Home

TRAK & SPORT BED MILLS (Service Manual for Non

Contents

1. Item P N Title Qty 1 FB192 QUILL HOUSING 1 2 FB31 CLUSTER GEAR SHAFT 1 3 FB33 BEVEL GEAR BEARING 1 4 FB94 SNAP RING 95 DOWEL PIN 14 1 5 FB29 CLUSTER GEAR KEY 3x3x45L 1 6 FB28 CLUSTER GEARS ASSEMBLY 1 7 FB41 NEEDLE BEARING KO BA66Z 1 8 FB27 CLUSTER GEAR SHAFT UPPER BEARING 1 9 20698 1 WORM GEAR CRADLE SUB ASSY 4VK H1 1 10 FB19 SHIFT SLEEVE 1 11 FB18 WORM GEAR CRADLE THROW OUT 1 12 FB20 CAP SCREW M5 P0 8x12L 1 13 FB24 STEEL BALL 1 14 FB25 A SPRING 1 15 FB23 SHIFT CRANK 1 16 FB68 SET SCREW M6 P1 0x8L 1 17 20698 2 QUILL FEED SELECTOR SUB ASSY 4VK H2 1 18 FB67 CAP SCREW M6 P1 0x18L 4 19 FB186 WORM GEAR 1 20 FB189 ADJ WORM SHAFT 1 21 FB187 KEY 4x4x18L 1 22 20698 3 SUB ASSY QUILL PINION SHAFT 40 TAPER 1 23 FB178 CLOCK SPRING CLOCK SPRING ASSY 1 24 FB177 SPRING COVER 1 26 FB176 PINION SHAFT HUB SLEEVE 1 27 FB171 KEY 3x3x20L 1 28 FB89 OVERLOAD CLUTCH LEVER SPRING PLUNGER 1 29 FB88 COMPRESSION SPRING 1 30 FB88 1 INTERNAL COMPRESSION SPRING 1 31 20698 4 OVERLOAD CLUTCH TRIP SUB ASSY 4VK H4 1 32 FB99 CLUTCH ARM COVER 1 33 FB73 CAP SCREW M5 P0 8x40L 2 35 FB101 CHEM BLACKED LOCKNUT M6 P1 0 1 36 20698 5 FEED REVERSE CLUTCH SUB ASSY 4VK H5 1 37 FB109 KEY 3x3x20L 1 38 FB106 FEED TRIP BRACKET 0 39 FB118 CAM ROD SLEEVE ASSY 1 40 FB120 COMPRESSION SPRING 1 41 FB121 TRIP PLUNGER 1 42 FB123 TRIP PLUNGER BUSHING 1 43
2. 2 10 VS48 BRAKESHOEPIVOTSLEEVE 1 11 VS17 SOCKET CAP SCREW M6 P1 0x35L 1 39 VS172 NUT M6 P1 0 1 1 144 VS49 BRAKESPRING CT SCREW PAN HEAD PHILIP 5 40NC SOCKET CAP SCREW M5 0 8x12L eee 100695 K2 K3 213 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual L Upper Vari Disc Drive Sub Assy Figure 124 P N 20778 6 214 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Upper Vari Disc Drive Sub Assy Item P N DESCRIPTION Qty 1 VS42 SPINDLE PULLEY BEARING HOUSING VS43 JBEARING DEEP GROVE 6210ZZ VS44 JADJUSTABLE DRIVEN VARIDISC VS36 JSPEED CHANGE PLATE VS37 WASHER M5 P0 8x20L VS123 SCREW SHCS M5 0 8X20L 2 3 4 5 VS38 SLEEVE Q 5 6 7 8 VS39 SPEED CHANGE PLATE PIVOT STUD 9 VS41 WASHER 8 2 10 VS40 JROLL PIN 3x15L 11 VS35 JADJUSTMENT NUT 12 VS34 CHAIN END STUD 13 VS33 CHAIN FRONT SCREW M4 P0 7x5L 14 VS7 RING 35 15 FVS96 JJAM NUT 3 8 16NC 16 24564 BEARING HOUSING ASSY N N IN 17 24631 VARI DISC ADJUSTABLE ASSY i20778 6 215 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Ma
3. Limit Switch failure Does the limit switch problem move to the other axis If it does then the switch is most likely the problem Try this If it stays with the original axis then it could be the Switch 2 limit switch cables on the cable cable breakout box breakout box 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 62 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual on the DRO zero the display and repeat the procedure If the measurement does not repeat you have a repeatability problem that must be resolved Test for accumulative error by moving the axis a number of times to see ifthe 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 Perform the following service codes and procedures where sensor glass scales are used e Code 304 Toggle X sensor glass scale on off SM only e Code 305 Toggle Y sensor glass scale on off SM only Possible Cause Check This Machine Too
4. 16806 M BALL SCREW ASSY Z AXIS 2205E 2RSITN9 7 M6 1 0X25 25B SCREW SHCS STL BO 10 11 M10 1 5X10 40B SCREW SOC SET STL BO CUP 1 1 1 1 1 1 1 1 1 31 MIO738 JWASHER SPLITLOCK STL BO EA 8 143 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 5 27 Z Axis Drive Assembly DPMS3 DPMS5 144 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Z Axis Drive Assembly Parts List DPMS3 DPMS5 emp Besenp en 6 M10 L5X10 408 SCREW SOCSETSTLBO UP 8 M6738 WASHER SPLITLOCKSTLBO 9 M6 1 0x25 258 SCREW SHCS STLBO i00771 Z S 145 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 5 28 DPME2 Z Axis Drive Traing NI ca i 146 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Z Axis Drive Train Parts List DPME2 Item P N Description Oty 1 23662 BALL SCREW ASSY Z AXIS LM0010 1 2 23658 BRACKET LOWER ELEVATING BALL SCREW SW0008 1 3 2205E 2RS1TN9 BEARING SELF ALIGNMENT SKF 1 4 16774 COVER BEARING SW00007 1 5 6 7 16770 MODIFICATION OF RAM PING J
5. Apply a good grade of general purpose grease through the grease fittings on the back of the head and on the left side of the head This grease lubricates the Low range gear set and the feed change gears respectively Also lubricate vari disk on spindle motor by means of grease fitting on motor shaft Every Four Months DPMS5 X Handwheel Drive Mechanism Remove X handwheel drive cover and apply a general purpose grease to the drive gears See Section 5 Figure 5 17 for an illustration Every Six Months DPMS3 Remove lower cover under spindle motor and apply general purpose grease to the fitting on the spindle motor shaft You must set the RPM range on the head such that grease enters the vari disk cavity Apply two pumps of grease to adequately grease the vari disks In high gear set the RPM to between 975 and 1440 RPM In low gear set the RPM to between 115 and 165 RPM Note Due to the design of the vari disk keyway the motor shaft on the DPMS5 does not need to be greased 47 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 2 17 ProtoTRAK Euclid Block Procedure TRAK amp Sport Bed Mills 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 6 or T4 e Blank Size minimum dimensions 3 x 3 x 1 provided in tool box e T
6. Figure D 101 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual SIXV A HOSN3S UNOD EHE OA ILS SOHSMAHOSJ e 09 15 5095 1X2 mHd Hd M3HOS wixece9 8 TVAO O8 11S 13S JOS mquosl 04 115 5945 443435 992 fL LXO HL SVX HOSHIS HBAODTWLAWLASHS borze e SIXV X HJOVAS gosN3SSMdOdivid c SIXVX HOSNAS 13wOvua _ ___ Nd __ 2 a E im un c m 9 i 0 9 in 22 DA LQ 102 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service 8 Parts List Manual 5 1 7 Glass Scale Replacement 5 1 7 1 Remove the X Y or Z Glass Scale where applicable 1 2 3 4 Unplug the glass scale connector from the cable breakout box Unbolt the reader head of the glass scale from its mounting surface Unbolt the glass scale enclosure from the table on X or the mounting spar on Y 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 1 align the reader head on the new scale before removing it to fasten the old scale Once the head alignment bracket i
7. Parts List Lubrication X amp Y Axis DPMS3 Item P N Description Qty Wu lc e v j l 1 e rr EM PLUG M8 X 1 0 PG004 6 L014 siEEVEAMM B4 11 10 11012 TEE ADAPTER PKD4 1 i jus HOSE ER 12 L006 X DISTRIBUTOR DB10 1 pst OIL DISTRIBUTOR HM 1005 TUBING 4MM ALUM A4 WE OEDMENENET HANI EIA 100783 V3 PL 245 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Lubrication System X amp Y Axis DPMS DPMS5 Figure 141 100662 246 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Lubrication System X amp Y Axis DPM5 ww sermon imm XENI f mer kemm ma p pas poem sj 29 s OAPTER RIGHT ANGLES Parts List Lubrication Drawing A amp Y Axis DPMS5 PG004 PLUG MBX10 1 wr I a 108 2 346 BRACKET LUBE X AXIS BALL SCREW II 18 21737 BRACKET X amp Y AXIS LUBRICATION 1 19 PD408 ADAPTER 2 20 PH408 A ADAPTER RIGHTANGLE 13 22 CLAMP y 1 23 5 08 1010 SCREW PH PHIL STL BO 1 24 PH4 8 CONNECTO 1 100662 247 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Mai
8. 245 Cable Guard DPM Other Bed Parts Parts List TY PART NO DESCRIPTION _1 230 Vent Left Side _1 231 Vent Right Side _1 B232 Vent Left Front TRM d B233 Vent Right Front _2 B238 Coolant Screen 6 B239 Foot Pads 6 240 Footpad Bolt Nut _1 246 Vent Left Front DPM Other Table Saddle Parts Parts List OTY PART NO DESCRIPTION 2 260 Table Gib Lock Handle Plunger 1 B261 Saddle Gib Lock Handle amp Plunger ox B262 Table Gib _2 263 Saddle Bottom Gib d B264 Saddle Side Gib able Gi ustment Screw 2 B265 Table Gib Adjustment S _ 266 Saddle Gib Adjustment Screw _1 267 DPM Way Cover Back Bed DPM5 B267 1 _1 268 Way Cover Front Bed DPM5 B268 1 jed B269 Table Stop Dog _2 270 Table Adjustable Stops set B271 Saddle Gib Chip Guards amp Gaskets _1 B273 15955 Y TRAK Sensor Bracket amp Guard 16482 guard _1 274 16479 X TRAK Sensor Bracket Guard 16481 guard _1 277 Table Tray 1 278 Table Tray Rubber Pad Set B279 Chip Guard Plates Covering Y Ball Screw 253 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual TRAK A G E Control System Parts List QTY PART NO DESCRIPTION _1 20296 Motor Driver Assembly Y Axis 1 20276 Motor Driver Assembly X Axis _1 20328 Motor Driver Assembly Z Axis
9. TRM DPM DPM5 Sport Sport B5 DPMS3 DPMS5 Way covers DPME2 front 23676 and rear 23677 of saddle Way covers DPME2 bottom on column 23675 top on column 23675 Way covers TRM DPM SPORT B3 DPMS3 front B268 and rear B267 of saddle Way covers DPM5 SPORT B5 DPMS5 front B268 and rear B267 1 of saddle 8 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Way covers TRM DPM DPM5 Sport B3 Sport B5 DPMS3 DPMS5 bottom on column B202 top on column B201 In case of shortages contact the representative from whom you purchased the machine 2 4 Installation I nstructions amp Checklist Installer Use this checklist to assure a complete set up of the TRAK or SPORT BED MILL 2 Visually inspect the 220V 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 3 Clean the machine if needed and remove any remaining grease 4 Unlock the table saddle and ram gib locks 5 For DPME2 only use a 10 mm socket to turn the Z axis ball screw at the top of the column in order to lower the head until the counterweight is raised off the counterweight support rods 6 For TRM DPM DPM5 Sport B3 amp Sport B5 check to ensure that the Z axis upper way cover spacers a
10. 100159 Figure 5 43 Ram Side Gib Adjustment 5 2 2 Calibration amp Backlash Constants Sport B3 Sport B5 DPMS3 DPMS5 amp DPME2 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 170 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 2 2 1 Y Z Ram and Quill Calibration DPMS3 DPMS5 amp DPME2 Calibration is used to 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 Refer to Figure 5 44 1 If you have installed TRAK Sensors move each axis through its travel 4 6 times in order to allow the gage wheel to establish its track 2 Set up a gauge block or standard and indicate it parallel to the axis you are calibrating Note Put the display in Inch or mm to match your gage block Recommended gage blocks are e XandY 150mm or 6 e 75mm or 3 3 Seta 0 0001 indicator in the spindle and move it up to one side of the gage block or standard 4 Go to setup mode go to section B and press CODE 123 Select the axis you want to calibrate X Y or Z For the quill press the F1 key labeled QUILL 6 Follow the instructions on the sc
11. 14 1 21 K B32 BEVEL GEAR THRUST SPACER 1 22 K B33 BEVEL GEAR BEARING 1 23 K B31 CLUSTER GEAR SHAFT 6602BB 1 24 20779 1 WORM GEAR CRADLE SUB ASSY 3VK B1 1 25 K B18 WORM GEAR CRADLE THROW OUT 1 26 K B19 SHIFT SLEEVE 1 27 K B25 CAP SCREW 3REQ M5 P0 8x12L 3 28 K B20 GEAR SHIFT PLUNGER 1 29 K B21 COMPRESSION SPRING 1 30 K B22 ROLL PIN 3x20L 1 31 K B23 SHIFT CRANK 1 33 K B186 WORM GEAR 1 34 K B128 QUILL SKIRT 1 35 K B189 1 ADJ WORM SHAFT SET SCREW M6 P1 0x6L 1 36 K B42 BUSHING 2 37 K B187 KEY 4x4x18L 1 38 K B189 ADJ WORM SHAFT 1 39 K B171 KEY 3x3x20L 1 40 K B178 CLOCK SPRING CLOCK SPRING ASSY 1 41 K B177 SPRING COVER 1 42 K B169 RD HEAD SCREW 2REQ M5 P0 8x15L 2 43 K B170 ROLL PIN 1 44 K B175 3 SET SCREW M8 P1 25x6L 2 45 K B175 2 COMPRESSION SPRING 2 46 K B175 1 STEEL BALL 2 47 K B176 PINION SHAFT HUB SLEEVE 1 48 K B175 RACK FEED HANDLE HUB 1 219 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 49 K B172 PINION SHAFT HUB SEREW 1 50 20836 SPINDLE ASSY R8 0 51 VS109 DRAWBAR 7 16 20UNF 1 52 VS109 1 SPACER 1 53 K B191 BLACK PLASTIC BALL HANDLES sold as assy 20849 only 1 54 K B190 PINION SHAFT HUB HANDLE sold as assy 20849 only 1 55 K B148 QUILL LOCK SLEEVE 1 56 K B148 1 COMPRESSION SPRI
12. 2 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual O MODEL S N ELECTRICAL RATINGS Res L _ PHASE Hz SOUTH WESTERN INDUSTRIES 2615 HOMESTEAD PLACE RANCHO DOMINGUEZ CA 90220 FLA OF LARGEST MOTOR SHORT CIRCUIT INTERRUPT ELECTRICAL DRAWING O Ki pe AMPS AMPS CNC CONTROL ELECTRICAL RATINGS IF APPLICABLE 60 Hz MACHINE ONLY MADE IN XXXXXX VOLTS 8 AMPS 1 JPHASE o i01158 Power Requirements at 220 and 440 Volts 3 phase 60 HZ DPME2 DPM DPM5 Sport Sport B5 DPMS3 DPMS5 Overload Setting 85A 85 14A 85 14A 85A 14 220 V Overload Setting na 425A 425A 7A 425A 4 25A 7A 440 V FLA of Largest Motor 11A 85A 85A 14A 85A 14A 85A 14A at 220 V FLA of Largest Motor n a 425A 425A 7 425A 4 25A 7A at 440 V FLA of Machine at 85A 85 14A 85 14A 85A 14A 220 V FLA of Machine at na 425A 425A 7A 425A 4 25A TA 440 V TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 3 Southwestern Industries Inc 10 11 12 13 14 15 Safety Precautions Do not operate the machine before this TRAK Bed and Sport Mills Installation Maintenance Service and Parts List Manual and also your model s corresponding
13. Co EA FB139 PINDLE BEARING KNOCK NUT 100608 K4 204 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 118 Top Housing Assembly R8 100690 K2 K3 205 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Head Top Assembly 24692 item PN Qty 6 VSe4 BULLGEARPINIONBEARINGCAP 8 5117 KEY5x525L 9 VS62 TIMINGBELTPULLEY 1 1 15 VS135 KEY8x7X60L 1 1 17 20778 6 UPPER VARI DISC DRIVE SUB ASSY 3VK A6 1 19 VS137 SOCKET CAP SCREW M amp P1 25x25L Tt 20 VS13 TOPBEARNGCAP 1 21 513 1 WAVEWASHER 0 0 1 S SPEED CHANGE HANDWHEEL SUB ASSY 3VK A7 SCREW SOC HD CAP M6 P1 0x35L 97 28 29 30 31 32 33 34 35 36 37 38 39 40 MOTOR ASSY K2 8 K3 3HP WHITE reference only not part of 26 20819 1 upper head housing assembl VS130 27 VS130 WASHER FLAT 10 2 28 vs111 SOC HD SCREW 3 8 16NCx32L 29 VS1 MOTORPULEYCOVER y O 30 VS104 COPPERCHIP 2REG y O 31 VS131 SCREW FLAT HD PHILIP M5 P0 8x10L 32 5132 STUDO 716 1000 CCCs 33 VS96 JJAMNUT 3 8 1GNC O 34 VS101 IVENTILATOR 2REQ 35 VS136 SCREW SOC HD CAP M6 P1 0x10L 36 VS54 HANDLEFIXBLOCK 37 VS55 SETSCREW eC O
14. DPMS5 P N Description item 4 ne BEARING 5 i39 RING BEARING HOUSING 1 6 i608 SEALBEARINGHOUSNG O 1 7 39e 1 8 i6 NUTQAMPX amp YAAS 1i 9 isxo 1 ii is13 BRACKETWAYCOVERTRONT 13 125305258 SCREW SHCeSTLEO 4 14 amp oswis femme i 15 203 4 BEARING ANGULAR CONTACT 7205 BECBP M gt 33 u220517 NUFHEXJAWSILZNO 2 2 U270 WASHERHATUSSSTLRAIN 2 35 u275z QWASHEREXTOOTRSTLZNC 2 28 316X1 281P PWSPRINGSTLPLAN 2 31 3 12 108 SCREW PHHILSTLBO 8 32 98481090 KEYWOODRUFF amp 0H8Xi2 OOO 1 35 sei HANDWHEELASSYMX E 34 23016 i00771 Y S5 N p NINININ 137 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual MOTOR REF 23198 123158 KO Figure 5 25 Y Drive Train DPME2 138 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Y Drive Train Parts List DPME2 Item P N Description Use AS Qty 1 15966 3 BRACKET Y AXIS MOTOR MOUNT EA 1 2 M10 1 5X60 25B SCREW SHCS STL BO EA 4 3 15968 2 LOWER COVER EA 1 4 15967 2 UPPER COVER EA 1 5 6 3
15. Maintenance Service amp Parts List Manual Item P N DESCRIPTION Qty 1 FVS89 HI LOW DETENT PLATE FVS87 CLUTCH GEAR SHAFT FVS92 HI LOW PINION BLOCK FVS91 SPRING FVS94 HI LOW SHAFT CRANK FVS88 PIN 319L 2 3 4 5 FVS90 HI LOW DETENT PLUNGER 6 7 8 FVS93 SCREW SOC HD M5 PO 8x15L 9 FVS92 1 SET SCREW M5 P0 8x5L 10 FVS92 2 WASHER FLAT 11 11 FVS57 BAKELITE BALL HANDLE 12 FVS116 JWASHER FLAT 6 A a COD a a a n 13 24083 SHAFT HI LOW SHAFT ASSY 100596 K4 Figure 103 Hi Low Shift Sub Assembly P N 20697 3 186 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Item P N DESCRIPTION Qty 1 FVS67 BULL GEAR PINION COUNTER SHAFT 1 2 FVS69 KEY 5518L 1 3 FVS66 BULL GEAR PINION 1 4 AK118 BEARING DEEP GROOVE 6203ZZ 2 5 FVS3 SOCKET SET SCREW M6 P1 0x6L 1 6 23954 BEARING DEEP GROOVE SET 2 6203ZZ 1 i00597 K4 Figure 104 Pulley Pinion Sub Assembly P N 20697 4 187 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100598 Figure 105 Lower Vari Disc Sub Assembly P N 20697 5 assembly not available order parts separately 188 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Instal
16. Programming Operating amp Care Manual have been studied and understood 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 Protect your eyes Wear approved safety glasses with side shields at all times Don t get caught in moving parts Before operating this machine remove all jewelry including watches and rings neckties and any loose fitting clothing Keep your hair away from moving parts Wear adequate safety headgear Protect your feet Wear safety shoes with oil resistant anti skid soles and steel toes Take off gloves before you start the machine Gloves are easily caught in moving parts Remove all tools wrenches chuck keys etc from the machine before you start Loose items can become dangerous flying projectiles Never operate a milling machine after consuming alcoholic beverages or taking strong medication or while using non prescription drugs Protect your hands Stop the machine spindle and ensure that the CNC control is in the stop mode e Before changing tools e Before changing parts e Before you clear away the chips oil or coolant Always use a chip scraper or brush e Before you make an adjustment to the part fixture coolant nozzle or take measurements e Before you open safeguards protective shields etc Never reach for the part tool or fixture around a safeguard Protect your e
17. a dial indicator in the quill and sweeping around the part 50 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 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 If more precise circles are required then it is recommended to use a precision boring head boring bar Perform the following Service Codes and document values e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 11 Measures backlash in the system Only used on Dual feedback systems e Code 12 Feed Forward Constant e Code 127 Measures backlash in the system Only used on Single feedback systems e Code 128 Enter backlash compensation Possible Cause Check This Torque values on X and Y axis are too Make sure torque is lower than 20 in lbs Normal values for a high machine that is aligned and adjusted properly should be between 10 and 15 in Ibs 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 amp Setup Section 4 1 Machine not level Verify that the machine is level to specification the Head Check the adjustment of the X Y and Z axis Gibs using the X properly Y and Z axis Gib adjustment procedures Ca
18. all local codes and regulations Incoming 220 or 440 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 DANGER Only a qualified electrician should wire the 220 or 440 volt 3 phase electricity To convert a DPMS3 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 DPMS5 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 See Section 5 30 and 5 31 for diagrams on wiring the spindle motor Southwestern Industries recommends the machine be earth grounded by driving a copper rod into the ground It is the responsibility of the customer to install this rod 20 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Part number reference table for TRAK amp Sport Bed Mill Pendants Description Part Number TRM DPM DPM5 Sport B3 Sport DPMS3 DPMS5 DPME2 B5 MX2 MX3 AGE3 M3 M3 SM SM EDGE 15814 16274 20180 1 20347 2 20347 4 22328 3 22328 3 23688 USA Penda
19. 115V 60HZ 15 amps Feedrate Override of programmed feedrate and rapid Polycarbonate Sealed Membrane Keypad and Gasket Sealed Control Enclosures to lock out contamination 9 CRT for clear presentation of prompts status information and part graphics Built in Floppy Disk Storage for program storage RS 232 Port for interface with computers Auxiliary Function to interface with Haas type rotary indexers B3 option only Auxiliary Function to control A C outlet B3 option only Auxiliary Function to control Air Solenoid System spray misters B3 option only Electronic Handwheels for the X and Y axes B5 only 2 7 3 ProtoTRAK SM Control DPMS3 amp DPMS5 3 axis CNC 3 axis DRO 233 PC based processor 11 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 32 MB of RAM D C Servo Motors rated at 560 in oz continuous torgue for X Y and Z axes Precision ground ball screws in the table saddle and ram 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 32 color LCD for clear presentation of prompts status information and part graphics RS232 port for interface to computers Modular design simplifies service and maximizes uptime 64 GB flash drive Optional flash expansion slot Single floppy disk drive for addit
20. 18 X 1 1 4 Figure 5 19 Ball Screw Yoke Assembly P N 15990 TRM amp DPM 127 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual VAN IS SUPPLIED WITH MACHINE NOTES UNLESS OTHERWISE SPECIFIED MOTOR REF Figure 5 20 Y Drive Assembly TRM amp DPM 128 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Y Drive Assembly Parts List TRM amp DPM item P N Description Qty 4 15967 _ COVER UPPER 1 9 115616 JHANDWHEEL ASSY MX 16 15885 RING BEARING HOUSING 17 15626 20 15613 NUT BEARING HOUSING 129 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 5 21 Y Drive Assembly DPM5 Sport 130 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Y Drive Assembly DPM5 amp Sport B5 NO P N DESCRI PTI ON QTY 1 15966 2 BRACKET MOTOR MOUNT 1 2 15967 2 COVER UPPER 1 3 15968 2 COVER LOWER 1 4 121662 BEARING HOUSING 1 5 16302 BEARING RING 1 6 16078 SEAL BEARING l 7 16983 1 PULLEY 44 TOOTH 1 8 16066 NUT CLAMP 1 9 16350 SLEEVE TAPERED 1 10 21685 MOTOR
21. 3 22328 3 23688 Pendant P N without USA with control sensors model AGE2 AGE3 20347 3 20180 20180 1 B3 with sensors All replacement part numbers have a suffix R For example 20065 220R 20065 440R and 22758 SDPM3R See Figures 2 25 2 30 for cable diagrams for each machine model 39 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual SPINDLE aov 44DV PENDANT DISPLAY 110V SWITCH BOX E STOP 110V Figure 2 25 95 xxx and earlier COOLANT PUMP OPTIONAL 220V 440V FUSED BOX DEDICATED LINE AUXILIARY BOX 110V 220V 5V COMPUTER ENCLOSURE 110V SV 220V 440V 101313 Cable I nterconnections TRM MX2 40 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual PENDANT DISPLAY DEDICATED SERVICE SPINDLE LINE DISCONNECT AC IN 3 PROVIDED BY 220 440 CUSTOMER VAC 0 440VAC 115 VAC 115 VAC 7 SWITCH COMES IN KIT 115 VAC COOLANT OPM sims OPTIONAL 2 LUBE PUMP DPM 115 VAC HAAS OPTIONAL DPM AC IN PNEUMATIC DEVICE DPM E STOP COMPUTER CABINET 115 VAG X MOTOR se XSENSOR 115 VAC 365 000 CABLE ASSY AC TO PENDANT Y MOTOR ies CABLE ASSY E STOP INPUT Y SENSOR CABLE ASSY AUX PCB TO CIMPUTER 7 17000 CABLE ASSY SWITCH BOC 115 V
22. 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 e Problems with machine motion e 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 Code 12 When the heavy workpiece is removed run Code 12 again 1 Position the table and addle in the center of travel Note You will lose your DRO position reference 2 Go into the Service Codes and input the Code 12 3 For SM control press Auto 4 The system will run the routine automatically and then display values on the position readout 87 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List 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 inthe other direction The values should be within 3 or 4
23. 38071 91 59922 SOIAH3IS NI HSMOd Ov 19070 HHOML3N Dx igunoov 3NIHOVIN 26754 LON 13 NOLLdO LHOd 13 TM A LON Cable Connection Diagram Figure 2 29 DPMS3 S5 44 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 0199 089821 318VO 4015 4 NOILLO3NNOO YSMOd 38N1 NOLLOANNOOUZLNI FIBVA M31ndNOO NOLLOSNNOOUSLNI 318V2 TWNOIS HOLIMS NOILdO GUVN9 4000 NOUS NOILdO NOLLO3NNOO 31852 HILIMS SIXV Z FOYNOS TVNUILXI ASLL NOILdO NOLLO3NNOO 318V9 HO LIMS SIXV A NOILdO NOILO3NNOO JYO HOLIMS LINIT SIXV X TINO WO 3 318v9 HOLON SIXV A 318 9 NOLLdO 193NNOO 318v2 558 HOLON SIXV Z NO44 31890 YO LOW SIXV X WOuU3 318v2 Ed CI JIHNOS TVNH31X3 WOHA ahve divi 45 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service 8 Parts List Manual Cable Connection Diagram DPME2 Figure 2 30 2 16 Lubrication 2 16 1 Way Lubrication 2 16 1 1 1 DPM DPM5 Sport B5 DPMS3 DPMS5 amp DPME2 The auto lube system provides centralized automatic lubrication for the ways and ballscrews The lube pumps 2 liter reservoir is serviced with Mobil Vactra Oil No 2 or equivalent The pump is factory
24. 8x7x55 0 16501 11 AK039 SPRING 1 16501 12 AKO42L TOP BEARING CAP 1 13 25719 BEARING DEEP GROVE 6009ZZ 1 14 AK045L SPINDLE PULLEY HUB 1 15 AK047 SPINDLE PULLEY SPACER 1 16 AK048 OR 24640 BEARING DEEP GROOVE 6912ZZ 1 17 AK049L BRAKE BEARING CAP 1 18 AKOSIL STATIONARY DRIVEN VARIDISC 1 19 AKOS3L SNAP RING 1 ADJUSTABLE DRIVE VARIDISC includes AK055 8 20 AKOSAL AK056 1 21 55 KEY 8 x 7 x 20 INCLUDED IN AKOSAL 1 AKOSAL 22 AKO56 PIN INCLUDED IN AKOSAL 1 AKOSAL 23 FVS43 OR 2464 BEARING DEEP GROVE 6013ZZ 1 16522 2 24 AKO59L SPINDLE PULLEY BEARING SLIDING HOUSING 1 16522 2 25 AKO061 PIVOT SLEEVE 2 26 AKO62 SPEED CHANGE PLATE 1 27 AK063 SPEED CHANGE PLATE PIVOT STUD 1 28 AK067 ROLL PIN 1 29 AKO68K SPEED CHANGE CHAIN STUD 1 31 AKO95 BRAKE SHOE ASSV NOT SOLD SEPARATELY 1 25059 32 AK096 HEX HD SCREW 1 33 AK097 PIVOT SLEEVE 1 25059 35 AKO99 BRAKE SPRING 2 25059 36 AK099A GUIDE PIN FOR SPRING 4 25059 38 AK124 BAKELITE BALL HANDLE 1 16520 39 AK125 BRAKE LOCK HANDLE 1 16520 40 AK126 BRAKE LOCK PIN 1 16520 41 AK128H BRAKE LOCK SHAFT 1 42 AK129H SLEEVE FOR BRAKE LOCK SHAFT 1 44 AK131 SNAP RING 1 45 AK132 BRAKE OPERATING FINGER 2 46 AK133 BRAKE FINGER PIVOT STUD 1 47 AK134 SNAP RING 1 48 AK147L DRAWBAR 1 16528 49 AK149L SLEEVE 1 16528 50 AK158 BELT 1 51 AK041K SNAP RING 1 16501 52 AK127 SCREW SET M5x 8 1 232 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Part
25. Code 33 Software Identification This is needed if you call SWI Customer Service e Code 313 Check the line that specifies the product e Code 97 Axis configuration If the product does not match the machine the machine ID key will need to be replaced 3 4 5 X Y amp Z Axis Electric Handwheels Count in Wrong Direction The Electric Handwheels turn in the wrong direction The positive directions for each Electric Handwheel are e X axis Electric Handwheel turns clockwise e Y axis Electric Handwheel turns counterclockwise Perform the following service code and procedures e Code 308 Reverse X axis Handwheel Direction SM only e Code 309 Reverse Y axis Handwheel Direction SM only 3 5 Problems with the Machine Tool 3 5 1 Z Axis Noisy While jogging or cutting in the Z axis direction the axis makes unusual noises See below for head noise Possible Cause Check This Check for any looseness in the setup Tool Tool holder Part Vise or Fixture See Machine Tool amp Setup Section 4 1 Inadequate or no Lubrication to the Make sure all the Way surfaces are getting proper Ballscrew and Way surfaces 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 Z axis Gibs are not adjusted properly Check the adjustment of the Z axis Gibs using the Z axis Gib adjustment procedure See Z axis Gib Adjustments Section 5 2
26. DPM _1 20252 1 Control Cabinet Assembly TRM 1 20253 2 Control Cabinet Assembly DPM _1 20180 Pendant Assembly TRM 1 20180 1 Pendant Assembly DPM _3 250 Sensor M250C _1 16961 Switch Box Assembly _1 20065 220 Relay Module 220V 1 20065 440 Relay Module 440V TRM _1 17009 220 Relay Module 220V DPM _1 17009 440 Relay Module 440V DPM Figure 145 Electronic Hand Wheel Assembly and Parts List __ QUILL SENSOR LIMIT SWITCH LOTT i Ba NO P N DESCRIPTION QTV 1 20290 1 EXTERNAL CABLE BOX 2 21735 CABLE ASSV ELECTRONIC HANDWHEEL 2 3 20082 1 X amp Y AXIS HANDWHEEL 2 4 21583 HANDWHEEL BOX SHEET METAL REF 5 M6 73B WASHER LOCK BLK OX 8 6 M6 1 0x12 SCREW SOC HD CAP BLK OX 8 254 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 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 Warranty Period Broder Materials Factory Labor New TRAK 1Year 1Year Any EXCHANGE Unit 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 If a unit under warranty fails it
27. DRIVER ASSY REF 11 15913 2 COVER UPPER 1 13 M8 1 25 x 25 SCREW SOC HD CAP BLK OX 4 14 565 5M 15 TIMING BELT 1 15 20374 BEARING 2 16 M8 74B WASHER EXTERNAL TOOTH 4 17 M10 1 5 X 65 SCREW SOC HD CAP BLK OX 4 18 10 32 x 3 4 25B SCREW SOC HD CAP BLK OX 1 19 1 4 20x124B SCREW HEX HEAD 4 20 15759 WASHER FLAT 1 4 4 23 91079A033 NUT JAM ZINC PLATE 1 2 20 1 24 1 2 702 WASHER FLAT STL ZINC 1 25 1 2 75C WASHER EXT TOOTH 1 28 3 16 x 1 1 2 PIN SPRING STL PLAIN 2 29 21584 2 END COVER PLATE 1 30 21585 2 END COVER BALL SCREW 1 31 6 32 x 1 2 10B JSCREW PAN HD PHIL EXT SEMS 9 32 98481A090 KEY WOODRUFF 1 8 x 1 2 1 131 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual T REF A N part IS SUPPLIED WITH MACHINE Figure 5 22 Y Drive Assembly Sport B3 132 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual NOTES UNLESS OTHERWISE SPECIFIED MOTOR REF 20296 100564 Y Drive Assembly Parts List Sport B3 1 14 15968 2 1 17 1 18 1 19 1 1 1 ITEM 1 11 0 16865 2 1 1 2 2 24 15616 1 1 25 15614 1 27 1 32 565 5M 15 35 20373 JBEARING 2 12 1 62 4 4 52 53 57 ITEM SEEN 14 EAD 18 19 25 1 27 EY 49 Eg E fist 62 133 Southwestern Industries Inc TRAKS Spo
28. FB124 FEED TRIP PLUNGER 1 83 FB145 FEED TRIP LEVER 1 84 FB144 SOCKET SET SCREW 1 85 OIL 1 FRU K3 OIL CUP 1 86 FB125 HANDW HEEL 1 87 FB125 4 JHANDWHEEL SPRING PIN 3x3x10L 1 88 FB125 2 JHHANDWHEEL HANDLE 1 89 FB111 REVERSE KNOB 1 90 FB100 SOCKET SET SCREW M6 P1 0x20L 2 91 FB124 1 FEED TRIP PLUNGER SOC SET SCREW M4 P0 7x20L 1 92 FB124 2 FEED TRIP PLUNGER NUT M4 P0 7x20L 2 93 FB128 QUILL SKIRT 1 94 FVS109_ DRAWBAR 5 8 11NC 1 95 FVS109 1 JSPACER 1 96 25041 SCALE HEAD ROTATION NT40 1 97 25043 POINTER SCALE 1 98 25044 DRIVE SCREW SCALE 4 99 20834 FEED REVERSE KNOB ASSV 1 100 20835 HANDWHEEL ASSV 1 196 TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Southwestern Industries Inc 101 24099 TRIP HANDLE ASS Y INCLUDES PLASTIC BALL 1 102 20833 FRU K4 FEED TRIP ASSY 1 103 20847 QUILL MICRO NUT 8 SCREW ASSY 1 104 20846 QUILL LOCK HANDLE ASSY 1 105 20850 FEED HANDLE ASSY 1 106 24095 CLOCK SPRING ASSEMBLY SPRING amp COVER 1 107 20844 QUILL LOCK SLEVE ASSY 1 108 FB142 QUILL 1 109 A071 T BOLT ASSY includes A070 A071 A069 not shown on drawing A TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual i20698 197 Southwestern Industries Inc 100603 K4 Item P N Title Qty 1 FB17 WORM GEAR CRADLE 1 2 FB5 WORM CRADLE
29. GROUND SCREW 440V 220V CONFIGURATION CONFIGURATION 100882 Figure 5 30 Spindle Motor Wiring except DPME2 150 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual MOTOR JUNCTION BOX FROM SPINDLE FAN REMOVE JUMPER BLK BLK PAINT FOR GROUND GROUND SCREW CONFIGURATION 100882 1 ee Figure 5 31 Spindle Motor Wiring Spindle Control DPME2 only 151 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 1 14 Electric Box Service TRM P N 20655 220 or 20655 440 DPM DPM5 only P N 17009 220 or 17009 440 The electric box contains a relay module which comprises all electrics for the machine and control relays contacts fuses etc Figure 2 15 in Section 2 shows the electrical diagram for the relay module Refer to Section 5 1 15 for Auxiliary Function Interface DPM DPM5 only The entire relay module may easily be exchanged or replaced with the following procedure DANGER Always disconnect the 220V 440V 3 phase input and the 15 VAC input before opening the electrics box 1 Unplug all plugs connected to the relay module located on the side of the electrics box 2 Unscrew the two Philips head screws on the clamps that hold the electrics box door shut Open the electrics box door The door interlock must be in the Off position to open 3 D
30. Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 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 Perform the following Service Codes and document values e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 11 Measure s the backlash in the system Only used on machines with Dual feedback systems e Code 12 Feed Forward Constant e Code 127 Measure s the backlash in the system Only used on machines with Single feedback e Code 128 Enter backlash compensation Check for any looseness in the setup Tool Tool holder Part Vise or Fixture See Machine Tool amp Setup Section 4 1 Check the adjustment of the X Y and Z axis Gibs using the X Y and Z axis Gib adjustment procedures See Section 5 2 1 X and 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 3 1 4 Parts Have I ncorrect Dimensions Parts are being machined with dimensions that are different than those programmed Typical accuracy expectations should be e Circles 0 002 TIR over 3 00 DIA e Positional A
31. MOTOR 3 HP 3 1725 220 VOLTS 1 2 23629 CONTROL BOX HEAD DPME 1 3 23698 WIRING ASSY SPINDLE HEAD DPME CONTROL BOX TO SWITCHES 1 3A 23621 NAMEPLATE DPME SPINDLE HEAD 1 3B 23624 POTENTIOMETER 1 3C 23623 TACHOMETER RPM 0 5000 HIGH 0 600 LOW 1 3D 23628 FWD REV SWITCH 1 3E 22125 03 SLEEVE SHRINKABLE TUBING 3 IN 21953 18 TERMI NAL RING TONGUE 2 3G 22404 18 TERMINAL WIRE PIDG FORK 8 3H 22285 YL 20G UL1007 118 IN 3J 22475 TIE WRAP 4 IN PLASTIC 1 7 23632 SPINDLE PULLEY 117 mm 1 8 23597 BELT MI CRO V J PROFILE 10 RIBS J 1 9 23631 MOTOR PULLEY 117 mm DPME l 10 23695 HARNESS ASSY SPINDLE CONTROL DPME ELECTRIC BOX TO SWITCHES l 11 23573 SPACER SPINDLE SHAFT BUSHING DPME 1 12 23574 PLATE RETAINER SPINDLE SHAFT DPME 1 13 23755 KEY 8 mm x 8 mm 1 14 23756 KEY 10 mm x 10 mm 1 15 M8 70B WASHER FLAT USS STL BO 4 16 M8 73B WASHER SPLIT LOCK STL BO 4 17 8 1 25 40 248 SCREW HEX HEAD STL BO 4 18 VS109 FRU K3 DRAWBAR 7 16 20UNF 1 19 VS109 1 SPACER DRAWBAR 1 20 20849 QUILL HANDLE l 21 23696 HARNESS ASSV SPINDLE MOTOR DPME2 l i23610 XXX 158 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 1 19 Drive Belt Replacement 5 1 19 1 DPM DPM5 Sport Sport B5 DPMS3 amp DPMS5 1 Remove the motor 2 Remove the draw bar and its bushing 3 Remove the three Screws A and use M6 x 35mm screws in the adjacent tapped holes to remove t
32. Maintenance Service amp Parts List Manual DPM Sport B3 amp Sport B5 Lubrication System m 7 12000008 1003 1005 101 1014 e L004 TI L007 CULA UUUUUO 015 006 j LOOB 16530 ene ini LI LI LI 010 1009 Figure 138 Lubrication System DPM Sport B3 amp Sport B5 240 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Lubrication System Parts List DPM Sport B3 amp Sport B5 QTY PART NO DESCRIPTION 1 L002 RAM MANIFOLD A 7 2 L003 LUB MACHINE COUPLING SET PH 401 PA 4 PB 4 14 L004 LUB MANIFOLD COUPLING SS 2 L005 LUB TUBING 1 L006 SADDLE MANIFOLD A 10 1 L007 FLEXIBLE LUB HOSE RAM 44 X 300 LG 1 L008 FLEXIBLE LUB HOSE SADDLE 46 X 700 LG 4 X 700 LG 1 L009 OIL FEEDING SYSTEM CEA 2 4 X 110V 1 L010 OIL REGULATING DISTRIBUTOR B 2 64 2 L011 TWIN JOINT SET JD 4 PA 4 PB 4 1 L012 T JOINT SET PKD 4 PA 4 PB 4 2 L013 THIMBLE SET PA 4 PB 4 14 L014 SCREW NUT R 08 PB 4 2 L015 PLUG PG 004 1 16530 OILER COVER 241 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 4mm TUBING TO BACK SLIDING SURFACE OF THE COLUMN RIGHT SIDE TO COLUMN RIGHT SIDE GiB SLIDING SURFACE TOZAXIS BALL SCREW TO B
33. NOSEPIECE ERN LEFT HAND SS HOLE FOR SPANNER 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 Adjustment X Axis 5 2 1 1 1 TRM DPM Sport DPMS3 DPME2 1 Clean all chips dirt and excess oil from the table and saddle 2 Center the saddle on the bed ways 3 Move the table fully to the left side of the saddle Note For machines that have excessive wear n the center of the table way it will be necessary to center the table on the saddle The resulting adjustment of the 161 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual gib will be compromised to account for the varying clearance from the center to the ends of the table 4 Attach a 0001 dial indicator with a magnetic base to the left front of the saddle Place the indicator stylus on the front surface of the table as close to the indicator base as possible 100023 Figure 5 37 Table Gib Adjustment 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 e To adjust the
34. WAY FOR CLARITY 100910 Figure 5 17 X Handwheel Drive Mechanism DPMS5 only 122 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual X Handwheel Drive Mechanism Parts List DPMS5 only P N 23021 Gear Box Assembly item PN Description 4 23017 COVER HUB XAXIS HANDWHEELBOX 111 5 7 ji 23028 COVER EXTENSION BALL SCREW X AXIS HANDWHEEL ASSY Da EA 1 1 9 1620527 BEARING DEEPGROOVE 2 1 M j aem Ma E 123 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 5 18 X Axis Drive Assembly DPME2 120255 XX 15608 XX BALL SCREW REF 124 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual X Axis Drive Assembly Parts List DPME2 Item P N Description UseAs Qty 1 15621 DRIVE HOUSING EA 1 4 15624 FRONT COVER EA il 5 15622 BACK COVER EA 1 6 15616 HANDWHEEL ASSY MX EA 1 7 15614 TAB WASHER EA 1 8 15612 HOUSING BEARING EA 1 9 15885 RING BEARING HOUSING EA 1 10 15638 STOP X AXIS EA 1 11 15626 SEAL BEARING HOUSING EA 1 12 16983 1 PULLEY SOLID 44 TEETH W O GUIDES EA 1 13 16452 NUT CLAMP X Y amp Z AXIS EA 1 14 16350 FERRULE SPROCKET EA 1 15 98481A090 WOODRUFF 40
35. amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Upper Vari Disc Sub Assembly Item P N DESCRIPTION Qty 1 FVS44 ADJUSTABLE DRIVEN VARIDISC FVS42 SPINDLE PULLEY BEARING HOUSING FVS43 BEARING DEEP GROVE 6013ZZ FVS36 SPEED CHANGE PLATE FVS37 WASHER M5 P0 8x20L FVS3123 SOCKET CAP SCREW 2 3 4 5 FVS38 PIVOT SLEEVE 5 6 7 8 FVS39 SPEED CHANGE PLATE PIVOT STUD JS JS N IN 9 FV841 WASHER 82 10 FVS40 ROLL PIN 3x15L 11 FVS35 CHAIN END STUD 12 FVS34 ADJUSTMENT NUT 13 FVS33 CHAIN FRONT SCREW M4 P0 7x5L 14 FVS97 SNAP RING 50 15 FVS96 JAM NUT 3 8 16NC 16 24599 BEARING HOUSING ASSY K4 17 24603 VARIDISC ASSY ADJUSTABLE i20697 6 191 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Item P N Title Q lt 1 FVS16 JSPEED CHANGE HOUSING FVS20 JBEARING SELF LUBRICATING FVS22 JSPEED CHANGER GEAR FVS21 FVS25 JSPEED CHANGE SHAFT 2 3 4 FVS31 JSPEED CHANGE CHAIN DRUM 5 7 8 FVS40 JROLL PIN 3x15L a ND ND a a 9 FVS24 COPPER BUSHING 10 FVS32 CHAIN 3109 525 11 FVS31 1 DOWEL PIN 23x25L 12 FVS30 SPEED CHANGE STUD
36. chip wiper guard and chip wiper from the front and rear of the left side box way du Ur epa 100024 Figure 5 40 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 e Toadjust the gib for excessive clearance Loosen the gib lock screw on the back of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the front of the saddle Tighten the gib lock screw on the back end of the saddle to lock the gib in place and recheck Repeat as necessary e adjust the gib for too small of a clearance Loosen the gib lock screw on the front of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the back of the saddle Tighten the gib lock screw on the front of the saddle to lock the gib in place and recheck Repeat as necessary 165 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 7 Replace the front and rear chip wiper and chip wiper guard 8 Center the table on the saddle and run Service Code 12 to set the Feed Forward Constant 5 2 1 3 Saddle Bottom Gib Adjustm
37. displayed X table encoder reading nothing should be 0 Motor encoder reading the maximum feedrate attained 89 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Your input X table encoder reading X Y ing should be 0 Z motor encoder reading recat the mada ederet attained Your input Y E Your input Feed Your input Z emis Your input Z Feed Interpretation of the resulting values displayed The values for the encoder displays should be in the range of 3 0000 to 5 0000 e fthe 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 e The feedrate should be a minimum of 120 ipm for X and Y axis and 180 ipm for Z The DPMS3 and DPMS5 should be a minimum of 180 ipm on the X Y and Z axes e fthe feedrate is less than 180 ipm and inconsistent in both directions check the incoming AC voltage and mechanics of the drive train 4 11 5 2 EDGE Control SM control and M control without feedback Your input nothing should be 0 nothing should be 0 the maximum feedrate attained Your input X Vour input nothing should be 0 Y motor encoder reading nothing should be 0 the maximum feedrate attained 90 Southwestern Industries Inc TRAK amp
38. 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 Repeat as necessary adjust the gib for too small of a clearance Loosen the gib lock screw on the left end of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the right end of the saddle Tighten the gib lock screw on the left end of the saddle to lock the gib in place and recheck Repeat as necessary 6 Center the table on the saddle and run Service Code 12 to set the Feed Forward Constant 162 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual TABLE GIB SCREW S Figure 5 38 TABLE Table Gib Screw SADDLE 5 2 1 1 2 DPM5 Sport B5 DPMS5 The X axis has 2 gibs for the table because of the length of the saddle Each gib is adjusted from each end of the table There are not 2 adjustment screws at either end of the gib like the Y axis and Z axis Clean all chips dirt and excess oil from the table Remove the table trays 1 Move the table to the left and mount the indicator at Point D and move the table back and forth Note the amount of movement of the dial indicator Adjust gib until the mo
39. in the cables for the pendant to rotate 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 For DPMS3 S5 only Ensure that an option key is plugged into the option key port of the pendant This key activates any converters or options ordered The part for this key is 22648 5 The key must be programmed according to the type of machine it is on and the options ordered 38 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual The Machine ID port must have a key or the machine may not run CAUTI ON Ensure that the main power is turned off on the back ofthe electrical cabinet before plugging in the cables Part Number Reference Table for TRAK amp SPORT Cable Connections Description Part Number TRM DPM DPM5 Sport Sport DPMS3 DPMS5 DPME2 B3 B5 Electrical Box 20065 17009 21800 20676 20676 1 220 23630 Relay Module 220 440 220 440 220 440 20676 440 220V Cable N A N A N A N A N A 21856 21856 21856 Assembly 23050 23050 Cable N A N A N A N A N A 23050 1 23050 1 N A Breakout Box 1 with AuX Option Key N A N A N A N A N A 22648 5 22648 5 N A Machine ID N A N A N A N A N A 22758 22758 N A Key SDPM3 SDPM5 MX2 MX3 AGE3 M3 M3 SM SM EDGE 15814 16274 20180 1 20347 2 20347 4 22328
40. of each other in both directions A value of 6 08 would still be considered normal On Sport products do not eguate Code 12 values to torgue on ball screw Measure friction in system with an in Ib torque wrench SM and EDGE only 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 4 11 3 CODE 33 Software ID 411 3 1 EDGE amp SM Controls Code 33 is the software identification procedure The two types of software in the control include e Software Version the version of the system you have installed e Firmware Version the version of firmware software that is responsible for control to servo interface 411 3 2 AGE and M3 Controls The code 33 is the software identification procedure The two types of software in the control include e Floppy the version of the system you have installed Slave the version of EPROM software that is responsible for control to servo interface 1 Go into the Service Codes and input the Code 33 2 f you are working with the SWI Customer Service Group write the values down
41. position B After reading position B it will backup about 4 inches and return to read position B again Turn the flats out of the way again to allow the indicator to move beyond position B about 3 inches at which time it will return to position B Return the flats to the readable position again to read the position at B Movement 1 A B Pause Record indicator reading Press Go Movement 2 B p Pause Record indicator reading Turn flat away from the path of indicator travel Press Go 177 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Movement 3 B Pause Turn flat so position B is readable again Record indicator reading End program Movement 1 Positional Accuracy Checks the calibration of the machine Typical values for a new machine are 0 0005 or less Movement 2 Uni directional Repeatability Measures how well the machine comes back to a point from one direction Typical values for a new machine are 0 0005 or less Movement 3 Bi directional Repeatability Measures how well the machine comes back to a point from both directions This value when measured is the difference between the uni directional value and the value from the other direction Typical values for a new machine are 0 0005 or less Example If the uni directional value was 0 0002 and the value from the other direction is 0 0002 the bi directio
42. pump can be turned on either by the switch box or via a CNC auxiliary function 6 LED 6 is on when the overload relay is tripped LED 6 is off during normal operation 7 LED 7 is on when the E Stop on the switch box is in the Out position LED 7 is on during normal operation 8 LED 8 flashes on when the Haas rotary table is being indexed one cycle or step The function is controlled through Auxiliary Function 3 9 LED 9 flashes on when the Haas rotary table has completed indexing one cycle or step 10 LED 10 is on when Auxiliary Function 1 coolant pump is on 84 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List 11 LED 11is on when Auxiliary Function 2 air relay is on 12 LED 12 is on when Auxiliary function spindle morot is on 4 11 Service Codes All Service Codes are accessed in the SET UP mode by pressing the SERV CODES softkey For the EDGE control SET UP is accessed through the DRO mode To access a service code press the CODE softkey enter the number you want and press INC SET Follow the prompts on your monitor 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 The following table depicts a brief description of all service codes used on the bed mills 8 2 zs 9 poe Q m DESCRIPTION 11X X X X X X Ba
43. set to pump oil for 15 seconds for every 60 minutes of spindle time There is an internal memory on the pump so that the pump will not reset every time the spindle is turned off The pumping output can be regulated electronically to control the pause time between pumping cycles and the duration of the pumping cycle The following describes the buttons used to program the lube pump In order to modify any of the settings the spindle must be on The pump has an alarm that will sound if any of the following problems arise Oil line breakage Oil filter blockage Bad motor Low oil pressure No oil in tank INT Interval this button programs the interval between pumping cycles Each press of the button increases the interval by one minute DIS Discharge this button programs the amount of time the pump will discharge each pumping cycle Each press of the button increases the discharge time by one minute FEED this button is used to manually feed the ways and ballscrews RST this button tells the pump to discharge for the time programmed Factory Default Values Interval Time 60 min Discharge Time 15 sec Discharge Pressure Approximately 100 150psi To adjust the amount of Discharge Pressure displayed on the lube pump gauge loosen the jam nut and turn the adjustment screw located on the top right side of the lube pump while the lube pump is activated At the beginning of each day check the oil level in the Auto Lub
44. start the machine including the rotation of the spindle if the tool is in contact with the part Check the direction or of movement of the table saddle and ram when using the jog or power feed 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 Large overhang on cutting tools when not required result in accidents and damaged parts Handwheels must have the crank folded inside when using CNC programmed machining or rapid feeds power feed or jog 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 Prevent fires Keep flammable materials and fluids away from the machine and hot flying chips 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 Interlocked Table Guards Interlocked table guards may be purchased from Southwestern Industries Inc if deemed necessary by the user 5 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 2 0 Installation Read and understand this entire installation section before beginning the installation procedure 2 1 Floor Plan Layo
45. surfaces 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 Z axis Gibs are not adjusted Check the adjustment of the X Y and Z axis Gibs using properly the X Y and Z axis 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 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 Perform the following Service Code and procedures e Code11 Measures backlash in system Used only with glass scales and sensors e Code12 Sets a feed forward power constant to drive axis motors e Code 127 Measure s the backlas
46. surfaces on Machine not level ram gibs loose See Tramming Head Section 5 2 3 bottom of pockets 68 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service 8 Parts List 4 1 2 A Special Word About X Y Z Gibs The slideway surfaces are vital to the performance of the bed mill Gibs should be e flat e free of twist e free of burrs e free of blockages in the oil passages and channels Defective or scarred gibs must be replaced Shimming of gibs will not yield acceptable results It is good machining practice to avoid the use of shop air to clean the chips off a machine This risks blowing chips into the sliding way surfaces and compromising the performance of the machine 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 bed 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 Mac
47. the calibration values for the motor encoders Encoder and the position feedback encoders Scales The calibration values are written in Hexadecimal Recalibrate the system and see ifthe values change Turn the system off and on and see ifthe values are held Perform the following service codes and procedures 59 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 313 Configuration Values e Code 123 Calibration Mode 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 If calibration factors are being saved but the measurements are not repeating or are not accurate e See Measurements Are Not Repeating e See Measurements Are Not Accurate 3 3 10 Auxiliary Functions Not Working TRM not applicable 3 3 10 1 AGE 3 MX3 amp M3 Controls where applicable The auxiliary functions will not turn on or off at the programmed times There are 4 auxiliary functions 1 VAC coolant pump 2 Activates a solenoid for an air mister 3 Electrical signal to activate Haas Indexer 4 Spindle on and off Run the following service code and procedures e Code 200 Auxiliary Function Test Code 200 will turn on and off the auxiliary
48. the cutter dull Is the tool loose in the holder Am taking a bigger cut then is possible on the machine Is the part moving in the vice Am 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 To check if the nosepiece is bottomed out try to insert spindle 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 67 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 4 0 Diagnostics This section explains the diagnostic procedures used to isolate service problems 4 1 The Machine Tool amp 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 Can Contribute To Most Suspect When and why Sp
49. will be repaired or exchanged at our option for a properly functioning unit in similar or better condition Such repairs or exchanges will be made FOB Factory Los Angeles or the location of our nearest factory representative or authorized distributor Disclaimers of Warranties e This warranty is expressly in lieu of any other warranties express or implied including any implied warranty of merchantability or fitness fora particular purpose and of any other obligations or liability on the part of SWI or any producing entity if different e Warranty repairs exchanges do not cover incidental costs such as installation labor freight etc e SWlis not responsible for consequential damages from use or misuse of any of its products e products are precision mechanical electromechanical measurement systems and must be given the reasonable care that these types of instruments require e Replacement of chip scrapers and wipers is the responsibility of the customer Consequently the warranty does not apply if chips have been allowed to enter the mechanism e Accidental damage beyond the control of SWI is not covered by the warranty Thus the warranty does not apply if an instrument has been abused dropped hit disassembled or opened e Improper installation by or at the direction of the customer in such a way that the product consequently fails is considered to be beyond the control of the manufacturer and outside the scope o
50. 0 Bearing 6006Z _1 021 Screw Gear Bearing Cover _1 B022 Riser Transfer Shaft _1 B023 Riser Transfer Shaft Bracket _2 B024 Bearing 6006Z _1 B025 Bearing Sleeve 1 B026 Bearing Cover _1 B027 Dial Holder _1 B028 Dial _1 B029 Bushing _1 B030 Clutch _1 B031 Spring _1 B032 Ram Riser Crank _1 B033 Snap Ring 51 B034 Handle Grip Counter Balance System Parts List PART DESCRIPTION ees _1 B100 Counter Balance TRM _4 B101 Chain Attachment Bolt Nut _2 102 Chain Gear Seat _4 B103 Chain Gear _2 B104 Chain Gear Shaft nap Ring S _4 B105 Snap Ri S 20 1 B107 Counter Balance DPM _2 B108 Chain Gear Seat DPM _2 B109 Chain Gear DPM _2 B110 Chain Gear Shaft DPM B111 Snap Ring DPM 252 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Other Column Parts Parts List PART NO DESCRIPTION _1 200 Column Top Cover TRM 1 B201 Way Cover Top Column Accordian 1 B202 Way Cover Bottom Column Accordian _2 203 Ram Gib Lock Handle and Plunger _2 204 Ram Back Gib el B205 Ram Side Gib _ 206 Ram Gib Adjustment Screw set B208 Ram Gib Chip Guards and Gaskets _1 B209 ProtoTRAK Pendant Arm Assembly _1 B242 Column Top Cover DPM _2 243 Ram Back Gib DPM 1 B244 Ram Side Gib DPM _1
51. 0 FVS132 STUD 7 16 92L 2 31 FVS133 STUD 7 16 56L 1 32 FVS96 JJAM NUT 3 8 16NC 1 33 FVS101 VENTILATOR 2REQ 2 34 FVS136 SCREW SOC HD CAP M6 P1 0x10L 12 35 FVS16 1 VARI SPEED DIAL 1 36 FVS95 JHEX CAP NUT 5 16 18NC 1 37 FVS16 2 INAME PLATE 1 38 FVS19 DRIVE SCREW 1 39 OIL 1 JFRU K3 OIL CUP 1 TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100593 K4 183 Southwestern Industries Inc Figure 101 Gear Housing Sub Assembly P N 20697 1 i20697 1 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Item P N Description Aty 1 FVS82 GEAR HOUSING 1 2 FV112 GUIDE SPRING 3 3 FV113 SPRING GUIDE PIN 3 100594 K4 184 Figure 102 Hi Low Slip Clutch Sub Assembly P N 20697 2 i20697 2 Item P N DESCRIPTION Qty 1 FVS75 BEARING SLIDING HOUSING 1 2 23943 BEARING DEEP GROVE U SET 2 6910ZZ 1 SET 3 FVS78 BEARING SPACER 1 4 FVS79 BEARING SPACER 1 5 FVS80 SNAP RING R 75 1 6 FVS73 SPLINED GEAR HUB 1 7 FVS72 KEY 8x7x10L 1 8 FVS74 SPINDLE BULL GEAR 1 9 IFVS114 WASHER 1 10 FVS115 EXTERNAL TOOTH WASHER 50 1 11 FVS81 LOCK WASHER 50 18NC 1 12 FVS76 RING 1 13 20818 SPACER BEARING 1 i20697 2 185 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation
52. 0001 indicator on the spindle and move it up to one side of the gage block or standard If using a 150 mm standard position the flats toward the motor side of the table for the X axis position the flats toward the Z column for the Y axis 3 Selectthe axis you want to check by selecting the appropriate program file as stated in the above paragraph 4 When running the program rotate the standard out of the way of the oncoming indicator The program will allow sufficient time to turn the standard for a clear path after which time it can be turned again for another reading 176 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual START here 101080 1 FIGURE 5 46 Typical set up for an X axis accuracy repeatability check 5 2 5 1 Program for the X axis Will Run as Follows Movement from START to point A about 2 0 of travel From the START position manually advance the table to position A Then zero out the indicator and the DRO at point A Set the Z retract position To set Z retract first set the DRO at the desired value X Y Z 0 then press JOG and move Z to 2 0 inches Then press MODE press RUN press SET Z RETRACT then press INC ABS SET Turn the flat position A out of the way so the indicator will not crash into it Run the program After the indicator starts to move away from position A turn the flat back into place so the indicator will read
53. 1 Mechanical Drive Train Misalign ballscrew or top and lower bearing failure Z axis motor failure Replace Z axis motor See Motor Diagnostics Section 4 4 65 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 3 5 2 Spindle Stalls or Turns Off During Machining During machining the spindle turns off and loses power First check incoming voltage and connections Possible Cause Check This Machine Tool and Setup problem Check the type of material being cut type and size of cutting tool RPM and Feed rate Also check the condition of the cutter to verify that the cutter is not dull See Machine Tool amp Setup Section 4 1 Drive Belt 3 5 3 Spindle Motor Hums or Will Not Run The spindle motor makes a constant humming noise during operation or will not turn on Sport and SM models only If the spindle does not run you must make sure 110 V 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 then 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 110 V power in the E stop circuit See Section 3 3 11 If power has reached the electrical box then use the schematic in Section 4 8 for how the power is routed Po
54. 13 FVS27 SPEED CHANGE HANDWHEEL 14 FVS18 FULL DOG SOCKET SET SCREW M6 P1 0x10L 15 FVS28 HANDLE 3 8 16NC 16 VS24 1 JWASHER WAVE i20697 7 Figure 107 Speed Change Handwheel Sub Assembly P N 20697 7 192 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 9 4 i00601 K4 Item P N Title Qty Notes 1 FVS110 MOTOR 5 HP 1 only available as 20820 1 2 FVS3 1 KEY 6x6x45L 1 only available as 20820 1 3 FVS2 STATIONARY MOTOR VARIDISC 1 only available as 20820 1 4 FVS6 JBUSHING 1 Javailable as 24054 or 20820 1 5 FVS5 ADJUSTABLE MOTOR VARIDISC 1 Javailable as 24054 or 20820 1 6 FVS6 1 KEY 7x7x50L 1 available as 24054 or 20820 1 7 FVS8 SPRING FOR VARIDISC MOTOR SHAFT 1 Jonly available as 20820 1 8 FVS9 ADJUSTABLE VARIDISC SPRING COLLAR 1 only available as 20820 1 9 FVS10 SCREW SOC HD CAP M8 P1 25x30L 1 Jonly available as 20820 1 10 24054 VARIDISC ASSY 1 100601 K4 Figure 108 Spindle Motor Sub Assembly P N 20820 1 193 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Bottom Housing Assembly Figure 109 194 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Bottom Housing Assembly
55. 16516 57 AK142 ROLL PIN 2 16516 58 AK143 SPRING 1 16516 59 AK144 HI LOW DETENT PLUNGER 1 16516 60 AK145 HI LOW SHIFT CRANK 1 16516 23912 61 AK146 BAKELITE BALL HANDLE 1 16516 23912 SPACER BULL GEAR BEARING SPACER 8 62 16529 SLEEVE 1 63 23912 HI LOW SHAFT ASSEMBLY 1 64 AK162K 1 NAMEPLATE 1 65 AK157L VARI SPEED DIAL 1 66 16517 DPM SPINDLE SPEED HANDWHEEL ASSY 1 67 16514 DPM LOW RANGE BULL GEAR ASSY 1 68 16515 DPM LOW RANGE PINION ASSY 1 69 16516 DPM LOW RANGE PINION ASSY 1 70 AKO75 SCREW SET 1 16517 71 20752 UPPER HEAD ASSV 1 100105 230 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 135 Head Back Gear TRM DPM Sport B3 amp DPMS3 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Head Back Gear Item P N DESCRIPTION Qty Assy 1 AK001H BELT HOUSING ASSY SPECIAL ORDER 1 2 AK002K BELT HOUSING BASE 1 3 AK003H GEAR HOUSING SPECIAL ORDER 1 4 AK006K MOTOR PULLEY COVER 1 5 AK007 MOTOR 3 HP 4P 3PH not sold separately 1 16501 7 AK030 KEY FOR STATIONARY VARIDISC MOTOR SHAFT 1 16501 8 AK032 STATIONARY VARIDISC NEW KEY NOT INCLUDED 1 16501 9 AK036 ADJUSTABLE VARIDISC ASSY WITH KEY AK037 1 16501 10 AK037 KEY
56. 2X3 8 317 SCREW PH PHIL EXT SEMS STL ZINC EA 8 7 1 2 70P WASHER FLAT USS STL PLAIN EA 1 9 15616 HANDWHEEL ASSY MX EA 1 10 1 2 752 WASHER EXT TOOTH STL ZINC EA 1 11 1 2 20 51Z NUT HEX JAM STL ZINC EA 1 12 15614 WASHER 1 13 14772 SPACER 100 THICK EA 1 14 15980 BEARING HOUSING EA 1 15 20373 BEARING ANGULAR CONTACT 7204 BECBP EA 2 16 15885 RING BEARING HOUSING EA 1 17 15626 SEAL BEARING HOUSING EA 1 18 16350 FERRULE SPROCKET EA l 19 16983 1 PULLEV SOLI D 44 TEETH W O GUI DES EA 1 20 16452 NUT CLAMP X Y 8 Z AXIS EA 1 21 500 5M 15 TIMING BELT EA 1 22 15627 1 DIAL HOLDER EA l 24 10 32X3 4 25B SCREW SHCS STL BO EA l 28 1 4 20X124B SCREW HEX HD STL BO EA 4 29 15759 WASHER 1 4 HARD BLK OX 1 8 THK EA 4 30 98481A090 KEY WOODRUFF 404 1 8 X 1 2 EA 1 31 15836 DIAL NUT EA 1 32 M5 0 8X10 102 JSCREW PH PHIL STL ZINC EA 2 123158 2 139 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 1 11 Z Axis Ball Screw Removal amp Replacement Refer drive to the following chart for illustrations and parts lists of the Z axis assembly for each model Z axis Drive Train Machine Model Figure Ballscrew TRM N A B004 DPM 5 26 16806 m DPM5 5 26 16806 m Sport B3 5 26 16806 m Sport B5 5 26 16806 m DPMS3 5 27 16806 m DPMS5 5 27 16806 m DPME2 5 28 23662 CAUTI ON Never screw a ball screw parti
57. 3 FEED ENGAGE PIN 1 16511 96 A206H WORM GEAR CRADLE THROW OUT 1 16519 97 A208H SHIFT SLEEVE 1 16519 102 A217 FEED REVERSE BEVEL GEAR 1 16511 103 A217H CLUSTER GEAR KEY 1 16511 104 A218H FEED DRIVING GEAR 1 16511 TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 236 Southwestern Industries Inc 105 A221H FEED DRIVE GEAR 1 16511 106 A222H KEY 1 16511 107 A223 BEARING NEEDLE 1 108 A224 HANDLE 1 16509 109 A225 HANDWHEEL 1 16509 110 A226 FEED REVERSE KNOB STUD 1 16525 111 A227 REVERSE KNOB 1 16525 112 A228 SNAP RING 1 16525 113 A230 KEY 1 114 A231H REVERSE CLUTCH ROD 1 115 A232H FEED WORM SHAFT 1 116 A233 HANDWHEEL CLUTCH 1 117 A235 1 FEED WORM SHAFT THRUST WASHER 1 118 A235L BUSHING 1 119 A236 FEED WORM SHAFT BUSHING 1 120 A237 WORM 1 121 A238 PIN 1 122 A239 BUSHING 1 123 A240 PIN 1 125 A242 KEY 1 126 A241 FEED REVERSE BEVEL GEAR 2 127 A243 ROLL PIN 1 128 A244 FEED REVERSE CLUTCH 1 129 A245 FEED REVERSE BEVEL GEAR 1 130 A246H LOCK HANDLE 1 16527 131 A247H QUILL LOCK SLEEVE 1 132 A248H QUICK LOCK BOLT 1 16527 133 A267 COMPRESSION SPRING 1 134 A269 STEEL BALL 1 135 A270 OVERLOAD CLUTCH WASHER 1 16512 136 A273 SNAP RING 1 16512 137 A274 FEED REVERSE TRIP PLUNGER 1 138 A276 TRIP PLUNGER BUSHING 1 139 A277 OVERLOAD CLUTCH LEV
58. 38 VS56 BRAKELOCKHANDLE 39 VS57 BAKELITEBALLHANDLE 40 100690 K2 K3 206 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100691 K2 K3 VS82 GEAR HOUSING 1 2 VS112 GUIDE SPRING 3 VS113 SPRING GUIDE PIN i00691 K2 K3 Figure 119 Gear Housing P N 20778 1 207 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Tira CA i20697 2 Figure 120 Hi Low Shift Clutch Sub Assembly P N 20778 2 208 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List High Low Shift Clutch item PN DESCRIPTION Qy 6 573 SPLINEDGEARHUB 0 1 8 VS74 SPINDLEBULLGEAR j 1 SHIA WASHERS aa t 10 VS115 EXTERNALTOOTHWASHER 40 1 11 VS81 OCKWASHERO916 18NC 1 12 VS76 RING 1 1 13 20817 SPACERBEARING 1 1 100692 K2 K3 209 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 121 Hi Low Shift P N 20778 3 Item P N DESCRIPTION Qty 1 VS89 HI LOW DETENT PLATE 1 2 VS87 JCLUTCH GEAR SHAFT 1 3 VS92 HI LOW PINION BLOCK 1 4 VS91 JSPRING 1 5 VS90 HI LOW DETENT PLUNGER 1 7 VS8
59. 4 1 8 X 1 2 1 16 14772 SPACER 100 THICK EA 5 19 400 5M 15 TIMING 5 MM POWERGRIP EA 1 20 20373 BEARING ANGULAR CONTACT 7204 BECBP EA 2 22 14772 2 SPACER 020 THICK EA 2 23 14772 5 SPACER 050 THICK EA 2 41 8 32X3 8 25B SCREW SHCS STL BO EA 6 42 5 16 18X1 25B SCREW SHCS STL BO EA 1 45 M10 1 5X65 25B SCREW SHCS STL BO EA 4 46 1 4 20X124B SCREW HEX HD STL BO EA 7 47 8 32X3 8 20B SCREW RH PHIL STL BO EA 3 48 10 32X3 4 25B SCREW SHCS STL BO EA 1 49 1 2 20 512 NUT HEX JAM STL ZI NC EA 2 52 15759 WASHER 1 4 HARD BLK OX 1 8 THK EA 7 54 M10 70P WASHER FLAT USS STL PLAIN EA 4 55 1 2 73B WASHER SPLIT LOCK STL BO EA l 56 1 2 70P WASHER FLAT USS STL PLAIN EA 1 TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 120255 2 125 Southwestern Industries Inc 5 1 10 Ball Screw Replacement Y Axis Saddle Refer to the following chart for illustrations and parts lists of the Y axis drive assembly for each model Y axis Drive Train Machine Model Figure Ballscrew P N TRM 5 19 5 20 15609 16 DPM 5 19 5 20 15609 16 DPM5 5 21 21564 Sport B3 5 22 15609 16 Sport B5 5 21 21564 DPMS3 5 23 15609 16 DPMS5 5 24 21564 DPME2 5 25 15609 16 CAUTI ON Never screw a ball screw partially or totally out of its nut They cannot be reassembled Position the saddle all the way forward Remove the hand wheel assembly and brack
60. 4 6 or 4 7 properly 3 3 5 Problems Reading the Floppy Disk Programs Not Saved Properly The floppy drive will not read or write programs from a disk Possible Cause Check This Improper Boot up Shut down the system and wait 10 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 Floppy Disk full Put the Floppy Disk into a Personal Computer to see how many bytes remain A floppy can typically hold 1 4 MB of information 58 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 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 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 Remove fuses and check continuity cabinet Where applicable Flash Drive failure When the Computer Module starts the boot up process look at the 8 line on the Display Screen If the Mother Board of the Computer Module is commun
61. 4 a 4 Remove key item 13 Remove front hub assembly item 5 from hand wheel box Remove gear item 11 at the end of the ball screw 6 a Remove extension cover item 8 use Allen wrench on item 14 to help support ball screw from rotating and back out the extension cover support screw 6 b Loosen setscrew item 14 6 c Slide Left Gear out 6 d Remove key item 13 Remove hand wheel box item 1 Remove ball screw extension item 7 8 a back out setscrews item 14 8 b back off extension by sliding a 3 16 Allen wrench through thru hole pushing it up against the end of the ball screw pushing the extension slightly away from the bearing 8 c Using two large screwdrivers pushing off the saddle slide the extension off Use a mechanical puller to remove the bearing Re Assembly of Handwheel Box 1 Slide bearing on to the end of the ball screw item 9 use a socket or piece of aluminum tubing and a dead blow hammer to tap bearing till it flushes up against the step of the ball screw Slide the extension on and flush it up against the bearing lock down with both setscrews item 14 Item 19 can be used to push the extension from the end of the ball screw to adjust the gear spacing Bolt the handwheel box item 1 down Bolt the front hub assembly items 6 10 and 5 on Slide the shaft assembly items 3 12 9 and 4 in through the backside and bolt the cover hub on 112 Southwestern Indus
62. 5 33 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100907 CONTACTER FORWARD Figure 2 21 Wiring the DPMS3 amp DPMS5 20676 20676 1 34 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 2 12 4 Pendant and Wiring Diagrams for DPME2 EDGE Figure 2 22 EDGE 3 Pendant Rear DPME2 23689 USA 35 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 101306 Figure 2 23 Electrical Box Without Transformer DPME2 SWIPN Descripton 22127 DPME2 AC DRIVE PROGRAMMED DPME2 3 HP 22961 RELAY POWER 115V DPST 22595 RELAY POWER 115V SPDT 22890 200 RESISTOR 200W 600 101306 36 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual LIMIT NOTE OUTSIDE VIEW CONNECTION SWITCH AN A WT AC NEUTRAL AC NEUTRAL Z LIMIT s DOOR GUARD 9 a o E STOP 220 TO SPINDLE MOTOR FAN 3 PHASE AC TO SPINDLE MOTOR 101307 Figure 2 24 Electrical Schematic DPME2 2 12 5 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 phas
63. 5V AC TO COMPUTER BOX TO SWITCH BOX LOGIC TO INDEXER HAAS AUX FUNCTIONS FROM COMPUTER BOX DPM 115V AC TO COOLANT PUMP SHOP AIR IN DPM PNEUMATIC DEVICE OUT DPM Figure 2 13 Electric Box Connections DPM amp DPM5 26 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual A V 1 1 691 YSWYOASNVYL LNOHLIM Wd 111 01 p 1 90153 01 YSLNdWOI OL IV INVON3d dWAd OL _ m gt 23Nvd JSN 1 IVA 511 JANVA INQuj 0310N 3SIMYSHLO SSJINA NOVI 3NV SIHIM TW 310N DPM DPM5 Diagram continued on following page iring W Figure 2 14 27 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual w 86 21 E avi vevegl 82d EM H 8IE Y691 amp 829 XAV 501812414 Wdd JILVWIHIS SAIMISNONI NHILSIMHLMOS B Utd EN OL 01 vid i Bsp npo NO mda QVO TH3AD Sa wan 217 FAS STT veli TaNVd STI METSSEA E WIA 134VdS 0 vail t ISNETF NI ov d el 918 Xepui ra x m DPM amp DPM5 iagram iring Di 28 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation M
64. 7 e motor encoder and position encoder is not within 5 of each other recalibrate the system If the problem persists the motor encoder is suspected Note If the motor encoder is bad it will be necessary to replace the entire motor 91 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List 4 11 7 CODE 102 Y Axis Motor Encoder Test Manually move the saddle handwheel See Code 100 above 4 11 8 CODE 103 Z Axis Motor Encoder Test Manually move the quill and ball screw See Code 100 chart above for displayed values 4 11 9 CODE 123 Calibration See Section 5 2 2 for a further explanation of this code 4 11 10 CODE 127 Set X or Y Backlash Constant See Section 5 22 for a further explanation of this code 4 11 11 CODE 128 Input Backlash Constant Code 128 allows you to enter the feedback controlers backlash values for each axis It displays the value after it enters This code is used on machines with motor encoders only no secondary feedback encoders 4 11 12 Code 129 Arc Accuracy When the control operates at high feedrates it may create small part machining errors as it goes around sharp corners This exists on all CNCs 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 app
65. 73H SPEED CHANGE SHAFT 1 16517 21 AK076 SPEED CHANGE HANDWHEEL 1 16517 22 AKO080 HANDLE 1 16517 23 AKO82 PIN 1 24 AK083 SPEED CHANGER CHAIN DRUM 1 25 AK084 SPEED CHANGER SPUR GEAR 1 26 AK085 KEY 3X3X8 1 27 AK086 PIN 1 28 AK087 HEX CAP NUT 1 29 88 PLATE CAUTION 1 16517 30 AK092 SET SCREW 1 31 AK100L SPINDLE BULL GEAR ASSY 1 16514 32 AK101L SPINDLE GEAR HUB 1 16514 33 AK102 KEY 8X8X12 1 16514 34 AK103L LOCK WASHER 1 16514 35 AK103L 1 COLLAR 1 16514 36 AK104L NUT 1 16514 37 AK105L BEARING SLEEVE 1 16514 38 AK106L BEARING GEAR SLEEVE WASHER 1 16514 BEARING DEEP GROVE U SET 2 691077 39 23943 AK109L 1 16514 40 AK110L BULL GEAR BEARING SPACER 1 6514 16529 41 AK111L SLEEVE 1 16514 16529 42 AK113 COMPRESSION SPRING 3 16514 43 AK114 BULL GEAR PINION COUNTER SHAFT 1 16515 44 115 KEY 5X5X18 1 16515 45 AK116 KEY 5X5X11 5 1 16515 46 AK117 BULL GEAR PINION 1 16515 47 23954 BEARING DEEP GROOVE SET 2 6203ZZ AK118 1 16515 48 AK119 PULLEY TIMING 1 49 AK120 JAM NUT 1 229 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 50 AK121 BELT 1 51 AK121L SNAP RING 1 16514 52 AK122 BULL GEAR PINION BEARING CAP 1 53 AK136 BULL GEAR SHIFT PINION 1 16516 54 AK137 HI LOW DETENT PLATE 1 16516 56 AK141 HI LOW PINION BLOCK 1
66. 7L BEARING SPACER SMALL 1 16502 51 A109H QUILL 1 16502 52 A110H SPINDLE 40 NOT FOR SALE 1 16502 26392 53 A112H BEARING DEEP GROVE 6008ZZ 1 16502 54 A113H SNAP RING 1 16502 55 A114H LOCKNUT 1 16502 56 A114H 1 SPECIAL SOCKET SET SCREW 1 16502 57 A114H 2 WASHER 1 16502 58 A154 WORM GEAR 1 59 A155 TRM KEY 1 60 A156H TRM WORM SHAFT 1 61 A164 BLACK PLASTIC BALL HANDLE 1 16506 62 A165 PINION SHAFT HUB HANDLE 1 16506 63 A166 BACK FEED HANDLE HUB 1 16506 64 A167 PINION SHAFT HUB SCREW 1 16505 65 A168 PINION SHAFT HUB SLEEVE 1 66 A169 KEY 1 67 A170 BALL 1 16506 68 A170A COMPRESSION SPRING 1 16506 69 A173 CLOCK SPRING 1 16504 70 A174 SPRING COVER 1 16504 71 A176 QUILL PINION SHAFT BUSHING 2 16505 72 A176 1 SNAP RING 1 73 A177 PINION SHAFT WORM GEAR SPACER 1 74 A178 OVERLOAD CLUTCH WORM GEAR 1 75 A180 OVERLOAD CLUTCH RING 1 16512 76 A181 OVERLOAD CLUTCH 1 16512 78 A182L QUILL PINION SHAFT 1 16505 79 A183 SAFETY CLUTCH SPRING 1 16512 80 A185 PLUG BRASS 1 16512 81 A186 OVERLOAD CLUTCH LOCKNUT 1 16512 82 A187 CLUTCH RING 1 16512 83 A188 CLUTCH RING PIN 1 16512 84 A189 SNAP RING 1 16512 85 A190 OVERLOAD CLUTCH SLEEVE 1 16512 86 A190A KEY 1 16512 87 A192L WASHER 1 16511 88 A193L FEED DRIVE WORM GEAR SHAFT 1 16511 89 A196L FEED WORM GEAR SHAFT SLEEVE 1 16511 90 A197L WORM CRADLE BUSHING 1 16511 91 A198L WORM GEAR SPACER 1 16511 92 A199L FEED DRIVE WORM GEAR 1 16511 93 A200 WORM SHAFT KEY 1 16511 94 A202L WORM GEAR CRADLE 1 16511 95 A20
67. 8 PIN 3X19L 1 8 VS93 SCREW M5 P0 8x15L 2 9 VS92 1 SET SCREW M5 P0 8x5L 1 10 VS92 2 WASHER FLAT 11 1 12 VS116 WASHER FLAT M5 1 13 24083 SHAFT HI LOW SHAFT ASSY 1 i00693 K2 K3 210 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Teg see 100694 2 A Item P N DESCRIPTION Qty 1 VS67 JBULL GEAR PINION COUNTER SHAFT VS69 KEY 5X5X18L VS66 JBULL GEAR PINION AK118 JBEARING DEEP GROOVE 6203ZZ VS3 SOCKET SET SCREW M6 P1 0x6L JOJN N a 23954 BEARING SET 2 BEARING 620342 100694 K2 K3 Figure 122 Pulley Pinion P N 20778 4 211 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 123 Lower Vari Disc Drive P N 20778 5 assembly not available order parts separately 212 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Lower Vari Disc Drive PN DESCRIPHION Qy 2 VS59 BRAKEBLOCK ff 2 3 558 TURNINGBLOCKSHAFT 1 4 5103 RETANINGRINGO7 1 5 5 51 SET SCREW M6 1 0X6L 2 6 VS58 BRAKELOCKBUSHNG 7 VS582 BRAKELOCKSHAFT Tt 8 VS52 2 BRAKELOCKPINDIA3X5 8 L 1 9 VS BRAKESHOE
68. AC 7 MOTOR CABLE ASSY LOGIC 5 VDC Z SENSOR Figure 2 26 Cable Interconnection DPM amp DPM5 41 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual UMBILICAL DB 25 115 VAC TO ECB 115 VAC TO COOL ELECTRICS BOX 115 VAC TO WORK LIGHT OPTIONAL Figure 2 27 Cable I nterconnections Sport B3 42 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual LUBE PUMP Z hH ZMOTOR 2 ELECTRIC HANDAHER Y LMT SMTCHX Y amp Z ELECTRIC CABLE BOX _ ZGLASSSCAE Figure 2 28 Cable Interconnections Sport B5 43 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 88001 HOLIMS 8 4 NI dO1S 3 6 ee INV 1000 7 OL Orbi0zz SSVHd AOET 230V OPPJOZZ 3S vHd M3X3dNI e e e 9 o T 885 1 9 HOLMS Z AX C 91 69922 zi voniawn Nd
69. ACK SLIDING SURFACE OF THE COLUMN LEFT SIDE TO COLUMN LEFT SIDE SLIDING SURFACE TO COLUMN Z AXIS RIGHT SIDE SLIDING SURFACE TO X amp Y LUBRICATION SYSTEM ALL TUBES ARE 4mm ALLUMINUM TUBE NOTES UNLESS OTHERWISE SPECIFIED Figure 139 Lubrication Pump amp Ram DPM5 DPMS3 DPMS5 242 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Lubrication Pump amp Ram DPM5 DPMS3 DPMS5 Item P N Description Qty 1 211571 LUBRICATION PUMP DPM5 0 3 B3 DISTRIBUTOR OILREGULATINGB 3 4 j PG004 PLUG M8X10 0 6 1 SLIEEVE MM 19 8 PAN4 NUT 6 13 PSS4 OILDISTRIBUTOR 1 86 17 701064 CLAMP 20 16532 OILERGAUGEDIAL 1 100661 243 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual EA E8200 as Lubrication X amp Y Axis DPMS3 Figure 140 woLnanuisia MEMOSTIVS SIXVX oL Ne JOVIHAS AVM LHOIH SIXV A OL x 819 WOL1O8 1HOhI SiXV AOL 97 Nauos IVa SIXY A OL NG JOVIUNS AVM vau SIXV X oL y 3ov44ns AVA 1431 SIXW AOL 819 WOLLOG 1431 SIXV AOL V sixvx oi W YOLNENYLSIC WOH X 244 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual
70. BUSHING 1 3 FB6 JSETSCREW M6 PP1 0x10L 1 4 FB8 FEED DRIVEWORM GEAR 1 5 FB4 FEED WORM GEAR SHAFT SLEEVE 1 6 FB9 FEED DRIVE WORM GEAR SHAFT 1 7 FB11 KEY 3x3x20L 1 8 FB10 WORM SHAFT KEY 3x3x8L 1 9 FEED BEVEL PINION 1 10 FB2 BEVEL PINION WASHER 5 1 11 FB1 SOC HD SCREW M5 P0 8x10L 1 12 FB16 FEED ENGAGE PIN 1 13 FB36 FEED DRIVING GEAR 1 14 FB36 1 KEY 3x3x8L 1 15 FB15 FEED REVERSE BEVEL GEAR 1 16 FB13 WASHER 6 22 1 17 FB14 SOC HD SCREW M6 P1 0x15L 1 18 FB37 3x3x10L 1 19 FB40 FEED DRIVE GEAR 1 100603 K4 Figure 110 Worm Gear Cradle Sub Assembly P N 20698 1 TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 198 Southwestern Industries Inc 120698 2 Hem P N DESCRIPTION Qty e FB seen 1 8 Fees FEEDGEARSHIFTFORK T rs FB FEEDSHFTROD T i00604 K4 Figure 111 Quill Feed Selector Sub Assembly P N 20698 2 199 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Item P N Title UseAs Qty 1 FB166 QUILL PINION SHAFT EA 1 3 K B92 OVERLOAD CLUTCH WORM GEAR EA 1 4 K B93 OVERLOAD CLUTCH RING EA 1 5 K B92 1 GCREW SOC HD CAP M4 P0 7x15L EA 3 6 K B94 SNAP RING 95 DOWEL PIN 2 14 EA 1 7 K B168 SCREW PIN EA 1 8 25707 BUSHING KIT PINION SHAFT 40 TAPER EA 1 i20698 3 Figure 112 Quill Pi
71. ENG PART 1 8 M6 73B WASHER SPLIT LOCK STL BO 6 9 M6 1 0X25 25B SCREW SHCS STL BO 6 10 7205 AVH NILOS RING 7205 1 11 16295 1 HOUSING BEARING Z AXIS 1 12 16302 RING BEARING HOUSING 1 13 20374 BEARING ANGULAR CONTACT 7205 BECBP 2 14 16773 NUT CLAMP Z AXIS 1 15 10 32 3 4 25B SCREW SHCS STL BO 1 16 16350 FERRULE SPROCKET 1 17 16983 PULLEY SOLID 44 Z AXIS 1 18 N01 LOCKNUT 1 19 W01 LOCKWASHER 1 20 M8 73B WASHER SPLIT LOCK STL BO 4 21 98481A090 KEY WOODRUFF 404 1 8 X 1 2 1 22 M8 1 25X20 25B JSCREW SHCS STL BO 4 23 710 5M 15 BELT TIMING 1 24 23664 PLATE BALL SCREW SUPPORT Z AXIS LM0011 1 25 1 4 20X1 1 4 25B SCREW SHCS STL BO 4 26 15759 WASHER 1 4 HARD BLK OX 1 8 THK 4 27 23655 BRACKET Z AXIS MOTOR DPME2 l 28 23198 MOTOR DRIVER ASSV PT4 DPM SM 4050 1 31 M10 73B WASHER SPLIT LOCK STL BO 8 32 17030 LOUVER SPACER 1 34 M10 1 5X45 25B SCREW SHCS STL BO 8 35 M10 71B WASHER FLAT SAE STL BO 4 116790 XXX 147 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 1 12 Air Solenoid Replacement for Power Drawbar DPMS3 DPMSS only 1 Unhookthe air from the machine 2 Unplug the power cable that connects to the right side of the air regulator bracket 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 th
72. ER SPRING PLUNGER 1 140 A278 COMPRESSION SPRING 1 141 16502 DPM SPINDLE ASSY 1 142 16506 DPM QUILL HANDLE ASSY 1 143 16507 DPM FEEDRATE SELECTOR ASSY 1 144 16509 DPM FEED HANDWHEEL ASSY 1 145 16525 DPM TRM ASSY FEED REVERSE KNOB 1 146 16526 DPM TRM ASSY SHIFT CRANK 2 147 16527 DPM LOCK HANDLE AND BOLT 1 148 16503 SPINDLE QUILL ASSY 1 149 16504 CLOCK SPRING ASSY 1 150 16511 FEED CRADLE ASSY 1 151 16512 FEED CLUTCH ASSY 1 152 16513 MICRO SCREW ASSY 1 153 16519 HANDLE FEED ENGAGE HANDLE ASSY 1 154 16521 FEED REVERSE KNOB ASSY 1 155 23913 TRIP HANDLE ASSEMBLY 1 156 16505 FRU DPM QUILL PINION ASSY 1 TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 237 Southwestern Industries Inc 157 16508 FRU DPM FEED TRIP ASSY 1 158 M5 8X15 SCREW 1 159 3 8 24X1 1 4 SCREW 1 100107 238 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Lubrication Drawings TRM Lubrication System QTY PART NO DESCRIPTION L n l L2 L001 Lubrication Pump L1 L002 Ram Manifold L L003 Lub Machine Coupling Set L 14 j 004 Lub Minifold Coupling Set L L005 Lub Tubing 2 feet L1 1006 Saddie Manifold 1 L007 Flexible Lub Hose 100313 Figure 137 Lubrication System TRM 239 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation
73. FB103 CAM ROD 1 44 FB117 ROLL PIN 3x15L 1 45 FB104 TRIP HANDLE 1 46 FB105 BLACK PLASTIC BALL 1 47 FB119 1 A ROLL PIN 3x20L 1 48 FB107 CAP SCREW M6 P1 0x25L 2 49 FB113 HAND WHEEL CLUTCH 1 195 TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Southwestern Industries Inc 51 FB115 COMPRESSION SPRING 1 53 FB108 SET SCREW M6 P1 0x8L 1 54 FB42 BUSHING 1 55 20836 1 SPINDLE ASSY 40 TAPER 1 56 FB148 QUILL LOCK SLEEVE TAPPED 1 57 FB148 1A JCOMPRESSION SPRING 1 58 FB153 QUILL LOCK SLEEVE 1 59 FB152 QUILL LOCK BOLT 1 60 FB149 LOCK HANDLE 1 61 FB149 1 CONICAL COMPRESSIONAL SPRING 1 62 FB149 2 SCHREW PHILLIP HD 1 63 FB175 RACK FEED HANDLE HUB 1 64 FB114 STEEL BALL 2 65 FB175 2A COMPRESSION SPRING 1 66 FB116 HANDWHEEL CLUTCH SPRING SCREW M8 P1 25x6L 2 67 FB175 3 DOWEL PIN 1 68 FB190 PINION SHAFT HUB HANDLE 1 69 FB191 PLASTIC BALL HANDLES 1 70 FB169 SOC HEAD SCREW M5 P0 8x15L 4 71 FB163 QUILL STOP KNOB 1 72 FB200 SCREW SOC HD 3 8 24NF x 1 1 4 1 73 FB164 QUILL STOP MICRO SCREW 1 74 FB160 SNAP RING 16 1 75 FB161 QUILL MICRO STOP NUT 1 76 FB162 MICROMETER NUT 1 77 FB184 FEED REVERSE TRIP PLUNGER 1 78 FB183 REVERSE TRIP BALL LEVER 1 79 FB185 REVERSE TRIP BALL LEVER SCREW 1 80 FB202 INDICATOR ROD 1 81 FB201 INDICATOR ROD SCREW 1 82
74. IVEGEAR 1 1 19 K B16 JFEEDENGAGEPN 1 20 KB06 SETSCREW M6 P1 0x6L 1 100700 K2 K3 Figure 128 Worm Gear Cradle P N 20779 1 a a a a a a a a a 222 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100701 K2 K3 item PN Title CLUSTER GEAR COVER CLUSTER GEAR SHAFT CRANK SHIFT CRANK 4 K B69 SPRING 2 3 x 20L 5 KB68 GEAR SHIFT PLUNGER 6 KB72 SHIFT KNOB 5 16 18NC ROLL PIN 3 x 20L 8 KB63 FEED GEAR SHIFT FORK 9 1 10 61 SET SCREW M5 P0 8x5L 100701 K2 K3 Figure 129 Ouill Feed Selector P N 20779 2 223 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Item P N Title UseAs Qty 1 K B166 QUILL PINION SHAFT EA 1 2 25706 BUSHING KIT PINION SHAFT R8 EA 1 3 K B91 WASHER EA 1 4 K B92 OVERLOAD CLUTCH WORM GEAR EA 1 5 K B93 OVERLOAD CLUTCH RING EA 1 6 K B92 1 SCREW SOC HD CAP M4 P0 7x15L EA 3 7 K B94 SNAP RING 95 DOWEL PIN 14 EA 1 8 168 SCREW PIN EA 1 i20779 3 Figure 130 Quill Pinion Shaft P N 20779 3 TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 224 Southwestern Industries Inc item PN Title OVER
75. LOAD CLUTCH SLEEVE KEY 5x8x13L OVERLOAD CLUTCH SAFETY CLUTCH SPRING 6 76 SOCKET SET SCREW Me P10x8L 1 8 KB97 OVERLOADCLUTCHWASHER 1 9 KB98 SNAPRINGO 10 1 1 x jggzogg ko ks Figure 131 Overload Clutch Trip P N 20779 4 225 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100704 K2 K3 item P N Title 1 K B57 FEEDWORMSHAFT Tt 2 KB47 FEEDWORMSHAFTTHRUSTWASHER 1 3 K B44 FEEDWORMSHAFTBUSHNG 1 5 kB59 PINOSI2L 1 4 6 KB49 FEEDREVERSEBEVELGEAR 1 1 7 KB48 BUSHING 1 4 8 KBe2 KEYSX3xiSL c r j 1 9 KB50 FEED REVERSE CLUTCH j 1 10 KB56 JPINO3OL 1 1 11 K B51 FEEDREVERSEBEVELGEAR 1 1 18 KB55 REVERSECLUTCHROD Ct i00704 K2 K3 Figure 132 Feed Reverse Clutch P N 20779 5 226 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual DESCRIPTION PINDLE R8 PINDLE DIRT SHIELD EARING ANGULAR CONTACT U SET 2 7207 P4 ASET EARING SPACER SMALL 1 EARING SPACER LARGE 1 OSE PIECE 1 LEEVE 1 EARING DEEP GROVE 6206ZZ 1 1 i 1 1 1 1 PT KEE PT RES AE EARING LOCKWASHER9 30 1 1 1 2 1 SET K B129 SPINDLE BEARING LOCK NUT 030 20N K B150 1 1 1 TRAIGHT L
76. NG 1 57 K B153 QUILL LOCK SLEEVE TAPPED 1 58 KB 201 INDICATOR ROD SCREW 1 59 K B149 LOCK HANDLE 1 60 KB 202 INDICATOR ROD 1 61 K B164 QUILL STOP MICRO SCREW 1 62 K B160 SNAP RING 16 1 63 K B124 2 FEED TRIP PLUNGER NUT M40 P0 7 2 64 K B124 1 FEED TRIP PLUNGER SOC SET SCREW M4 P0 7x20L 1 65 K B145 FEED TRIP LEVER 1 66 K B124 FEED TRIP PLUNGER 1 67 K B185 REVERSE TRIP BALL LEVER SCREW 1 68 K B144 SOCKET SET SCREW 1 69 K B183 REVERSE TRIP BALL LEVER 1 70 K B161 QUILL MICRO STOP NUT 1 71 K B162 MICROMETER NUT 1 72 K B123 TRIP PLUNGER BUSHING 1 73 K B184 FEED REVERSE TRIP PLUNGER 1 74 K B121 TRIP PLUNGER 1 75 K B120 COMPRESSION SPRING 1 76 K B158 CHEM BLACKED RD HD SCREWS 2 REQ M5 P0 8x8L 2 77 K B118 CAM ROD SLEEVE ASSY 1 78 K B159 MICROMETER SCALE 1 79 KB 200 SCREW SOC HD 3 8 24NFx15L 1 80 K B163 QUILL STOP KNOB 1 81 20779 5 FEED REVERSE CLUTCH SUB ASSY 3VK B5 1 82 OIL 1 OIL CUP 1 83 K B109 KEY 3x3x20L 1 84 K B17 1 WORM GEAR SET SCREW M6 P1 0x8L 1 85 K B88 1 COMPRESSION SPRING 1 86 K B89 OVERLOAD CLUTCH LEVER SPRING PLUNGER 1 87 20779 3 SUB ASSY QUILL PINION SHAFT R8 1 88 K B167 KEY 5x5x25L 1 89 K B27 1 SET SCREW M6 P1 0x8L 1 90 K B41 NEEDLE BEARING BA66 BEARING SIZE KO BA66Z 1 91 K B192 QUILL HOUSING 1 92 K B104 TRIP HANDLE 1 93 K B105 BLACK PLASTIC BALL 1 94 125 1 HANDWHEEL SPRING PIN 3x3x10L 1 95 K B125 HANDW HEEL 1 96 K B111 REVERSE KNOB 1 97 K B100 CAP SET SCREW M5 P0 8x35L 3 TRAK amp Sport Bed M
77. Note Remember that there are two floppy disk drives The bottom disk drive is for the system disk 4 11 4 CODE 97 System Axis Configuration This procedure sets the Plus and Minus motion for the Motor encoders It is often necessary to perform this procedure after a new installation or after installing a new Computer Pendant Steps l Center the table and saddle and position the quill about halfway down 2 Go into Service Codes and input Code 97 3 Very carefully move the table the saddle and the quill in the positive direction less than 6 inches for each axis Positive motion is e X table moves to the left so the tool moves to the right relative to the workpiece CW 88 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service 8 Parts List Y saddle moves toward the front so the tool moves up relative to the workpiece CCW e Z the quill moves up the ram moves up The ram and quill must both be moved in the positive direction To move the ram turn the ball screw manually If you do not move correctly from the beginning repeat the procedure 4 Press INC SET to signal the procedure is complete 4 11 5 CODE 100 Axis Open Loop Test Code 100 procedure is used to diagnose problems with the configuration of the system the encoders and incoming A C voltage IMPORTANT SAFETY NOTICE During this procedure the designated axis will be given a command to move at maximum
78. OWER CLAMP 4 151 ELT OIL STRAINER K B150 2 TRAINER UPPER CLAMP K B139 CREW PH HD M5 0 8X8L 20840 EARING SPACER SET K B150 1 1 2 14 2 6 1 100705 K2 K3 Figure 133 Spindle Assembly P N 20836 227 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual TRM DPM Sport B3 amp DPMS3 Head Top Housing Figure 134 1 9 2 228 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Head Top Housing P N 20752R Item P N DESCRIPTION Qty ASSY 1 AKOO1H BELT HOUSING ASSY SPECIAL ORDER 1 2 GEAR HOUSING SPECIAL ORDER 1 3 AKOO4H FIXED CLUTCH BRACKET 1 4 SPEED CHANGER HOUSING 1 5 AKOO6K MOTOR PULLEY COVER SPECIAL ORDER 1 6 16501 MOTOR VARI DISC ASSY AK007 1 7 AK014 1 GREASE CAP 1 8 AK016 STUDS 7 16 THREAD SHORT 3 9 AK019 STUDS 7 16 THREAD LONG 3 10 AK022 OIL CUP 1 11 2 TOP BEARING CAP 1 13 AKO45L SPINDLE PULLEY HUB 1 14 AK046 CLUTCH SLEEVE 1 15 AK067 ROLL PIN 1 16 AKO68K SPEED CHANGE CHAIN STUD 1 17 AK069 SPEED CHANGER CHAIN 1 18 AKO71 BOSTON WORM GEAR 1 19 AKO72 ROLL PIN 1 20 AK0
79. PM5 Sport B3 DPMS3 S5 DPM Sport B5 E2 1 Electrical Box 20065 17009 21800 20676 220 20676 1 23630 Relay Module 220 220 220 220V amp 440V 440 20676 220V 20065 17009 21800 220V 20676 1 only 440 440 440 B5 Only 2 Cable Breakout Box N A N A N A 20290 23050 N A 3 Cable Breakout Box N A N A N A 20290 1 23050 1 N A with AUX Functions All replacement part numbers have a suffix R 15 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual For example 20065 220R and 20676 1R 2 8 Lifting and or Moving the Machine CAUTION The TRAK amp Sport bed milling machines weigh between 3200 and 4400 Ibs Proper equipment of sufficient capacity must be used when lifting and or moving the machine Method 1 see Figure 2 5 1 Insert a steel bar 1 0 dia x 36 long through the rear side holes of the bed under column 2 Usea steel cable with protective sleeving min 3 4 dia or a 3 ton sling 3 Use cardboard pieces or other suitable protective sheets on both sides of the machine to prevent scratching Remove the 4 nuts and screws holding the machine to the wood skid Lift the machine the front side of the machine should be lower than the back side Insert the 6 screws for leveling pads in their place in the bed 4 screws for DPME2 Who Place the machine in its location see floor plan and bed footprint
80. PULLEV SOLID 44 TEETH W O GUIDES 1 37 16350 FERRULE SPROCKET 1 i00771 X S3 ee eee eel 119 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual So So Su P 29 REF 9 80 REF 4X 29 14 100626 Figure 5 16 X Drive Train DPMS5 120 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual DPMS5 X Drive Train Parts List lem Description 4 15967 X COVER UPER 6 21585 1 JCOVER BALLSCREWEND 1 11 6 32X1 210B SCREW PH PHIL STL BO 9 RING BEARING HOUSING mu SEAL BEARING HOUSING NUT HEX STL PLAIN M8 1 25X25 SCREW SHCS STL BO 25B M8 74B WASHER EXT TOOTH STL BO 1 4 20X1 24B JSCREW HEX HD STL BO l S 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 1 F 6350 ERRULE SPROCKET 2 20 512 NUT HEX JAM STL ZINC 2 752 WASHER EXT TOOTH STL ZINC 1 1 2 1 25B 1 5616 HANDWHEEL ASSY MX 15614 TAB WASHER 100771 X S5 2 70P WASHER FLAT USS STL PLAIN 1 4 4 EN CREW SHCS STL BO WASHER 1 4 HARD BLK OX 1 8 THK 40 121 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual X AXIS BALLSCREW N A kaka BA RS H o W e NOTE ITEM 11 MUST BE REMOVED FROM INSIDE THE BOX IT IS SHOWN THIS
81. S REAR WAY SURFACE TO Y AXIS BALLSCREW TO Y AXIS RIGHT WAY SURFACE TO X AXIS BALLSCREW 100783 E2 FROM DISTRUBUTOR Item P N Description Oty il 2 PH4 8 ELBOW 1 3 4 L015 PLUG M8 X 1 0 PG004 1 5 L013 BUSHING PA4 9 6 L014 SLEEVE 4 MM PB4 9 7 8 10 1012 TEE ADAPTER PKD4 1 11 FHC405 HOSE 1 12 L006 DISTRIBUTOR DB10 1 13 PSS4 OIL DISTRIBUTOR 6 14 L005 TUBING 4MM ALUM A4 XX 15 i00783 E2 250 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 144 Head Ram Riser Drive System TRM B021 B019 251 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Head Ram Riser Drive System for Figure 6 45 OLY PART NO DESCRIPTION _1 B001 Ram Riser Feed Nut Bracket 1 B002 Ram Riser Nut Top B003 Ram Riser Nut Bottom _1 B004 Ram Riser Screw _1 B005 Bearing 62042 _1 B006 Ram Riser Top Bracket 51 B007 Bearing 51104 _1 B008 Nut AN04 _1 B009 Bearing Protector _2 B010 Bearing 30205 _1 B011 Ram Riser Screw Lower Bracket B012 Nut AN05 _1 B013 DC Motor Seat X B014 Gear Box _1 015 Screw Gear Shaft _1 B016 Bearing 60092 _1 B017 Bevel Angle Spur Gear 1 B018 Bearing 6004Z 1 1 B019 Bevel Angle Spur Gear 1 B02
82. Sport B3 amp DPMS3 Glass Scale Alignment DPM5 Sport B5 DPMS5 Power Drawbar Assembly X Drive Assembly for TRM DPM amp Sport B3 X Drive Assembly left side DPME2 X Drive Assembly DPM5 amp Sport B5 X Axis Drive Assembly DPMS3 X Drive Train DPMS5 X Handwheel Drive Mechanism DPMS5 Only X Axis Drive Assembly DPME2 Ball Screw Yoke Assembly TRM amp DPM Y Drive Assembly TRM amp DPM Y Drive Assembly DPM5 amp Sport B5 Y Drive Assembly Sport B3 Y Drive Train DPMS3 Y Drive Train DPMS5 Y Drive Train DPME2 Z Axis Motor amp Ball Screw DPM DPM5 Sport B3 amp Sport B5 Z Axis Drive Assembly DPMS3 amp DPMS5 DPME2 Z Axis Drive Train Power Drawbar Spindle Motor Wiring Except DPME2 Spindle Motor Wiring Spindle Control DPME2 only Feed Trip Adjustment Quill Clock Spring Replacement Drive Belt Replacement Drive Belt Replacement Spindle Replacement 5 48 5 49 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 Table Gib Adjustment Table Gib Screw Table Gib amp Saddle Bottom Gib Adjustment Saddle Side Gib Adjustment Saddle Bottom Gib Adjustment TRM DPM Sport B3 DPMS3 Ram Back Gib Ram Side Gib Adjustment Calibration Set Up Tramming of Head Typical Set Up for X Axis Accuracy Repeatability Check Typical Set
83. Sport Bed Mills Safety Installation Maintenance Service amp Parts List Your input x Your input Z Your input 2 the maximum feedrate attained Interpretation of the resulting values displayed The values for the encoder displays should be in the range of 3 0000 to 5 0000 e fthe motor encoder reading is not within this value then the one that is out of specification may be the problem If one of the encoders has no output then the motor assembly will need to be replaced e The feedrate should be a minimum of 120 ipm for X and Y axis and 180 ipm for Z The DPMS3 and DPMS5 should be a minimum of 180 ipm on the X Y and Z axes e fthe feedrate is inconsistent in both directions check the incoming AC voltage and mechanics of the drive train 4 11 6 CODE 101 X Axis Motor Encoder Test A manual diagnostic routine to compare the motor and position encoders Used only on machine with glass scales Steps 1 Go into Service Codes and input 101 2 Crankthe X axis fast for two inches then reverse direction and position the X so that the readout is 1 000 3 Read the resulting values from the position readout The chart above Code 100 shows the data this is displayed The values for the motor encoder and the position encoder should be very close to each other within 5 or so They should also have the same value Ifthev have different values i e for one and for the other perform Service Code 9
84. T SPACER 1 13 A056 SNAP RING 2 14 A060 CLUSTER GEAR KEY 1 15 A062 CLUSTER GEAR SHAFT UPPER BEARING 1 16 A063 CLUSTER GEARS ASSY 1 17 A065 QUILL STOP KNOB 1 18 A066 REVERSE TRIP BALL LEVER SCREW 1 19 A067 REVERSE TRIP BALL LEVER 1 20 A068 QUILL STOP MICRO SCREW 1 16513 23 A071 T BOLT ASSY 4 24 A073 MICROMETER SCALE 1 25 A074 MICROMETER NUT 1 16513 26 A075 QUILL MICRO STOP NUT 1 16513 27 A076 SNAP RING 1 16513 28 A078 TRIP LEVER PIN 1 29 A079 FEED TRIP LEVER 1 30 A080 FEED TRIP PLUNGER 1 31 A082 TRIP PLUNGER 1 16508 32 A083 ROLL PIN 2 16508 33 A084 COMPRESSION SPRING 1 16508 34 A085 CAM ROD SLEEVE ASSY 1 16508 35 A086 ROLL PIN 1 16508 36 A087L CAM ROD 1 16508 37 A089 TRIP HANDLE 1 23913 16508 38 A092 FEED TRIP BRACKET 1 16508 39 A094 CLUTCH ARM COVER 1 40 A096H OVERLOAD CLUTCH TRIP LEVER 1 41 A098 PIN 1 16508 42 A098 1 BLACK PLASTIC BALL 1 23913 16508 43 A101H 1 DRIVE KEY 2 16502 44 A102H NOSE PIECE 40 1 16502 45 A102L 3 SET SCREW 1 16502 46 A103L SPINDLE DIRT SHIELD 1 16502 47 A104L QUILL SKIRT 1 20839 48 A105L BEARING ANG CT U SET 2 7010 P4 1 16502 49 A106L BEARING SPACER LARGE 1 16502 TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 235 Southwestern Industries Inc 50 A10
85. TOR Figure 5 42 10015 Ram Back Gib 6 Extend the quill until it touches the wood block Using the quill handle push the spindle nose against the wood block and note the amount of movement on the dial indicator Adjust the left side gib until the registered movement is 001 0015 To adjust the gib for excessive clearance Loosen the gib lock screw on the bottom of the ram Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the top of the ram Tighten the gib lock screw on the bottom of the ram to lock the gib in place and recheck Repeat as necessary To adjust the gib for too small of a clearance Loosen the gib lock screw on the top of the ram Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the bottom of the ram Tighten the gib lock screw on the bottom of the ram Tighten the gib lock screw on the top of the ram to lock the gib in place and recheck Repeat as necessary 7 Run Service Code 12 to set the feed forward constant 8 Repeat the procedure for the back gib on the right side of the machine 5 2 1 5 Ram Side Gib Adjustment Z Axis TRM DPM DPM5 Sport B3 Sport B5 DPMS3 amp DPMS5 1 Clean all chips dirt and excess oil from the column ways 2 Attach a 0001 dial indicator with a magnetic base towards the rear of the table on the right side of the ram Place the indicator stylus on the ram in line and below the lower mounting bol
86. TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Document P N 24941 Version 012512 Covering Machine Models Covering Non current Control Models TRAK TRM TRAK DPM TRAK DPM5 SPORT B3 SPORT B5 TRAK DPMS3 TRAK DPMS5 TRAK DPME2 ProtoTRAK MX2 amp MX3 TRAK AGE2 amp AGE3 ProtoTRAK M3 ProtoTRAK SM ProtoTRAK EDGE 3 Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 USA T 310 608 4422 F 310 764 2668 Service Department 800 367 3165 e mail sales southwesternindustries com service southwesternindustries com web southwesternindustries com Copyright 2011 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 reguired for the purposes of this guide Southwestern Industries Inc assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from the use of the information contained in this guide All brand names and products are trademarks or registered trademarks of their respective holders Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 5610 Phn 310 608 4422 e F
87. TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual WARNI NG 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 See Figures 5 8 through 5 10 for an illustration of how to install glass scales 5 1 7 3 Install the Z Axis Glass Scale where applicable See Figure 5 8 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 do
88. Turn off and unplug the system from the wall CAUTION Do not plug and unplug connectors with the system power on This may cause damage to the connector board 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 If the connection is sloppy squeeze the connectors together to make a better connection 5 Assure that the ground strap runs from the computer display to the External connector box The External connector box must be protected from excessive debris or moisture 4 10 Red LED Diagnostic Status I ndicators DPM DPM5 Sport B3 B5 with special electrics option There are 12 red LED diagnostic status indicators located on the right side of the relay module The meaning of these LED s is as follows LED 1 is on the top 1 LED 1 is on when the pendant is switched on LED 1 also indicates that the computer module is receiving 115 VAC 2 LED 2 is on when the E Stop on the switch box is in the Out position and the overload relay has not been tripped LED 2 is on during normal operation 3 LED 3 is on when the switch box is receiving 115 VAC LED 3 is on during normal operation 4 LED 4 is on when the spindle switch on the switch box is in the 1 or 2 position and the spindle is on 5 LED 5 is on when the coolant pump is on The coolant
89. Up for Y Axis Accuracy Repeatability Check Typical Set Up for Z Axis Accuracy Repeatability Check Program Movement Top House Assembly 184 Gear Housing Sub Assembly Hi Low Shift Clutch Sub Assembly Hi Low Shift Sub Assembly Pulley Pinion Sub Assembly Lower Vari Disc Sub Assembly Upper Vari Disc Sub Assembly Speed Change Handwheel Sub Assembly Spindle Motor Sub Assembly Bottom Housing Assembly Worm Gear Cradle Sub Assembly Quill Feed Selector Sub Assembly Quill Pinion Shaft Sub Assembly Overload Clutch Trip Sub Assembly Feed Reverse Clutch Sub Assembly Spindle Sub Assembly Head Top Assembly Gear Housing Hi Low Shift Clutch Sub Assembly Hi Low Shift DPEM2 Pulley Pinion DPEM2 Lower Vari Disc Drive DPEM2 Upper Vari Disc Drive DPEM2 Speed Change Handwheel DPEM2 Spindle Motor DPME2 Lower Head Assembly DPEM2 Worm Gear Cradle DPEM2 Quill Feed Selector DPEM2 Quill Pinion Shaft DPEM2 Overload Clutch Trip DPEM2 Feed Reverse Clutch DPEM2 Spindle Assembly DPEM2 Head Top Housing Head Back Gear Head Lower Housing Lubrication System TRM Lubrication System DPM Sport B3 Sport B5 Lubrication Pump amp Ram Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service 8 Parts List Manual 140 Lubrication X Y amp Z DPMS3 141 Lubrication System X amp Y Axis DPM5 amp DPMS5 142 Pump amp Lube System DPEM2 143 Lubrication Drawing X
90. V5 Y AXIS GLASSCALE T sn Figure 5 10 Glass Scale Alignment DPM5 Sport B5 DPMS5 107 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 1 8 Power Drawbar Optional for DPME2 DPMS3 and DPMS5 The optional power drawbar is bolted to the top of the head by the use of 3 SHCS Some machines may reguire a washer to space the unit up to the proper height to allow the drawbar to engage properly Air Regulator and Oiler This unit reguires 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 32 to of aturn 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 DPMS3 amp DPMS5 only 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
91. VS8 SPRING FOR VARIDISC MOTOR SHAFT 1 Jonly available as 20819 1 8 VS9 JADJUSTABLE VARIDISC SPRING COLLAR 1 Jonly available as 20819 1 9 VS10 SCREW SOC HD CAP M8 P1 25x30L 1 Jonly available as 20819 1 10 23953 VARIDISC ASSY ADJUSTABLE MOTOR 1 100698 K2 K3 217 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 127 Lower Head Assembly 218 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Lower Head Assembly Item P N Title Qty 1 125 2 IHHANDWHEEL HANDLE AVAILABLE ONLY IN ASSY 20835 1 2 K B113 HAND WHEEL CLUTCH 1 3 K B117 ROLL PIN 3x15L 1 4 K B103 CAM ROD 1 5 K B108 SOCKET SET SCREW M6 P1 0x8L 1 6 K B119 1 ROLL PIN 3x20L 1 7 K B103 1 CAM ROD PIN 6x15L 1 8 K B107 CAP SCREW M6 P1 0x25L 2 9 K B106 FEED TRIP BRACKET 1 10 20779 4 JOVERLOAD CLUTCH TRIP SUB ASSY 3VK B4 1 11 K B73 SOCKET SET SCREW M6 P1 0x20L 1 12 K B101 CHEM BLACKED LOCKNUT M6 P1 0 1 13 K B99 CLUTCH ARM COVER 1 15 20779 2 QUILL FEED SELECTOR SUB ASSY 3VK B2 1 16 K B67 CAP SCREW M6 P1 0x18L 4 17 K B29 CLUSTER GEAR KEY 3x3x45L 1 18 K B27 CLUSTER GEAR SHAFT UPPER BEARING 1 19 K B28 CLUSTER GEARS ASSEMBLY 1 20 K B94 SNAP RING 95 DOWEL PIN
92. 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 Figures 2 15 fora layout of the cable connections 5 1 6 TRAK Sensor Replacement where applicable 5 1 6 1 Replacing the M5 Base See Figures 5 4 and 5 5 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 5 4 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 dial indicator may be used to align the bumps on the base instead of a bubble level 98 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100018 Figure 5 4 M5 Base Mounting 5 1 6 2 Replacing the TRAK Sensor 1 Remove the old senso
93. X X X 201 202 X X X 304 305 312 313 314 316 317 318 319 321 322 323 324 325 326 327 335 336 818X X X X X gt gt gt gt gt gt gt 3943 gt gt gt WS gt gt gt gt gt lt gt lt gt gt gt gt gt gt XX X x X X gt DESCRIPTION Displays Calibration Factors Single Encoder Axis Backlash Calibration See Section 5 2 2 for details Enters Single Encoder Axis Backlash Calibration Constant Enters Arc Accuracy Manual DRO Disables Electronic Handwheels Irregular Pocket Stepover Distance Adjustments Restores EEPROM From System Disk Saves EEPROM to System Disk Brightness control Auxiliary Function Test Displays error codes Enables Disables Z J og Toggles X Sensor or Glass Scale On Off Toggles Y Sensor or Glass Scale On Off Toggles Limit Switch On Off Displays Configuration Toggles Test Lights On in Status Line Updates Master Software Updates Slave Software Activates Converters or Options Error Log Captures All Commands Sent to Servo System Reverses Y Position Sensor Direction Reverses X Position Sensor Direction Switches between COM ports for RS232 applications Toggles Simulation Mode Reverses Quill Sensor Direction Error Message Display Memory Status Toggles Spindle On Off During Pause Events Enables Spindle to Stay On throughout All Modes Displays available memory 86 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installatio
94. a Programmed Straight Line Move 3 1 4 Parts Have Incorrect Dimensions 3 2 Problems Regarding Motion of Machine 3 2 1 Run Away Axis 3 2 2 Slow Down Axis 3 2 3 Axis Will Not Jog 3 2 4 Axis Motor Motion Is Not Smooth 3 2 5 Vibration in Motion 3 2 6 Searching Axis 3 3 Problems Relating to Operation of Control 3 3 1 Display Blanks 3 3 2 Bad Picture on Display 3 3 3 Keyboard Lockup 3 3 4 Fault X Y or Z 3 3 5 Problems Reading Floppy Disk 3 3 6 System Will Not Turn on or Boot Up 3 7 System Reboots by Itself 3 8 System Shuts Off 3 9 Will Not Hold Calibration 3 3 10 Auxiliary Functions Not Working 3 3 11 E Stop Error 3 3 12 Limit Switch Error 3 4 Problem with the Measurements 3 4 1 X Y 8 Z Axis Measurements Do Not Repeat 3 42 X Y amp Z Axis Measurements Are Not Accurate 3 4 3 The DRO Is Not Counting 3 4 4 X Y amp Z Axis DRO Counting in Wrong Direction 3 4 5 X Y amp Z axis Electric Handwheels Turn in Wrong Direction 3 5 Problems with the Machine Tool 3 5 1 Z Axis Noisy 3 5 2 Spindle Stalls or Turns Off During Machining 3 5 3 Spindle Motor Hums or Will Not Run 3 5 4 Spindle Runs Backwards 3 5 5 Spindle Motor Intermittently Stops and Starts or Does Not Operate 3 5 6 Head Noise CJ w 4 0 Diagnostics 4 1 The Machine Tool amp Set Up 69 4 1 1 The Milling Machine Checklist 4 1 2 A Special Word About X Y Z Gibs 4 1 3 Lubrication 4 1 4 Machining Set Up 4 2 The Mechanical Drive Train X Y 4 2 1 X Ballscrew Ali
95. ade with the back ram gibs Tightening the gibs will tend to tilt the head up from the table Loosening the gibs tends to allow the head to droop down toward the table Over tightening or loosening can lead to other problems with the machine Typical adjustments with the gibs is 0 0005 or less 5 2 4 Limit Switch Option DPMS3 DPMS5 amp DPME2 5 2 4 1 X Axis Limit Switch Stop Installation and Adjustment The limit switch stops for the X axis are mounted to the front side of the table The limit switch stop consists of a square bracket which is fastened to the T slot on the front side of the table 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 Limit Switch Loosen the X axis square bracket on each side of the table Slide each X axis square bracket within the T slot to the end of the table Slowly move the table to one side by hand until the end of the travel is reached In DRO mode set X 0 ABS fay Be m CAUTI ON The limit switch must be triggered a minimum of 32 before the machine reaches its travel limits in both directions This allows sufficient room for the servomotors to stop when the limit switch is hit at 150 ipm 5 Using the DRO display back the table off 1 2 6 Lockt
96. aintenance Service amp Parts List Manual W continued from previous page 14 Figure 2 2 12 2 Pendant and Wiring Diagrams for Sport B3 amp B5 M3 STOP I O 9 D 5 lt AIC IN 115 V L t Va LOPPY DISK DRIVE PARALLEL PORTA RS232 5 a LU LU c Figure 2 15 Pendant Display Basic Configuration Sport B3 amp B5 29 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 220 440 3 PHASE POWR IN GROUND WIRE 115V 1 PHASE POWER IN LIILILLZLLZL 8 AMP SAMP AUX 11 AUX 210 AC ING l a LUBE o PUMP r TERMINALS FOR OWER PLUGS EE Ven SPINDLE OVERLOAD des GROUND BAR s jajalal AC POWER IN AA A 8 a ES me s e m x ee SSS E STOP TN t REVERSE CONTACTER id ii FORWARD CONTACTER 230 VOLTS i POWER OUT TO MOTOR ZZZZZZZZZZZZ SPINDLE CONTROL Figure 2 16 20676 20676 1 Wiring the Sport B3 amp Sport B5 i00907 Part Number Description 220V amp 440V 20676 Electrical Box 220V amp 440V 23438 3 Overload 23436 Con
97. alibration amp Backlash Constants Section 5 2 2 Incorrect backlash values If the machine does not repeat bi directionally check the backlash on the axis in question See Section 5 2 2 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 Faulting Axis Section 4 7 1 Perform the following Service Codes e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting e Code 304 amp 305 Turns off X and Y sensor or scale where applicable SM control only Possible Cause Check This Servo driver failure See Servo Driver Section 4 5 Motor Encoder not counting See Motor diagnostics not applicable with Glass Scale option Glass Scale or Sensor Failure Does axis now count If so replace scale Computer Pendant failure See Computer Pendant diagnostics 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 e X axis Table moves to the left e Y axis Saddle moves toward the front of the machine e Z axis Ram moves up 64 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Perform the following service code and procedures e
98. ally or totally out of its nut They cannot be reassembled 1 C eg npa 00 cu CON 12 13 14 15 16 Ensure that there is sufficient vertical clearance above the top of the machine to remove the ball screw Minimum clearance required is 32 inches Remove vertical column top cover Remove servomotor belt and Z motor mounting bracket Remove upper and lower Z axis way covers Lower head to table Place 1 or 2 inch wood board between spindle nose and table to protect Lower head until weight of head is supported by the table Tighten both ram locks on the right side of ram Remove locknut and lock washer from the top of the Z ball screw Remove pulley and woodruff key Loosen 10 32 socket screw on clamp nut Using wrench flats on clamp nut and wrench flats on ball screw remove clamp nut Remove the four cap screws from bearing housing flange Remove the clamp nut Remove bearing nilos ring and bearing housing with matched spacer from ball Screw Remove 6 M6 cap screws and lock washers from ball nut flange Extract ball screw assembly from machine until ball nut flange is above the top of the ram Support ball screw and remove lubrication line from ball nut flange 140 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 17 Raise the ball screw until the bottom end of the ball screw is above the ram Angle the ball screw
99. amount of play between the gibs and ways and mostly by the accumulative bending or elasticity of all the parts of the drive train under load The backlash constant is factory set but may need to be adjusted periodically 1 Seta 0001 inch dial indicator in the spindle and touch off on a block or the vise along the direction X Y or Z you wish to check or set the backlash constant 2 Turn on the ProtoTRAK and at the Main Menu follow the procedure below precisely 172 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual fae oum Cis PresSMODE f Backlash Value _ _ _ _ f What is shown is the current value Follow the instruction on the screen and press the appropriate soft keys Wait a few seconds between each INCR VALUE or DECR VALUE press g The following is an example of what you For example if the up and down Oscillation might see when running this code Value shown in the conversation line is 00278 inch and the dial indicator is moving back and forth 0012 the true backlash value is 00278 0012 00158 inch Input this by pressing MODE SET UP SERV CODE 128 SET and then 00158 SET RETURN 3 The X backlash identified and stored in Step 2 should be less than 0 003 on a new machine If it is appreciably larger inspect the drive train for loose bolts brackets bearings etc The backlash can also be found manually with a 0 0001 indic
100. amp Y Axis 144 Head Ram Riser Drive System 145 Electronic Hand Wheel Assembly Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 1 0 Safety The safe operation of TRAK and Sport Bed mills depends on its proper use and the precautions taken by each operator Read and study this manual and your model s corresponding Programming Operating and Care Manual Be certain every operator understands the operation and safety reguirements of this machine before its use e Always wear safety glasses and safety shoes e Always stop the spindle and check to ensure the CNC control is in the stop mode before changing or adjusting the tool or workpiece e Never wear gloves rings watches long sleeves neckties jewelry or other loose items when operating or around the machine e 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 ANS 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 Publi
101. and Z axis to verify that the feedrate shown on the display is at least 180 ipm 30 Where applicable perform Service Code 124 to calibrate the Z axis ram ball screw You will need to reinstall the ram manual crank mechanism Be careful not to jog the Z axis while the crank is installed 31 Install the Z axis upper way cover Install the Z axis lower way cover and its bracket 32 Install the Y axis front and rear way covers 33 If machine has an auxiliary function option use accessory key on pendant and ensure that the coolant pump or solenoid for the mister works 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 turn this on and off to test 34 If the machine has a power drawbar option check to ensure that the tools load and unload 35 Cuta Euclid block Visually inspect the block and make any required machine adjustments See Euclid block instructions in Section 2 17 36 Wipe down the machine prior to leaving Specifications DPME2 TRM DPM SPORT B3 DPM5 SPORT B5 DPMS3 DPMS5 Table Size 49 x 9 50 x 10 50 x 12 T Slots number x width x pitch 3 x 16 mm x 64mm 3 x 16 mm x 64 mm 3 x 16 mm x 64 mm Travel X Y Z axis 31 x 16 x 23 5 31 x 17 x 23 5 40 x 20 x 23 5 Quill D
102. 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 10 Check the ball screw mounting to the yoke Make sure the SHCS are tight 11 Inspect the ball screw ball nut and yoke for the potential problems shown in the chart on the next page CAUTI ON Unlike a lead screw do not unscrew the ball screw from its nut This will destroy the ball screw Potential Problem Check By Bad ball screw e 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 e Cranking the ball screw through a significant part of its travel If it jams feel loose or has rough spots replace the ball screw e Using the dial indicator on a vertical flat of the ball screw to check for backlash between the ball screw and ball nut Potential Problem Check By Ball nut not tightened to Inspection for space between the head of the bolt and the ball nut i e the yoke the retaining bolt has bottomed out in its thread and is not securing the ball nut to the yoke properly 71 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenan
103. andle 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 18 Spindle Motor Removal and Replacement 5 1 18 1 DPM DPM5 Sport Sport B5 DPMS3 amp DPMS5 CAUTI ON The motor is heavy about 60 pounds Be certain you have the proper equipment or assistance 1 While the spindle is running change the RPM to its lowest value 2 Disconnect the power to the motor It is recommended that the power disconnect be made from the shop feeder box 3 Disconnect the electrical connection in the conduit box attached to the motor 4 Crank the speed changer to the highest RPM value 5 Remove the two screws that fasten the motor to the top of the housing 155 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 6 Tiltthe motor forward and remove the belt from the motor pulley Remove the motor 7 If the motor is to be replaced remove the M8 socket head cap screw at the end of the motor shaft Slide the pulley assembly off the motor shaft and onto the new motor Figure 5 34 Spindle Motor 100155 5 1 18 2 Spindle Motor Removal amp Replacemen
104. as 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 ofthe scale extrusion Movethe 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 e 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 e 2 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 5 8 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 e Mount a dial indicator in the quill e Touch off a fixed point on the table and set the DRO and indicator to 0 e Traverse away approxim
105. at physically is in the system Machine Tool amp 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 amp Setup Section 4 1 unlocked Never use gib locks with a CNC machine Inadequate or no Lubrication to Make sure all the Way surfaces are getting proper Ballscrews and Way surfaces 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 Check the adjustment of the X Y and Z axis Gibs See X properly Y and Z axis Gib Adjustments in Section 5 2 1 X amp 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 Visually check the condition of all the Way surfaces For excessively worn 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 1 2 Circles Out of Round Circles are not round within 0 002 TIR over 3 0 DIA This is best measured by placing
106. ately 6 inches e Return the touch off again at DRO 0 point e Compare with indicator reading e not Re zero the DRO traverse away and return several times e Again compare DRO with indicator reading Note 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 glass scale that have resulted in a loss of rigidity Common sources of random error include e Loose scale mounting hardware e Loose reader head e Very loose motion of the table or saddle 3 Accumulating error is commonly the result of e Scale out of parallel to the axis travel 77 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service 8 Parts List e Dirt or chip on the glass scale e Broken glass 4 7 TRAKSensors TRM DPM amp DPM5 optional on DPMS3 DPMS5 Sport B3 amp Sport B5 TRAK Sensors are used on the X and Y axis for secondary feedback 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 e Faulting Axis e The DRO measurements do not repeat e The DRO measurements are not accurate Objectives e To determine if the TRAK Sensor is bad and needs to be replace
107. ator with the following method e Load the indicator to zero from one direction and zero out the DRO e Move the indicator to 0 002 and then back to zero Do not over shoot 0 otherwise start over e Whatever number appears on the screen is the backlash value e Enter this value into service code 128 e 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 motor encoders only 5 2 3 Head Rotation and Tramming The TRAK Bed Mills head is free to rotate up to 90 degrees to the right or left 5 2 3 1 To Rotate the Head 1 Loosen the four locknuts 2 Rotate the head with the adjusting worm shaft 173 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Note Make sure to support head when exceeding 45 angle 3 Tighten the locknuts Snug each locknut then lightly tighten each locknut then fully tighten each locknut in a crisscross pattern 4 Use the method shown in Figure 5 45 and a parallel bar to square the head to the table 5 2 3 2 Tramming the Head The purpose of tramming the head is make sure the head is perpendicular to the top of the table from both side to side and back to front Side to side tolerance 0 001 Side
108. ax 310 764 2668 Service Department Phn 800 367 3165 e Fax 310 886 8029 Table of Contents 1 0 Safety 1 1 Safety Publications 1 1 2 Danger Warning Caution Note Labels amp Notices as Used in this Manual 1 3 Safety Precautions 2 0 Installation 2 1 Floor Plan Layout amp Space Requirements 7 2 2 Uncrating 2 3 Shortages Inventory Checklist 2 4 Installation Instructions amp Checklist 2 5 Machine Specifications 2 6 Maximum Work Capacities 2 7 Control Hardware 271 TRAK AGE ProtoTRAK MX Controls 2 7 2 ProtoTRAK M3 Controls Sport B3 amp B5 2 7 3 ProtoTRAK SM Control DPMS3 amp DPMS5 2 7 4 ProtoTRAK Edge 3 Control DPME2 2 8 Lifting and or Moving the Machine 2 9 Releasing the Head Counterweight Supports 2 10 Cleaning 2 11 Leveling Tolerance for DPMS is 0005 10 2 12 Electrical Connection 2 12 1 Pendant and Wiring Diagrams for TRM DPM amp DPM5 Pendant and Wiring Diagrams for Sport B3 amp B5 Pendant and Wiring Diagrams for DPMS3 amp DPMS5 Pendant and Wiring Diagrams for DPME2 EDGE 2 12 5 Phase Converters 2 13 Air Connection Optional 2 14 Mounting the Display Pendant 2 15 Cable Interconnections 2 16 Lubrication 2 16 1 Way Lubrication 2 16 2 Head Lubrication TRAK Bed Mills 2 17 ProtoTRAK SMX Euclid Block Procedure 2 12 2 2 12 3 2 12 4 3 0 Troubleshooting by Symptom 3 1 Problems Relating to Machining Results 51 3 1 1 Poor Finish 3 1 2 Circles Out of Round 3 1 3 Taper Cut on
109. cation Number 3067 Available from The Publication Office O S H A U S Department of Labor 200 Constitution Avenue NW Washington DC 20210 1 2 Danger Warning Caution and Note Labels amp Notices As Used In This Manual DANGER mmediate hazards that will result in severe personal injury or death Danger labels on the machine are in red WARNING Hazards or unsafe practices that cou d result in severe personal injury and or damage to the equipment Warning labels on the machine are in orange CAUTION Hazards or unsafe practices which cou d result in minor personal injury or equipment product damage Caution labels on the machine are in yellow NOTE Call attention to specific issues requiring special attention or understanding 1 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual HIGH VOLTAGE NOTICE The manufacture is not liable responsible for any damages or injury of any kind to persons or property caused by or resulting from the improper or unauthorized use operation maintenance alteration modification change in configuration of this machine or any of its component parts or the use of this unit with any third party accessories or parts 100775 Safety amp Information Labels Used On The TRAK Bed Milling Machines It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels
110. cator 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 63 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 3 4 2 X Y and Z Axis Measurements are not Accurate Measurements repeat but with a dial indicator mounted to the bottom of the spindle traversing the length of a gage block or some other measurement standard the measurement is not accurate Note If your part has incorrect dimensions see Parts Have Incorrect Dimensions Section 3 1 4 Note First check for repeatability of the DRO With a dial indicator mounted to the bottom of the spindle touch off a fixed surface either in the X Y or Z axis direction and set the DRO equal to 0 Crank away several inches and touch off again at the same place If the reading has not returned to 0 on the DRO zero the display and repeat the procedure If the measurement does not repeat you have a repeatability problem that must be resolved before the accuracy problem can be resolved See Measurements That Do Not Repeat Section 3 4 1 Possible Cause Do This The Calibration is incorrect Recalibrate the machine See C
111. ccuracy 0 0005 e 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 Furthermore the system should be expected to repeat within the resolution of the displayed DRO numbers of 0 0005 Perform the following Service Code e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 123 Calibration e Code 11 Measure s the backlash in the system Only used on machines with Dual feedback systems e Code 12 Feed Forward Constant e Code 127 Measure s the backlash in the system Only used on machines with Single feedback e Code 128 Enter backlash compensation 52 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 3 1 4 1 Every Part Has the Same Error Possible Cause Check This Machine Tool amp Setup problem See Machine Tool amp 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 calibra Verify configuration file Code 313 does not read default tion file and backlash cons
112. ce Service amp Parts List Yoke loose in the saddle e Inspection for any motion of the yoke or looseness in the Yoke mounting screws Oil lines sheared e Visual inspection Oil line blockage e Pump the oil and ensure that it flows evenly to the ways and ball screw Ball screws not aligned e Measure from the ball screw to the back of the saddle on both sides of properly 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 Ball Screw Alignment 4 2 1 1 TRM DPM Sport B3 DPMS3 DPME2 Ball Screw Alignment e 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 t
113. ce Service amp Parts List Manual Figure 5 15 X Axis Drive Assembly DPMS3 118 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100771 X S3 DPMS3 X Axis Drive Assembly Parts List item A Description Qi 4 M10 1 5X3025B SCREW SHCS STL BO 1 1 1 8 6 15759 WASHER 1 4HARD BLKOX1 8THK C 11 8 1 4 20X124B SCREW HEXHD STL BO g 9 15638 jSTOP XAXS 1 SPACER 100 THICK 4 15 16452 NUT CLAMP X Y amp ZAXIS 1 16 425 5M 15 BELT TIMING 5 POWERGRIP A Z 1 17 15612 JHOUSING BEARING 1 18 20373 JBEARING ANGULAR CONTACT 7200 BECBP 2 19 15885 JRING BEARINGHOUSING 1 20 15626 A JSEAL BEARINGHOUSING 21 1 4 20X3 425B SCREW SHCS STL BO f 3 22 5 16 18X1 1 4 25B SCREW SHCS STL BO f f f 1 23 15616 HANDWHEELASSY MX 1 24 1 2752 WASHER XTTOOTH STL ZINC 1 25 15180 a JSHAFT EXTENSION 1 1 28 1 4 28X143B SCREW SOC SET STL BO KNURLED 1 29 22069 TRAYMACHINE 1 30 15977 1 31 22008 A BEARING204AKTT 1 32 1 4 28X3 4 428 1 33 10 32X3 425B X SCREW SHCS STL BO 1 SPACER 050 THICK E 35 14772 2 SPACER 020 THICK 36 16983 1 J
114. cklash Hysterisis Test only with X amp Y Sensors or Glass Scales 12X X X X X X X Determines Feed Forward Constant 13X X X X X Sets Default Feed Forward Constant 14X X Enters Program Scale Factor 0 1 to 10 22X X X X X X Simulation Mode 33X X X X X X X Software Identification 34 X X X Variable Fixed Depth Drill Pecking 36 X X X Fast Slow Pecking 37 X X X X Selects DNC Baud Rate 38 X X X Toggles on off hard disk zip drive 54X X X X X X X Continuous Run Mode 66X X X X X X X Metric Default Bytes of ram for CNC2 67X X X X X X X English Default 68X X X X X X 0 01 mm 0005 Display 69X X X X X X 0 01 mm 001 7OX X X X X X 0 005 mm 0 0001 79X X X X X X X Turns on Beeper 80X X X X X X X Turns off Beeper 81 X X Keyboard Test 89X X X X X X Out of Simulation Mode 97X X X X X X Axis Configurationn dual feedback only 98 X Sets Default Configuration 99X X X X X X Master Reset and Clear Program Memory 100X X X X X X X Axis Open Loop Test 101X X X X X X Axis Motor Encoder Test 102X X X X X Y Axis Motor Encoder Test 103 X X X Z Axis Motor Encoder Test 123X X X X X X X Sensor Calibration Mode See Section 5 2 2 for details 124 X X Z Axis Encoder Calibration 85 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List 1409 1 1A43IS ZXW TIDV EXN EWN 3DV H N gt gt gt gt gt 127 X X 128 X X 129 X X X 131 140X X X X X 141 142 X X X X 160 200
115. coder and secondary feedback machines run Service Codes 100 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 SM M Products only 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 75 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List e Umbilical 1 carries the X and Y axis signals and Umbilical 2 carries 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 could be due to a bad motor servo driver or computer module but it is not always obvious which component is causing the problem In order to determine which component is causing the problem try the following Swap these components Resul
116. d determine if there is a problem with the sensor set up 4 7 1 Faulting Axis If a sensor has stopped 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 SM only The first thing that can be done to see if it is the sensor 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 codes needed to turn the sensors on and off 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 triangular 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 f no outward signs of damage are present remove the sensor from its base and inspect the wheel for damage and wear Look for chip contamination in gauge wheel and damage to running surface 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 fthe sensor looks normal it is probably OK and there is a mechanical obstruction somewhere in the set u
117. de this box If one of these relays fail then these features will not work Perform the following service code and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service Possible Cause Check This Bad 110VAC Coolant or solenoid Check if the fuse light indicator next to the plug is lit receptacle fuse 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 output of the Haas Indexer connector is activated Bad cable breakout box Check 110 V power coming out of the AC E stop port e NE with the E stop in the out position This will cause the spindle to not run 3 3 11 E Stop Error The E Stop turns the power off to the axis and spindle motors This is done by breaking the 110 V contact Spindle Motor 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 If the E Stop button is depressed and no message is displayed on the screen either the E Stop button or the Computer Module is at fault 61 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Ma
118. drawing carefully positioning each leveling pad under each leveling screw 8 Remove the lifting cable or sling the steel bar and all protective cardboard STEEL CABLE 3 4 DIA OR 3 TON SLING 1 DIA STEEL BAR Figure 2 5 Lifting the Machine Method 1 HOLES FOR i00879 LEVELING PADS 16 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Method 2 see Figure 2 6 1 Insert 2 steel bars 1 dia x 36 long through both sides in the existing holes in the machine base front and back 2 Position 4 two each side wood vee blocks under the steel bars and over a suitable lift truck 3 Lift the machine up somewhat tilted towards the front 4 6 from the ground and move it to its floor plan position WARNI NG The lift truck must have sufficient lifting capacity and be equipped with suitably long forks 4 Insert the 6 screws for the leveling pads in their place in the bed 5 Place the machine in its location see floor plan bed footprint carefully positioning each leveling pad under each leveling screw 4 x4 x 8 WOOD BLOCKS VEE GROVED i00878 Figure 2 6 Lifting the Machine Method 2 17 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 2 9 Releasing the Head Counterweight Supports In order to move raise or lower the spindle head ram it is first necessa
119. e Break these bolts free and move the table back and forth along its travel and then retighten the bolts e Left side table bearing housing To align the bracket move the yoke table left as close to the bracket as possible Loosen the bracket bolts and then retighten This should allow the bearing housing to align itself up with the yoke 72 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List e Right side table bearing housing once again move the yoke as close to the bearing housing as possible table right 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 Make sure the mechanical handwheel is not causing the misalignment e Y axis the only component that can cause a misalignment problem is the motor mounting bracket To align this bracket move the saddle as far 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 The yoke is pinned at SWI should not become misaligned unless the machine has been repeatedly crashed 4 3 Computer Pendant Diagnostics 4 3 1 Diagnostics for Computer Modules contained in Pendant EDGE SM3 M3 The pendant consists of 2 separate modules the computer m
120. e 2 screws on the left side of the bracket that holds the air manifold to the U shaped bracket 6 With the assembly in hand unthread the solenoid from the rear of the air regulator The solenoid and cable will be replaced as a unit Power Drawbar Parts List Item P N Title 1 22581 1 AIR GUN ASSY ONLY TORQUE RITE 2 22603 NST DRAWBAR DPMS3 3 20893 TOP WASHER 4 22380 2 AIR REGULATOR ASSY 5 22603 CAT DRAWBAR DPMS3 6 7 8 22581 2 SWITCH CONTROL HEAD TORQUE RITE 22581 4 NOSEPIECE FOR SPINDLE 1 4 NPT AIR FITTING 90 9 3 8 O D TUBING 132 LG 10 3 8 O D TUBING 27 LG 11 22641 NMTB JDRAWBAR DPMSS 12 22641 CAT J DRAWBAR DPMS5 100875 148 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 5 29 Power Drawbar 5 1 13 Spindle Motor Wiring All bed mill spindle motors are wired for 220 or 440 volts except the DPME2 which is wired for 220 volts only See Figure 5 29 for how to wire all motors with exception to model DPME2 See Figure 5 30 for how to wire the spindle control motor for DPME2 149 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual MOTOR JUNCTION BOX REMOVE JUMPER GROUND GROUND SCREW 220V 440V CONFIGURATION CONFIGURATION MOTOR JUNCTION BOX JUMPER REMOVE PAINT FOR GROUND
121. e and protective packaging paying attention not to scratch damage or mar any parts of the machine Remove the cardboard boxes with the PENDANT DISPLAY handle carefully the box containing the TOOL BOX and Z crank The leveling pads and screws for the machine can be found in the toolbox The Y way covers are shipped in a separate tube The lower Z way cover can be found in a box as well Remove two steel bars 1 0 inch in diameter These items are necessary for lifting and moving the machine Loosen and remove 4 screws and nuts holding the machine to the wood pallet 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 3 Shortages Inventory Checklist Sat Machine check model and serial number Manual drawbar with washer Leveling pads B239 and screws B240 Note 4 each for DPME2 and 6 each for TRM DPM DPM5 Sport B3 Sport B5 DPMS3 DPMS5 Table tray with rubber pad assembled to machine TRM DPM SPORT B3 DPMS3 15977 Pendant Display with four 1 4 20 screws for mounting Pendant Arm assembled to the column Toolbox with various tools Safety Operation Programming Manual for either ProtoTRAK SM MX M3 EDGE 3 or TRAK AGE TRAK 8 SPORT BED MILLS Safety Installation Maintenance Service amp Parts List Manual P N 24941 Table trays DPM5 SPORT B5 DPMS5 only Manual Z axis crank 16526
122. e column DANGER Always unplug power at the back of the display pendant and press in engage the Emergency Stop E Stop before opening the computer cabinet l Turn off power 2 Unplug the four AC plugs on the bottom of the enclosure 3 Disconnect the two ribbon cables and ground wire 4 Unscrew the two silver Philips head screws The entire module can now slide out of the cabinet 5 Sensors and Z ball screw must be recalibrated when the computer module is replaced 6 Z backlash must be re inputted when the computer module is replaced 96 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 1 3 3 SM3 Computer Module 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 4 screws on the right side of the unit and 2 screws on the left side of the unit The module is now free to slide toward the right side of the pendant 4 Slide the computer module a few inches and stop Pulling the computer module too far will damage the LCD cable 5 Now reach from the pendant arm side of the unit inside and remove the 37 pin LCD cable 6 Now slide the module about 32 way out of the pendant sheet metal 7 Remove the ground stud from the side of the computer module 8 Next remove the 37 and 9 pin connectors from the top of the computer module 9 Lastly slide the unit comple
123. e 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 The following chart depicts the phase converter ratings per machine model Machine Model Minimum Phase Converter Rating TRM 5 KVA DPM 5 KVA DPM5 7 KVA Sport B3 5 KVA Sport B5 7 KVA DPMS3 5 KVA DPMS5 7 KVA DPME2 5 KVA 37 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 2 13 Air Connection Optional for DPME2 DPMS3 amp DPMS5 The TRAK amp Sport Bed milling machines have an air hookup in the rear of the machine if the machine has a power drawbar or auxiliary function option The drawbar option includes an air regulator air manifold and an oiler The auxiliary option includes an air regulator air manifold and a solenoid If both options are included on the same machine a regulator manifold oiler and solenoid will be included The air fitting is V4 NPT An additional air line port is on the manifold to be used for an optional mister Remove the plug to gain access to this port The air regulator is set to 90 PSI at the factory for the power drawbar unit and solenoid See Section 5 1 8 for more information on the power drawbar unit The air comes in through the manifold and passes through the air regulator The regu
124. e high and low gears speeds and check spindle brakes 20 Check and use the quill power feed to ensure that it works 21 Check the level of the machine The machine should be level to within 0 0005 10 front to back and 0 0005 10 side to side Even though it is the responsibility of the customer make any necessary adjustments 23 Perform Service Code 12 Feed Forward Constant X and Y axis values should be between 2 and 8 Z axis values should be between 10 and 12 This code must be run any time that a mechanical adjustment or change is made to the machine 24 Perform Service Code 123 to calibrate the X Y amp Z axis quill ram Use a 150 mm standard for all axes except use a 75 mm standard for Z quill 9 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual properly 25 Perform Service Code 11 to automatically calculate the backlash for the X and Y axis of dual feedback machines onl i e TRAK sensor or glass scale with a motor encoder 2 5 Machine Specifications 26 Perform Service Code 127 and 128 to manually calculate the backlash for the X and Y axis of single feedback machines only no glass scale or sensor 27 Check for positional accuracy and repeatability on the X and Y axis using the machine s relevant test program Positioning and repeatability values should be within 0 0005 28 Perform Service Code 100 in both directions for the X Y
125. e system If low fill with Mobil Vactra Oil No 2 or equivalent CAUTION Failure to manually activate the pump at the beginning of each day or allowing the Auto Lube to run dry may cause severe damage to the TRAK amp Sport Bed Mills way surfaces and ball screws 2 16 1 2 Manual Lubrication TRM The TRAK TRM X Y Z way surfaces and ball screws are lubricated manually with the lubrication pumps located on the right side of the bed and the left side of the ram Pull 46 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual each handle fully and release 4 to 6 times at the beginning of each shift and once every four hours of operation thereafter At the beginning of each day check the oil level in each pump If low fill with SAE 30 or 30W oil or Mobil Vectra 2 Every six months of operation remove the vertical column way covers and apply a liberal coating of Mobile Grease MP or eguivalent to the ACME screw 2 16 2 Head Lubrication ALL TRAK amp Sport Bed Mills Once Each Week 1 Fill the oil cup on the front of the head with SAE 30 or 30 W oil This oil lubricates the Hi Lo range shifter 2 Fill the ball oiler located in the front lower right corner of the speed changer housing This oil lubricates the speed changer shaft 3 Extend the quill fully and apply a coating of SAE 30 or 30W oil to the outside diameter of the quill Every Four Months
126. ement of Levels 2 8 Leveling Screws 2 9 Pendant Drawer AGE2 3 amp MX2 3 2 10 Computer Cabinet AGE3 amp MX3 Connections DMP amp DPM5 2 11 AGE2 MX2 Computer Cabinet TRM 2 12 TRM Wiring P N 16042 for 1995 and Earlier 2 13 Electrical Box Connections DPM amp DPM5 2 14 Wiring Diagram DPM amp DPM5 2 14 continued 2 15 M3 Pendant Display Basic Configuration Sport B3 amp B5 2 16 Wiring the Sport B3 amp B5 2 17 Sport B3 amp B5 Electric Box Connections 2 18 Schematic Standard Electric Box Sport B3 amp B5 2 19 Pendant Cable Connections SM 2 20 Pendant SM 2 21 Wiring the DPMS3 amp DPMS5 2 22 Edge 3 Pendant Rear DPME2 2 23 Electrical Box without Transformer DPME2 2 24 Electrical Schematic DPEM2 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service 8 Parts List Manual Cable Interconnections TRM MX2 Cable Interconnections DPM amp DPM5 Cable Interconnections Sport B3 Cable Interconnections Sport B5 Cable Connection Diagram DPMS3 amp DPMS5 Cable Connection Diagram DPME2 Euclid Block Electrical Box Schematic Electrical Box Schematic DPME2 Servo Driver Replacement Computer Module Replacement Edge Computer Module amp Flash Drive Replacement SM3 M5 Base Mounting TRAK Sensor Mounting DPMS3 Sensor Assembly DPMS5 Sensor Assembly Z Axis Glass Scale Assembly Glass Scale Alignment TRM DPM
127. ent Y Axis 5 2 1 3 1 DPM Sport B3 DPMS3 See Figure 5 41 Clean all chips dirt and excess oil from the table and saddle Center the saddle on the bed ways Move the table fully to the left side of the saddle 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 Fee ES 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 Adjust the Y axis right bottom gib until the registered movement is 0010 0015 e To adjust the gib for excessive clearance Loosen the gib lock screw on the back of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the front of the saddle Tighten the gib lock screw on the back end of the saddle to lock the gib in place and recheck Repeat as necessary e To adjust the gib for too small of a clearance Loosen the gib lock screw on the front of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the back of the saddle Tighten the gib lock screw on the front of the saddle to lock the gib in place a
128. er 4 11 8 Z Axis Motor Encoder Calibration Set X or Y Backlash Input Backlash Procedures for Replacements amp Maintenance Replacements 96 5 1 1 Servo Motor Replacement 5 1 2 Servo Driver Replacement 5 1 3 Computer Module 5 1 4 Svstem Flash Disk Replacement 5 1 5 Cable Routing on Machine 5 1 6 Sensor Replacement 5 1 7 Glass Scale Replacement 5 1 8 Power Drawbar 5 1 9 Ball Screw Replacement X Axis Table DPMSX2 5 1 10 Ball Screw Replacement Y Axis Saddle DPMSX2 li 5 1 11 Z Axis Screw Removal Replacement Air Solenoid Replacement for Power Drawbar DPMS3 DPMS5 only Spindle Motor Wiring Electric Box Service Auxiliary Function Interface Feed Trip Adjustmemt Quill Clock Spring Replacement amp Adjustment Spindle Motor Removal amp Replacement Drive Belt Replacement Timing Belt Replacement 5 1 21 Brake Shoe Replacement 5 1 22 Spindle Replacement Maintenance 5 2 1 Adjustments 5 2 2 Calibration amp Backlash Constants 5 2 3 Head Rotation and Tramming 5 2 4 Limit Switch Option 5 2 5 Accuracy and Repeatability Measurements 5 1 12 UI uro Pi jj ja ja NOW DW 5 1 18 5 1 19 5 1 20 Figures amp Parts List 2 1 Machine Footprints 2 2 Overall Dimensions 2 3 TRAK amp Sport Bed Mills Component Identification 2 4 TRAK amp Sport Bed Mill Rear View 2 5 Lifting the Machine Method 1 2 6 Lifting the Machine Method 2 2 7 Plac
129. et Remove the sheet metal covers on the front of the machine bed and on the motor mounting bracket Remove the motor then remove the motor mounting bracket Remove the rest of the parts on the ball screw journal Note the orientation of the bearings for reassembly Remove the 5 16 x 1 inch screw that attaches the ball nut to the yoke Remove the ball screw and oil line attached to the elbow fitting on the ball nut Remove the elbow and setscrew from the old ball screw flange and fit them similarly in the new ball screw 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 Note Letters on bearings must face each other in the housing 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 Ib 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 126 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual AND Wi SOCKET HEAD SCREW 5 16 18 X 1 1 4 5 16
130. f the warranty
131. functions To test the auxiliary functions enter Service Code 200 and press INC SET Check the LED lights in the electrics box For example press auxiliary function 2 then press Turn On the corresponding LED light should come on and you should hear the air mister solenoid engage Press RSTR then press Turn Off and LED should go off and the solenoid should disengage See Section 4 10 for the explanation of the LED lights Possible Cause Check This Auxiliary functions malfunction Check lights on electrics box See Red LED Diagnostics Lights Indicator Section 4 10 If lights are not on replace electrics box Coolant line clogged Voltage problem 220 440V 60 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 3 3 10 2 SM Controls where applicable 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 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 All of the auxiliary function signals are carried down to the cable breakout box through umbilical 2 Each function then has its own relay insi
132. g correctly See TRAK Sensors or Glass Scales Section 4 6 amp 4 7 Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants Section 5 2 2 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 3 2 5 Vibration in Motion While axis is moving there is vibration or noise coming from the X or Y axis Perform the following Service Codes and procedures e Code 11 Measure s the backlash in the system Only used on machines with Dual Feedback systems 55 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual e Code 12 Feed Forward Constant High feed forward constants will cause an unstable servo system e Code 127 Measure s the backlash in the system Only used on machines with Single feedback e Code 128 Enter backlash compensation e Code 123 Calibrate Possible Cause Check This Too much backlash entered in Code 128 Recheck the machine s backlash or Code 11 Inadequate or no Lubrication to Make sure all the Way surfaces are getting proper Ballscrews and Way
133. gital Servo Amplifiers custom designed for ProtoTRAK AGE 2 AGE 3 operation D C Servo Motors rated at 280 in oz continuous torque for X and Y and 560 in oz for Z Ball screws in the table saddle and column ensure smooth accurate contours without backlash Closed loop Feedback utilizing TRAK Sensors with 0002 underlying resolution This is optional for the Sport B3 amp B5 Modular Design simplifies service and maximizes uptime 115V 60HZ 15 amps Feedrate Override of programmed feedrate and rapid Polycarbonate Sealed Membrane Keypad and Gasket Sealed Control Enclosures to lock out contamination 9 CRT for clear presentation of prompts status information and part graphics Built in Floppy Disk Storage for program storage RS 232 Port for interface with computers Auxiliary Function to interface with Haas type rotary indexers DPM Auxiliary Function to control A C outlet DPM Auxiliary Function to control Air Solenoid System spray misters DPM 2 7 2 ProtoTRAK M3 Controls Sport B3 amp B5 Digital Servo Amplifiers custom designed for ProtoTRAK M3 operation D C Servo Motors for the X and Y axes at 280 in oz for the B3 and 560 in oz for the B5 The Z axis is rated at 560 in oz for both the B3 and B5 Ball screws in the table saddle and column ensure smooth accurate contours without backlash Closed loop Feedback utilizing 000036 resolution motor encoders Modular Design simplified service and maximizes uptime
134. gnment 4 3 Computer Pendant Diagnostics 4 3 1 Diagnostic for Computer Modules Contained in Pendant 4 3 2 Diagnostics for Computer Modules Separate from Pendants 4 3 2 Checking Floppy Drive by Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 5 0 5 1 Formatting a Disk Motor Diagnostics 4 4 1 Cable Connections 4 4 2 To Check the Motor Encoders 4 4 3 Encoder Counts to Pendant 4 4 4 Moving Problem From One Axis to Another Servo Drivers Glass Scales 4 6 1 Alignment of Scales 4 6 2 Measurements Do Not Repeat TRAK Sensors 4 7 1 Faulting Axis 4 7 2 Measurements Do Not Repeat Electrical 4 8 1 Checking A C Voltage 4 8 2 Checking Fuses 5 2 4 8 3 Cable Breakout Box Connections 4 8 4 Cable Connections External Connector Box Red LED Diagnostic Status Indicators Service Codes 4 11 1 CODE 11 Hysteresis 4 11 2 Code 12 Feed Forward Constant 4 11 3 Code 33 Software ID 4 11 4 Code 97 System Axis Configuration Code 100 Axis Open Loop Test Code 101 X Axis Motor Encoder Test Code 102 Test Code 103 Test 4 11 9 Code 123 4 11 10 Code 127 Constant 4 11 11 Code 128 Constant 4 11 12 Code 129 Arc Accuracy 4 11 13 Code 314 Toggle Test Lights On in Status Line SM only 4 11 14 Code 319 Error Log SM only 6 0 4 11 5 4 11 6 4 11 7 Y Axis Motor Encod
135. h in the system Only used on machines with Single feedback Code 128 Backlash compensation on Single feedback machines compensation Code 128 Run Code 11 on dlial feedback machines should be between 10 to 15 in lbs See Machine Tool amp Setup Section 4 1 Looseness in the drive train The drive train of the axis that is searching especially the tightness of the drive assembly See Mechanical Drive Train X Y Section 4 2 56 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 3 3 Problems Relating to the Operation of the Control 3 3 1 Display Blanks The display is completely blank Possible Cause Check This Where applicable System flash drive Make sure flash drive is seated properly SM only loose 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 SM only See Electrical Section 4 8 Poor cable connection from Computer Module to LCD Liguid Crystal Display module to the LCD 3 3 2 Bad Picture on the Display The display has strange characters horizontal bars or other unfamiliar images or the display continually rolls Possible Cause Check This Poor cable connection fr
136. harm to the technician 2 Visually inspect the connections for excessive debris moisture or obvious damage 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 81 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service 8 Parts List ET UN O blu 129 R R R F F T1 T2 T3 TA 2 IT3 L I i AAA Figure 4 1 Electrical Box Schematic P N 20676 20676 1 82 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List LUS H eil S OV dWNd 38N1 YOLOW 3IQNIdS O1 OV 3SVHd HOLOW 3 OLOZZ TWwALNAN asvHdt 4 A Wallan IV IM NOLLO3NNOO MIIA ACIS LNO 3LON cf 94018 3 o e o 9 uood HOLIMS LINI DPME2 Electrical Box Schematic Figure 4 2 83 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service 8 Parts List 4 9 External Connector Box Sport B3 amp B5 Indications e Control problems chronic or intermittent e Motor problems e measurement problems Explanation It is often the case that what appears to be the failure of an electrical component is actually attributable to a poor connection 1
137. he Bearing Cap 4 Remove the nut from the fine speed adjustment Screw B and turn the screw all the way down through the casting Catch it from the motor hole 5 Remove six Screws C holding the belt housing to the subplate 6 Remove the four screws holding the speed changer 7 Remove the belt housing 8 Replace the belt by sliding it over the speed changer 9 n reassembly be certain the fine speed adjustment Screw B goes into the slot of the Speed Change Plate D in the area in which the screw is not threaded BELT CHANGER HOUSING 0 SUBPLATE 100156 Figure 5 35 Drive Belt Replacement 159 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 1 19 2 Drive Belt Replacement for Spindle Control DPME2 Remove the draw bar and its bushing remove power drawbar if present Remove the three Screws A and use M6 x 35mm screws in the adjacent tapped holes to remove the Bearing Cap Follow instructions for spindle motor removal and remove motor so top head housing can be removed with ease Remove the six screws C that hold the belt housing to the subplate Disconnect the spindle control harness at the head control box Lift off the belt housing then remove belt 5 1 20 Timing Belt Replacement 1 2 3 4 5 6 Remove the motor and drive belt Slide the top or adjustable varidisc pulley assembly off the shaft Rem
138. he elbow and setscrew from the old ball screw flange and fit them similarly in the new ball screw Pump oil to be certain it flows through the oil line and then attach the oil line to the elbow Reassemble all assemblies Important The clamp nut must be reassembled as follows e Install rear bearing and seal into bearing housing and slide housing onto the ball screw Note Letters on bearings must face each other in the housing 111 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 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 Ib 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 5 1 9 1 X Axis Handwheel Box DPMS5 only See Figure 5 17 Teardown and Part Replacement 1 2 3 4 9 Remove top sheet metal cover item 2 Remove the manual hand wheel Release back cover hub item 4 Slide cover hub and shaft assembly items 12 3 9 and 4 out 4 a Shaft assembly removal 4 a 1 Slide shaft assembly item 12 and 3 off of back cover hub assembly item 9 and 4 4 a 2 Loosen setscrew item 14 4 a 3 Slide shaft gear off item 12
139. he limit switch bracket in place 7 Jog the table at 150ipm to each side and verify that the limit switch is working properly Also make sure that the table does not exceed its travel and crash 5 2 4 2 Y amp Z Axis Limit Switch Stops The limit switch stops for the Y axis are mounted on the side of the bed The limit switch is triggered by hitting the cam stop on the saddle The cam is placed to ensure maximum travel The limit switch stops for the Z axis are mounted on the side of the column The limit switch is triggered by hitting the trip lever After contact is made with the limit switch 175 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual lift the trip lever and jog the head up or down to movethe machine away from the limit The trip levers are placed to ensure maximum travel 5 2 5 Accuracy and Repeatability Measurements Positional accuracy and repeatability programs are included in the program list of the control Use these programs to check positional accuracy uni directional repeatability and bi directional repeatability These programs are used to check each machine during the assembly process and can be utilized for checking the machine in the field when necessary 1 Set up a gage block or standard and indicate it parallel to the axis you are checking Recommended gage blocks are 150 mm or 6 0 inches for X and Y 75 mm or 3 0 inches for Z 2 Seta 0
140. hining Set Up The machining set up can greatly influence the performance of your mill Be aware of the following Problems With Can Contribute To Feed and Speeds spindle rpm Poor finish See below Machine chatter Excessive speeds and feeds can break cutting tools or wear tools prematurely Tooling Poor finish Using the wrong cutter for an application Entering the wrong size diameter and Parts incorrect size programming with tool compensation Cutting too deep Part dimensions incorrect Driving and cutting forces cause deflections since no material is totally rigid Machine chatter Poor finish decrease the life of the cutter 69 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service 8 Parts List 4 2 4 1 4 1 Spindle Speeds Spindle speeds are influenced by a number of variables Material e Rigidity of the Machine Setup e Coolant e Cutter type material and diameter e Cutting Depth As a general rule e Lower spindle speeds are used to machine hard or tough material or where heavy cuts are taken e 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 4 1 4 2 Feedrates Factors that affect feed
141. ial indicator in the quill and check the circles 8 Check the runout of the sides of the square frame 9 Inspect the machined surfaces for smoothness 48 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 250 250 250 250 Figure 2 31 Euclid Block 49 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 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 Perform the following Service Codes and document values e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 11 Measures backlash in the system Only used on Dual feedback systems e Code 12 Feed Forward Constant e Code 127 Measures backlash in the system Only used on Single feedback systems e Code 128 Enter backlash compensation Only used on Single feedback systems Possible Cause Check This Too much backlash entered for Code Verify nothing is mechanically loose and the backlash 128 or calculated with Code 11 values are not higher than wh
142. iameter 86 mm 100 mm 100 mm Spindle Taper R8 40 taper 40 taper Spindle Speed Range Low 60 600 70 4200 RPM 70 3950 RPM High 550 5000 Spindle Nose to Table max part height 23 5 23 5 23 5 Spindle Center to Column Face 18 19 20 Spindle Motor Power 3HP 3HP 5 HP Voltage 220 V 220 440 V 220 440 V Phase Cycle 3 phase 60Hz 3 phase 60 Hz 3 phase 60 Hz Current Full load amps 8 5 FLA 8 5 4 25 FLA 14 7 FLA Machine Net Weight Shipping Weight 3200 Ibs 3500 Ibs 4100 Ibs 4400 Ibs 4400 Ibs 4600 Ibs Maximum Weight of Workpiece 1320 Ibs 1320 Ibs 1760 Ibs 2 6 Maximum Work Capacities DPME2 TRM DPM SPORT B3 DPM5 SPORT DPMS3 DPMS5 Drilling Mild Steel 1 1 1 Tapping Mild Steel 75 1 1 Milling metal removal rate mild 2 inch3 min 3 inch3 min 5 inch3 min steel 10 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Maximum work capacities are dependent on a lot of variables that cannot be controlled by the machine manufacturer Each one of the following will have an impact on the above numbers speeds feeds cutter cutter sharpness material setup coolant and machine adjustments The numbers above assume all conditions are optimal and may be higher or lower depending on material composition 2 7 Control Hardware 2 7 1 TRAK AGE amp ProtoTRAK MX Controls TRM amp DPM DPM5 AGE only Di
143. ical box SM and M only 4 Checkthe 110 power cord to the pendant e Power cord defective 4 8 2 Checking Fuses To check all 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 e A good fuse reads 0 zero or close to it e A bad fuse reads Open or Infinity 4 8 3 Cable Breakout Box Connections Sport DPMS3 amp DPMS5 only This module is located on the backside 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 milling machines use several cables to communicate between systems What appears to be the failure of an electrical component might be due to a poor connection Indications e Control problems chronic or intermittent e Motor problems e Measurement problems 80 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Explanation 1 Turn off and unplug the system from the wall WARNI NG Do not plug and unplug connectors with the system power on This may cause damage to the connector board and
144. icating 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 SM only 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 seguence 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 3 3 8 System Shuts Off During operation the system shuts off and will not turn back on Possible Cause Check This Fuse blown in pendant Remove fuse and check continuit 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 Flash disk failure Remove and reseat the flash disk Computer Pendant has failed See Computer Pendant Diagnostics Section 4 3 3 3 9 Will Not Hold Calibration The control will not hold calibration Go to the Configuration Values screen and write down
145. if connected especially remove the cable for a while to see ifthere is a if intermittent difference 3 3 4 Fault X Y or Z The program run or jogging operation is interrupted with a Fault Message on the display Note EDGE MX2 amp AGE 2 do not have computerized Z axis control Perform the following Service Codes and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 11 Measure s the backlash in the system Only used on machines with Dual feedback systems e Code 12 Feed Forward Constant e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting Possible Cause Check This Cable connection problems Check umbilical 1 and 2 Check 1 for X and Y axis OO Table Saddle or Ram Locks are locked Make sure the Table Saddle and Ram Locks are unlocked High torque on any axis may cause faulting problems during alignment routine X Y and Z axis Gibs are adjusted Check the adjustment of the X Y and Z axis Gibs extremely tight using the X Y and Z axis Gib adjustment procedures See X Y and Z axis Gib Adjustments Section 5 2 1 Excessive friction in the slideways See Machine Tool amp 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 See Section
146. ification This is needed if you call SWI Customer Service e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting properly 53 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Possible Cause Check This Where applicable Sensors or Glass Reverse directions with codes 321 and 322 SM Scales are counting in opposite direction Code 97 for M A G E MX Edge Control of motor encoder correctly manual is not reading Section 4 6 or 4 7 Bad Motor Encoder See Motor Diagnostics Section 4 4 3 2 2 Slow Down Axis The axis slows down and moves at a feedrate that is lower than rapid or than the programmed feedrate Perform the following Service Codes e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting e Code 129 Set s the maximum allowable arc accuracy error This applies to arcs only Possible Cause Check This The maximum allowable Arc Accuracy is This value will only slow down the machine during arc moves set too low The factory default is set at 0 001 Perform Code 129 to check or change this value See Service Codes Section 4 9 Incoming AC voltage is inadequate Perform Code 100 See Service Codes Section 4 9 and Electrical Section 4 8 Inadequate or
147. ights There are two drives with exception to the MX2 which has one drive 3 Check the fuses Drive How to Check When to Check Turn the system off and then back on Observe the floppy Bottom drive light as the system boots up It should come on and Problems with the System disk stay on until the Select Mode or Main Menu screen System booting up appears Top While in the Program In Out mode give the system a Store rect Part Programs or Retrieve command and observe the light It should comet 001615 SA the part programs Disk on after the system command is given 4 With the system power on check the large orange light at the bottom left of the cabinet This indicates whether the power strip assembly is receiving AC power 5 Check the LEDs that are mounted to a PC board on the right side of the cabinet These LEDs may be viewed through a slot through the black sheet metal cover You may also remove the sheet metal cover Use the following guidelines for diagnoses with the LEDs CAUTION The computer cabinet contains voltages that are very dangerous 74 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Position Purpose Comment Should be on whenever the system is on A If not replace the computer module Top Indicates power to the motherboard Check to see if power is reaching the computer mod
148. ills Safety Installation Maintenance Service amp Parts List Manual 220 Southwestern Industries Inc 98 25042 SCALE HEAD ROTATION R8 1 99 25043 POINTER SCALE 1 100 25044 DRIVE SCREW SCALE 4 101 20835 HANDWHEEL ASSY 1 102 20834 FEED REVERSE KNOB ASSY 1 103 24052 TRIP HANDLE ASSEMBLY INCLUDES PLASTIC BALL 1 104 20832 FEED TRIP ASSY 1 105 20847 QUILL MICRO NUT 8 SCREW ASSY 1 106 24051 CLOCK SPRING ASSEMBLY SPRING 8 COVER 1 107 20849 FEED HANDLE ASSY GUILL HANDLE 1 108 20843 QUILL LOCK SLEVE ASSY 1 109 K B142 QUILL 1 110 K B155 T BOLT ASSY not shown on drawing 1 TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual i20779 221 Southwestern Industries Inc i00700 K2 K3 2 K B07 WORMGEARSPACER 1 1 3 K B08 FEEDDRIVEWORMGEAR 0 1 4 K B05 WORM CRADLE BUSHING 1 1 5 KB04 FEEDWORMGEARSHAFTSLEEVE 1 6 KB09 FEEDDRIVEWORMGEARSHAFT 1 7 JKEYSx3x25L 1 1 8 K B10 WORM SHAFT KEY 3x3x8L 1 9 KB03 FEEDBEVELPINION 1 10 K B02 BEVELPINONWASHERO5 1 1 11 SOC HD SCREW M5 P0 8x10L 00 1 12 K B36 FEEDDRIVINGGEAR 1 KB361 KEYS3x3x8L 1 14 K B15 FEEDREVERSEBEVELGEAR 1 15 WASHER 6 22 OD 1 16 K B14 SOC HD SCREW M6 P1 0x15L 1 CI ERB so t 18 KB40 FEEDDR
149. indle bearings Noisy head Older machines machines that are See Spindle Replacement Poor finish pushed hard Circles out of round Lubrication system Premature wear of ball screws New installations may not be wear surfaces hooked up or line sheared Poor finish Inadequate lubrication habits Premature wear of ball screws New installations more motion than wear surfaces the machinist is used to with a Poor finish manual mill Lubricate machine every morning before use machine never tighten the gib locks X and Y gibs loose Taper on straight Y moves When machine hasn t been serviced See Gib Adjustment Section 5 2 1 Poor finish in a long while Circle out of round Gibs too tight Not getting to position does not N A repeat axis faults Poor finish Gibs floating Not getting to position does not Contact area of gibs May need to repeat axis faults be scraped Very old machines may Poor finish 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 Inadequate gib contact side to side Way surfaces pocked scarred or Poor finish Inadequate lubrication excessively worn Out of round circles Faulting Head out of tram in Y direction Machine not level Parts incorrect New installation or heavy crash Weight not distributed evenly on all Machine geometry off i e tram six screws See Leveling procedures Head out of tram Leaves uneven
150. intenance Service amp Parts List Manual 11 i20778 7 13 Item P N DESCRIPTION Qty 1 VS16 SPEED CHANGE HOUSING 1 2 VS20 BEARING SELF LUBRICATING 1 3 VS22 SPEED CHANGER GEAR 1 4 VS31 SPEED CHANGE CHAIN DRUM 1 5 VS21 WORM 1 7 VS25 SPEED CHANGE SHAFT 1 8 VS40 ROLL PIN 3x15L 2 9 VS24 COPPER BUSHING 2 10 VS24 1 WASHER WAVE 1 11 VS27 SPEED CHANGE HANDWHEEL 1 12 VS18 FULL DOG SOCKET SET SCREW M6 P1 0x10L 1 13 VS28 HANDLE 3 8 16NC 1 14 VS32 CHAIN 310X9 525 1 15 VS31 1 DOWEL PIN 3x25L 1 16 VS30 SPEED CHANGE STUD 1 17 VS16 1 SPEED DIAL 1 18 VS95 NUT ACORN 5 16 18 NC 1 19 VS16 2 NAME PLATE 1 20 VS19 SCREW DRIVE 4 21 M5 0 8X14 40B SCREW SOC SET STL BO CUP 1 22 M5 0 8X5 408 SCREW SOC SET STL BO CUP 1 Figure 125 Speed Change Handwheel P N 20778 7 TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 216 Southwestern Industries Inc i20778 7 100598 K2 K3 Figure 126 Spindle Motor P N 20819 1 Item P N DESCRIPTION Qty Notes 1 V8110 MOTOR 3 HP 1 only available as 20819 1 2 VS3 1 KEY 6x6x45L 1 only available as 20819 1 3 VS2 STATIONARY MOTOR VARIDISC 1 Jonly available as 20819 1 4 VS6 JBUSHING 1 Javailable as 23953 or 20819 1 5 VS5 JADJUSTABLE MOTOR VARIDISC 1 Javailable as 23953 or 20819 1 6 VS6 1 KEY 7x7x50L 1 Javailable as 23953 or 20819 1 7
151. intenance Service amp Parts List Manual 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 pendant Does 110 V power come out ofthe cable breakout box power cord on the pendant If yes and the screen has an E stop message replace the pendant 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 Critical Error 64 Servo Error X axis Limit Switch Correct the fault condition and continue 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 the 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 Possible Cause Check This box are making poor contact Limit Switches are s Reset the Limit Switches Ea the procedures A a E 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
152. ional 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 2 7 4 ProtoTRAK Edge 3 Control DPME2 Precision ground ball screws in the table saddle and ram 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 7 4 LCD for presentation of prompts and status information Modular design simplifies service and maximizes uptime Single floppy disk drive for additional part program storage 3 Axis CNC 3 Axis DRO The Edge 3 CNC works like what is commonly referred to as 2 21 axis means that there is a third axis present Z axis but you cannot program all three axes to move at the same time In the ProtoTRAK Edge 3 the Z axis will always move first and then X and Y Therefore you cannot program any type of part where you would need to move the Z axis at the same time as X or Y The D C Servo Motors for the X and Y axis are rated at 280 in oz maximum continuous torque The Z axis is rated at 560 in oz maximum continuous torque 12 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List TRAK amp Sport Bed Mills Component dentification Figure 2 3 SPINDLE BRAKE ACCESS TO COOLANT PUMP 101121 13 So
153. isconnect the 3 phase into the relay module and the 3 phase out to the spindle motor see Figure 2 15 4 Unscrew the 21 black Philip head screws on the side of the electrics box and the 2 black Philips head screws inside the electrics box that connect the relay module to the electrics box The entire relay module can now slide out of the electrics box 5 1 14 1 Fuses The fuse identification is shown on the relay module label Use only the correct fuses 5 1 14 2 Red LED Diagnostic Status Indicators There are 12 red LED diagnostic status indicators located on the right side of the relay module The meaning of these LED s is as follows LED 1 is on the top 1 LED Lis on when the pendant is switched on LED 1 also indicates that the computer module is receiving 115 VAC 2 LED 2 is on when the E Stop on the switch box is in the Out position and the overload relay has not been tripped LED 2 is on during normal operation 3 LED 3 is on when the switch box is receiving 115 VAC LED 3 is on during normal operation 4 LED 4 is on when the spindle switch on the switch box is in the 1 or 2 position and the spindle is on 152 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 LED 5 is on when the coolant pump is on The coolant pump can be turned on either by the switch box or via a CNC auxiliary function see Section 5 1 15 DPM only 6 LED 6 is on when the
154. it is a cable with a connector for the Electrics Box and a Haas Indexer AUX FUNCTION 4 Spindle Motor Auxiliary Function 4 turns the spindle motor off at a tool change and at the end of the part program This capability is designed into the DPM amp DPM5 5 1 16 Feed Trip Adjustment All bed mills except DPME2 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 Engage the trip handle move it left Adjust the micrometer nut against the quill stop knob 2 3 4 Slowly turn the adjusting screw until the handle trips 5 Tighten the lock nut 6 Check the reaction If too sensitive lower the adjusting screw slightly If too heavy raise it QUILL STOP Figure 5 32 NUT METER Feed Trip Adjustment TRIP HANDLE ka ee ENGAGE E mif m LOCK 100153 NUT ADJUSTING 5 1 17 Quill Spring Replacement and Adjustment The quill Clock Spring counterbalances the weight of the quill and tool 154 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 5 33 Ouill Clock Spring Repl acement QUILL HANDLE KEY HUB amp SCREW A SPRING KA HOUSING 1 1 2 TURNS 1 Move the quill to its top position and lock it in place 2 Remove the quill h
155. l amp 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 amp Setup Section 4 1 Check the adjustment of the X Y and Z axis Gibs using the X Y and Z axis Gib adjustment procedures Where applicable TRAK Sensor or Glass Make sure that the Sensor or Glass Scale is installed Scale problem 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 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 Encoder Disk or Reader Head on motor Swap the motor in question with a known good motor are loose 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 Indi
156. l to the motion of the axis This causes the wheel to skip at certain regular points in its travel e 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 e 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 e 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 e Use a Voltmeter reading A C volts e Acceptable range is 100V to 130V 79 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List 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 Problems Here May Indicate 1 The wall outlet e 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 e Power cord defective Check the end that goes to the electrics box 3 Checkthe top fuse on the electrical If this is blown then power will not reach cabinet It should be an 8 amp fuse the 4 outlets on the electr
157. lation Maintenance Service amp Parts List Manual Parts List Lower Vari Disc Sub Assembly Item P N DESCRIPTION Qty 1 FVS50 BELT HOUSING BASE 1 2 FVS59 BRAKE BLOCK 2 3 FVS58 TURNING BLOCK SHAFT 1 4 FVS103 RING 7 1 5 FVS51 SET SCREW M6 P1 06L 2 6 FVS53 BRAKE LOCK BUSHING 1 7 FVS52 LOCK SHAFT 1 8 FSV119 RETAINING RING 11 1 9 FVS47 SHOE 2 10 FVS48 BRAKE SHOE PIVOT SLEEVE 1 11 FVS17 SOCKET CAP SCREW M6 P1 0x35L 1 12 FVS49 SPRING 2 13 FVS122 WASHER 6 4 14 FVS120 JSCREW PHILLIP PAN HD 3 16 24NC6L 4 15 FVS46 BRAKE BEARING CAP 1 16 AK048 BALL BEARING 6912ZZ 1 17 FVS14 SOCKET CAP SCREW M 5 PO 8x12L 4 18 FVS45 STATIONARY DRIVEN VARIDISC 1 19 FVS70 SPINDLE PULLEY ASSY 1 20 FVS100 JSPINDLE PULLEY SPACER 1 21 FVS71 KEY 8x8x20L 1 22 FVS97 SNAP RING 50 1 23 FVS52 1 BRAKE LOCK SHAFT SWIVEL 1 24 FVS56 _ BRAKE LOCK HANDLE 1 25 FVS54 HANDLE FIX BLOCK 3 8 16NC 1 26 FVS55 SPRING PIN 6x20L 1 27 FVS57 1 JBAKELITE BALL HANDLE 3 8 16NC 1 28 24055 BRAKE SHOE ASSY 1 29 FVS98 CLUTCH WASHER 1 100598 K4 189 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual i20697 6 Upper Vari Disc Sub Assembly Figure 106 P N 20697 6 190 Southwestern Industries Inc TRAK
158. lator branches into two components an oiler for the power drawbar unit and an air solenoid The solenoid is used for a misting system that the user may install later on this machine The mister air hose can be plugged into the 34 quick disconnect air fitting on the solenoid 2 14 Mounting the Display Pendant The display pendants for the ProtoTRAK M3 SM amp MX and the TRAK AGE mount to the pendant arm with four 1 4 20 x 34 SHCS that are shipped screwed into the left side of the display The ProtoTRAK Edge 3 display pendant mounts the same way except with 3 studs The Edge 3 requires 3 3 8 16 nuts and washers to fasten the pendant to the arm For all models a locating screw on the pendant arm helps align the pendant with the mounting holes CAUTION The locating screw in the arm is used for positioning Hold the pendant firmly until the screws are fastened 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 15 Cable I nterconnections All cable interconnections are made at the factory except for those connecting to the pendant display 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 label on the pendant to match the connectors with the correct port Ensure that there is sufficient slack
159. liary Function 2 turns shop air on and off Shop air in is connected through the bracket on the back of the column The fitting is ready to accept a standard quick disconnect device with a 1 4 inch pipe thread Air pressure is not to exceed 100 psi Shop air out is at the Pneumatic Device Out port Connect the plastic tubing supplied in the hardware kit The most common use for this function is for a spray mister Lube and water separators are recommended Minimum 24 from DPM AUX FUNCTION 3 Rotary Indexer Auxiliary Function 3 transmits an electronic signal to be used by a relay or another electronically driven device It also transmits input back from the device to restart the program The most common use is a Haas type rotary indexer 153 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual The signal output is a 0 3 second activation of a solid state relay between Pins 3 and 4 The maximum permissible voltage is 60 VDC or 40 VAC with a maximum current of 025 amps The input is a 0 1 second or greater activation of the external device indexer relay between Pins 1 and 2 The relay impedance must be less than 500 ohms The connector for this output is located on the side of the Electrics Box and is labeled Logic To Indexer On this connector Pin 1 is on the bottom Pin 2 is on the left Pin 3 is on the right and Pin 4 is on the top Included in the hardware k
160. libration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants Section 5 2 2 Where applicable TRAK Sensor or Glass Make sure that the Sensor or Glass Scale is installed correctly Scale problem 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 amp 4 7 X amp 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 Head Bolts are loose Verify that all the head bolts are tight 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 Y axis The DRO shows motion of a few thousandths of an inch in the axis that is not supposed to be moving Explanation For straight line cuts along the X or Y axis the control is designed to lock the motor of the axis that is not moving A taper is created when there is play in the system The force of the tool shoves the table or saddle out of position 51 Southwestern
161. lies 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 4 11 13 Code 314 Toggle Test Lights On in Status Line SM only 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 3 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 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 4 11 14 Code 319 Erro
162. lls Safety Installation Maintenance Service amp Parts List Manual Parts List Top Housing Assembly 24688 1 Item P N DESCRIPTION Qty 1 20697 1 GEAR HOUSING SUB ASSY 4VK A1 1 2 20697 2 HI LOW SHIFT CLUTCH SUB ASSY 4VK A2 1 3 20697 3 HI LOW SHIFT SUB ASSY 4VK A3 1 4 FVS12 SOCKET CAP SCREW M6 P1 0x15L 2 5 20697 4 PULLY PINION SUB ASSY 4VK A4 1 6 FVS64 BULL GEAR PINION BEARING CAP 1 7 FVS93 SCREW SOC HD M5 P0 8x15L 1 8 FVS117 5x520L 1 9 FVS62 TIMING BELT PULLEY 1 10 FVS126 WASHER 5 8 1 11 FVS61 JAM NUT 5 8 11NC 1 12 20697 5 LOWER VARI DISC DRIVE SUB ASSY 4VK A5 1 13 FVS63 BELT 8YU 600L 1 14 FVS135 KEY 8x7x60L 1 UPPER VARI DISC DRIVE SUB ASSY 4VK A6 Shown for 15 20697 6 reference only See figure 106 1 16 FVS4 1 17 FVS1 JBELT HOUSING 1 18 FVS17 SOCKET CAP SCREW M6 P1 0x35L 1 19 FVS13 TOP BEARING CAP 1 20 FVS15 BALL BEARING 6909VV 1 21 FVS129 SCREW SOC HD CAP M6 P1 0x18L 1 22 20697 7 SPEED CHANGE HANDWHEEL SUB ASSY 4VK A7 1 23 FVS10 SCREW SOC HD CAP M8 P1 25x30L 1 MOTOR ASSY DPM5 5HP WHITE shown for reference only not 24 20820 1 part of upper head housing assembly 1 25 FVS130 WASHER FLAT 9 10 2 4 26 FVS111 SOC HD SCREW 3 8 16NCx32L 4 27 FVS11_ MOTOR PULLEY COVER 1 28 FVS104 COPPER CHIP 2REQ 2 29 FVS131 SCREW FLAT HD PHILIP M5 P0 8x10L 1 3
163. ms etc If the machine must be installed on vibration mounts pads rubber commercially available leveling and vibration mounts etc follow the instructions delivered with the mounts pads ordering them to satisfy the load of the machine and the maximum weight of the workpiece 6 000 Ib When machine is correctly level lock the adjusting screws in place with their hex nuts 100877 Figure 2 7 Placement of Levels LEVEL SCREW LOCK HEX NUT MACHINE BED LEVEL PAD 100138 Figure 2 8 Leveling Screws 19 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 2 12 Electrical Connection The TRAK amp Sport Bed Mills can be configured for 220 or 440 volt 3 phase electricity with exception to the DPME2 which is only configured for 220 volt electricity These machines also require a 110V power source to power the control 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
164. n Maintenance Service amp Parts List 4 11 1 CODE 11 Hysteresis Note This code is use only for systems with Sensors or Glass Scales on the table and saddle 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 e Play How much backlash must be taken up when motion is reversed e 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 Note You will lose your DRO position reference 2 Go intothe 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 11 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
165. nal repeatability value is 0 0004 Other considerations for accuracy or repeatability are 1 Is it constant 2 Is it random 3 Is it changing at a particular rate This leads to the possibility of running the program several times or manually running a repeatability test For example Set the indicator on the flat of position A Zero the indicator and the DRO Move away from the flat about 4 inches then return to read the flat and record the result Do this approximately 6 times for positional accuracy repeatability concerns The following is an example for manually checking positional accuracy repeatability i01080 3 5 2 5 2 The Program for the Y axis Will Run as Follows The Y axis program will function in relatively the same way as the X axis program Set up is the same except that the Y direction it utilizes a different program file 178 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Spindle Flats A amp B 150 mm Standard 101080 2 FI GURE 5 47 Typical set up for a Y axis accuracy repeatability check 5 2 5 3 Program for the Z axis 1 Place 75 mm gage block on the table One end of the 3 0 inch dimension in contact with the table and the other end touching off the indicator Seta 0 0001 indicator on the spindle and move it to read the top of the 77 mm gage block Set the indicator and the DRO X Y amp Z values to zero a
166. nd recheck Repeat as necessary 166 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100025 Figure 5 41 Saddle Bottom Gib Adjustment TRM DPM Sport B3 DPMS3 167 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 2 1 3 2 DPM5 Sport B5 DPMS5 It is unrealistic to adjust the Y bottom ways the same way as we do on the lighter mills because of the extra weight of the saddle and table 1 Clean all chips dirt and excess oil from the table and saddle Center the saddle on the bed ways Mount your indicator on the left side of the saddle Point C with the table in the center of its travel and zero out your indicator 4 Move the table all the way to the right side When the gibs are adjusted properly you should see no more than 0 0003 movement on the indicator 5 Do the same thing on the right side of the saddle Point B this time moving the table all the way to the left The reading should be positive on the indicator because the saddle should rise where you are indicating Note You can get better readings than 0 0003 but the torque on the Y ball screw may exceed our recommended levels Remove the ball screw cover and check the torque with an in Ib torque wrench Normally the torque should be around 15 in lbs Do not exceed 20 in lbs Values higher than this may cause circularity
167. nd set Z retract at this position also Then press MODE press RUN press SET Z RETRACT then press INC ABS SET To run the program press MODE RUN START GO Press GO again and the Z axis will move to 75 mm and stop Record indicator reading This is your positional accuracy value Press GO Z moves up to zero then back down to 75 mm then stops Record the change This is the uni directional repeatability value Press GO Z will move to zero then stop Move the 75 mm gage block back into position and note the indicator reading This movement will yield the value for bi directional repeatability Record the reading End 179 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 7 Adjust backlash values as needed START here Set indicator 101080 4 Figure 5 48 Typical set up for a Z axis accuracy repeatability check 180 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Program movement 49 9 is 2 0 amp 2 Retract Z 75mm Gage Block 101080 5 Figure 5 49 Program Movement 181 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 6 0 Figures and Parts Lists Figure 100 Top Housing Assembly 40 Taper 100593 4 182 Southwestern Industries Inc TRAK 8 Sport Bed Mi
168. nion Shaft Sub Assembly P N 20698 3 TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 200 Southwestern Industries Inc Hem PN Tre 6 FB 6 SOCKET SET SCREW M6 PLOGL T NENEN ENEN lt FB 5 acan 1 FB97 OVERLOADCLUTCHWASHER 1 T FBSB SNAPRINGO10 1 f FB96 OVERLOAD CLUTCH TRIP LEVER 1 FB 4 CLUTCH RING PIN REQ 2 Deer BRASSPLUG O O i00606 K4 mi Figure 113 Overload Clutch Trip Sub Assembly P N 20698 4 201 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100607 K4 em PN e FB4 FEED REVERSE BEVEL GEAR 8 Fee Ereda o FBs0 FEEDREVERSECLUTCH 100607 K4 lt Figure 114 Feed Reverse Clutch Sub Assembly P N 20698 5 202 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 115 Ouill Spindle Sub Assembly P N 20836 1 203 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Spindle Sub Assembly PN DESCRIPTION Qy FB127 20839 BEARING ANGULAR CONTACT U SET 2 7010 18et FB136 BEARING SPACER LARGE FB137 JBEARING SPACER SMALL S
169. no Lubrication to Make sure all the Way surfaces are getting proper lubrication Ballscrews and Way surfaces 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 Z axis Gibs are not adjusted Check the adjustment of the X Y and Z axis Gibs using the properly X Y and Z axis Gib adjustment procedures Binding in the Drive Train Check Repeatability using the Repeatability and Positional Accuracy procedure Check the torque reading of the Drive Train Step by step carefully inspect the Drive Train for any binding It may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 4 2 Servo Drive failure See Servo Driver Section 4 5 Motor failure See Motor Diagnostics Section 4 4 3 2 3 Axis Will Not Jog The system powers up but will not respond to the jog command Perform the following Service Codes and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting 54 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Possible Cause Check This Shut down the system and wait 10 seconds before rebooting E Stop is pressed in Check E Stop Especially if both axes will no
170. not allow user to save or pull up programs from a floppy disk See Section 4 3 1 LCD backlight burns out SM only Check all cable connections to LCD distribution board and computer module Make sure the power is turned off before doing so 73 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Possible Problems Can Lead to 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 1 amp fuse in pendant blows Pendant will not turn on spikes Slave Board not functioning If no slave data is found in Code 33 replace the module 4 3 2 Diagnostics for Computer Modules Separate from Pendants AGE2 AGE MX2 Indications e Problems that are manifested in the Display Pendant e g Blank Screen but the Display Pendant passes the logic cable test e There are problems with axis motion Objective e To determine if the computer module has failed Note SWI s exchange program provides for an exchange of the entire computer module once a problem has been isolated to this subassembly This makes it unnecessary to identify the exact nature of the failure within the computer 1 Open the computer cabinet Be sure to clean the area around the cabinet first so that chips are not allowed to enter the computer module 2 Check the floppy disk drive l
171. nt P N without sensors AGE2 AGE3 20347 3 20180 20180 1 B3 with sensors Part number reference table for wiring the TRAK amp Sport Bed Mills Description Part Number TRM DPM DPM5 Sport B3 Sport B5 DPME2 DPMS3 S5 Electrical Box 20065 220 17009 220 21800 220 20676 220 20676 1 23630 Relay Module 20065 440 17009 440 21800 440 220V amp 440V 440 20676 220V only Relay Overload 220V Z00 N A N A 220V 23438 1 220V 23438 1 N A 10 440V 23438 440V 23438 440V Z00 6 Relay Module N A 20157 220 N A N A N A N A with transformer 20157 440 option Contactor Qty DILOOM N A 2 Reverse or 94 xxx or older Forward only All replacement part numbers with exception to LOO1 pumps have a suffix R For example 17009 220R and 23438 1R 21 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 2 12 1 Cable Connections for TRM DPM amp DPM5 Pendant ON OFF 3 4 Amp Slo Blo Fuse RS232 O 8 Amp Slo Blo Fuse 2 Remote Stop Go i 115V AC Power Out to Computer Cabinet Logic Cable to 115V AC Power in Computer Cabinet Oles sear SO eme Ground Stud Figure 2 9 Pendant Drawer AGE 2 3 amp MX2 3 TRM DPM amp DPM5 22 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Se
172. ntenance Service amp Parts List Manual DPME2 Lubrication System Figure 142 Pump amp Lube System NOTES UNLESS OTHERWISE SPECIFIED TO BACK SLIDING SURFACE OF THE COLUMN RIGHT SIDE TO COLUMN RIGHT SIDE GIB SLIDING SURFACE TO Z AXIS BALL SCREW TO BACK SLIDING SURFACE OF THE COLUMN LEFT SIDE TO COLUMN LEFT SIDE SLIDING SURFACE TO X Y 8 Z LUBRICATION SYSTEM d ALL TUBES ARE 4mm ALLUMINUM TUBE So ad E TO COLUMN Z AXIS RIGHT SIDE SLIDING SURFACE 100661 E2 ORAN 248 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Lubrication Pump 8 Lube System DPME2 Item P N Description Oty 21157 1 blue 1 21157 1 green LUBRICATION PUMP DPME2 0 3 B 3 OIL OIL REGULATING B 3 0 4 PG004 PLUG M8 X 1 0 0 5 PA4 BUSHING 13 6 PB4 SLEEVE 4 MM 19 8 PAN4 NUT 6 10 JD 4 2 WAY JUNCTION 1 11 L008 TUBE STEEL ROPE 8 HOSE 1 12 DB7 DISTRIBUTOR 1 13 PSS4 OIL DISTRIBUTOR 6 14 4 TUBING 4MM ALUM AIR 16 PZ0204 CLAMP 1 17 PZ0104 CLAMP 1 18 PD401 ADAPTER 3 19 PD408 ADAPTER 1 249 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 143 Lubrication Drawing X amp Y Axis DPME2 TOXAXIS GIB TO Y AXIS LEFT WAY SUFFACE TO X AXI
173. o 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 e Y axis the only component that can cause a misalignment problem is the motor mounting bracket To align this bracket move the saddle as far 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 2 1 2 DPM5 DPMS5 amp Sport B5 Ball Screw Alignment e X axis there are 3 components that can cause misalignment the yoke the left side bearing housing bracket and the right side bearing housing This machine has a separate yoke for the X and Y axis e X Axis Yoke the yoke is aligned at the factory If you suspect the yoke is misaligned the bolts for the yoke can be accessed from an opening on the bottom left side of the saddl
174. odule and screen enclosure SM and EDGE only 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 Make sure to first unplug any accessories like the Remote Stop Go switch external keyboard mouse etc to eliminate any interference Possible problems Can lead to Poor cable connections There are 4 cable connections to the left side of the pendant Make sure all cables are properly fastened SM only 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 SM only 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 EDGE amp M3 have no flash drive drive module with voltmeter It should be 4 8 DC volts and above Lower values than this can cause problems SM only Where applicable 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
175. om Computer Check connections on computer module SM only Module to LCD Liguid Crystal Display Computer Pendant failed See Computer Pendant Section 4 3 3 3 3 Keyboard Lockup The screen display is normal but the system will not respond to key presses Perform the following Service Codes and procedures e Code81 check if the pendant keys are working properly press each key If the key is working the corresponding key on the screen will light up The pendant will also beep SM only Possible Cause Check This Logic Cable Test Unplug logic cable and look for 9 bars on screen Voltage drop spike has occurred Shut down the system and wait 10 seconds to reboot the system Remote Stop Go RSG switch has a Remove the RSG Turn the system off and then on short if connected again If the problem goes away and then re appears when the RSG is plugged in replace the RSG Poor cable connections from the Re seat cable connectors by pulling out and pushing Computer Module to the Distribution back in Board and from the Distribution Board to the Keyboard Computer Pendant failed See Computer Pendant Section 4 3 Where applicable Electromagnetic Especially suspected if the network cable is run near interference has entered through the any electrical conduit If the problem is chronic 57 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual network cable
176. ool 750 end mill 2 flute high speed steel sharp e Coolant Flood coolant Cool Tool or Kerosene 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 SM or ProtoTRAK Edge 3 flash drive For SM the part number is euclid PT4 which is found under the PT4 folder followed by the SWI TEST PROGRAMS folder For PT3 the part number is 99999999 MX3 or 99999999 MX2 which is located on your parts disk 3 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 4 Load the 750 end mill and set Z Absolute 0 at the top of the part and set Z reference positions in the SET UP mode Set Z retract a few inches above the part 5 Begin to run the program The part will be machined in the following sequence 6 After the program run the program will locate to the following position e X 1 318 e Y 1318 Event s 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 0 250 remaining on Euclid block 4 roughs material in upper right hand corner 0 500 5 12 cuts triangle on Euclid block 0 500 13 rectangular frame cuts outer 2 750 rectangle 0 7500 7 Mount a d
177. ough 5 25 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 X axis for all models Ensure that the screws that hold the bearing housing in place to the bracket are not loose 7 Y axis Ensure that the bearing housing is clamped in place by the bracket This design uses the bracket to secure the bearing housing in place It should not allow the bearing housing to float between the bracket and machine 8 Ensure that the Clamp Nut is secured The following applies to the clamp nut e When loosening make sure to back out the 10 32 screw from the clamp nut e 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 50 165 and then tighten the screw down 9 Take out the angular contact bearings and inspect them They should roll smoothly
178. out and away from the head Lowerthe ball screw on the right side of the machine until the top of the ball screw clears the support plate 18 Reassemble all components in reverse order as shown above except leave off the pulley locknut and lock washer until ball screw is realigned Torgue clamp nut to 50 ft Ib 19 With the ball screw assembly installed loosen four 5 16 18 cap screws from bearing housing raise head to the uppermost position and re tighten 5 16 18 cap screws Note that there is 060 clearance between the bearing housing outside diameter and the inside diameter of the support plate to allow for realignment Traverse the head to the extreme of the up and down travel manually to check for freedom of movement Use torque wrench to make sure torque is consistent along length of screw Use torque wrench to make sure torque is consistent along length of screw See Section 5 2 2 to properly measure and set the Z Backlash Compensation and calibration 141 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 5 26 Z Axis Motor and Ball Screw DPM 5 Sport amp Sport B5 100925 142 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Z Axis Motor and Ball Screw DPM DPM5 Sport B3 amp Sport B5 P N Description
179. ove the three M8 screws holding the belt housing base to the gear housing Lower the guill about 4 inches Remove the belt housing base and lower or stationary varidisc pulley assembly Replace the timing belt 5 1 21 Brake Shoe Replacement 1 Remove the motor drive belt and complete Steps 1 5 of the timing belt replacement procedure Remove the two M6 cap screws from the bottom of the belt housing base Separate the belt housing base from the lower or stationary varidisc pulley This is a slight press fit Remove the 2 springs Replace the brake shoes 5 1 22 Spindle Replacement 1 2 Remove the draw bar and its bushing Lower the quill about 1 inch and lock 160 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 3 Remove the setscrew from the back of the spindle 4 Loosen unscrew the large black ring nosepiece with a spanner wrench Note The nosepiece has a left hand thread rotate counterclockwise to loosen 5 Using a soft bar about 12 inches long alternately tap on the top of the spindle and loosen a few threads on the nosepiece until fully unscrewed the nosepiece will remain attached to the spindle 6 Continue to tap the spindle out of the quill The spindle bearings will come out with the spindle QUILL Figure 5 36 Z AN 2 m y A N SET Z ji 2 SCREW q Q AX lt AS ISS
180. overload relay is tripped LED 6 is off during normal operation 7 LED 7 is on when the E Stop on the switch box is in the Out position LED 7 is on during normal operation 8 LED 8 flashes on when the Haas rotary table is being indexed one cycle or step The function is controlled through Auxiliary Function 3 see Section 5 1 15 DPM only 9 LED 9 flashes on when the Haas rotary table has completed indexing one cycle or step DPM only 10 LED 10 is on when Auxiliary Function 1 coolant pump is on see Section 5 1 15 DPM only 11 LED 11 is on when Auxiliary Function 2 air relay is on see Section 5 1 15 DPM only 12 LED 12 is on when Auxiliary function spindle motor is on see Section 5 1 15 DPM only 5 1 15 Auxiliary Function I nterface DPM DPM 5 only Refer to the machine programming operating and care manual for the procedures to use the auxiliary functions AUX FUNCTI ON 1 A C Relay Auxiliary Function 1 turns power to 115V A C 2 amp socket on and off The socket is located on the side of the Electrics Box Power to this socket can also be controlled by the Coolant Switch on the front panel of the Switch Box The 115V is turned on when either the programming AUX 1 is activated or when the Switch Box switch is turned to the On position The most common use for this function is the coolant pump but other A C driver devices may be substituted for example a light AUX FUNCTION 2 Air Relay Auxi
181. p Look for the following possible problems e Broken or loose sensor base e Broken or loose bracket e Sensor tilted too much so that the wheel is not engaging the running surface 78 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List 4 7 2 Measurements Do Not Repeat 1 Determine if the error in repeatability is random or accumulating e Mount a dial indicator in the quill e Touch off a fixed point on the table and set the DRO to 0 e Traverse away approximately 6 inches e Return and touch off again e Write down the reading on the DRO e Do not re zero the DRO traverse away and return several times e 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 Machines that have TRAK Sensors are TRM DPM amp DPM5 optional on DPMS3 DPMS5 Sport B3 amp Sport B5 Common sources of random error include e broken base e broken bracket e loose puller screws e loose run bar e very loose motion of the table or saddle e loose clamp screw 3 Accumulating error is almost always the result of the wheel not traveling in a path paralle
182. problems See Figure 5 41 for an illustration adjust the gib for excessive clearance Loosen the gib lock screw on the back of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the front of the saddle Tighten the gib lock screw on the back end of the saddle to lock the gib in place and recheck Repeat as necessary e adjust the gib for too small of a clearance Loosen the gib lock screw on the front of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the back of the saddle Tighten the gib lock screw on the front of the saddle to lock the gib in place and recheck Repeat as necessary 5 2 1 4 Back Gib Adjustment Z Axis All Machines 1 Clean all chips dirt and excess oil from the table and saddle 2 Disconnect one end of the upper and lower way cover where it is attached to the ram 3 Position the milling head such that the table can be reached by extending the quill approximately 3 4 of its travel 4 Place a wood block on the table underneath the spindle 5 Attach a 0001 dial indicator with a magnetic base to the column near the base of the ram on the left side of the machine Place the indicator stylus on the rear surface of the ram near the bottom 168 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual DIAL INDICA
183. r Log SM only 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 92 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List may be helpful for identifying problems between programmed commands and executed commands To turn on the error log press the F6 softkey The page forward and backward keys allow you to scroll through the file one page at a time The data forward and data backward keys allow you to scroll through the file one line at a time The data bottom key takes you to the bottom of the file and then changes to data top which will take you back to the top The file will capture data until the file reaches a size of approximately 600 KB At this time the file is saved to a backup file and the original file is cleared and data is once again captured Once again as the file reaches a size of 600 KB it copies over the previous backup file From here the user can save the file to the floppy drive by pressing the F8 softkey Once this in done it prompts you for which file you want to save to disk The F1 key saves the current file to disk and the F2 key saves the backup file to disk To clear the files press the F7 softkey 93 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service 8 Parts List 5 0 Procedures for Replacement
184. r 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 99 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100019 Figure 5 5 TRAK Sensor Mounting Parts List Item P N DESCRI PTI ON 1 250 SENSOR ALL TRAK PRODUCTS 2 M5 M 5 BASE 3 LDCEL C LOADCELL M250C 4 5 HDWR HARDWARE M5 BASE 5 16023 1 BRACKET SENSOR X AXIS 6 21511 EXTENSION 7 24227 BAR RUN Y AXIS 8 13777 1 BRACKET SENSOR Y AXIS 9 13346 3PK CHIP SCRAPER M250C 101160 100 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual aa SLONJOHAMVUL Tv HOSNaS Po SXvAHOSNsSWaAOO cere 15 5 5 5 ase wexoe 6 09 15 5035 LXd 1lHd Hd MIHOSI siempees e TWAQ DS ILS 14S DOS MdHOS dark 9 A 992001 6 DPMS3 Sensor Assembly 5
185. rates e Depth and width of cut e Design or type of cutter e Sharpness of the cutter Workpiece material e Type of finish or accuracy required e 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 The Mechanical Drive Train X Y Indications e 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 l Check for machine considerations especially gib locks and gib adjustments See Gib Adjustments Section 5 2 1 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 Ibs 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 for more information 70 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Note The following steps take you in logical seguence through the assemblies For drawings of these assemblies see Figures 5 12 thr
186. re in place to prevent the way cover from getting caught in the Z axis counterweight chain support sprockets 7 Using the manual hand crank lower the head until the counterweight is raised off the counterweight support rods 8 Remove the two 2 counterweight support rods 9 Remove the manual Z axis hand crank TRM DPM DPM5 Sport B3 Sport B5 DPMS3 DPMS5 only 10 Attach 2 wiper brushes to each table tray using 2 M5 X10 button head cap screws supplied per brush Install 1 table tray on each end of the table DPM5 SPORT B5 DPMS5 only NOTE Ensure that the tray does not scrape the TURCITE Check TURCITE for damage 11 Mount the pendant to the pendant arm using 4 1 4 20 x 3 4 socket head cap screws For DPME2 only mount the pendant to the arm using 3 3 8 16 nuts and lock washer 12 Make and check all the proper electrical connections from the pendant to the electric box See the pendant and electric box wiring diagrams 13 If applicable load TRAK sensors 14 Ensure that the 220 440V and if applicable the 110V lines are plugged in Turn on power to machine and pendant 15 Fill all the head oil cups with SAE 30 oil 16 Lubricate all the way surfaces and the ball screws 17 Jogthe table saddle and ram back and forth until the way surfaces are well lubricated Oil should be visible on all the way surfaces 18 Crank the X and Y electronic handwheels to check for functionality 19 Run the spindle through th
187. reen to complete calibration 5 2 2 2 2 Ram Ball Screw Calibration DPM only Whenever the Z Ram ball screw or system TRAK A G E computer module is replaced the Z Ram motion must be recalibrated 1 Create a set up similar to that shown in Figure 5 44 except orient the gage block and reference to measure vertical ram motion 2 Lock the quill 3 Press MODE SET UP SERV CODES 124 INC SET 4 Follow the instructions on the screen 5 If the difference between the measured length and standard length is more than 0 75 percent no ballscrew has this much error check your standard and repeat the procedure 171 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual SPINDLE USE SHORTEST gt BLE DI POSSIBLE DIAL ROD DIAL INDICATOR ZERO SAGE MOSI REFERENCE MACHINE ABLE MACHINE FRAME i00022 Figure 5 44 Calibration Set Up 5 2 2 3 Backlash Compensation MX2 MX3 AGE2 AGE3 Optional for M3 SM3 Code 11 Set X or Y backlash constant Note this procedure is on systems with dual feedback only Go to setup mode SERV codes and enter CODE 11 Refer to service codes in Section 4 11 for further explanation Code 127 Set X or Y Backlash Constant Note this procedure is only for systems without single feedback M SM EDGE Every mechanical system has at least a little backlash or lost motion It is produced by the small
188. rt Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 1 9 Ball Screw Replacement X Axis Table Refer to the following chart for illustrations and parts lists of the X axis drive assembly for each model X axis Drive Train Machine Model Figure Ballscrew P N TRM 5 12 15608 48 DPM 5 12 15608 48 DPM5 5 14 21564 Sport B3 5 12 5 13 15608 48 Sport B5 5 14 21564 DPMS3 5 15 15608 48 DPMS5 5 16 5 17 21564 DPME2 5 18 15608 48 Early MX2TRM may have 42 table ballscrews CAUTI ON Never screw a ball screw partially or totally out of its nut They cannot be reassembled 1 2 3 4 5 Position the table in the center of travel Remove the X motor assembly Remove the motor mounting bracket and bearing housing Remove the right side bearing housing TRM amp DPM only Remove X axis sensor guard cover and X TRAK sensor from its mounting base 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 CAUTI ON The weight of the table must be supported by the lift to prevent damage or breakage to the dovetails Remove the 5 16 x 1 screw holding the ball nut to the yoke and loosen the 4 screws that mount the yoke to the saddle Remove the oil line Remove the Y axis motor and bracket assembly Tilt the yoke it is pinned to remove the X ball screw Remove t
189. rt Bed Mills Safety Installation Maintenance Service amp Parts List Manual E Figure 5 23 Y Drive Train DPMS3 134 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual MOTOR REF 23198 100771 Y S3 Y Drive Train Parts List DPMS3 Desripin Qty 1 3 4 15967 5 6323 8 312 7 10 11 12 SPACER 100 THICK BEARING HOUSING 15 20373 BEARING ANGULAR CONTACT 7204 2 16 15885 RIN EANNGHOUSNG 1 17 15626 JSEAL BEARINGHOUSING 1 18 16350 rERRUESPROKET 1 19 160831 PULLEY SOUD 44 TEETH W O GUIDES 1 20 16452 NUTCLAMPX Y amp ZAXS O 1 21 e 5wis BErrMNG OOO o 1 2 56271 pLHOoER 1 23 15913 BRACKETWAYCOVERFRON 1 27 10 3218 425B SCREWSHCS STLBO 1 28 1 4 20X124B SCREW HEXHD STLBO 29 15759 WASHER AHARDBIKOXISTHK 30 984814090 KEY WOODRUFF 404 18X12 1 100771 53 s 135 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100771 Y S5 Figure 5 24Y Drive Train DPMS5 136 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Y Drive Train Parts List
190. rvice amp Parts List Manual Program Storage Floppy Disk Drive on front lid Cable Logic to Pendant Auxiliary Function Connection Parallel Port Position Encoders TRAK Sensors e e Limit Switches Motor Connectors 115V AC Power From Pendant E Stop Figure 2 10 Computer Cabinet AGE3 amp MX3 Connections DPM amp DPM5 23 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Cable Logic to Pendant Portable Floppy Drive Position Encoders TRAK Sensors Motor Connectors 115V AC Power From Pendant E Stop 101315 Figure 2 11 AGE2 MX2 Computer Cabinet TRM 24 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 115V AC IN TO EMERGENCY STOP SWITCH Figure 2 12 Wiring 16042 for 1995 and earlier 200 10 220V Motor Overload Relay 200 6 440 V Motor Overload Relay 2 DILOOM 220 440 Motor Contactor 25 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual INTERLOCK DOOR 220V 440V 3 PHASE INPUT 115V AC FROM PENDANT 115V AC TO PENDANT 115V AC TO LUBE PUMP DPM 115V AC INPUT FROM DEDICATED LINE 220V 440V 3 PHASE OUT TO MOTOR E STOP TO COMPUTER BOX 11
191. ry to remove the 2 steel rods with flanges inserted through the holes in the column These rods support the counterweight during shipping to prevent damage to the counterweight chains and sprockets 1 Release ram gib locks 2 DPME2 Lower the head slowly with a 10mm socket on the top end of the Z axis ball screw until the chain between the ram and the counterweight is tight TRM DPM DPM5 Sport Sport B5 DPMS3 DPMS5 Lower the head slowly with the ram crank until the chain between the ram and counterweight is tight 3 Lower a little further until the 2 support steel rods are loose Remove the 2 steel rods and store them for future machine moves or transportation 4 DPM DPM5 DPMS3 amp DPMS5 only Remove the panel on the bottom rear of the bed Verify that the lower end of the counterbalance rod guide at the bottom of the column is attached using the 2 socket head cap screws supplied Replace the panel 5 Do not continue to move the ram until all ways have been cleaned CAUTI ON Do not remove the steel rods unless they are loose 2 10 Cleaning 1 Remove rust protective coating from the machine before moving any slideways table saddle ram 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 WARNI NG Do not use gasoline or other flammable cleaning agents for cleaning the machine 3 It may be necessar
192. s 8 Maintenance 5 1 Replacements 5 1 1 Servo Motor Replacement WARNI NG 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 14 20 screws Be careful not to over tighten these bolts and strip the threads 5 1 2 Servo Driver Replacement WARNI NG Do not work with the Servo Drivers unless the power is disconnected from the machine The servo drivers are run by 110 VAC There is possibility of death by electrocution The Servo Driver for each axis is integrated into the servo motor casting DANGER 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 l Press in the Emergency Stop E Stop 2 Remove the servo motor driver assembly from its mounting bracket the Y axis assembly is located inside the front of the bed 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 94 Sou
193. s List Manual 53 16520 BRAKE HANDLE ASSY 1 54 16528 DRAWBAR 8 SLEEVE MANUAL 1 55 16522 2 HOUSING BEARING HOUSING ASSY NEW 6013 1 57 16501 MOTOR VARIDISC ASSY 1 58 25059 BRAKE SHOE ASS Y NOT SOLD SEPARATELY 1 59 AKO37 1 ROLL PIN 1 16501 60 AK040K ADJUSTABLE VARIDISC SPRING COLLAR 1 16501 61 M6X1 0X20 25B SCREW SHCS STL BO 6 62 JM8X1 25X20 25B SCREW SHCS STL BO 6 63 M5X0 8X15 25B SCREW SHCS STL BO 3 64 3 8 1650B JNUT HEX STL BO 1 i00106 1 233 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 136 Head Lower Housing TRM DPM Sport B3 DPMS3 100107 234 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Head Lower Housing Item P N DESCRIPTION Qty ASSY 1 A012H QUILL HOUSING SPECIAL ORDER ONLY 1 2 A042H SHIFT CRANK 2 16507 16526 3 A042H 1 PLUNGER 2 16507 16526 4 A042H 4 COMPRESSION SPRING 2 16507 16526 5 A042H 5 BALL 2 16507 16526 6 A045 CLUSTER GEAR SHIFT CRANK 1 16507 7 A047 FEED GEAR SHIFT FORK 1 16507 8 A048 CLUSTER GEAR COVER 1 16507 9 A049 FEED SHIFT ROD 1 16507 10 A053 CLUSTER GEAR SHAFT 1 11 A054 BEVEL GEAR BEARING 1 12 A055 BEVEL GEAR THRUS
194. s installed do not traverse the axis or the CAUTI ON reader head will break 5 1 7 2 Install the X or Y Replacement Scale If the scale is not long enough for the table it will break when the machine is CAUTI ON traversed past the scale travel 1 2 Mount the scale to the back of the table or Y axis mounting spar 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 4 005 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 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 103 Southwestern Industries Inc
195. 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 The following 6 steps apply to all controls Refer to Sections 4 11 5 1 through 4 11 5 3 for specific control display data and interpretation 1 Center the table and saddle and raise the head Make sure the gib locks are released 2 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 e f you want to run in the plus direction press INC SET e f 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 4 11 5 1 All controls with dual feedback sensors or glass scale Yourinput Display Data
196. ssible Cause Check This Wrong voltage Check the 220V 440V voltage to the machine Check all the wiring connections to the electric s box Defective cables or poor cable Check all cable connections connections Spindle Motor is bad Check the resistance of the Spindle Motor windings on the Spindle Motor between L1 amp L2 L2 amp L3 and L1 amp L3 using an Ohmmeter The resistance should range from 7 to 1 2 Ohm for the DPMS3 from 5 to 9 OHM for the DPMS5 and from 1 0 to 1 8 for the DPME2 If the Ohmmeter reads 0 Ohms or OL replace Spindle Motor Next check the resistance between L1 amp Ground L2 amp Ground and L3 amp Ground using an Ohmmeter The resistance should read OL If not replace Spindle Motor Spindle will not run because 110 V Check 110 V coming out of the AC e stop port on the power is not reaching the spindle cable breakout box Relay failure in cable breakout contactor box Replace cable breakout box Sport and SM 3 5 4 Spindle Runs Backwards The spindle motor runs in the opposite direction The spindle will run in opposite directions from high to low gear 66 Southwestern Industries Inc TRAK and Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 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 Caution Be sure to shut off all power to the machine before at
197. stern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List X Drive Assembly DPM5 amp Sport B5 NO P N DESCRI PTI ON QTY 1 21685 MOTOR DRIVER ASSY REF 3 15966 2 BRACKET MOTOR MOUNT 1 4 115967 2 COVER UPPER 1 5 15968 2 COVER LOWER 1 6 21585 2 COVER BALL SCREW END 1 7 21573 BEARING HOUSING REF 8 21572 COVER BALL SCREW END REF 10 21584 2 END COVER PLATE 1 11 6 32x1 210B JSCREW PAN HD EXT SEMS STL BLK OX 9 13 98481A090 KEY WOODRUFF 1 8 x 1 2 1 15 16066 CLAMP NUT l 16 565 5 15 BELT TIMING 5 HTD 1 17 21662 BEARING HOUSING X AXIS 1 18 20374 BEARING ANG CONTACT 2 19 16302 RING BEARING l 20 16078 SEAL l 25 M8 1 25 x 25 25B SCREW SOC HD CAP BLK 4 26 M8 74B WASHER EXTERNAL TOOTH 4 27 1 4 20x124B SCREW HEX HD 4 28 15759 WASHER FLAT 1 4 4 29 M10 1 5 x 40 25B SCREW SOC HD CAP BLK OX REF 30 M6 1 0 x 10 25B SCREW SOC HD CAP BLK OX REF 31 6205 BALL BEARING DEEP GROOVE REF 33 10 32 x 3 4 25B JSCREW SOC HD CAP BLK OX 1 36 16983 1 PULLEY SOLID 44 TOOTH 1 37 16350 SLEEVE TAPERED l 38 1 2 WASHER FLAT 1 4 1 39 91079A033 NUT JAM 1 2 20 51Z l 40 1 2 75C WASHER EXT TOOTH 1 41 M10 1 5 x 65 SCREW SOC HD CAP BLK OX 4 117 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenan
198. t Spindle Control DPME 2 only refer to Figure 5 34 Item 1 amp Figure 6 21 Item 26 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 CAUTI ON The motor is heavy about 60 pounds Be certain you have the proper equipment or assistance 6 Loosen the 32 nut on the belt tensioner puller screw at the back of the motor Release the belt tension using a 6 hex key to unscrew the tensioner puller screw from the motor housing 7 Tilt the motor towards the back and remove the belt from the motor pulley Remove the motor 8 If the motor is to be replaced remove pulley assembly off the motor shaft and onto the new motor 156 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual JUNCTION BOX i23610 XXX 2 D z BELT Figure 5 34 DPME2 157 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual DPME2 Spindle Head Parts List Item P N Description Qty 1 23585
199. t for the coolant hose connector block See Figure 5 43 169 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 3 Lock and unlock the lower ram side gib lock and note the amount of movement on the dial indicator Adjust the ram side gib until the registered movement is 0005 0010 To adjust the gib for excessive clearance Loosen the gib lock screw on the bottom of the ram Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the top of the ram Tighten the gib lock screw on the bottom of the ram to lock the gib in place and recheck Repeat as necessary To adjust the gib for too small of a clearance Loosen the gib lock screw on the top of the ram Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the bottom of the ram Tighten the gib lock screw on the top of the ram to lock the gib in place and recheck Repeat as necessary 4 Run Service Code 12 to set the feed forward constant 5 Reattach the upper and lower way cover to the ram CAUTION Be careful not to over tighten the ram gibs Over tightening may lead to faulting and repeatability problems Double check the gib adjustment by checking the torque on the Z axis Use an in Ib torque wrench on top of the ball screw and typical readings should be from 12 to 17 in lbs and consistent across the Z travel DIAL INDICATOR
200. t jog Servo Drive failure Especially if only one axis will not jog See Servo Driver Section 4 5 Shorted motor See Motor Diagnostics Section 4 4 Poor cable or wiring connections See Electrical Connection Section 2 12 Computer Pendant failed See Computer Pendant Diagnostics Section 4 3 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 Perform the following Service Codes and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 11 Measure s the backlash in the system Only used on machines with Dual feedback systems e Code 12 Feed Forward Constant High feed forward constants will cause an unstable servo system e Code 127 Measure s the backlash in the system Only used on machines with Single feedback e Code 128 Enter backlash compensation e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting Possible Cause Check This Check the adjustment of the X Y and Z axis Gibs using properly the X Y and Z axis Gib adjustment procedures Where applicable TRAK Sensor or Glass Make sure that the Sensor or Glass Scale is installed Scale problem 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 functionin
201. tactor Qty 2 Reverse or Forward 30 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual FROM SERVICE FUSE 8 ji FUSE SAMP S 5 m Er TT f L i e p 0 o H AUX 1 77 Bl AUX2 15 ED ACIN la COMPUTER 71 _ 11 e H LUBE PUMP 7 Ld L L 5 ur TO SPINDLE d MOTOR E STOP F R SWITCH e e 8 KA 8 100630 Figure 2 17 Sport B3 amp B5 20676 20676 1 Electric Box Connections 31 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 0598 1 amp WU men n Figure 2 18 Schematic Standard Electric Box Sport B3 amp B5 20676 20676 1 32 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 2 12 3 Pendant and Wiring Diagrams for DPMS3 DPMS5 100871 Figure 2 19 Pendant Cable Connections SM Left Side DPM S3 S5 SYSTEM FLASH DISK OPTIONAL FLASH DISK DRIVE MOUSE KEYBOARD RSG Figure 2 20 Pendant SM Right Side DPMS3 S
202. tants has values Load saved configuration file from floppy disk in been erased or corrupted electrics cabinet with Code 141 Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants Section 5 2 2 3 1 4 2 The Dimensional Errors Are Random or Accumulate in Size Over the Part Program Run Possible Cause Check This Machine Tool amp Setup problem See Machine Tool amp Setup Section 4 1 Where applicable TRAK Sensor or Glass Make sure that the Sensor or Glass Scale is installed Scale problem 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 amp 4 7 X and 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 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 Perform the following Service Codes e Code 33 Software Ident
203. tely out of the sheet metal 10 Follow the instructions in reverse order when reinstalling the new computer module 11 Make sure the connectors are fully seated before bolting the unit back in place Note if the flash drive is functional you may want to remove the flash disk and install it in the new flash drive COMPUTER MODULE TO ADAPTER CABLE 22754 DISTRUBUTION BOARD TO E STOP CABLE 21794 1 COMPUTER MODULE TO DISTRUBUTION BOARD CABLE 21795 HARD DRIVE CABLE 22572 4 GROUND CABLE 22260 1 AMP FUSE 21824 1 COMPUTER MODULE BUSS 100884 CABLE 22427 DRIVE MODULE 22960 Figure 5 3 Computer Module amp Flash Drive Replacement SM3 97 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 1 4 System Flash Disk Replacement SM3 only The system software for the SM control is contained on a 64 MB flash disk that is located under the door on the right side of the pendant in the upper flash drive slot If this needs to be replaced push the bottom to eject the disk and reload the new disk Turn power off to the machine before doing this replacement CAUTION It is a good idea to back up your flash drive from time to time via a network or floppy disk If your flash drive needs to be replaced you will loose all of your programs See your programming manual for instruction on how to do this 5 1 5 Cable Routing on Machine
204. tempting to switch any wires 3 5 5 Spindle motor intermittently stops and starts or does not operate Possible Cause Check This In spindle control electrics box loose Ensure that the screws on the FWD REV relays are screws holding the spade lugs down to holding down the spade lugs and that the screws are the FWD REV relays causing tight intermittent contact In spindle control electrics box Ensure that the spade lugs are installed back to back FWD REV contactor wiring spade lugs on the FWD REV relays that the screws are tight and installed improperly causing loose that the spades are fully locked beneath the hold contact or burned wires downs 3 5 6 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 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
205. thwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual WIRE HARNESS SERVO AMPLIFIER GREEN GROUND WIRE OVER CORD 0 PLATE LOOP CONNECTOR unplug here 100015 using loop Figure 5 1 Servo Driver Replacement Part 14 Description 20327 2 Z Servo Driver 20201 X amp Y Servo Driver 5 1 3 Computer Module Replacement 5 1 3 1Edge 3 Computer Module 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 2 screws on the right side of the unit and 2 screws on the backside of the unit The module is now free to slide toward the right side of the pendant 4 Slide the computer module a few inches and stop Pulling the computer module too far will damage the LCD cable 5 Now reach from the pendant arm side of the unit and disconnect 3 ribbon cables from the module 6 Follow the instructions in reverse order when reinstalling the new computer module 7 Make sure the connectors are fully seated before bolting the unit back in place 95 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 2X10 32x V8312 Figure 5 2 Computer Module Replacement EDGE 5 1 3 2 AGE and MX Computer Module Replacement The computer module is a black box located inside the computer cabinet mounted on the back of th
206. to Side Alignment 1 2 Figure 5 45 Tramming of Head Make sure the machine is level Make sure the table has been clean and the Z gibs are adjusted properly Mount a dial indicator in a tool holder and mount in the quill Adjust the Y axis so that the spindle is in the center of the table Adjust the Z ram so thatthe dial indicator will reach the table Move the dial indicator to 6 o clock position and adjust the face so the needle is Zero Do a series of sweeps from 3 o clock to 9 o clock and check for the repeatability of the setup The head should be trammed with an 0 001 If the head is out of tram from side to side loosen the 4 head bolts and rotate the head with the worm shaft Once the head has been trammed tighten the 4 heads bolts Be careful not to move the head while tightening Tighten the bolts in a criss cross pattern m zi i00149 174 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Back to Front Adjustment Note The head of the bed mill machine is adjusted at the factory This procedure should only be needed for a head replacement Using the dial indicator sweep the table from 6 o clock to 12 o clock The head should be trammed within 0 0000 to 0 0005 from front to back Note the head must droop down rather than up because tool pressure will take care of the extra 0 0005 Note Minor adjustments can be m
207. tool CAUTI ON 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 108 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 101131 Figure 5 11 Power Drawbar Assembly 109 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Parts List Item P N DESCRI PTI ON 1 22581 1 AIR GUN ASSY ONLY TOROUE RITE 2 See table below DRAWBAR 3 See table below TOP WASHER 4 22380 2 AIR REGULATOR ASSY 5 See table below DRAWBAR 6 22581 2 SWITCH CONTROL HEAD TOROUE RITE 7 22581 4 NOSEPIECE FOR SPINDLE 8 1 4 NPT AIR FITTING 90 9 3 8 O D TUBING 132 LG 10 3 8 O D TUBING 27 LG 11 See table below DRAWBAR 12 See table below DRAWBAR 13 See table below DRAWBAR 101131 Drawbar Table Model Mill Power Drawbar Power Drawbar Manual Drawbar Manual Drawbar Spacer Spacer DPME2 22605 22604 VS09 V5108 DPMS3 B3 TRM DPM 22603 NMTB 21661 AK147L AK149L DPMS3 B3 TRM DPM 22603 CAT 21661 AK147L AK149L DPMS5 B5 22641 NMTB 23888 FVS109 FVS108 DPMS5 B5 22641 CAT 23888 FVS109 FVS108 110 Southwestern Industries Inc TRAK amp Spo
208. tries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual CAUTI ON Assemble the hand wheel move it back and forth and see if there is some play in meshing the two gears together If the gears mesh tightly against one another it can generate noise during movement of the X axis It is normal to have a small amount of backlash between the gears 6 Screw on top cover Parts List X Drive Assembly TRM DPM amp Sport B3 PIN DESCRIPTION E 1594 JEND PLATE PLATE ADAPTER SERVO MOTOR a STOP X AXIS E jn men 25 ja Sr mies E LX s Housing seaming SSS enn conte 1 jo ses RING BEARING CS aja 1 I paar soe WO GHC OX A O O sou ae F60R E 113 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 5 12 X Drive Assembly for 00549 TRM Sport 114 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 5 13 X Drive Assembly Left Side DPME2 115 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 5 14 X Drive Assembly DPM5 amp Sport B5DD 116 Southwe
209. ts Physically switch the X and Y Has problem moved to Y axis If yes replace amp If no the servo amp motor is the problem 4 5 Servo Driver Note the Servo Driver is located in the black box on the side of each motor WARNI NG Do not work with the Servo Driver unless the power is disconnected from the machine There is possibility of death by electrocution Indications e Problems moving just one axis including hard turning in one direction 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 The Z glass scale is standard with the following machines DPME2 TRM DPM DPMS3 DPMS5 amp Sport B3 The X and Y axis glass scales are optional for the DPMS3 and DPMS5 machines for secondary feedback only 4 6 1 Alignment of Scales e 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 76 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List cause the scale to not read in the certain are
210. ule Indicates if the system is receiving countsView the light while moving an axis of the Middle from the independent position encoder machine using a handwheel The LED TRAK Sensor should flicker as the axis moves Indicates if the slave board is sending a A A View the light while moving axes under Lower to the motors Motor Encoder power The light should be on Failure of these lights to come on during the operations shown above indicates that the computer module should be replaced 4 4 Motor Diagnostics The Motor subsystem is comprised of 2 parts The Motor Encoder and the Motor 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 WARNI NG 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 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 en
211. ut amp Space Requirements TRAK amp Sport Bed Mills i00881 Figure 2 1 Machine Footprints DPME2 TRM DPM Sport B3 DPM5 Sport B5 DPMS3 DPMS5 Footprint of Machine 23 1 x 40 5 24 x 44 24 x 48 4 Weight approximate net 3200 lbs 4100 Ib 4400 Ib Weight approximate shipping 3500 Ibs 4400 lb 4700 Ib Pallet Size 70 x 70 6 x 6 6 6 A Overall width 101 108 136 B Overall length w electric 72 76 81 box door open C Bed width 23 125 24 24 D Bed width between leveling 20 5 21 7 21 7 screws E Distance between leveling 32 5 18 1 20 5 screws F Bed length 40 5 43 3 48 4 6 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List 100880 Figure 2 2 Overall Dimensions DPME2 TRM DPM Sport DPM5 Sport B5 B3 DPMS3 DPMS5 G Height oftable from bottom of 34 38 41 bed H Maximum distance from 23 5 23 5 23 5 spindle nose to table Maximum height of machine 78 85 87 from bottom of bed to top of column cover J Height of machine from bottom 89 95 98 of bed to top of spindle motor K Width of machine including 70 73 70 table L Length of machine with electric 64 66 71 box door closed 7 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 2 2 Uncrating Carefully remove the wood crat
212. uthwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual TRAK amp Sport Bed Mills Component Identification Item Description Part Number TRM DPM DPM5 Sport Sport DPMS3 DPMS5 DPME2 B3 B5 1 Spindle 16501 16501 20820 16501 20820 20820 20820 23585 Motor 2 MX2 MX3 AGE3 M3 M3 SM SM EDGE 15814 16274 20180 1 20347 2 20347 4 22328 3 22328 3 23688 Pendant AGE2 AGE3 20347 3 USA 20180 20180 1 B3 with sensors 3 Y Axis 15616 15616 20082 1 15616 15616 15616 15616 15616 Handwheel 4 15616 15616 20082 1 15616 15616 15616 15616 15616 Handwheel 5 Lube Pump LOOIL 21688 4 21157 1 21688 4 21157 1 21157 1 21157 1 21157 2 LOO1R X Y or Z 20276 x 20276 x 21685 20276 x 21685 23198 23198 20296 Motor 20296 y 20296 y x 20296 y x y X yz X y Z X y 20328 z 20328 z 20328 z 20238 z 23198 z All replacement part numbers with exception to lube pumps that are sold as new have a suffix R For example 23585 1R and 20296R 20082 1 Electric Handwheel Programmable spindle motor 14 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List qu K WORK LAMP 100874 Figure 2 4 TRAK amp Sport Bed Mill Rear View Item Description Part Number TRM DPM D
213. vement is between 0005 001 2 Move the table to the right and mount the indicator at Point A and move the table back and forth Note the amount of movement of the dial indicator Adjust gib until the movement is between 0005 001 e To adjust the gib for excess clearance Loosen the nut closest to the table and tighten the nut furthest from the table Once the clearance has been taken up tighten each nut against the gib bracket Do this for each end of the table e To adjust the gib for too small of a clearance Loosen the nut furthest from the table and tighten the inside nut up against the bracket to pull the gib away from the machine Once the clearance has been taken up tighten each nut against the gib bracket Do this for each end of the table 3 Center the table on the saddle and run Service Code 12 to set the Feed Forward Constant 4 Replace the table trays See Figure 5 39 163 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Figure 5 39 DPMS5 Table Gib amp Saddle Bottom Gib Adjustment 164 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 5 2 1 2 Saddle Side Gib Adjustment Y Axis All machines See Figure 5 40 Clean all chips dirt and excess oil from the table and saddle Center the saddle on the bed ways Move the table fully to the left side of the saddle Remove the
214. wn 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 Ifthe 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 WARNI NG The gap must be no larger than 0 060 between the readerhead and glass scale Part Description 22800 4 Z Glass Scale NR aS PART OF REF Figure 5 8 Z Axis Glass Scale Assembly ARES REF 104 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual SCALE REF item PIN Description 5 5 10 32X1 1 4 25B SCREW SHCS STL BO 8 116X1 281B SPRINGPIN 9 1 428X3 825B SCREW SHCS STL BO 105 Southwestern Industries Inc TRAKS Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 100787 V3 A NS 1 4 20x1 0 2 PLCS REF Figure 5 9 Glass Scale Alignment TRM DPM Sport B3 DPMS3 106 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Part Description 22800 42 X Glass Scale 22800 24 Y Glass Scale 28 32 x 75 2 PLCS REF DPM
215. y 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 on the ram on the right side of the column before attempting to move the above parts CAUTI ON Never move any of the above parts over ways that were not previously cleaned Serious damage to the TURCITE surface of slideways can occur 4 Becertain the table saddle ram and spindle move freely and smoothly over their entire length 2 11 Leveling Leveling Tolerance for TRAK amp Sport Bed Mills is 0005 10 l Setthe machine on its 6 leveling pads on a solid level floor prepared in accordance with the state and local rules for machine tool installation The DPME2 only uses 4 leveling screws 18 Southwestern Industries Inc TRAK amp Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual Put one or two precision Spirit Levels or Electronic Levels in the center of the table in the positions illustrated in Figure 2 7 Adjust the 4 corner leveling screws on their pads until the machine is level to 0005 in 10 For DPM DPM5 Sport Sport B5 DPMS3 and DPMS5 snug the 2 middle leveling screws being careful to not affect the level 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 shi
216. yes and the machine as well Don t use compressed air to remove the chips or clean the machine Disconnect power to the machine before you change belts pulley and gears Keep work areas well lighted Ask for additional light if needed Do not lean on the machine while it is running Prevent slippage Keep the work area dry and clean Remove the chips oil coolant and obstacles of any kind around the machine 4 Southwestern Industries Inc TRAK 8 Sport Bed Mills Safety Installation Maintenance Service amp Parts List Manual 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Avoid getting pinched in places where the table saddle or spindle head create pinch points while in motion 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 Use correct cutting parameters speed feed depth and width of cut in order to prevent tool breakage 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 After an emergency stop always turn the FORWARD REVERSE switch to Off STOP before releasing or resetting the E Stop Prevent damage to the workpiece or the cutting tool Never

Download Pdf Manuals

Related Search

Related Contents

Annex 08  ASUS (ME180A) User's Manual  PDFファイル - 製品評価技術基盤機構  Here  No．1 商 品 仕 様 書 全 4 1．型 式 1－1 定 格 1―2 適合法規 1－3 極  Moxa VPORT P06-1MP-M12-CAM42 surveillance camera    datasheet: pdf  

Copyright © All rights reserved. Failed to retrieve file