ProtoTRAK SMX K2, K3, K4 & Retrofit ® Safety, Installation, Maintenance, Service & Parts List Manual Document: P/N 24319 Version: 060911 Southwestern Industries, Inc P. O. Box 9066 Compton, CA 90224-9066 USA T | 310.608.4422 | F | 310. 764.2668 Plant location: 2615 Homestead Place Rancho Dominguez, CA 90220-5610 USA Service Department: 800.367.3165 e-mail: sales@southwesternindustries.com | service@southwesternindustries.com |web: southwesternindustries.
Copyright 2010, 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.
Table of Contents 1.0 1.1 1.2 Safety 1.3 Safety Publications Danger, Warning, Caution & Note Labels & Notices as used in this Manual Safety Precautions 2.0 Installation 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.16 Floor Plan, Layout & Space Requirements Uncrating Shortages: Inventory Checklist Installation Instructions & Checklist Machine Specifications Maximum Work Capacities ProtoTRAK SMX Control Hardware Lifting and/or Moving the Machine Cleaning Leveling: Leveling Tolerance is .
5.0 5.1 5.2 Procedures for Replacements & Maintenance Replacements 5.1.1 Servo Motor Replacement 5.1.2 Servo Driver Replacement 5.1.3 Computer Module Replacement 5.1.4 System Flash Disk Replacement 5.1.5 Cable Routing on Machine 5.1.6 TRAK Sensor 5.1.6.1 Replacing the M5 Base 5.1.6.2 Replacing The TRAK Sensor 5.1.7 Glass Scale Replacement 5.1.8 Power Drawbar 5.1.9 Ball Screw Replacement, X-Axis 5.1.10 Ball Screw Replacement, Y-Axis 5.1.11 Air Solenoid Replacement: Auxiliary Function Machines Only 5.1.
Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. 27 28 29 30 31 32 33 34 35 K-Mill Sensor Assembly K-Mill Z-Axis Glass Scale Assembly Glass Scale Alignment Power Drawer Assembly X-Axis Drive Assembly Y-Axis Drive Assembly Spindle Motor Wiring Feed Trip Adjustment Quill Clock Spring Replacement & Adjustment Fig. 36 Spindle Removal & Replacement Fig. 37 Drive Belt Replacement Fig. 38 Spindle Replacement Fig. 39 Table Gib Adjustment Fig. 40 Table Gib Screen Fig.
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.
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 2 Southwestern Industries, Inc.
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 Power Requirements at 220 and 440 Volts, 3-phase 60 Hz SMX K2/K3 Vari-speed Head Overload Setting 220 V Overload Setting 440 V FLA of Largest Motor at 220 V FLA of Largest Motor at 440 V FLA of Machine at 220 V FLA of Machine at 440 V SMX K4 Spindle Control Vari-speed Head 8.5 A 11 A 14 A 4.25 A n/a 7A 8.5 A 11 A 14 A 4.
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.
18. Use correct cutting parameters (speed, feed, depth, and width of cut) in order to prevent tool breakage. 19. Use proper cutting tools for the job. Pay attention to the rotation of the spindle: Left hand tool for counterclockwise rotation of spindle, and right hand tool for clockwise rotation of spindle. 20. After an emergency stop, always turn the FORWARD/REVERSE switch to "Off" (STOP) before releasing or resetting the E-Stop. 21. Prevent damage to the workpiece or the cutting tool.
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 Weight (approximate) net Weight (approximate) shipping Pallet Size A Overall width B Overall length C Base width D Width between leveling screws E Distance between leveling screws F Base length K2 2200 lbs 2500 lbs 6’ x 6’ 101” 66” 24.2” 21.9” 29.1” 37.4” K3 2800 lbs 3100 lbs 6’ x 6’ 103” 70” 24.2” 21.
Figure 2 - Overall Dimensions Table Size T-Slots (number x width) Dimension G Dimension G Min Dimension H Min Dimension H Max Dimension I Min Dimension I Max Dimension J Max Dimension K K2 9” x 49” 3” x 5/8” 86” 65” 56” 67” 36” 49” 18” 69” K3 10” x 50” 3” x 5/8” 87” 65” 64” 78” 38” 49’ 17” 69” K4 10” x 50” 3” x 5/8” 92” 73” 64” 78” 36” 54.5 23” 77” 7 Southwestern Industries, Inc.
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.
2.4 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. 1. Shut off power to the machine. 2. 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.
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. 27. If the machine has a power drawbar option, check to make sure that the tools load and unload properly. N/A to retrofits. 28.
2.7 ProtoTRAK SMX Control Hardware • • • • • • • • • • • • 2 or 3-axis CNC, 3-axis DRO 400 PC-based processor 256 MB of RAM D.C.
Figure 3 Knee Mill Component Identification Item Part Number SMX K2 + K3 1 2 3 4 5 20819 SMX K2 + K3 Spindle Control 24162 24000-1 15616 15616 20296 Description SMX K4 20820 SMX K4 Spindle Control 24163 Spindle Motor SMX Pendant Y-Axis Handwheel (Saddle) X-Axis Handwheel (Table) X, Y or Z Motor 12 Southwestern Industries, Inc.
Figure 4 - Knee Mill Rear View Item Part Number SMX K2/K3 Description 2 3 220V=20676 440V=20676 24999 24999-1 SMX K2/K3 Spindle Control 24060-1 220V only 24999 24999-1 220V=20676-1 440V=20676 24999 24999-1 SMX K4 Spindle Control 24060-2 220V only 24999 24999-1 4 5 9001 20676-2 9001 n/a 9001 20676-2 9001 n/a 1 SMX K4 Electrical Box Cable Breakout Box Cable Breakout Box with AUX Functions Lube Pump Electrical box (if have tableguard option) 13 Southwestern Industries, Inc.
2.8 Lifting and/or Moving the Machine 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. (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.
Figure 5 Lifting the Machine 15 Southwestern Industries, Inc.
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. WARNING! Do not use gasoline or other flammable cleaning agents for cleaning the machine. 3. It may be necessary to move back and forward, left and right, and up and down the table, saddle and the ram.
Figure 6 Placement of Levels I00138 Item 1 2 3 P/N FC112 FC113 FC114 Title LEVEL SCREW LOCK HEX NUT LEVELING PAD i00138 Figure 7 Leveling Screws 17 Southwestern Industries, Inc.
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. 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.
Figure 8 Wiring K2, K3 or K4 – Non Spindle Control Not for retrofit Part Number Description K2/K3/K4 220V & 440V = 20676 220V & 440V = 23438-3 23436 Electrical Box Overload Contactor (Qty = 2) (Reverse or Forward) NOTE: If equipped with Table Guard Option, the Electrical Box the P/N is 20676-2. 19 Southwestern Industries, Inc.
Figure 9 Wiring the K2, K3 or K4 – Spindle Control Item 1 5 8 12 14 15 Part Number Description K2/K3 K4 24060-1 24060-2 22890-500-120 22890-500-64 25105-K2/K3SX 25106-K4SX 22961 21824-5 21824-8 Electrical Box Resistor (Qty = 2) AC Drive - Mini Vector - 220V Relay - Power - 115V DPST Fuse - 3 AG - Slow Blow 5 AMP Fuse - 3 AG - Slow Blow 8 AMP See Figure 117 in the rear of the manual for a more detailed breakdown of parts.
Figure 9-1 Wiring the K2, K3 or K4 – Spindle Control 2.11.1 Phase Converters 2.11.2 Flange Disconnect/Transformer (Optional) 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 non-varying load.
Figure 10 – Flange Disconnect/Transformer Option P/N: 23440-220, 23440-1-220, & 23440-440 22 Southwestern Industries, Inc.
Parts List – Flange Disconnect/Transformer Item 1 4 5 6 7 8 9 11 13 14 16 17 18 19 20 22 23 24 25 26 40 41 42 45 48 P/N 21258 23434 23435 23436 23437 23438 23438-1 22199-1 21871 23297-1 21820 21824-5 21830-12 22868 22869 21753-3 21901-150 23036 23153-3 22303-16G 22557-1 24299-3 22571-8.
Figure 11 Transformer Option Schematic 24 Southwestern Industries, Inc.
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.
Figure 12 - Air Regulator/Solenoid Assembly - P/N: 22380-1 Item 2 3 8 9 11 12 18 19 20 24 25 P/N 22378 22607 22644-4 22645-4 22646-4 22647-2 4-40X3/8 31B 10-32X3/8 10B M6-1.0X25 25B 22772 22581-5 Title MANIFOLD-PT4 AIR FILTER/REGULATOR-PT4 PLUG-1/4 NPT HEX SOCKET NIPPLE-1/4 NPT x 1.37 LG ADAPTOR-ELBOW MALE 1/4 x 1/8 NPT NIPPLE-1/8 NPT x 0.750" LG SCREW-PH-PHIL-EXT SEMS-STL-BO SCREW-PH-PHIL-STL-BO SCREW-SHCS-STL-BO SOLENOID ASSY- AIR REGULATOR OILER Qty 1 1 3 1 1 1 2 2 2 1 1 i22380-1 2.
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.
Figure 14 Pendant - Right Side P/N: 24000-1 28 Southwestern Industries, Inc.
Figure 15 Cable Connection Diagram Non-Spindle Control 29 Southwestern Industries, Inc.
Figure 15 Cable Connection Part List Non-Spindle Control Item 1 2 3 4 5 6 Part Number K2/K3 220V = 20676 440V = 20676 Description K4 220V = 20676-1 440V = 20676-1 21856 24999 22648-7 22758-SKNEE2X 24000-1 Electrical Box Cable Assembly Cable Breakout Box (-1 with AUX Functions) Option Key—SMX Key—Machine ID SMX Pendant Figure 16 Part List for Cable Connection Diagram with Spindle Control See next page Item Part Number 1 24000-1 2 24060-1 2 24060-2 3 24999 3 24999-1 4 22555-10 5 22555-10 6 22556-10 7 225
Figure 16 Cable Connection Diagram with Spindle Control 31 Southwestern Industries, Inc.
2.15 Lubrication CAUTION! Failure to properly lubricate the mill will result in the premature failure of bearings, sliding surfaces & ballscrews 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.
Figure 17 Knee Mill Lubrication 33 Southwestern Industries, Inc.
Parts List – Figure 17, Knee Mill Lubrication Item 1 2 3 4 5 6 7 8 9 10 11 12 13 P/N 9001 9002 9003 9004 9005 9006 9007 9008 9009 9010 9011 9012 9013 Title HAND OILER ALUMINUM PIPE ELBOW T-JOINT - 4 HOLES- M8 X 1.0 CONNECTOR REGULATING DISTRIBUTOR FLEXIBLE TUBE - 21 inches SCREW NUT - M8 X 1.0 MALE SCREW NUT - PD 1/8- 19MM SCREW - M5 X 20 mm LG SCREW NUT - M8 X 1.0 FEMALE ADAPTER SLEVE - 4.1 mm I.D. i00889 Qty 1 6 6 1 3 1 1 15 2 8 3 1 18 2.15.2 Head Lubrication Once Each Week: 1.
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: Event # Description Depth of Cut 1 Circle pocket – cuts middle circle -0.250” 2 Circle frame – cuts outer 1.830 diameter circle -0.250” 3 Circle frame – cuts material from corners remaining on Euclid block -0.
Figure 18 Euclid Block 36 Southwestern Industries, Inc.
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.
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.
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.
• 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 Sam e Error Possible Cause Machine Tool & Setup problem Programming Error Configuration file that contains calibration file and backlash constants has been erased or corrupted. Calibration or Backlash problem 3.1.4.2 Check This See Machine Tool & Setup Section 4.
Possible Cause Sensors or glass scales are counting in opposite direction of motor encoder The home positions or tools are not set correctly The Sensor or Glass Scale is not reading. Bad Motor Encoder Check This Reverse directions with codes 321 and 322 See the Controls Programming, Operations and Care manual. See TRAK Sensors or Glass Scales diagnostic Section 4.6 or 4.7 See Motor diagnostics Section 4.4 3.2.
Possible Cause Improper Boot-up E-Stop is pressed in Servo Drive failure Check This Shut down the system and wait 10 seconds before rebooting Check E-Stop. Especially if both axes will not jog Especially, if only one axis will not jog; See Servo Driver Section 4.5 See Motor Section 4.4 See Electrical Connection Section 2.12 See Computer/Pendant diagnostics Section 4.3 Shorted motor Poor cable or wiring connections Computer/Pendant failed 3.2.
• 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. Possible Cause Too much backlash entered in Code 128 or Code 11.
3.3 Problems Relating to the Operation of the Control 3.3.1 Display Blanks The display is completely blank. Possible Cause Screen saver has been activated The system has shut down Poor cable connection from Computer Module to LCD (Liquid Crystal Display) Fuse blown in pendant Computer/Pendant failed Check This 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.
• 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.
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. Possible Cause 110 V line is not plugged in Pendant On/Off switch is Off. Fuse blown in pendant or electrical cabinet Flash Drive failure Computer/Pendant has failed Check This Check incoming 110 V power source to black electrical cabinet Check the Pendant On/Off switch Remove fuses and check continuity.
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. Possible Cause Configuration file corrupt Not saving Calibration values Check This Load default configuration by going to code 313 Replace Computer/Pendant module.
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.
Possible Cause Limit switch jumpers in cable breakout box are making poor contact. Limit Switches are triggered Poor Limit Switch Cable connection Limit Switch failure Try this Switch 2 limit switch cables on the cable breakout box. Check This Remove and reseat jumpers. Reset the Limit Switches using the procedures described above. 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.
Possible Cause X and Y-axis Drive Trains are loose Encoder Disk or Reader Head on motor are loose Spindle and/or Quill are loose Head bolts are loose Check This 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 Swap the motor in question with a known good motor.
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.
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.
Spindle will not run because 110 V power is not reaching the spindle contactor 3.5.2.1 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. 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 3-Phase wires backwards Check This 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. 3.5.
M achines w ith spindle control drive Possible Cause Machine setup or tooling problem Upper spindle bearing is worn out. Verify nosepiece is tight on bottom of spindle. Spindle bearings are worn out The belt is not lined up with the grooves on the pulleys. Check This 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.
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. Problems With: Spindle bearings See Spindle Replacement Lubrication system Inadequate lubrication habits Gib locks - on X and Y axis X and Y gibs loose See Gib Adjustment - Section 5.2.
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 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.
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.
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.
Potential Problem: Ball nut not tightened to the yoke Yoke loose in the saddle Oil lines sheared Oil line blockage Ball screws not aligned properly Check By: • 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. • Inspection for any motion of the yoke or looseness in the Yoke mounting screws. • Visual inspection.
Possible problems Poor cable connections Pendant locks up No voltage to RSG port Low voltage to flash drive or slave board. Flash disk failure Floppy disk failure LCD backlight burns out Faulty E-stop switch Overlay failure (keys on pendant) Low voltage to pendant or current spikes Can lead to There are 4 cable connections (6 spindle control) to the left side of the pendant. Make sure all cables are properly fastened.
Do not work with the motors unless the power is disconnected from the machine. The motors are run by 110 VAC. There is possibility of death by electrocution! Rarely do both the X and 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.
Indications: • Problems moving just one axis, including hard turning in one or both directions. Servo Types: • X and Y servos are identical Objective: • Isolate the problem to the particular Servo Driver Steps: 1. Turn off and unplug the system. WARNING! Do not work with the Servo Driver unless the power is disconnected from the machine. There is possibility of death by electrocution! 2. Physically swap the servo module from the axis that is not working to one that is.
• • • • • • 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.
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.
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.
• • 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.
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. 69 Southwestern Industries, Inc.
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 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.
Figure 20 Schematic Diagram of Spindle Control Option 71 Southwestern Industries, Inc.
Figure 21 LEDs on Spindle Control Board 72 Southwestern Industries, Inc.
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.
(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.
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 Forw ard 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.
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”.
• 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.
4.9.3.2 Code 81: K eyboard Test This code is used to check if the keyboard is functioning correctly. It allows you to test each key on the pendant individually. When you press the keys, the corresponding box for that key will highlight on the screen. The pendant will also beep, indicating that the key is working correctly. If one of the keys does not work the pendant assembly may need to be replaced. If none of the keys are working chances are that the computer module will need to be replaced. 4.9.3.
4.9.4.1 Code 66: Default M etric 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.
5.0 Procedures for Replacements & Maintenance 5.1 Replacements 5.1.1 Servo Motor Replacement WARNING! Do not work with the Servo Motors unless the power is disconnected from the machine. The servomotors are run by 110 VAC. There is possibility of death by electrocution! 1. Turn off power to the machine. 2. Each motor is mounted by the use of (4) ¼ - 20 screws. Be careful not to over tighten these bolts and strip the threads. 5.1.
Figure 22 Part # 20201 5.1.3 Computer Module and LCD/Enclosure Replacement Description X, Y or Z Servo Driver 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.
Figure 23 Computer Module & LCD/Enclosure Replacement 82 Southwestern Industries, Inc.
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.
Figure 24 Flask Disk Replacement Figure 24 Flash Disk Replacement Flash Disk Parts List Item 1 2 3 P/N 24008-1 24030-1 25078 25078-1 Description PENDANT WITHOUT COMPUTER MODULE COMPUTER MODULE FLASH DISK (used on Revision D or later pendant) FLASH DISK (used on Revision C or earlier pendant) 84 Southwestern Industries, Inc.
5.1.5 Cable Routing on Machine 5.1.6 TRAK Sensor 5.1.6.1 R eplacing the M 5 Base 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.
Figure 25 M5 Base Mounting 86 Southwestern Industries, Inc.
5.1.6.2 R eplacing the TR AK 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.
Figure 27 K Mill Sensor Assembly 88 Southwestern Industries, Inc.
K Mill Sensor Assembly Parts List Item 1 2 3 4 5 6 7 8 9 10 11 P/N M250C M5 LDCEL-C M5 HDWR 16023-1 21511 14600 13384-4 15346 16023-2 13777-1 DESCRIPTION SENSOR - ALL TRAK PRODUCTS M-5 BASE LOADCELL - M250C HARDWARE - M5 BASE BRACKET-SENSOR X-AXIS (K2) EXTENSION BAR-RUN Y-AXIS BRACKET-SENSOR Y-AXIS (K2) CHIP SCRAPER-M250C BRACKET-SENSOR X-AXIS (K3 & K4) BRACKET UNIVERSAL BR17-RY MODIFIED (K3 & K4) i01117 5.1.7 Glass Scale Replacement 5.1.7.1 R em ove the X, Y or Z Glass Scale 1.
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.
Part # 22800-4 20586 Description Z Glass Scale Bracket Assembly Figure 28 K Mill Z-Axis Glass Scale Assembly Item 1 2 3 4 5 6 7 8 9 P/N 20550 20551 20548 20549 10-32X3/4 25B 10-32X1 1/4 25B 15759 1/16X1/2 81B 1/4-28X3/8 25B Description ARM- Z-AXIS MOUNTING PLATE MOUNTING PLATE-Z-AXIS GLASS SCALE ADAPTER-Z-AXIS GLASS SCALE ADAPTER PLATE- Z-AXIS GLASS SCALE SCREW-SHCS-STL-BO SCREW-SHCS-STL-BO WASHER-1/4 HARD BLK OX 1/8 THK SPRING PIN SCREW-SHCS-STL-BO i00891 Qty 1 1 1 1 4 3 1 1 1 91 Southwestern Indust
Figure 29 Glass Scale Alignment Part # 22800-35 22800-13 22800-16 QTY 4 4 4 2 2 2 4 2 1 2 1 1 PART NUMBER 91120A130 91166A230 1/4-20x1.00 25B 1/4 72Z 1/4 71Z 1/4x1.00-79Z 1/4 73Z 1/4-20x2.00 25B 20904 20545 20546-1 20544 DESCRIPTION WASHER - EXTERNAL SERRATED LOCK WASHER - FLAT M4 70B SCREW-SHCS-STL-BO WASHER-SPHERICAL (1 SET) WASHER-USS FLAT-STL-BO WASHER-FENDER 1/4" x1.00 O.D.
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.
Figure 30 Power Drawbar Assembly For item 4, see section 2.12 for a breakdown of parts. Item 1 2 3 4 5 6 7 8 9 10 11 12 P/N 22581-1 22605 20893 22380-1 or -2 23888 22581-2 22581-4 13 TR220 22641-NMTB 22641-CAT Title AIR GUN ASSY ONLY- TORQUE RITE DRAWBAR-R8 SPINDLE SPACER - DRAWBAR - R8 SPINDLE AIR REGULATOR ASSY (-2 with solenoid) SPACER - DRAWBAR - 40 TAPER SPINDLE SWITCH - CONTROL HEAD - TORQUE RITE NOSEPIECE FOR SPINDLE (40 taper heads only) 1/4" NPT AIR FITTING 90° 3/8 O.D. TUBING 132" LG. 3/8 O.
5.1.9 Ball Screw Replacement, X-Axis (Table) CAUTION! Never screw a ball screw partially or totally out of its nut. They cannot be reassembled. 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.
Figure 31 X-Axis Drive Assembly 96 Southwestern Industries, Inc.
X-Axis Drive Assembly Parts List Item 1 2 4 5 6 8 9 10 11 12 13 14 15 16 17 19 20 22 23 41 42 43 44 45 46 47 48 49 51 52 53 54 55 56 62 63 P/N 15621 25729 15624 15622 15616 15612 15885 15638 15626 16983-1 16452 16350 98481A090 14772 22008 400-5M-15 23930 14772-2 14772-5 8-32X3/8 25B 5/16-18X1 25B 3/8-16X2 1/2 25B M8-1.25X65 25B M10-1.
5.1.10 Ball Screw Replacement, Y-Axis (Saddle) CAUTION! Never screw a ball screw partially or totally out of its nut. They cannot be reassembled. 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.
Figure 32 - Y-Axis Drive Assembly 99 Southwestern Industries, Inc.
Y-Axis Drive Assembly Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 31 P/N 15626 23930 15885 15980 16452 20623 16983-1 16350 890-5M-15 16533 20621 15627-2 15836 15614 15616 1/2 71Z 1/2 75Z 1/2-20 51Z 10-32X1 25B M10-1.
40 25729 5.1.11 HANDLE REPLACEMENT KIT 1 Air Solenoid Replacement – Auxiliary Function Machines Only 1. Unhook the air from the machine. 2. Unplug the power cable that connects to the right side of the air regulator bracket. 3. Remove the 2 screws that hold the connector to the bracket. 4. Undo the airline that runs from the oiler to the power drawbar if that option is installed on the machine. 5. Remove the 2 screws on the left side of the bracket that holds the air manifold to the Ushaped bracket.
5.1.13 Feed Trip Adjustment (not applicable to 3 axis controls) If the feed trip is adjusted too light it will inadvertently trip when drilling. If too heavy, it will not trip accurately and stress the mechanism. The correct adjustment depends on the operation to be performed. To adjust: 1. Release the lock nut. 2. Engage the trip handle--move it left. 3. Adjust the micrometer nut against the quill stop knob. 4. Slowly turn the adjusting screw until the handle trips. 5. Tighten the lock nut. 6.
1. Move the quill to its top position and lock it in place. 2. Remove the quill handle, hub (by removing Screw A) and key. 3. Remove Screws B and allow the spring housing to unwind. 4. Remove the spring. It is held by a pin on the shaft and slot in the housing. 5. Replace the spring. Rotate the housing clockwise until the spring catches the shaft pin. 6. Rotate (wind up) the housing 1 1/2 turns, replace Screws B, key hub, Screw A, and handle. 5.1.15 Spindle Motor Removal and Replacement 1.
5.1.15.1 Spindle M otor Rem oval and R eplacem ent for m achine w ith the Spindle Control option 1. Disconnect the power to the motor. It is recommended that the power disconnect be made from the shop feeder box. 2. Disconnect the electrical connection in the conduit box attached to the motor. 3. Remove the three bolts that hold the motor pulley cover in place to gain access to the belt. 4. Remove the four bolts that mount the motor to the top head housing and slide motor forward and remove belt.
Figure 37 i00156 5.1.16.1 Drive Belt Replacem ent for m achine w ith the Spindle Control option 1. Remove the draw bar and its bushing (remove power drawbar if present). 2. Remove the three Screws A and use M6 x 35mm screws in the adjacent tapped holes to remove the Bearing Cap (see Figure 36). 3. Follow instructions for spindle motor removal and remove motor so top head housing can be removed with ease. 4. Remove the six screws “C” that hold the belt housing to the subplate. 5.
5.1.18 Brake Shoe Replacement 1. Remove the motor, drive belt and complete Steps 1-5 of the timing belt replacement procedure. 2. Remove the two M6 cap screws from the bottom of the belt housing base. 3. Separate the belt housing base from the lower or stationary vari-disc pulley. This is a slight press fit. 4. Remove the 2 springs. 5. Replace the brake shoes. 5.1.19 Spindle Replacement 1. Remove the draw bar and its bushing. 2. Lower the quill about 1 inch and lock. 3.
5.2 Maintenance 5.2.1 Gib Adjustments The objective of adjusting the gibs is to eliminate as much play in the table, saddle and ram sliding surfaces as possible without having the tightness of the gib interfere with their free movement and cause a decrease in the accuracy and/or performance of the machine due to excessive friction. 5.2.1.1 Table Gib Adjustm ent, X-Axis See Figure 39. 1. Clean all chips, dirt and excess oil from the table and saddle. 2. Center the saddle on the bed ways. 3.
5. Move the left end of the table back and forth and note the amount of movement on the dial indicator. Adjust the X-axis gib until the registered movement is .0010-.0015. • To adjust the gib for excessive clearance: Loosen the gib lock screw on the right end of the saddle. Estimate the amount of gib lock screw adjustment required, and tighten the gib lock screw on the left end of the saddle. Tighten the gib lock screw on the right end of the saddle to lock the give in place, and recheck.
Figure 41 Saddle Side Gib Adjustment 5. Attach a .0001 dial indicator with a magnetic base to the left front of the saddle. Place the indicator stylus on the edge of the large box way. 6. Move the left end of the table back and forth and note the amount of movement on the dial indicator. Adjust the Y-axis side gib until the registered movement is .0010-.0015. • To adjust the gib for excessive clearance: Loosen the gib lock screw on the back of the saddle.
4. Attach a .0001 dial indicator with a magnetic base to the left front of the saddle. Place the indicator stylus on the top surface of the box way. 5. Lift the end of the table up and note the amount of movement on the dial indicator. Adjust the Y-axis left bottom gib until the registered movement is .0010-.0015. 6. Move the table fully to the right. 7. Reposition the indicator to the right front of the saddle. 8. Lift the right end of the table up and note the amount of movement on the dial indicator.
5.2.2 Calibration & Backlash Constants Calibration and backlash constants were set as part of the installation and set-up of your system. They should be re-set when indicated in the Troubleshooting section or after the replacement of the Computer module, or any parts of the drive train. 5.2.2.1 X, Y, Z and Quill Calibration Calibration is used teach the machine a known distance. We typically calibrate our machines over a 150 mm distance. There is no limit to how far you can calibrate the machine. 1.
5.2.2.2 Backlash Com pensation Code 11: Set X or Y backlash constant Note: this procedure is on systems with TRAK Sensors or Glass Scales only. Go to setup mode, go to section “B” and press CODE 11. Refer to service code section for further explanation. Code 127: Set X or Y Backlash Constant Note: this procedure is only for systems without TRAK Sensors or Glass Scales. Every mechanical system has at least a little backlash or lost motion.
• Whatever number appears on the screen is the backlash value. • Enter this value into service code 128. • After entering this number redo the process. The DRO and indicator should now both read 0. CODE 128: Input Backlash Constant Code 128 allows you to enter the backlash values for each axis. It displays the value after it enters. This code is only used on machines with single feedback. 5.2.3 Head Rotational and Tramming The TRAK knee head is free to rotate up to 90 degrees to the right or left.
Figure 44 Tramming of Head Back to Front Adjustm ent Note: The head of the K4 milling machine is adjusted at the factory. With the dial indicator sweep the table from 6 o’clock to 12 o’clock. The head should be trammed within ± 0.0006” over 9 or 10” tram diameter. 9 or 10” is based on the table width. 5.2.3.3 Back to Front Adjustment – K2/K3 only 1. Make sure the table has been clean and the gibs are adjusted properly. 2. Mount a dial indicator in a tool holder and mount in the quill. 3.
Once the head has been trammed tighten the three bolts. Be careful not to move the head while tightening. Tighten the bolts a little at a time. (Note: the head must droop down rather than up because tool pressure will take care of the extra 0.0005”.) 5.2.4 Limit Switch Option See figures 64 and 65 in section 7. The limit switch option design was changed from when we first released the SX control. Early limit switch kits came with a single input limit switch as shown in the figure.
5.2.4.1 X-Ax is Lim it Sw itch-Stop Installation and Adjustm ent The limit switch-stops/cams for the X-axis are mounted to the front side of the table and can be adjusted along the length of the T slot. Each limit switch-stop must be set to a specific distance from the end of the table in order to maximize travel and simultaneously prevent serious damage to the machine in the event of a crash. All limit switches are set at the factory for maximum travel. Procedure for Setting X Lim it Sw itch 1.
6.0 Retrofit Installation This section of the manual is intended to provide step-by-step instructions for installing a ProtoTRAK SMX 2 or 3-axis control on a vertical knee milling machine. Within Sections 6, 7 and 8 it may refer to other sections of the manual for certain procedures or figures. 6.1 Installation Tools and Hardware The following section lists the required tools and hardware for installing a ProtoTRAK SM control.
6.
7.0 Installation Procedures 7.1 X and Y Ball Screw Installation 7.1.1 Removing the Table and Leadscrews Note: Before removing any of the assemblies as directed below, crank the table all the way to the right or left in order to be able to position the lift table next to the machine. 1. Remove the left and right bearing assemblies. Save the parts removed from the right side for use in installing the X-Axis ball screw.
Figure 47 Y Leadscrew Assembly 5. Remove the X and Y leadscrews. Note: to remove a leadscrew, remove the nut retaining screw and slide the brass acme nut and the leadscrew out of the yoke together. Figure 48 Leadscrew/Yoke Assembly 120 Southwestern Industries, Inc.
6. Remove the yoke from the saddle. Disconnect the oil lines from the yoke. If the yoke is to be re-used, it will be necessary to remove the brass nut key and pins. If the kit came with a yoke, the original yoke may be discarded. 7. Clean the X and Y-axis gibs, oil grooves and slideways thoroughly. Also remove the sliding covers and clean them. Inspect the operation of the oiling system.
Figure 50 Ball Screw/Yoke Assembly 9. In the ballnut flange there are two tapped 10-32 holes. One for the provided elbow oil fitting, and one for a 10-32 setscrew. For the X ball screw put the elbow oil fitting in the hole on the radius of the flange, and the setscrew in the hole on the flat. The function of the setscrew is only to prevent oil from flowing out of the ballnut. Screw it as far as possible being careful not to contact and deform the nylon wiper. 10.
Take measurement “A” on the left and right sides of the saddle casting. So that the measurements are comparable, measure from the OD of the thread of the ballscrew on both sides. Note: If the back of the saddle casting is not a suitable reference, it may be necessary to position a piece of round stock inside the back dovetail to be used as a reference point. Adjust the position of the yoke until the two measurements are within 0.005” end to end (maximum). CAUTION! The alignment of the ballscrew is crucial.
the yoke. These flats are there so that the yoke and ballnut will clear the bevel gear. Check that these clear now by pushing the saddle back. If the yoke provided in the kit does not clear the bevel gear, it will be necessary to remove enough material from it so that it will clear. Also check that the elbow fitting will clear the casting at the top front of the knee. If it interferes, it will be necessary to screw it down more, or grind away the casting to clear. 20.
Figure 52 - Y-Axis Drive Assembly 125 Southwestern Industries, Inc.
Y-Axis Drive Assembly Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 31 P/N 15626 23930 15885 15980 16452 20623 16983-1 16350 890-5M-15 16533 20621 15627-2 15836 15614 15616 1/2 71Z 1/2 75Z 1/2-20 51Z 10-32X1 25B M10-1.
21. Place the bearing housing on a flat surface and install the following as shown below: Figure 53 Bearing Housing 22. With the saddle all the way forward, install the assembly from the previous step on the ball screw with the bearing seal towards the machine. (Kit Variation: the Y-Axis bearing housing is designed to float to find its own center. For some machines, the hole in the knee is too large for the flange of the bearing housing to contact. Use the supplied backing plate shown below.
28. Hang the timing belt over the pulley now. 29. Install the top cover of the motor mounting bracket and check for clearance between the vernier dial and the cover. If the dial rubs, add shims to the vernier dial holder. Note: Sometimes it will be necessary to use the shims from the original X-axis hardware. 30. Tighten the 1/2 - 20 hex nut to 50 ft/lb. Move the saddle back and forth through full travel to inspect for smoothness. 7.1.
Figure 55 X-Axis Drive Assembly 129 Southwestern Industries, Inc.
X-Axis Drive Assembly Parts List Item 1 2 4 5 6 8 9 10 11 12 13 14 15 16 17 19 20 22 23 41 42 43 44 45 46 47 48 49 51 52 53 54 55 56 62 63 P/N 15621 25729 15624 15622 15616 15612 15885 15638 15626 16983-1 16452 16350 98481A090 14772 22008 400-5M-15 23930 14772-2 14772-5 8-32X3/8 25B 5/16-18X1 25B 3/8-16X2 1/2 25B M8-1.25X65 25B M10-1.
33. Install the left end assembly items as shown in Figure 55. 34. Slide the table so that the left end of the table is approximately over the left end of the ball screw and install the drive housing onto the table with the four 3/8 -16 x 2 1/2” socket head cap screws. 35. Slide the table to the right and secure the drive housing bracket to the bearing housing per Figure 55. 36. Install the rest of the items of Figure 55 and tighten 1/2-20 nut to 50 ft/lb. 37.
7.2 Motor/Servo Driver Installation 7.2.1 X-Axis Motor/Servo Driver Installation Parts required: • motor assembly 20296 • X drive assembly (opened in previous step) Figure 56 X Motor Mounting 132 Southwestern Industries, Inc.
1. Hang the belt on the pulley. 2. Install the front cover with the six 8-32 socket head screws. 3. Install the motor/servo driver assembly with the servo driver toward the rear of the machine. Install the motor so that there is very little play in the belt, a ¼ turn when twisting in the middle of the belt. 4. Install the back cover plate. 7.2.
7.3 Pendant Installation 7.3.1 Pendant Arm Installation Figure 57 Pendant Arm Assembly 134 Southwestern Industries, Inc.
Pendant Arm Assembly Parts List Item 2 3 4 5 6 7 9 10 11 16 17 18 19 22 27 28 29 30 31 P/N 15896 16797 16738 20695 16919 16920 1/4-20X3/4 40B 10-32X1 1/4 25B 1/2-13X6 24P 9712K93 3/16X3/4 80P 5/8 71P 1/4-20X3/4 25B 5/8-18 57Z 1/4-20X5/8 25B 23139 10-32X3/8 31B 21934 #4 x 3/8 34J Description PENDANT CUP RAM SUPPORT MACHINED PENDANT ARM MACHINED-M2/B5/SK2 PLUG-SPORT E-STOP PLATE-LEVELING CLAMP - CABLE SCREW-SOC SET-STL-BO-CUP SCREW-SHCS-STL-BO SCREW-HEX HD-STL-PLAIN WASHER - BELLEVILLE PIN-DOWEL-STL-PLAIN W
7.4 Cable Breakout Box Mounting The cable breakout box can come in 2 different configurations, one with auxiliary functions and one without. The physical size of the box is the same for both versions. The only difference is the 2 auxiliary ports found on the right side of the box. The auxiliary function box will have a 110 V outlet and a 4-pin amp connector to run an indexer. Mount the cable breakout box on the rear of the machine as shown in Figure 4 in Section 2.
WARNING The gap must be no larger than 0.060” between the readerhead and glass scale.
7.6 TRAK Sensor Installation - Optional See Section 5 of this manual for more sensor information. Parts required: • Sensor M250C • X Y bracket kit, one of the following: 15926 16191 15927 15929 16105 7.6.1 X and Y Axis Sensor 1. Install the brackets and run bar to the machine. The bracket should position the TRAK Sensor so that it is: • • • • As low as possible on the back of the table Does not run the gage wheel over the drain hole or any other existing holes in the table.
Figure 60 Y Bracket Installation The Run Bar should be: • • • • Installed with 2 screws - minimum size 1/4 - 20 Spaced from the knee appropriately to reach the sensor Free of twist Parallel to the saddle travel within 0.010” Note: Before installing the bracket, it is a good idea to assemble the bracket, mounting base and TRAK Sensor and hold the assembly against the planned mounting area. Kit Variation: Figures 60 and 61 show the bracket that comes with the ProtoTRAK SMX 2-1 and other kits.
Figure 61 Other X & Y Brackets Supplied with Kits 140 Southwestern Industries, Inc.
1. Install the M5 Base on the bracket. See Section 5.1.6.1, Figure 25. Parts required: M250C sensor and included hardware a) Put in pusher screws. These are the screws with the rounded ends. b) Position base and install puller screws and spherical washer sets. Use the pusher screws to square the M5 base to the running surface. c) Adjust the puller screws so that the raised bumps on the front of the base are parallel to the table. Note: The drawing shows a bubble level used for this adjustment.
3. Mount the scale to the table: • • • • Transfer the center hole first to use as a pivot point. Align the scale so that it is within 0.005” end to end. Transfer the holes on the ends and install the screws. Re-check the alignment. 4. From the readerhead on the scale, remove the nameplate, shield and wires so that the mounting holes are accessible. 5.
Figure 62 Readerhead Mounting Figure 63 Scale Mounting 143 Southwestern Industries, Inc.
7.8 Limit Switch Installation Drawing Figure 64 X & Y Limit Switch Assembly 144 Southwestern Industries, Inc.
Figure 65 X & Y Limit Drilling Chart 145 Southwestern Industries, Inc.
Limit Switch Installation Drawing Part List Item P/N 1 22108 2 24920 3 4 Title UseAs Qty CAM-LIMIT SWITCH EA 2 BALLS - STAINLESS STEEL EA 8 22547 CAM HOLDER-PT4-Y & Z AXIS EA 2 22113 NUT TEE- X AXIS EA 4 5 22438 SPACER-DPMV3-LIMIT SWITCH-RH EA 1 6 22437 CAM-LIMIT SWITCH-RH EA 1 7 22439 CAM-LIMIT SWITCH-LH EA 2 8 22440 SPACER-DPMV3-LIMIT SWITCH-LH EA 1 9 22551-1 LIMIT SWITCH ASSY-RIGHT EA 1 10 22551-2 LIMIT SWITCH ASSY-LEFT EA 1 11 22436-1 SHEET METAL -
8.0 Z Motor/Ball Screw Assembly Note: This section is for the installation of ProtoTRAK SMX 3 axis controls only. Note: Tram the head before beginning this procedure. 8.1 Installation of the Base Plate For the microfeed assembly, remove in this order: 1. 2. 3. 4. D, E F, G, H J K, L Figure 66 1. Remove the mill head assemblies indicated in Figure 66. Caution! After the quill stop knob is removed, take care that the quill is not allowed to fall out.
Figure 67 - Base Plate& Ball Screw Mounting 148 Southwestern Industries, Inc.
Note: Various components on Figure 67 have multiple balloons due to these parts varying on different machines. Note: The overall strategy is: The position locator (9), and the hex head screw (18) align the baseplate side to side. The leveling nuts (17) align the baseplate front to back. 2. Replace the machine’s head bolts with the Jackscrew nuts (items 12 through 16) on the right side. Replace the machine’s head bolts with the socket head couplers on the left side.
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 16213-13 16213-12 16213-175L 16213-12L 16213-175 16214 16216 98029A036 3/4-16 51Z 16364-3 16739 14932 15759 16355-3 16365 16212-175 1/4-20 56Z 16357-2 1/2-13X1 1/2 25B 1/4-20X1 3/4 25B 1/4-20X1 40B 1/4-20X3/4 25B 1/4-20X3/8 40B 3/8-16 50B 3/8 70P 3/8 73B 16210-1 M6-1.0X25 25B M10 73B 16740 M6-1.0X75 25B 3/8-24 x 2 ¼ 25B JACKSCREW NUT 1/2-13--1/2-13 JACKSCREW NUT 1/2-12--1/2-13 JACKSCREW NUT M12-1.
8.3 Installation of the Motor and Remaining Components See figure 67 & 68 1. Install the motor mounting bracket to the top of the base plate. 2. Install the motor to this bracket. Install the belt between the pulleys and tension it by sliding the motor away from the head. Tighten the 4 screws that hold the motor down. 3. Install the limit switch brackets that hold the upper and lower quill limit switches in place. Manually move the ballscrew up until you reach a hard stop.
Figure 68 Z-Axis Motor, Electronic Handwheel & Covers Assembly 152 Southwestern Industries, Inc.
Parts List Z-Axis Motor, Electronic Handwheel & Covers Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 P/N 24217 24221 24222 24240-1 24250 21774 710-5M-15 22585 24251 5/16-18X2 1/4 25B 10-32X3/8 31B 24231 9688K321 10-32X1/2 25B 10 70B Description BRACKET-SERVO MOTOR COVER - FRONT COVER LATERAL BASE PLATE BALLSCREW MODULE Z-AXIS ELECTRONIC HANDWHEEL-DPMV Z-AXIS BELT - TIMING CABLE ASSY-ADAPTOR (DB15 TO AMP) LIMIT SWITCH ASSY SCREW-SHCS-STL-BO SCREW-PH-PHIL-EXT SEMS-STL-BO BRACKET-LIMIT SWITCH PLUG-BLK SC
Figure 68-1 Ball Screw Module P/N 24250 154 Southwestern Industries, Inc.
Parts List Ball Screw Module Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 P/N Description Use As 24223 NUT CLAMP-Z AXIS EA 16263 PLUG BRASS EA 10-32X1/4 41B SCREW-SOC SET-STL-BO-FLAT EA 10-32X3/4 25B SCREW-SHCS-STL-BO EA 16268 FERRULE EA 24218 PULLEY-Z AXIS EA 6002-AV NILOS RING EA 20372 BEARING-ANGULAR CONTACT 7202 BECBP EA 24220 BEARING HOUSING-Z AXIS EA 1/2 73B WASHER-SPLIT LOCK-STL-BO EA 1/2-13X2 3/4 25B SCREW-SHCS-STL-BO EA 16226 RING BEARING EA 95571A837 WASHER- FLAT FELT 3/4 X 1/4 X 1/4 E
8.4 Lagun Z Axis Cutout The ProtoTRAK SMX3 installation for the Lagun FTV2 requires the following material to be removed from the box that holds the Lagun nameplate. Figure 69 Unfortunately, there is not a really good way to do this. Your choices are: • • • Have the head machined Use a hacksaw Drill a series of holes and use a wrench to break away pieces (our favorite) The good news is that the resulting mess will be completely covered with the Z-axis assembly. 156 Southwestern Industries, Inc.
9.0 Introduction to Self-Service The objective of this section of the manual is to allow the user of the ProtoTRAK Control to resolve the majority of potential service problems. This manual assumes that the user is not experienced with CNC troubleshooting and repairs. Special tools are not required for the procedures described in the manual. Please see Sections 3, 4 and 5 for in depth troubleshooting, diagnostics and procedure sections of the manual. 9.
Factory/Los Angeles or the location of our nearest factory representative or authorized distributor. 9.2.1 Disclaimers of Warranties • This warranty is expressly in lieu of any other warranties, express or implied, including any implied warranty of merchantability or fitness for a particular purpose, and of any other obligations or liability on the part of SWI (or any producing entity, if different). • Warranty repairs/exchanges do not cover incidental costs such as installation, labor, freight, etc.
9.3 Replacements 9.3.1 Exchange Program SWI keeps in stock the major subassemblies required to resolve service problems. With very few exceptions, the part needed to resolve any given service problem is on the shelf and ready to ship. A little bit of troubleshooting on your part means that we can get the right part to you fast. After replacing the failed unit with the replacement unit, simply put the failed unit in the same box that the replacement part came in and ship it back to us via UPS ground service.
10.0 Figures and Parts Lists Figure 100 Top Housing Assembly – 40 Taper 160 Southwestern Industries, Inc.
Parts List - Top Housing Assembly – 24688-1 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 P/N 20697-1 20697-2 20697-3 FVS12 20697-4 FVS64 FVS93 FVS117 FVS62 FVS126 FVS61 20697-5 FVS63 FVS135 DESCRIPTION GEAR HOUSING SUB-ASSY (4VK-A1) HI-LOW SHIFT CLUTCH SUB-ASSY (4VK-A2) HI-LOW SHIFT SUB-ASSY (4VK-A3) SOCKET CAP SCREW M6-P1.0x15L PULLY PINION SUB-ASSY (4VK-A4) BULL GEAR PINION BEARING CAP SCREW SOC HD M5-P0.
Figure 101 Gear Housing Sub-Assembly P/N: 20697-1 Item 1 2 3 P/N Description FVS82 GEAR HOUSING FV112 GUIDE SPRING FV113 SPRING GUIDE PIN i00594-K4 Qty 1 3 3 162 Southwestern Industries, Inc.
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 P/N FVS75 23943 FVS78 FVS79 FVS80 FVS73 FVS72 FVS74 FVS114 FVS115 FVS81 FVS76 20818 DESCRIPTION Qty BEARING SLIDING HOUSING 1 BALL BAEARING (2 REQ.) 6910ZZ 1 SET BEARING SPACER 1 BEARING SPACER 1 SNAP RING R-75 1 SPLINED GEAR HUB 1 KEY 8x7x10L 1 SPINDLE BULL GEAR 1 WASHER 1 EXTERNAL TOOTH WASHER Ø 50 1 LOCK WASHER Ø 50-18NC 1 RING 1 SPACER, BEARING 1 i00595-K4 Figure 102 Hi-Low Slip Clutch Sub-Assembly P/N: 20697-2 163 Southwestern Industries, Inc.
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 P/N FVS89 FVS87 FVS92 FVS91 FVS90 FVS94 FVS88 FVS93 FVS92-1 FVS92-2 FVS57 FVS116 24083 DESCRIPTION HI-LOW DETENT PLATE CLUTCH GEAR SHAFT HI-LOW PINION BLOCK SPRING HI-LOW DETENT PLUNGER HI-LOW SHAFT CRANK PIN Ø 319L SCREW SOC HD M5-P0.8x15L SET SCREW M5-P0.8x5L WASHER- FLAT Ø 11 BAKELITE BALL HANDLE WASHER- FLAT Ø 6 SHAFT HI/LOW SHAFT ASSY Qty 1 1 1 1 1 1 1 3 1 1 1 1 1 i00596-K4 Figure 103 Hi-Low Shift Sub-Assembly P/N: 20697-3 164 Southwestern Industries, Inc.
Item 1 2 3 4 5 6 P/N FVS67 FVS69 FVS66 AK118 FVS3 23954 DESCRIPTION BULL GEAR PINION COUNTER SHAFT KEY 5518L BULL GEAR PINION BALL BEARING (2 REQ.) 6203ZZ SOCKET SET SCREW M6-P1.0x6L BEARING SET (2) -BEARINGS 6203ZZ i00597-K4 Qty 1 1 1 2 1 1 Figure 104 Pulley Pinion Sub-Assembly P/N: 20697-4 165 Southwestern Industries, Inc.
Figure 105 Lower Vari-Disc Sub-Assembly P/N: 20697-5 (assembly not available, order parts separately) 166 Southwestern Industries, Inc.
Parts List - Lower Vari-Disc Sub-Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 P/N FVS50 FVS59 FVS58 FVS103 FVS51 FVS53 FVS52 FSV119 FVS47 FVS48 FVS17 FVS49 FVS122 FVS120 FVS46 AK048 FVS14 FVS45 FVS70 FVS100 FVS71 FVS97 FVS52-1 FVS56 FVS54 FVS55 FVS57-1 24055 FVS98 DESCRIPTION BELT HOUSING BASE BRAKE BLOCK TURNING BLOCK SHAFT RETAINING RING Ø 7 SET SCREW M6-P1.
Figure 106 Upper Vari-Disc Sub-Assembly P/N: 20697-6 168 Southwestern Industries, Inc.
Parts List - Upper Vari-Disc Sub-Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 P/N FVS44 FVS42 FVS43 FVS36 FVS38 FVS37 FVS3123 FVS39 FVS41 FVS40 FVS35 FVS34 FVS33 FVS97 FVS96 24599 24603 DESCRIPTION ADJUSTABLE-DRIVEN VARIDISC SPINDLE PULLEY BEARING HOUSING BALL BEARING 6013ZZ SPEED CHANGE PLATE PIVOT SLEEVE Ø 5 WASHER M5-P0.8x20L SOCKET CAP SCREW SPEED CHANGE PLATE PIVOT STUD WASHER Ø 8.2 ROLL PIN Ø3x15L CHAIN END STUD ADJUSTMENT NUT CHAIN FRONT SCREW M4-P0.
Item 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 P/N FVS16 FVS20 FVS22 FVS31 FVS21 FVS25 FVS40 FVS24 FVS32 FVS31-1 FVS30 FVS27 FVS18 FVS28 VS24-1 Title SPEED CHANGE HOUSING BEARING SELF LUBRICATING SPEED CHANGER GEAR SPEED CHANGE CHAIN DRUM WORM SPEED CHANGE SHAFT ROLL PIN Ø3x15L COPPER BUSHING CHAIN #3109.525 DOWEL PIN Ø3x25L SPEED CHANGE STUD SPEED CHANGE HANDWHEEL FULL DOG SOCKET SET SCREW M6-P1.
Item 1 2 3 4 5 6 7 8 9 10 P/N FVS110 FVS3-1 FVS2 FVS6 FVS5 FVS6-1 FVS8 FVS9 FVS10 24054 Title MOTOR 5 HP KEY 6x6x45L STATIONARY MOTOR VARIDISC BUSHING ADJUSTABLE MOTOR VARIDISC KEY 7x7x50L SPRING FOR VARIDISC MOTOR SHAFT ADJUSTABLE VARIDISC SPRING COLLAR SCREW- SOC HD CAP M8-P1.
Figure 109 Bottom Housing Assembly 172 Southwestern Industries, Inc.
Parts List - Bottom Housing Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 27 28 29 30 31 32 33 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 P/N FB192 FB31 FB33 FB94 FB29 FB28 FB41 FB27 20698-1 FB19 FB18 FB20 FB24 FB25-A FB23 FB68 20698-2 FB67 FB186 FB189 FB187 20698-3 FB178 FB177 FB176 FB171 FB89 FB88 FB88-1 20698-4 FB99 FB73 FB101 20698-5 FB109 FB106 FB118 FB120 FB121 FB123 FB103 FB117 FB104 FB105 FB119-1 FB107 FB113 Title QUILL HOUSING CLUSTER GEAR SHAFT BEVEL GEAR BEAR
51 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 FB115 FB108 FB42 20836-1 FB148 FB148-1A FB153 FB152 FB149 FB149-1 FB149-2 FB175 FB114 FB175-2A FB116 FB175-3 FB190 FB191 FB169 FB163 FB200 FB164 FB160 FB161 FB162 FB184 FB183 FB185 FB202 FB201 FB124 FB145 FB144 OIL-1 FB125 FB125-1 FB125-2 FB111 FB100 FB124-1 FB124-2 FB128 FVS109 FVS109-1 25041 25043 25044 20834 20835 COMPRESSION SPRING SET SCREW M6-P1.
101 102 103 104 105 106 107 108 24099 20833 20847 20846 20850 24095 20844 FB142 109 A071 TRIP HANDLE ASS'Y (INCLUDES PLASTIC BALL) FRU-K4-FEED TRIP ASSY QUILL MICRO NUT & SCREW ASSY QUILL LOCK HANDLE ASSY FEED HANDLE ASSY CLOCK SPRING ASSEMBLY (SPRING & COVER) QUILL LOCK SLEVE ASSY QUILL T BOLT ASSY (includes A070, A071, A069) (not shown on drawing) i20698 175 Southwestern Industries, Inc.
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 P/N FB17 FB5 FB6 FB8 FB4 FB9 FB11 FB10 FB3 FB2 FB1 FB16 FB36 FB36-1 FB15 FB13 FB14 FB37 FB40 Title WORM GEAR CRADLE WORM CRADLE BUSHING SETSCREW M6-PP1.0x10L FEED DRIVEWORM GEAR FEED WORM GEAR SHAFT SLEEVE FEED DRIVE WORM GEAR SHAFT KEY 3x3x20L WORM SHAFT KEY 3x3x8L FEED BEVEL PINION BEVEL PINION WASHER Ø 5 SOC.HD.SCREW M5-P0.8x10L FEED ENGAGE PIN FEED DRIVING GEAR KEY 3x3x8L FEED REVERSE BEVEL GEAR WASHER Ø 6 Ø 22 SOC HD SCREW M6-P1.
Item 1 2 3 4 5 6 7 8 9 10 P/N FB66 FB64 FB69-1 FB69 FB71 FB70 FB68 FB63 FB60 FB61 DESCRIPTION CLUSTER GEAR COVER CLUSTER GEAR SHIFT CRANK DIAL SHIFT KNOB SPRING STEEL BALL SET SCREW M6-P1.0x8L FEED GEAR SHIFT FORK FEED SHIFT ROD KP.SET SCREW M5-P0.8x6L i00604-K4 Qty 1 1 1 1 1 1 1 1 1 1 Figure 111 Quill Feed Selector Sub-Assembly P/N: 20698-2 177 Southwestern Industries, Inc.
Item 1 3 4 5 6 7 8 P/N FB166 K-B92 K-B93 K-B92-1 K-B94 K-B168 25707 Title QUILL PINION SHAFT OVERLOAD CLUTCH WORM GEAR OVERLOAD CLUTCH RING SCREW SOC HD CAP M4-P0.7x15L SNAP RING 95 DOWEL PIN Ø 14 SCREW PIN BUSHING KIT-PINION SHAFT-40 TAPER UseAs EA EA EA EA EA EA EA i20698-3 Figure 112 Quill Pinion Shaft Sub-Assembly P/N: 20698-3 178 Southwestern Industries, Inc.
Item 1 2 3 4 5 6 7 8 9 10 11 12 P/N FB81 FB81-1 FB80 FB79 FB78 FB76 FB75 FB97 FB98 FB96 FB74 FB77 Title OVERLOAD CLUTCH SLEEVE KEY 5x8x13L OVERLOAD CLUTCH SAFETY CLUTCH SPRING OVERLOAD CLUTCH LOCKNUT SOCKET SET SCREW M6-P1.0x8L CLUTCH RING OVERLOAD CLUTCH WASHER SNAP RING Ø 10 OVERLOAD CLUTCH TRIP LEVER CLUTCH RING PIN (2REQ.) BRASS PLUG i00606-K4 Qty 1 1 1 1 1 1 1 1 1 1 2 1 Figure 113 Overload Clutch Trip Sub-Assembly P/N: 20698-4 179 Southwestern Industries, Inc.
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 P/N FB57 FB44 FB47 FB43 FB59 FB49 FB48 FB62 FB50 FB50-1 FB55 FB52 FB51 Title FEED WORM SHAFT FEED WORM SHAFT BUSHING FEED WORM SHAFT THRUST WASHER WORM PIN Ø 3x12L FEED REVERSE BEVEL GEAR BUSHING KEY 3x3x15L FEED REVERSE CLUTCH PIN Ø 3x19L REVERSE CLUTCH ROD BUSHING FEED REVERSE BEVEL GEAR i00607-K4 Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 Figure 114 Feed Reverse Clutch Sub-Assembly P/N: 20698-5 180 Southwestern Industries, Inc.
Figure 115 Quill Spindle Sub-Assembly P/N: 20836-1 181 Southwestern Industries, Inc.
Parts List - Spindle Sub-Assembly Item 1 2 3 4 5 6 7 8 10 11 12 13 14 P/N FB127 FB133 FB134 20839 FB136 FB137 FB139 FB139-1 A112H FB143 FB140 FB141 20841 DESCRIPTION SPINDLE BT-40 NOSE-PIECE SPINDLE DIRT SHIELD BEARING (7010CP4) SET of 2 BEARING SPACER-LARGE BEARING SPACER-SMALL SPINDLE BEARING KNOCK NUT SET SCREW M8-P1.25x6L BEARING 6008ZZ LOCK RING Ø 40 SPINDLE FIXED NUT COLLET ALIGNMENT SCREW M8-P1.
Figure 116 Head Top Assembly with Spindle Control Option 183 Southwestern Industries, Inc.
Parts List - Head Top Assembly – K4SX with Spindle Control Option Item 1 2 3 4 5 6 8 10 11 12 13 14 17 P/N 24163 23965 23967 23597 24169 3/8 70P 3/8-16X1 1/4 24B 23968 23969-2 M4-0.7X16 25B M5-0.
Figure 117 Electrical Enclosure-Spindle Control Option PART # 24060-1 24060-2 DESCRIPTION SPINDLE CONTROL-3HP SPINDLE CONTROL-5HP i01128 185 Southwestern Industries, Inc.
Parts List – Electrical Enclosure – K4SX with Spindle Control Option Item 2 5 7 8 12 13 14 15 16 17 21 25 26 P/N 24063-3 22890-500-64 23433-04 25106-K4SX 22961 21820 21824-5 21824-8 22199 21827 22443 24182 24183 DESCRIPTION PCB ASSY-SMX-SPINDLE CONTROL RESISTOR-500W-64ohm (5 HP MACHINES) TERMINAL BLOCK 4 POLE AC DRIVE - 5 HP MINI VECTOR-220V RELAY-POWER - 115V DPST FUSE HOLDER FUSE-3AG-SLOW BLOW 5 AMP FUSE-3AG-SLOW BLOW 8 AMP RECEPTACLE- PANEL MOUNT NEMA STD 15A 125V SNAP RING 35X1.
Figure 118 Top Housing Assembly – R8 187 Southwestern Industries, Inc.
Parts List Head Top Assembly - 24692 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 P/N 20778-1 20778-2 20778-3 VS12 20778-4 VS64 VS93 VS117 VS62 VS126 VS61 20778-5 VS63 VS14-1 VS135 VS4 20778-6 VS1 VS137 VS13 VS13-1 VS15 VS129 20778-7 VS07 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20819 VS130 VS111 VS11 VS104 VS131 VS132 VS96 VS101 VS136 VS54 VS55 VS56 VS57 OIL-1 Title GEAR HOUSING SUB-ASSY (3VK-A1) HI-LOW SHIFT CLUTCH SUB-ASSY (3VK-A2) HI-LOW SHIFT SUB-ASSY (3VK-A3) SOCKET C
Item 1 2 3 P/N VS82 VS112 VS113 Title GEAR HOUSING GUIDE SPRING SPRING GUIDE PIN i00691-K2-K3 Qty 1 3 3 Figure 119 Gear Housing P/N: 20778-1 189 Southwestern Industries, Inc.
Figure 120 Hi-Low Shift Clutch Sub-Assembly P/N: 20778-2 190 Southwestern Industries, Inc.
Parts List – High-Low Shift Clutch Item 1 2 3 4 5 6 7 8 9 10 11 12 13 P/N VS75 23970 VS78 VS79 VS80 VS73 VS72 VS74 VS114 VS115 VS81 VS76 20817 DESCRIPTION BEARING SLIDING HOUSING BALL BEARING 6908ZZ BEARING SPACER BEARING SPACER SNAP RING R-65 SPLINED GEAR HUB KEY 8x7x10L SPINDLE BULL GEAR WASHER EXTERNAL TOOTH WASHER Ø 40 LOCK WASHER Ø 9/16-18NC RING SPACER-BEARING i00692-K2-K3 Qty 1 1 SET 1 1 1 1 1 1 1 1 1 1 1 191 Southwestern Industries, Inc.
Figure 121 Hi-Low Shift P/N: 20778-3 Item 1 2 3 4 5 7 8 9 10 12 13 P/N VS89 VS87 VS92 VS91 VS90 VS88 VS93 VS92-1 VS92-2 VS116 24083 DESCRIPTION HI-LOW DETENT PLATE CLUTCH GEAR SHAFT HI-LOW PINION BLOCK SPRING HI-LOW DETENT PLUNGER PIN Ø 3X19L SCREW M5-P0.8x15L SET SCREW M5-P0.8x5L WASHER- FLAT Ø 11 WASHER- FLAT Ø M5 SHAFT-HI/LOW SHAFT ASSY i00693-K2-K3 Qty 1 1 1 1 1 1 2 1 1 1 1 192 Southwestern Industries, Inc.
Item 1 2 3 4 5 6 P/N VS67 VS69 VS66 AK118 VS3 23954 DESCRIPTION BULL GEAR PINION COUNTER SHAFT KEY 5X5X18L BULL GEAR PINION BALL BEARING (2 REQ.) 6203ZZ SOCKET SET SCREW M6-P1.0x6L BEARING-DEEP GROOVE-SET (2)-6203ZZ i00694-K2-K3 Qty 1 1 1 2 1 1 Figure 122 Pulley Pinion P/N: 20778-4 193 Southwestern Industries, Inc.
Figure 123 Lower Vari-Disc Drive P/N: 20778-5 (assembly not available, order parts separately) 194 Southwestern Industries, Inc.
Parts List – Lower Vari-Disc Drive Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 P/N VS50 VS59 VS58 VS103 VS51 VS53 VS52 VS52-2 VS47 VS48 VS17 VS17-1 VS17-2 VS49 VS122 VS120 VS46 VS43-1 VS14 VS45 VS70 VS100 VS71 VS97 VS50-1 VS50-2 24055 DESCRIPTION BELT HOUSING BASE BRAKE BLOCK TURNING BLOCK SHAFT RETAINING RING Ø 7 SET SCREW M6-1.0X6L BRAKE LOCK BUSHING BRAKE LOCK SHAFT BRAKE LOCK PIN DIA 3 X 5/8"L BRAKE SHOE BRAKE SHOE PIVOT SLEEVE SOCKET CAP SCREW M6-P1.
Figure 124 Upper Vari-Disc Drive Sub-Assy P/N: 20778-6 196 Southwestern Industries, Inc.
Parts List – Upper Vari-Disc Drive Sub-Assy Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 P/N VS42 VS43 VS44 VS36 VS38 VS37 VS123 VS39 VS41 VS40 VS35 VS34 VS33 VS7 FVS96 24564 24631 DESCRIPTION SPINDLE PULLEY BEARING HOUSING BALL BEARING 6210ZZ ADJUSTABLE-DRIVEN VARIDISC SPEED CHANGE PLATE PIVOT SLEEVE Ø 5 WASHER M5-P0.8x20L SCREW-SHCS M5-0.8X20L SPEED CHANGE PLATE PIVOT STUD WASHER Ø 8.2 ROLL PIN Ø3x15L ADJUSTMENT NUT CHAIN END STUD CHAIN FRONT SCREW M4-P0.
Item 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 P/N VS16 VS20 VS22 VS31 VS21 VS25 VS40 VS24 VS24-1 VS27 VS18 VS28 VS32 VS31-1 VS30 VS16-1 VS95 VS16-2 VS19 M5-0.8X14 40B M5-0.8X5 40B DESCRIPTION SPEED CHANGE HOUSING BEARING SELF LUBRICATING SPEED CHANGER GEAR SPEED CHANGE CHAIN DRUM WORM SPEED CHANGE SHAFT ROLL PIN Ø3x15L COPPER BUSHING WASHER-WAVE SPEED CHANGE HANDWHEEL FULL DOG SOCKET SET SCREW M6-P1.0x10L HANDLE 3/8-16NC CHAIN #310X9.
Figure 126 Spindle Motor P/N: 20819 Item 1 2 3 4 5 6 7 8 9 10 P/N VS110 VS3-1 VS2 VS6 VS5 VS6-1 VS8 VS9 VS10 23953 DESCRIPTION MOTOR 3 HP KEY 6x6x45L STATIONARY MOTOR VARIDISC BUSHING ADJUSTABLE MOTOR VARIDISC KEY 7x7x50L SPRING FOR VARIDISC MOTOR SHAFT ADJUSTABLE VARIDISC SPRING COLLAR SCREW- SOC HD CAP M8-P1.
Figure 127 Lower Head Assembly 200 Southwestern Industries, Inc.
Parts List – Lower Head Assembly Item 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 P/N K-B125-2 K-B113 K-B117 K-B103 K-B108 K-B119-1 K-B103-1 K-B107 K-B106 20779-4 K-B73 K-B101 K-B99 20779-2 K-B67 K-B29 K-B27 K-B28 K-B94 K-B32 K-B33 K-B31 20779-1 K-B18 K-B19 K-B25 K-B20 K-B21 K-B22 K-B23 K-B186 K-B128 K-B189-1 K-B42 K-B187 K-B189 K-B171 K-B178 K-B177 K-B169 K-B170 K-B175-3 K-B175-2 K-B175-1 K-B176 K-B175 Title HANDWHEEL HA
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 K-B172 20836 VS109 VS109-1 K-B191 K-B190 K-B148 K-B148-1 K-B153 KB-201 K-B149 KB-202 K-B164 K-B160 K-B124-2 K-B124-1 K-B145 K-B124 K-B185 K-B144 K-B183 K-B161 K-B162 K-B123 K-B184 K-B121 K-B120 K-B158 K-B118 K-B159 KB-200 K-B163 20779-5 OIL-1 K-B109 K-B17-1 K-B88-1 K-B89 20779-3 K-B167 K-B27-1 K-B41 K-B192 K-B104 K-B105 K-B125-1 K-B125 K-B111 K-B100 PINION SHAF
98 99 100 101 102 103 104 105 106 107 108 109 110 25042 25043 25044 20835 20834 24052 20832 20847 24051 20849 20843 K-B142 K-B155 SCALE-HEAD ROTATION-R8 POINTER SCALE DRIVE SCREW-SCALE HANDWHEEL ASSY FEED REVERSE KNOB ASSY TRIP HANDLE ASSEMBLY (INCLUDES PLASTIC BALL) FEED TRIP ASSY QUILL MICRO NUT & SCREW ASSY CLOCK SPRING ASSEMBLY (SPRING & COVER) FEED HANDLE ASSY (QUILL HANDLE) QUILL LOCK SLEVE ASSY QUILL T BOLT ASSY (not shown on drawing) 1 1 4 1 1 1 1 1 1 1 1 1 1 i20779 203 Southwestern Industries,
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 P/N K-B17 K-B07 K-B08 K-B05 K-B04 K-B09 K-B11 K-B10 K-B03 K-B02 K-B01 K-B36 K-B36-1 K-B15 K-B13 K-B14 K-B37 K-B40 K-B16 K-B06 Title WORM GEAR CRADLE WORM GEAR SPACER FEED DRIVEWORM GEAR WORM CRADLE BUSHING FEED WORM GEAR SHAFT SLEEVE FEED DRIVE WORM GEAR SHAFT KEY 3x3x25L WORM SHAFT KEY 3x3x8L FEED BEVEL PINION BEVEL PINION WASHER Ø 5 SOC.HD.SCREW M5-P0.8x10L FEED DRIVING GEAR KEY 3x3x8L FEED REVERSE BEVEL GEAR WASHER Ø 6, 22 OD SOC HD SCREW M6-P1.
Item 1 2 3 4 5 6 7 8 9 10 P/N K-B66 K-B64 K-B70 K-B69 K-B68 K-B72 K-B71 K-B63 K-B65 K-B61 Title CLUSTER GEAR COVER CLUSTER GEAR SHAFT CRANK SHIFT CRANK SPRING Ø 3 x 20L GEAR SHIFT PLUNGER SHIFT KNOB-5/16-18NC ROLL PIN Ø 3 x 20L FEED GEAR SHIFT FORK SHAFT CAP SET SCREW M5-P0.8x5L i00701-K2-K3 Qty 1 1 1 1 1 1 1 1 1 1 Figure 129 Quill Feed Selector P/N: 20779-2 205 Southwestern Industries, Inc.
Item 1 2 3 4 5 6 7 8 P/N K-B166 25706 K-B91 K-B92 K-B93 K-B92-1 K-B94 K-B168 Title UseAs EA EA EA EA EA EA EA EA QUILL PINION SHAFT BUSHING KIT-PINION SHAFT-R8 WASHER OVERLOAD CLUTCH WORM GEAR OVERLOAD CLUTCH RING SCREW SOC HD CAP M4-P0.7x15L SNAP RING 95 DOWEL PIN Ø 14 SCREW PIN i20779-3 Figure 130 Quill Pinion Shaft P/N: 20779-3 206 Southwestern Industries, Inc.
Item 1 2 3 4 5 6 7 8 9 10 11 12 P/N K-B81 K-B81-1 K-B80 K-B79 K-B78 K-B76 K-B75 K-B97 K-B98 K-B96 K-B74 K-B77 Title OVERLOAD CLUTCH SLEEVE KEY 5x8x13L OVERLOAD CLUTCH SAFETY CLUTCH SPRING OVERLOAD CLUTCH LOCKNUT SOCKET SET SCREW M6-P1.0x8L CLUTCH RING OVERLOAD CLUTCH WASHER SNAP RING Ø 10 OVERLOAD CLUTCH TRIP LEVER CLUTCH RING PIN (2REQ.) BRASS PLUG i00703-K2-K3 Qty 1 1 1 1 1 1 1 1 1 1 2 1 Figure 131 Overload Clutch Trip P/N: 20779-4 207 Southwestern Industries, Inc.
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 P/N K-B57 K-B47 K-B44 K-B43 K-B59 K-B49 K-B48 K-B62 K-B50 K-B56 K-B51 K-B52 K-B55 Title FEED WORM SHAFT FEED WORM SHAFT THRUST WASHER FEED WORM SHAFT BUSHING WORM PIN Ø 3x12L FEED REVERSE BEVEL GEAR BUSHING KEY 3x3x15L FEED REVERSE CLUTCH PIN Ø 3x19L FEED REVERSE BEVEL GEAR BUSHING REVERSE CLUTCH ROD i00704-K2-K3 Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 Figure 132 Feed Reverse Clutch P/N: 20779-5 208 Southwestern Industries, Inc.
Item 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 P/N K-B127 K-B134 20838 K-B136 K-B137 K-B133 K-B132 K-B131 K-B130 K-B129 K-B150-1 K-B151 K-B150-2 K-B139 20840 DESCRIPTION SPINDLE R8 SPINDLE DIRT SHIELD BEARING 7207CTYNSULP4 BEARING SPACER-SMALL BEARING SPACER-LARGE NOSE-PIECE SLEEVE BEARING-6206ZZ BEARING LOCKWASHERØ 30 SPINDLE BEARING LOCK NUT- Ø30-20N STRAIGHT LOWER CLAMP FELT OIL STRAINER STRAINER UPPER CLAMP SCREW-PH-HD-M5-0.
Figure 134 K2/K3 Base Machine P/N 20785 Parts List – K2 & K3 Base Machine (reference only) 210 Southwestern Industries, Inc.
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 P/N C01 C02 C04 C06 C07 C08 C09 C10 C13 C14 C15 C16 C17 C18 C19 C23 C31 C32 C33 C37 C38 C39 C40 C41 C42 26 C43-K2 C43-K3 C44 C46 C47 C48 C49-K2 C49-K3 27 28 29 30 31 32 33 34 35 36 C50 C51 C53-1 C52 C54-1 37 C55-K2 C55-K3 C56 C57-1 C58-1 C59 C60 C61 C62 C64 38 39 40 41 42 43 44 45 Title QUILL HOUSING ADJ.GEAR RAM ADAPTER NUT VERTICAL ADJUSTING WORM WORM THRUST WASHER(2REQ.
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 C65 C69 C71 C72 C73 C74 C75 C76 C77 C79 C80 C81 C82 C83 C84 C85 C86 C87 C88 C89 C90 C91 C92 C93 C94 C95 C96 C97 C98 C99 C102 C103 C104 C105 C118 C119 C120 C121 C122 C123 C124 C125 C126 C127 C128 C129 C130 C131-K2 C131-K3 KNEE LOCK SHAFT ASSEMBLY KNEE LOCK PLUNGER KNEE BINDER PLUG(PLASTIC) DOG POINT SET SCREW SET SCREW JAM NUT KEY WASHER BEVEL GEAR SEALED BALL BEAR
94 95 96 97 98 99 100 101 20851 20852 20853 20854 20873 FC112 FC113 FC114 STOP PIECE T-BOLT ASSY TABLE LOCK HANDLE KNEE LOCK HANDLE & SHAFT KNEE CRANK HANDLE ASSY CHIP GUARD SET K2/K3 LEVELING SCREW LEVELING NUT LEVELING PAD i20785 213 Southwestern Industries, Inc.
Figure 135 K4 Base Machine P/N 26900 214 Southwestern Industries, Inc.
Parts List - K4 Base Machine Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 P/N FC1 FC10 FC11 FC23 FC24 FC25 FC26 FC27 FC28 FC29 FC31 FC32 FC33 FC37 FC39 FC42 FC43 FC44 FC45 FC46 FC48 FC49 FC51 FC52 FC53 FC54 FC55 FC56 FC57 FC58 FC59 FC60 FC61 FC62 FC65 FC66 FC67 FC68 FC69 FC70 FC71 FC72 FC73 FC74 FC75 FC76 FC77 Title QUILL HOUSING GEAR RAM LIFTING EYE BOLT TABLE 50" SADDLE BOTTOM GIB GIB BLOCK GIB GIB BLOCK SET SCRE
48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 FC78 FC79 FC80 FC82 FC83 FC85 FC86 FC87 FC88 FC89 FC90 FC91 FC92 FC93 FC94 FC95 FC96 FC97 FC98 FC102 FC103 FC104 FC105 FC112 FC113 FC114 FC115 FC118 FC119 FC120 FC121 FC122 FC123 FC124 FC125 FC126 FC127 FC128 FC129 FC130 FC131 20855 20867 20868 20869 SCREW SEALED BALL BEARING BEARING RETAINER RING ELEVATING SCREW ASSY HANDLE GEARSHAFT CLUTCH INSERT DIAL LOCK NUT DIAL WITH
Figure 136 Transformer Option 220V &440V P/N: 23470-220 or 23470-440 217 Southwestern Industries, Inc.
Figure 137 Transformer Options 220V & 440V P/N 23470-220 or 23470-440 218 Southwestern Industries, Inc.
Transformer Options Part List P/N 23470-220 & 23470-440 Item 3 5 5 7 12 12 13 13 - P/N 23430-M0D 23440-220 23440-440 23454-3 24927-10 24927-5 24910-15 24910-10 Title SAFETY SWITCH - 30A - 600VAC - MODIFIED ENCLOSURE ASSY-TRANSFORMER OPTION-220V ENCLOSURE ASSY-TRANSFORMER OPTION-440V CABLE ASSY-SAFETY SWITCH/XFMR MODULE-DPM LABEL-FUSE CHART REPLACEMENT-220V LABEL-FUSE CHART REPLACEMENT-440V FUSE-TIME DELAY-15 AMPS-220V FUSE-TIME DELAY-10 AMPS-440V i23470-220 219 Southwestern Industries, Inc.
Southwestern Industries, Inc TRAK Warranty Policy Warranty TRAK products are warranted to the original purchaser to be free from defects in work-manship and materials for the following periods: Product New TRAK Any EXCHANGE Unit Warranty Period Materials Factory Labor 1 Year 1 Year 90 Days 90 Days The warranty period starts on the date of the invoice to the original purchaser from Southwestern Industries, Inc. (SWI) or their authorized distributor.
