of travel.

3. Remove the left side table tray by pulling it up, and remove the X motor (If machine has tray).

4. Remove the motor mounting bracket and bearing housing.

5. Remove the right side bearing housing.

6. Loosen the table gibs. Slide the table to the right and on to a lift that will support the table's weight. Slide

the table until the yoke is exposed.

7. Remove the 5/16 x 1" screws holding the ball nut to the yoke and loosen the 4 screws that mount the yoke

to the saddle. Remove the oil line.

8. Tilt the yoke (it is pinned) to remove the ball screw.

9. Remove the elbow and setscrew from the old ball screw flange and fit them similarly in the new ball screw.

10. Pump oil to be certain it flows through the oil line and then attach the oil line to the elbow.

11. Reassemble all assemblies.

Important: The clamp nut must be reassembled as follows:

 Install rear bearing and seal into bearing housing and slide housing onto the ball

screw.

 Thread the split nut onto the ball screw and tighten the #10-32 clamp screw until

you feel the split nut contact the ball screw threads. It should drag as you tighten the clamp nut.

 Torque the split nut to 50 ft. lb.  Firmly tighten the #10-32 clamp screw to lock the clamp nut in place.

See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw.

See Figure 31 for an illustration of the X-axis drive train.

(Note: Letters on bearings must face each other in the housing.).

TRAK Machine Tools

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Southwestern Industries, Inc.

Figure 31 X-Axis Drive Assembly

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

Southwestern Industries, Inc.

Item

P/N

Title

Qty

15621

DRIVE HOUSING

1 2 25729

HANDLE REPLACEMENT KIT

15624

FRONT COVER

15622

BACK COVER

15616

HANDWHEEL ASSY-MX

15612

HOUSING - BEARING

1 9 15885

RING-BEARING HOUSING

15638

STOP - X-AXIS (not shown on drawing)

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

22008

BEARING- 204KTT

400-5M-15

BELT - TIMING 5MM POWERGRIP

23930

BEARING-ANGULAR CONTACT- 7204 BECBP

SET

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

3/8-16X2 1/2 25B

SCREW-SHCS-STL-BO

M8-1.25X65 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

M8 70P

WASHER-FLAT USS-STL-PLAIN

15759

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

3/8 70P

WASHER-FLAT USS-STL-PLAIN

M10 70P

WASHER-FLAT USS-STL-PLAIN

1/2 73B

WASHER-SPLIT LOCK-STL-BO

1/2 70P

WASHER-FLAT USS-STL-PLAIN

22007

END CAP

15181

BALLSCREW EXTENSION

15608-48

BALLSCREW - X AXIS

22718

SPACER-45 DEGREES X-AXIS

21992

BUSHING-BALLSCREW (X-AXIS)

14772

SPACER-.100” THICK

M6-1.0X75 25B

SCREW-SHCS-STL-BO

21946

ELECTRONIC HANDWHEEL

Parts List X-Axis Drive Assembly (Figure 31)

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

Southwestern Industries, Inc.

CAUTION!

Never screw a ball screw partially or totally out of its nut. They cannot be

reassembled.

5.1.10 Ball Screw Replacement, Y-Axis (Saddle)

1. Position the saddle all the way forward.

2. Remove the hand wheel assembly and bracket.

3. Remove the sheet metal covers on the front of the machine bed and on the motor mounting bracket.

4. Remove the motor, then remove the motor mounting bracket.

5. Remove the rest of the parts on the ball screw journal. Note the orientation of the bearings for reassembly.

6. Remove the 5/16 x 1 inch screws that attach the ball nut to the yoke.

7. Remove the ball screw and oil line attached to the elbow fitting on the ball nut.

8. Remove the elbow and setscrew from the old ball screw flange and fit them similarly in the new ball screw.

9. Pump oil to be certain it flows through the oil line, and then attach the oil line to the elbow.

10. Reassemble all assemblies.

Important: The clamp nut must be reassembled as follows:

 Install rear bearing and seal into bearing housing and slide housing onto the

ball screw.

 Thread the split nut onto the ball screw and tighten the #10-32 clamp screw until

you feel the split nut contact the ball screw threads. It should drag as you tighten the clamp nut.

 Torque the split nut to 50 ft. lb.  Firmly tighten the #10-32 clamp screw to lock the clamp nut in place.

See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw.

See Figure 32 for an illustration of the Y-axis drive train.

(Note: Letters on bearings must face each other in the housing.)

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

Southwestern Industries, Inc.

Figure 32 - Y-Axis Drive Assembly

TRAK Machine Tools

Southwestern Industries, Inc.

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

Item

P/N

Description

Qty 1 15626

SEAL-BEARING HOUSING

1 2 23930

BEARING SET-ANGULAR CONTACT- 7204 BECBP

1 3 15885

RING-BEARING HOUSING

1 4 15980

BEARING HOUSING

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

1 9 890-5M-15

BELT - TIMING 5MM POWERGRIP (Y AXIS)

16533

VERNIER DIAL-PT4

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

10-32X1 25B

SCREW-SHCS-STL-BO

M10-1.5X65 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

10-32X3/8 10B

SCREW-PH-PHIL-STL-BO

10 73B

WASHER-SPLIT LOCK-STL-BO

30922

HANDLE FOLD-A-WAY

98481A090

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

14772-2

SPACER - .020" THICK

1 20296R

MOTOR ASSY

1 15609-12

Y BALLSCREW – K2

1 15609-16

Y BALLSCREW – K3/K4

21984

BRACKET-WAY COVER FRONT Y-AXIS DRIVE

¼-20X5/8 26B

SCREW-FHCS-STL-BO

21992-1

BUSHING-BALL SCREW (Y-AXIS)

14772

SPACER-.100” THICK

21985

SPACER-30 DEGREES Y-AXIS

M6-1.0X25 25B

SCREW-SHCS-STL-BO

21946

ELECTRONIC HANDWHEEL

M6-1.0X75 25B

SCREW-SHCS-STL-BO

25729

HANDLE REPLACEMENT KIT

Parts List Y-Axis Drive Assembly (Figure 32) i00912

ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual

TRAK Machine Tools

Southwestern Industries, Inc.

Trak Machine Tools ProtoTRAK SMX K2, ProtoTRAK SMX Retrofit, ProtoTRAK SMX K3, ProtoTRAK SMX K4 Safety, Installation, Maintenance, Service And Parts List

Specifications and Main Features

Frequently Asked Questions

User Manual

1.0 Safety

2.0 Installation

3.0 Troubleshooting by Symptom

4.0 Diagnostics

5.0 Procedures for Replacements & Maintenance