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Service manual - Clark Science Center

1. 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 assv 20849 oniv 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 SPRING 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 016 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
2. 100598 K2 K3 Figure 126 Spindle Motor P N 20819 ltem P N DESCRIPTION Qty Notes 1 V8110 MOTOR 3 HP 1 pnly available as 20819 2 VS3 1 KEY 6x6x45L 1 jonly available as 20819 3 VS2 JSTATIONARV MOTOR VARIDISC 1 only available as 20819 4 VS6 JBUSHING 1 available as 23953 or 20819 5 VS5 JADJUSTABLE MOTOR VARIDISC 1 available as 23953 or 20819 6 VS6 1 KEY 7x7x50L 1 Javailable as 23953 or 20819 7 VS8 JSPRING FOR VARIDISC MOTOR SHAFT 1 only available as 20819 8 VS9 ADJUSTABLE VARIDISC SPRING COLLAR 1 Jonly available as 20819 9 VS10 SCREW SOC HD CAP M8 P1 25x30L 1 Jonly available as 20819 10 23953 VARIDISC ASSY ADJUSTABLE MOTOR 1 100698 K2 K3 153 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 127 Lower Head Assembly 154 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List Lower Head Assembly Item P N Title Qty 1 K B125 2 HANDWHEEL 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 M
3. 45 C64 STOP SCREW 46 C65 KNEE LOCK SHAFT ASSEMBLY 47 C69 KNEE LOCK PLUNGER 48 C71 KNEE BINDER PLUG PLASTIC 49 C72 DOG POINT SET SCREW 50 C73 SETSCREW 51 C74 JAM NUT 52 C75 KEY 53 C76 WASHER 54 C77 BEVEL GEAR 55 C79 SEALED BALL BEARING 56 C80 BEARING RETAINER RING 57 C81 SOCKET HEAD CAP SCREW 58 C82 JELEVATING SCREW ASSEMBLY Available only in 20854 59 C83 HANDLE Available only in 20854 60 C84 JELEVATING CRANK 61 C85 GEARSHAFT CLUTCH INSERT 62 C86 DIAL LOCK NUT 63 C87 DIAL WITH 100 GRADUATIONS 64 C88 DIAL HOLDER 65 C89 SOCKET HEAD CAP SCREW 66 C90 BEARING RETAINING RING 67 C91 GREASE SEALED BEARING 68 C92 BEARING CAP 69 C93 KEY 70 C94 ELEVATING SHAFT FOR 12 KNEE 71 C95 GREASE SEALED BEARING 72 C96 BEVEL PINION 73 C97 SETSCREW 74 C98 JCOLUMN 75 C99 WASHER 76 C102 SOCKET HEAD CAP SCREW 77 C103 PEDESTAL 78 C104 ELEVATING SCREW NUT 79 C105 SOCKET HEAD CAP SCREW 80 C118 SPIDER 81 C119 RAMLOCK STUD 82 C120 JRAM PINION 83 C121 RAM PINION HANDLE 84 C122 PLASTIC BALL 85 C123 CHAMFERED HARDENED WASHER 86 C124 TURRET 87 C125 JGIB SCREW NUT 88 C126 JGIB SCREW 89 C127 LOCK BAR 90 C128 SCREW 91 C129 JLOCKING BOLT 92 C130 JRAM PINION SCREW 166 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual C131 K2 93 C131 K3 RAM TURRET GIB 94
4. Item P N Title Qty 1 FVS16 SPEED CHANGE HOUSING 1 2 FVS20 JBEARING SELF LUBRICATING 1 3 FVS22 SPEED CHANGER GEAR 1 4 FVS31 SPEED CHANGE CHAIN DRUM 1 5 FVS21 JWORM 1 7 FVS25 JSPEED CHANGE SHAFT 1 8 FVS40 ROLL PIN 3x15L 2 9 FVS24 COPPER BUSHING 2 10 FVS32 CHAIN 3109 525 1 11 FVS31 1 JDOWEL PIN 23x25L 1 12 FVS30 SPEED CHANGE STUD 1 13 FVS27 SPEED CHANGE HANDWHEEL 1 14 FVS18 FULL DOG SOCKET SET SCREW M6 P1 0x10L 1 15 FVS28 JHANDLE 3 8 16NC 1 16 VS24 1 WASHER WAVE 1 i20697 7 Figure 107 Speed Change Handwheel Sub Assembly P N 20697 7 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 128 Southwestern Industries Inc i20697 7 9 4 i00601 K4 Item P N Title Qty Notes 1 FVS110 MOTOR 5 HP 1 only available as 20820 2 FVS3 1 KEY 6x6x45L 1 only available as 20820 3 FVS2 STATIONARY MOTOR VARIDISC 1 Jonly available as 20820 4 FVS6 BUSHING 1 available as 24054 or 20820 5 FVS5 ADJUSTABLE MOTOR VARIDISC 1 Javailable as 24054 or 20820 6 FVS6 1 KEY 7x7x50L 1 available as 24054 or 20820 7 FVS8 SPRING FOR VARIDISC MOTOR SHAFT 1 Jonly available as 20820 8 FVS9 JADJUSTABLE VARIDISC SPRING COLLAR 1 only available as 20820 9 FVS10 SCREW SOC HD CAP M8 P1 25x30L 1 Jonly available as 20820 10 24054 VARIDISC ASSY 1 100601 K4 Figure 108 Spindle Motor Sub Assembly P N 20820 129 So
5. CAUTI ON The gap must be no larger than 0 060 between the readerhead and glass scale 95 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual ACURITE Z AXIS GLASS SCALE REF 2X 8 32 x 3 4 2X 1 420x1 100891 Part Description 22800 4 Z Glass Scale Figure 28 K Mill Z Axis Glass Scale Assembly Item PIN Description Qty ARM Z AXIS MOUNTING PLATE gt 20551 MOUNTING PLATE Z AXIS GLASS SCALE EI 20548 ADAPTER Z AXIS GLASS SCALE mn 20549 ADAPTER PLATE Z AXIS GLASS SCALE MM Deje 5 10 32X3 425B SCREW SHCS STIBO 4 6 10 32X11 425B SCREW SHCSSTLBO 1 3 7 15759 QWASHER I AHARDBLKOX1 8THK 1 8 1 16X1 281B SPRING PIN 9 1 428X3 825B SCREW SHCS STL BO J i00891 e vw gt 96 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 6 1 8 Power Drawbar A power drawbar is an optional item on a TRAK Knee mill machine It is bolted to the top of the head by the use of 3 SHCS Some machines may require a washer to space the unit up to the proper height to allow the drawbar to engage properly Air Regulator and Oiler This unit requires between 80 and 100 psi to operate properly Some units work fine at 80 psi while others may need 90 or 100 psi It is a
6. BALLSCREW 29 28 4x 20 SL Figure 32 Y Axis Drive Assembly 23083 3 43 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Y Axis Drive Assembly Parts List Item P N Title Qty 1 15626 SEAL BEARING HOUSING 1 2 23930 BEARING SET 2 ANGULAR CONTACT 7204 BECBP 1 Set 4 15980 BEARING HOUSING ASSY LARGE FLANGE Y AXIS 1 5 16452 NUT CLAMP X Y amp Z AXIS 6 20623 MOTOR BRACKET KNEE MILLS 40 DEGR 7 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 8 16350 FERRULE SPROCKET 9 890 5M 15 BELT TIMING 5MM POWERGRIP Y AXIS 11 20621 COVER SPORT 40 DEGREE 12 15627 2 DIAL HOLDER 13 15836 DIAL NUT 14 15614 TAB WASHER 15 15616 HANDWHEEL ASSY MX 16 1 2 71Z WASHER FLAT SAE STL ZINC 17 1 2 75Z WASHER EXT TOOTH STL ZINC 18 1 2 20 51Z NUT HEX JAM STL ZINC 19 10 32X3 4 25B SCREW SHCS STL BO 20 M10 1 5X60 25B SCREW SHCS STL BO 21 23082 WASHER 75X 394X 10 STL 22 1 4 20X1 24B SCREW HEX HD STL BO 23 15759 WASHER 1 4 HARD BLK OX 1 8 THK 24 6 32X3 8 10B SCREW PH PHIL STL BO 25 23141 SHEET METAL PT4 COOLANT MOTOR COVER ASSY 26 10 32X1 25B SCREW SHCS STL BO 27 10 73B WASHER SPLIT LOCK STL BO 30 98481A090 KEY WOODRUFF 404 1 8 X 1 2 31 14772 2 SPACER 020 THICK 32 20322 SPACER Y AXIS BALLSCREW 33 1 4 20X3 8 10B SCREW PH PHIL STL BO 20296 MOTOR ASSY ENCODER DR
7. Item P N Title Qty 1 15626 SEAL BEARING HOUSING 1 2 23930 BEARING SET 2 ANGULAR CONTACT 7204 BECBP 1Set 4 15980 BEARING HOUSING ASSY LARGE FLANGE Y AXIS 1 5 16452 NUT CLAMP X Y 8 Z AXIS 1 6 20623 MOTOR BRACKET KNEE MILLS 40 DEGR 1 7 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 1 8 16350 FERRULE SPROCKET 1 9 890 5M 15 BELT TIMING 5MM POWERGRIP Y AXIS 1 11 20621 COVER SPORT 40 DEGREE 1 12 15627 2 DIAL HOLDER 1 13 15836 DIAL NUT 1 14 15614 TAB WASHER 1 15 15616 HANDWHEEL ASSY MX 1 16 1 2 71Z WASHER FLAT SAE STL ZINC 1 17 1 2 75Z WASHER EXT TOOTH STL ZINC 1 18 1 2 20 51Z NUT HEX JAM STL ZINC 1 19 10 32X3 4 25B SCREW SHCS STL BO 4 20 M10 1 5X60 25B SCREW SHCS STL BO 4 21 23082 WASHER 75X 394X 10 STL 4 22 1 4 20X1 24B SCREW HEX HD STL BO 4 23 15759 WASHER 1 4 HARD BLK OX 1 8 THK 4 24 6 32X3 8 10B SCREW PH PHIL STL BO 8 25 23141 SHEET METAL PT4 COOLANT MOTOR COVER ASSY 1 26 10 32X1 25B SCREW SHCS STL BO 3 27 10 73B WASHER SPLIT LOCK STL BO 3 30 98481A090 KEY WOODRUFF 404 1 8 X 1 2 1 31 14772 2 SPACER 020 THICK 1 32 20322 SPACER Y AXIS BALLSCREW 1 33 1 4 20X3 8 10B SCREW PH PHIL STL BO 2 20296 MOTOR ASSY ENCODER DRIVER 4020 1 15609 12 BALLSCREW Y AXIS 1 15609 16 BALLSCREW Y AXIS 1 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual i23083 3 104 Southwestern Industries Inc 6 1 11 Spindle Motor Wiring The spindle motor is wired for 220 or 440 volts See F
8. 17 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 20600 YOLON OL 1NOY3MOd pi oleleleje O 2 ofelejeje SLIOA OEZ o olejeejeje NIH3MOd 3SVHd opp 0ZZ o o ia xnv Ht xn El as O aWV 8 NIHIMOd 3SVHd L ASLL UN o e en Bc SE wo tat O ot Dl c Eli D 9 9 a DE E o U 8 RS _ F o S A ljo 217 8 3 9 5 ea 2 5 O i gje 5 2 o Q ON 5 x SIE w O 3 clo E gt olL 2 ii O olu 8 IL 9 o en amp v JE 25 z AIL G a mm W o o co KRIMM v wo O st 00 S O m m m AAJNAA d ve mony TO PO gt gt gt gt i imim fu o o ool uvo O QIN sr mjo Ls N TIN FINN LL 18 Southwestern Industries Inc ProtoTRAK amp KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 2 12 Air Connection Optional The machine has an air hookup in the rear of the machine if the machine has a power drawbar If the machine has a power drawbar option then the machine will include an air regulator air manifold and an oiler The air fitting is Y NPT Within the manifold there is an additional air line port in case the user wants to hook up an air line to clean chips Remove the plug to gain access to this port 2 13 Lubrication CAUTI ON Failure to properly lubricate the mill will result in the premature failure of b
9. Possible Cause Check This Improper Boot up Shut down the system and wait 10 seconds before rebooting E Stop is pressed in Check E Stop Especially if both axes will not jog Especially if only one axis will not jog See Servo Driver Section 5 5 Computer Pendant failed See Computer Pendant diagnostics Section 5 3 4 2 4 Axis Motor Motion Is Not Smooth While under motor power the motion is not smooth The motion appears to be rough or jerky Do the following Service Codes and procedures Code 33 Software Identification This is needed if you call SWI Customer Service Code 12 Feed Forward Constant High feed forward constants will cause an unstable servo system Code 127 Measures the backlash in the system Code 128 Enter backlash compensation Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting 65 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Possible Cause Check This X and Y Gibs are not adjusted properly Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants section Binding in the Drive Train Check Repeatability using the Repeatability and Positional Accuracy procedure Check t
10. Use the machine s original vernier dial Install the top cover of the motor mounting bracket and check for clearance between the vernier dial and cover Add shims to the vernier dial holder if needed Tighten the 1 2 20 hex head nut to 50 ft Ib Warning Don t push down on the ballscrew as you are tightening this may bend the ballscrew Bearing ring Facing in Groove side out 45 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Now tighten socket head cap screw 46 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Og d l Woodruff key Brass ferrule Pulley Belt 47 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Motor proper orientation Vernier and spacer Dial nut tab washer and handwheel Tighten don t push down 48 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual E Y axis drive completed This step is completed when The drive train feels smooth as you crank the Y axis hand wheel through the entire travel You will feel the belt cogs engage and the balls move through the ball nut but it should be consistent and smooth 49 Southwestern Ind
11. will be used on future products with more axes 7 Y absolute zero LED this LED will be lit when the Y axis counter is set to zero This light should come on when you are or 0 001 from your zero 78 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual 8 X absolute zero LED this LED will be lit when the X axis counter is set to zero This light should come on when you are or 0 001 from your zero 9 110 volt power LED this light will be on when the applications board is seeing 110 volts Check the 8 amp fuse on the applications board if this light is not on 10 Not used 5 4 Motor Diagnostics The Motor subsystem is comprised of 3 parts The Motor Encoder and the Motor and Servo Driver The motors are powered by 110 VAC voltage The servo driver is also an integral part of servo system which is discussed in detail in the next section 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 5 4 1 Cable Connections Check the motor cable connections on the cable breakout box Verify there are no pushed in pins on the connector 5 4 2 To Check the Motor En
12. 31 32 33 34 35 36 37 38 39 40 MOTOR ASSY K2 8 K3 3HP reference only not part of upper 26 20819 head housing assembl VS130 27 vst30 28 vsttt SOC HD SCREW 3 8 10NCx32L 29 VS1 MOTORPULEYCOVER 30 VS104 COPPER CHIP 2REQ 31 VS131 SCREW FLAT HD PHILIP M5 P0 8x10L 32 VS132 STUDO 716 1000 38 VS96 JAMNUT3 8 18NC O Z 1 O 34 VS101 VENTILATOR 2REO 35 VS136 SCREW SOC HD CAP M6 P1 0x10L 36 VS54 HANDLE FIXBLOCK 37 VS55 SETSCREW O 38 VS56 BRAKELOCKHANDLE 39 VS57 BAKELITEBALLHANDLE 40 oiL 00690 K2 K3 142 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 100691 K2 K3 VS82 GEAR HOUSING VS112 1 2 VS112 GUIDE SPRING 3 VS113 SPRING GUIDE PIN i00691 K2 K3 Figure 119 Gear Housing P N 20778 1 143 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 120 Hi Low Shift Clutch Sub Assembly P N 20778 2 i20697 2 144 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List High Low Shift Clutch tem PIN DESCRIPTION Qy 6 VS73 SPLINED GEARHUB 1 8 VS74 SPINDLEBULLGEAR 1 VSt4 WASHER 10 VS
13. Hammer small Combination wrenches set 3 8 to 15 16 Counterbores or step drills set Combination wrench 10mm Transfer punch set Transfer screw set Feeler gage Z glass scales option Pliers set File set Xacto knife with flat blade 3 4 2 flute end mill For machining test Safety glasses 22 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 3 2 Kit parts 3 2 1 Ballscrews Warning never unscrew a ballscrew from its ball nut This will destroy the ballscrew This is especially important with the Y axis ballscrew Before installing be sure that the ballscrew is long enough for the saddle travel of your machine 1 BALLSCREW XAXI S P N 26031 42 P N 26031 48 P N 15608 36 or P N 15608 54 This item will have one of these part numbers based on the kit that is shipped 1 BALLSCREW YAXI S P N 26032 12 P N 26032 16 or P N 15609 19 This item will have one of these part numbers based on the kit that is shipped 3 2 2 Pendant Arm Assembly P N 26034 2 3or 4 This assembly will vary depending on the machine it is on 1 ea PENDANT ARM P N 26037 1 ea NAMEPLATE SYSTEM S N P N 21934 23 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 1 ea PLATE 4 ea TIE WRAP 4 IN PLASTIC 1 ea CAP PLUG LEVELING P N 22475 P N 2603
14. 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 gib will be compromised to account for the varying clearance from the center to the ends of the table 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 Figure 39 Table Gib Adjustment Southwestern Industries Inc 110 ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual 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 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 e To 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
15. 0 001 7 If the head is out of tram from side to side then loosen the 4 head bolts and rotate the head with the worm shaft 8 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 Y I SWIVEL BOLT A LOCKING BOLT 100149 Figure 44 116 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Tramming of Head Back to Front Adjustment With the dial indicator sweep the table from 6 o clock to 12 o clock The head should be trammed within 0 0005 from front to back 6 2 3 3 Back to Front Adjustment l Make sure the table has been clean and the gibs are adjusted properly 2 Mount a dial indicator in a tool holder and mount in the quill 3 Adjust the Y axis so that the spindle is in the center of the table 4 Adjust the knee so that the dial indicator will reach the table and lock the 2 clamps on the knee 5 Move the dial indicator to 6 o clock position and adjust the face so the needle is zero 6 Doa series of sweeps from 6 o clock to 12 o clock and check for the repeatability of the setup The head should be trammed as close as possibility to 0 0005 7 Loosen the three bolts and adjust the tram with the bolt mounted on the top of the ram Once the head has been trammed tighten the three bolts Be careful not to move the head while tighten
16. 1 4 HARD BLK OX 1 8 THK 7 54 M10 70P WASHER FLAT USS STL PLAIN 4 55 1 2 75Z WASHER EXT TOOTH STL ZINC 2 56 1 2 71Z WASHER FLAT SAE STL ZINC 2 57 22008 BEARING 204KTT 1 26031 42 BALLSCREW X AXIS 1 26031 48 BALLSCREW X AXIS 1 i20255 2 Crushing slicing and pinching hazard Use extreme caution when replacing the table Don t Danger work alone Tips ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service 6 Parts List Manual 51 Southwestern Industries Inc Screw the X ballscrew to the opposite side to make it easier to slide the table back on Temporarily install the 1 2 20 hex head nut on the ballscrew and use a wrench to turn it Before you slide the table back on attach the oil lines and test the oil flow Liberally lubricate the ways Make sure the gib locks have not fallen out of their holes and into the saddle Reinstall the table gib after the table is back on the machine Unlike the Y axis drive the X axis bearing housing attaches to the drive housing See Step 4 for tips about the assembly of bearing housing and the clamp nut e Position the left end of the table almost flush with the left side of the saddle to install the left side drive train and motor e Make sure the belt is tight on the pulleys e Position the motor so the cable can be routed to the left your left facing the machine and around the machine e When more than one fastener is called out in the drawin
17. 20851 STOP PIECE T BOLT ASSY 95 20852 TABLE LOCK HANDLE 96 20853 KNEE LOCK HANDLE amp SHAFT 97 20854 KNEE CRANK HANDLE ASSY 98 20873 CHIP GUARD SET K2 K3 99 FC112 LEVELING SCREW 100 FC113 JLEVELING NUT 101 FC114 LEVELING PAD 167 Southwestern Industries Inc 20785 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service Parts List Manual i26900 S Te b m d Figure 135 K4 Base Machine P N 26900 168 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List K4 Base Machine Item P N Title Comments 1 FC1 QUILL HOUSING GEAR FC10 RAM FC11 LIFTING EYE BOLT FC23 TABLE 50 FC25 GIB BLOCK FC26 GIB 2 3 4 5 FC24 SADDLE BOTTOM GIB 6 7 8 FC27 GIB BLOCK 9 FC28 SET SCREW 10 FC29 SET SCREW 11 FC31 STOP PIECE T BOLT Available only in 20869 12 FC32 TABLE STOP PIECE Available only in 20869 13 FC33 HEX NUT Available only in 20869 14 FC37 TABLE LOCK HANDLE Available only in 20868 15 FC39 SADDLE LOCK PLUNGER Available only in 20868 16 FC42 TABLE STOP BRACKET not shown on dwg 17 FC43 SADDLE TABLE GIB 18 FC44 SADDLE CHIP WIPER 19 FC45 SADDLE CHIP WIPER PLATE 20 FC46 TABLE LOCK PLUNGER 21 FC48 TABLE LOCK BOLT HANDLE 22 FC49 JSADDLE GIB 23 FC51 CAP
18. CONNECTOR 6 9006 FRU K3 REGULATING DISTRIBUTOR 8 9008 FRU K3 SCREW NUT M8 X 1 0 MALE 9 9009 FRU K3 SCREW NUT PD 1 8 19MM 3 100889 2 13 2 Head Lubrication 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 Extend the quill fully and apply a coating of SAE 30 or 30W oil to the outside diameter of the quill Every Four Months 1 Apply a good grade of general purpose grease through the grease fitting on the back of the head This grease lubricates the Low range gear set and the feed change gears 2 Grease vari disk on spindle motor through the grease fitting on the motor shaft 21 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 3 0 ProtoTRAK EMX Retrofit I nstallation 3 1 Recommended Tools Allen wrenches set inch and metric Drill motor Drills set Taps set and tap handle Machinist square Bubble level Crescent wrench 10 Torque wrench up to 60 ft lbs Optional better if you have it Crowfoot wrench 1 1 4 open end to fit torque wrench Socket set with 3 and 6 extension and ratchet wrench Dial calipers Flat blade screwdriver set Phillips screwdriver set Gauge block 6 or 150mm Calibrate X Y Gauge block 3 or 75mm Calibrate optional Z scale 0001 dial indicator and magnetic base Center punch
19. Code 33 Software Identification This is needed if you call SWI Customer Service 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 Table and Saddle Locks are locked Make sure the Table and Saddle Locks are unlocked High torque on any axis may cause faulting problems during alignment routine X and Y Gibs are adjusted extremely Check the adjustment of the X and Y Gibs using the X tight and Y Gib adjustment procedures See X and Y Gib Adjustments Section 6 2 1 See Mechanical Drive Train X Y Section 5 2 4 3 5 System Will Not Turn On Nothing happens when the switch is turned on or the system does not boot up 67 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 IDE Flash is properly installed See section 5 3 4 3 6 System Reboots by Itself During operation the screen suddenly blanks and then shows that the system has begun the boot up sequence Possible Cause Check This Interruption of 110 V power to pendant Using a Voltmeter check the incoming 110VAC to the pendant Poor wiring and cable connecti
20. MOUNT EA 4 11 22475 TIE WRAP 4 IN PLASTIC EA 4 12 3 8 16X2 3 4 25B SCREW SHCS STL BO EA 1 13 1 4 20X 1 227B SCREW BHCS STL BO EA 4 14 1934 NAME PLATE SYSTEM S N EA 1 15 4X3 8 34 SCREW DRIVE 4SS EA 2 16 1 2 13 50Z NUT HEX STL ZINC EA 1 17 26066 BRACKET PENDANT ARM EA 1 18 5 16 18X1 25B SCREW SHCS STL BO EA 2 19 5 8 11X3 1 2 25B SCREW SHCS STL BO EA 1 i01274 ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual The drawing illustrates the two ways of mounting the pendant arm to the machine Your kit will include one of the two sets of hardware depending on the model of your machine For Bridgeport models if it is necessary to use the 5 8 bolt supplied you will have to open up the through hole in the pendant arm Attach the nameplate serial number plate 21934 on the pendant arm This serial number plate is the serial number that you will need to reference for service parts and other support in the future The Service Department will not be able to help you efficiently without the serial number This step is completed when The display pendant is mounted securely to the machine ram and the serial number name plate is attached to the pendant arm Step 8 I nstall the Z glass Scale There are several different brackets that come with the Z axis glass scale kit depending on the machine model Illustrated instructions will come with the scale kit This step is comple
21. 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 Y 14 EA 1 8 K B168 SCREW PIN EA 4 i20779 3 Figure 130 Ouill Pinion Shaft P N 20779 3 ProtoT RAK KEMX Retrofit Safety Installation Maintenance Service Parts List Manual 160 Southwestern Industries Inc item PN Title OVERLOAD CLUTCH SLEEVE KEY 5x8x13L OVERLOAD CLUTCH SAFETY CLUTCH SPRING 6 K B76 SOCKET SET SCREW Me P10x8L 1 8 K B97 OVERLOAD CLUTCHWASHER 1 9 KB98 SNAPRINGO 10 1 OOOO Lo EA mx AA Figure 131 Overload Clutch Trip P N 20779 4 161 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual i00704 K2 K3 item P N Title 1 KB57 FEEDWORMSHAFT 1 1 2 KB47 FEEDWORMSHAFTTHRUSTWASHER 1 3 KB44 FEEDWORMSHAFTBUSHNG 1 5 KB59 JPINOSI2L 1 1 6 KB49 FEEDREVERSEBEVELGEAR 1 1 7 KB48 BUSHING 1 1 8 KB62 KEYSX3xiSL 1 1 9 KB50 FEED REVERSE CLUTCH 1 1 10 KB56 JPINO3OL 5 5 0 0 1 11 KB51 FEEDREVERSEBEVELGEAR 1 18 KB55 REVERSECLUTCHROD 1 1 i00704 K2 K3 Figure 132 Feed Reverse Clutch P N 20779 5 162 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service
22. SCREW 24 FC52 SADDLE 25 FC53 LEFT HAND COLUMN WIPER HOLDER 26 FC54 KNEE WIPER FELT 27 FC55 KNEE COLUMN GIB 28 FC56 ALLEN CAP SCREW 29 FC57 RIGHT HAN COLUMN WIPER HOLDER 30 FC58 KNEE WIPER FELT 31 FC59 CHIP GUARDS UPPER Available only in 20867 32 FC60 CHIP GUARDS MIDDLE Available only in 20867 33 FC61 CHIP GUARD LOWER Available only in 20867 34 FC62 KNEE 35 FC65 KNEE PLATE 36 FC66 CAP SCREW 37 FC67 GIB BLOCK 38 FC68 KNEE GIB 39 FC69 GIB BLOCK 40 FC70 CAP SCREW 41 FC71 CAP SCREW 42 FC72 CAP SCREW 43 FC73 CAP SCREW 44 FC74 JAM NUT 45 FC75 KEY 46 FC76 WASHER 47 FC77 BEVEL GEAR 169 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 48 FC78 SCREW 49 FC79 SEALED BALL BEARING 50 FC80 BEARING RETAINER RING 51 FC82 ELEVATING SCREW ASSY 52 FC83 HANDLE Available only in 20855 53 FC85 GEARSHAFT CLUTCH INSERT 54 FC86 DIAL LOCK NUT 55 FC87 DIAL WITH GRADUATIONS 56 FC88 DIAL HOLDER 57 FC89 SOCKET HEAD CAP SCREW 58 FC90 BEARING RETAINING RING 59 FC91 GREASE SEALED BEARING 60 FC92 BEARING CAP 61 FC93 KEY 62 FC94 ELA
23. 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 K B125 1 HANDWHEEL SPRING PIN 3x3x10L 1 95 K B125 HANDWHEEL 1 96 K B111 REVERSE KNOB 1 97 K B100 CAP SET SCREW M5 P0 8x35L 3 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 156 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 amp SCREW ASSY 1 106 24051 CLOCK SPRING ASSEMBLY SPRING amp COVER 1 107 20849 FEED HANDLE ASSY QUILL 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 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual i20779 157 Southwestern Industries Inc i00700 K2 K3 2 K B07 WORMGEARSPACER 1 1 1 1 3 K B08 FEEDDRIVEWORMGEAR 1 4 K B05 WORM CRADLE BUSHING 1 5 KB04 FEED WORM GEAR SHAFT SLEEVE 1 6 KB09 FEED DRIVE WORM GEAR SHAFT 1 7 KBit
24. Z calibration offset 2 DRO actual 1 000 0 985 lt 1 0152 Once you have calculated your values use Service Code 122 to enter them 6 2 2 3 Backlash Compensation Code 127 Set X or Y Backlash Constant Every mechanical system has at least a little backlash or lost motion It is produced by the small 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 l Seta 0001 inch dial indicator in the spindle and touch off on a block or the vise along the direction X or Y you wish to check or set the backlash constant 2 Turn on the ProtoTRAK and at the Main Menu and follow the procedure below precisely It is recommended to have zero values in code 128 before proceeding a fa Press MODE b Select Mode b Press DRO c Press SERV CODES d Service Code d Press 127 and then ABS SET e Select Axis 114 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual f Travel gt This shows the amount of travel for oscillation Follow the instructions on the screen press GO and then press the appropriate soft keys INC or DEC to increase or decrease the amount of travel Wait a few seconds for the amount to take effect The value can also be manually input by pressing the T
25. amp Parts List Manual DESCRIPTION PINDLE R8 PINDLE DIRT SHIELD EARING ANGULAR CONTACT U SET 2 7207 P4 1SET EARING SPACER SMALL 1 EARING SPACER LARGE 1 OSE PIECE 1 LEEVE 1 EARING DEEP GROVE 6206ZZ 1 l 1 i 1 1 1 1 EH KEKE MEN REH EF EARING LOCKWASHER 30 L c s MEN MEN BEIM MEN 2 1 SET K B129 SPINDLE BEARING LOCK NUT 30 20N K B150 1 1 1 TRAIGHT LOWER CLAMP C K B151 ELT OIL STRAINER K B150 2 TRAINER UPPER CLAMP K B139 CREW PH HD M5 0 8X8L 20840 EARING SPACER SET K B150 1 al 1 2 14 2 6 1 100705 K2 K3 Figure 133 Spindle Assembly P N 20836 163 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual SI SS E Na b Figure 134 K2 K3 Base Machine P N 20785 Parts List K2 amp K3 Base Machine reference only 164 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Item P N Title Comments 1 C01 QUILL HOUSING ADJ GEAR 2 C02 RAM ADAPTER 3 C04 NUT 4 C06 VERTICAL ADJUSTING WORM 5 C07 WORM THRUST WASHER 2REQ 6 C08 VERTICAL ADJUSTING WORM SHAFT 7 C09 WORM KEY 8 C10 RAM 9 C13 SOCKET CAP SCREW 2REQ 10 C14 ROLL DOWEL PIN 11 C15 ANGLE PLATE 12 C16
26. be no more than 0 0003 of side to side movement Make sure that there is a few thousandths gap between the Spindle Collar and the Quill after tightening Head bolts are loose Tighten Ram bolts 4 4 2 X Y and Z Axis Measurements Are Not Accurate Measurements repeat but with a dial indicator mounted to the bottom the spindle traversing the length of a gage block or some other measurement standard the measurement is not accurate Possible Cause Do This The Calibration is incorrect Recalibrate the machine See Calibration amp Backlash Constants Incorrect backlash values If the machine does not repeat bi directionally check the backlash on the axis in question See Section 5 2 2 4 4 3 The DRO Is Not Counting The DRO for one axis is not counting when an axis is moved Often times if this is the case the axis will fault See section on faulting Do the following Service Codes 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 131 Motor encoder operation test Possible Cause Check This Motor Encoder not counting See Motor diagnostics section 5 4 Computer Pendant failure See Computer Pendant diagnostics 5 3 4 4 4 X Y and Z Axis DRO Counting in Wrong Direction The DRO is counting in the wrong direction The positive directions for each axi
27. e Code 33 Software Identification This is needed if you call SWI Customer Service 62 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual e Code 12 Feed Forward Constant e Code 127 Measures the backlash in the system 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 5 1 Gib adjustment procedures See Section 6 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 5 2 4 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 Accuracy 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 you should not expect the same level of accuracy from an older or worn machine Furthermore the system should be expected to repeat within the resolution of the displayed DRO numbers of 0 0005 Do the
28. end of the saddle to lock the gib in place and recheck Repeat as necessary TABLE GiB SCREW WM CE gt TABLE 100151 SADDLE Figure 40 Table Gib Screw 6 2 1 2 Saddle Side Gib Adjustment Y Axis See Figure 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 Remove the chip wiper guard and chip wiper from the front and rear of the left side box way To OG ue up 111 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual 100024 Figure 41 Saddle Side Gib Adjustment 5 Attach a 0001 dial indicator with a magnetic base to the left front of the saddle Place the indicator stylus on the edge of the large box way 6 Move the left end of the table back and forth and note the amount of movement on the dial indicator Adjust the Y axis side gib until the registered movement is 0010 0015 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 loc
29. 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 TRAK 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 of the warranty
30. following Service Code e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 123 Calibration using a measurement standard or e Code 122 Calibration using work piece measurements e Code 12 Feed Forward Constant e Code 127 Measures the backlash in the system e Code 128 Enter backlash compensation 4 1 4 1 Every Part Has the Same Error Possible Cause Check This Machine Tool amp Setup problem See Machine Tool amp Setup Section 5 1 Programming Error In the program look for common errors in programming such as transposing numbers tool diameters and pressing INC SET when ABS SET is meant This is especially suspected if the dimensional errors are larger than a few thousandths See the Controls Programming Operations and Care manual 63 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants 4 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 5 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 a
31. for each axis Center the table and saddle and raise the head Make sure the gib locks are released On the Pendant display go into the Service Codes and input the Code 100 The conversation line will say SELECT AXIS Inputthe axis Either X or Y In the conversation line it will say WHICH DIRECTION PLUS 00 ES 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 86 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 Your input X Your input X Your input Y Your input fe Interpretation of the resulting values displayed The values for the encoder displays should be in the range of 3 0000 to 5 0000 e If the motor encoder is not within this value then the one that is out of specification may be the problem e The feedrate should be a minimum of 120 ipm e fthe feedrate is less than 120 ipm and inconsistent in both directions check the incoming AC voltage and mechanics of th
32. 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 ANSI B11 8 2001 Available from The American National Standards Institute 1819 L Street N W Washington D C 20036 Concepts And Techniques Of Machine Safeguarding OSHA Publication Number 3067 Available from The Publication Office O S H A U S Department of Labor 200 Constitution Avenue NW Washington DC 20210 1 2 Danger Warning Caution and Note Labels amp Notices As Used In This Manual DANGER Immediate hazards that will result in severe personal injury or death Danger labels on the machine are red in color WARNI NG Hazards or unsafe practices which cou d result in severe personal injury and or damage to the equipment Warning labels on the machine are orange in color CAUTI ON Hazards or unsafe practices which cou d result in minor personal injury or equipment product damage Caution labels on the machine are yellow in color NOTE Call attention to specific issues requiring special atte
33. identify the type of motor by removing the brush and measuring its cross sectional size If the brush measures 3 8 x 1 8 then it is a Hathaway motor and if it measures 3 8 x 1 4 it is an AO Smith motor On Hathaway motors it will be time to replace the brushes when the brush reaches a length of approximately 34 79 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual On AO Smith motors it will be time to replace the brushes when the brush reaches a length of approximately 3 16 See Section 6 1 2 for the procedure for replacing motor brushes 5 4 4 Moving Problem from One Axis to Another Another way to troubleshoot a problem with a particular axis is to swap parts from 1 axis to another to see if the problem moves If the problem moves then that component is faulty See the example below Symptom X Axis will not move and faults This particular problem can happen because of any of following reasons bad motor servo driver or computer module In some cases it is not obvious which component is causing the problem This example will help us pinpoint the problem through a trial and error process Let s assume we have narrowed it down to the servo or electrical systems and the Y axis has no problems Lets also assume it is not an obvious problem like a loose connection Swap these components Results Physically switch the X and Y Has problem moved t
34. not yield acceptable results It is good machining practice to avoid the use of shop air to clean the chips off a machine This risks blowing chips into the sliding way surfaces and compromising the performance of the machine Gibs that are not adjusted correctly will affect the performance of the machine It will lead to positioning and repeatability problems The gibs should be adjusted at least twice a year See Gib Adjustments Section 5 2 1 5 1 3 Lubrication Lubrication is one of the single most important maintenance issues and plays a key role in assuring the performance and durability of the Knee mill At the beginning of each day manually supply oil to the way surfaces Lack of lubrication can lead to a variety of problems with your machine motion due to increased friction in the sliding ways This increased friction may lead to part inaccuracies and decreased life expectancies of your ball screws and way surfaces 5 1 4 Machining Set Up The machining set up itself is always something that can greatly influence the performance of the your mill The following are some things to keep in mind 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 compensa
35. or Fixture See Machine Tool amp Setup Section 5 1 Machine not level Verify that the machine is level to specification the Head Sec 6 2 3 adjustment procedures Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants Section 6 2 2 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 5 2 Head Bolts are loose Verify that all the head bolts are tight 4 1 3 Taper Cut on a Programmed Straight Line Move An unwanted tapered cut occurs when the machine is programmed to move in a straight line along either the X or Y axis The DRO shows motion of a few thousandths of an inch in the axis that is not supposed to be moving Explanation For straight line cuts along the X or Y axis the control is designed to lock the motor of the axis that is not moving A taper is created when there is play in the system The force of the tool shoves the table or saddle out of position The system will respond to being pushed out of position by making an adjustment at the end of the move An unwanted tapered cut is the result of looseness in the system Do the following Service Codes and document values
36. protective cardboard 13 Southwestern Industries Inc ProtoTRAK amp KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual PROPER LIFTING SLING 4 BOLT TIGHTEN TO 47 FT LBS TORQUE BEFORE LIFTING TIGHTEN RAM LOCKING BOLTS BEFORE LIFTING MOVE TABLE AGAINST COLUMN INSTALLED GROSS WEIGHT OF MACHINE APPROX 2800 LBS i01303 Figure 5 Lifting the Machine 14 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 2 9 Cleaning 1 Remove rust protective coating from the machine before moving any slideways table saddle knee etc 2 The coating is best removed with clean dry shop towels 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 necessary to move back and forward left and right and up and down the table saddle and the ram Always release the clamp levers two in front of the table one underneath the saddle on each side and two ram lockbolts on the right side of the column before attempting to move the above parts 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 and spindle move freely and smoothly over t
37. the 3 wires either coming into the machine or motor Warning Be sure to shut off all power to the machine before attempting to switch any wires 4 5 4 Head Noise Head noise pertains to any unusual noises coming from the head under load and no load situations Most often head noise will only be noticeable under load situations It is important to try to distinguish between problems with components in the head versus problems caused by the setup or tooling being used on a particular job Use the table below to try to pinpoint the possible cause Also try to pinpoint the noise by seeing if it exists in high low or neutral For example if the noise is evident in neutral then this eliminates the spindle bearings Possible Cause Check This Machine setup or tooling problem If the noise is most evident under load cutting situations then it is important to look at setup and tooling being used Ask the following questions Is the cutter dull Is the tool loose in the holder Am I taking a bigger cut then is possible on the machine Is the part moving in the vice Am 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 To check if the nosepiece is bottomed out try to insert a piece of spindle of paper
38. this procedure after a new installation or after installing a new Computer Module 85 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 2 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 e Y saddle moves toward the front so the tool moves up relative to the workpiece e Z the quill moves up If you do not move correctly from the beginning repeat the procedure 4 Press INC SET to signal the procedure is complete 5 7 2 3 CODE 100 Axis Open Loop Test Code 100 procedure is used to diagnose problems with the configuration of the system the encoders and incoming A C voltage CAUTI ON During this procedure the designated axis will be given a command to move at maximum speed for 1 second in the direction you choose Avoid crashes by making sure the quill is out of the way and by starting with the table and saddle centered MAKE SURE THAT NO ONE IS STANDING IN THE WAY OF THE TABLE OR SADDLE Note You Will lose the DRO reference position This procedure is to be run for each axis that is servo driven and for both the plus and minus direction
39. when the original end cap Needed to support the Y axis bore is too small relative is not usable bearing assembly when the hole in to the yoke bore the machine casting is too large 1 BEARING 1 BALLSCREW EXTENSION 1 BALLSCREW EXTENSIVE SUB P N 22008 ASSEMBLY ASSEMBLY Needed when the original P N 15181 P N 14975 floating bearing is not Needed for the X axis ballscrew for Needed the X axis ballscrew for usable tables that are 49 long tables that are 50 long 32 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual 3 3 Installation Steps The following steps suggest the best way to install the ProtoTRAK EMX retrofit We recommend you proceed with the installation by doing the following Follow the order of the steps Read the Warnings and Cautions to avoid injury and damage Refer to the drawings for the order of assembly of parts Use the photos and tips to save yourself some time Step 1 Remove the table and lead screws DANGER Crushing slicing and pinching hazards are present with this step Use extreme caution when removing the table Ensure you have adequate working area and support before you remove the table Don t work alone We suggest you remove the items in the following order Left and right hand wheel and bearing assemblies from the table Table gib easiest with table centered Table Saddle hand wheel and
40. 0 volt 3 phase 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 all local codes and regulations Incoming 220 or 440 volt power connects to the machine through the electrical box located on the back of the column The power cable enters the black box through a hole on the top of the box DANGER Only a qualified electrician should wire the 220 or 440 volt 3 phase electricity To convert a machine from 220 to 440 volt power or vice versa 3 things must happen spindle motor must be rewired overload relay must be set to 8 5 amps for 220 V and 4 25 for 440 volts and the voltage stickers on the electric s box must be replaced See Section 5 1 12 for a diagram of how to rewire the spindle motor Southwestern Industries recommends the machine be earth grounded by driving a copper rod into the ground It is the responsibility of the customer to install this rod
41. 049 worm shaft vertical adjusting 1 3 CC003 Nut 4 50 CC050 Key 1 4 CC004 pad machine 4 51 CC051 Adapter ram 1 5 CC005 Knee 1 52 CC052 bolt lifting eye 1 6 CC006 Turret 1 53 CC053 Gear quill housing adjusting 1 7 CC007 Gib ram turret 1 54 CC054 Socket cap screw 3 8 CC008 plate filter 1 55 CCO55 screw T 6 9 CC009 screw gib adjusting 1 56 CC056 jscrew cap T 6 10 CC010 screw gib 2 57 CC057 Washer 6 11 CC011 nut gib screw 2 58 CC058 Shaft elevating knee shaft 1 12 CC012 pinion ram 1 59 CC059 Bearing 2 13 CC013 screw ram pinion 1 60 CC060 Key 1 14 CC014 Washer 2 61 FC96 pinion bevel 1 15 CC015 bolt locking 4 62 CC062 Screw 2 16 CC016 washer screw 1 63 CC063 cap bearing 1 17 JCCO17 Spider 1 64 CC064 jring bearing retaining 1 18 JCCO18 Saddle 1 65 CC065 Key 1 19 CC019 gib saddle 1 66 FC88 Dial holder 1 20 CC020 gib table 1 67 FC85 shaft gear clutch insert 1 21 CC021 screw oval head 1 68 FC86 Dial 100 graduation 1 22 CC022 wiper iron felt 2 69 CC069 inut dial lock 1 23 CC023 wiper rubber felt 2 70 CC070 crank elevating 1 24 CC024 Screw 1 71 CC071 Handle 1 25 CC025 bracket table stop 1 72 CC072 PPin 1 26 CC026 Screw 2 73 CC073 crew socket cap 12 27 CC027 plate column 1 74 CCO74 ring bearing retainer 1 30 CC030 Bolt table lock 6 75 FC77 gear bevel 1 31 CC031 Handle table lock bolt 6 76 CC076 nut jam 1 32 CC032 Spring 6 78 CC07
42. 082 P N 10 D 25B 30 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 3 2 8 Yoke Kit P N 15844 1 2 3 5 6 or 13 This assembly will vary depending on the machine it is installed on J We E 1 and gt E IEEE 1 ea YOKE MACHINED 1 ea TUBING 1 ea FITTING 2 ea ELBOW P N 15546 x TYGOTHANE 1 4 OD P N P2 TUB 2 RIGHT ANGLE Needed when the original 1 8 1D 2FT Needed when knee mill THREADED machine yoke is not P N 5549K11 contains only 1 oil line LEADLOY A that supplies both the X P N 15187 usable This part may not be in every kit It will be included in kit P N 15844 2 and Y ballscrews 2 ea SCREW SCO SET 2 ea SCREW SHCS 2 ea PIN ROLLED 2 ea WASHER STL BO CUP STL BO STL PLAIN BELLEVILLE SPRING P N 10 32X3 8 40B P N 5 16 18X1 1 4 P N 3 16X1 1 4 81P LOCK 25B P N 24009 1 KE m a 2 ea oil line restrictor P N 15782 3l Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 3 2 9 Other parts The parts in this section are not needed for all machine models and do not appear in some kits Even if they are in your kit you may not need to use them See the instructions 1 YOKE SHIM 1 END CAP 1 BACKING PLATE P N 16568 P N 22007 P N 16029 Needed if the ballscrew Needed
43. 1 ea PENDANT ASSY PROTOTRAK EMX P N 26015 2 ProtoTRAK EMX Pendant Hardware P N 26035 2 2 ea CABLE ASSY AC 4 ea SCREW SHCS 4 ea WASHER 1 4 4 ea CLAMP POWER STL BO HARD BLK OX 1 8 CABLE 4160 P N 22608 P N 1 4 20X3 4 THK P N 21967 25B P N 15759 NO PHOTO NO PHOTO 55 ea CABLE TIE PLASTIC 8 IN LONG TCA1 1 ea MANUAL 1 ea MANUAL P N 21968 EMX SERVICE AND EMX INSTALLATION PROGRAMMING P N 26109 P N 26056 3 2 6 X Axis Drive Kit P N 20255 1 2 3 5 or 6 This assembly will vary depending on the machine it is installed on l 4 cs TIIGI 1 ea DRIVE HOUSING 1 ea FRONT COVER 1 ea BACK COVER 1 ea HOUSING P N 15621 P N 15624 P N 15622 BEARING P N 15612 1 Sold as set with 15885 under 15612 26 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual PRA 1 ea RING BEARING 1 ea BELT TIMING 2 ea WASHER FLAT 2 ea NUT HEX J AM HOUSING 5MM POWERGRIP SAE STL ZINC STL ZINC P N 15885 P N 400 5M 15 P N 1 2 71Z P N 1 2 20 51Z 2 ea WASHER EXT 2 ea SPACER 020 4 ea WASHER FLAT 7 ea WASHER 1 4 TOOTH STL ZINC THICK USS STL BO HARD BLK OX 1 8 P N 1 2 75Z P N 14772 2 P N 3 8 70P THK P N 15759 1 ea SPACER 100 1 ea STOP X AXIS 1 ea FERRULE 1 ea SEAL THICK P N 15638 SPROCKET BEARING HOUSING P N 14772 Use if needed Mount P N 1
44. 100 THICK 5 19 400 5M 15 BELT TIMING 5MM POWERGRIP 1 20 23930 BEARING SET 2 ANGULAR CONTACT 7204 BECBP 1Set 22 14772 2 SPACER 020 THICK 2 23 14772 5 SPACER 050 THICK 2 41 8 32X3 8 25B SCREW SHCS STL BO 6 42 5 16 18X1 25B SCREW SHCS STL BO 1 45 M10 1 5X65 25B SCREW SHCS STL BO 4 46 1 4 20X1 24B SCREW HEX HD STL BO 7 47 8 32X3 8 20B JSCREW RH PHIL STL BO 3 48 10 32X3 4 25B JSCREW SHCS STL BO 1 49 1 2 20 51Z NUT HEX JAM STL ZINC 2 52 15759 WASHER 1 4 HARD BLK OX 1 8 THK 7 54 M10 70P WASHER FLAT USS STL PLAIN 4 55 1 2 75Z WASHER EXT TOOTH STL ZINC 2 56 1 2 71Z WASHER FLAT SAE STL ZINC 2 57 22008 BEARING 204KTT 1 26031 42 BALLSCREW X AXIS 1 26031 48 BALLSCREW X AXIS 1 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual i20255 2 101 Southwestern Industries Inc 6 1 10 Ball Screw Replacement Y Axis Saddle CAUTI ON Never screw a ball screw partially or totally out of its nut They cannot be reassembled l Position the saddle all the way forward 2 Remove the hand wheel assembly and bracket 3 Remove the sheet metal covers on the front of the machine bed and on the motor mounting bracket 4 Remove the motor then remove the motor mounting bracket 5 Remove the rest of the parts on the ball screw journal Note the orientation of the bearings for reassembly 6 Remove the 5 16 x 1 inch screws that attach the ball nut to the yoke 7 R
45. 115 EXTERNAL TOOTH WASHER O40 1 11 vssi LOCKWASHER 9 16 18NC 1 12 vs7e RING pt 18 20817 SPACERBEARING CC 1 i00692 K2 K3 145 Southwestern Industries Inc ProtoTRAK KEMX Retrofit 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 VS88 JPIN 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 100693 K2 K3 146 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Vau seer i00694 K2 K3 av Item P N DESCRIPTION Qty 1 VS67 BULL GEAR PINION COUNTER SHAFT 1 2 VS69 KEY 5X5X18L 1 3 VS66 BULL GEAR PINION 1 4 AK118 BEARING DEEP GROOVE 6203ZZ 2 5 VS3 SOCKET SET SCREW M6 P1 0x6L 1 6 23954 BEARING DEEP GROOVE SET 2 6203ZZ 1 Set i00694 K2 K3 Figure 122 Pulley Pinion P N 20778 4 147 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 123 Lower Vari Disc Drive P N 20778 5 assembly not av
46. 2 1 Run Away Axis 4 2 2 Slow Down Axis 4 2 3 Axis Will Not Jog 4 2 4 Axis Motor Motion is Not Smooth 4 2 5 Searching Axis Problems Relation to the Operation of the Control 4 3 1 Display Blanks 4 3 2 Bad Picture on the Display 4 3 3 Keyboard Lockup 4 3 4 Fault X or Y 4 3 5 System Will Not Turn On 4 3 6 System Reboots by Itself 4 3 7 System Shuts Off 4 3 8 Will Not Hold Calibration 4 3 9 E Stop Error Problem with the Measurements 4 4 1 X Y 8 Z Axis Measurements Do Not Repeat 4 4 2 X Y Z Axis Measurements Are Not Accurate 4 4 3 The DRO is Not Counting 44 4 X Y amp Z Axis DRO Counting In Wrong Direction Problems with the Machine Tool 4 5 1 Spindle Stalls or Turns Off 4 5 2 X Spindle Motor Hums or Will Not Run 4 5 3 Spindle Runs Backwards 4 5 4 Head Noise PPS bou WNnr Diagnostics The Machine Tool amp Set Up 73 5 1 1 The Milling Machine Checklist 5 1 2 A Special Word About X Y Gibs 5 1 3 Lubrication 5 1 4 Machining Set Up The Mechanical Drive Train X Y 5 2 1 Keys to Ballscrew Alignment Computer Pendant Diagnostics Motor Diagnostics 5 4 1 Cable Connections 5 4 2 To Check Motor Encoders 5 4 3 Diagnosing a Brush Problem 5 4 4 Moving Problem from One Axis To Another Servo Driver Electrical 5 6 1 Checking A C Voltage 5 6 2 Checking Fuses 5 6 3 Cable Connections 5 7 Service Codes 5 7 1 Software Codes 5 7 2 Machine Set Up Codes 5 7 3 Diagnostic Codes 5 7 4 Operato
47. 203ZZ 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 4 123 Southwestern Industries Inc ProtoTRAK KEMX Retrofit 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 124 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation 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 RAKE BLOCK 2 3 FVS58 TURNING BLOCK SHAFT 1 4 FVS103 RETAINING RING Y 7 1 5 FVS51 SET SCREW M6 P1 06L 2 6 FVS53 BRAKE LOCK BUSHING 1 7 FVS52 BRAKE LOCK SHAFT 1 8 FSV119 RETAINING RING Y 11 1 9 FVS47 BRAKE SHOE 2 10 FVS48 BRAKE SHOE PIVOT SLEEVE 1 11 FVS17 SOCKET CAP SCREW M6 P1 0x35L 1 12 FVS49 BRAKE SPRING 2 13 FVS122 WASHER Y 6 4 14 FVS120 JSCREW PHILLIP PAN HD 3 16 24NC6L 4 15 FVS46 BRAKE BEARING CAP 1 16 AK048 BALL BEARING 6012ZZ 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
48. 5 20296 X or Y Motor 11 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual COOLANT PUMP ACCESS 101272 Figure 4 Knee Mill Rear View Part Number Description 220V 20676 Electrical Box 440V 20676 9001 Lube Pump If the machine was sold with a table guard option the electrical box part number is 20676 2 12 Southwestern Industries Inc ProtoTRAK amp KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 2 8 Lifting and or Moving the Machine CAUTI ON The K machine weighs approximately 2800 Ibs Proper equipment of sufficient capacity must be used when lifting and or moving the machine See Figure 5 To Prepare the Mill before Lifting 1 Using a steel cable with protective sleeving min 3 4 diameter or a 3 ton sling position sling loops on machine as shown in Figure 5 2 Use cardboard pieces or other suitable protective sheets on both sides of the machine to prevent scratching 3 Remove the 4 nuts and screws holding the machine to the wood skid 4 Lift the machine the machine should lift approximately level 5 Insert the 4 screws for leveling pads in their place in the bed 6 Place the machine in its location see floor plan and bed footprint drawing Carefully positioning each leveling pad under each leveling screw 7 Remove the lifting cable or sling and all
49. 6 P1 0x25L 2 9 K B106 FEED TRIP BRACKET 1 10 20779 4 OVERLOAD 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 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 SREQ 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 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service Parts List Manual 155 Southwestern Industries Inc
50. 6350 P N 15626 on saddle to prevent X motor bracket from pinching the oil manifold 1 ea NUT CLAMP X Y 1 ea KEY WOODRUFF 1 Set BEARING 2 ea SPACER Z AXIS 404 1 8 X 1 2 ANGULAR CONTACT 050 THICK P N 16452 P N 984814090 P N 23930 P N 14772 5 27 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual U api CEKET 4 ea SCREW SHCS STL BO 3 ea SCREW RH 1 ea PULLEY SOLID P N 3 8 16X2 1 2 25B P N M8 1 25X65 25B PHIL STL BO 44 TEETH W O or P N M10 1 5X65 25B P N 8 32X3 8 20B GUI DES Kits may conta n one or all of these parts P N 16983 1 7 ea SCREW HEX ND STL 1 ea HANDWHEEL ASSY MX 1 ea SCREW SHCS STL BO BO P N 15616 P N 8 32X3 8 25B P N 1 4 20X1 24B Josse ea SCREW SHCS STL BO 1 ea SCREW SHCS STL BO 3 ea SCREW SHCS STL BO P N 5 16 18X1 25B P N 10 32X3 4 25B P N 10 32X1 25B 3 2 7 Y Axis Drive Kit P N 23083 1 2 3 or 4 This assembly will vary depending on the machine it is installed on x 1 ea MOTOR BRACKET KNEE MILLS 40 DEGR 1 ea COVER SPORT 40 DEGREE P N 20623 P N 20621 28 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 1 ea PULLEY SOLID 1 ea BELT TIMING 5MM POWERGRIP Y AXIS o 44 TEETH W O P N 890 5M 15 GUIDES 1 ea HANDWHEEL ASSY
51. 8 P N 16919 2 ea SCREW DRIVE 4 SS P N 4X3 8 34J 4 ea BHCS P N 1 4 20 X 1 2 27B 4 ea SCREW SOC SET STL BO CUP P N 1 4 20X3 4 40B 4 ea CABLE MOUNT P N 26050 1 ea BUSHING 1 ea BUSHING 1 ea ve HEX STL 1 ea SCREW SHCS THREADED THREADED STL BO M 20X2 5 METRIC 3 4 10 STANDARD P N aa A 50B P N 3 8 16X2 3 4 25B P N 26016 2 P N 26016 1 1 ea WASHER EXT 1 ea WASHER 1 ea SCREW SHCS STL BO TOOTH STL ZINC BELLEVILLE SPRING P N 1 2 13X3 1 2 25B P N 1 2 75Z LOCK P N 5 8 11X3 1 2 25B P N 24009 2 24 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 3 2 3 Motors 2 ea MOTOR ASSY ENCODER DRI VER 4020 P N 20296 3 2 4 Options Z Glass scale and glass scale mounting bracket The Z Glass Scale and hardware are packaged in two separate boxes One box contains the scale and the other contains all hardware See the instructions that came with your glass scale kit for the listing of parts 1 Z GLASS SCALE P N 22800 4 Remote Stop Go switch Option 1 REMOTE STOP GO SWITCH P N P TRAK RSG USB Thumb Drive Option 1 USB FLASH DRIVE 256MB P N 24671 256 25 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 3 2 5 Pendant and pendant hardware X 0 0000 ses T 0 0000 sas Z 0 0000 us
52. 8 net oil 1 33 CC033 Screw cap 6 79 CC079 cover knee 1 34 CC034 Table 1 80 CC080 jbearing ball 1 35 CC035 Pedestal 1 81 CC081 JChip guard upper 1 36 CC036 screw socket head cap 2 82 CC082 Chip guard middle 1 37 CC037 nut elevating screw 1 83 CC083 Chip guard lower 1 38 CC038 screw assembly elevating 1 84 24962 wiper set chip 1 39 CC039 Screw cap 3 85 24973 chip guard set 1 40 CC040 Key 1 86 24963 lock gib 4 41 CC041 Ram 1 87 24974 crank knee 1 42 CC042 gib knee 1 172 Southwestern Industries Inc ProtoTRAK KEMX Retrofit 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 proda Materials Factory Labor New TRAK lYear lYear 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 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
53. 9 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 GREEN shown for reference only not 24 20820 jpart of upper head housing assembly 1 25 FVS130 WASHER FLAT Y 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 30 FVS132 STUD 7 16 92L 2 31 FVS133 STUD 7 16 56L 1 32 FVS96 JAM 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 NAME PLATE 1 38 FVS19 JDRIVE SCREW 1 39 OIL 1 JFRU K3 OIL CUP 1 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 100593 K4 119 Southwestern Industries Inc Figure 101 Gear Housing Sub Assembly P N 20697 1 120697 1 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Item P N Description Qty 1 FVS82 GEAR HOUSING 1 2 FV112 GUIDE SPRING 3 3 FV113 SPRING GUIDE PIN 3 100594 K4 120 Item P N DESCRIPTION Qty 1 FVS75 BEARING SLIDING HOUSING 23943 BEARING DEEP GROVE U SET 2 6910ZZ 1 SET FVS78 BEARING SPACER FVS79 BEARING SPACER SNAP RING R 75 FVS73 SPLINED GEAR
54. 9 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 016 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 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 HANDWHEEL 1 87 FB125 4 HANDWHEEL 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 SPACER 1 96 25041 SCALE HEAD ROTATION NT40 1 97 25043 POINTER SCALE 1 98 25044 DRIVE SCREW SCALE 4 99 20834 FEED REVERSE KNOB ASSY 1 100 20835 HANDWHEEL ASSY 1 132 ProtoTRAK KEMX Retrofit 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 amp 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 QUI
55. BRAKE LOCK HANDLE 1 25 FVS54 HANDLE FIX BLOCK 3 8 16NC 1 26 FVS55 SPRING PIN 6x20L 1 27 FVS57 1 BAKELITE BALL HANDLE 3 8 16NC 1 28 24055 BRAKE SHOE ASSY 1 29 FVS98 CLUTCH WASHER 1 100598 K4 125 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual s i20697 6 Upper Vari Disc Sub Assembly Figure 106 P N 20697 6 126 Southwestern Industries Inc ProtoTRAK KEMX Retrofit 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 IS JS a IN IN IN mw 9 FVS41 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 Y 50 15 FVS96 JAM NUT 3 8 16NC 16 24599 BEARING HOUSING ASSY K4 17 24603 VARIDISC ASSY ADJUSTABLE i20697 6 127 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service Parts List Manual
56. D CHANGE PLATE 1 5 VS38 JPIVOT SLEEVE Y 5 2 6 VS37 WASHER M5 P0 8x20L 2 7 VS123 SCREW SHCS M5 0 8X20L 2 8 VS39 SPEED CHANGE PLATE PIVOT STUD 1 9 VS41 WASHER 8 2 1 10 VS40 JROLL PIN 3x15L 2 11 VS35 JADJUSTMENT NUT 1 12 VS34 CHAIN END STUD 1 13 VS33 CHAIN FRONT SCREW M4 P0 7x5L 1 14 VS7 SNAP RING 35 1 1 1 1 17 24631 JVARI DISC ADJUSTABLE ASSY i20778 6 151 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Item P N DESCRIPTION 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 40B SCREW SOC SET STL BO CUP 1 Figure 125 Speed Change Handwheel P N 20778 7 152 Southwestern Industries Inc i20778 7 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual
57. DE FLASH EA 1 93 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 6 1 5 IDE Flash Disk Replacement l From the control go to SETUP SERV CODES SECTION A and then code 142 and save your Configuration file calibration values etc to a USB Thumb Drive Run code 340 to save your parts programs 2 Turn off power to the machine and control 3 Unplug all the connectors from the rear of pendant 4 Remove the pendant from the pendant arm by removing the 3 8 16 bolt and nut that secures it in place 5 Place the pendant assembly on a clean and secured table with the display pointing away from you 6 Remove the 6 8 32 x 3 8 Pan Phillips Head Screws securing the computer module to the LCD enclosure 7 Pull the computer module a few inches and stop Pulling the computer module too far will damage the ribbon cables 8 Now reach from the top and remove the overlay cable Remove the IDE flash drive from the motherboard Remove the extra adhesive from the motherboard 10 Firmly insert the replacement IDE Flash Drive into the motherboard While pressing the replacement in by sure the pins line up correctly Secure the connector with RTV adhesive such as REP Fast Gasket Adhesive Product 1430 11 Secure the computer module back to the LCD enclosure by following the instructions in reverse order 12 Make sure that the overlay cable is properly
58. HUB FVS72 KEY 8x7x10L 2 3 4 5 FVS80 6 7 8 FVS74 SPINDLE BULL GEAR 9 FVS114 WASHER 10 FVS115 EXTERNAL TOOTH WASHER G 50 LOCK WASHER 50 18NC RING SPACER BEARING a a a a fa a a fo S 11 FVS81 6 A 12 FVS76 ON 13 20818 i20697 2 Figure 102 Hi Low Slip Clutch Sub Assembly P N 20697 2 121 00595 K4 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation 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 Y 319L 2 3 4 5 FVS90 HI LOW DETENT PLUNGER 6 7 8 FVS93 SCREW SOC HD M5 P0 8x15L 9 FVS92 1 SET SCREW M5 P0 8x5L 10 FVS92 2 WASHER FLAT Y 11 11 FVS57 BAKELITE BALL HANDLE 12 FVS116 WASHER FLAT Y 6 COD a a O Ss a 13 24083 SHAFT HI LOW SHAFT ASSY 00596 K4 Figure 103 Hi Low Shift Sub Assembly P N 20697 3 122 Southwestern Industries Inc ProtoTRAK KEMX Retrofit 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 6
59. IVER 4020 26032 12 BALLSCREW Y AXIS 26032 16 BALLSCREW Y AXIS J J JJI SIDJ J JOJOJS JOJDJBJBJBIAJIS IS z gt gt Ja SIS Ja a i23083 3 The clamp nut is designed to trap the bearing against the ballscrew journal with the correct preload Thread the clamp nut onto the ball screw and tighten the 10 32 clamp screw until you feel the clamp nut contact the ball screw threads It should drag as you tighten the clamp nut Tighten the clamp nut to 50 ft lb Tighten the 10 32 clamp screw The bearing housing is designed to float to find its own center If it does not contact the saddle casting because the hole is too large use the backing plate PN 16029 that is provided for the machine models that need them Once the clamp nut is installed turn it until the bearing housing contacts the knee casting or backing plate and the saddle begins to move forward Then install the motor mounting casting 44 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service 6 Parts List Manual Bring the saddle forward until it is about an inch away from the front of its travel Having the ball nut retainer yoke close to the mounting bracket will help to align it properly Put the Y axis drive belt on the pulley before installing the vernier dial Install the motor next Position the motor so the cable can be routed to the left and around the machine
60. K KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 6 1 3 Servo Driver Replacement figure 22 DANGER 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 WARNI NG 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 2 Remove the servo motor driver assembly from its mounting bracket 3 Remove the 10 cap screws that hold the servo driver and its heat sink plate to the motor casting 4 Disconnect the cable connector Do not pull on the wires 5 Reinstall the new servo driver with its heat sink plate Be certain the gasket properly seals the assembly 6 Reinstall the motor driver assembly Make certain the belt is tight so that there is little play if pinched in the middle 91 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual WIRE HARNESS SERVO AMPLIFIER GREEN GROUND WIRE OVER CORD o PLATE LOOP CONNECTOR unplug here 100015 using loop Figure 22 Part Description 20201 X or Y Servo Driver 6 1 4 Computer Module and LCD Enclosure Repla
61. KEY3x3x25L 3 3 1d 8 K B10 WORM SHAFT KEY 3x3x8L 1 9 KB03 F EDBEVELPINON 1 so K B02 BEVELPINONWASHERO5 1 1 11 KB01 SOC HD SCREW M5 P0 8x10L 1 12 K B36 FEEDDRIVINGGEARR 1 18 KB361 KEYS3x3x8L 3 3 3 0 00 0 1 14 KB15 FEEDREVERSEBEVELGEAR 1 1 15 KBI3 WASHERO6 22 OD J 1 16 K B14 SOC HD SCREW M6 P1 0x18L 1 pe i KB KEY NAM de Si 18 KB40 FEEDDRIVEGEAR 0 0 0 1 19 K B16 JFEEDENGAGEPN 1 20 KB06 SETSCREWM6 P1 060L 1 i00700 K2 K3 Figure 128 Worm Gear Cradle P N 20779 1 a ae a a O a a ad aa MA 158 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual i00701 K2 K3 item PN Title CLUSTER GEAR COVER CLUSTER GEAR SHAFT CRANK SHIFT CRANK 4 K B69 SPRING 2 3 x 20L 5 K B68 GEAR SHIFT PLUNGER 6 KB72 SHIFT KNOB 5 16 18NC ROLL PIN Y 3 x 20L 8 KB63 FEED GEAR SHIFT FORK 9 EMI HAFT 10 K B61 AP SET SCREW M5 P0 8x5L 100701 K2 K3 Figure 129 Ouill Feed Selector P N 20779 2 159 Southwestern Industries Inc ProtoTRAK KEMX Retrofit 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
62. LL LOCK SLEVE ASSY 1 108 FB142 QUILL 1 109 A071 T BOLT ASSY includes A070 A071 A069 not shown on drawing A ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual i20698 133 Southwestern Industries Inc 100603 K4 Item P N Title Qty 1 FB17 WORM GEAR CRADLE 1 2 FB5 WORM CRADLE 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 FB3 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 JFEED DRIVING GEAR 1 14 FB36 1 KEY 3x3x8L 1 15 FB15 FEED REVERSE BEVEL GEAR 1 16 FB13 WASHER Y 6 22 1 17 FB14 SOC HD SCREW M6 P1 0x15L 1 18 FB37 KEY 3x3x10L 1 19 FB40 FEED DRIVE GEAR 1 00603 K4 Figure 110 Worm Gear Cradle Sub Assembly P N 20698 1 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service Parts List Manual 134 Southwestern Industries Inc i20698 2 iem PN DESCRIPTON O 6 rs STEEL BALL o 1 8 Fasa FEEDGEARSHIFTFORK 1 o Faso FEED SHIFTROD 1 100604 K4 Figure 111 Quill Feed Selector Sub Assembly P N 20698 2 135 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installa
63. MX P N 16983 1 P N 15616 EINEN TT 1 ea BEARING 1 ea RING BEARING 1 ea NUT CLAMP X Y 1 Set BEARING HOUSING HOUSING Z AXIS ANGULAR CONTACT P N 15980 1 P N 15885 P N 16452 P N 23930 Sold as set with 15885 under 15980 nN 1 ea SEAL BEARING 1 ea FERRULE 1 ea DIAL NUT lea WASHER FLAT HOUSING SPROCKET P N 15836 SAE STL ZI NC P N 15626 P N 16350 P N 1 2 71Z 1 ea WASHER EXT 1 ea NUT HEX JAM 4 ea SCREW SHCS STL BO TOOTH STL ZINC STL ZINC P N 3 8 16X2 1 2 25B P N M8 1 25X65 25B P N 1 2 75Z P N 1 2 20 51Z or P N M10 1 5X65 25B Kits may contain one or all of these parts 29 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual O TAIS 4 ea SCREW HEX ND 4 ea WASHER 1 4 1 ea SHEET METAL 1 ea KEY WOODRUFF STL BO HARD BLK OX 1 8 THK PT4 COOLANT MOTOR 404 1 8 X 1 2 P N 1 4 20X1 24B P N 15759 COVER ASSY P N 98481A090 P N 23141 This item is found in the Misc Parts box 1 ea SPACER 020 3 ea WASHER FLAT 1 ea TAB WASHER 1 ea DIAL HOLDER THICK USS STL BO P N 15614 P N 15627 2 P N 14772 2 P N 3 8 70P 8 ea SCREW PH PHIL 3 ea S SHCS STL 2 ea SCREW PH PHIL 3 ea WASHER SPLIT STL BO STL BO LOCK STL BO P N 6 32X3 8 10B P N 10 LAT 10B P N 1 4 20X3 8 10B P N 10 73B 4 ea WASHER 4 ea ire SHCS STL 75X 394X 10 STL P N 23
64. Parts List Manual This step is completed when The Y axis ballscrew is installed and it clears the bevel gear inside the saddle casting when the saddle is pushed back Both oil lines are attached to both ball nuts and oil is flowing to the ball nuts and all the ways 41 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Step 4 I nstall the Y axis drive train Y Axis Ballscrew Overall Length Maximum Y 5 ELBOW OIL A 2400 NG Zoon WC HERE 29 00 17 10 32 Emo RN d KNEE BEVEL GEAR 100673 Tips e Assemble bearing housing assembly on a flat surface before you assemble it onto the ballscrew Bearing seal item 1 with groove turned up press in or tap the seal with a hammer so it is flush Angular contact bearing item 2 inner race thick side facing up 100674 e There are two sets of bearing housings and bearing rings one for Y and one for X they are matched sets don t mix them e The bearing seal should fit flush into the bearing housing with the groove side out Press or gently tap it in with a hammer e The angular contact bearings must be oriented properly The thick part of the inner races should face away from each other and be separated by the bearing ring 42 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service 6 Parts List Manual
65. Parts List Manual 6 1 7 Replacement of the Optional Z Axis Glass Scale KEMX mill only not retrofit See Figure 28 1 Checkthe tram of the head in the X direction If it is within a few thousands then continue on If not tram 2 Assemble Z axis glass scale mounting bracket and mount to head Items 1 2 3 and 4 Tap items 3 and 4 together and tap item 3 into the quill stop knob Leave the bolt loose Use 2 screws item 6 and mount item 4 to the side of item 2 using a spacer between both items to provide a gap of approximately 0 040 between Items 2 and 4 This is to make sure item 2 does not rub against item 4 3 Align the glass scale bracket Item 2 with an indicator and tighten the mounting screws Leave the quill stop knob screws loose Remove the spacer and bolts from Item 4 4 Unscrew the shipping protection screw from the scale 5 Mount the glass scale to the mounting bracket and align it with an indicator It needs to be aligned within 0 008 with respect to the quill Tighten the screws down 6 Fasten the readerhead to the readerhead bracket 7 Move the readerhead up and down the glass scale and make sure the gap is consistent between the readerhead and the glass scale Tighten the screw to the quill stop knob 8 Remove the red head securing plate If the gap is not consistent between the readerhead and the glass scale when moving the quill up and down then adjust the angle of the scale to make the gap consistent
66. RAVEL button To change the speed of oscillation use the up and down arrow keys g The following is an example of what you For example if we were running this code for might see when running this code the X axis and the Oscillation Value shown in the conversation line is 00278 inch and the dial indicator is moving back and forth 0012 then the true backlash value is 00278 0012 00158 inch Input this by pressing MODE DRO SERV CODE 128 SET OK and then X 00158 SET RETURN 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 indicator with the following method assuming once again that code 128 has zero value 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 single feedback 6 2 3 Head Rotation and Tramming The TRAK knee head is free t
67. ROUND HD DRIVE SCREW 5REQ 13 C17 ADAPTER PIVOT PIN 14 C18 CHAMFERED amp HARDENED WASHER 7REQ 15 C19 ADAPTER LOCKING BOLT 3REQ 16 C23 TABLE 42 OR 48 17 C31 STOP PIECE T BOLT 3REQ Available only in 20851 18 C32 TABLE STOP PIECE 2REQ Available only in 20851 19 C33 HEX NUT 3REQ Available only in 20851 20 C37 TABLE LOCK BOLT HANDLE Available only in 20852 21 C38 SADDLE LOCK BOLT 22 C39 SADDLE LOCK PLUNGER Available only in 20852 23 C40 SOCKET HD CAP SCREW 2REQ 24 C41 GIB ADJUSTING SCREW 3REQ 25 C42 TABLE STOP BRACKET not shown on drawing C43 K2 26 C43 K3 SADDLE TABLE GIB 27 C44 FELT WIPERS 4REQ 28 C46 TABLE LOCK PLUNGER 29 C47 TABLE LOCK BOLT 30 C48 TABLE LOCK BOLT HANDLE C49 K2 31 C49 K3 SADDLE KNEE GIB 32 C50 SADDLE KNEE WIPER PLATE 4REQ 33 C51 OVAL HEAD SCREW 8REQ 34 C53 1 LEFT HAND COLUMN WIPER HOLDER 35 C52 JSADDLE 36 C54 1 KNEE WIPER FELT C55 K2 37 C55 k3 KNEE COLUMN GIB 38 C56 ALLEN CAP SCREW 2REQ 39 C57 1 RIGHT HAND COLUMN WIPER HOLDER 40 C58 1 JKNEE WIPER FELT 41 C59 CHIP GUARDS UPPER Available only in 20873 42 C60 CHIP GUARDS MIDDLE Available only in 20873 43 C61 CHIP GUARDS LOWER Available only in 20873 44 C62 KNEE 165 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual
68. 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 FB103 CAM ROD 1 44 FB117 ROLL PIN Y 3x15L 1 45 FB104 TRIP HANDLE 1 46 FB105 BLACK PLASTIC BALL 1 47 FB119 1 A ROLL PIN Y 3x20L 1 48 FB107 CAP SCREW M6 P1 0x25L 2 49 FB113 HAND WHEEL CLUTCH 1 131 ProtoTRAK KEMX Retrofit 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 6
69. Service 6 Parts List Manual yes KV Nya S a EN OS 4 AAT FRONT TO BACK RN m HEAD ROTATION NG 2 hi K2 amp K3 ONLY Ay UT G 100886 H Min H Max Figure 2 Overall Dimensions Table Size 10 x 50 7 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service 6 Parts List Manual 2 2 Uncrating Carefully remove the wood crate and protective packaging paying attention not to scratch damage or mar any parts of the machine Remove the cardboard box containing the TOOL BOX The leveling pads and screws for the machine can be found in the toolbox The Y way covers are shipped in a separate tube Loosen and remove 4 screws and nuts holding the machine to the wood pallet 2 3 Shortages Inventory Checklist SESSU Machine check model and serial number Manual drawbar with washer Leveling pads B239 and screws B240 4 each Pendant Display installed on machine SER S Pendant Arm assembled to the column CREME Toolbox with various tools ProtoTRAK EMX Safety Operation amp Programming Manual P N 26056 TRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual P N 26109 Way covers front amp rear of saddle 8 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 2 4 Installation I nstructions amp Ch
70. Sub Assembly K4 Fig 115 Quill Spindle Sub Assembly K4 Fig 118 Top Housing Assembly K2 K3 Fig 119 Gear Housing Sub Assembly K2 K3 Fig 120 Hi Low Shift Clutch Sub Assembly K2 K3 Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 121 123 124 125 126 127 128 129 130 131 132 133 134 135 136 Hi Low Shift Sub Assembly K2 K3 Pulley Pinion Sub Assembly K2 K3 Lower Vari Disc Drive Sub Assembly K2 K3 Upper Vari Disc Drive Sub Assembly K2 K3 Speed Change Handwheel Sub Assembly K2 K3 Spindle Motor Sub Assembly K2 K3 Bottom Housing Assembly K2 K3 Worm Gear Cradle Sub Assembly K2 K3 Quill Feed Selector Sub Assembly K2 K3 Quill Pinion Shaft Sub Assembly K2 K3 Overload Clutch Trip Sub Assembly K2 K3 Feed Reverse Clutch Sub Assembly K2 K3 Spindle Sub Assembly K2 K3 K2 K3 Base Machine K4 Base Machine KE Base Machine 1 0 Safety The safe operation of the TRAK K Mills and the ProtoTRAK CNC depends on their proper use and the precautions taken by each operator e Read and study this manual and the ProtoTRAK EMX Programming Operating and Care Manual Be certain every operator understands the operation and safety requirements of this machine 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
71. T MOTOR AMPS SHORT CIRCUIT INTERRUPT AMPS ELECTRICAL DRAWING CNC CONTROL ELECTRICAL RATINGS IF APPLICABLE VOLTS 8 JAMPS sE o 1 60 Hz MACHINE ONLY MADE IN XXXXXX i01158 Safety amp Information Labels Used On TRAK Milling Machines It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels Power Requirements at 220 and 440 Volts 3 phase 60 Hz KEMX Overload Setting 220 V 8 5 A Overload Setting 440 V 4 25 A FLA of Largest Motor at 220 V 8 5A FLA of Largest Motor at 440 V 4 25 A FLA of Machine at 220 V 8 5A FLA of Machine at 440 V 4 25 A 3 Southwestern Industries Inc ProtoTRAKE K EMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Safety Precautions Do not operate this machine before the TRAK K Mill I nstallation Maintenance Service and Parts List Manual and ProtoTRAK EMX 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
72. TRAK EMX KNEE MILLS ProtoTRAK EMX CNC Safety Installation Maintenance Service amp Parts Document 26109 Version 072211 Covers Models ProtoTRAK EMX Retrofits TRAK KEMX Knee Mill gt TRAK K3EMX Knee Mill Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 5610 USA T 800 421 6875 F 310 764 2668 Service Department 800 367 3165 e mail sales 9 southwesternindustries com service southwesternindustries com web southwesternindustries com Copyright O 2010 Southwestern Industries Inc All rights are reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical photocopying recording or otherwise without the prior written permission of Southwestern Industries Inc While every effort has been made to include all the information required for the purposes of this guide Southwestern Industries Inc assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from the use of the information contained in this guide All brand names and products are trademarks or registered trademarks of their respective holders Table of Contents 1 0 Safety 1 1 Safety Publications 1 1 2 Danger Warning Caution amp Note Labels amp Notices as used in this Manual 1 3 Safety Precautions 2 0 Installation 2 1 Floor Plan Layout amp Space Requirements 6 2 2 Uncratin
73. VATING SHAFT 63 FC95 GREASE SEALED BEARING 64 FC96 BEVEL PINION 65 FC97 SET SCREW 66 FC98 COLUMN amp BASE K4 67 FC102 SOCKET HEAD CAP SCREW 68 FC103 PEDESTAL 69 FC104 ELEVATING SCREW NUT 70 FC105 SOCKET HEAD CAP SCREW 71 FC112ICAP SCREW 72 FC113 NUT 73 FC114 MACHINE MAT 74 FC115 OIL FILTER 75 FC118 SPIDER 76 FC119 RAM LOCK STUD 77 FC120 RAM PINION 78 FC121 RAM PINION HANDLE 79 FC122 PLASTIC BALL 80 FC123 CHABERED HARDENED WASHER 81 FC124 TURRET 82 FC125 GIB SCREW NUT 83 FC126 GIB SCREW 84 FC127 LOCK BAR 85 FC128 SCREW 86 FC129 LOCKING BOLT 87 FC130 RAM PINION SCREW 88 JFC131 RAM TURRET GIB 89 120855 FRU SK4 KNEE CRANK HANDLE ASSY 90 20867 FRU SK4 CHIP COVER ASSY 91 20868 FRU SK4 HANDLE 8 BAR LOCK ASSY 92 20869 FRU SK4 FC31 FC32 FC333 170 Southwestern Industries Inc 20699 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 101305 Figure 136 Base Machine KE 171 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List KE Base Machine PIN DESCRIPTION QTY P N DESCRIPTION QTY 1 CCO01 Column 1 47 CC047 worm vertical adjusting 1 2 CC002 screw set 4 49 CC
74. ailable order parts separately 148 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List Lower Vari Disc Drive ttem PN A pESCRPTION Qy 2 VS59 BRAKEBLOCK a 1 1 1 2 3 VS58 TURNING BLOCKSHAFT____________ 1 4 VS103 RETANINGRINGO7 1 5 VS51 SETSCREW Me 1 0XX6L 2 6 VS53 BRAKELOCKBUSHNG 1 7 VS52 BRAKELOCKSHAFT 1 8 VS52 2 BRAKE LOCKPINDIA3X58L 1 1 9 VS47 BRAKESHE 2 10 VS48 BRAKESHOEPIVOTSLEEVE 1 11 VS17 SOCKET CAP SCREW M6 P1 0x35L 1 19 VS172 NUT M6 P1 0 1 1 14 VS49 BRAKESPRING_____________ 2 SCREW PAN HEAD PHILIP 5 40NC SOCKET CAP SCREW M5 0 8x12L bade 100695 K2 K3 149 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Upper Vari Disc Drive Sub Assy Figure 124 P N 20778 6 150 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List Upper Vari Disc Drive Sub Assy 15 FVS96 JJAM NUT 3 8 16NC 16 24564 BEARING HOUSING ASSY Item P N DESCRI PTI ON Qty 1 VS42 SPINDLE PULLEY BEARING HOUSING 1 2 VS43 JBEARING DEEP GROVE 6210ZZ 1 3 VS44 JADJUSTABLE DRIVEN VARIDISC 1 4 VS36 JSPEE
75. bearing assembly with saddle cranked all the way forward Table and saddle lead screws Yoke or lead screw nut retainer Nut bushing key and pins from the yoke if a new yoke came with the kit you don t have to do this API oJ NE Tips e Keep the original machine hardware organized as you remove it You will need some of it later e Before removing any of the hardware from the machine crank the table all the way to the right or left in order to be able to position the lift table next to the machine e With the machine disassembled do a good job of cleaning the gibs oil grooves and slideways This will help ensure smooth operation of your ProtoTRAK e Assure that the lubrication system is working properly Caution When removing the table make sure it does not cock or it may break the dovetails as it slides out 33 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual Left Assembly DIAL BUSHING Right Assembly mf BAER 1748 kat y aN qu 100670 FRONT BEARING HOUSING Y AXIS HAND CRANK RETAINER NUT 3 8 CAP SCREWS 4 VERNIER DIAL BEARING RETAINER CUP BEARINGS 100671 34 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual p A D a Sy ka FG WARNING Use proper support for the table Ready for Ste
76. beep indicating that the key is working correctly If one of the keys does not work the pendant assembly may need to be replaced If none of the keys are working chances are that the computer module will need to be replaced 5 7 3 3 Code 131 Manual DRO A manual diagnostic routine to check the motor encoder and table encoders Turn the X hand wheel to display the encoder readings This code will display the actual DRO counts and the raw encoder counts 5 7 3 4 Code 319 Error Log This service code keeps track of all commands being sent to the servo system This may be asked for when troubleshooting a problem specific to motion of the ProtoTRAK 5 7 3 5 CODE 320 History Log This code keeps track of incidents such as servo faults and software updates and allows for it to be saved onto a USB drive This is useful for keeping track how often an error occurs You may be asked by a customer service representative to send in for evaluation 5 7 3 6 CODE 327 Check Available Memory This code monitors how much memory RAM is available within the system as well as much space is available within our internal storage device 5 7 3 7 CODE 342 Toggle test lights on or off Use this service code to toggle a set of test lights visible on screen The top green light will blink indicating that our operating system and User Interface software is responding properly The middle orange light is to indicate that commands are being sent to our servo syste
77. burns out Check all cable connections to LCD distribution board and computer module Make sure the power is turned off before doing so Faulty E stop switch It can be stuck open or closed pressed If it is stuck closed the pendant will need to be replaced because the user will have no way to get rid of the message If it is open it will allow the machine to still operate but it will be unsafe for the user The pendant will still need to be replaced Overlay failure keys on pendant Certain buttons on overlay do not work Do code 81 to verify each key beeps Low voltage to pendant or current spikes 10 or 8 amp fuse in pendant blows Pendant will not turn on if the 10 amp fuse in the on off switch is blown The following is the list of diagnostic LED s found on the back of the applications board Remove the black cover on the rear of the pendant to access them See figure 23 LED lights the applications board has 10 LED lights with LED 1 found on the left of the LED segment 1 5 volt power LED signifies that 5 volts is present on the applications board which is being supplied from the power supply Overlay Key LED this LED will flash each time a key is pressed on our overlay Z absolute zero LED this LED will be lit when the Z axis counter is set to zero This 2 3 Watchdog timer not used 4 Not used 5 light should come on when you are or 0 001 from your zero 6 Not used
78. cceptable range Test the following in the order presented Problems Here May Indicate 1 The wall outlet e Fuse blown in the shop electrical panel e Incoming service from local utility is bad Call the electric company 2 The control power cord from the wall For e Power cord defective TRAK Knee mills check the end that goes E to the electrics box e 3 Checkthe top fuse on the electrical If this is blown then power will not reach cabinet It should be a 10 amp fuse the 4 outlets on the electrical box 4 Check the 110 power cord to the pendant e Power cord defective 5 6 2 Checking Fuses CAUTI ON Turn off power before removing and replacing There are 4 fuses to check in the system There are 2 in the pendant and for TRAK Knee mills 2 in the electrical cabinet The top fuse in the electrical cabinet is 10 amps and fuses power to the pendant The bottom fuse is 5 amps and fuses power to the lube pump outlets The 2 fuses in the pendant are 10 amp and 8 amps The 10 amp fuse in the pendant is found in the on off switch The 8 amp fuse is found on the applications board inside the pendant To check fuses 1 Use a Volt Ohmmeter select OHM 2 Remove the fuses completely from the pendant or electrics box for TRAK Knee mills 3 Place a lead of the meter on each end of the fuse e A good fuse reads 0 zero or close to it e A bad fuse reads Open or Infinity 5 6 3 Cable Connections The TRAK knee mi
79. cement figure 23 1 Turn off power to the machine and control 2 3 10 Unplug all the connectors from the rear of pendant Remove the pendant from the pendant arm by removing the 3 8 16 bolt and nut that secures it in place Place the pendant assembly on a clean and secured table with the display pointing away from you Remove the 6 8 32 x 3 8 Pan Phillips Head Screws securing the computer module to the LCD enclosure Pull the computer module a few inches and stop Pulling the computer module too far will damage the ribbon cables Now reach from the top and remove the overlay cable and LCD cable from the computer module The LCD cable will have some RTU holding it in place Remove the two e stop wires LCD inverter cable and the ground wire from the LCD enclosure side Replace computer module or LCD enclosure Follow the instructions in reverse order when reinstalling the new computer module or LCD enclosure Make sure that all connectors are properly seated before fastening the unit back in place 92 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual REMOVE FUSE FROM FRONT OF SWITCH TO REPLACE i01275 Figure 23 Computer Module and LCD Enclosure Replacement Item P N Title Use As Qty 1 21824 8 FUSE 8 AMP SLOW BLOW EA 1 2 1824 10 FUSE 10 AMP SLOW BLOW EA 1 3 26027 32 MEMORY I
80. coders If the motor encoder inside the motor has failed or is not reading the machine will fault out on that axis Do the following to verify this problem Run Service Codes 100 or 131 This will display on the DRO if the motor encoder is counting If the axis does not count the encoder is not counting This means either the encoder or the cable is the problem Visually check the cable for any problems If the encoder has failed the motor must be replaced 5 4 3 Diagnosing a Brush Problem Each of the axis motors on the machine contains 4 brushes These are a wear item and may need to be replaced during the life of the control system When the brushes begin to wear out you may start to see intermittent faulting of an axis Please note your brushes will last for a number of years before they need replacement so if you are seeing this symptom in the 1 year of 2 of your product this is probably not the cause Motor I dentification Before ordering your brush replacement kit you 1 will need to identify the type of motor you have on your machine This can be done by identifying the diameter of the cap that holds the brushes in place Each motor has 4 caps spaced 90 apart They are found at the end of the motor furthest away from the motor pulley If the diameter of the cap holding the brush in place is 34 in diameter then the motor is a Hathaway motor If the diameter of the cap is 1 in diameter then the motor is an AO Smith motor You can also
81. cting 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 feels 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 76 Southwestern Industries Inc ProtoTRAK amp KEMX 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual Potential Problem Check By Ball nut not tightened to eInspection for space between the head of the bolt and the ball nut i e the retaining bolt has bottomed out in its thread and is not securing the ball nut to the yoke properly mounting screws Oil lines sheared Oil line ME x e Pump the oil and ensure that it flows Full to the ways and ball Full B 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 resolv
82. curacy 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 Electrical Section 5 8 Table and Saddle Locks are locked Make sure the Table and Saddle Locks are unlocked Inadequate or 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 5 1 3 X and Y Gibs are not adjusted properly Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures Binding in the Drive Train Check Repeatability using the Repeatability and Positional Accuracy procedure Check the torque reading of the Drive Train Step by step carefully inspect the Drive Train for any binding It may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 5 2 Servo Drive failure See Servo Drive Section 5 5 Motor failure See Motor Section 5 4 4 2 3 Axis Will Not J og The system powers up but will not respond to the jog command Do the following Service Codes and procedures Code 33 Software Identification This is needed if you call SWI Customer Service Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting
83. d and you already loaded the information on the thumb drive using code 142 5 7 1 3 CODE 142 Save Configuration file to USB thumb drive This code allows you to save your configuration file to a USB thumb drive The configuration file consists of items such as calibration and backlash constants Use this process before a computer module or IDE Flash Drive needs to be replaced It stores the configuration file from the ProtoTRAK s internal IDE Flash Drive to the USB thumb drive It is a good idea to do this code after the machine is initially setup so these values can be saved and used in the future If the computer or IDE flash drive fails then you will not have the ability to save the configuration file and the machine will need to be re setup when the computer or IDE flash drive is replaced 5 7 1 4 CODE 313 Display Configuration File This code displays the configuration file This file contains pertinent information about the machine Some of the common service code values are displayed on this page as well such as code 12 100 128 and 129 Press the Load Default if you wish to load factory defaults for all of the control s settings and configurations 5 7 1 5 CODE 316 Update Software Load in USB thumb drive and enter this service code New software will automatically download and control will reboot 5 7 1 6 CODE 340 copy part programs to USB Thumb drive Load in USB thumb drive and enter this service code All the part programs tha
84. d or no power is applied to the machine 2 When the motor is mounted to the casting that holds the Servo Driver it is necessary to remove the four Phillips head bolts at the shaft end of the motor which hold the motor to the housing to access all four brush assemblies DO NOT Remove Disconnect any wires it is not necessary 3 Before removing caps please note they are made of plastic and care must be taken when removing them to not damage the screw slots To this end apply firm downward force while gently turning the caps counter clockwise 4 Note there are four 4 caps to be removed to access and replace all of the brush assemblies When the caps is loose and before removing it hold your finger over the top of the cap hole to contain the parts 5 Remove the O ring Keeper and brush assembly 6 Insert new brush assembly re insert keeper Note No Keeper is used on the Hathaway EmoteQ Motor and install new O Ring taking care to use the edge of a small screw driver to gently force the O Ring into the hole down onto the Washer Keeper If the O ring is installed properly it will hold the brush assembly in place while you install the cap 7 Install Cap to complete installation and repeat this process for the remaining three 3 brush assemblies 8 Re assemble motor to housing while pushing wiring back into housing taking care to not pinch it 9 Re install the assembly to the machine 90 Southwestern Industries Inc ProtoTRA
85. der one of the headings listed on the main screen Press the heading you want to access the code in question Press CODE enter the number you want press SET 83 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service 6 Parts List Manual 5 7 1 Software Codes The following codes pertain to software functions in the control To get to any of these codes go to Service Codes press A and press the code you wish to view Note If you are working with the SW Customer Service Group write the values down for Code 33 or Code 313 These values will be valuable for troubleshooting 5 7 1 1 CODE 33 Software ID The Code 33 is the software identification procedure The software ID will display the various software modules The two that are important for resolving problems are e Userlnterface Tool Path write down the numbers if service support is needed e Motion Control write down the numbers if service support is needed Other software information displayed on this screen is rarely needed You should provide it on request of a service technician 5 7 1 2 CODE 141 Load Configuration file from USB thumb drive This code allows you to load your configuration file from the USB thumb drive to the ProtoTRAK s internal IDE Flash drive The configuration file consists of items such as calibration and backlash constants This code is used when a computer module or IDE Flash Drive has been replace
86. e Thread the split nut onto the ball screw and tighten the 410 32 clamp screw until you feel the split nut contact the ball screw threads It should drag as you tighten the clamp nut e Torque the split nut to 50 ft Ib e Firmly tighten the 410 32 clamp screw to lock the clamp nut in place See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw See Figure 31 for an illustration of the X axis drive train 99 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual BALL BEARING DIAL HOLDER FIBER SPACER VERNIER DIAL DIAL LOCK NUT BEARING HOUSING Figure 31 X Axis Drive Assembly 20255 2 BALLSCREW 20296 100 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual REF X Axis Drive Assembly Parts List Item P N Title Qty 1 15621 DRIVE HOUSING 1 4 15624 COVER X AXIS DRIVE HOUSING MX 1 5 15622 BACK COVER 1 6 15616 HANDWHEEL ASSY MX 1 8 15612 BEARING HOUSING ASSY X AXIS 1 10 15638 STOP X AXIS 1 11 15626 SEAL BEARING HOUSING 1 12 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 1 13 16452 NUT CLAMP X Y 8 Z AXIS 1 14 16350 FERRULE SPROCKET 1 15 98481A090 KEY WOODRUFF 404 1 8 X 1 2 1 16 14772 SPACER
87. e a ballscrew extension included in the kit If you use the ballscrew extension note that there is a setscrew inside the extension First install the extension use two wrenches to tighten it securely Then install and tighten the setscrew lock tight is recommended Use the bushing to seat the floating bearing that came with the machine Once the handwheels are installed on both sides crank the table back and forth It should move smoothly throughout the entire travel with no binding Adjust the table and saddle gibs to be snug but allow smooth motion Warning Don t push down on the ballscrew as you are tightening this may bend the ballscrew This step is completed when The drive train feels smooth as you crank the X axis hand wheel through the entire travel You will feel the belt cogs engage and the balls move through the ball nut but it should be consistent and smooth 55 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Extension only if needed Tighten extension Set screw to tighten extension Bushing Housing on table e Use cable ties to secure the cables to the pendant mounting arm You may want to do this after the system check out in step 10 Just don t forget to come back to it because the machine will look a lot nicer with the cables all tied up e Note The tableguard port is not used for retrofits 56 Southwe
88. e drive train 5 7 2 4 Code 122 Calibration using part measurements See Section 6 2 2 2 for a further explanation of this code 5 7 2 5 CODE 123 Calibration See Section 6 2 2 1 for a further explanation of this code 5 7 2 6 CODE 127 Set X or Y Backlash Constant See Section 6 2 2 3 for a further explanation of this code 5 7 2 7 CODE 128 Input Backlash Constant Code 128 allows you to enter the backlash values for each axis It displays the value after it enters 87 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service 6 Parts List Manual 5 7 3 Diagnostic Codes The following codes are used primarily when diagnosing a problem with the machine To get to any of these codes go to Service Codes press C and press the code you wish to view 5 7 3 1 Code 54 Program Continuous Run This Code runs a program continuously without stopping for SET Z or CHECK Z commands It is helpful in running a long period to identify an intermittent problem l Prepare a program as you normally would 2 Press MODE SET UP C Code 54 INCSET The program run will start automatically 3 Press STOP to stop and GO to continue 5 7 3 2 Code 81 Keyboard Test This code is used to check if the keyboard is functioning correctly It allows you to test each key on the pendant individually When you press the keys the corresponding box for that key will highlight on the screen The pendant will also
89. e manufacturer Each one of the following will have an impact on the above numbers speeds feeds cutter cutter sharpness material setup coolant and machine adjustments The numbers above assume all conditions are optimal and may be higher or lower depending on material composition 2 7 ProtoTRAK EMX Control Hardware Digital Servo Amplifiers custom designed for ProtoTRAK operation D C Servo Motors rated at 280 in oz continuous torgue are twice that reguired Precision Ball Screws in the table and saddle Modular Design simplifies service and maximized uptime 115V 60HZ 10 amps Feedrate Override of programmed feedrate and rapid Polycarbonate Sealed Membrane Keypad to lock out contamination 7 0 Color LCD On board I DE flash memory storage for part programs USB port for interface with a storage device Rugged Industrial PC Glass Scale on quill for Z axis readout Optional 10 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service 6 Parts List Manual SPINDLE MOTOR SPINDLE BRAKE X AXIS MOTOR ASSEMBLY QUILL HANDLE X AXIS HANDWHEEL Y AXIS HANDWHEEL NOTES i01270 1 BOX WAY MACHINE MOTOR SHOWN ABOVE ASSEMBLY 2 OPTIONAL QUILL SCALE SHOWN ABOVE Figure 3 Knee Mill Component I dentification Item Part Number Description 1 20819 Spindle Motor 2 26015 1 EMX Pendant 3 15616 Y Axis Handwheel Saddle 4 15616 X Axis Handwheel Table
90. e to the LCD Computer Pendant failed See Computer Pendant Section 5 3 4 3 2 Bad Picture on the Display The display has strange characters horizontal bars or other unfamiliar images or the display continually rolls 66 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Possible Cause Check This Computer Pendant failed See Computer Pendant Section 5 3 Poor cable connection from Computer Double check the connection from the computer Module to LCD Liquid Crystal Display module to the LCD 4 3 3 Keyboard Lockup The screen display is normal but the system will not respond to key presses Do the following Service Codes and procedures e Code 81 To check if the pendant keys are working properly press each key Ifa key is working properly the corresponding key on the screen will light The pendant will also beep Possible Cause Check This Voltage drop spike has occurred Shut down the system and wait 10 seconds to reboot the system Remote Stop Go RSG switch has a 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 Computer Pendant failed See Computer Pendant Section 5 3 4 3 4 Fault X or Y The program run or jogging operation is interrupted with a Fault Message on the display Do the following Service Codes and procedures e
91. earings sliding surfaces amp ballscrews 2 13 1 Manual Lubrication The TRAK mill X amp Y way surfaces and ball screws need to be manually lubricated The Manual Lube automatically discharges about 4ml of oil every plunge 1 At the beginning of each day manually pull the pump handle Note If the machine has been sitting for a long while run the machine through the full length of its travel to ensure lubrication reaches all surfaces 2 At the beginning of each day check the oil level in the system If low fill with Mobil Vactra Oil No 2 or equivalent CAUTI ON Failure to manually activate the pump at the beginning of each day and allowing the pump to run dry may cause severe damage to the TRAK mill way surfaces and ball screws 19 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 17 Knee Mill Lubrication i FRONT SADDLE SLIDE WAY XD RIGHT KNEE SQUARE WAY LONGITUDINAL BALLNUT CROSS FEED BALLNUT 8 OS 2 LEFT KNEE SQUARE WAY S a 8 8 o G BE z B 2 B O F O D i E Q E e e e l em HER A 181 A gt s OS DK g 3 d b 20 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service 6 Parts List Manual Parts List Figure 17 Knee Mill Lubrication Item P N Description 1 FRU K3 ALUMINUM PIPE FRU K3
92. ecklist Installer Use this checklist to assure a complete set up of the Ki or EMX retrofit 2 Visually inspect the 220 or 440V wiring going into the electrical panel Visually verify the wiring is correct per our wiring diagram Make sure a strain relief is being used where the wiring enters the cabinet 3 Clean the machine if needed and remove any remaining grease 4 Unlock the table saddle and knee gib locks 5 Make and check all the proper electrical connections from the pendant to the electric box See the pendant and electric box wiring diagrams Turn on the power to the machine and to the pendant 7 Lubricate all the way surfaces and the ball screws 8 Jog the table and saddle back and forth until the way surfaces are well lubricated Oil should be visible on all the way surfaces 9 Check the level of the machine The machine should be level to within 0 0005 front to back and 0 0005 side to side 10 Check to make sure that the E Stop button is functioning correctly 11 Perform Service Code 12 Feed Forward Constant 12 Perform Service Code 123 to calibrate the X and Y axis using a 150mm standard 13 Perform Service Code 127 and 128 to manually calculate the backlash for the X and Y axis 14 Assure the Z axis quill glass scale is working and the Z axis DRO is functioning Use Service Code 15 to turn on the Z axis readout Z axis quill scale is optional 15 Perform Service Code 123 and press QUILL softkey to calib
93. ed to 0 on the DRO zero the display and repeat the procedure If the measurement does not repeat you have a repeatability problem that must be resolved Test for accumulative error by moving the axis a number of times to see if the error gradually grows by a small amount or if the error abruptly changes by a large amount it may be caused by a bad encoder Expected repeatability numbers should be 0 0005 or less Possible Cause Check This Machine Tool 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 5 1 X and Y Gibs are loose Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures 69 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 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 5 2 Spindle and or Quill are loose Use a Dial Indicator and check for side to side movement between the Spindle and the Head Next check for side to side movement between the Quill and the Head There should
94. electrical box use the schematic in Section 5 8 to see how the power is routed If the spindle motor makes a constant humming noise during operation check the 3 phase power to the machine by checking line to line Possible Cause Check This Wrong voltage Check the 220V 440V voltage to the machine Poor wiring connections Check all the wiring connections to the electric s box Defective cables or poor cable 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 If the Ohmmeter reads 0 Ohms or OL then 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 then replace Spindle Motor Spindle will not run because 110 V Check 110 V coming out of the AC e stop port on the pendant If power is not reaching the spindle no voltage replace or repair the pendant contactor 71 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 4 5 3 Spindle Runs Backwards The spindle motor runs in the opposite direction The spindle will run in opposite directions from high to low gear Possible Cause Check This 3 Phase wires backwards Need to switch any 2 of
95. emove the ball screw and oil line attached to the elbow fitting on the ball nut 8 Remove the elbow and setscrew from the old ball screw flange and fit them similarly in the new ball screw 9 Pump oil to be certain it flows through the oil line and then attach the oil line to the elbow 10 Reassemble all assemblies Important The clamp nut must be reassembled as follows 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 e Thread the split nut onto the ball screw and tighten the 410 32 clamp screw until you feel the split nut contact the ball screw threads It should drag as you tighten the clamp nut e Torque the split nut to 50 ft Ib e Firmly tighten the 410 32 clamp screw to lock the clamp nut in place See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw See Figure 32 for an illustration of the Y axis drive train 102 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual Figure 32 Y Axis Drive Assembly 23083 3 103 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Y Axis Drive Assembly Parts List
96. erall Length Maximum Y 5 ELBOW OIL A 2400 pena ET KESE 29 00 17 10 32 SET SCREW EE FLAT TO m KNEE BEVEL GEAR 100673 Caution never unscrew the ballscrew from its ball nut This will destroy the ballscrew Tips e Note that the oil fitting and set screw for the Y axis ballscrew are in different positions than for the X ballscrew e Make sure the oil fitting clears the machine casting at the front If it doesn t you will have to grind away some of the casting for it to clear e Pull the saddle all the way forward to make it easier to slide the ballscrew into the yoke e The flat of the ball nut should match the flat of the yoke These flats are there in order to clear the beveled gear of the knee crank e f you are using a yoke provided in the kit and not the original yoke make sure the flat of the new yoke clears the beveled gear If it does not you will have to grind some of the yoke away e Runthe oil line for the ballscrew to the right and rear of the yoke Don t trim it too short having it longer will make maintenance easier in the future Make sure to install an oil line restrictor e Leave the oil line to the ballscrew long for easier maintenance access Caution Make sure the sliding way covers will not shear the oil line when the saddle moves The ballscrew must have oil 40 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp
97. finish is marred with scallops or is very rough Do the following Service Codes and document values e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 12 Feed Forward Constant e Code 127 Measures backlash in the system e Code 128 Enter backlash compensation Possible Cause Check This Too much backlash entered for code Verify nothing is mechanically loose and the backlash 128 values are not higher than what 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 5 1 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 5 1 3 properly Gib Adjustments in Section 6 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 t may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 5 2 Way surfaces are pocked scarred or Visually check the condition of al
98. g 2 3 Shortages Inventory Checklist 2 4 Installation Instructions amp Checklist 2 5 Machine Specifications 2 6 Maximum Work Capacities 2 7 ProtoTRAK EMX Control Hardware 2 8 Lifting and or Moving the Machine 2 9 Cleaning 2 10 Leveling Leveling Tolerance is 0005 10 2 11 Electrical Connection 2 12 Air Connection Optional 2 13 Lubrication 2 13 1 Manual Lubrication 2 13 2 Head Lubrication 3 0 ProtoTRAK EMX Retrofit nstallation 3 1 Recommended Tools 22 3 2 Kit Parts 3 2 1 Ballscews 3 2 2 Pendant Arm Assembly 3 2 3 Motors 3 2 4 Options 3 2 5 Pendant amp Pendant Hardware 3 2 6 X Axis Drive Kit 3 2 7 Y Axis Drive Kit 3 2 8 Yoke Kit 3 2 9 Other Parts 3 3 Installation Steps Step 1 Remove the table and lead screws Step 2 Install the X Table Ballscrew Step 3 Install the Y Saddle Ballscrew Step 4 Install the Y Axis Drive Train Step 5 Replace the table and install the X Drive Train Left Side Motor Step 6 Install the Right Side End Cap and Handwheel Assembly Step 7 Install the Display Pendant Step 8 Install the Z Glass Scale Step 9 Connect the Cables and the Power Step 10 Check Out 4 0 Troubleshooting by Symptom 4 1 Problems Relating to Machining Results 61 4 2 4 3 4 4 4 5 5 0 5 1 5 2 5 3 5 4 aun anu Poor Finish Circles Out of Round Taper Cut on a Programmed Straight Line Move 4 1 4 Parts Have Incorrect Dimensions Problems Regarding the Motion of the Machine 4
99. g use the ones that work for your machine e tem 10 in the list above may be installed on the saddle if needed to prevent the X motor casting from damaging the oil manifold Use the 5 16 18 X 1 SHCS to fasten the stop 1 4 20x1 HEX HEAD SCREWS AND 1 4 FLAT WASHERS 4 EACH DRIVE HOUSING BRACKET P N 15621 MOTOR SERVO DRIVER i00001 52 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Ready for drive housing Drive housing installed on table 33 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual i P 1 Securing the bearing housing assembly Washer star washer hex nut Tighten to 50 ft Ibs Front cover Motor 54 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual omplete Note motor orientation This step is completed when The motor is installed with the cable pointing down and toward the rear of the machine Step 6 I nstall the right side end cap and hand wheel assembly See the figure from Step 5 above Tips Use the original right or left side hardware from the machine Position the table by screwing the ballscrew so that the right end is almost flush with the right side of the saddle to install the hardware Some installations requir
100. has been added to the table you should run a Code 12 When the heavy workpiece is removed Code 12 should be run again 1 Position the table and addle in the center of travel Note You will lose your DRO position reference 2 Go into the Service Codes and input the Code 12 3 Press Auto 4 The system will run the routine automatically and then display values on the position readout Explanation Typical values should be between 4 04 and 11 11 are considered normal for each axis Higher values indicate excessive friction in the system Lower values indicate a loose system and may mean a gib adjustment is necessary Value 4 04 means the friction is a factor of 4 in one direction and 4 in the other direction The values should be within 3 or 4 of each other in both directions A value of 6 08 would still be considered normal The feed forward gain can be adjusted manually by pressing the manual button Choose the axis you would like to change and then enter values in the positive and negative direction to adjust Adjusting the gain can help solve circularity problems Default values can be set by pressing the Reset button The manual feature should only be used in extreme cases where the AUTO routine did not solve the problem Manual adjusts above 12 may lead to servo related problems 5 7 2 2 Code 97 set positive motor encoder direction This procedure sets the Plus and Minus motion for the Motor encoders It may be necessary to perform
101. hat the tapered sleeve that seats the pulley has not clamped to the ball screw prematurely It should be seated firmly against the pulley Tightening the nut may not have ensured this Also make sure the pulley is keyed to the ball screw 6 Ensure that the screws that hold the bearing housing in place to the bracket are not loose 7 Ensure that the Clamp Nut is secured The following applies to the clamp nut 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 ft Ibs and then tighten the screw down 8 Take out the angular contact bearings and inspect them They should roll smoothly and be lightly greased If not replace them When putting the bearings back into the housing make sure to put them in correctly Failure to do this will cause problems The thin race of each bearing should be facing inward toward the spacer ring Note the bearing housing and spacer ring are matched sets keep them together 9 Checkthe ball screw mounting to the yoke Make sure the SHCS are tight 10 Inspect the ball screw ball nut and yoke for the potential problems shown in the chart on the next page 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 inspe
102. he torque reading of the Drive Train Step by step carefully inspect the Drive Train for any binding It may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 5 2 4 2 5 Searching Axis The handwheels are slowly turning back and forth when the servos are engaged Several thousandths of motion are observed on the vernier dial and the frequency is one cycle every couple of seconds Do the following Service Code and procedures e Code 12 Sets a feed forward power constant to drive axis motors e Code 128 Backlash compensation Possible Cause Check This Most often causes by excess backlash Use code 127 Check physical backlash in system and compensation re enter in code 128 High feed forward values Check ball screw torque Typical values should be between 10 to 15 in Ibs See Machine Tool amp Setup Section 5 1 Especially the tightness of the drive assembly See Mechanical Drive Train X Y Section 5 2 4 3 Problems Relating to the Operation of the Control 4 3 1 Display Blanks The display is completely blank Possible Cause Check This Screen saver has been activated Press any key to turn back on The system has shut down Turn the power switch off check the computer pendant fuses and cable connections See Electrical Section 5 8 Poor cable connection from Computer Double check the connection from the computer Module to LCD Liquid Crystal Display modul
103. 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 10 Protect your hands Stop the machine spindle and ensure that the CNC control is in the stop mode Before changing tools Before changing parts Before you clear away the chips oil or coolant Always use a chip scraper or brush Before you make an adjustment to the part fixture coolant nozzle or take measurements e Before you open safeguards protective shields etc Never reach for the part tool or fixture around a safeguard 11 Protect your eyes and the machine as well Don t use compressed air to remove the chips or clean the machine 12 Disconnect power to the machine before you change belts pulley and gears 13 Keep work areas well lighted Ask for additional light if needed 14 Do not lean on the machine while it is running 15 Prevent slippage Keep the work area dry and clean Remove the chips oil coolant and obstacles of any kind around the machine 16 Avoid getting pinched in places where the table saddle or spindle head create pinch points
104. heir entire length 2 10 Leveling Leveling Tolerance is 0005 10 l Setthe machine on its 4 leveling pads on a solid level floor prepared in accordance with the state and local rules for machine tool installation 2 Putone or two precision Spirit Levels or Electronic Levels in the center of the table in the positions illustrated in Figure 6 3 Adjust the 4 corner leveling screws on their pads until the machine is level to 0005 in 10 in 4 fthe machine must be anchored to the floor follow the general instruction for installing machine tools and use for leveling any well known methods shims etc 5 If the machine must be installed on vibration mounts pads rubber commercially available leveling and vibration mounts etc follow the instructions delivered with the mounts pads ordering them to satisfy the load of the machine and the maximum weight of the workpiece 6 When machine is correctly level lock the adjusting screws in place with their hex nuts 15 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 6 Placement of Levels LEVEL SCREW LOCK HEX NUT MACHINE BED LEVEL PAD 100138 Figure 7 Leveling Screws 16 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual 2 11 Electrical Connection The TRAK Knee Mill can be configured for 220 or 44
105. hten 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 Machine not level Parts incorrect New installation or heavy crash Weight not distributed evenly on all Machine geometry off i e tram Relocation of mill four screws See Leveling procedures Head out of tram Leaves uneven surfaces on Machine not level See Tramming Head Section 5 2 3 bottom of pockets 73 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service 6 Parts List Manual 5 1 2 A Special Word About X amp Y 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 may
106. ign the X ballscrew either to the back of the saddle or to a piece of round stock you clamp into the back dovetail The ballscrew should be aligned within 0 005 end to end A 1 BALLSCREW BACK OF SAODLE i00010 e Trim excess oil line tubing to get it out of your way e T fittings are provided in case they are needed Use provided restrictors in the oil lines to both the x and y ball nuts so that there will be enough pressure to force oil to the ways Caution Ballscrews must be aligned Damage to the ballscrew and drive assemblies will occur if the ballscrews are not aligned properly Caution Assure that the oil line will provide for proper oil flow to the ball nut The ballscrew must have oil 37 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual Ra Sr Install casting screws snugly not tight yet 38 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Ma Now tighten Check alignment again This step is completed when the X ballscrew is tightly attached to the saddle casting and is aligned within 0 005 from end to end 39 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Step 3 I nstall the Y axis saddle ballscrew Y Axis Ballscrew Ov
107. igure 33 for how to wire the motor MOTOR JUNCTION BOX REMOVE PAINT FOR GROUND GROUND SCREW Figure 33 Spindle Motor Wiring 105 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 6 1 12 Feed Trip Adjustment 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 Release the lock nut Engage the trip handle move it left Adjust the micrometer nut against the quill stop knob Slowly turn the adjusting screw until the handle trips Tighten the lock nut Qu Ur BL MM ES Check the reaction If too sensitive lower the adjusting screw slightly If too heavy raise it QUILL STOP NOB MICROMETER NUT Figure 34 a ENGAGE br LOCK NUT ADJUSTING SCREW 100153 6 1 13 Ouill Clock Spring Replacement and Adjustment The guill Clock Spring counterbalances the weight of the guill and tool QUILL HANDLE KEY HUB Figure 35 2 EN va A SPRING HOUSING m 5 1 1 2 TURNS 106 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 1 Move the quill to its top position and lock it in place 2 Remove the quill handle hub by removing Screw A and key 3 Remove Screws B and allo
108. 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 72 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 0 Diagnostics This section explains the diagnostic procedures used to isolate service problems 5 1 The Machine Tool amp Set Up 5 1 1 The Milling Machine Checklist The following is a quick reference for the types of problems that may arise if problems are noticed in these areas Problems With Can Contribute To Most Suspect When and why Spindle bearings Noisy head Older machines machines that are See Spindle Replacement Parts incorrect pushed hard Circles out of round Lubrication system Premature wear of ball screws New installations may not be wear surfaces Faulting 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 Faulting every morning before use machine never tig
109. ing Tighten the bolts a little at a time Note the head must droop down rather than up because tool pressure will take care of the extra 0 0005 117 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual 7 0 Figures and Parts Lists Figure 100 Top Housing Assembly 40 Taper 100593 K4 118 Southwestern Industries Inc ProtoTRAK KEMX Retrofit 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 KEY 5x520L 1 9 FVS62 TIMING BELT PULLEY 1 10 FVS126 WASHER 5 8 1 11 FVS61 JJAM 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 BELT 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 FVS12
110. ing the real problem 5 2 1 Keys to 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 e Yoke the yoke is aligned at the factory and pinned in place It is aligned to within 0 0005 with a precise alignment tool The yoke most likely is not causing the problem If this were the problem you would need to remove the pins and align the X ball screw with the back of the saddle Drill new holes and pin the yoke in place The Y axis ball screw bore is machined perpendicular to the X bore If the X axis is aligned the Y axis will also be aligned e 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 e 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 close to the front of the
111. k 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 7 Replace the front and rear chip wiper and chip wiper guard 112 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 6 2 2 Calibration amp Backlash Constants Calibration and backlash constants were set as part of the installation and set up of your system They should be re set when indicated in the Troubleshooting section or after the replacement of the Computer module or any parts of the drive train 6 2 2 1 X Y Z and Quill Calibration using a standard Calibration is used teach the machine a known distance We typically calibrate our machines over a 150 mm distance There is no limit to how far you can calibrate the machine l 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 Z 75mmor 3 3 Seta 0 0001 indicator in the spindle and move it up to one side of the gage block or standard 4 Goto setup mode go to section B and press CODE 123 5 Select the axis you want to calibrate X Y or Z For the quill press the F1 key labeled QUILL The Z key is used to calibrate 3 axis machines on
112. l 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 4 1 2 Circles Out of Round Circles are not round within 0 002 TIR over 3 0 DIA This is best measured by placing a dial indicator in the quill and sweeping around the part 61 Southwestern Industries Inc ProtoTRAK KEMX Retrofit 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 may produce better results If more precise circles are required then it is recommended to use a precision boring head boring bar Do the following Service Codes and document values e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 12 Feed Forward Constant e Code 127 Measures backlash in the system 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 Ibs 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
113. lation Maintenance Service amp Parts List Manual 6 1 9 Ball Screw Replacement X Axis Table CAUTI ON Never screw a ball screw partially or totally out of its nut They cannot be reassembled l Y axis motor mounting bracket and hardware must be removed to remove X yoke Position the table in the center of travel Remove the left side table tray by pulling it up and remove the X motor If machine has tray 2 3 4 Remove the motor mounting bracket and bearing housing 5 Remove the right side bearing housing 6 Loosen the table gibs Slide the table to the right and on to a lift that will support the table s weight Slide the table until the yoke is exposed CAUTI ON The weight of the table must be supported by the lift to prevent damage or breakage to the dovetails 7 Remove the 5 16 x 1 screws holding the ball nut to the yoke and loosen the 4 screws that mount the yoke to the saddle Remove the oil line 8 Tilt the yoke it is pinned to remove the ball screw 9 Remove the elbow and setscrew from the old ball screw flange and fit them similarly in the new ball screw 10 Pump oil to be certain it flows through the oil line and then attach the oil line to the elbow 11 Reassemble all assemblies Important The clamp nut must be reassembled as follows 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
114. ll machines use 5 cables to communicate between systems It is often the case that what appears to be the failure of an electrical component is actually attributable to a poor connection Indications 81 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual e Control problems chronic or intermittent e Motor problems e Measurement problems Explanation 1 Turn off and unplug the system from the wall CAUTI ON Do not plug and unplug connectors with the system power on This may cause damage to the connector board and harm to the technician Visually inspect the connections for excessive debris moisture or obvious damage Carefully clean any chips away from the connectors One by one take out each connector and then plug them back in Qro E I dM Make sure to tighten up the screws on each of the connectors 82 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 7 FEN 11 L2 L3 L1 L2 L3 R R R E TE TE T1 72 T3 TA iT2 T3 I T IGG HEr to motor Figure 19 Electrical Box Schematic Service Codes Service codes are broken down into the 4 following categories software machine setup diagnostics and user options defaults All Service Codes are accessed in the DRO Mode by pressing the soft key for SERV CODES The service codes can be found un
115. lso 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 Y to 34 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 97 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual Figure 30 Power Drawbar Assembly Item P N Title 1 22581 1 AIR GUN ASSY ONLY TORQUE RITE 2 22605 DRAWBAR R8 SPINDLE 3 20893 SPACER DRAWBAR R8 SPINDLE 4 22380 1 or 2 AIR REGULATOR ASSY 2 with solenoid 5 23888 SPACER DRAWBAR 40 TAPER SPINDLE 6 22581 2 SWITCH CONTROL HEAD TORQUE RITE 7 22581 4 NOSEPIECE FOR SPINDLE 40 taper heads only 8 1 4 NPT AIR FITTING 90 9 3 8 O D TUBING 132 LG 10 3 8 O D TUBING 27 LG 11 22641 NMTB DRAWBAR NMTB 40 TAPER 12 22641 CAT DRAWBAR CAT 40 TAPER SOCKET AIR GUN REPLACEMENT not shown 18 TR220 on drawing 00875 1 98 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Instal
116. ly 6 Follow the instructions on the screen to complete calibration SPINDLE USE SHORTEST gt z gt Pi BLE DI OSSIBLE DIAL ROD DIAL INDICATOR MACHINE FRAME 100022 Figure 43 Calibration Set Up 113 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual 6 2 2 2 X Y Z Calibration using part measurements Measure your part and compare the actual measurement to the dimension desired For example say you sguared a block using a 3 by 3 rectangular frame When you measure the parts you find the actual measurements are the following X dimension lt 3 003 Y dimension lt 2 995 To calculate your offset do the following X calibration offset 2 programmed actual lt 3 000 3 003 lt 0 9990 Y calibration offset 2 programmed actual lt 3 000 2 995 1 0017 For your guill scale calibration machine a reference plane and set your DRO Z readout to 0 Use the DRO to position the guill down some number for example 1 00 Machine some material away from a corner so it will be easy to measure the difference between your reference plane and your new plane To calculate your offset with a 1 000 difference in position measure the actual amount machined and compare it with 1 000 For example if your measurement showed the difference between the reference plane and the machined plane is 0 985 calculate the offset
117. m The bottom turns red when our servos are in position and green when they are not 5 7 4 Operator Defaults Options Codes The following codes allow the user to set programming defaults or turn features on or off To get to any of these codes go to Service Codes press D and press the code you wish to view 88 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 7 4 1 CODE 22 Turn on Simulation Mode This code allows the ProtoTRAK to emulate RUN POWER FEED and JOG modes without having to move the servos 5 7 4 2 Code 66 Metric Mode This code gives you the choice of switching to Metric Measurements for temporary use or setting Metric as the default which means it will not change unless you change it with code 67 5 7 4 3 Code 67 English Mode This code gives you the choice of switching to English inch Measurements for temporary use or setting English as the default which means it will not change unless you change it with code 66 5 7 4 4 Code 79 Beeper On This turns on the beeper to the control keys 5 7 4 5 Code 80 Beeper Off This turns off the beeper to the control keys 5 7 4 6 Code 89 Turn off Simulation Mode Use this code to turn off the simulation mode and return to normal operation 5 74 7 Code 129 Arc Accuracy When the EMX control operates at high feedrates it may create small part machining errors as it goes around shar
118. machine as possible Loosen the bracket and then retighten it Once again moving the saddle forward allows the yoke to be as close to the bearing housing as possible 5 3 Computer Pendant Diagnostics The pendant consists of 2 separate modules the computer module and LCD screen enclosure In general the pendant computer module is best diagnosed by eliminating all other possible alternatives The following table lists some problems and what these problems can lead to 77 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Possible problems Can lead to Poor cable connections There are 4 cable connections to the rear of the pendant Make sure all cables are properly fastened Warning do not unplug and plug cables with the control on This will destroy the computer Pendant locks up Press the E stop button and see if lock up clears if not then do the following Turn the pendant off wait at least 30 seconds and turn it back on and check to see if the malfunction has been reset No voltage to RSG port RSG will not work should be 5 DC volts present Check with a voltmeter IDE flash drive failure If the IDE flash drive fails the system will not boot up or operate It will need to be replaced All programs and machine configurations will be lost Make sure to back up your flash disk from time to time LCD backlight
119. move the 2 springs 5 Replace the brake shoes 6 1 18 Spindle Replacement 1 Remove the draw bar and its bushing 2 Lower the quill about 1 inch and lock 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 a EG A AR N N ANNA Ew Al m AS 29 BN IY AX IO AN NI NOSEPIECE ERN Ne LEFT HAND VEERE SS HOLE FOR SPANNER 109 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual 6 2 Maintenance 6 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 6 2 1 1 Table Gib Adjustment X Axis See Figure 39 1 2 3 Clean all chips dirt and excess oil from the table and saddle Center the saddle on the bed ways
120. ng saved but the measurements are not repeating or are not accurate e See Measurements Are Not Repeating e See Measurements Are Not Accurate 4 3 9 E Stop Error For TRAK Knee mills the E Stop turns the power off to the axis and spindle motors for retrofits the e stop does not cut power to the spindle motor For the machine this is done by stopping 110V power from reaching the electrical box through the use of a relay in the pendant 110V Power reaches the electrical box through the AC E stop cable It is used to energize the spindle motor contactor If this contactor is not energized the spindle will not turn on See Figure 19 If the E Stop button is depressed and no message is displayed on the screen then either the E Stop button or the Computer Module is at fault Possible Cause Check This Faulty E Stop switch Check the cable connections from the computer module to the E Stop switch Check the E Stop switch for functionality Bad Computer Module Does 110 V power come out of the pendant through the e stop connector If yes and the screen has an E stop message replace the computer module 4 4 Problem with the Measurements 4 4 1 X Y and Z Axis Measurements Do Not Repeat With a dial indicator mounted to the bottom of the spindle touch off a fixed surface either in the X or Y axis direction and then set the DRO equal to 0 Crank away several inches and then touch off again at the same place If the reading has not return
121. ntion or understanding ALWAYS WEAR SAFETY GLASSES AND f NEVER WEAR GLOVES RINGS WATCHES LONG SLEEVES SAFETY SHOES NECKTIES JEWELRY OR OTHER LOOSE ITEMS ALWAYS STOP THE SPINDLE AND CHECK TO ENSURE THE M USE ADEQUATE POINT OF OPERATION SAFEGUARDING IT CHIC GRE ORNS IN TOE Va ceret f A IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE ENG GE SA eL aru ENG AND ENSURE POINT OF OPERATION SAFEGUARDING OR ADJUSTING THE TOOL OR WORKPIECE OSHA 1910 212 MILLING MACHINES Southwestern Industries Inc ProtoTRAK K EMX amp Retrofit 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 K Milling Machines It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels 2 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual SOUTH ME ab Bi S 2615 HOMESTEAD P RANCHO DOMINGUEZ CA 90220 Kemer S N ELECTRICAL RATINGS VOLTS JAMPS _ PHASE Hz FLA OF LARGES
122. ny looseness t may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 5 2 4 2 Problems Regarding the Motion of the Machine 4 2 1 Run Away Axis The axis makes an unwanted move at rapid speed in one direction and faults out This is usually caused by an encoder signal being interrupted Do the following Service Codes 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 properly e Code 131 Motor encoder operation test Possible Cause Check This The home positions or tools are not set See the Controls Programming Operations and Care correctly manual Bad Motor Encoder See Motor diagnostics Section 5 4 4 2 2 Slow Down Axis The axis slows down and moves at a feedrate that is lower than rapid or than the programmed feedrate Do the following Service Codes 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 Sets the maximum allowable arc accuracy error This applies to arcs only 64 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Possible Cause Check This The maximum allowable Arc Ac
123. o Y axis If yes replace motor If no motors the motor is not the problem Warning turn off the power before plugging or unplugging motors or you will destroy the computer 5 5 Servo Driver Note the Servo Driver is located in the black box on the side of each motor Indications e Problems moving just one axis including hard turning in one or both directions Servo Types e Xand Y servos are identical Objective e Isolate the problem to the particular Servo Driver Steps l Turn off and unplug the system WARNI NG Do not work with the Servo Driver unless the power is disconnected from the machine There is possibility of death by electrocution 2 Physically swap the servo module from the axis that is not working to one that is 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 80 Southwestern Industries Inc ProtoTRAK amp KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 6 Electrical 5 6 1 Checking A C Voltage This procedure tests for the 110V power for the control e Use a Voltmeter reading A C volts e Acceptable range is 100V to 130V Note systems running consistently close to the low values may have problems when normal voltage fluctuations push the voltage out of the a
124. o rotate up to 90 degrees to the right or left The K2 and K3 can also rotate 45 front to back The K4 machine cannot rotate front to back 6 2 3 1 To Rotate the Head Side to Side 1 Loosen the four locknuts 2 Rotate the head with the adjusting worm shaft When rotating to greater than a 45 angle support head by hand 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 the figure below and a parallel bar to square the head to the table 115 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual 6 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 to Side Alignment l Make sure the machine is level 2 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 3 Adjust the Y axis so that the spindle is in the center of the table 4 Adjustthe Knee so that the dial indicator will reach the table 5 Move the dial indicator to 6 o clock position and adjust the face so the needle is zero 6 Doa series of sweeps from 9 o clock to 3 o clock and check for the repeatability of the setup The head should be trammed within
125. ons Check for any loose wiring or cables Computer Pendant failed See Computer Pendant diagnostics Section 5 3 4 3 7 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 electrical box to the Pendant See Electrical Section 5 8 Computer Pendant has failed See Computer Pendant diagnostics Section 5 3 4 3 8 Will Not Hold Calibration The control will not hold calibration Go to the Configuration Values screen and write down the calibration values for the motor encoders Encoder Recalibrate the system and see if the values change Turn the system off and on and see if the values are held Do the following service codes and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 313 Configuration Values e Code 123 Calibration using a measurement standard or e Code 122 Calibration using work piece measurements Possible Cause Check This Configuration file corrupt Load default configuration by going to code 313 68 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Not saving Calibration values Replace Computer Pendant module See Computer Pendant If calibration factors are bei
126. otoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 115 Quill Spindle Sub Assembly P N 20836 1 139 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List Spindle Sub Assembly item PIN DESCRIPTION Qty 5 FB136 BEARING SPACERLARGE 1 6 FB137 BEARING SPACER SMAL Tt 7 FB139 SPINDLE BEARING KNOCK NUT 1 8 FBI391 SET SCREW M8 P1 25x6L 2 10 A112H BEARING 600822 1 11 FB143 LOCKRING S pf 1 00608 K4 lt a N 140 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Figure 118 Top Housing Assembly R8 19 3X 100690 K2 K3 141 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List Head Top Assembly 24692 item PN Title Qty 6 VSe4 BULLGEARPINIONBEARINGGAP 8 VS117 KEY5x525L 1 9 vs62 TIMINGBELTPULLEY 14 15 VS135 KEY 8x7x60L 1 17 20778 6 UPPER VARI DISC DRIVE SUB ASSY SVK A6 1 19 VS137 SOCKET CAP SCREW M amp P1 25x25L 1 20 VS13 TOPBEARNGCAP 1 0 14 21 VS13 1 WAVEWASHER 0 0 0 0 0 1 S SPEED CHANGE HANDWHEEL SUB ASSY 3VK A7 SCREW SOC HD CAP M6 P1 0x35L 97 28 29 30
127. p 2 This step is completed when the table is removed the casting is cleaned and the parts are organized for later 35 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Step 2 Install the X table ballscrew X Axis Ballscrew LEFT A RIGHT BALLNUT WRENCH FLAT i i WRENCH FLAT X i HANDWHEEL 10 32 SET SCREW HERE MOUNTS THIS MOTOR MOUNTS FLANGE Y SIDE THIS SIDE A Nominal Length qas SECTION AA ga F ELBOW OIL 4409 FITTING HERE 42 o 5009 62 09 100672 36 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Caution Never unscrew the ballscrew from the nut This will destroy the ballscrew Tips Install the elbow oil fitting and 10 32 set screws on the ball nut The set screw goes in flush to the surface to prevent oil from draining out of the hole Don t tighten too much or it will damage the ballnut First position the yoke in the saddle without the casting screws then slide the ballscrew into the yoke Once the ballscrew is in you can screw in the screws that go through the yoke and into the saddle casting although you should not tighten them until the ballscrew is aligned If you are using the original machine yoke and it was pinned to the casting simply replace the pins If not it will be necessary to align the ballscrew Al
128. p corners This exists on all CNC s and is commonly called a following error The control is factory preset to allow a maximum following error of 0 001 inch The feedrate will automatically be adjusted around sharp corners so as to not violate this limit This code only applies to arcs that are programmed and ones that are created in the tool path to generate the shape you want This code will not make a difference on mill moves You may adjust the maximum following error to a value as small as 0001 inch However the smaller the value the slower the feedrate around corners To input a new Following Error use the following procedure Follow the instructions on the screen and input the Following Error value from 0001 to 0100 and press INC SET 89 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 6 0 Procedures for Replacements amp Maintenance 6 1 Replacements 6 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 l Turn off power to the machine 2 Each motor is mounted by the use of 4 20 screws Be careful not to over tighten these bolts and strip the threads 6 1 2 Motor brush replacement l This procedure assumes the motor assembly has either been removed from the machine an
129. r Defaults Options Codes 6 0 Procedures for Replacements amp Maintenance 6 1 Replacements 90 6 1 1 Servo Motor Replacement 6 1 2 Motor Brush Replacement 6 1 3 Servo Driver Replacement 6 1 4 Computer Module Replacement 6 1 5 IDE Flash Disk Replacement 6 1 6 Cable Routing on Machine 6 1 7 Replacement Z Axis Scale Mill Only 6 1 8 Power Drawbar 6 1 9 Ball Screw Replacement X Axis 6 1 10 Ball Screw Replacement Y Axis 6 1 11 Spindle Motor Wiring 6 1 12 Feed Trip Adjustment 6 1 13 Quill Clock Spring Replacement Adjustment 6 1 14 Spindle Motor Removal amp Replacement 6 1 15 Drive Belt Replacement 6 1 16 Timing Belt Replacement 6 1 17 Brake Shoe Replacement 6 1 18 Spindle Replacement 6 2 Maintenance 6 2 1 Gib Adjustments 6 2 2 Calibration amp Backlash Constants 6 2 3 Head Rotational and Tramming Figures found in Section 7 0 118 Fig 100 Top Housing Assembly K4 Fig 101 Gear Housing Sub Assembly K4 Fig 102 Hi Low Slip Clutch Sub Assembly K4 Fig 103 Hi Low Shift Sub Assembly K4 Fig 104 Pulley Pinion Sub Assembly K4 Fig 105 Lower Vari Disc Sub Assembly K4 Fig 106 Upper Vari Disk Sub Assembly K4 Fig 107 Speed Change Handwheel Sub Assembly Fig 108 Spindle Motor Sub Assembly K4 Fig 109 Bottom Housing Assembly K4 Fig 110 Worm Gear Cradle Sub Assembly K4 Fig 111 Quill Feed Selector Sub Assembly K4 Fig 112 Quill Pinion Shaft Sub Assembly K4 Fig 113 Overload Clutch Trip Sub Assembly K4 Fig 114 Feed Reverse Clutch
130. rate the Z axis quill using a 75mm standard 16 Perform Service Code 100 in both directions for the X and Y axes to verify that the feed rate shown on the display is at least 120 ipm 17 Run the spindle at various speeds in both high and low gear for 15 minutes Verify head shifts from high to low gear smoothly Test quill feed and spindle brake N A to retrofits 18 Install the Y axis front and rear way covers 19 Ifthe machine has a power drawbar option check to make sure that the tools load and unload properly N A to retrofits 20 Wipe down the machine 9 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance Service 6 Parts List Manual 2 5 Machine Specifications KEMX Movement and ranges X Y Z axis 32 x 16 x 16 Quill Travel maximum 5 Quill Diameter 86 mm Spindle Taper R8 Speed Range 60 4200 RPM Spindle to Column 8 to 32 Quill Feeds Per Revolution of Spindle 0015 003 006 Head Tilt 90 Head Swivel 45 Spindle Motor Power 3HP Voltage 220 440 V Phase Cycle 3 phase 60 Hz Current 8 5 4 3 amps Maximum Weight of Workpiece 850 lbs 2 6 Maximum Work Capacities Drilling Mild Steel 2 axis manual feed 1 Tapping Mild Steel 1 Milling metal removal rate mild steel 1 inch min Maximum work capacities are dependent on a lot of variables that cannot be controlled by the machin
131. s are e X axis Table moves to the left e Y axis Saddle moves toward the front of the machine e Z axis Quill moves up 70 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Do the following service code and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 97 set positive motor encoder direction e Code 313 Check the line that specifies the product 4 5 Problems with the Machine Tool 4 5 1 Spindle Stalls or Turns Off During Machining During machining the spindle turns off and loses power First check incoming voltage and connections 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 5 1 Drive Belt in the head is slipping Check the alignment condition and tension of the Drive Belt Cut more than the machine is capable Check width and depth of cut Insufficient voltage excessive amp load Check incoming power Check overload setting 4 5 2 Spindle Motor Hums or Will Not Run If the spindle will not run you must ensure that 110V power is reaching the spindle motor contactors in the electrics box Check your 110V power across terminals wire 3 and ground If power has reached the
132. seated before fastening the unit back in place 13 Turn power on to the machine and control 14 Update the System Software by inserting a Thumb Drive that contains updated system software from our website www prototrak com Use service codes 316 found in section A to update the software 15 Use Service Code 141 to restore the Configuration file saved on your USB Thumb Drive if you were able to save it using Code 142 Otherwise do the calibration and backlash procedures described in section 6 2 2 CAUTI ON It is a good idea to back up your flash disk from time to time Service Code 340 If your IDE Flash Drive needs to be replaced you will loose all of your programs See your programming manual for instructions on backing up programs 6 1 6 Cable Routing on Machine Whenever you replace a cable or reroute a cable it is very important to keep the high voltage power cables and glass scale cable separated from each other The power cables consist of the 2 110 volt motor cables and 1 110 volt power cable for the pendant and the 220 or 440 Volt power cables for the spindle motor The glass scale cable should not be tied to the 220 or 440 volt cable Mixing of the power and scale cables may cause noise from the power cable to interrupt the signals in the scale cable This can lead to measurement repeatability problems 94 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service
133. stern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Spacers as needed Handwheel washer star washer nut Tighten don t push down to 50 ft Ibs 57 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Step 7 Install the display pendant VIEW OF TOP MOUNT DESIGN VIEW OF SIDE MOUNT DESIGN BACK PANEL AND BRACKET SHOWN FOR REFERENCE ONLY USE SET SCREWS TO LEVEL PENDANT ARM ZA ONLY USED ON RETROFITS 58 Southwestern Industries Inc Item P N Title UseAs Qty 1 26037 PENDANT ARM EA 1 2 16919 PLATE LEVELI NG EA 1 3 26038 CAP PLUG EA 1 4 26016 1 BUSHING THREADED 3 4 10 EA 1 26026 2 BUSHING THREADED M20X2 5 5 1 2 13X3 1 2 25B SCREW SHCS STL BO EA 1 6 1 2 75Z WASHER EXT TOOTH STL ZINC EA 1 7 3 8 16 50B NUT HEX STL BO EA 1 8 24009 2 WASHER BELLEVILLE SPRING LOCK EA 1 9 1 4 20X3 4 40B SCREW SOC SET STL BO CUP EA 4 10 26050 CABLE
134. t are stored in the ProtoTRAK s internal storage will be copied to the USB Thumb Drive 84 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 7 1 7 CODE 341 copy part programs from the USB Thumb drive Load in USB thumb drive and enter this service code All the part programs that are stored on the USB Thumb Drive will be copied to the ProtoTRAK s internal storage 5 7 2 Machine Set up Codes The following codes are used primarily when setting up a new machine To get to any of these codes go to Service Codes press B and press the code you wish to view 5 7 2 1 CODE 12 Feed Forward Constant The Code 12 procedure helps the control learn the friction characteristics of the machine by sending a graduated series of motor signals and observing the results The process takes less than 30 seconds to run It is both a diagnostic routine that displays values and a routine that sets the parameters of the control for the particular machine The Code 12 is used for diagnosing and resolving 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
135. ted when the glass scale is mounted securely to the machine quill and moves smoothly with quill travel Step 9 Connect the cables and the power PORTS TABLE GUARD FAN ASSY AIR I AIR EXIT i dnd X MOTOR ACCESS TO Y MOTOR DIAGNOSTIC LED S GND Z SCALE MOUNTING BRACKET AC ON OFF 101273 Caution do not turn the power on to the pendant until all cables are plugged in properly Plugging or unplugging with power on will destroy the computer Tips e Loosely route the cables and check that there will be enough slack to accommodate full table and saddle traverse 59 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual e Use cable ties to secure the cables to the pendant mounting arm You may want to do this after the system check out in step 10 Just don t forget to come back to it because the machine will look a lot nicer with the cables all tied up e Note The tableguard port is not used for retrofits This step is completed when The cables are plugged into the display Pendant arm and cables Z cables plug in all cables with system off Step 10 Check out Do the following Plug the ProtoTRAK EMX into a 110 volt outlet Turn the ProtoTRAK EMX on Go into DRO mode press J og Push the X the table should move under power Press the key and press the X again It should move the opposite direction 5 Note The table should mo
136. that the drive train is potentially the problem and other more easily checked variables have been exhausted e Roughness looseness tightness or jamming movement in the table or saddle 1 Check for machine considerations especially gib locks and gib adjustments See Gib Adjustments section 2 Check the torque of the axis in three places both ends and center of ball screw along the length of the ball screw The torque should be within 2 or 3 in 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 75 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 2 1 and 5 2 2 for more information The following steps take you in logical sequence through the assemblies for the knee mills For drawings of these assemblies see figures 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 Checkt
137. tion 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 74 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 5 2 5 1 4 1 Spindle Speeds Spindle speeds are influenced by a number of variables e 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 5 1 4 2 Feedrates Factors that affect feedrates e Depth and width of cut e Design or type of cutter e Sharpness of the cutter e 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
138. tion 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 SCREW SOC HD CAP M4 P0 7x15L EA 3 6 K B94 SNAP RING 95 DOWEL PIN Y 14 EA 1 7 K B168 SCREW PIN EA 4 8 25707 BUSHING KIT PINION SHAFT 40 TAPER EA 1 i20698 3 Figure 112 Quill Pinion Shaft Sub Assembly P N 20698 3 ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 136 Southwestern Industries Inc P N Title Mem or i MG alala Q9 lt Fere SAFETY CLUTCH SPRING 1 5 F878 OVERLOADCLUTCHLOCKNUT 1 6 FB 6 SOCKETSETSCREWMe PIOGL 1 7 rem LUrHRNG O O 1 8 F897 OVERLOADGLUTGHWASHER 1 9 res NAPHNGO10 1 10 F896 OVERLOADGLUTGHTRIPLEVER 1 11 Few JCLUTOH RING PIN 2REQ 2 i2 FB BRssPlUG 1 i00606 K4 a N Figure 113 Overload Clutch Trip Sub Assembly P N 20698 4 137 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 100607 K4 em pe e FB4 FEED REVERSE BEVEL GEAR 8 se KV O o FB50 FEED REVERSE CLUTCH i00607 K4 lt Figure 114 Feed Reverse Clutch Sub Assembly P N 20698 5 138 Southwestern Industries Inc Pr
139. ustries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual Step 5 Replace the table amp install the X drive train left side amp motor DIAL LOCK NUT DIAL HOLDER BALL BEARING BEARING HOUSNG Figure 31 X Axis Drive Assembly 20255 2 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual X Axis Drive Assembly Parts List Item P N Title Qty 1 15621 DRIVE HOUSING 1 4 15624 COVER X AXIS DRIVE HOUSING MX 1 5 15622 BACK COVER 1 6 15616 HANDWHEEL ASSY MX 1 8 15612 BEARING HOUSING ASSY X AXIS 1 10 15638 STOP X AXIS 1 11 15626 SEAL BEARING HOUSING 1 12 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 1 13 16452 NUT CLAMP X Y 8 Z AXIS 1 14 16350 FERRULE SPROCKET 1 15 98481A090 KEY WOODRUFF 404 1 8 X 1 2 1 16 14772 SPACER 100 THICK B 19 400 5M 15 BELT TIMING 5MM POWERGRIP 1 20 23930 BEARING SET 2 ANGULAR CONTACT 7204 BECBP 1Set 22 14772 2 SPACER 020 THICK 2 23 14772 5 SPACER 050 THICK 2 41 8 32X3 8 25B__ SCREW SHCS STL BO 6 42 5 16 18X1 25B SCREW SHCS STL BO 1 45 M10 1 5X65 25B SCREW SHCS STL BO 4 46 1 4 20X1 24B SCREW HEX HD STL BO 7 47 8 32X3 8 20B__ SCREW RH PHIL STL BO 3 48 10 32X3 4 25B SCREW SHCS STL BO 1 49 1 2 20 51Z NUT HEX JAM STL ZINC 2 52 15759 WASHER
140. uthwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual i20698 iz A p D S DS TESS S aci Bottom Housing Assembly Figure 109 130 Southwestern Industries Inc ProtoTRAK KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual Parts List Bottom Housing Assembly 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
141. ve 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 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 may be purchased from Southwestern Industries Inc if deemed necessary by the user 5 Southwestern Industries Inc ProtoTRAK K EMX 8 Retrofit Safety Installation Maintenance Service amp Parts List Manual 2 0 KEMX Machine Installation Read and understand this entire installation section before beginning the installation procedure 2 1 Floor Plan Layout amp Space Requirements FF oer i jep o BED FOOTPRINT pc Figure 1 Machine Footprints KEMX Weight approximate net 2800 lbs Weight approximate shipping 3100 lbs Pallet Size 6 x 6 A Overall width 103 B Overall length 70 C Base width 24 2 D Width between leveling screws 21 9 E Distance between leveling screws 29 7 F_ Base length 38 8 6 Southwestern Industries Inc ProtoTRAK KEMX 8 Retrofit Safety Installation Maintenance
142. ve to the left for positive X counting and the saddle should move towards the operator for positive Y counting Moving the quill up should result in positive Z counting Use Service Code 97 to change if needed 6 Do the same with the Y key and observe the saddle 7 Press Return to get out of Jog 8 Move the quill handle There should be a readout on the Z If the Z isn t activated see section 5 9 for instructions on how to do service code 15 IES If the system is jogging we recommend that you calibrate and set backlash constants now See section 6 2 2 Also run service code 12 see Section 5 7 2 1 If you have any problems see the troubleshooting section in this manual for what to do Don t worry there isn t anything too tough You may just have to reinstall something Congratulations See your ProtoTRAK EMX Safety Programming Operating and Care Manual for instructions for using the ProtoTRAK EMX a tutorial and some sample programs Now you can machine 60 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service amp Parts List Manual 4 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 4 1 Problems Relating to Machining Results 4 1 1 Poor Finish The part
143. w 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 6 1 14 Spindle Motor Removal and Replacement 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 CAUTI ON The motor is heavy about 60 pounds Be certain you have the proper equipment or assistance 6 Tilt the motor toward ram and remove the belt from the motor pulley Remove motor 7 f 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 36 SPRING M5 x 35mm COVER 100155 107 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual 6 1 15 Drive Belt Replacement 1 2 3 o 0 Mu Remove the motor Remove the draw bar and its bushing Remove the three Screws A and use M6 x 35mm scre
144. while in motion 17 Securely clamp and properly locate the workpiece in the vise on the table or in the fixture Use stop blocks to prevent objects from flying loose Use proper holding clamping attachments and position them clear of the tool path 4 Southwestern Industries Inc ProtoTRAK amp KEMX Retrofit Safety Installation Maintenance Service amp Parts List Manual 18 19 20 21 22 23 24 25 26 27 28 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 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 ha
145. ws in the adjacent tapped holes to remove the Bearing Cap 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 Remove six Screws C holding the belt housing to the subplate Remove the four screws holding the speed changer Remove the belt housing Replace the belt by sliding it over the speed changer In 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 Figure 37 BELT HOUSING SUBPLATE 00156 6 1 16 Timing Belt Replacement 1 2 3 Remove the motor and drive belt Slide the top or adjustable vari disc pulley assembly off the shaft Remove the three M8 screws holding the belt housing base to the gear housing Lower the quill about 4 inches Remove the belt housing base and lower or stationary vari disc pulley assembly Replace the timing belt 108 Southwestern Industries Inc ProtoTRAK KEMX amp Retrofit Safety Installation Maintenance Service Parts List Manual Figure 38 6 1 17 Brake Shoe Replacement 1 Remove the motor drive belt and complete Steps 1 5 of the timing belt replacement procedure 2 Remove the two M6 cap screws from the bottom of the belt housing base 3 Separate the belt housing base from the lower or stationary vari disc pulley This is a slight press fit 4 Re

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