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Service manual - Clark Science Center

1. Item P N DESCRIPTION Qty 1 15966 BRACKET Y AXIS MOTOR MOUNT 1 2 15967 COVER UPPER 1 3 15968 COVER LOWER 1 4 21662 BEARING HOUSING 1 5 16302 RING BEARING HOUSING 1 6 16078 SEAL BEARING HOUSING 1 7 23026 PULLEY SOLID 44 TEETH 1 8 16066 NUT CLAMP X amp Y AXIS 1 9 16350 FERRULE SPROCKET 1 11 15913 BRACKET WAY COVER FRONT 1 13 M8 1 25X25 25B SCREW SHCS STL BO 4 14 600 5M 15 BELT TIMING 1 15 23940 BEARING SET ANGULAR CONTACT 7205 BECBP 1 16 M8 74B WASHER EXT TOOTH STL BO 4 17 M10 1 5X65 25B SCREW SHCS STL BO 4 18 10 32X3 4 25B SCREW SHCS STL BO 1 19 1 4 20X1 24B SCREW HEX HD STL BO 4 20 15759 WASHER 1 4 HARD BLK OX 1 8 THK 4 23 1 2 20 51Z NUT HEX J AM STL ZINC 2 24 1 2 70P WASHER FLAT USS STL PLAIN 2 25 1 2 75Z WASHER EXT TOOTH STL ZI NC 2 28 3 16X1 1 2 81P PIN SPRING STL PLAIN 2 31 6 32X1 2 10B SCREW PH PHIL STL BO 8 32 98481A090 KEY WOODRUFF 404 1 8 X 1 2 1 33 15616 HANDWHEEL ASSY MX 1 34 23016 EXTENSION BALLSCREW Y AXI S HANDWHEEL ASSY 1 35 1 4 20X1 3 4 25B SCREW SHCS STL BO 3 36 15614 TAB WASHER 1 37 21946 ELECTRONIC HANDWHEEL KIT DPMS5 1 38 M6 1 0x75 25B SCREW SHCS STL BO 4 39 M6 1 0x25 25B SCREW SHCS STL BO 4 40 21985 SPACER 30 DEGREE Y AXIS 1 41 1 4 20X1 5 8 26B SCREW SHCS STL BO 4 42 22348 BEARING HOUSING 1 101132 Y SX5 127 Southwestern Industries nc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts Li
2. A LUBE pump L 101159 Parts List Cable Connection Non Spindle Control 7 3 PHASE 220440 TO SPINDLE MOTOR Item Part Number Description SX2 SX3 SX5 1 220V 220V Electrical Box 20676 20676 1 440V 440V 20676 20676 2 21856 Cable Assembly 3 24999 1 Cable Breakout Box 1 with AUX Functions 4 22648 7 Option Key SMX 5 22758 DPMSX XXX Key Machine ID 6 24000 1 SMX Pendant 33 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual a ES FETE JOE epe TO LUBE PUMP 99 POWER FWD h 4 ON OFF REV WITCH SOURCE E i2 TO GEAR Z AXIS LIMIT SWITGH SWITCHES 3RD AXIS T j SPINDLE i MOTOR ROTARY INDEXER a e OG LIMIT SWITCH oren OPTION z SECONDARY 1t ANE FEEDBACK ZAXISEHW OPTION 3RD AXIS KIT XYZ ee int COOLANT PUMP MIST z A 0 2 D e 101113 BREAK OUT BOX SHOWN WITH AUX FUNCTIONS Figure 17 Cable Connection Diagram with Spindle Control Option 34 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Cable Connection Spindle Control Item Part Number Description 1 24000 1 SMX Pendant Assembly 24060 1 Enclosure Assembly SX2 24060
3. 3 4 Problem with the Measurements 3 4 1 X Y and Z Axis Measurements Do Not Repeat With a dial indicator mounted to the bottom of the spindle touch off a fixed surface either in the X or Y axis direction and then set the DRO equal to 0 Crank away several inches and then touch off again at the same place If the reading has not returned to 0 on the DRO zero the display and repeat the procedure If the measurement does not repeat you have a repeatability problem that must be resolved Test for accumulative error by moving the axis a number of times to see if the error gradually grows by a small amount If so it may be caused by a misaligned sensor or scale If the error abruptly changes by a large amount it may be caused by a bad encoder Expected repeatability numbers should be 0 0005 or less Do the following service codes and procedures e Code 304 Toggle X sensor glass scale on off e Code 305 Toggle Y sensor glass scale on off 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 4 1 Check the adjustment of the X Y and Z axis Gibs using the X Y and Z axis Gib adjustment procedures TRAK Sensor or Glass Scale problem Make sure that the Sensor or Glass Scale is installed correctly according to the Sensor or Glass Scale
4. 1 4 vs PRUKSSPRNG ff 5 VS90 JFRU KSHILOW DETENT PLUNGER 1 VS57 FRU K3 BAKELITE BALL HANDLE VS116 FRU K3 WASHER FLAT M5 24083 SHAFT HI LOW SHAFT ASSY 100693 K2 K3 E e ai 184 Southwestern Industries Inc DPMSX2 SX3 8 SX5 Safety Installation Maintenance Service 8 Parts List Manual Dmm see 100694 2 WzZ 2 DESCRIPTION VS67 FRU K3 BULL GEAR PINION COUNTER SHAFT VS69 FRU K3 KEY 5X5X18L VS65 FRU K3 BALL BEARING 2 REQ 620372 FRU K3 SOCKET SET SCREW M6 P1 0x6L 23954 BEARING SET 2 BEARING 6203ZZ 100694 K2 K3 Hem FRU K3 BULL GEAR PINION 6 Figure 79 Pulley Pinion DPMSX2 P N 20778 4 185 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 80 a Lower Vari Disc Drive DPMSX2 P N 20778 5 186 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Lower Vari Disc Drive DPMSX2 Hem PIN DESCRIPTION Qy 2 VS59 FRU k3 BRAKEBLOCK 1 1 1 1 1 1 2 3 VS58 FRU STURNINGBLOCKSHAFT I 4 VS103 FRU K3 RETAININGRINGG7 1 1 FRU K3 BRAKE SHOE PIVOT SLEEVE VS17 2 FRU K3 NUT M6 P1 0 n co F FRU K3 BRAKE SPRING F 5122 FRU K3 WASHER DIA 3 3 9 VS120 FRU K3 SCREW
5. 2 3 4 5 FVS38 SOCKET CAP SCREW 6 7 8 FVS39 SPEED CHANGE PLATE PIVOT STUD ID N Ph a 9 FVS41 WASHER 8 2 10 FVS40 ROLL PIN 3x15L 11 FVS35 CHAIN END STUD 12 FVS34 ADJUSTMENT NUT 13 FVS33 CHAIN FRONT SCREW M4 P0 7x5L 100599 K4 Parts List 24599 Sub Assy Bearing Housing K4 Item P N Title Aty 1 FVS42 SPINDLE PULLEY BEARING HOUSING 1 2 FVS43 BALL BEARING 601322 1 Parts List 24603 Sub Assy Vari Disc Adjustable Item P N Title Qty 1 FVS42 SPINDLE PULLEY BEARING HOUSING 1 2 FVS43 J BALL BEARING 601377 1 3 FVS44 JADJUSTABLE DRIVEN VARIDISC W KEY 1 162 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100600 K4 E Item P N Title Qty 1 FVS16 SPEED CHANGE HOUSING FVS20 JBEARING SELF LUBRICATING FVS22 SPEED CHANGER GEAR FVS31 SPEED CHANGE CHAIN DRUM FVS125 WASHER FVS25 SPEED CHANGE SHAFT 2 3 4 5 FVS21 WORM 6 7 8 FVS40 ROLL PIN 3x15L N ej 9 FVS24 COPPER BUSHING 10 FVS32 CHAIN 3109 525 11 FVS31 1 DOWEL PIN 3x25L 12 FVS30 SPEED CHANGE STUD 13 FVS27 SPEED CHANGE HANDWHEEL 14 FVS18 FULL DOG SOCKET SET SCREW M6 P1 0x10L 15 FVS28 HANDLE 3 8 16NC i00600 K4 Figure 64 Spee
6. Do the following Service Codes and procedures 44 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual e Code 11 Measure s the backlash in the system Only used on machines with Dual Feedback systems e Code 12 Feed Forward Constant High feed forward constants will cause an unstable servo system e Code 127 Measure s the backlash in the system Only used on machines with Single Feedback e Code 128 Enter backlash compensation Code 123 Calibrate Possible Cause Check This Too much backlash entered in Code 128 Recheck the machines backlash or Code 11 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 X Y and Z axis Gibs are not adjusted Check the adjustment of the X Y and Z axis Gibs using properly the X Y and Z axis Gib adjustment procedures Gibs not making good contact Pull gibs out and mark with a blue die to check where the gibs are making contact It is recommended that the gibs uniformly contact at least 80 of the surface Binding or looseness in the Drive Train Check Repeatability using the Repeatability and Positional Accuracy procedure Check the torque reading of the Drive Train Step by step carefully inspect the D
7. System Shuts Off 3 4 3 5 4 0 4 1 4 2 4 3 44 4 5 4 6 4 7 4 8 Will Not Hold Calibration Auxiliary Functions Not Working 3 3 11 E Stop Error 3 3 12 Limit Switch Error Problem with the Measurements 3 3 9 3 3 10 3 4440 X Y amp Z Axis Measurements Do Not Repeat 3 4 2 X Y amp Z Axis Measurements Are Not Accurate 3 4 3 The DRO Is Not Counting 3 44 X Y amp Z Axis DRO Counting in Wrong Direction 3 4 5 X Y amp Z axis Electric Handwheels Turn in Wrong Direction Problems with the Machine Tool 3 5 1 2 Noisy 3 5 2 Spindle Stalls or Turns Off During Machining 3 5 3 Spindle Motor Hums or Will Not Run 3 5 4 Runs Backwards 3 5 5 Head Noise Diagnostics The Machine Tool amp Set Up 4 1 1 The Milling Machine Checklist 4 1 2 ASpecial Word About X Y Z Gibs 4 1 3 Lubrication 4 1 4 X Machining Set Up The Mechanical Drive Train X Y 4 2 1 DPMSX2 3 Ballscrew Alignment 4 2 20 DPMSXS Ballscrew Alignment Computer Pendant Diagnostics 4 3 1 Checking Floppy Drive Motor Diagnostics 4 4 1 Cable Connections 4 4 2 To Check the Motor Encoders 4 4 3 Encoder Counts to Pendant 4 4 4 Moving Problem From One Axis to Another Servo Drivers Glass Scales 4 6 1 Alignment of Scales 4 6 2 Measurements Do Not Repeat TRAK Sensors 4 7 1 Faulting Axis 4 7 2 Measurements Do Not Repeat Electrical 4 8 1 Checking A C Voltage 4 8 2 Checking Fuses 4 8 3 Cable
8. 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 10 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 10 32 clamp screw to lock the clamp nut in place See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw See 38 for an illustration of the Y axis drive train 117 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 101132 Y SX2 15609 XX BALLSCREW Figure 38 DPMSX3 Y Axis Drive Assembly 118 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual DPMSX3 Y Axis Drive Assembly Parts List Item P N DESCRI PTI ON Oty 1 15966 3 BRACKET Y AXIS MOTOR MOUNT 1 2 M10 1 5X60 25B SCREW SHCS STL BO 4 3 15968 2 LOWER COVER 1 4 15967 2 UPPER COVER 1 5 6 32X3 8 31Z SCREW PH PHIL EXT SEMS STL ZI NC 8 7 1 2 70P WASHER FLAT USS STL PLAIN 1 8 30922 HANDLE FOLD A WAY 1 9 15616 HANDWHEEL ASSY MX 1 10 1 2 752 WASHER EXT TOOTH STL ZI NC 1 11 1 2 20 51Z NUT HEX JAM STL ZINC 1 12 15614 TAB WASHER 1 13 14772 SPACER 100 THICK
9. 106 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual DPMSX2 X Axis Drive Assembly Parts List Item P N Description Qty 1 15621 DRIVE HOUSING 1 4 15624 FRONT COVER 1 5 15622 BACK COVER 1 6 15616 HANDWHEEL ASSY MX 1 7 15614 TAB WASHER 1 8 15612 HOUSING BEARING 1 9 15885 RING BEARING HOUSING 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 amp Z AXIS 1 14 16350 FERRULE SPROCKET 1 15 98481A090 KEY WOODRUFF 404 1 8 X 1 2 1 16 14772 SPACER 100 THICK 5 19 400 5M 15 TIMING 5MM POWERGRIP 1 20 23930 BEARING ANGULAR CONTACT 7204 BECBP SET 22 14772 2 SPACER 020 THICK 2 23 14772 5 SPACER 050 THICK 2 41 8 32X3 8 25B ISCREW SHCS STL BO 6 42 5 16 18X1 25B SCREW SHCS STL BO 1 45 M10 1 5X65 25BISCREW SHCS STL BO 4 46 1 4 20X124B 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 JNUT HEX JAM STL ZINC 2 52 15759 WASHER 1 4 HARD BLK OX 1 8 THK 7 54 M1070P IWASHER FLAT USS STL PLAIN 4 55 1 2 73B WASHER SPLIT LOCK STL BO 1 56 1 2 70P WASHER FLAT USS STL PLAIN 1 57 22008 BEARING 204KTT 1 100911 DPMSX2 X Axis Electronic Handwheel Option Parts List Item P N
10. 78 79 52 53 54 55 56 57 58 59 60 61 62 63 inerti 65 66 E 68 69 70 72 73 76 7 178 BEN 80 82 2 99 20835 HANDWHEELASSY 101 20847 MICRO SCREW MICRO STOP NUT amp MICROMETERNUTASSY 1 12 24051 JCLOCKSPRING O TT 194 Southwestern Industries Inc DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 91 92 93 94 95 97 100699 K2 K3 195 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual i00700 K2 K3 2 K B07 FRU K3 WORM GEAR SPACER _ T e KB09 FRU K3 FEED DRIVE WORM GEAR SHAFT 8 KBi0 FRUKSWORMSHAFTKEV SEL o K B03 FRUKSFEEDBEVELPINON 100700 K2 K3 Figure 84 Worm Gear Cradle DPMSX2 P N 20779 1 196 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100701 K2 K3 Title FRU K3 CLUSTER GEAR COVER FRU K3 CLUSTER GEAR SHAFT CRANK FRU K3 SHIFT CRANK K B69 RU K3 SPRING Q 3 x 20L Item RU K3 GEAR SHIFT PLUNGER 6 K _ 7 8 K 9 K 10 7 RU K3 SHIFT KNOB 5 16 18NC 7 RU K3 ROLL PIN 3 x 20L RU K3 FEED GEAR SHIFT FORK RU K3 SHAFT 10 R
11. FRU K3 W ASHER FLAT 10 2 VS111 FRU K3 SOC HD SCREW 3 8 16NCx32L VS11 FRU K3 MOTOR PULLEY COVER F FRU K3 SCREW FLAT HD PHILIP M5 P0 8x10L 5 36 OL 100690 K2 K3 lt 1 5 6 1 0 2 3 4 7 8 9 0 2 3 4 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 180 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 1 2 3 i00691 K2 K3 Figure 76 Gear Housing DPMSX2 P N 20778 1 181 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 77 Hi Low Shift Clutch Sub Assembly DPMSX2 P N 20778 2 100692 K2 K3 182 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List High Low Shift Clutch DPMSX2 DESCRIPTION PIN DESCRIPTION FRU K3 BEARING SLIDING HOUSING 23970 FRU K3 BALL BEARING 6908 2 5 VS78 JFRU K3 BEARING SPACER 6 FRU K3 SNAP RING R 65 FRU K3 EXTERNAL TOOTH WASHER 40 i00692 K2 K3 183 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 78 Hi Low Shift DPMSX2 P N 20778 3 Hem PN DESCRIPTION Qy 2 VS amp 7 FRUKSCLUTCHGEARSHAFT 1 3 VS92 FRU K3 HE LOW PINION BLOCK
12. Item 1 Coolant Pump P N 23265 SECTION A A 100788 205 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual i00783 V3 ii a m Q lt 265 m lt lt o u m z 53 o e 2 2 E x F gt E lt S lt x ase PEERS EE ea LL 2890 d D S o o o Oo o mn 2 Ka E E Figure 93 Lubrication Drawing X amp Y Axis DPMSX3 206 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Lubrication Drawing X amp Y Axis DPMSX3 Hem PN me TAW 6 Lot JSLEEVEAMMPBAT i0 lor TEE ADAPTER 1 11 00 ose i2 1006 DSTRIBUTORDBIO 1 i3 Pssa OLLDISTRIBUTOR 8 i00783 V3 PL 207 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100662 NOTES UNLESS OTHERWISE SPECIFIED 1 ALL TUBES ARE 4mm ALLUMINUM TUBE 2 ALL TUBES ARE 4mm NYLON A PLACE ITEMS 5 6 20 19 amp 24 IN PLASTIC BAG THEN PLACE IN SADDLE Figure 94 Lubrication Drawing X amp Y Axis DPMSX5 208 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service
13. Lower Head Assembly DPMSX2 DESCRIPTION Qty K B125 2 FRU K3 HANDWHEEL HANDLE AVAILABLE ONLY IN ASSY 20835 K B113 FRU K3 HAND WHEEL CLUTCH K B117 FRU K3 ROLL PIN 3x15L F FRU K3 CAM ROD FRU K3 SOCKET SET SCREW M6 P1 0x8L FRU K3 CAP SCREW M6 P1 0x25L K B73 JFRU K3 SOCKET SET SCREW M6 P1 0x20L K B101 FRU K3 CHEM BLACKED LOCKNUT M6 P1 0 K B99 FRU K3 CLUTCH ARM COVER 20779 2 FRU SK2 SK3 QUILL FEED SELECTOR SUB ASSY 3VK B2 K B67 FRU K3 CAP SCREW M6 P1 0x18L K B29 FRU K3 CLUSTER GEAR KEY 3x3x45L K B27 FRU K3 CLUSTER GEAR SHAFT UPPER BEARING 1 1 1 FRU K3 BEVEL GEAR BEARING K B18 FRU K3 WORM GEAR CRADLE THROW OUT K B19 FRU K3 SHIFT SLEEVE F FRU K3 ROLL PIN 3x20L K B23 FRU K3 SHIFT CRANK 33 K B186 FRU K3 WORM GEAR 34 K B128 FRU K3 QUILL SKIRT FRU K3 QULLSKIRT K B189 1 FRU K3 ADJ WORM SHAFT SET SCREW M6 P1 0x6L K B42 JFRU KS BUSHING F F 3 5 7 3 0 3 5 6 7 8 9 0 1 2 4 5 6 7 8 9 0 2 2 2 2 2 2 2 2 2 2 3 EI EH 7 8 9 10 20 21 22 23 24 25 26 27 28 29 30 33 34 K B187 FRU K3 KEY 4x4x18L K B189 FRU K3 ADJ WORM SHAFT K B171 FRU K3 KEY 3x3x20L K B178 F K B178 FRU K3 CLOCK SPRING K B177 FRU K3 SPRING COVER FRU K3 SET SCREW M8 P1 25x6L FRU K3 COMPRESSION SPRING FRU K3 STEEL BALL FRUKSSTEELBALL 193 Southwestern Industries Inc
14. T3 or going into the Spindle Motor U V amp W Caution Be sure to shut off all power to the machine before attempting to switch any wires 3 5 5 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 Itis 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 taking a bigger cut then is possible on the machine Is the part moving in the vice Am using realistic speeds and feeds 56 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Any one ofthese 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 the
15. amp Parts List Manual Parts List Lubrication Drawing X amp Y Axis DPMSX5 Qty 5 22 6 PB SLEVE4MM 13 2 6 4 2 8 PAN 2 i00662 209 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 16793 ASSY 100233 Figure 95 Manual Ram Elevation 210 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 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 Factory Labor New TRAK Any EXCHANGE Unit The warranty period starts on the date ofthe 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 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
16. e Code 308 Reverse X axis Handwheel Direction e Code 309 Reverse Y axis Handwheel Direction 3 5 Problems with the Machine Tool 3 5 1 Z Axis Noisy While jogging or cutting in the Z axis direction the axis makes unusual noises See below for head noise Possible Cause Check This Machine Tool and Setup problem Check for any looseness in the setup Tool Tool holder Part Vise or Fixture See Machine Tool amp Setup Section 4 1 53 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Inadeguate or no Lubrication to the Make sure all the Way surfaces are getting proper Ballscrew and Way surfaces lubrication If not check to make sure that the lube pump is functioning properly Also check for any pinched or blocked oil lines See Lubrication Section 4 1 3 Z axis Gibs are not adjusted properly Check the adjustment of the Z axis Gibs using the Z axis Gib adjustment procedure See Z axis Gib Adjustments Section 5 2 1 Mechanical Drive Train Misalign ballscrew or top and lower bearing failure Z axis motor failure Replace Z axis motor See Motor Diagnostics Section 4 4 3 5 2 Spindle Stalls or Turns Off During Machining During machining the spindle turns off and loses power First check incoming voltage and connections Possible Cause Check This Machine Tool and Setup problem Check the type of material being cut type and size of cutting tool RPM an
17. 1 14 15980 BEARING HOUSING 1 15 20373 BEARING ANGULAR CONTACT 7204 BECBP 2 16 15885 RING BEARI NG HOUSING 1 17 15626 SEAL BEARING HOUSING 1 18 16350 FERRULE SPROCKET 1 19 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 1 20 16452 NUT CLAMP X Y 8 Z AXIS 1 21 500 5M 15 TIMING BELT 1 22 15627 1 DIAL HOLDER 1 27 10 32X3 4 25B SCREW SHCS STL BO 1 28 1 4 20X1 24B SCREW HEX HD STL BO 4 29 15759 WASHER 1 4 HARD BLK OX 1 8 THK 4 30 98481A090 KEY WOODRUFF 404 1 8 X 1 2 1 31 15836 DIAL NUT 1 32 M5 0 8X10 1024 SCREW PH PHI L STL ZI NC 2 33 21946 ELECTRONIC HANDWHEEL X amp Y AXIS 1 34 M6 1 0X75 25B SSCREW SHCS STL BO 4 35 M6 1 0X25 25B SCREW PH PHIL STL ZINC 4 36 21985 SPACER 30 DEGREE Y AXIS DRIVE ASSY 1 37 21992 1 BUSHI NG BALLSCREW 1 38 1 4 20X5 8 26B SCREW FHCS STL BO 4 39 14772 2 SPACER 020 THICK 1 40 21984 WAY COVER FRONT Y AXIS DRIVE 1 41 30922 HANDLE FOLD A WAY 1 101132 Y SX2 119 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 14 Ball Screw Replacement X Axis Table DPMSX5 1 Remove table trays from each side of the table 2 Remove bearing housing from right side of table 3 Remove the sheet metal covers from the motor mounting brackets 4 Remove the X axis motor and belt from the left side of the table 5 Remove the pulley and ferrule from the ball screw 6 Remove the motor mounting bracket 7 Loosen and r
18. 11 FLA 17 5 FLA 17 5 FLA Machine Net Weight Shipping Weight 3200 Ibs 3500 Ibs 4100 Ibs 4400 Ibs 4400 Ibs 4600 Ibs Maximum Weight of Workpiece 1320 Ibs 1320 Ibs 1760 Ibs 11 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 2 6 Maximum Work Capacities DPMSX2 DPMSX3 DPMSX5 Drilling Mild Steel 1 1 1 Tapping Mild Steel 75 1 iT Milling metal removal rate mild 2 inch2 min 5 inch3 min 5 inch3 min steel Maximum work capacities are dependent on a lot of variables that cannot be controlled by the machine manufacturer Each one of the following will have an impact on the above numbers speeds feeds cutter cutter sharpness material setup coolant and machine adjustments The numbers above assume all conditions are optimal and may be higher or lower depending on material composition 2 7 ProtoTRAK SMX Control Hardware 3 axis CNC 3 axis DRO 400 MHz PC based processor 128 MB of RAM D C Servo Motors rated at 560 in oz continuous torque for X Y and Z axes Precision ground ballscrews in the table saddle and ram to ensure smooth accurate contours without backlash Feedrate override of programmed feedrate and rapid 10 32 color LCD for clear presentation of prompts status information and part graphics Modular design simplifies service and maximizes uptime 256 MB flash drive Single floppy
19. 154 Southwestern Industries Inc 100594 K4 Figure 59 Gear Housing Sub Assembly DPMSX3 amp DPMSX5 P N 20697 1 Item P N Description Qty 1 FVS82 GEAR HOUSING 1 2 FV112 GUIDE SPRING 3 3 FV113 SPRING GUIDE PIN 3 100594 K4 155 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Item P N DESCRIPTION Qty 1 FVS75 BEARING SLIDING HOUSING 1 2 23943 BALLBAEARING 2 REQ 6910ZZ 1 SET 3 FVS78 BEARING SPACER 1 4 FVS79 BEARING SPACER 1 5 FVS80 SNAP RING R 75 1 6 FVS73 SPLINED GEAR HUB 1 7 FVS72 KEY 8x7x10L 1 8 FVS74 SPINDLE BULL GEAR 1 9 FVS114 WASHER 1 10 FVS115 EXTERNAL TOOTH WASHER 2 50 1 11 FVS81 LOCK WASHER 9 50 18NC 1 12 FVS76 RING 1 13 20818 SPACER BEARING 1 i00595 K4 Figure 60 Hi Low Slip Clutch Sub Assembly DPMSX3 amp DPMSX5 P N 20697 2 156 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual P K i00595 K Item P N DESCRIPTION Qty 1 FVS89 HI LOW DETENT PLATE FVS87 CLUTCH GEAR SHAFT FVS92 HI LOW PINION BLOCK FVS91 SPRING FVS94 HI LOW SHAFT CRANK FVS88 PIN 319L 2 3 4 5 FVS90 HI LOW DETENT PLUNGER 6 7 8 FVS93 SCREW SOC HD M5 P0 8x15L 9 FVS92 1 S
20. 2 Y on only 3 XY both on Code 11 values X 0 002 Y 0 001 Code 128 X 0 001 Y 0 0014 Z 0 0016 Code 12 000005 Y 000006 Z 000006 X 000005 Y 000005 Z 000006 Code 100 210 5 Y 208 9 Z 200 1 X22071 Y 208 4 Z 203 6 4 9 1 5 CODE 316 Update Master Software Load upgrade disk in floppy drive and press this service code New software will automatically download and control will reboot 4 9 1 6 CODE 317 Update Slave Software Load upgrade disk in floppy drive and press this service code New software will automatically download 4 9 1 7 CODE 318 Activate Converters or Options See programming and operating manual To turn software features on and off see Service Code 334 in Section 4 9 4 6 of this service manual 4 9 2 Machine Set Up Codes The following codes are used primarily when setting up a new machine To get to any of these codes go to Service Codes press B and press the code you wish to view 4 9 2 1 CODE 11 Hysteresis Note This code is use only for systems with Sensors or Glass Scales on the table and saddle The Code 11 service routine checks the readings of the motor encoder against the sensor encoder It is a measurement of how much motor motion is necessary to create table or saddle motion This test helps us to look at two things e Play How much backlash must be taken up when motion is reversed e Friction How much the mechanical components must be torqued up in orde
21. 220V only 440V 20 440V 20676 676 2 24999 24999 24999 24999 Cable Breakout Box 3 24999 1 24999 1 24999 1 24999 1 Cable Breakout Box with AUX Functions 2 8 Lifting and or Moving the Machine CAUTI ON The DPMSX2 SX3 amp SX5 machines weigh approximately 3200 4100 and 4400 lbs respectively Proper equipment of sufficient capacity must be used when lifting and or moving the machine Method 1 see Figure 5 l Insert a steel bar 1 0 dia x 36 long through the rear side holes of the bed under column 2 Use a steel cable with protective sleeving min 3 4 dia or a 3 ton sling 3 Use cardboard pieces or other suitable protective sheets on both sides of the machine to prevent scratching 4 Remove the 4 nuts and screws holding the machine to the wood skid 5 Lift the machine the front side of the machine should be lower than the back side 6 Insert the 6 screws for leveling pads in their place in the bed 4 screws for DPMSX2 7 Place the machine in its location see floor plan and bed footprint drawing carefully positioning each leveling pad under each leveling screw 8 Remove the lifting cable or sling the steel bar and all protective cardboard 15 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List STEEL CABLE 3 4 DIA OR 3 TON SLING 6 THREADED HOLES FOR 100879 LEVELING PADS Figure 5 Lifting the M
22. 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 85 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual WIRE HARNESS SERVO AMPLIFIER GREEN GROUND WIRE OVER CORD A PLATE LOOP unplug here 100015 using loop Figure 22 Servo Driver Replacement Part Description 20327 2 X Y or Z Servo Driver 5 1 3 Computer Module and LCD Enclosure Replacement 8 9 Turn power off to the machine and control Unplug all the connectors on the pendant arm side of the pendant Remove the pendant from the pendant arm by removing the 4 34 20 x 3 4 SCHS that secure it in place Place the pendant assembly on a clean and secured table with the display pointing away from you Remove the 6 10 32 x 3 8 Pan Phillips Head Screws and 4 10 32 x 3 8 FHCS securing the computer module to the LCD enclosure 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 37 pin LCD cable 37 pin distribution cable a
23. 335 Toggles spindle on off during pause events 4 9 4 8 Code 336 Enables spindle to stay on throughout all modes 2 axis mills ONLY 83 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 84 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 5 0 Procedures for Replacements amp Maintenance 5 1 Replacements 5 1 1 Servo Motor Replacement WARNI NG Do not work with the Servo Motors unless the power is disconnected from the machine The servomotors are run by 110 VAC There is possibility of death by electrocution l Turn off power to the machine 2 Each motor is mounted by the use of 4 14 20 screws Be careful not to over tighten these bolts and strip the threads 5 1 2 Servo Driver Replacement WARNI NG Do not work with the Servo Drivers unless the power is disconnected from the machine The servo drivers are run by 110 VAC There is possibility of death by electrocution The Servo Driver for each axis is integrated into the servo motor casting DANGER Always engage push in the Emergency Stop switch turn the ProtoTRAK SM Control off and disconnect the servo motor driver cable at the cable breakout box l Press in the Emergency Stop 2 Remove the servo motor driver assembly from its mounting bracket the Y axis assembly is located inside the front of the bed
24. 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 Note If your part has incorrect dimensions see Parts Have Incorrect Dimensions Section 3 1 4 Note First check for repeatability of the DRO With a dial indicator mounted to the bottom of the spindle touch off a fixed surface either in the X Y or Z axis direction and set the DRO equal to 0 Crank away several inches and touch off again at the same place If the reading has not returned to 0 on the DRO zero the display and repeat the procedure If the measurement does not repeat you have a repeatability problem that must be resolved before the accuracy problem can be resolved See Measurements That Do Not Repeat Section 3 4 1 Possible Cause Do This The Calibration is incorrect Recalibrate the machine See 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 3 4 3 The DRO is not Counting The DRO for one axis is not counting when an axis is moved Often times if this is the case the axis will fault See Faulting Axis Section 4 7 1 Do the following Service Codes e Code 33 Software Identification This is needed if you call SWI Customer Service
25. Description Use As Qty 57 22718 SPACER 45 DEGREES X AXIS EA 1 58 21992 BUSHING BALL SCREW EA 1 59 14772 SPACER 100 THICK EA 1 60 M6 1 0X75 25B SCREW SHCS STL BO EA 4 61 21946 ELECTRONIC HANDWHEEL EA 1 DPMSX2 SX3 8 SX5 Safety Installation Maintenance Service amp Parts List Manual 107 Southwestern Industries Inc 5 1 10 Ball Screw Replacement Y Axis Saddle DPMSX2 CAUTI ON Never screw a ball screw partially or totally out of its nut They cannot be reassembled 10 Position the saddle all the way forward Remove the hand wheel assembly and bracket Remove the sheet metal covers on the front of the machine bed and on the motor mounting bracket Remove the motor then remove the motor mounting bracket Remove the rest of the parts on the ball screw journal Note the orientation of the bearings for reassembly Remove the 5 16 x 1 inch screw that attaches the ball nut to the yoke Remove the ball screw and oil line attached to the elbow fitting on the ball nut Remove the elbow and setscrew from the old ball screw flange and fit them similarly in the new ball screw Pump oil to be certain it flows through the oil line and then attach the oil line to the elbow 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 t
26. F860 FEDSHFTROD 1 100604 K4 Figure 68 Quill Feed Selector Sub Assembly DPMSX3 amp DPMSX5 P N 20698 2 169 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual xa G s Ke gt s INNFAS KA 2 iem PN BESCRPTON QW 6 K B94 FRU K3 SNAP RING 95 DOWEL PIN 14 K B168 FRU K3 SCREW PIN 8 K B90 FRU K3 QUILL PINION SHAFT BUSHING LEFT i00605 K4 Figure 69 Quill Pinion Shaft Sub Assembly DPMSX3 amp DPMSX5 P N 20698 3 170 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100606 K4 tem PN Title 4 FB79 SAFETY CLUTCH SPRING 7 5 FB 8 OVERLOADCLUTCHLOCKNUT 1 6 FB 6 SOCKETSETSCREWMe amp PIOGL T alala Q9 lt 7 FB CLUTCHRING 8 FB97 OVERLOADGLUTGHWASHER 1 9 FB98 SNAP RING 10 10 FB96 OVERLOAD CLUTCH TRIP LEVER 1 11 FB74 CLUTCHRING PIN 2 i2 rer RassPluG 1 100606 K4 Pym oye Figure 70 Overload Clutch Trip Sub Assembly DPMSX3 amp DPMSX5 P N 20698 4 171 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 13 Na e 100607 K4 hem PN we e FB4 FEED REVERSE BEVEL GEAR 8 se Kyss O o FB50 FEEDREVERSECLUT
27. Installation procedures Check for any loose brackets or misalignment etc Also check to make sure the Sensor or Glass Scale assemblies are functioning correctly Use service codes 304 for X and 305 for Y to turn off the suspect encoder Does problem still exist after turning it off 51 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 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 4 2 Encoder Disk or Reader Head on motor Swap the motor in guestion with a known good motor are loose For example swap the X axis motor with the Y axis motor If the symptom stays with the motor in question then replace the motor If not then the motor is not at fault and something else is causing the problem Spindle and or Quill are loose Use a Dial Indicator and check for side to side movement between the Spindle and the Head Next check for side to side movement between the Quill and the Head There should be no more than 0 0003 of side to side movement Make sure that there is a few thousandths gap between the Spindle Collar and the Quill after tightening Head bolts are loose Tighten Ram bolts 3
28. Is the cutter dull Is the tool loose in the holder Am I taking a bigger cut then is possible on the machine Is the part moving in the vice Am I using realistic speeds and feeds Any one of these can have a significant impact Upper spindle bearing is worn out Remove the upper bearing plate above the spindle This will unload the bearing If the noise goes away then this bearing should be replaced Verify nosepiece is tight on bottom To check if the nosepiece is bottomed out try to insert a of spindle piece of paper in between the nosepiece and the quill If a piece of paper does fit then this may be the problem Before tightening or loosening the nosepiece make sure to loosen the setscrew that holds it in place Spindle bearings are worn out This is categorized by a high pitch sound and is most evident at high RPM s It should also cause chatter under load Replace the spindle if this is the case See spindle replacement in Section 5 The belt is not lined up with the Make sure the 10 ribs on the belt are lined up with the 10 grooves on the pulleys grooves on the 2 pulleys If the belt is frayed then replace the belt 57 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 58 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 4 0 Diagnostics This section
29. Manual i01132 X SX5 123 Southwestern Industries Inc ES pon 1 MUS BOX ERLA YY G Figure 40 X Handwheel Drive Mechanism mempen Desipion uo 6 30 0 CVERXAXSHANDWHELBOX 8 23078 COVER EXTENSION BALLSCREW X AXIS HANDWHEEL ASSY I Ls gr Bening per 0 002 BANNG O f 11 0331 GEAR HARDENED STEEL SPIRAL MITERLET 1 12 230334 GEAR HARDENEDSTEELSPIRALMITER NGHT i 3 uei kewaa 2 14 U420K 2408 SCREW SOCSET STLEO UP fe 15 1 42013 4258 SCREW SHCSSTLEO 8 124 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 16 Ball Screw Replacement Y Axis Saddle DPMSX5 1 Remove the sheet metal from the front of the machine and from the motor mounting bracket 2 Move the saddle toward the front of the machine and remove the electronic hand wheel 3 Remove the Y axis motor and belt 4 Remove the pulley and ferrule from the ball screw 5 Remove the motor mounting bracket 6 Loosen and remove the clamp nut Loosen the setscrew on the clamp nut before loosening the clamp nut 7 Remove the bearing housing Note which way the bearings are in the bearing housing 8 Remove the oil line and the 4 screws holding the ball nut to the yoke 9 Pull the ball screw out Reassemble 10 Install Y ball
30. 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 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 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
31. See X Y and Z axis Gib Adjustments Section 5 2 1 Excessive friction in the slideways See Machine Tool amp Setup Section 4 1 Incoming electrical power Incoming voltage See Electrical Section 4 8 Measurement system not functioning See Section 4 6 or 4 7 properly Binding or looseness in the Drive Train See Mechanical Drive Train X Y Section 4 2 Servo Drive failure See Servo Driver Section 4 5 Motor failure See Motor diagnostics Section 4 4 Computer Pendant failure See Computer Pendant diagnostics Section 4 3 3 3 5 Problems Reading the Floppy Disk Programs Not Saved Properly The floppy drive will not read or write programs from a disk Possible Cause Check This Improper Boot up Shut down the system and wait 10 seconds before rebooting Floppy Disk failure The Floppy Disk may be bad See if the Floppy Disk can be read by a Personal Computer Does the green light on the floppy drive come on when you access the disk If so power is getting to the floppy drive If not check connections of floppy drive inside the computer module See Computer Pendant Section 4 3 for more information Floppy Disk full Put the Floppy Disk into a Personal Computer to see how many bytes remain A floppy can typically hold 1 4 MB of information 47 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 3 3 6 System Will Not Turn On or Boot Up Nothing happens
32. TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 39 40 41 42 43 44 45 46 47 48 49 50 VS109 FRU K3 DRAWBAR 7 16 20UNF VS109 1 FRU K3 SPACER FRU K3 BLACK PLASTIC BALL HANDLES K B190 FRU K3 PINION SHAFT HUB HANDLE FRU K3 QUILL LOCK SLEEVE ASSY FRU K3 COMPRESSION SPRING 20836 SPINDLE ASSY KB 201 FRU K3 INDICATOR ROD SCREW 20845 FRU K3 LOCK HANDLE ASSY K B164 FRU K3 QUILL STOP MICRO SCREW K B160 FRU K3 SNAP RING 016 K B124 2 FRU K3 FEED TRIP PLUNGER NUT M40 P0 7 K B124 1 FRU K3 FEED TRIP PLUNGER SOC SET SCREW M4 P0 7x20L K B145 FRU K3 FEED TRIP LEVER K B124 FRU K3 FEED TRIP PLUNGER FRU K3 MICROMETER NUT K B123 FRU K3 TRIP PLUNGER BUSHING K B184 FRU K3 FEED REVERSE TRIP PLUNGER K B121 FRU K3 TRIP PLUNGER K B120 FRU K3 COMPRESSION SPRING F KB 202 FRU K3 INDICATOR ROD K B158 FRU K3 CHEM BLACKED RD HD SCREWS 2 REG M5 P0 8x8L K B118 FRU K3 CAM ROD SLEEVE ASSY K B159 FRU K3 MICROMETER SCALE FRU K3 SCREW SOC HD 3 8 24NFx15L FRU K3 QUILL STOP KNOB 82 85 88 1 FRU K3 COMPRESSION SPRING 1 86 K B89 FRU K3 OVERLOAD CLUTCH LEVER SPRING PLUNGER 1 87 20779 3 FRU SK2 SK3 QUILL PINION SUB ASSY SVK B3 1 88 K B167 FRUXS KEY5xxobL tr 89 K B27 1 FRU K3 SET SCREW M6 P1 0x8L 1 1 K B104 FRU K3 TRIP HANDLE 51 52 53 54 55 56 57 58 59 61 62 63 64 65 67 70 71 72 73 74 75 76 77
33. Use the Up and Down arrow 55 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual keys to choose between Lo Local Run Spindle Motor from Spindle Drive or rE Remote Run Spindle Motor from the Pendant Spindle Motor is faulty Check the resistance of the spindle motor windings on the spindle motor between L1 U and L2 V L2 V and L3 W then L1 U and L3 W using a digital ohmmeter If the ohmmeter reads more than one 1 ohm difference or OL infinite between any pair replace the motor The next check is for resistance to ground using a digital ohmmeter Check L1 U to ground L2 V to ground and L3 W to ground The meter reading in the display window should be OL infinite with reference to ground Any other reading indicates a problem and the motor should be replaced Spindle Drive contains incorrect Contact customer service parameters and is not programmed correctly Drive Spindle Control Board Board is lit 3 5 4 Spindle Runs Backwards The spindle motor runs in the opposite direction The spindle will run in opposite directions from high to low gear Possible Cause Check This 3 Phase wires backwards Need to switch any 2 of the 3 wires either coming into the machine or motor Note For machine fitted with the optional Spindle Control switch any 2 of the 3 wires either coming out of the AC Drive T1 T2 amp
34. amp Parts List Manual DI S Discharge this button programs the amount of time the pump will discharge each pumping cycle Each press of the button increases the discharge time by one minute FEED this button is used to manually feed the ways and ballscrews RST this button tells the pump to discharge for the time programmed Factory Default Values Interval Time 60 min Discharge Time 15 sec Discharge Pressure Approximately 100 150psi To adjust the amount of Discharge Pressure displayed on the lube pump gauge loosen the jam nut and turn the adjustment screw located on the top right side of the lube pump while the lube pump is activated At the beginning of each day check the oil level in the Auto Lube 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 or allowing the Auto Lube to run dry may cause severe damage to the TRAK DPMSX2 DPMSX3 and DPMSX5 way surfaces and ballscrews 2 16 2 Head Lubrication TRAK Bed Mills Once Each Week l Fill the oil cup on the front of the head with SAE 30 or 30 W oil This oil lubricates the Hi Lo range shifter 2 Fill the ball oiler located in the front lower right corner of the speed changer housing This oil lubricates the speed changer shaft 3 Extend the quill fully and apply a coating of SAE 30 or 30W oil to the outside diameter of the quill Every Four Months Appl
35. and repeatability on the X and Y axis using programs XREPEAT PT4 and YREPEAT PT4 respectively Positioning and repeatability values should be less than or to 0 0005 Programs can be found on flash drive under the PT4 folder followed by the SWI TEST PROGRAMS folder 24 Perform Service Code 123 and press Z to calibrate the Z axis ram using a 75mm standard 25 Perform Service Code 127 and 128 to manually calculate the backlash for the Z axis ram 26 Check for positional accuracy and repeatability on the Z axis using program ZREPEAT PT4 Positioning and repeatability values should be less than or to 0 0005 27 Perform Service Code 123 and press QUILL softkey to calibrate the Z axis quill using a 75mm standard 28 Perform Service Code 100 in both directions for the X Y and Z axis to verify that the feed 10 Southwestern Industries Inc DPMSX2 SX3 8 SX5 Safety Installation Maintenance Service 8 Parts List rate shown on the display is at least 180 ipm 29 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 30 Install the Z axis upper way cover Install the Z axis lower way cover and its bracket 31 Install the Y axis front and rear way covers If machine has an auxiliary function option then use accessory key on pendant and make sure the coolant pump or solenoid for the mister fires The accessory key s
36. at 150ipm to each side and verify that the limit switch is working properly Also make sure that the table does not exceed its travel and crash 5 2 4 2 Y amp Z Axis Limit Switch Stops The limit switch stops for the Y axis are mounted on the side of the bed The limit switch is triggered by hitting the cam stop on the saddle The cam is placed to ensure maximum travel The limit switch stops for the Z axis are mounted on the side of the column The limit switch is triggered by hitting the trip lever After contact is made with the limit switch lift the trip lever and jog the head up or down to move the machine away from the limit The trip levers are placed to ensure maximum travel 151 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 152 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 6 0 Figures and Parts Lists Figure 58 Top Housing Assembly DPMSX3 amp DPMSX5 100593 4 153 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Top Housing Assembly Item P N DESCRIPTION Qty 1 20697 1 FRU SK4 GEAR HOUSING SUB ASSY 4VK A1 1 2 20697 2 FRU SK4 HI LOW SHIFT C
37. gib lock screw adjustment reguired and tighten the gib lock screw on the front of the saddle Tighten the gib lock screw on the back end of the saddle to lock the gib in place and recheck Repeat as necessary e To adjust the gib for too small of a clearance Loosen the gib lock screw on the front of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the back of 141 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 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 5 2 1 4 Saddle Bottom Gib Adjustment Y Axis DPMSX2 amp DPSX3 only See Figure 53 Clean all chips dirt and excess oil from the table and saddle Center the saddle on the bed ways Move the table fully to the left side of the saddle Attach a 0001 dial indicator with a magnetic base to the left front of the saddle Place the indicator stylus on the top surface of the box way i We KOE 5 Lift the end of the table up and note the amount of movement on the dial indicator Adjust the Y axis left bottom gib until the registered movement is 0010 0015 6 Move the table fully to the right 7 Reposition the indicator to the right front of the saddle 8 Lift the right end of the table up and note th
38. infinite between any pair replace the motor The next check is for resistance to ground using a digital ohmmeter Check L1 U to ground L2 V to ground and L3 W to ground The meter reading in the display window should be OL infinite with reference to ground Any other reading indicates a problem and the motor should be replaced Spindle will not run because 110 V Check 110 V coming out of the AC e stop port on the power is not reaching the spindle cable breakout box Relay failure in cable breakout contactor box Replace cable breakout box 3 5 3 1 Spindle Motor Hums or Will Not Run for Machine with the Optional Spindle Control Drive The spindle motor makes a constant humming noise during operation or will not turn on Note machines can only be wired for 220 volts 440 volts will ruin electrical components in the machine These components will not be covered under warranty Wrong voltage Check the voltage to the machine before and after the Ho MER Spindle Drive with a Voltmeter Also check the voltage to the Spindle Drive L1 L2 and L3 and Spindle Motor See Electrical Connection I mproper wiring jumper configuration Check to make sure that the Spindle Motor has the on the Spindle Motor correct wiring jumper configuration for 220VAC See Electrical wiring section EN Drive may be in Local Mode On the Spindle Drive push the DSPL button until can not be run from the Pendant LO RE lights up
39. limit switch connections 3 encoder connections and an E stop connection Machines with an auxiliary function option have 2 more outlets A 110 V outlet for a coolant pump or air solenoid and an indexer outlet The coolant pump signal and indexer signal comes down from umbilical 2 4 8 4 Cable Connections The DPMSX machines use 10 cables to communicate between systems It is often the case that what appears to be the failure of an electrical component is actually attributable to a poor connection Indications e Control problems chronic or intermittent e Motor problems e Measurement problems Explanation 1 Turn off and unplug the system from the wall WARNI NG Do not plug and unplug connectors with the system power on This may cause damage to the connector board and harm to the technician 2 Visually inspect the connections for excessive debris moisture or obvious damage 3 Carefully clean any chips away from the connectors 4 One by one take out each connector and then plug them back in Do the same at the computer display 5 Make sure to tighten up the screws on each of the connectors 71 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List A LEY D Im L1 L2 L3 L1 12 L3 R JR JR EE NE T1 72 13 M T2 73 L3 R F 5 gt Q f ae ANG I Figure 19 Electrical Box Schematic Non Spindle Control P N
40. of the Z axis ball screw until the chain between the ram and the counterweight is tight DPMSX3 amp SX5 Lower the head slowly with the ram crank until the chain between the ram and counterweight is tight 3 Lower a little further until the 2 support steel rods are loose Remove the 2 steel rods and store them for future machine moves or transportation 4 Do not continue to move the ram until all ways have been cleaned CAUTI ON Do not remove the steel rods unless they are loose 2 10 Cleaning 1 Remove rust protective coating from the machine before moving any slideways table saddle ram etc 2 The coating is best removed with clean dry rags Do not use a cleaning solution that may damage the rubber way scrapers plastic parts or paint WARNI NG Do not use gasoline or other flammable cleaning agents for cleaning the machine 3 It may be 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 on the ram on the right side of the column before attempting to move the above parts CAUTI ON Never move any of the above parts over ways that were not previously cleaned Serious damage to the TURCITE surface of slideways can occur 4 Be certain the table saddle ram and spindle move freely and smoothly over their entire length 18 Southwestern Industries In
41. on the pendant arm to help align the pendant with the mounting holes CAUTI ON The locating screw in the arm is used for positioning Keep a hold of the pendant until the screws are fastened If the pendant arm rotates too freely remove the painted cap on the bracket attached to the column and tighten the hex nut to adjust it Replace the cap 2 15 Cable I nterconnections All cable interconnections are made at the factory except for those connecting to the pendant display There are a total of 4 cables that need to be connected to the pendant See Section 6 for a complete illustration of cable interconnections for all components There are 2 additional cables for the electronic handwheel option and 2 more cables for the spindle control option digital I O and spindle control parts With the main power to the machine turned off plug in the connectors that are bundled on the pendant arm Each cable mates to only one connector on the pendant display back panel Use the label on the pendant to match the connectors with the correct port The machine ID port and option key port LPT1 will have keys plugged into them The handwheel spindle control and network ports will be left empty during installation Make sure there is sufficient slack in the cables for the pendant to rotate about the pendant arm The worst case is when the pendant is all the way forward toward the operator The following drawing describes all of the cable connections
42. open safeguards protective shields etc Never reach for the part tool or fixture around a safeguard 11 Protect your eyes and the machine as well Don t use compressed air to remove the chips or clean the machine 12 Disconnect power to the machine before you change belts pulley and gears 13 Keep work areas well lighted Ask for additional light if needed 14 Do not lean on the machine while it is running 15 Prevent slippage Keep the work area dry and clean Remove the chips oil coolant and obstacles of any kind around the machine 16 Avoid getting pinched in places where the table saddle or spindle head create pinch points while in motion 17 Securely clamp and properly locate the workpiece in the vise on the table or in the fixture Use stop blocks to prevent objects from flying loose Use proper holding clamping attachments and position them clear of the tool path 4 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 18 19 20 21 22 23 24 25 26 27 28 29 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 FO
43. screw to yoke and install oil line to ball nut 11 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 Slide spacer onto ball screw Slide top bearing onto ball screw and seat with clamp nut Slide top bearing onto ball screw and seat with clamp nut Be sure to clamp nut to at least 50 ft lbs Don t forget to tighten setscrew after clamp nut is tight 12 Install motor mounting bracket woodruff key ferrule pulley star washer and nut Before tightening down the motor mounting bracket move the saddle to the front of the machine 13 Assemble motor to bracket The servo should be facing the right of the machine 14 Install belt Tighten lower 2 bolts followed by the top 2 bolts to properly tension belt 15 Install electronic hand wheel 16 Install all sheet metal See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw See Figure 41 for an illustration of the Y axis drive train 125 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 41 DPMSX5 Y Axis Drive Assembly 126 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 101132 Y SX5 DPMSX5 Y Axis Drive Assembly Parts List
44. that can cause misalignment the yoke the left side bearing housing bracket and the right side bearing housing Yoke the yoke is aligned at the factory and pinned in place It is aligned to within 0 0005 with a precise alignment tool The yoke most likely is not causing the problem If this were the problem you would need to remove the pins and align the X ball screw with the back of the saddle Drill new holes and pin the yoke in place The Y axis ball screw bore is machined perpendicular to the X bore If the X axis is aligned the Y axis will also be aligned 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 Right side table bearing housing once again move the bearing housing as close to the yoke as possible Loosen the bearing housing and retighten This should allow the bracket to align itself If you do not move the table toward the yoke the ball screw will tend to bend down slightly and cause misalignment Y axis the only component that can cause a misalignment problem is the motor mounting bracket To align this bracket move the saddle as far to the front of the machine as possible Loosen the bracket and then retighten it Once again moving the saddle forward allows the
45. the gib lock screw on the top of the ram Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the bottom of the ram Tighten the gib lock screw on the top of the ram to lock the gib in place and recheck Repeat as necessary 4 Run Service Code 12 to set the feed forward constant 5 Reattach the upper and lower way cover to the ram CAUTI ON Be careful not to over tighten the ram gibs Over tightening may lead to faulting and repeatability problems Double check the gib adjustment by checking the torque on the Z axis Use an in Ib torque wrench on top of the ball screw and typical readings should be from 12 to 17 in Ibs and consistent across the Z travel i00159 Figure 55 Ram Side Gib Adjustment 5 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 146 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 2 2 1 X Y Z Ram and Quill Calibration Calibration is used teach the machine a known distance We typically calibrate our machines over a 150 mm distance There is no limit to how far you can calibrate the machine 1 2 Set up a gauge block or standard and indicate it
46. to the pendant Make sure that an option key is plugged into the option key port of the pendant This key activates any converters or options ordered The part for this key is 22648 7 The key must be programmed according to the type of machine it is on and the options ordered The Machine ID port must have a key or the machine may not run Note Spindle Control machines use a different machine ID key then non spindle control machines CAUTI ON Make sure the main power is turned off on the back of the electrical cabinet before plugging in the cables 30 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 101115 Figure 14 Pendant Cable Connections Left Side P N 24000 1 31 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual FAN FLOPPY DRIVE USB PORTS BEEPER RSG 1 AMP FUSE 12 AMP FUSE AC ON OFF wives Figure 15 Pendant Right Side P N 24000 1 32 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Z AXIS LIMIT SWITCHES 3RD AXIS SECONDARY FEEDBACK OPTION X Y 2 R Y MOTOR COOLANT PUMP 4 _ MISTER 74 AC TO PENDANT Vi BREAKOUT BOX SHOWN WITH AUX FUNCTIONS Figure 16 Cable Connection Diagram Non Spindle Control
47. will break when the machine is traversed past the scale travel 1 2 Mount the scale to the back of the table or Y axis mounting spar Align the sale so that it is within 0 005 end to end Notes For the Y axis the mounting spar should already be aligned It must be parallel to the Y axis travel within 005 end to end both horizontally and vertically The mounting spar can be aligned in and out by the use of the adjustment screw 3 Line the reader head up with the mounting holes on the back of the saddle for the X axis or the bracket on the Y axis Install the reader head bolts but leave them loose Use the jackscrews on the reader head to compensate for some gap between the reader head and the reader head mounting bracket Leave the alignment brackets attached to the reader head This bracket assures the reader head is aligned to the glass scale Tighten each jackscrew until it touches the bracket and then back it off 0 001 or 0 002 Use a feeler gage to set the gap Tightening the reader head mounting screws This ensures the reader head is aligned within a few thousandths Remove the shipping bracket that fixes the reader head to the scale for shipping WARNI NG After the reader head is attached to the reader head mounting bracket do not move the machine axis until the shipping bracket is removed This will break the reader head This is not covered under warranty See Figure 31 and 32 fo
48. yoke to be as close to the bearing housing as possible 4 2 2 DPMSX5 Ballscrew Alignment e X axis there are 3 components that can cause misalignment the yoke the left side bearing housing bracket and the right side bearing housing This machine has 2 separate yokes for the X and Y axis The yoke is bolted to the table on the X axis e X Axis Yoke the yoke is aligned at the factory If you suspect the yoke is misaligned the bolts for the yoke can be accessed from an opening on the bottom left side of the saddle Break these bolts free and move the table back and forth along its travel and then retighten the bolts 63 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List e Left side table bearing housing To align the bracket move the yoke table left as close to the bracket as possible Loosen the bracket bolts and then retighten This should allow the bearing housing to align itself up with the yoke e Right side table bearing housing once again move the yoke as close to the bearing housing as possible table right Loosen the bearing housing and retighten This should allow the bracket to align itself If you do not move the table toward the yoke the ball screw will tend to bend down slightly and cause misalignment Make sure the mechanical handwheel is not causing the misalignment e Y axis the only component that can cause a misalignment problem is the motor m
49. 0 otherwise start over 148 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual e Whatever number appears on the screen is the backlash value e Enter this value into service code 128 e After entering this number redo the process The DRO and indicator should now both read 0 CODE 128 Input Backlash Constant Code 128 allows you to enter the backlash values for each axis It displays the value after it enters This code is only used on machines with motor encoders only 5 2 3 Head Rotational and Tramming The TRAK Bed Mills head is free to rotate up to 90 degrees to the right or left 5 2 3 1 To Rotate the Head 1 Loosen the four locknuts 2 Rotate the head with the adjusting worm shaft 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 5 2 3 2 Tramming the Head The purpose of tramming the head is make sure the head is perpendicular to the top of the table from both side to side and back to front Side to side tolerance 0 001 Side to Side Alignment 1 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 t
50. 0 Schematic Diagram of Spindle Control Option 21 LED s on Spindle Control Board 22 Servo Driver Replacement 23 Computer Module amp LCD Enclosure Replacement 24 Flash Disk Replacement 25 M5 Base Mounting 26 TRAK Sensor Mounting 27 DPMSX2 Sensor Assembly 28 DPMSX3 Sensor Assembly 29 DPMSX5 Sensor Assembly 30 Z Glass Scale Assembly 31 Glass Scale Alignment DPMSX3 32 Glass Scale Alignment DPMSX5 33 Power Drawbar Assembly 34 DPMSX2 X Axis Drive Assembly 35 DPMSX2 3 Y Axis Drive Train 36 DPMSX2 Z Axis Drive Train 37 DPMSX3 X Axis Drive Assembly 38 DPMSX3 Y Axis Drive Assembly 39 DPMSX5 X Axis Drive Assembly 40 X Handwheel Drive Mechanism 41 DPMSX5 Y Axis Drive Assembly 42 Z Axis Drive Assembly 43 Spindle Motor Wiring 44 Feed Trip Adjustment 45 Quill Clock Spring Replacement amp Adjustment 46 Spindle Motor Removal amp Replacement 47 Drive Belt Replacement 48 Spindle Replacement 49 Table Gib Adjustment 50 Table Gib Screw 51 DPMSX5 Table Gib amp Saddle Bottom Gib Adjustment 52 Saddle Side Gib Adjustment 53 Saddle Bottom Gib Adjustment DPMSX3 Only O 100 101 103 106 109 112 115 118 122 124 126 129 132 132 133 134 136 137 138 139 140 141 143 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig
51. 12 2 13 2 14 2 15 2 16 2 17 3 0 3 1 3 2 3 3 Safety Safety Publications Danger Warning Caution Note Labels amp Notices as Used in this Manual Safety Precautions Installation Floor Plan Layout 8 Space Reguirements Uncrating Shortages Inventory Checklist Installation Instructions 8 Checklist Machine Specifications Maximum Work Capacities ProtoTRAK SMX Control Hardware Lifting and or Moving the Machine Releasing the Head Counterweight Supports Cleaning Leveling Tolerance for DPMS is 0005 10 Electrical Connection 2 12 1 Phase Converters 2 12 2 Flange Transformer Air Connection Optional Mounting the Display Pendant Cable Interconnections Lubrication 2 16 1 Way Lubrication 2 16 2 Head Lubrication TRAK Bed Mills ProtoTRAK SMX Euclid Block Procedure Troubleshooting by Symptom Problems Relating to Machining Results 3 1 1 Poor Finish 3 1 2 Circes Out of Round 3 1 3 Taper Cut on a Programmed Straight Line Move 3 1 4 Parts Have Incorrect Dimensions Problems Regarding Motion of Machine 3 2 1 Away Axis 3 2 2 Slow Down Axis 3 2 3 Axis Will Not Jog 3 2 4 Axis Motor Motion Is Not Smooth 3 2 5 Vibration in Motion 3 2 6 Searching Axis Problems Relating to Operation of Control 3 3 1 Display Blanks 3 3 2 Bad Picture on Display 3 3 3 Keyboard Lockup 3 3 4 Fault X Yor Z 3 3 5 Problems Reading Floppy Disk 3 3 6 System Will Not Turn on or Boot Up 3 3 7 System Reboots by Itself 3 3 8
52. 12 Feed Forward Constant High feed forward constants will cause an unstable servo system e Code 127 Measure s the backlash in the system Only used on machines with Single Feedback e Code 128 Enter backlash compensation e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting Possible Cause Check This Check the adjustment of the X Y and Z axis Gibs using properly the X Y and Z axis Gib adjustment procedures TRAK Sensor or Glass Scale problem Make sure that the Sensor or Glass Scale is installed correctly according to the Sensor or Glass Scale Installation procedures Check for any loose brackets or misalignment etc Also check to make sure the Sensor or Glass Scale assemblies are functioning correctly See TRAK Sensors or Glass Scales Section 4 6 amp 4 7 Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants section Binding in the Drive Train Check Repeatability using the Repeatability and Positional Accuracy procedure Check the torque reading of the Drive Train Step by step carefully inspect the Drive Train for any binding It may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 4 2 3 2 5 Vibration in Motion While axis is moving there is vibration or noise coming from the X or Y axis
53. 2 Enclosure Assembly SX3 and SX5 23050 Cable Breakout Box 22555 15 Cable Assy Logic 22555 15 Cable Assy Logic 22556 15 Cable Assy Parallel 22556 15 Cable Assy Parallel 22608 Power Cord W W O O1 B CO IN IN 20267 Cable Assy AC to Computer 2 16 101113 Lubrication 2 16 1 Way Lubrication DPMSX2 DPMSX3 amp DPMSX5 The auto lube system provides centralized automatic lubrication for the Ways and ballscrews The lube pumps 2 liter reservoir is serviced with Mobil Vactra Oil No 2 or equivalent The pump is factory set to pump oil for 15 seconds for every 60 minutes of spindle time There is an internal memory on the pump so that the pump will not reset every time the spindle is turned off The pumping output can be regulated electronically to control the pause time between pumping cycles and the duration of the pumping cycle The following describes the buttons used to program the lube pump In order to modify any of the settings the spindle must be on The pump has an alarm that will sound if any of the following problems arise Oil line breakage Oil filter blockage Bad motor Low oil pressure No oil in tank INT Interval this button programs the interval between pumping cycles Each press of the button increases the interval by one minute 35 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service
54. 20676 4 8 5 Spindle Control Electrical Box The spindle control electrical box is made up of the following main components 1 AC drive used to control the spindle motor 2 4 output 110 volt outlets 1 outlet is used to power the pendant 1 is used to power the lube pump and is turned on based on the spindle being on 2 additional outlets 72 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 2 braking resistors used to brake the spindle motor The mechanical brake should not be used to brake the spindle To verify the resistors are good measure the resistance across B1 and B2 of the AC drive For 3 HP machines it should read 60 ohms and for 5 HP machines it should read 32 ohms Values lower or higher than this could be one or both resistors are bad relay used to turn on and off the lube pump and spindle motor fan Spindle control PCB board controls the auxiliary signals from the pendant to the AC drive and electrical outlets The following explains the LED lights on the spindle control board There are 2 10 LED segments on the board Not all of the LEDs are used See figure 21 for an illustration 1 10 LED Segment LED labeled Gear 1 this light should be on whenever the machine is in low gear LEDs labeled Gear 2 thru Gear 4 are not used LED labeled SPD FAULT this light will be on whenever the AC drive is in a fault condition which includes an E stop me
55. 52 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting e Code 304 8 305 Turns off X and Y sensor or scale Possible Cause Check This Servo driver failure See Servo driver Section 4 5 Motor Encoder not counting See Motor diagnostics not applicable with Glass Scale option Glass Scale or Sensor Failure Does axis now count If so replace scale Computer Pendant failure See Computer Pendant diagnostics 3 4 4 X Y and Z Axis DRO Counting in Wrong Direction The DRO is counting in the wrong direction The positive directions for each axis are e X axis Table moves to the left e Y axis Saddle moves toward the front of the machine e Z axis Ram moves up Do the following service code and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 313 Check the line that specifies the product If the product does not match the machine then the machine ID key will need to be replaced 3 4 5 X Y amp Z Axis Electric Handwheels Turn in Wrong Direction The Electric Handwheels turn in the wrong direction The positive directions for each Electric Handwheel are e X axis Electric Handwheel turns clockwise e Y axis Electric Handwheel turns counterclockwise Do the following service code and procedures
56. 6 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 2 0 Installation Read and understand this entire installation section before beginning the installation procedure 2 1 Floor Plan Layout amp Space Requirements DPMSX2 DPMSX3 amp DPMSX5 100881 Figure 1 Machine Footprints DPMSX2 DPMSX3 DPMSX5 Footprint of Machine 23 1 x 40 5 24 x 44 24 x 48 4 Weight approximate net 3200 lbs 4100 Ib 4400 Ib Weight approximate shipping 3500 Ibs 4400 lb 4700 Ib Pallet Size 70 x 70 6 x 6 6 x 6 A Overall width 101 108 136 B Overall length w electric box 72 76 81 door open C Bed width 23 125 24 24 D Bed width between leveling 20 5 21 7 21 7 screws E Distance between leveling 32 5 18 1 20 5 screws F length 40 5 43 3 48 4 7 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual d f AV ai SIL es 4 n M Height of table from bottom of bed Maximum distance from spindle nose to table Maximum height of machine from bottom of bed to top of column cover Height of machine from bottom of bed to top of spindle motor Width of machine including table Length of machine with electric box door closed Figure 2 Overall Dimensions DPMSX2 DPMSX3 34 38 23 5 23 5 78 85 89 95 70 73 64 66 8 Southwestern
57. 7 16350 FERRULE SPROCKET 1 38 98481A090 KEY WOODRUFF 404 1 8 X 1 2 1 39 22718 SPACER 45 MACHINE 1 40 21992 BUSHING BALLSCREW 1 41 14772 SPACER 100 THICK 1 42 M6 1 0X75 25B SCREW SHCS STL BO 4 43 21946 ELECTRONIC HANDWHEEL KIT KNEE MILL 1 DPMSX2 SX3 8 SX5 Safety Installation Maintenance Service amp Parts List Manual 101132 X SX3 116 Southwestern Industries Inc 5 1 13 Ball Screw Replacement Y Axis Saddle DPMSX3 CAUTI ON Never screw a ball screw partially or totally out of its nut They cannot be reassembled 10 Position the saddle all the way forward Remove the hand wheel assembly and bracket Remove the sheet metal covers on the front of the machine bed and on the motor mounting bracket Remove the motor then remove the motor mounting bracket Remove the rest of the parts on the ball screw journal Note the orientation of the bearings for reassembly Remove the 2 5 16 x 1 inch screws that attach the ball nut to the yoke Remove the ball screw and oil line attached to the elbow fitting on the ball nut Remove the elbow and setscrew from the old ball screw flange and fit them similarly in the new ball screw Pump oil to be certain it flows through the oil line and then attach the oil line to the elbow 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
58. 9 4 1 Code 66 Default Metric This code causes the control to turn on in the metric mode 4 9 4 2 Code 67 Default English This code causes the control to turn on in the English mode 4 9 4 3 Code 79 Beeper On This turns on the beeper to the control keys 4 9 4 4 Code 80 Beeper Off This turns off the beeper to the control keys 4 9 4 5 Code 129 Arc Accuracy When the SMX control operates at high feedrates it may create small part machining errors as it goes around sharp corners This exists on all CNC s and is commonly called a following error The control is factory preset to allow a maximum following error of 0 001 inch The feedrate will automatically be adjusted around sharp corners so as to not violate this limit This code only applies to arcs that are programmed and ones that are created in the tool path to generate the shape you want This code will not make a difference on mill moves You may adjust the maximum following error to a value as small as 0001 inch However the smaller the value the slower the feedrate around corners 82 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List To input a new Following Error use the following procedure Follow the instructions on the screen and input the Following Error value from 0001 to 0100 and press INC SET 4 9 4 6 Code 334 Set Control Options This code turns software features on and off 4 9 4 7 Code
59. ACT 7204 BECBP 2 16 15885 RING BEARING HOUSING 1 17 15626 SEAL BEARING HOUSING 1 18 16350 FERRULE SPROCKET 1 19 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 1 20 16452 NUT CLAMP X Y amp Z AXIS 1 21 500 5M 15 TIMING BELT 1 22 15627 1 DIAL HOLDER 1 27 10 32X3 4 25B SCREW SHCS STL BO 1 28 1 4 20X1 24B SCREW HEX HD STL BO 4 29 15759 WASHER 1 4 HARD BLK OX 1 8 THK 4 30 984814090 KEY WOODRUFF 404 1 8 X 1 2 1 31 15836 DIAL NUT 1 32 M5 0 8X10 10Z SCREW PH PHIL STL ZINC 2 33 21946 ELECTRONIC HANDWHEEL X amp Y AXIS 1 34 6 1 0 75 25B SCREW SHCS STL BO 4 35 M6 1 0X25 25B SCREW PH PHIL STL ZINC 4 36 21985 SPACER 30 DEGREE Y AXIS DRIVE ASSY 1 37 21992 1 BUSHING BALLSCREW 1 38 1 4 20X5 8 26B SCREW FHCS STL BO 4 39 14772 2 SPACER 020 THICK 1 40 21984 WAY COVER FRONT Y AXIS DRIVE 1 41 30922 HANDLE FOLD A WAY 1 101132 Y SX2 110 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 11 Z Axis Ball Screw Removal amp Replacement CAUTI ON Never screw a ball screw partially or totally out of its nut They cannot be reassembled 1 Qo OI 29 OT xs Uus PrP PP PP WN P O 17 18 19 Ensure that there is sufficient vertical clearance above the top of the machine to remove the ball screw Minimum clearance required is 32 inches Remove vertical column top cover Remove servomotor belt and Z motor mounting bracket Remove upper
60. ANDLE ASSY EKSI 97 20847 MICRO SCREW MICRO STOP NUT amp MICROMETER NUT ASSY 1 98 20850 FEED HANDLE ASSY 1 99 24095 CLOCKSPRINGASSY 11 100602 K4 M 167 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 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 3x3x20L 1 8 FB10 WORM SHAFT KEY 3x3x8L 1 9 FEED BEVEL PINION 1 10 FB2 BEVEL PINION WASHER 5 1 11 FB1 SOC HD SCREW M5 P0 8x10L 1 12 FB16 FEED ENGAGE PIN 1 13 FB36 FEED DRIVING GEAR 1 14 FB36 1 KEY 3x3x8L 1 15 FB15 FEED REVERSE BEVEL GEAR 1 16 FB13 WASHER 6 22 1 17 FB14 SOC HD SCREW M6 P1 0x15L 1 18 FB37 KEY 3x3x10L 1 19 FB40 FEED DRIVE GEAR 1 100603 K4 Figure 67 Worm Gear Cradle Sub Assembly DPMSX3 amp DPMSX5 P N 20698 1 TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 168 Southwestern Industries Inc 100604 K4 hem PN DESCRIPTON Qy 2 B4 CLUSTERGEARSHIFTCRANK 1 e STEEL BALE 7 ses SETSCREWMePIOGL T 8 FB63 FEEDGEARSHIFTFORK T
61. Breakout Box Connections 4 8 4 Cable Connections 4 8 5 Electrical Box Schematic 48 49 50 50 51 51 52 52 53 53 53 53 54 55 56 56 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 4 9 5 0 5 1 5 2 6 0 Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 Service Codes 76 4 9 1 Software Codes 76 4 9 2 Machine Set up Codes 77 4 9 3 Diagnostic Codes 81 4 9 4 Operator Defaults Options Codes 82 Procedures for Replacements amp Maintenance Replacements 85 5 1 1 Servo Motor Replacement 85 5 1 2 Servo Driver Replacement 85 5 1 3 Computer Module amp LED Enclosure Replacement 86 5 1 4 System Flash Disk Replacement 89 5 1 5 Cable Routing on Machine 91 5 1 6 Sensor 91 5 1 7 Glass Scale Replacement 98 5 1 8 Power Drawbar 102 5 1 9 Ball Screw Replacement X Axis Table DPMSX2 105 5 1 10 Ball Screw Replacement Y Axis Saddle DPMSX2 108 5 1 11 Z Axis Screw Removal amp Replacement 111 5 1 12 Ball Screw Replacement X Axis Table DPMSX2 114 5 1 13 Ball Screw Replacement Y Axis Saddle DPMSX3 117 5 1 14 Ball Screw Replacement X Axis Table DPMSX5 120 5 1 15 DPMSX5 X Axis Handwheel Box 121 5 1 16 Ball Screw Replacement Y Axis Saddle DPMSX5 125 5 1 17 Z Axis Ball Screw Removal amp Replacement 128 5 1 18 Air Solenoid Replacement 131 5 1 19 Spindle Motor Wiring 131 5 1 20 Feed Trip Adjustment 133 5 1 21 Quill Cl
62. CAUTI ON The weight of the table must be supported by the lift to prevent damage or breakage to the dovetails Remove the 5 16 x 1 screw holding the ball nut to the yoke and loosen the 4 screws that mount the yoke to the saddle Remove the oil line Remove the Y axis motor and bracket assembly Tilt the yoke it is pinned to remove the X ball screw Remove the elbow and setscrew from the old ball screw flange and fit them similarly in the new ball screw Pump oil to be certain it flows through the oil line and then attach the oil line to the elbow 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 10 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 10 32 clamp screw to lock the clamp nut in place See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw See Figure 34 for an illustration of the X axis drive train 105 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 101118 Figure 34 DPMSX2 X Axis Drive Assembly
63. CH 100607 K4 lt Figure 71 Feed Reverse Clutch Sub Assembly DPMSX3 amp DPMSX5 P N 20698 5 172 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 72 Quill Spindle Sub Assembly DPMSX3 amp DPMSX5 P N 20836 1 173 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Spindle Sub Assembly em PN DESCRIPTION Qty 3 FB134 SPINDLE DIRT SHIELD Tt 4 FB135 BEARING 70100P4 0 2 5 FB136 BEARING SPACERLARGE 1 6 FB137 BEARING SPACER SMALL 1 7 FB139 SPINDLE BEARING KNOCK NUT 1 8 FBI391 SET SCREW M8 P1 25x6L 2 10 FB138 BEARING 600822 1 0 0 11 FB143 LOCKRING S 0 TT 100608 K4 EHH 174 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 8 8 NOILO3S 33S AVMAZJ L IVHS WOHH 081 SI MIYDS HLIM GIS 91 WAL dAV15 SNIN3IHOLL NSHM NI l WALI ASSY HOLIMS LIWM 40 NOLLISOd ONLINNOW Nf zi ET 9 9 NOILOAS 311 901 0 V NOILONAL Head Top Assembly with Spindle Control Option DPMSX2 DPMSX3 amp DPMSX5 Figure 73 175 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service
64. Drive DPMSX2 Speed Change Handwheel DPMSX2 Spindle Motor DPMSX2 Lower Head Assembly DPMSX2 Worm Gear Cradle DPMSX2 Quill Feed Selector DPMSX2 Quill Pinion Shaft DPMSX2 Overload Clutch Trip DPMSX2 Feed Reverse Clutch DPMSX2 Spindle Assembly DPMSX2 Lubrication Drawing Pump amp Lube DPMSX2 Lubrication Drawing X amp Y Axis DPMSX 145 146 147 150 153 155 156 157 158 159 163 164 165 169 170 171 172 173 174 176 178 180 182 183 185 186 187 191 192 193 197 198 199 200 201 202 203 205 Fig 92 Fig 93 Fig 94 Fig 95 Coolant Pump Mounting Lubrication Drawing X amp Y Axis DPMSX3 Lubrication Drawing X amp Y Axis DPMSX5 Manual Ram Elevation 206 207 209 211 TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Southwestern Industries Inc 1 0 Safety The safe operation of the TRAK DPMSX2 DPMSX3 amp DPMSX5 depends on its proper use and the precautions taken by each operator e Read and study this manual and the ProtoTRAK SMX Programming Operating and Care Manual Be certain every operator understands the operation and safety requirements of this machine before its use e Always wear safety glasses and safety shoes e Always stop the spindle and check to ensure the CNC control is in the stop mode before changing or adjusting the tool or workpiece e Never wear gloves rings watches long
65. Drive Trains are loose Check Repeatability using the Repeatability and Positional Accuracy procedure Step by step carefully inspect the Drive Train for any looseness It may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 4 2 Way surfaces are pocked scarred or Visually check the condition of all the Way surfaces For excessively worn machines that may have excessively worn Way surfaces you may need to adjust the Gibs in this area This will affect performance when using the machine outside of this area Check lubrication to affected areas 39 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 3 1 2 Circles Out of Round Circles are not round within 0 002 TIR over 3 0 DIA This is best measured by placing a dial indicator in the guill and sweeping around the part Note The typical slideway milling machine is not capable of achieving more precise results although careful adjustments to a new milling machine have produced 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 11 Measures backlash in the system Only used on Dual Feedback systems e Code 12 Feed Forward Constant e Code 127 Measur
66. ET SCREW M5 P0 8x5L 10 FVS92 2 WASHER FLAT 11 11 FVS57 BAKELITE BALL HANDLE 12 FVS116 WASHER FLAT 6 COD a a 13 24083 SHAFT HI LOW SHAFT ASSY 100596 K4 Figure 61 Hi Low Shift Sub Assembly DPMSX3 amp DPMSX5 P N 20697 3 157 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 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 FVS65 BALL BEARING 2 REA 620377 2 5 FVS3 SOCKET SET SCREW M6 P1 0x6L 1 6 23954 BEARING SET 2 BEARINGS 620377 1 i00597 K4 Figure 62 Pulley Pinion Sub Assembly DPMSX3 DPMSX5 P N 20697 4 158 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100598 Figure 63 a Lower Vari Disc Sub Assembly DPMSX3 amp DPMSX5 P N 20697 5 159 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 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 BRAKE BLOCK 2 3 FVS58 TURNING BLOCK SHAFT 1 4 FVS103 RETAINING RING 7 1 5 FVS51 SET
67. Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 Ram Back Gib Ram Side Gib Adjustment Calibration Set Up Tramming of Head Top Housing Assembly DPMSX3 amp DPMSX5 Gear Housing Sub Assembly DPMSX3 amp DPMSX5 Hi Low Slip Clutch Sub Assembly DPMSX3 amp DPMSX5 Hi Low Slip Clutch Sub Assembly DPMSX3 amp DPMSX5 Pulley Pinion Sub Assembly DPMSX3 amp DPMSX5 Lower Vari Disc Drive Sub Assembly DPMSX3 amp DPMSX5 Speed Change Handwheel Sub Assembly DPMSX3 8 DPMSX5 Spindle Motor Sub Assembly DPMSX3 amp DPMSX5 Bottom Housing Assembly DPMSX3 amp DPMSX5 Worm Gear Cradle Sub Assembly DPMSX3 amp DPMSX5 Quill Feed Selector Sub Assembly DPMSX3 amp DPMSX5 Quill Pinion Shaft Sub Assembly DPMSX3 amp DPMSX5 Overload Clutch Trip Sub Assembly DPMSX3 amp DPMSX5 Feed Reverse Clutch Sub Assemblies DPMSX3 amp DPMSX5 Quill Spindle Sub Assembly DPMSX3 amp DPMSX5 Head Top Assembly w Spindle Control Option DPMSX2 DPMSX3 amp DPMSX5 Electrical Enclosure Spindle Control Options DPMSX2 DPMSX3 DPMSX5 Top Housing Assembly DPMSX2 Gear Housing DPMSX2 Hi Low Shift Clutch Sub Assembly DPMSX2 Hi Low Shift DPMSX2 Pulley Pinion DPMSX2 Vari Disc
68. Fuse blown in pendant Remove fuse and check continuit Poor wiring and cable connections Check for any loose wiring Also check the 110VAC Power Cable connection from the 110VAC Power Strip to the Pendant See Electrical Section 4 8 Flash disk failure Remove and reseat the flash disk Computer Pendant has failed See Computer Pendant diagnostics Section 4 3 3 3 9 Will Not Hold Calibration The control will not hold calibration Go to the Configuration Values screen and write down the calibration values for the motor encoders Encoder and the position feedback encoders Scales The calibration values are written in Hexadecimal Recalibrate the system and see if the values change Turn the system off and on and see if the values are held 48 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 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 Mode Possible Cause Check This Configuration file corrupt Load default configuration by going to code 313 Not saving Calibration values Replace Computer Pendant module See Computer Pendant If calibration factors are being saved but the measurements are not repeating or are not accurate e See Measurements Are Not Repeating e See Measurements Are Not Accurate 3 3 10 Auxili
69. HOUSING BEARING Z AXIS EA 1 12 16302 RING BEARING HOUSING EA 1 13 20374 BEARING ANGULAR CONTACT 7205 BECBP EA 2 14 16773 NUT CLAMP Z AXIS EA 1 15 10 32 3 4 25B SCREW SHCS STL BO EA 1 16 16350 FERRULE SPROCKET EA 1 17 16983 PULLEY SOLID 44 TEETH Z AXIS EA 1 18 NO1 LOCKNUT EA 1 19 W01 LOCKWASHER EA 1 20 M8 73B WASHER SPLIT LOCK STL BO EA 4 21 98481A090 KEY WOODRUFF 404 1 8 X 1 2 EA 1 22 M8 1 25X20 25B SCREW SHCS STL BO EA 4 23 710 5M 15 BELT TIMING EA 1 24 21944 PLATE BALLSCREW SUPPORT Z AXIS EA 1 25 1 4 20X1 1 4 25B SCREW SHCS STL BO EA 4 26 15759 WASHER 1 4 HARD BLK OX 1 8 THK EA 4 27 23197 BRACKET Z AXIS MOTOR DPMS EA 1 28 23198 MOTOR DRIVER ASSY PT4 DPM SM 4050 EA 1 31 M10 73B WASHER SPLIT LOCK STL BO EA 8 32 17030 LOUVRE SPACER EA 1 34 M10 1 5X45 25B SCREW SHCS STL BO EA 8 35 M10 71B WASHER FLAT SAE STL BO EA 4 i16790 XX 113 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 12 Ball Screw Replacement X Axis Table DPMSX3 CAUTI ON Never screw a ball screw partially or totally out of its nut They cannot be reassembled Position the table in the center of travel Remove the left side table tray by pulling it up and remove the X motor 1 2 3 Remove the motor mounting bracket and bearing housing 4 Remove the right side bearing housing 5 Loosen the table gibs Slide the table to the right and on to a lift that will s
70. Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 100880 DPMSX5 41 23 5 87 98 70 71 2 2 Uncrating Carefully remove the wood crate and protective packaging paying attention not to scratch damage or mar any parts of the machine Remove the cardboard boxes with the PENDANT DISPLAY handle carefully the box containing the TOOL BOX and Z crank The leveling pads and screws for the machine can be found in the toolbox The Y way covers are shipped in a separate tube The lower Z way cover can be found in a box as well Remove two steel bars 1 0 inch in diameter These items are necessary for lifting and moving the machine Loosen and remove 4 screws and nuts holding the machine to the wood pallet ATTENTION Immediately report in writing any damages observed at this time that can be attributed to the transportation or improper handling moving of the machine 2 3 Shortages Inventory Checklist MEM Machine check model and serial number Manual drawbar with washer Leveling pads B239 and screws B240 Note 4 each for DPMSX2 and 6 each for DPMSX3 amp SX5 Table tray with rubber pad assembled to machine DPMSX3 only 15977 Pendant Display with four 1 4 20 screws for mounting PRI Pendant Arm assembled to the column PEL Toolbox with various tools ProtoTRAK SMX Safety Operation amp Programming Manual P N 24495 TRAK DPMSX2 SX3 amp S
71. K3 WORM FRU K3 WASHER FRU K3 SPEED CHANGE SHAFT FRU K3 ROLL PIN 3x15L FRU K3 COPPER BUSHING RU K3 WASHER WAVE RU K3 SPEED CHANGE HANDWHEEL RU K3 FULL DOG SOCKET SET SCREW M6 P1 0x10L RU K3 HANDLE 3 8 16NC RU K3 CHAIN 310X9 525 RU K3 DOWEL PIN 3x25L RU K3 SPEED CHANGE STUD RU K3 SPEED DIAL RU K3 NUT ACORN 5 16 18 NC 7 i00697 K2 K3 Figure 81 Speed Change Handwheel DPMSX2 P N 20778 7 190 Southwestern Industries Inc DPMSX2 SX3 8 SX5 Safety Installation Maintenance Service 8 Parts List Manual ot 100598 K2 K3 Figure 82 Spindle Motor DPMSX2 P N 20819 1 item PN DESCRIPTION Qy 2 VS3 1 FRU K3KEY6GxexdbL j 1 3 VS2 FRUKS STATIONARY MOTOR VARIDISC 1 4 VS6 J FRUKSBUSHNG 0 j 4 5 VS5 FRU K3 ADJUSTABLE MOTOR VARIDISC 1 6 vet JFRUK amp KEY7S pr 7 vse FRUKSSPRINGFORVARIDISCMOTORSHAFT 1 e VS9 JFRU KS ADJUSTABLE VARIDISC SPRING COLLAR I o VS10 FRUKS SCREW SOCHDCAPM amp Pi25xG0L 1 10 23953 VARIDISG ASSY ADJUSTABLE MOTOR VARIDISC ASSY 1 100698 K2 K3 191 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 83 Lower Head Assembly DPMSX2 192 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List
72. LUTCH SUB ASSY 4VK A2 1 3 20697 3 FRU SK4 HI LOW SHIFT SUB ASSY 4VK A3 1 4 FVS12 SOCKET CAP SCREW M6 P1 0x15L 2 5 20697 4 FRU SK4 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 9 5 8 1 11 FVS61 JAM NUT 5 8 11NC 1 12 20697 5 FRU SK4 LOWER VARI DISC DRIVE SUB ASSY 4VK A5 1 13 FVS63 BELT 8YU 600L 1 14 FVS135 KEY 8x7x60L 1 15 20697 6 FRU SK4 UPPER VARI DISC DRIVE SUB ASSY 4VK A6 1 16 FVS4 BELT 1 17 FVS1 BELT HOUSING 1 18 FVS17 SOCKET CAP SCREW M6 P1 0x35L 1 19 FVS13 TOP BEARING CAP 1 20 FVS15 BALL BEARING 6909VV 1 21 FVS129 SCREW SOC HD CAP M6 P1 0x18L 1 22 20697 7 FRU SK4 SPEED CHANGE HANDWHEEL SUB ASSY 4VK A7 1 23 FVS10 SCREW SOC HD CAP M8 P1 25x30L 1 24 20820 1 MOTOR ASSY DPM5 5HP WHITE 1 25 FVS130 WASHER FLAT 9 10 2 4 26 FVS111 SOC HD SCREW 3 8 16NCx32L 4 27 FVS11 MOTOR PULLEY COVER 1 28 FVS104 COPPER CHIP 2REQ 2 29 FVS131 SCREW FLAT HD PHILIP M5 P0 8x10L 1 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 HEX CAP NUT 5 16 18NC 1 37 FVS16 2 PLATE 1 38 FVS19 DRIVE SCREW 1 39 OIL 1 FRU K3 OIL CUP 1 TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service 8 Parts List Manual 100593 K4
73. MN LEFT SIDE SLIDING SURFACE TO X Y amp Z LUBRICATION SYSTEM ALL TUBES ARE O 4mm ALLUMINUM TUBE Figure 90 Lubrication Drawing Pump amp Lube System DPMSX 202 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Lubrication Drawing Pump 8 Lube System DPMSX em PN Tile Joy 1 211572 LUBRICATONPUMP DPME2 o 3 83 DISTRBUTOROILREGULATINGE3 0 4 PGo04 PUG MBXiO O o 9 6 pea SEEVE4MM 19 8 PNM Nr i3 Pssa jOLDISTRIBUITOR 6 AR 100661 203 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual No X AXS GIB Bea Y AXIS LEFT WAY SURFACE ANro X AXS REAR WAY SURFACE sNro Y AXIS BALLSCREW 8 Nro YAXIS RIGHT EAY SURFACE X ANS BALLSCREW SN FROM DISTRIBUTOR Figure 91 Lubrication Drawing X amp Y Axis DPMSX PN Tile Qty 2 PH 8 ELBOW _ ioi 5 103 BUSHING PA4 9 1014 __ISLEEVE AMM PB4 1 i10 lor TEEADAPTERPKDA moss se i2 100 DISTRIBUTOR DBIO 7 i8 pss4 OILDISTRIBUTOR 6 i00783 E2 204 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 2222222 Figure 92 Coolant Pump Mounting
74. MOV V150LA20B 5 24 23036 FUSE HOLDER 32 AMP 690V 2 25 123153 3 FUSE 600 VAC TIME DELAY CLASS CC 2 26 22303 16G WIRE BUSS 16 GA AWG 12 STRAIGHT 12 25 40 22557 1 TERMINAL BLOCK 6mm BLOCK 3 41 24299 3 TERMINAL BLOCK RAIL END STOP GROUND 2 42 22571 8 125 RAIL DIN 8 13 45 23429 SHEETMETAL COVER PLATE LEFT PT4 SM TRANSFORMER OPTION 11 48 24407 NAMEPLATE TRANSFORMER 1 26 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual i01397 101398 E s 69 SP ALLE EWAN h Figure 12 Transformer Option Schematic P N 23440 220 440 2 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 2 13 Air Connection Optional The DPMSX machines have an air hookup in the rear of the machine if the machine has a power drawbar or auxiliary function option The drawbar option includes an air regulator air manifold and an oiler The auxiliary option includes an air regulator air manifold and a solenoid If both options are included on the same machine a regulator manifold oiler and solenoid will be included The air fitting is Y4 NPT An additional air line port is on the manifold to be used for an optional mister Remove the plug to gain access to this port See Figure 13 below The air regulator is set to 90 PSI at the factory for the power drawbar unit and solen
75. OF LARGEST MOTOR AMPS SHORT CIRCUIT INTERRUPT 7 AMPS ELECTRICAL DRAWING CNC CONTROL ELECTRICAL RATINGS IF APPLICABLE voLTs 8 Aves _1_ PHASE L60 uz MACHINE ONLY MADE IN TAIWAN o o DPMSX3 DMPSX5 NO SPINDLE CONTROL OPTION SOUTH WESTERN INDUSTRIES 1 2615 HOMESTEAD PLACE RANCHO DOMINGUEZ CA 90220 MODEL TRAK DPMSX3 OR TRAK DPMSX5 SN Js eS ELECTRICAL RATINGS Eos 3 pese 60 JHz FLA OF LARGEST MOTOR AMPS SHORT CIRCUIT INTERRUPT AMPS ELECTRICAL DRAWING 20676 1 CNC CONTROL ELECTRICAL RATINGS IF APPLICABLE VvoLTs _8_Jamps Pus 60 JHz MACHINE ONLY MADE IN TAIWAN DPMSX3 DMPSX5 SPINDLE CONTROL OPTION SOUTH WESTERN INDUSTRIES 2615 HOMESTEAD PLACE RANCHO DOMINGUEZ CA 90220 MODEL TRAK DPMSX3 OR TRAK DPMSX5 SN oS ELECTRICAL RATINGS Eee AMPS _3_JPHASE 60 Hz FLA OF LARGEST MOTOR AMPS SHORT CIRCUIT INTERRUPT AMPS ELECTRICAL DRAWING CNC CONTROL ELECTRICAL RATINGS IF APPLICABLE voLTs 8 James Ee L 60 Hz MACHINE ONLY MADE IN TAIWAN 101255 Safety amp Information Labels Used On The TRAK DPMSX2 DPMSX3 amp DPMSX5 Milling Machines It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 1 3 Safety Precautions 1 Do not operate this machine before
76. Oty 2 Reverse or Forward 22 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 1 101256 2 Figure 10 1 Wiring the DPMSX2 DPMSX3 or DPMSX5 Spindle Control Item Part Number Description SX2 SX3 SX5 1 24060 1 24060 2 Electrical Box 5 22890 500 120 22890 500 64 Resistor Qty 2 8 22127 DPMSX2 22128 DPMSX3 5 AC Drive Mini Vector 220V 12 22961 Relay Power 115V DPST 14 21824 5 Fuse 3 AG Slow Blow 5 AMP 15 21824 8 Fuse 3 AG Slow Blow 8 AMP South western 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 23 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Figure 10 2 Wiring the DPMSX2 DPMSX3 or DPMSX5 Spindle Control 2 12 1 Phase Converters For those machines that will be run with a phase converter it is recommended that it is a rotary type rather than a static phase converters Rotary phase converters allow for varying loads in the system The electrical load on the machine will vary based on the type of cut taken Static phase converters can only be used on machines with a non varying load The phase converter for the DPMSX machin
77. PAN HEAD PHILIP 5 40NC V546 JFRU K3 BRAKE BEARING CAP 5 N V543 1 FRU K3 BALL BEARING 6010ZZ FRU K3 KEY 8x7x20L VS50 2 FRU K3 SCREW FH PH STL BOM6 1 0X6L 4 i00695 K2 K3 1 1 1 2 2 2 2 2 2 2 7 10 11 12 6 8 9 0 1 2 3 4 5 6 7 2 187 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 80 b Upper Vari Disc Drive Sub Assy DPMSX2 P N 20778 6 188 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Upper Vari Disc Drive Sub Assy DPMSX2 Q FRU K3 SPEED CHANGE PLATE 7 FRU K3 SCREW SHCS M5 0 8X20L 10 FRU K3 ROLL PIN 3x15L i00696 K2 K3 lt Parts List 24564 Sub Assy Bearing Housing 1 FVS42 SPINDLE PULLEY BEARING HOUSING 1 1 FVS43 BALL BEARING 6013ZZ 124599 Parts List 24631 Sub Assy Vari Disc Adjustable Item P N Title Aty 1 VS42 FRU K3 SPINDLE PULLEY BEARING HOUSING 1 2 VS43 FRU K3 BALL BEARING 6210ZZ 1 3 VS44 FRU K3 ADJUSTABLE DRIVEN VARIDISC 1 i24631 189 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100697 K2 K3 DESCRIPTION Qty VS16 FRU K3 SPEED CHANGE HOUSING FRU K3 BEARING SELF LUBRICATING FRU K3 SPEED CHANGER GEAR FRU K3 SPEED CHANGE CHAIN DRUM FRU
78. RSG Poor cable connections from the Re seat cable connectors by pulling out and pushing Computer Module to the Distribution back in Board and from the Distribution Board to the Keyboard Electromagnetic interference has Especially suspected if the network cable is run near entered through the network cable if any electrical conduit If the problem is chronic connected especially if intermittent remove the cable for a while to see if there is a difference 46 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 3 3 4 Fault X Y or Z The program run or jogging operation is interrupted with a Fault Message on the display Do the following Service Codes and procedures Code 33 Software Identification This is needed if you call SWI Customer Service Code 11 Measure s the backlash in the system Only used on machines with Dual Feedback systems Code 12 Feed Forward Constant Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting Possible Cause Check This problems and 2 for the Z axis Table Saddle or Ram Locks are locked Make sure the Table Saddle and Ram Locks are unlocked High torque on any axis may cause faulting problems during alignment routine X Y and Z axis Gibs are adjusted Check the adjustment of the X Y and Z axis Gibs using the X Y and Z axis Gib adjustment procedures
79. RWARD 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 reguired result in accidents and damaged parts Handwheels must have the crank folded inside when using CNC programmed machining or rapid feeds power feed or jog Prevent fires When machining certain materials magnesium etc the chips and dust are highly flammable Obtain special instruction from you supervisor before machining these materials Prevent fires Keep flammable materials and fluids away from the machine and hot flying chips Changing the speed of rotation of the spindle must be done while the rotation is on It is recommended to stop and start the spindle at a low rate of speed Interlocked Table Guards Interlocked table guards may be purchased from Southwestern Industries Inc if deemed necessary by the user 5 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual
80. SCREW M6 P1 06L 2 6 FVS53 BRAKE LOCK BUSHING 1 7 FVS52 BRAKE LOCK SHAFT 1 8 FSV119 RETAINING RING 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 6 4 14 FVS120 JSCREW PHILLIP PAN HD 3 16 24NC6L 4 15 FVS46 BRAKE BEARING CAP 1 16 FVS43 1 BALL BEARING 601244 1 17 FVS14 SOCKET CAP SCREW M 5 PO 8x12L 4 18 FVS45 STATIONARY DRIVEN VARIDISC 1 19 FVS70 SPINDLE PULLEY ASSY 1 20 FVS100 JSPINDLE PULLEY SPACER 1 21 FVS71 KEY 8x8x20L 1 22 FVS97 SNAP RING 50 1 23 FVS52 1 BRAKE LOCK SHAFT SWIVEL 1 24 FVS56 _ BRAKE LOCK HANDLE 1 25 FVS54 HANDLE FIX BLOCK 3 8 16NC 1 26 FVS55 SPRING PIN 6x20L 1 27 FVS57 1 BAKELITE BALL HANDLE 3 8 16NC 1 28 24055 BRAKE SHOE ASSY 1 29 FVS98 CLUTCH WASHER 1 100598 K4 160 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 63 b Upper Vari Disc Sub Assembly DPMSX3 amp DPMSX5 P N 20697 6 161 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Upper Vari Disc Sub Assembly Item P N DESCRIPTION Qty 1 FVS42 SPINDLE PULLEY BEARING HOUSING FVS43 BALL BEARING 601377 FVS44 JADJUSTABLE DRIVEN VARIDISC FVS36 SPEED CHANGE PLATE FVS37 JPIVOT SLEEVE 5 FVS123 WASHER M5 P0 8x20L
81. SX5 X axis DPMSX3 and DPMSX5 Y axis bearing housings Ensure that the bearing housing is clamped in place by the bracket This design uses the bracket to secure the bearing housing in place It should not allow the bearing housing to float between the bracket and machine 8 Ensure that the Clamp Nut is secured The following applies to the clamp nut e When loosening make sure to back out the 10 32 screw from the clamp nut e When tightening snug the 10 32 screw so the clamp goes onto the ball screw thread with some drag Thread it onto the ball screw and torque the clamp nut to 50 ft Ibs and then tighten the screw down 9 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 10 Check the ball screw mounting to the yoke Make sure the SHCS are tight 11 Inspect the ball screw ball nut and yoke for the potential problems shown in the chart on the next page CAUTI ON Unlike a lead screw do not unscrew the ball screw from its nut This will destroy the ball screw Potential Problem Check By Bad ball screw e Visually inspecting the ball nut if the nylon seal is broken or deform
82. T4 VL VM 15 PIN SPINDLE CONTROL 1 25 24182 DISCONNECT SWITCH 1 26 24183 ROD DISCONNECT HANDLE 1 i01128 K4 Parts List Electrical Enclosure DPMSX2 with Spindle Control Option DESCRIPTION Wem DESCRIPTION 8 22127 SMX3HP ACDRIVE 3HPMINIVECTOR22V 16 22199 RECEPTACLE PANEL MOUNT NEMA STD 15A 125V 1 i01128 K2 K3 lt 178 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 75 Top Housing Assembly DPMSX2 100690 K2 K3 179 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Head Top Assembly DPMSX2 item PN Tie Qt 5 20778 4 FRU SK3 PULLY PINION SUB ASSY 3VK A4 1 6 VS64 FRU K3 BULLGEARPINIONBEARINGGAP 1 7 VS93 FRU K3 SCREWM5P08x1SL 8 VS117 FRUX3 KEY amp xBaBL TT 9 vse2 FRUK3TIMING BELT PULLEY 10 VS126 FRU K3 WASHER 5 8 1 11 VS61 FRU K3 JAMNUT B ING 1 12 20778 5 FRU SK3 LOWER VARI DISC DRIVE SUB ASSY 3VK A5 1 FRU K3 BELT 3 8 225 3 15 VS135 FRU KS KEY 8x7X60L 1 17 20778 6 FRU SK3 UPPER VARI DISC DRIVE SUB ASSY 3VK A6 1 18 VS FRU K3 BELTHOUSING FRU K3 WAVE WASHER VS07 JFRU K3 SCREW SOC HD CAP M6 P1 0x35L 20819 FRU SK2 SK3 MOTOR ASSY K2 amp K3 3HP VS130
83. TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Document P N 24317 Version 070109 Southwestern Industries Inc P O Box 9066 Plant location 2615 Homestead Place Rancho Dominguez CA 90220 5610 USA Compton CA 90224 9066 USA T 310 608 4422 F 310 764 2668 Service Department 800 367 3165 e mail sales southwesternindustries com service southwesternindustries com web southwesternindustries com Copyright O 2008 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 Southwestern I ndustries Inc 2615 Homestead Place Rancho Dominguez 90220 5610 Phn 310 608 4422 4 Fax 310 764 2668 Service Department Phn 800 367 3165 Fax 310 886 8029 Table of Contents 1 0 1 1 1 2 1 3 2 0 2 1 2 2 2 3 2 4 2 6 2 7 2 9 2 10 2 11 2
84. U K3 CAP SET SCREW M5 P0 8x5L i00701 K2 K3 Figure 85 Quill Feed Selector DPMSX2 P N 20779 2 197 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100702 K2 K3 Title Qty FRU K3 QUILL PINION SHAFT 1 FRU K3 QUILL PINION SHAFT BUSHING LEFT FRU K3 WASHER 6 K B92 1 ERU K3 SCREW SOG HD M4 POIS 3 8 KBi68 FRUKSSCREWPIN Tf 1 o TK B90 1 FRU K3 QUILL PINION SHAFT BUSHING RIGHT 1 100702 K2 K3 Figure 86 Quill Pinion Shaft DPMSX2 P N 20779 3 198 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Title FRU K3 OVERLOAD CLUTCH SLEEVE FRU K3 KEY 5x8x13L FRU K3 OVERLOAD CLUTCH FRU K3 SAFETY CLUTCH SPRING FRU K3 OVERLOAD CLUTCH LOCKNUT FRU K3 SOCKET SET SCREW M6 P1 0x8L Mem HE 8 9 e FRU K3 SNAP RING 9 10 FRU K3 OVERLOAD CLUTCH TRIP LEVER x lt Figure 87 Overload Clutch Trip DPMSX2 P N 20779 4 199 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100704 K2 K3 Hem P N Title Qty 1 KB57 FRU K3FEEDWORMSHAFT 1 2 K B47 FRU K3 FEED WORM SHAFT THRUST WASHER 1 3 KB44 FRU K3 FEEDWORMSHAFTBUSHING 1 FRU KS WORM 0 FRU K3 WORM FRU K3 PIN 3
85. Using the manual hand crank lower the head until the counterweight is raised off of the counterweight support rods 8 Remove the two 2 counterweight support rods 9 Remove the manual Z axis hand crank DPMSX3 amp SX5 only 10 Attach 2 wiper brushes to each table tray using 2 M5 X10 button head cap screws supplied per brush Install 1 table tray on each end of the table DPMSX5 only NOTE Make sure that the tray does not scrap the TURCITE Check TURCITE for any damage 11 Mount the pendant to the pendant arm using 4 1 4 20 x 3 4 socket head cap screws 12 Make and check all the proper electrical connections from the pendant to the electric box See the pendant and electric box wiring diagrams 13 If applicable load TRAK sensors 16 Jog the table saddle and ram back and forth until the way surfaces are well lubricated Oil should be visible on all the way surfaces 17 Check the level of the machine The machine should be level to within 0 0005 front to back and 0 0005 side to side Even though it is the responsibility of the customer make any adjustments if necessary 21 Perform Service Code 11 to automatically calculate the backlash for the X and Y axis of dual feedback machines i e TRAK sensor or glass scale with a motor encoder 22 Perform Service Code 127 and 128 to manually calculate the backlash for the X and Y axis of single feedback machines i e motor encoder only 23 Check for positional accuracy
86. X5 Safety Installation Maintenance Service amp Parts List Manual P N 24317 Table trays DPMSX5 only NONE Manual Z axis crank 16526 DPMSX3 amp SX5 only Way covers DPMSX2 front 23676 and rear 23677 of saddle Way covers DPMSX2 bottom on column 23675 top on column 23675 Way covers DPMSX3 front B268 and rear B267 of saddle Way covers DPMSX5 front B268 and rear B267 1 of saddle Way covers DPMSX3 amp SX5 bottom on column B202 top on column B201 In case of shortages contact the representative from whom you purchased the machine 9 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 2 4 Installation Instructions amp Checklist Installer Use this checklist to assure a complete set up of the DPMSX2 SX3 or SX5 2 Visually inspect the 220 or 440V wiring going into the electrical panel Visually verify the wiring is correct per our wiring diagram Make sure a strain relief is being used where the wiring enters the cabinet Have the customer repair any wiring discrepancies NOTE Machine with Spindle Control Option is only available in 220V configuration 5 Use a 10mm socket to turn the Z axis ball screw at the top of the column in order to lower the head until the counterweight is raised off of the counterweight support rods DPMSX2 only 6 nstall the manual Z axis hand crank DPMSX3 amp SX5 only 7
87. achine Method 1 16 Southwestern Industries Inc DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service 8 Parts List Method 2 see Figure 6 1 Insert 2 steel bars 1 dia x 36 long through both sides in the existing holes in the machine base front and back 2 Position 4 two each side wood vee blocks under the steel bars and over a suitable lift truck 3 Lift the machine up somewhat tilted towards the front 4 6 from the ground and move itto its floor plan position WARNING The lift truck must have sufficient lifting capacity 3 tons and be eguipped with suitably long forks 4 Insert the 6 screws for the leveling pads in their place in the bed 5 Place the machine in its location see floor plan bed footprint carefully positioning each leveling pad under each leveling screw 4 x4 x 8 WOOD aie i00878 Figure 6 Lifting the Machine Method 2 17 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 2 9 Releasing the Head Counterweight Supports In order to move raise or lower the spindle head ram it is first necessary to remove the 2 steel rods with flanges inserted through the holes in the column These rods support the counterweight during shipping to prevent damage to the counterweight chains and sprockets 1 Release ram gib locks 2 DPMSX2 Lower the head slowly with a 10mm socket on the top end
88. adjusted at least twice a year See Gib Adjustments Section 5 2 1 4 1 3 Lubrication Lubrication is one of the single most important maintenance issues and plays a key role in assuring the performance and durability of the bed mill At the beginning of each day manually supply oil to the way surfaces Lack of lubrication can lead to a variety of problems with your machine motion due to increased friction in the sliding ways This increased friction may lead to part inaccuracies and decreased life expectancies of your ball screws and way surfaces 4 1 4 Machining Set Up The machining set up can greatly influence the performance of your mill Be aware of the following Problems With Can Contribute To Feed and Speeds spindle rpm Poor finish See below Machine chatter Excessive speeds and feeds can break cutting tools or wear tools prematurely Tooling Poor finish Using the wrong cutter for an application Entering the wrong size diameter and Parts incorrect size programming with tool compensation Cutting too deep Part dimensions incorrect Driving and cutting forces cause deflections since no material is totally rigid Machine chatter Poor finish decrease the life of the cutter 60 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 4 2 4 1 4 1 Spindle Speeds Spindle speeds are influenced by a number of variables Material Rigidity of the Mac
89. agnostics section under Mechanical Drive Train for an explanation of how to align the ball screw See Figure 39 for an illustration of the X axis drive train 120 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 15 DPMSX5 X Axis Handwheel Box See Figure 40 Teardown and Part Replacement 1 2 3 4 gt 9 Remove top sheet metal cover item 2 Remove the manual hand wheel Release back cover hub item 4 Slide cover hub and shaft assembly items 12 3 9 and 4 out 4 a Shaft assembly removal 4 a 1 Slide shaft assembly item 12 and 3 off of back cover hub assembly item 9 and 4 4 a 2 Loosen setscrew item 14 4 8 3 Slide shaft gear off item 12 4 a 4 Remove key item 413 Remove front hub assembly item 5 from hand wheel box Remove gear item 11 at the end of the ballscrew 6 a Remove extension cover item 8 use Allen wrench on item 414 to help support ball screw from rotating and back out the extension cover support screw 6 b Loosen setscrew item 14 6 c Slide Left Gear out 6 d Remove key item 13 Remove hand wheel box item 1 Remove ballscrew extension item 7 8 a back out setscrews item 14 8 b back extension off by sliding a 3 16 Allen wrench through thru hole pushing it up against the end of the ball screw pushing the extension slightly away from the bearing 8 c Using two large screw
90. amp Parts List Manual Parts List Head Top Assembly DPMSX3 amp DPMSX5 with Spindle Control Option 23965 NAMEPLATE E HEADOPTION 1 1 23967 PULLEY SPINDLE NT 40 23597 BELT MICRO V J PROFILE 10 RIBS J 8 870P WASHER FLAT USS STL BO BRACKET GEAR SWITCH 5 HP 101127 K4 ke Parts List Head Top Assembly DPMSX2 with Spindle Control Option 176 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual NY nl AV PART DESCRIPTION SPINDLE CONTROL 3HP Figure 74 SPINDLE CONTROL 5HP Electrical Enclosure Spindle Control Option 101128 DPMSX2 DPMSX3 DPSMX5 177 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Electrical Enclosure DPMSX3 amp DPMSX5 with Spindle Control Option See Figure 74 Item P N DESCRIPTION Qty 2 24063 3 PCB ASSY SMX SPINDLE CONTROL 1 5 22890 500 64 RESISTOR 500W 640hm 5 HP MACHINES 2 7 23433 04 TERMINAL BLOCK 4 POLE 1 8 22127 SMX5HP JAG DRIVE 5 HP MINI VECTOR 220V 1 12 22961 RELAY POWER 115V DPST 1 13 21820 FUSE HOLDER 2 14 21824 5 FUSE 3AG SLOW BLOW 5 AMP 1 15 21824 8 FUSE 3AG SLOW BLOW 8 AMP 1 16 22199 RECEPTACLE PANEL MOUNT NEMA STD 15A 125V 1 17 21827 SNAP RING 35X1 5 1 21 22443 CABLE ASSY P
91. and lower Z axis way covers Lower head to table Place 1 or 2 inch wood board between spindle nose and table to protect Lower head until weight of head is supported by the table Tighten both ram locks on the right side of ram Remove locknut and lock washer from the top of the Z ball screw Remove pulley and woodruff key Loosen 10 32 socket screw on clamp nut Using wrench flats on clamp nut and wrench flats on ball screw remove clamp nut Remove the four cap screws from bearing housing flange Remove the clamp nut Remove bearing nilos ring and bearing housing with matched spacer from ball screw Remove 6 M6 cap screws and lock washers from ball nut flange Extract ball screw assembly from machine until ball nut flange is above the top of the ram Support ball screw and remove lubrication line from ball nut flange Raise the ball screw until the bottom end of the ball screw is above the ram Angle the ball screw out and away from the head Lower the ball screw on the right side of the machine until the top of the ball screw clears the support plate Reassemble all components in reverse order as shown above except leave off the pulley locknut and lock washer until ball screw is realigned Torque clamp nut to 50 ft Ib With the ball screw assembly installed loosen four 5 16 18 cap screws from bearing housing raise head to the uppermost position and re tighten 5 16 18 cap screws Note that there is 060 clearan
92. anger 9 n reassembly be certain the fine speed adjustment Screw B goes into the slot of the Speed Change Plate D in the area in which the screw is not threaded 135 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 47 BELT HOUSING SUBPLATE 100156 5 1 23 1 Drive Belt Replacement for Machine with the Spindle Control Option 1 Remove the draw bar and its bushing remove power drawbar if present 2 Remove the three Screws A and use M6 x 35mm screws in the adjacent tapped holes to remove the Bearing Cap see Figure 47 3 Follow instructions for spindle motor removal and remove motor so top head housing can be removed with ease 4 Remove the six screws C that hold the belt housing to the subplate 5 Disconnect the spindle control harness at the head control box 6 Lift off the belt housing then remove belt 5 1 24 Timing Belt Replacement 1 Remove the motor and drive belt 2 Slide the top or adjustable varidisc pulley assembly off the shaft 3 Remove the three M8 screws holding the belt housing base to the gear housing 4 Lower the quill about 4 inches 5 Remove the belt housing base and lower or stationary varidisc pulley assembly 6 Replace the timing belt 136 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 25 Brake Shoe Replacement 1 Re
93. ary Functions Not Working Option on Machine The Auxiliary Functions will not turn on or off at the programmed times There are 3 Auxiliary Functions l Activates or deactivates a 110VAC Receptacle typically used for a coolant pump or solenoid for mister 2 Sends an electrical signal to rotate the turret on a Haas Indexer 3 Turns the Spindle Off at the end of a programmed event In order to run the above auxiliary functions in run mode the accessory key on the front of the pendant must be in the AUTO mode All of the auxiliary function signals are carried down to the cable breakout box through umbilical 2 Each function then has its own relay inside this box If one of these relays fail then these features will not work Do the following service code and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service Possible Cause Check This Bad 110VAC Coolant or solenoid Check if the fuse light indicator next to the plug is lit receptacle fuse Verify that the fuses are good or bad by checking the resistance of the fuses using an Ohmmeter Poor cable connections Check all the cable connections on the cable breakout box Coolant Pump and Air Solenoid Located on the Air Regulator In particular check umbilical 2 cable which carries the auxiliary function signals output of the Haas Indexer connector is activated Bad cable breakout box Check 110 V power coming out of the AC E st
94. ave software Restore the Configuration file saved on your backup configuration disk with service code 141 found in section A of the service code section 89 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual INSERT AS FOLLOWS A NOTE THE WHITE LABEL CONTAINING THE PART NUMBER OF THE FLASH DISK MUST FACE THE BACK OF THE MOTHERBOARD Figure 24 Flash Disk Replacement Flash Disk Parts List 101119 Item P N Description 1 24008 1 PENDANT WITHOUT COMPUTER MODULE 2 24030 1 COMPUTER MODULE 3 25078 FLASH DISK used on Revision D or later pendant 4 25078 1 FLASH DISK used on Revision C or earlier pendant 90 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 5 Cable Routing on Machine Whenever you replace a cable or reroute a cable it is very important to keep the power cables and logic cables separated from each other The power cables consist of the 3 110 volt motor cables and 2 110 volt power cables for the pendant and a coolant pump or solenoid power cable The logic cables are used to carry encoder signals between the cable breakout box and computer module Mixing of the power and logic cables may cause noise from the power cables to interrupt the signals in the logic cables This can lead to intermittent axis faul
95. c TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 2 11 Leveling Leveling Tolerance for DPMSX is 0005 10 1 Set the machine on its 6 leveling pads on a solid level floor prepared in accordance with the state and local rules for machine tool installation The DPMSX2 only uses 4 leveling screws Put one or two precision Spirit Levels or Electronic Levels in the center of the table in the positions illustrated in Figure 7 Adjust the 4 corner leveling screws on their pads until the machine is level to 0005 in 10 in Snug the 2 middle leveling screws being careful to not affect the level for the DPMSX3 and DPMSX5 If the machine must be anchored to the floor follow the general instruction for installing machine tools and use for leveling any well known methods shims etc If the machine must be installed on vibration mounts pads rubber commercially available leveling and vibration mounts etc follow the instructions delivered with the mounts pads ordering them to satisfy the load of the machine and the maximum weight of the workpiece 6 000 Ib When machine is correctly level lock the adjusting screws in place with their hex nuts 19 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service 8 Parts List Figure 7 Placement of Levels SCREW LOCK HEX NUT MACHINE BED LEVEL PAD 100138 Figure 8 Leveling Screw
96. ce between the bearing housing outside diameter and the inside diameter of the support plate to allow for realignment Traverse the head to the extreme of the up and down travel manually to check for freedom of movement Use torque wrench to make sure torque is consistent along length of screw Use torque wrench to make sure torque is consistent along length of screw See Figure 36 for an illustration of the Z axis drive train See Section 5 2 2 to properly measure and set the Z Backlash Compensation and calibration 111 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 36 DPMSX2 Z Axis Drive Train 0 9 i cme co 116790 XXX 112 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Z Axis Drive Train Parts List Item P N Title UseAs Qty 1 16806 M BALLSCREW ASSY Z AXIS EA 1 2 PJ540015 BRACKET LOWER ELEVATING BALL SCREW EA 1 3 2205E 2RS1TN9 BEARING SELF ALIGNMENT SKF EA 1 4 16774 COVER BEARING EA 1 5 16795 MODIFIED BEVEL GEAR BS1236 2A EA 1 6 M10 1 5X10 40B SCREW SOC SET STL BO CUP EA 1 7 16770 MODIFICATION OF 3 HP RAM PING JENG PART EA 1 8 M6 73B WASHER SPLIT LOCK STL BO EA 6 9 M6 1 0X25 25B SCREW SHCS STL BO EA 6 10 7205 AVH NILOS RING 7205 EA 1 11 16295 1
97. cessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 4 2 Servo Drive failure See Servo Drive Section 4 5 Motor failure See Motor Section 4 4 3 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 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 43 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Possible Cause Check This Shut down the system and wait 10 seconds before rebooting E Stop is pressed in Check E Stop Especially if both axes will not jog Servo Drive failure Especially if only one axis will not jog See Servo Driver Section 4 5 Shorted motor See Motor Section 4 4 Poor cable or wiring connections See Electrical Connection Section 2 12 Computer Pendant failed See Computer Pendant diagnostics Section 4 3 3 2 4 Axis Motor Motion is not Smooth While under motor power the motion is not smooth The motion appears to be rough or jerky Do the following Service Codes and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 11 Measure s the backlash in the system Only used on machines with Dual Feedback systems e Code
98. ck e Code 128 Enter backlash compensation Possible Cause Check This Machine Tool amp Setup problem Check for any looseness in the setup Tool Tool holder Part Vise or Fixture See Machine Tool amp Setup Section 4 1 X Y and Z axis Gibs are loose Check the adjustment of the X Y and Z axis Gibs using the X Y and Z axis Gib adjustment procedures See Section 5 2 1 X and Y axis Drive Trains are loose Check Repeatability using the Repeatability and Positional Accuracy procedure Step by step carefully inspect the Drive Train for any looseness It may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 4 2 3 1 4 Parts Have I ncorrect Dimensions Parts are being machined with dimensions that are different than those programmed Typical accuracy expectations should be e Circles 0 002 TIR over 3 00 DIA e Positional 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 Furthermore the system should be expected to repeat within the resolution of the displayed DRO numbers of 0 0005 Do the following Service Code e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 123 Calibration e Code 11 Measure s the backlash in the system Only used on machines with Dual Fe
99. correct parameters Contact Customer Service for assistance Spindle run command not reaching AC Verify spindle run LED is on Spindle Control Board Drive 54 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 3 5 3 Spindle Motor Hums or Will Not Run The spindle motor makes a constant humming noise during operation or will not turn on If the spindle does not run you must make sure 110 V power is reaching the spindle motor contactors in the electrics box Check your 110V power across terminals wire 3 and ground If power is not reaching the electrical cabinet but is reaching the cable breakout box then most likely a relay has failed in the cable breakout box The cable breakout box will need to be replaced This relay is in series with the 110 V power in the E stop circuit See Section 3 3 11 If power has reached the electrical box then use the schematic in Section 4 8 for how the power is routed Possible Cause Check This Wrong voltage Check the 220V 440V voltage to the machine Check all the wiring connections to the electric s box Defective cables or poor cable Check all cable connections connections Spindle Motor is faulty Check the resistance of the spindle motor windings on the spindle motor between L1 U and L2 V L2 V and L3 W then L1 U and L3 W using a digital ohmmeter If the ohmmeter reads more than one 1 ohm difference or OL
100. d Change Handwheel Sub Assembly DPMSX3 amp DPMSX5 P N 20697 7 163 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 9 4 i00601 K4 hem PN we Oy 2 pr 3 FVS2 STATIONARYMOTORVARIDISOC 7 4 Fvs6 BUSHING BUSHING 1 1 FVS5 ADJUSTABLE MOTOR VARIDISC 6 KEY ZXIxBOL e FVS9 ADJUSTABLE VARIDISC SPRING COLLAR o FVS10 SCREW SOC HD CAP M amp P1 25x30L 100601 K4 Figure 65 Spindle Motor Sub Assembly DPMSX3 8 DPMSX5 P N 20820 1 164 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Bottom Housing Assembly DPMSX3 amp DPMSX5 Figure 66 165 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Bottom Housing Assembl Hem PN DESCRIPTION Qy BALL BAEARING 2 REQ 691077 4 FVS79 BEARINGSPAGER 1 5 FVS80 SNAPRINGR75 pf 1 6 FVS73 SPLINED GEAR HUB 1 7 FVS72 KEY8x7310L 4 8 FVS74 SPINDLEBUILGEAR pf 1 9 FVS114 10 FVS115 EXTERNALTOOTHWASHEROS0 pf 1 11 FVS8 LOCKWASHER 50 18NC 1 18 20818 SPACER BEARNG 0 1 14 FB25 B SPRINGGOVR 7 15 FB28 SHIFTCRANK CE 16 FB68 SET SCREW M6 P1 0x8L p
101. d Feed rate Also check the condition of the cutter to verify that the cutter is not dull See Machine Tool amp Setup Section 4 1 Drive Belt 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 3 5 2 1 Spindle Stalls or Turns Off During Machining for Machine with the Optional Spindle Control Drive During machining the spindle turns off and loses power First check incoming voltage and connections Possible Cause Check This Machine Tool and Setup problem Check the type of material being cut type and size of cutting tool RPM and Feed rate Also check the condition of the cutter to verify that the cutter is not dull See Machine Tool amp Setup Section 4 1 Drive Belt in the head is slipping Check the alignment condition and tension of the Drive Belt Spindle Drive Thermal Overload Relay I OUT Current Out located on the Spindle Drive has tripped cannot exceed 12 75A for DPMSX2 and 21 for DPMSX3 SX5 for more than a few minutes When the Overload Relay is enabled an oL1 error occurs shutting off the Spindle Drive The harder the Spindle Motor works trying to make heavy cuts the more current the Spindle Motor utilizes This can be caused by a cut so large that it exceeds the machine capability or a problem with the spindle motor or AC drive Spindle Drive parameters are not May need to re download the Spindle Drive
102. disk drive for additional part program storage Optional auxiliary function box for control of coolant pump or spray mist coolant spindle off and a programmable rotary table or indexer 12 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Polycarbonate sealed membrane and gasket sealed control enclosure to lock out contamination SPINDLE BRAKE 101121 Figure 3 DPMSX Component Identification RAM ACCESS TO COOLANT PUMP Item Part Number Description SX2 SX2 SX3 SX5 SX3 SX5 Spindle Control Spindle Control 1 20819 1 24162 20820 1 24163 Spindle Motor 2 24000 1 SMX Pendant 3 15616 Y Axis Handwheel Saddle 4 15616 X Axis Handwheel Table 5 21157 1 Lube Pump 23198 X Y or Z Motor 13 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 14 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List WORK LAMP REAR ACCESS 100874 Figure 4 DPMSX Rear View 14 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Item Part Number Description SX2 SX2 SX3 SX5 SX3 SX5 Spindle Spindle Control Control 1 220V 20 24060 1 220V 20676 24060 2 Electrical Box 676 220V only 1
103. drivers pushing off the saddle slide the extension off Use a mechanical puller to remove the bearing Re Assembly of Handwheel Box 1 FR Slide bearing on to the end of the ball screw item 9 use a socket or piece of aluminum tubing and a dead blow hammer to tap bearing till it flushes up against the step of the ball screw Slide the extension on and flush it up against the bearing lock down with both setscrews item 14 Item 19 can be used to push the extension from the end of the ball screw to adjust the gear spacing Bolt the handwheel box item 1 down Bolt the front hub assembly items 6 10 and 5 on Slide the shaft assembly items 3 12 9 and 4 in through the backside and bolt the cover hub on CAUTI ON Assemble the hand wheel move it back and forth and see if there is some play in meshing the two gears together If the gears mesh tightly against one another it can generate noise during movement of the X axis It is normal to have a small amount of backlash between the gears 6 Screw top cover on 121 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual ELECRTONIC HANDWHEEL OPTION DPMSXS X AXIS Figure 39 DPMSX5 X Axis Drive Assembly 122 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 101132 X SX5 DPMSX5 X Axis Drive Assemb
104. e machine will not crash in the direction and axis that you have specified 6 Afterward the screen will display values next to the DRO position axes The table below assumes machine has secondary feedback Machines with motor encoders only will display the reading next to the axis in question Your input Display Datadisplayed X Your input X Vour input Your input yn Your input Z Your input 79 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 7 nothing should be 0 the maximum feedrate attained Interpretation of the resulting values displayed The values for the encoder displays should be in the range of 3 0000 to 5 0000 e If the motor encoder and sensor or glass scale reading is not within this value then the one that is out of specification may be the problem If one of the encoders is not reading then it will need to be replaced e The feedrate should be a minimum of 180 ipm e Ifthefeedrate is less than 180 ipm and inconsistent in both directions check the incoming AC voltage and mechanics of the drive train 4 9 2 4 CODE 123 Calibration See Section 5 22 for a further explanation of this code 4 9 2 5 CODE 127 Set X or Y Backlash Constant See Section 5 22 for a further explanation of this code 4 9 2 6 CODE 128 Input Backlash Constant Code 128 allows you to enter the backlash values for each axis It displays
105. e amount of movement on the dial indicator Adjust the Y axis right bottom gib until the registered movement is 0010 0015 e To adjust the gib for excessive clearance Loosen the gib lock screw on the back of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the front of the saddle Tighten the gib lock screw on the back end of the saddle to lock the gib in place and recheck Repeat as necessary e To adjust the gib for too small of a clearance Loosen the gib lock screw on the front of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the back of the saddle Tighten the gib lock screw on the front of the saddle to lock the gib in place and recheck Repeat as necessary 142 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100025 Figure 53 Saddle Bottom Gib Adjustment DPMSX3 Only 143 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 2 1 5 Saddle Bottom Gib Adjustment Y Axis DPMSX5 only It is unrealistic to adjust the Y bottom ways the same way as we do on the DPMSX2 amp DPMSX3 because of the extra weight of the saddle and table 1 Clean all chips dirt and excess oil from the table and saddle Center the saddle on the bed ways Mount your indicator on the left sid
106. e of the saddle Point C with the table in the center of its travel and zero out your indicator 4 Then move the table all the way to the right side When the gibs are adjusted properly you should see no more than 0 0003 movement on the indicator 5 Do the same thing on the right side of the saddle Point B this time moving the table all the way to the left The reading should be positive on the indicator because the saddle should rise where you are indicating Note You can get better readings than 0 0003 but the torque on the Y ball screw may exceed our recommended levels Remove the ball screw cover and check the torque with an in lb torque wrench Normally the torque should be around 15 in Ibs Do not exceed 20 in Ibs Values higher than this may cause circularity problems See Figure 51 for an illustration e Toadjust the gib for excessive clearance Loosen the gib lock screw on the back of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the front of the saddle Tighten the gib lock screw on the back end of the saddle to lock the gib in place and recheck Repeat as necessary e To adjust the gib for too small of a clearance Loosen the gib lock screw on the front of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the back of the saddle Tighten the gib lock screw on the front of the saddle to lock the gib in place and
107. e voltage stickers on the electric s box must be replaced To convert a DPMSX3 amp SX5 machine from 220 to 440 volt power 3 things must happen spindle motor must be rewired overload relay must be replaced and set to 14 amps for 220 V and 7 for 440 volts and the voltage stickers on the electric s box must be replaced Note Voltage conversion from 220V to 440V not applicable to machine fitted with Spindle Control Option See Section 5 for a diagram of how to rewire the spindle motor 21 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List JAE 115V 1 PHASE POWER IN r gy KA R xm men 551 220 440 3 PHASE POWR IN GROLND WIRE TERMINALS FOR f POWERPLUGS gt f HA si REVERSE Ja dE E esil PR HT 2 T 1 4 230 VOLTS POWER OUT A r TO MOTOR B AMP SAMP 77 AUX a i Auxa2 2 AC INS a J povemes I I 1 053 PUMP SPINDLE CONTROL ee I E I LER l a 100907 Figure 9 Wiring the DPMSX2 DPMSX3 or DPMSX5 Non Spindle Control Part Number Description SX2 SX3 SX5 220V amp 440V 20676 Electrical Box 220V amp 440V 23438 3 Overload 23436 Contactor
108. eck Repeat as necessary e adjust the gib for too small of a clearance Loosen the gib lock screw on the left end of the saddle Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the right end of the saddle Tighten the gib lock screw on the left end of the saddle to lock the gib in place and recheck Repeat as necessary Ny I Figure 50 Ls i00151 Table Gib Screw 5 2 1 2 Gib Adjustment X Axis DPMSX5 only The X axis has 2 gibs for the table because of the length of the saddle Each gib is adjusted from each end of the table There are not 2 adjustment screws at either end of the gib like the Y axis and Z axis l Clean all chips dirt and excess oil from the table 2 Remove the table trays 3 Move the table to the left and mount the indicator at Point D and move the table back and forth Note the amount of movement of the dial indicator Adjust gib until the movement is between 0005 001 4 Move the table to the right and mount the indicator at Point A and move the table back and forth Note the amount of movement of the dial indicator Adjust gib until the movement is between 0005 001 139 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual e To adjust the gib for excess clearance Loosen the nut closest to the table and tighten the nut furthest from the table Once the clearance has been tak
109. ed correctly according to the Sensor or Glass Scale Installation procedures Check for any loose brackets or misalignment etc Also check to make sure the Sensor or Glass Scale assemblies are functioning correctly See TRAK Sensors or Glass Scales Sections 4 6 amp 4 7 X and Y axis Drive Trains are loose Check Repeatability using the Repeatability and Positional Accuracy procedure Step by step carefully inspect the Drive Train for any looseness t may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 4 2 3 2 Problems Regarding the Motion of the Machine 3 2 1 Run Away Axis The axis makes an unwanted move at rapid speed in one direction and faults out This is usually caused by an encoder signal being interrupted 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 42 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Possible Cause Check This Sensors or glass scales are counting in Reverse directions with codes 321 and 322 opposite direction of motor encoder correctly manual reading 4 6 or 4 7 Bad Motor Encoder See Motor diagnostics Section 4 4 3 2 2 Slow Down Axis The axis slows down and moves at a f
110. ed if contamination has visibly entered the ball nut or if balls are out of the ball nut replace the ball screw e Cranking the ball screw through a significant part of its travel If it jams feel loose or has rough spots replace the ball screw e Using the dial indicator on a vertical flat of the ball screw to check for backlash between the ball screw and ball nut Potential Problem Check By Ball nut not tightened to e Inspection for space between the head of the bolt and the ball nut i e 62 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List the ball nut to the yoke properly mounting screws Oil lines sheared e Visual inspection Oil line blockage e Pump the oil and ensure that it flows evenly to the ways and ball screw Ball screws not aligned e Measure from the ball screw to the back of the saddle on both sides of properly the yoke the table must be removed The measurements must be within 3 005 end to end See above explanations Note Ball screws are inspected throughout their entire travel for backlash and consistent torque A ball screw should be good for millions of inches of travel if installed properly Do not be too quick to replace a ball screw if there is insufficient indication that it is bad this will just be a costly delay to resolving the real problem 4 2 1 DPMSX2 amp DPMSX3 Ballscrew Alignment e X axis there are 3 components
111. edback systems 41 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual e Code 12 Feed Forward Constant e Code 127 Measure s the backlash in the system Only used on machines with Single Feedback e Code 128 Enter backlash compensation 3 1 4 1 Every Part Has the Same Error Possible Cause Check This Machine Tool amp Setup problem See Machine Tool amp Setup Section 4 1 Programming Error In the program look for common errors in programming such as transposing numbers tool diameters and pressing INC SET when ABS SET is meant This is especially suspected if the dimensional errors are larger than a few thousandths See the Controls Programming Operations and Care manual Configuration file that contains calibra Verify configuration file Code 313 does not read default tion file and backlash constants has values Load saved configuration file from floppy disk in been erased or corrupted electrics cabinet with Code 141 Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants 3 1 4 2 The Dimensional Errors Are Random or Accumulate in Size Over the Part Program Run Possible Cause Check This Machine Tool amp Setup problem See Machine Tool amp Setup Section 4 1 TRAK Sensor or Glass Scale problem Make sure that the Sensor or Glass Scale is install
112. eedrate 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 Set s the maximum allowable arc accuracy error This applies to arcs only Possible Cause Check This The maximum allowable Arc Accuracy is This value will only slow down the machine during arc moves The factory default is set at 0 001 Perform Code 129 to check or change this value See Service Codes section Incoming AC voltage is inadequate Perform Code 100 See Service Codes Section 4 9 and Table Saddle or Ram Locks are locked Make sure the Table Saddle and Ram 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 4 1 3 X Y and Z axis Gibs are not adjusted Check the adjustment of the X Y and Z axis Gibs using the properly X Y and Z axis Gib adjustment procedures Binding in the Drive Train Check Repeatability using the Repeatability and Positional Accuracy procedure Check the torque reading of the Drive Train Step by step carefully inspect the Drive Train for any binding It may be ne
113. emove the clamp nut Loosen the setscrew on the clamp nut before loosening the clamp nut 8 Pushthe table to the left so the bearing housing moves away from the saddle Remove the bearing housing Note which way the bearings are in the bearing housing 10 Slide the table to the right and remove the oil line and the 4 screws holding the ball nut to the yoke 11 Pull the ball screw out Reassemble 12 Install the new ball screw into the yoke 13 Slide table back to the left and assemble the left side of the X axis 14 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 Slide spacer onto ball screw Slide top bearing onto ball screw and seat with clamp nut Be sure to clamp nut to at least 50 ft lbs Don t forget to tighten setscrew after clamp nut is tight 15 Install motor mounting bracket motor spacer bracket woodruff key ferrule pulley star washer and nut Before tightening down the motor mounting bracket move the table all the way to the left 16 Move table to the right and assemble right side bearing housing 17 Assemble motor to bracket The servo should be facing toward the rear of the machine 18 Install belt Tighten lower 2 bolts followed by the top 2 bolts to properly tension belt 19 Install mechanical hand wheel 20 Attach the sheet metal to the motor mounting bracket 21 Install the table trays See the di
114. en up tighten each nut against the gib bracket Do this for each end of the table e To adjust the gib for too small of a clearance Loosen the nut furthest from the table and tighten the inside nut up against the bracket to pull the gib away from the machine Once the clearance has been taken up tighten each nut against the gib bracket Do this for each end of the table 5 Replace the table trays See Figure 51 Figure 51 DPMSX5 Table Gib amp Saddle Bottom Gib Adjustment 140 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 2 1 3 Saddle Side Gib Adjustment Y Axis DPMSX2 SX3 amp SX5 See Figure 52 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 ar OG Esp Remove the chip wiper guard and chip wiper from the front and rear of the left side box way 100024 Figure 52 Saddle Side Gib Adjustment 5 Attach a 0001 dial indicator with a magnetic base to the left front of the saddle Place the indicator stylus on the edge of the large box way 6 Move the left end of the table back and forth and note the amount of movement on the dial indicator Adjust the Y axis side gib until the registered movement is 0010 0015 e Toadjust the gib for excessive clearance Loosen the gib lock screw on the back ofthe saddle Estimate the amount of
115. end mill and set Z Absolute 0 at the top of the part and set Z reference positions in the SET UP mode Set Z retract a few inches above the part Begin to run the program The part will be machined in the following sequence 7 After the program run the program will locate to the following position e X 1 318 e 1 318 37 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Event s Description Depth of Cut 1 circle pocket cuts middle circle 0 250 2 circle frame cuts outer 1 830 diameter circle 0 250 3 circle frame cuts material from corners 0 250 remaining on Euclid block 4 roughs material in upper right hand corner 0 500 5 12 cuts triangle on Euclid block 0 500 13 rectangular frame cuts outer 2 750 rectangle 0 7500 8 Mount a dial indicator in the quill and check the circles 9 Check the runout of the sides of the square frame 10 Inspect the machined surfaces for smoothness 250 3 000 250 250 250 100763 5 Figure 18 Euclid Block 38 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 3 0 Troubleshooting by Symptom Use this section to begin the process of resolving a service problem Each symptom type is described in a few words and then more fully described in an explanatory paragraph Following
116. errors stop and go commands etc It may be helpful for identifying problems between programmed commands and executed commands To turn on the error log press the F6 softkey The page forward and backward keys allow you to scroll through the file one page at a time The data forward and data backward keys allow you to scroll through the file one line at a time The data bottom key takes you to the bottom of the file and then changes to data top which will take you back to the top The file will capture data until the file reaches a size of approximately 600 KB At this time the file is saved to a backup file and the original file is cleared and data is once again captured Once again as the file reaches a size of 600 KB it copies over the previous backup file From here the user can save the file to the floppy drive by pressing the F8 softkey Once this in done it prompts you for which file you want to save to disk The F1 key saves the current file to disk and the F2 key saves the backup file to disk To clear the files press the F7 softkey 4 9 3 6 Code 324 Toggle Simulation Mode Simulation Mode allows the control to run a program without actually moving the table It is helpful in diagnosing Computer display problems 4 9 4 Operator Defaults Options Codes The following codes allow the user to set programming defaults or turn features on or off To get to any of these codes go to Service Codes press D and press the code you wish to view 4
117. es backlash in the system Only used on Single Feedback systems e Code 128 Enter backlash compensation Possible Cause Check This Torque values on X and Y axis are too Make sure torque is lower than 20 in lbs Normal values for a high machine that is aligned and adjusted properly should be between 10 and 15 in Ibs Make sure torque is consistent across axis travel Machine Tool and Setup problem Check for any looseness in the setup Tool Tool holder Part Vise or Fixture See Machine Tool amp Setup Section 4 1 Machine not level Verify that the machine is level to specification Head is not Trammed Verify that the Head is Trammed to specification See Tramming the Head X Y and Z axis Gibs are not adjusted Check the adjustment of the X Y and Z axis Gibs using the X properly Y and Z axis Gib adjustment procedures Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration amp Backlash Constants Section 5 2 2 TRAK Sensor or Glass Scale problem Make sure that the Sensor or Glass Scale is installed correctly according to the Sensor or Glass Scale Installation procedures Check for any loose brackets or misalignment etc Also check to make sure the Sensor or Glass Scale assemblies are functioning correctly See TRAK Sensors or Glass Scales Sections 4 6 amp 4 7 X amp Y axis Drive Trains are loose Check Repeatability using the Repeatability and Po
118. es must be rated at a minimum of 5 to 7 KVA for DPMSX2 and 7 to 10 KVA for DPMSX3 amp SX5 2 12 2 Flange Transformer Optional The Flange Disconnect Option eliminates the need for the user to provide a power disconnect for the machine on their own while the Transformer Option allows the user to provide one power source to the machine Note This option is not available to machine fitted with the Spindle Control Option 24 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 101397 INSIDE VIEW Figure 11 Flange Disconnect Transformer Option P N 23460 220 440 25 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Flange Disconnect Transformer Option Qty 1 21258 TRANSFORMER 1000VA EI 1 4 123434 SOCKET RELAY 1 5 23435 RELAY POWER 100 120 VAC DPDT 1 6 23436 CONTACTOR 4 POLE 2 7 123437 MECHANICAL INTERLOCK 1 8 23438 OVERLOAD RELAY 220V TO 440V CONVERSION 1 11 22199 1 RECEPTACLE PANEL MOUNT NEMA STD 15A 125V 4 13 121871 CONNECTOR 4 POSITION SIZE 11 1 14 1 23297 1 CONNECTOR REVERSE SEX 18 7 CPC 1 16 121820 FUSE HOLDER 2 17 21824 5 FUSE 3AG SLOW BLOW 1 18 21830 12 FUSE TYPE 3AB 12A SLO BLO 1 19 22868 TERMINAL BLOCK 4 20 22869 END PLATE 1 22 21753 3 GROUND BAR 6 HOLE 1 23 21901 150
119. explains the diagnostic procedures used to isolate service problems 4 1 The Machine Tool amp Set Up 4 1 1 The Milling Machine Checklist The following is a quick reference for the types of problems that may arise if problems are noticed in these areas Problems With Can Contribute To Most Suspect When and why Spindle bearings See Spindle Replacement Lubrication system Inadequate lubrication habits Gibs floating Gibs defective bowed scarred Way surfaces pocked scarred or excessively worn Noisy head Parts incorrect Circles out of round Premature wear of ball screws wear surfaces Poor finish Premature wear of ball screws wear surfaces Poor finish Taper on straight Y moves Poor finish Circle out of round Not getting to position does not repeat axis faults Poor finish Not getting to position does not repeat axis faults Poor finish Excess play when gib is checked side to side Poor finish Out of round circles Faulting New installations may not be hooked up or line sheared Older machines machines that are pushed hard New installations more motion than the machinist is used to with a manual mill Lubricate machine every morning before use Gib locks on X and Y axis If locked can lead to axis faults Note when using the CNC to machine never tighten the gib locks X and Y gibs loose See Gib Adjustment Section 5 2 1 Gibs too tight When machine hasn t bee
120. f 1 17 206982 FRU SK4 QUILL FEED SELECTOR SUB ASSY 4VK H2 1 18 FB67 GAPSGREWM6 P1 08L 1 4 19 FB186 JWORMGEAR 4 20 FB189 ADJWORMSHAFT TT 21 22 20698 3 FRU SK4 QUILL PINION SHAFT SUB ASSY AVI H3 1 29 FB178 CLOCK SPRING pf 1 24 FB177 SPRING COVER pf 1 26 FB176 PINONSHAFTHUBSLEEVE 1 FRU SK4 FEED REVERSE CLUTCH SUB ASSY 4VK H5 45 FB104 TRIP HANDLE pf 1 46 FB105 BLACKPLASTICBALL f I 1 47 FB1191 ROLL JA 48 FB107 DAPSCREWM PIOGBL 49 FB113 HANDWHEELCLUTCH 1 51 FB115 COMPRESSION SPRING pf 1 53 FB108 SET SCREW M6 P1 0x8L 0 1 166 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual a PD ma 60 FB149 LOCKHANDLE 66 FB116 HANDWHEEL CLUTCH SPRING SCREW M8 P1 25x6L 67 68 FB190 PINION SHAFT HUB HANDLE 69 FB191 PLASTICBALLHANDLES 80 FB202 NDICATORROD OOO 86 FB125 HANDWHEEL 89 Feil JREVERSEKNOB C o o 90 FB100 JSOCKET SET SCREW M6 P1 0x20 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 ouilLsKRT 1 94 Fysio9 DRAWBARS ETINOC 4 95 FVS109 1 SPACER 0 1 9 20846 QUILL LOCK H
121. from ball nut flange Raise the ball screw until the bottom end of the ball screw is above the ram Be careful to remove bevel gear as the ball screw is raised Angle the ball screw out and away from the head Lower the ball screw on the right side of the machine until the top of the ball screw clears the support plate Reassemble all components in reverse order as shown above except leave off the pulley locknut and lock washer until ball screw is realigned Torque clamp nut to 50 ft Ib With the ball screw assembly installed loosen four 5 16 18 cap screws from bearing housing raise head to the uppermost position and re tighten 5 16 18 cap screws Note that there is 060 clearance between the bearing housing outside diameter and the inside diameter of the support plate to allow for realignment Traverse the head to the extreme of the up and down travel manually to check for freedom of movement Use torque wrench to make sure torque is consistent along length of screw Use torque wrench to make sure torque is consistent along length of screw See Figure 42 for an illustration of the Z axis drive assembly See Section 5 2 2 to properly measure and set the Z Backlash Compensation and calibration 128 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 42 Z Axis Drive Assembly 129 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installati
122. ges its friction characteristic the Feed Forward Constant should change too or the system will not servo properly Whenever gibs are adjusted or a heavy workpiece has been added to the table you should run a Code 12 When the heavy workpiece is removed Code 12 should be run again l Position the table and addle in the center of travel Note You will lose your DRO position reference 2 Go intothe Service Codes and input the Code 12 3 Press Auto 4 The system will run the routine automatically and then display values on the position readout Explanation Typical values should be between 4 04 and 11 11 are considered normal for each axis Higher values indicate excessive friction in the system Lower values indicate a loose system and may mean a gib adjustment is necessary Value 4 04 means the friction is a factor of 4 in one direction and 4 in the other direction The values should be within 3 or 4 of each other in both directions A value of 6 08 would still be considered normal On S products do not equate Code 12 values to torque on ballscrew Measure friction in system with an in Ib torque wrench The feed forward gain can be adjusted manually by pressing the manual button Choose the axis you would like to change and then enter values in the positive and negative direction to adjust Adjusting the gain can help solve circularity problems Default values can be set by pressing the Reset button The manual feature should only be
123. h drive module with voltmeter It should be 4 8 DC volts and above Lower values than this can cause problems Flash disk failure If the flash disk fails the system will not boot up or operate It will need to be replaced programs and machine configurations will be lost Make sure to back up your flash disk from time to time Floppy disk failure Will not allow user to save or pull up programs from a floppy disk Can the floppy drive format a disk See Section 4 3 1 LCD backlight burns out Check all cable connections to LCD distribution board and computer module Make sure the power is turned off before doing so 64 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Possible Problems Can Lead to 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 1 amp fuse in pendant blows Pendant will not turn on spikes 4 3 1 Checking Floppy Drive by Formatting a Disk Find a new disk and install in floppy drive Insta
124. he glass scale when moving the quill up and down then adjust the angle of the scale to make the gap consistent WARNING The gap must be no larger than 0 060 between the readerhead and glass scale Part Description 22800 6 Z Glass Scale FAGOR Z AXIS GLASS SCALE REF PART OF REF Figure 30 Z Axis Glass Scale Assembly M4 0 7x25B 100160 SUSTE Item P N Description Qty 1 20550 ARM Z AXIS MOUNTING PLATE 1 MOUNTING PLATE Z AXIS GLASS SCALE 3 20548 JADAPTER Z AXIS GLASS SCALE 4 2059 JADAPTERPLATE Z AXIS GLASS SCALE SCREW SHCS STL BO 6 10 32X1 1 4 25B SCREW SHCS STL BO 7 7 WASHER 1 4 HARD BLK OX 1 8 8 1 16X1 281B SPRINGPN 9 1 4 28X3 825B SCREW SHCS STL BO 1 99 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100787 V3 1 4 20x1 0 2 PLCS REF Figure 31 Glass Scale Alignment DPMSX3 100 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Part Description 22800 42 X Glass Scale 28 32 x 75 2 PLCS REF DPMV5 Y AXIS GLASSCALE 1 4 20 x 1 0 2 PLCS REF Figure 32 Glass Scale Alignment DPMSX5 101 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 8 P
125. he housing e Thread the split nut onto the ball screw and tighten the 10 32 clamp screw until you feel the split nut contact the ball screw threads It should drag as you tighten the clamp nut e Torque the split nut to 50 ft Ib e Firmly tighten the 10 32 clamp screw to lock the clamp nut in place See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw See Figure 35 for an illustration of the Y axis drive train 108 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 101132 Y SX2 Figure 35 DPMSX2 and DPMSX3 Y Drive Train 109 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual DPMSX2 and DPMSX3 Y Axis Drive Assembly Parts List Item P N DESCRIPTION Qty 1 15966 3 BRACKET Y AXIS MOTOR MOUNT 1 2 M10 1 5X60 25B SCREW SHCS STL BO 4 3 15968 2 LOWER COVER 1 4 15967 2 UPPER COVER 1 5 6 32X3 8 31Z SCREW PH PHIL EXT SEMS STL ZINC 8 7 1 2 70P WASHER FLAT USS STL PLAIN 1 8 30922 HANDLE FOLD A WAY 1 9 15616 HANDWHEEL ASSY MX 1 10 1 2 75Z WASHER EXT TOOTH STL ZINC 1 11 1 2 20 51Z NUT HEX JAM STL ZINC 1 12 15614 TAB WASHER 1 13 14772 SPACER 100 THICK 1 14 15980 BEARING HOUSING 1 15 20373 BEARING ANGULAR CONT
126. he spindle is in the center of the table 4 Adjustthe Z ram 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 3 o clock to 9 o clock and check for the repeatability of the setup The head should be trammed with an 0 001 7 Ifthe 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 149 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100149 Figure 57 A issz zz Tramming of Head Back to Front Adjustment Note The head of the DPM bed mills machine is adjusted at the factory This procedure should only be needed for a head replacement It is placed in this section for continuity with the tramming discussion With the dial indicator sweep the table from 6 o clock to 12 o clock The head should be trammed within 0 0000 to 0 0005 from front to back Note the head must droop down rather than up because tool pressure will take care of the extra 0 0005 Note Minor adjustments can be made with the back ram gibs Tightening the gibs will tend to tilt the head up from the table Loosening the gibs tends to allow the head to droop d
127. hine Setup Coolant Cutter type material and diameter Cutting Depth As a general rule Lower spindle speeds are used to machine hard or tough material or where heavy cuts are taken Higher spindle speeds are used to machine softer materials in order to achieve better surface finishes Higher speeds also apply when using small diameter cutters for light cuts on frail work pieces and delicate setups Note Cutter diameter greatly affects spindle speeds The larger the diameter the lower the spindle speed 4 1 4 2 Feedrates Factors that affect feedrates Depth and width of cut Design or type of cutter Sharpness of the cutter Workpiece material Type of finish or accuracy required Climb or conventional milling If a fine finish is required reduce the feed rather than increase the spindle speed Cutters are dulled by higher spindle speeds rather than high feedrates The Mechanical Drive Train X Y Indications Troubleshooting instructions indicate that the drive train is potentially the problem and other more easily checked variables have been exhausted Roughness looseness tightness or jamming movement in the table or saddle Check for machine considerations especially gib locks and gib adjustments See Gib Adjustments section 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 bal
128. hould be in the ON position to test coolant pump or solenoid The control should be in DRO mode Make sure air is hooked up to the machine during the test If the machine has a separate coolant pump switch mounted on the pendant arm then turn this on and off to test 33 If the machine has a power drawbar option check to make sure that the tools load and unload properly 34 Wipe down the machine prior to leaving kal B i 32 2 5 Machine Specifications Specifications DPMSX2 DPMSX3 DPMSX5 Table Size 49 x 9 50 x 10 50 x 12 T Slots number x width x pitch 3 x 16 mm x 64mm 3 x 16 mm x 64 mm 3 x 16 mm x 64 mm Travel X Y Z axis 31 16 23 5 31 x 17 x 23 5 40 x 20 x 23 5 Quill Diameter 86 mm 100 mm 100 mm Spindle Taper R8 40 taper 40 taper Spindle Speed Range 70 4200 RPM 70 3950 RPM 70 3950 RPM Optional Spindle Control Speed Range Low 40 600 Low 40 600 Low 40 600 High 300 5000 High 300 5000 High 300 5000 Spindle Nose to Table max part height 23 5 23 5 23 5 Spindle Center to Column Face 18 19 20 Spindle Motor Power 3 HP 5 HP 5 HP Voltage 220 440 V 220 440 V 220 440 V Machine with Optional Speed Control 220 V 220 V 220 V Phase Cycle 3 phase 60Hz 3 phase 60 Hz 3 phase 60 Hz Current Full load amps Non Spindle 8 5 4 25 FLA 14 7 FLA 14 7 FLA Control Current Full load amps Spindle Control
129. indicator on the saddle and move the Y axis back and forth along its travel Z Axis The Z scale must be aligned parallel with the quill Make sure the gap on the readerhead is consistent along the length of travel Align the scale within 0 005 up and down See Figure 22 in Section 5 for an illustration of the Z glass scales 4 6 2 Measurements Do Not Repeat 1 Determine if the error in repeatability is random or accumulating e Mount a dial indicator in the quill e Touch off a fixed point on the table and set the DRO to 0 e Traverse away approximately 6 inches e Return the touch off again 67 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List e Write down the reading on the DRO e Do not Re zero the DRO traverse away and return several times e Write down the DRO readings Random error will be unpredictable and give scattered readings adding and or subtracting the error after each traverse with no pattern See Step 2 Accumulating error will add roughly the same amount to the reading after each traverse See Step 3 2 For random error look for problems in the set up of the glass scale that have resulted in a loss of rigidity Common sources of random error include e Loose scale mounting hardware e Loose reader head e Very loose motion of the table or saddle 3 Accumulating error is commonly the result of e Scale out of parallel to the axi
130. ir free movement and cause a decrease in the accuracy and or performance of the machine due to excessive friction 5 2 1 1 Table Gib Adjustment X Axis DPMSX2 amp DPMSX3 See Figure 49 l Clean all chips dirt and excess oil from the table and saddle 2 Center the saddle on the bed ways 3 Move the table fully to the left side of the saddle Note For machines that have excessive wear in 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 4 Attach a 0001 dial indicator with a magnetic base to the left front of the saddle Place the indicator stylus on the front surface of the table as close to the indicator base as possible Figure 49 Table Gib Adjustment 138 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 Movethe left end ofthe 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 rech
131. ive Assembly Figure 37 115 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual DPMSX3 X Axis Drive Assembly Parts List Item P N DESCRI PTI ON Oty 1 15974 END PLATE 1 2 15973 SERVO MOTOR ADAPTER 1 3 30922 HANDLE FOLD A WAY 1 4 M10 1 5X30 25B SCREW SHCS STL BO 8 5 15614 TAB WASHER 1 6 15759 WASHER 1 4 HARD BLK OX 1 8 THK 11 8 1 4 20X1 24B SCREW HEX HD STL BO 8 9 15638 STOP X AXIS 1 10 1 2 20 51Z NUT HEX J AM STL ZINC 2 11 1 2 70P WASHER FLAT USS STL PLAIN 1 12 14772 SPACER 100 THICK 4 15 16452 NUT CLAMP X Y amp Z AXIS 1 16 425 5M 15 BELT TIMING 5MM POWERGRIP 1 17 15612 HOUSING BEARING 1 18 23930 BEARING SET ANGULAR CONTACT 7204 BECBP 1 19 15885 RING BEARI NG HOUSING 1 20 15626 SEAL BEARING HOUSING 1 21 1 4 20X3 4 25B SCREW SHCS STL BO 3 22 5 16 18X1 1 4 25B SCREW SHCS STL BO 1 23 15616 HANDWHEEL ASSY MX 1 24 1 2 752 WASHER EXT TOOTH STL ZI NC 1 25 15180 SHAFT EXTENSION 1 1 26 15058 875 BUSHI NG 1 28 1 4 28X1 43B SCREW SOC SET STL BO KNURLED 1 29 22069 TRAY DPMV3 MACHI NE 1 30 15977 TRAY PAD 1 3l 22008 BEARING 204KTT 1 32 1 4 28X3 4 42B SCREW SOC SET STL BO CONE 1 33 10 32X3 4 25B SCREW SHCS STL BO 1 34 14772 5 SPACER 050 THICK 3 35 14772 2 SPACER 020 THICK 1 36 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 1 3
132. ke you directly to the code in question Press CODE enter the number you want press SET 4 9 1 Software Codes The following codes pertain to software functions in the control To get to any of these codes go to Service Codes press A and press the code you wish to view Note If you are working with the SWI Customer Service Group write the values down for Code 33 or Code 313 These values will be valuable for troubleshooting 4 9 1 1 CODE 33 Software ID The Code 33 is the software identification procedure The two types of software in the control include e Software Version the version of the system you have installed e Firmware Version the version of firmware software that is responsible for control to servo interface e Converter Version the version of software that is responsible for converters and options e Operating System Version shows the version of the XP operating system 49 12 CODE 141 Load Configuration File from Floppy A drive This code allows you to load your configuration file from the floppy disk to your hard drive The configuration file consists of items such as calibration and backlash constants This code is used when a computer module or hard drive has been replaced 4 9 1 3 CODE 142 Save Configuration File to Floppy A drive This code allows you to save your configuration file to a floppy disk The configuration file consists of items such as calibration and backlash constants Thi
133. l Clock Spring counterbalances the weight of the quill and tool Figure 45 ANGER A SCREWA SPRING HOUSING p m B 1 Move the quill to its top position and lock it in place 133 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 2 Remove the guill handle hub by removing Screw A and key 3 Remove Screws B and allow the spring housing to unwind 4 Remove the spring It is held by a pin on the shaft and slot in the housing 5 Replace the spring Rotate the housing clockwise until the spring catches the shaft pin 6 Rotate wind up the housing 1 1 2 turns replace Screws B key hub Screw A and handle 5 1 22 Spindle Motor Removal and Replacement CAUTI ON The motor is heavy about 60 pounds Be certain you have the proper equipment or assistance 1 While the spindle is running change the RPM to its lowest value 2 Turn off spindle 3 Disconnect power to the machine 4 Remove motor pulley cover 5 Screw a 4 x 20 mm SHCS into the bottom of the adjustable vari disk to keep the vari disk open 6 With the power disconnected manually crank the speed changer to its highest RPM value This will allow the main drive belt enough slack to slide off the motor pulley 7 Remove the four SHCS that fasten the motor to the belt housing 8 Tilt the motor toward the rear of the machine and remove the belt from the motor pulley Remove the mot
134. l screw If it is not chances are the ball screw is misaligned A misaligned ball screw can lead to parts being out of round and servo problems at low feedrates A bad ball screw can also cause high torque although this is highly unlikely See Sections 4 2 1 and 4 2 2 for more information The following steps take you in logical sequence through the assemblies for the DPMSX2 DPMSX3 and DPMSX5 For drawings of these assemblies see Figures 29 through 37 in Section 5 61 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List These instructions break the machine down from fully assembled and point out the areas to look at specifically 3 Check that the belt is properly tightened A loose belt can lead to excessive backlash compensation values on motor encoder only machines 4 Check that the nut that tightens up against the ball screw pulley is tight If this is loose the pulley may not run true on the ball screw 5 Check that the tapered sleeve that seats the pulley has not clamped to the ball screw prematurely It should be seated firmly against the pulley Tightening the nut may not have ensured this Also make sure the pulley is keyed to the ball screw 6 DPMSX3 X axis only Ensure that the screws that hold the bearing housing in place to the bracket are not loose This assembly should also contain an M6 flat washer and a serrated lockwasher See Figure 38 7 DPM
135. ll keyboard into middle port Press CTRL ESC to get to start menu Press R for run Type Format a press enter If the format works your disk drive is working If format does not work reboot control and see if it now works If it does not work replace the computer module 7 Press ALT ESC to get back to PT4 software euros OG Gu 4 4 Motor Diagnostics The Motor subsystem is comprised of 2 parts The Motor Encoder and the Motor The motors are powered by 110 VAC voltage The servo driver is also an integral part of servo system which is discussed in detail in the next section WARNING Do not work with the motors unless the power is disconnected from the machine The motors are run by 110 VAC There is possibility of death by electrocution 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 The motors on the X Y and Z axis are identical The motors are heavy duty motors 4 4 1 Cable Connections Check the motor cable connections on the cable breakout box Verify there are no pushed in pins on the connector 4 4 2 To Check the Motor Encoders If the motor encoder inside the motor has failed or is not reading the machine will fault out on that axis Do the following to verify this problem Motor encoder only machines run Service Codes 100 or 131 This will display on the DRO if the motor encoder is c
136. lowing reasons bad motor servo driver or computer module In some cases it is not always 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 This particular example was done on a machine with motor encoders only Swap these components Results Physically switch the X and Y Has problem moved to Y axis If yes replace motor If no motors the motor is not the problem Note motors are always replaced with the servo driver 4 5 Servo Driver Note the Servo Driver is located in the black box on the side of each motor WARNI NG Do not work with the Servo Driver unless the power is disconnected from the machine There is possibility of death by electrocution Indications e Problems moving just one axis including hard turning in one direction Servo Types e X Y and Z servos are identical Objective e Isolate the problem to the particular Servo Driver 66 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Steps 1 Turn off and unplug the system 2 Physically swap the servo module from the axis that is not working to one that is Note To avoid pulling the wires out of the connecto
137. ly Parts List Item P N DESCRIPTION Qty 2 30922 HANDLE FOLD A WAY 1 3 15966 BRACKET Y AXIS MOTOR MOUNT 1 4 15967 COVER UPPER 1 5 15968 COVER LOWER 1 6 21585 1 COVER BALLSCREW END 1 10 21584 1 PLATE END COVER 1 11 6 32 1 2 10B SCREW PH PHIL STL BO 9 13 98481A090 _ KEY WOODRUFF 404 1 8 X 1 2 1 15 16066 NUT CLAMP X amp Y AXIS 1 16 600 5M 15 JBELT TIMING 1 17 21662 BEARING HOUSING 1 18 23940 BEARING SET ANGULAR CONTACT 1 19 16302 RING BEARING HOUSING 1 20 16078 SEAL BEARING HOUSING 1 22 M10 1 5 NUT HEX STL PLAIN 2 23 M10 73B WASHER SPLIT LOCK STL BO 2 25 M8 1 25X25 25B SCREW SHCS STL BO 4 26 M8 74B WASHER EXT TOOTH STL BO 4 27 1 4 20X1 24B SCREW HEX HD STL BO 4 28 15759 WASHER 1 4 HARD BLK OX 1 8 THK 4 33 10 32X3 4 25B SCREW SHCS STL BO 1 36 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 1 37 16350 FERRULE SPROCKET 1 38 1 2 70P WASHER FLAT USS STL PLAIN 2 39 1 2 2051Z NUT HEX JAM STL ZINC 2 40 1 2 75Z WASHER EXT TOOTH STL ZINC 2 41 M10 1 5X75 25B SCREW SHCS STL BO FULLY THD 8 42 15616 HANDWHEEL ASSY MX 1 43 15614 TAB WASHER 1 44 21946 ELECTRONIC HANDWHEEL KIT DPMS5 1 45 M6 1 0x75 25B SCREW SHCS STL BO 4 46 M6 1 0x25 25B SCREW SHCS STL BO 4 47 22348 BEARING HOUSING 1 48 21985 SPACER 30 DEGREE Y AXIS DRIVE ASSY 1 TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List
138. move 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 varidisc pulley This is a slight press fit 4 Remove the 2 springs 5 Replace the brake shoes 5 1 26 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 Figure 48 2 AY NN N SET 2 S SCREW Av PD AS Vh NOSEPIECE LEFT HAND SS THREAD SS HOLE FOR SPANNER WRENCH i00157 137 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 2 Maintenance 5 2 1 Gib Adjustments The objective of adjusting the gibs is to eliminate as much play in the table saddle and ram sliding surfaces as possible without having the tightness of the gib interfere with the
139. n the top of the ram Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the bottom of the ram Tighten the gib lock screw on the bottom of the ram Tighten the gib lock screw on the top of the ram to lock the gib in place and recheck Repeat as necessary Run Service Code 12 to se the feed forward constant Repeat the procedure for the back gib on the right side of the machine 5 2 1 7 Ram Side Gib Adjustment 2 Axis 1 2 Clean all chips dirt and excess oil from the column ways Attach a 0001 dial indicator with a magnetic base towards the rear of the table on the right side of the ram Place the indicator stylus on the ram in line and below the lower mounting bolt for the coolant hose connector block See Figure 55 Lock and unlock the lower ram side gib lock and note the amount of movement on the dial indicator Adjust the ram side gib until the registered movement is 0005 0010 145 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual To adjust the gib for excessive clearance Loosen the gib lock screw on the bottom of the ram Estimate the amount of gib lock screw adjustment reguired and tighten the gib lock screw on the top ofthe ram Tighten the gib lock screw on the bottom of the ram to lock the gib in place and recheck Repeat as necessary To adjust the gib for too small of a clearance Loosen
140. n serviced in a long while Contact area of gibs May need to be scraped Very old machines may not have any more adjustments on gib A new gib will need to be fit on the machine Inadequate gib contact Inadequate lubrication Ram gibs loose Parts incorrect dimensions Vibration or jerky motion in Z axis Head out of tram in Y direction Machine not level Weight not distributed evenly on all six screws See Leveling procedures Parts incorrect Machine geometry off i e tram New installation or heavy crash Head out of tram Leaves uneven surfaces on Machine not level ram gibs loose See Tramming Head Section 5 2 3 bottom of pockets 59 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 4 1 2 A Special Word About X Y Z Gibs The slideway surfaces are vital to the performance of the bed mill Gibs should be e flat e free of twist e free of burrs e free of blockages in the oil passages and channels Defective or scarred gibs must be replaced Shimming of gibs will not yield acceptable results It is good machining practice to avoid the use of shop air to clean the chips off a machine This risks blowing chips into the sliding way surfaces and compromising the performance of the machine Gibs that are not adjusted correctly will affect the performance of the machine It will lead to positioning and repeatability problems The gibs should be
141. n this bearing should be replaced Verify nosepiece is tight on bottom of To check if the nosepiece is bottomed out try to insert spindle a piece of paper in between the nosepiece and the quill If a piece of paper does fit then this may be the problem Before tightening or loosening the nosepiece make sure to loosen the setscrew that holds it in place Spindle bearings are worn out This is categorized by a high pitch sound and is most evident at high RPM s It should also cause chatter under load Replace the spindle if this is the case See spindle replacement in Section 5 3 5 5 1 Head Noise for Machine with the Optional Spindle Control Drive 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 isolate the noise by seeing if it exists in high low or neutral speed range 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
142. nd the 9 pin E Stop cables The cables are to stay with the computer module Now slide the module about 32 way out of the LCD enclosure Remove the ground wire from the LCD enclosure side 10 Lastly slide the unit completely out of the LCD enclosure 11 Replace computer module or LCD enclosure 86 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 12 Follow the instructions in reverse order when reinstalling the new computer module or LCD enclosure 13 Make sure that all connectors are properly seated before fastening the unit back in place 87 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 10 32 FLAT HEAD SCREWS A A D e 10 32 SCREWS TYPICAL SMX PENDANT ASS Y WITHOUT COMPUTER 24008 1 SLX PENDANT ASSY WITHOUT COMPUTER 24008 3 SMX PENDANT ASSY PART 24000 1 SLX PENDANT ASSY PART 24000 3 Figure 23 Computer Module amp LCD Enclosure Replacement 88 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 4 System Flash Disk Replacement 10 11 12 13 14 15 From the control go to SETUP SERV CODES SECTION A and then code 142 and save your Configuration file calibration values etc on a floppy disk There is a disk in the electric s cabinet for this pu
143. ng or elasticity of all the parts of the drive train under load The backlash constant is factory set but may need to be adjusted periodically 1 Seta 0001 inch dial indicator in the spindle and touch off on a block or the vise along the direction X Y or Z you wish to check or set the backlash constant 2 Turn on the ProtoTRAK and at the Main Menu follow the procedure below precisely aa 0 00 a Press MODE C 5 f Backlash Value f What is shown is the current value Follow the instruction on the screen and press the appropriate soft keys Wait a few seconds between each INCR VALUE or DECR VALUE press g The following is an example of what you For example if the up and down Oscillation might see when running this code Value shown in the conversation line is 00278 inch and the dial indicator is moving back and forth 0012 then the true backlash value is 00278 0012 00158 inch Input this by pressing MODE SET UP SERV CODE 128 SET and then 00158 SET RETURN 3 The X backlash identified and stored in Step 2 should be less than 0 003 on a new machine If it is appreciably larger inspect the drive train for loose bolts brackets bearings etc The backlash can also be found manually with a 0 0001 indicator with the following method e Load the indicator to zero from one direction and zero out the DRO e Move the indicator to 0 002 and then back to zero Do not over shoot
144. nsor Direction This service code reverses the direction of the encoder 4 9 2 13 Code 337 Spindle calibration for machines with programmable spindle This service code is used to calibrate a programmable spindle You must also use a tachometer 4 9 2 14 Code 338 Selects 1 or 2 input type limit switch 4 9 3 Diagnostic Codes The following codes are used primarily when diagnosing a problem with the machine To get to any of these codes go to Service Codes press C and press the code you wish to view 4 9 3 1 Code 54 Program Continuous Run This Code runs a program continuously without stopping for SET Z or CHECK Z commands It is helpful in running a long period to identify an intermittent problem 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 4 9 3 2 Code 81 Keyboard Test This code is used to check if the keyboard is functioning correctly It allows you to test each key on the pendant individually When you press the keys the corresponding box for that key will highlight on the screen The pendant will also beep indicating that the key is working correctly If one of the keys does not work the pendant assembly may need to be replaced If none of the keys are working chances are that the computer module will need to be replaced 4 9 3 3 Code 131 Manual DRO A manual diagnostic routine to check the mot
145. ock Spring Replacement amp Adjustment 133 5 1 22 Spindle Motor Removal amp Replacement 134 5 1 23 Drive Belt Replacement 135 5 1 24 Timing Belt Replacement 136 5 1 25 Brake Shoe Replacement 137 5 1 26 Spindle Replacement 137 Maintenance 5 2 1 Adjustments 138 5 2 2 Calibration amp Backlash Constants 146 5 2 3 Head Rotation and Tramming 149 5 2 4 Limit Switch Option 150 Figures amp Parts List Machine Footprints 7 Overall Dimensions 8 DPMSX3 Component Identification 13 DPMSX Rear View 14 Lifting the Machine Method 1 16 Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Lifting the Machine Method 2 Placement of Levels Leveling Screws Wiring the DPMSX2 DPMSX3 amp DPMSX5 Non Spindle Control 10 1Wiring the DPMSX2 DPMSX3 or DPMSX5 Spindle Control 10 2Wiring the DPMSX2 DPMSX3 or DPMSX5 Spindle Control 11 Flange Disconnect Transformer Option 12 Transformer Option Schematic 13 Air Regulator Solenoid Assembly 14 Pendant Cable Connections Left Side 15 Pendant Right Side 16 Cable Connection Diagram Non Spindle Control 17 Cable Connection Diagram w Spindle Control Option 18 Euclid Block 19 Electrical Box Schematic Non Spindle Control 2
146. of the M5 base Do not tighten the clamp screw fully until after loading the sensor 100019 Figure 26 TRAK Sensor Mounting 93 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 101160 Figure 27 DPMSX2 Sensor Assembly 94 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Item P N DESCRIPTION 1 M250C SENSOR ALL TRAK PRODUCTS 2 M5 M 5 BASE 3 LDCEL C LOADCELL M250C 4 M5 HDWR HARDWARE M5 BASE 5 16023 1 BRACKET SENSOR X AXIS 6 21511 EXTENSION 7 24227 BAR RUN Y AXIS 8 13777 1 BRACKET SENSOR Y AXIS 9 13346 3PK CHIP SCRAPER M250C 101160 95 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual p ae cu 1 e pp S10Nd0yd TY HOSNIS 205214 i st SKv AHOSNaS HdAOO mer Og MS S2HSMwuuos asz mere 6 09 15 5035 LXd 1lHd Hd MIHOSI s ewixeeo e TWAQ DS ILS 14S 20S MdHOS dora 9 EN 99200 DPMSX3 Sensor Assembly Figure 28 p 96 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual _ was oo sw 08e SOHSMAHOSJ SionacHdovul TIS XOSMASP SxvANosNsSHuAOD i SOVA HOSNAS i2wo
147. oid See Section 5 1 8 for more information on the power drawbar unit The air comes in through the manifold and passes through the air regulator The regulator branches into two components an oiler for the power drawbar unit and an air solenoid The solenoid is used for a misting system that the user may install later on this machine The mister air hose be plugged into the 34 quick disconnect air fitting on the solenoid See the figure below for an illustration 28 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual t HOOK AIR HERE WA FOR MISTER 101257 POWER CONNECTION FOR MISTER FROM ELECTRICS BOX ON VM 8 CABLE BREAKOUT BOX ON SM Figure 13 Air Regulator Solenoid Assembly P N 22380 1 Item P N Description 2 22378 MANI FOLD PT4 AIR 3 22607 FILTER REGULATOR PT4 4 22607 1 BRACKET MOUNTING KIT 8 22644 4 PLUG 1 4 NPT HEX SOCKET ADAPTOR ELBOW MALE 1 4 x 1 8 11 22646 4 20 M6 1 0X25 25B SCREW SHCS STL BO 24 22772 SOLENOID ASSY AIR REGULATOR 25 22773 OILER 29 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 2 14 Mounting the Display Pendant The ProtoTRAK SMX display pendant mounts to the pendant arm with four 1 4 20 x 34 SHCS that are shipped screwed into the left side of the display There is a locating screw
148. on Maintenance Service amp Parts List Manual Z Axis Drive Assembly Parts List em PN Description 16806 M BALLSCREW ASSY Z AXIS mal PJ540015 BRACKET LOWER ELEVATING BALL SCREW 22583 BEARING SELF ALIGNMENT SKF 2205E 2RS1TN9 4 116774 I COVER BEARING gt BEARING e rires HODIFEDBEVEL GERTBSTERRZR SCREW SOC SET STL BO CUP 8 M6738 WASHERSPLITLOCKSTLBO 9 M610x25258 SCREW SHCS STLBO NILOS RING 7205 RING BEARING HOUSING 13 23940 BEARING SET ANGULAR CONTACT 7205 BECBP SCREW SHCS STL BO SCREW SHCS STL BO 17030 LOUVRE SPACER M10 1 5X45 25B SCREW SHCS STL BO M10 71B WASHER FLAT SAE STL BO 98481A090 KEY WOODRUFF 404 1 8 X 1 2 100771 Z S 130 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 18 Air Solenoid Replacement for Power Drawbar Unhook the air from the machine Unplug the power cable that connects to the right side of the air regulator bracket Remove the 2 screws that hold the connector to the bracket Tops Undo the airline that runs from the oiler to the power drawbar if that option is installed on the machine 5 Remove the 2 screws on the left side of the bracket that holds the air manifold to the U shaped bracket 6 With the assembly in hand unthread the solenoid from the rear of the air regulator The solenoid and cable will be replaced a
149. op port with the E stop in the out position This will cause the spindle to not run 49 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 3 3 11 E Stop Error The E Stop turns the power off to the axis and spindle motors This is done by stopping 110V power from reaching the cable breakout box through the use of a relay in the pendant Once power reaches the cable breakout box it distributes power to the axis motors auxiliary functions and 110V power to the spindle contactor If power does not reach the cable breakout box then none of these functions will work for non spindle control machines Spindle Control Electrical Box A 5 volt signal is sent to the spindle control board which energizes a relay that enables the AC drive Non Spindle Control Electrical Box 110V Power reaches the electrical box through the AC E stop cable It is used to energize the spindle motor contactor If this contactor is not energized the spindle will not turn on 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 pendant Does 110 V power come out of the cable breakout box power cord on the pendant If yes and
150. or 9 To reinstall motor do these steps in reverse Figure 46 100155 134 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 22 1 Spindle Motor Removal and Replacement for Machine with the Spindle Control Option 1 Disconnect the power to the motor It is recommended that the power disconnect be made from the shop feeder box 2 Disconnect the electrical connection in the conduit box attached to the motor 3 Remove the three bolts that hold the motor pulley cover in place to gain access to the belt 4 Remove the four bolts that mount the motor to the top head housing and slide motor forward and remove belt CAUTION The motor is heavy about 80 pounds Be certain you have the proper equipment or assistance 5 Tilt the motor towards the back and remove the belt from the motor pulley Remove the motor 5 1 23 Drive Belt Replacement 1 Remove the motor 2 Remove the draw bar and its bushing 3 Remove the three Screws A and use M6 x 35mm screws in the adjacent tapped holes to remove the Bearing Cap 4 Remove the nut from the fine speed adjustment Screw B and turn the screw all the way down through the casting Catch it from the motor hole 5 Remove six Screws C holding the belt housing to the subplate 6 Remove the four screws holding the speed changer 7 Remove the belt housing 8 Replace the belt by sliding it over the speed ch
151. or 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 before the calibration and backlash factors have been factors into the counts 4 9 3 4 Code 314 Toggle Test Lights On in Status Line This code toggles on and off 2 test lights that appear in status line The top light signifies if the master software is working If functioning it should flash a green light The bottom light signifies if the slave firmware is functioning It will appear orange in run mode when it is processing information Pressing the mode key will change this orange box to black The orange box will also change to black when the program you are running reaches the 3 event from the end of the program If the firmware is locked up no keys will work This code is useful for diagnosing intermittent problems with the control locking up Turn the X Y or Z axis electronic hand wheel The display should show movement as the hand wheel is being turned There should be no skipping and it should count smoothly while the hand wheel is being turned One revolution of hand wheel should read 0 2000 81 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 4 9 3 5 Code 319 Error Log This code when turned on captures the commands that were sent to the servo system It includes items such as positioning commands
152. ounting 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 65 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Motor encoder and secondary feedback machines run Service Codes 100 or 131 Both the motor encoder and sensor or glass scale encoder should count on the DRO screen The motor value should be displayed under the Z axis and the sensor or glass scale under the X or Y axis depending on which axis you are doing 4 4 3 Encoder Counts to Pendant Before replacing the motor due to a bad motor encoder it is a good idea to check the cables that take those signals back to the pendant If these signals are not getting back to the pendant then the axis will fault Check the following cable connections e Umbilical 1 and 2 at the cable breakout box e Umbilical 1 and 2 at the pendant e Umbilical 1 carries the X and Y axis signals and Umbilical 2 carries the Z signals 4 4 4 Moving Problem from One Axis to Another Another way to troubleshoot a problem with a particular axis is to swap parts from 1 axis to another to see if the problem moves If the problem moves then that component is faulty See the example below Symptom X Axis will not move and faults This particular problem can happen because of any of fol
153. ounting bracket To align this bracket move the saddle as far to the front of the machine as possible Loosen the bracket and then retighten it Once again moving the saddle forward allows the yoke to be as close to the bearing housing as possible The yoke is pinned at SWI should not become misaligned unless the machine has been repeatedly crashed 4 3 Computer Pendant Diagnostics 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 Make sure to first unplug any accessories like the Remote Stop Go switch external keyboard mouse etc to eliminate any interference Possible problems Can lead to Poor cable connections There are 4 cable connections 6 spindle control to the left side of the pendant Make sure all cables are properly fastened Pendant locks up Press the E stop button and see if lock up clears if not then do the following Turn the pendant off wait at least 30 seconds and turn it back on and check to see if the malfunction has been reset No voltage to RSG port RSG will not work should be 5 DC volts present Check with a voltmeter Low voltage to flash drive or slave board Can cause the system to lock up and the flash drive to act abnormally Check voltage to power cable at flas
154. ower Drawbar A power drawbar is an optional item on the DPMSX machine It is bolted to the top of the head by the use of 3 SHCS Some machines may reguire a washer to space the unit up to the proper height to allow the drawbar to engage properly Air Regulator and Oiler This unit reguires between 80 and 100 psi to operate properly Some units work fine at 80 psi while others may need 90 or 100 psi It is also important to make sure the oiler for this unit is kept filled with oil Fill the reservoir about 2 3 full using AIR TOOL OIL ONLY Failure to do this will not allow oil to lubricate the internal components of the unit and it may wear out prematurely It is also important to make sure the oiler is set properly To set the oiler first close the adjustment screw CW on top of the oiler completely making sure to not over tighten Then open the screw CCW between 32 to of a turn Any more than this will cause too much oil to get into the unit and oil may come out of the exhaust port of the unit Tool Alignment Device This unit also comes with a tool alignment device which attaches to the bottom of the spindle This device allows the tool to easily be aligned with the dogs when loading a tool CAUTI ON Some tools may not work with this device and the original spindle dogs will need to be used The original spindle dogs are shipped with each machine in the toolbox Some boring bar holders may not work with this device 102 Sou
155. own toward the table Over tightening or loosening can lead to other problems with the machine Typical adjustments with the gibs is 0 0005 or less 5 2 4 Limit Switch Option 5 2 4 1 X Axis Limit Switch Stop Installation and Adjustment The limit switch stops for the X axis are mounted to the front side of the table The limit switch stop consists of a square bracket which is fastened to the T slot on the front side of the table Each limit switch stop must be set to a specific distance from the end of the table in order to maximize travel and simultaneously prevent serious damage to the machine in the event of a crash All limit switches are set at the factory for maximum travel Procedure for Setting X Limit Switch l Loosen the X axis square bracket on each side of the table 2 Slide each X axis square bracket within the T slot to the end of the table 150 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 3 Slowly move the table to one side by hand until the end of the travel is reached 4 n DRO mode set X 0 ABS CAUTI ON The limit switch must be triggered a minimum of 12 before the machine reaches its travel limits in both directions This allows sufficient room for the servomotors to stop when the limit switch is hit at 150 ipm 5 Using the DRO display back the table off 1 2 6 Lock the limit switch bracket in place 7 Jog the table
156. 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 75 mm or 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 6 Follow the instructions on the screen to complete calibration SPINDLE USE SHORTEST mn Qi POSSIBLE DIAL ROD DIAL INDICATOR MACHINE TABLE MACHINE FRAME i00022 Figure 56 Calibration Set Up If you have installed TRAK Sensors move each axis through its travel 4 6 times in order to allow the gage wheel to establish its track 147 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 2 2 2 Backlash Compensation Code 11 Set X or Y backlash constant Note this procedure is on systems with TRAK Sensors or Glass Scales only Go to setup mode go to section B and press CODE 11 Refer to service code section for further explanation Code 127 Set X or Y Backlash Constant Note this procedure is only for systems without TRAK Sensors or Glass Scales Every mechanical system has at least a little backlash or lost motion It is produced by the small amount of play between the gibs and ways and mostly by the accumulative bendi
157. properl Screen saver has been activated Press any key to turn back on All LED keys on pendant will blink when the screen saver is on Press any key to deactivate Hitting this key will not activate any feature on the control The system has shut down Turn the power switch off check the TI computer pendant fuses and cable connections See Electrical Section 4 8 Poor cable connection from Computer Module to LCD Liguid Crystal Display module to the LCD 3 3 2 Bad Picture on the Display The display has strange characters horizontal bars or other unfamiliar images or the display continually rolls Possible Cause Check This Poor cable connection from Computer Check connections on computer module Module to LCD Liguid Crystal Display Computer Pendant failed See Computer Pendant Section 4 3 3 3 3 Keyboard Lockup The screen display is normal but the system will not respond to key presses Do the following Service Codes and procedures e Code81 To check if the pendant keys are working properly press each key If the key is working the corresponding key on the screen will light up The pendant will also beep 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
158. r use the loop to pull the connector from the Servo Driver If the problem moves to the other axis and clears up from the original axis replace the Servo Driver 4 6 Glass Scales Glass scales are used on the X and Y axis for secondary feedback They are optional on the DPMSX machines The Z glass scale comes standard with the machine 4 6 1 Alignment of Scales X Axis The X axis scale must be aligned within 0 005 in the up and down direction over the length of the scale for proper operation Misalignment can cause the scale to not read in the certain areas of the scale that are not aligned with the reader head If this happens the axis will mostly likely fault out in this area Also make sure the mounting hardware for the reader head is tight Loose hardware can cause excess backlash when reversing direction To align the scale place a 0 001 indicator on the bed ways and on top of the scale extrusion Move the table along its full travel from one end to another to verify it is aligned If the scale is misaligned loosen the 2 screws at either end to shift the scale up or down as needed You will also need to loosen the center support bracket to allow the scale to pivot Y Axis The Y axis must be aligned in the up and down direction and must be parallel to the Y axis way surface Both surfaces must be aligned to within 0 005 Failure to align the scale properly could cause the same problems as mentioned above Mount your 0 001
159. r an illustration of how to align glass scales 98 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 7 3 Install the Z Axis Glass Scale See Figure 30 1 Check the tram of the head in the X direction If it is within a few thousands then continue on If not tram 2 Assemble Z axis glass scale mounting bracket and mount to head Items 1 2 3 and 4 Tap items 3 and 4 together and tap item 3 into the quill stop knob Leave the bolt loose Use 2 screws item 6 and mount item 4 to the side of item 2 using a spacer between both items to provide a gap of approximately 0 040 between Items 2 and 4 This is to make sure item 2 does not rub against item 4 3 Align the glass scale bracket Item 2 with an indicator and tighten the mounting screws Leave the quill stop knob screws loose Remove the spacer and bolts from Item 4 4 Unscrew the shipping protection screw from the scale 5 Mount the glass scale to the mounting bracket and align it with an indicator It needs to be aligned within 0 008 with respect to the quill Tighten the screws down 6 Fasten the readerhead to the readerhead bracket 7 Move the readerhead up and down the glass scale and make sure the gap is consistent between the readerhead and the glass scale Tighten the screw to the quill stop knob 8 Remove the red head securing plate 9 Ifthe gap is not consistent between the readerhead and t
160. r to break the friction and create motion The Code 11 procedure is very useful and will help in diagnosing all types of motion and performance problems 1 Position the table and saddle in the center of travel Note You will lose your DRO position reference 2 Go into the Service Codes and input Code 11 3 The system will run the checking routine automatically and then display the values in the position readout 71 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Explanation As an overall measure of the system hysteresis we are looking for the X and Y values to be less than 004 A value greater than this indicates a problem with either excessive friction or play that may affect the finish or accuracy of machined parts 49 2 2 CODE 12 Feed Forward Constant The Code 12 procedure helps the control learn the friction characteristics of the machine by sending a graduated series of motor signals and observing the results The process takes less than 30 seconds to run It is both a diagnostic routine that displays values and a routine that sets the parameters of the control for the particular machine The Code 12 is used for diagnosing and resolving 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 chan
161. range Test the following in the order presented 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 e Power cord defective Check the end that goes to the electrics box It should be an 8 amp fuse the 4 outlets on the electrical box 4 8 2 Checking Fuses There are 5 fuses to check in the system There are 2 in the pendant and 2 in the electrical cabinet The top fuse in the electrical cabinet is 8 amp and fuses power to the pendant The bottom fuse is 5 amps and fuses power to the auxiliary 1 auxiliary 2 and lube pump outlets The 2 fuses in the pendant are 1 amp and 8 amp The 8 amp fuses the cable breakout box and the 1 amp the pendant If you have the auxiliary function option then there is 1 more fuse to check on the cable breakout box for the coolant or mister option 70 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List To check fuses 1 Use a Volt Ohmmeter select OHM 2 Removethe fuse completely from the pendant electrics box or cable breakout box 3 Place a lead of the meter on each end of the fuse e A good fuse reads 0 zero or close to it e bad fuse reads Open or Infinity 4 8 3 Cable Breakout Box Connections This module is located on the back side of the machine It consists of 3 motor connections 3
162. recheck Repeat as necessary 5 2 1 6 Ram Back Gib Adjustment Z Axis 1 Clean all chips dirt and excess oil from the table and saddle 2 Disconnect one end of the upper and lower way cover where it is attached to the ram 3 Position the milling head such that the table can be reached by extending the quill approximately 3 4 of its travel 4 Place a wood block on the table underneath the spindle 5 Attach a 0001 dial indicator with a magnetic base to the column near the base of the ram on the left side of the machine Place the indicator stylus on the rear surface of the ram near the bottom 144 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Figure 54 Ram Back Gib WOOD BLOCK DIAL INDICATOR 100158 6 Extend the guill until it touches the wood block Using the guill handle push the 7 8 spindle nose against the wood block and note the amount of movement on the dial indicator Adjust the left side gib until the registered movement is 001 0015 To adjust the gib for excessive clearance Loosen the gib lock screw on the bottom of the ram Estimate the amount of gib lock screw adjustment reguired and tighten the gib lock screw on the top of the ram Tighten the gib lock screw on the bottom of the ram to lock the gib in place and recheck Repeat as necessary To adjust the gib for too small of a clearance Loosen the gib lock screw o
163. rive Train for any binding or looseness It may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 4 2 Axis Motor belt too tight Loosen belt Misalignment of ball screw See Mechanical Drive Train X Y Section 4 2 3 2 6 Searching Axis The handwheels are slowly turning back and forth when the servos are engaged Several thousandths of motion are observed on the vernier dial and the frequency is one cycle every couple of seconds Do the following Service Code and procedures e Code 11 Measures backlash in system Used only with glass scales and sensors e Code12 Sets feed forward power constant to drive axis motors e Code 127 Measure s the backlash in the system Only used on machines with Single Feedback Code 128 Backlash compensation on single feedback machines compensation code 128 Run code 11 on dual TEN machines should be between 10 to 15 in Ibs See Machine Tool amp Setup Section 4 1 The drive train of the axis that is searching especially the tightness of the drive assembly See Mechanical Drive Train X Y Section 4 2 45 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 3 3 Problems Relating to the Operation of the Control 3 3 1 Display Blanks The display is completely blank Possible Cause Check This System flash drive loose Make sure flash drive is seated
164. rpose Label this disk as Backup Configuration and store it for later use Turn power off to the machine and control Unplug all the connectors on the pendant arm side of the pendant Remove the pendant from the pendant arm by removing the 4 34 20 x 3 4 SCHS that secure it in place Place the pendant assembly on a clean and secured table with the display pointing away from you Remove the 6 10 32 x 3 8 Pan Phillips Head Screws and 4 10 32 x 3 8 FHCS securing the computer module to the LCD enclosure Pull the computer module a few inches and stop Pulling the computer module too far will damage the ribbon cables Remove the defective System Flash Disk located on the back side of the mother board by pushing the eject button on the flash drive Firmly insert the replacement System Flash Disk into the drive making sure that the label with the serial number is pointing towards the motherboard Secure the computer module back to the LCD enclosure by following the instructions in reverse order Make sure that all connectors are properly seated before fastening the unit back in place Turn power on to the machine and control When the system boots you may get a message stating that the system cannot find your configuration file Press NO if asked to load defaults Update the System Software by inserting the PT4 update disk into the floppy drive Go to service codes 316 and 317 found in section A Update the master and sl
165. s 2 12 Electrical Connection The DPMSX2 SX3 amp SX5 Bed Mills can be configured for 220 or 440 volt 3 phase electricity These machines also require a 110V power source to power the control 20 Southwestern Industries Inc DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service 8 Parts List Note Machines with Optional Spindle Control is only available in 220V configuration DANGER Be certain that 200 volt electricity typical range 208 240V is used only with a machine labeled 220 volts at the motor and atthe 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 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 qualified electrician should wire the 220 or 440 volt 3 To convert a DPMSX2 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 th
166. s a unit See Figure 13 in Section 2 for an illustration of this assembly 5 1 19 Spindle Motor Wiring The DPMSX spindle motors are wired for 220 or 440 volts See Figure 43 for how to wire the motor Note Machine with the Spindle Control Option can only be wired for 220V 131 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual MOTOR JUNCTION BOX REMOVE JUMPER PAINT FOR GROUND GROUND SCREW 220V CONFIGURATION JUMPER 440V CONFIGURATION i00869 Figure 43 Spindle Motor Wiring 132 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 20 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 l Release the lock nut 2 Engage the trip handle move it left 3 Adjust the micrometer nut against the quill stop knob 4 Slowly turn the adjusting screw until the handle trips 5 Tighten the lock nut 6 Check the reaction If too sensitive lower the adjusting screw slightly If too heavy raise it QUILL STOP NOB MICROMETER NUT Figure 44 TRIP HANDLE amp 3t D m ENGAGE a NUT ADJUSTING SCREW 100153 5 1 21 Quill Clock Spring Replacement and Adjustment The quil
167. s code is used when a computer module or hard drive needs to be replaced This stores the configuration file from the hard drive to the floppy disk It is a good idea to do this code after the machine is initially setup so these values can be saved and used in the future If the computer or hard drive fails then you will not have the ability to save the configuration file and the machine will need to be re setup when the computer or hard drive is replaced Note All machines will have a copy of the configuration file on the included parts program floppy disk 4 9 1 4 CODE 313 Display Configuration File This code displays the configuration file This file contains pertinent information about the machine The file will look similar to the following If the file becomes corrupt you can load default values by pressing the F4 softkey Product DPMSX3 displays machine ID key of machine Motor encoder calibration constants X 1143 9002 Y 1143 8982 Z 1143 7922 Secondary feedback calibration constants X 3302 6122 Y23302 6045 2 3302 7122 76 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List These numbers above are typical numbers for the calibration constants the numbers for secondary feedback are default numbers which means no calibration has been done or the machine does not have secondary feedback Arc accuracy 0 001 Secondary feedback 0 1 2 or 3 0 off 1 Xon only
168. s light will be on only when the Z axis plus limit switch is triggered This only applies to a 3 axis product LED labeled Z LIMIT MINUS this light will be on only when the Z axis minus limit switch is triggered This only applies to a 3 axis product 73 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List E pa OE ord SD H A A tet Aee PAHBL 5 A BBhbhbER E Ep E z 4 lt z b Figure 20 Schematic Diagram of Spindle Control Option 74 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service 8 Parts List 01112 SPINDLE CONTROL ELECTRICAL BOX GEARS GEAR 1 NOTUSED NOT USED OTn LED D VIEW OF PCB ASSY LEDS LABEL Figure 21 LEDs on Spindle Control Board 75 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 4 9 Service Codes Service codes are broken down into the 4 following categories software machine setup diagnostics and user options defaults All Service Codes are accessed in the SET UP Mode by pressing the soft key for SERV CODES The service codes can be found under one of the headings listed on the main Screen Press the heading you want to access the code in question If you know code you want press the CODE softkey and it will ta
169. s travel e Dirt or chip on the glass scale e Broken glass 4 7 TRAK Sensors TRAK Sensors are used on the X and Y axis for secondary feedback They are optional on the DPMSX machines The following section talks about some of the common symptoms associated with a problem sensor and how to isolate or fix the problem Common symptoms e Faulting Axis e The DRO measurements do not repeat e The DRO measurements are not accurate Objectives e To determine if the TRAK Sensor is bad and needs to be replaced e determine if there is a problem with the sensor set up 4 7 1 Faulting Axis If a sensor has stopped reading and you try to move an axis the axis will run away and fault Our control uses the counts from the sensor and motor when reading position If either one of these signals is not working our system will fault l The first thing that can be done to see if it is the sensor is to turn off the sensor on the axis in question This will allow the system to run only on the motor encoders If the fault continues then the sensor was not the problem Turn the sensor back on See the service code section for a codes needed to turn the sensors on and off 68 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 2 The nextthing to do is to visually inspect the sensor and base to determine if there has been a crash A damaged base will usually have crinkles in the small
170. sitional Accuracy procedure Step by step carefully inspect the Drive Train for any looseness It may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Y Section 4 2 Head Bolts are loose Verify that all the head bolts are tight 3 1 3 Taper Cut on a Programmed Straight Line Move An unwanted tapered cut occurs when the machine is programmed to move in a straight line along either the X or Y axis The DRO shows motion of a few thousandths of an inch in the axis that is not supposed to be moving 40 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 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 e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 11 Measure s the backlash in the system Only used on machines with Dual Feedback systems e Code 12 Feed Forward Constant e Code 127 Measure s the backlash in the system Only used on machines with Single Feedba
171. sleeves neckties jewelry or other loose items when operating or around the machine e Use adequate point of operation safeguarding It is the responsibility of the employer to provide and ensure point of operation safeguarding per OSHA 1910 212 Milling Machine 1 1 Safety Publications Refer to and study the following publications for assistance in enhancing the safe use of this machine Safety Requirements for Manual Milling Drilling and Boring Machines with or without Automatic Control ANS B11 8 2001 Available from The American National Standards Institute 1819 L Street N W Washington D C 20036 Concepts And Techniques Of Machine Safeguarding OSHA Publication Number 3067 Available from The Publication Office O S H A U S Department of Labor 200 Constitution Avenue NW Washington DC 0210 1 2 Danger Warning Caution and Note Labels 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 that cou d result in severe personal injury and or damage to the equipment Warning labels on the machine are orange in color CAUTION Hazards or unsafe practices which could 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 attention or understanding 1 Sou
172. ssage from the pendant LED labeled SPD RUN this light should be on whenever the spindle is on LED labeled SPD ENABLE this light should be on whenever you are in DRO tool setup and RUN mode 2 10 LED Segment LED labeled E STOP OUT this light should be on whenever the E stop is in the out position When the E stop is pressed this light should go off LED labeled LATCH RELAY this light should be on when the spindle is running or if the spindle is not running and the fwd rev switch is in the off position when in DRO tool setup or RUN mode Note if spindle won t turn on and the spindle is enabled and the e stop is out then either the fwd rev switch is bad or the spindle control board is bad LED labeled TAP MODE light should be on whenever you are not tapping Light will be off when in the tap event Not applicable to knee mills or retrofits LED labeled TAP REVERSE this light will be on when the spindle changes direction at the bottom of a tap event and back off after the spindle changes direction once outside of the tap event Not applicable to knee mills or retrofits LED labeled REV RELAY when fwd rev switch is in reverse this light will be on Note this does not mean necessarily that the spindle will be running this direction LED labeled FWD RELAY when fwd rev switch is in forward this light will be on Note this does not mean necessarily that the spindle will be running this direction LED labeled Z LIMIT PLUS thi
173. st Manual 5 1 17 Z Axis Ball Screw Removal amp Replacement CAUTI ON Never screw a ball screw partially or totally out of its nut They cannot be reassembled 1 Qo 09 E Cons Ene xs Uus PPP ja B WN 17 18 19 Ensure that there is sufficient vertical clearance above the top of the machine to remove the ball screw Minimum clearance required is 32 inches Remove vertical column top cover Remove servomotor belt and Z motor mounting bracket Remove upper and lower Z axis way covers Lower head to table Place 1 or 2 inch wood board between spindle nose and table to protect Lower head using manual hand crank until weight of head is supported by the table Tighten both ram locks on the right side of ram Remove locknut and lock washer from the top of the Z ball screw Remove pulley and woodruff key Loosen 10 32 socket screw on clamp nut Using wrench flats on clamp nut and wrench flats on ball screw remove clamp nut Remove the four cap screws from bearing housing flange Remove the clamp nut Remove bearing nilos ring and bearing housing with matched spacer from ball screw Remove 6 M6 cap screws and lock washers from ball nut flange Loosen setscrew from bevel gear Rotate ball screw by hand if necessary to access setscrew Extract ball screw assembly from machine until ball nut flange is above the top of the ram Support ball screw and remove lubrication line
174. the TRAK DPMSX2 SX3 amp SX5 Installation Maintenance Service and Parts List Manual and ProtoTRAK SM Programming Operating amp Care Manual have been studied and understood 2 Do not run this machine without knowing the function of every control key button knob or handle Ask your supervisor or a qualified instructor for help when needed 3 Protect your eyes Wear approved safety glasses with side shields at all times 4 Don t get caught in moving parts Before operating this machine remove all jewelry including watches and rings neckties and any loose fitting clothing 5 Keep your hair away from moving parts Wear adequate safety headgear 6 Protect your feet Wear safety shoes with oil resistant anti skid soles and steel toes 7 Take off gloves before you start the machine Gloves are easily caught in moving parts 8 Remove all tools wrenches chuck keys etc from the machine before you start Loose items can become dangerous flying projectiles 9 Never operate a milling machine after consuming alcoholic beverages or taking strong medication or while using non prescription drugs 10 Protect your hands Stop the machine spindle and ensure that the CNC control is in the stop mode Before changing tools Before changing parts Before you clear away the chips oil or coolant Always use a chip scraper or brush Before you make an adjustment to the part fixture coolant nozzle or take measurements e Before you
175. the screen has an E stop message replace the pendant 3 3 12 Limit Switch Error Optional Limit switches are installed on the table saddle and ram to prevent serious damage to the machine in the event of a crash In the event a limit switch is triggered a limit switch error will appear on the screen Critical Error 64 Servo Error X axis Limit Switch Correct the fault condition and continue To return the machine to its normal state of operation perform the following procedure 1 Use mechanical handwheels on X and Y to move switch off of trigger For the Z axis manually lift the arm on the trigger to return the limit switch to its normal position Then jog the ram up or down as necessary 2 Press the Mode or Return key to reset the control 3 Press the DRO key to enable the machine to once again jog 50 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual box are making poor contact described above Poor Limit Switch Cable connection Check for any pins that are loose pushed in or bent Verify that there is a good connection between the cables on the cable breakout box Limit Switch failure Does the limit switch problem move to the other axis If it does then the switch is most likely the problem Try this If it stays with the original axis then it could be the Switch 2 limit switch cables on the cable cable breakout box breakout box
176. the value after it enters This code is only used on machines with motor encoders only 4 9 2 7 Code 304 Toggles X Sensor or Glass Scale On Off This service code toggles the X sensor or glass scale on or off It is used to configure the machine and also is a useful tool for troubleshooting Code 313 configuration file displays whether the sensors have been turned on or off The line labeled secondary feedback explains which sensors or glass scales are turned on This line can read any one of the following 0 sensors or glass scales turned off 1 X sensor or glass scale turned on only 2 Y sensor or glass scale turned on only 3 both X and Y sensor or glass scale turned on 4 9 2 8 Code 305 Toggles Y Sensor or Glass Scale On Off This service code toggles the Y sensor or glass scale on or off See Code 304 for further explanation 4 9 2 9 Code 312 Toggles Limit Switch On Off 4 9 2 10 Code 321 Reverse Y Position Sensor Direction This service code reverses the direction of the encoder It may be needed if sensors or glass scales are mounted on different sides of the machine 4 9 211 Code 322 Reverse X Position Sensor Direction This service code reverses the direction of the encoder It may be needed if sensors or glass scales are mounted on different sides of the machine 80 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 49 212 Code 325 Reverse Quill Se
177. this is a chart that directs in the most logical steps 3 1 Problems Relating To Machining Results 3 1 1 Poor Finish The part finish is marred with scallops or is very rough Do the following Service Codes and document values e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 11 Measures backlash in the system Only used on Dual Feedback systems e Code 12 Feed Forward Constant e Code 127 Measures backlash in the system Only used on Single Feedback systems e Code 128 Enter backlash compensation Possible Cause Check This Too much backlash entered for code Verify nothing is mechanically loose and the backlash 128 or calculated with code 11 values are not higher than 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 4 1 unlocked Never use gib locks with a CNC machine Inadequate or no Lubrication to Make sure all the Way surfaces are getting proper Ballscrews and Way surfaces lubrication If not check to make sure that the lube pump is functioning properly Also check for any pinched or blocked oil lines See Lubrication Section 4 1 3 Check the adjustment of the X Y and Z axis Gibs See X properly Y and Z axis Gib Adjustments in Section 5 2 1 X amp Y axis
178. thwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 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 DPMSX2 DPMSX3 amp DPMSX5 Milling Machines It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels 2 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual DPMSX2 NO SPINDLE CONTROL OPTION 9 SOUTH WESTERN INDUSTRIES 1 2615 HOMESTEAD PLACE RANCHO DOMINGUEZ CA 90220 MODEL SINUM mm St ELECTRICAL RATINGS Fors es 30 PHAsE 60 Hz FLA OF LARGEST MOTOR AMPS SHORT CIRCUIT INTERRUPT AMPS ELECTRICAL DRAWING t CNC CONTROL ELECTRICAL RATINGS IF APPLICABLE 115 vo rs 8 James Pus o Leo JH MACHINE ONLY MADE IN TAIWAN DPMSX2 SPINDLE CONTROL OPTION SOUTH WESTERN INDUSTRIES 1 2615 HOMESTEAD PLACE RANCHO DOMINGUEZ CA 90220 MODEL SIN Je ELECTRICAL RATINGS 25 Jvouts ir James Sp HAse 60 JHz FLA
179. thwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual UL OND l 101131 Figure 33 Power Drawbar Assembly 103 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Parts List Item P N DESCRIPTION 1 22581 1 AIR GUM ASSY ONLY TOROUE RITE 2 22603 NST DRAWBAR DPMS3 3 20893 TOP WASHER 4 22380 2 AIR REGULATOR ASSY 5 22603 CAT DRAWBAR DPMS3 6 22581 2 SWITCH CONTROL HEAD TOROUE RITE 7 22581 4 NOSEPIECE FOR SPINDLE 8 1 4 NPT AIR FITTING 90 9 3 8 O D TUBING 132 LG 10 3 8 O D TUBING 27 LG 11 22641 NMTB DRAWBAR DPMS5 12 22641 CAT DRAWBAR DPMS5 13 22605 DRAWBAR DPMSX2 14 22604 SPACER DRAWBAR DPMSX2 104 Southwestern Industries Inc 101131 DPMSX2 SX3 8 SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 9 Ball Screw Replacement X Axis Table DPMSX2 CAUTI ON Never screw a ball screw partially or totally out of its nut They cannot be reassembled OL er ABI T Position the table in the center of travel Remove the X motor assembly Remove the motor mounting bracket and bearing housing Remove the right side bearing housing 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
180. triangular plates on the front and back Next make sure the sensor is preloaded correctly against the running surface There is a setscrew on the base that allows for adjustment If no outward signs of damage are present remove the sensor from its base and inspect the wheel for damage and wear If the wheel is worn smooth in the center replace the sensor Note Sensors should not wear smooth for many years of normal operation 5 If the sensor looks normal it is probably OK and there is a mechanical obstruction somewhere in the set up Look for the following possible problems e Broken sensor base e Broken bracket e Sensor tilted too much so that the wheel is not engaging the running surface e Sensor chip scraper has doubled back and is pushing the wheel away from the running surface e Sensor chip scraper is defective or has worn and is pushing the sensor unevenly 4 7 2 Measurements Do Not Repeat 1 Determine if the error in repeatability is random or accumulating e Mount a dial indicator in the quill e Touch off a fixed point on the table and set the DRO to 0 e Traverse away approximately 6 inches e Return and touch off again e Write down the reading on the DRO e Do not re zero the DRO traverse away and return several times e Write down the DRO readings Random error will be unpredictable and give scattered readings adding and or subtracting the error after each traverse with no pattern See Step 2 Acc
181. ts or repeatability problems See Figures 16 and 17 for a layout of the cable connections 5 1 6 TRAK Sensor 5 1 6 1 Replacing the M5 Base See Figures 25 and 26 1 Remove the sensor by removing the clamp screw and then backing the load screw out a few turns The sensor should lift off the base easily 2 Remove the old M5 Base by removing the two 1 4 20 hex head screws that are threaded into the base 3 Assemble the new base as per Figure 25 4 Use a bubble level to align the raised bumps on the base with the table for X axis or saddle ways for Y axis 5 A dial indicator may be used to align the bumps on the base instead of a bubble level 91 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 100018 Figure 25 M5 Base Mounting 92 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 6 2 Replacing the TRAK Sensor 1 Remove the old sensor by removing the clamp screw and then backing the load screw out a few turns The sensor should lift off the base easily 2 Install the new sensor on the M5 base using the clamp screw 3 Load the sensor against the running surface table or run bar using the load screw The white lines on the side of the M5 base tell you when it is loaded correctly Note You want to load the gage wheel against the running surface using the flat spring
182. umulating error will add roughly the same amount to the reading after each traverse See Step 3 For random error look for problems in the set up of the TRAK Sensor that have resulted in a loss of rigidity Common sources of random error include e broken base e broken bracket e loose puller screws e loose run bar e very loose motion of the table or saddle e loose clamp screw 69 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List 3 Accumulating error is almost always the result of the wheel not traveling in a path parallel to the motion of the axis This causes the wheel to skip at certain regular points in its travel e Inspect the base to determine if it has been damaged A damaged base will usually have crinkles in the small triangle shaped plates on the front and back e Use a bubble level or an indicator to adjust the puller screws so that the base is parallel to the running surface e inspect that the sensor is not cocked so that the case contacts the running surface e inspect the wheel for chips that are adhered or for gouges 4 8 Electrical 4 8 1 Checking A C Voltage This procedure tests for the 115V power for the control e Use a Voltmeter reading A C volts e Acceptable range is 100V to 130V Note systems running consistently close to the low values may have problems when normal voltage fluctuations push the voltage out of the acceptable
183. upport the table s weight Slide the table until the yoke is exposed CAUTI ON The weight of the table must be supported by the left to prevent damage or breakage to the dovetails 6 Remove the 2 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 Tilt the yoke it is pinned to remove the ball screw 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 10 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 10 32 clamp screw to lock the clamp nut in place See the diagnostics section under Mechanical Drive Train for an explanation of how to align the ball screw See Figure 37 for an illustration of the X axis drive train 114 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual DPMSX3 X Axis Dr
184. used in extreme cases where the AUTO routine did not solve the problem Manual adjusts above 12 may lead to servo related problems 4 9 2 3 CODE 100 Axis Open Loop Test Code 100 procedure is used to diagnose problems with the configuration of the system the encoders and incoming A C voltage 78 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List IMPORTANT SAFETY NOTI CE During this procedure the designated axis will be given a command to move at maximum speed for 1 second in the direction you choose Avoid crashes by making sure the quill is out of the way and by starting with the table and saddle centered MAKE SURE THAT NO ONE IS STANDING IN THE WAY OF THE TABLE OR SADDLE Note You will lose the DRO reference position This procedure is to be run for each axis that is servo driven and for both the plus and minus direction for each axis 1 Center the table and saddle and raise the head Make sure the gib locks are released 2 On the Pendant display go into the Service Codes and input the Code 100 3 The conversation line will say SELECT AXIS Inputthe axis Either X Y or Z 4 Inthe conversation line it will say WHICH DIRECTION PLUS e f you want to run in the plus direction press INC SET e f you want to run in the minus direction press then INC SET 5 In the conversation line it will say PRESS GO Press Go after you are sure that th
185. vud __ osrsi oi 1 O087H 2HSMdM2OS szwexoz v 8 09 15 5095 DEG mHd Hd M3HOS sie wixece9 8 TVAO O8 11S 13S JOSMIYUDS Ser 115 5 5 5 5 HL LX0Z L HOSNASSWNdC UVENM Bree gt SkWXHOSHSS HHAO TWLIWL3I3HSP _ SIXV X 435VdS 5 5 5 dO 31v Id SIKYX HOSNIS 1309744 29 DPMS5 Sensor Assembly Figure 97 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual 5 1 7 Glass Scale Replacement 5 1 7 1 Remove the X Y or Z Glass Scale 1 2 3 4 Unplug the glass scale connector from the cable breakout box Unbolt the reader head of the glass scale from its mounting surface Unbolt the glass scale enclosure from the table on X or the mounting spar on Y Install the head alignment bracket that came with the replacement scale to this scale to secure it for shipping back to SWI Failure to do this may cause the glass scale to get damaged during shipment The head alignment bracket secures the reader head so it cannot move and damage the glass in the scale Note I align the reader head on the new scale before removing it to fasten the old scale CAUTI ON Once the head alignment bracket is installed do not traverse the axis or the reader head will break 5 1 7 2 Install the X or Y Replacement Scale CAUTI ON If the scale is not long enough for the table it
186. when the switch is turned on or the system does not boot up Possible Cause Check This 110 V line is not plugged in Check incoming 110 V power source to black electrical cabinet Pendant On Off switch is Off Check the Pendant On Off switch Fuse blown in pendant or electrical Remove fuses and check continuity cabinet Flash Drive failure When the Computer Module starts the boot up process look at the 8 line on the Display Screen If the Mother Board of the Computer Module is communicating with the Flash Drive you will see Detecting IDE Primary Master Scan Disk SDCFB 64 If the Mother Board of the Computer Module is not communicating with the Flash Drive you will see Detecting IDE Primary Master None Also check the wiring connection between the Flash Drive and the Mother Board See Computer Pendant diagnostics Section 4 3 Computer Pendant has failed See Computer Pendant diagnostics Section 4 3 3 3 7 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 connections Check for any loose wiring or cables Computer Pendant failed See Computer Pendant diagnostics Section 4 3 3 3 8 System Shuts Off During operation the system shuts off and will not turn back on Possible Cause Check This
187. x12L 6 KB49 FRU K3 FEED REVERSE BEVEL GEAR 1 7 JFRU K3 BUSHING O 4 8 KB62 FRUKSKEY3X EiSL 7 9 K B50 FRU KsFEEDREVERSEGLUIGH 7 10 KB56 FRUKSPINOG3d9L T 11 K B51 FRU K3 FEED REVERSEBEVELGEAR 1 12 KB52 FRUKSBUSHNG 1 1 18 KB55 FRU K3 REVERSE CLUTCHROD 1 i00704 K2 K3 Figure 88 Feed Reverse Clutch DPMSX2 P N 20779 5 200 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual DESCRIPTION RU K3 SPINDLE R8 RU K3 SPINDLE DIRT SHIELD RU K3 BEARING 720772 RU K3 BEARING SPACER SMALL RU K3 BEARING SPACER LARGE RU K3 NOSE PIECE RU K3 SLEEVE RU K3 BEARING 6206ZZ 10 RU K3 BEARING LOCKWASHER9 30 RU K3 SPINDLE BEARING LOCK NUT 30 20N RU K3 STRAIGHT LOWER CLAMP RU K3 FELT OIL STRAINER RU K3 STRAINER UPPER CLAMP RU K3 SCREW PH HD M5 0 8X8L EARING SPACER SET Figure 89 Spindle Assembly DPMSX2 P N 20836 Q lt 100705 K2 K3 201 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual NOTES UNLESS OTHERWISE SPECIFIED TO COLUMN Z AXIS RIGHT SIDE SLIDING SURFACE TO BACK SLIDING SURFACE OF THE COLUMN RIGHT SIDE TO COLUMN RIGHT SIDE GIB SLIDING SURFACE i00661 E2 TO Z AXIS BALL SCREW TO BACK SLIDING SURFACE OF THE COLUMN LEFT SIDE TO COLU
188. y a good grade of general purpose grease through the grease fittings on the back of the head and on the left side of the head This grease lubricates the Low range gear set and the feed change gears respectively Also lubricate vari disk on spindle motor by means of grease fitting on motor shaft 36 Southwestern Industries Inc TRAK DPMSX2 SX3 amp SX5 Safety Installation Maintenance Service amp Parts List Manual Every Four Months DPMSX5 X Handwheel Drive Mechanism Remove X handwheel drive cover and apply a general purpose grease to the drive gears 2 17 ProtoTRAK SMX Euclid Block Procedure The test part should be machined at the completion of the installation The material for the Euclid block test part is found in the toolbox e Material Specification Aluminum 6061 T6 or T4 e Blank Size minimum dimensions 3 x 3 x 1 provided in tool box e Tool 750 end mill 2 flute high speed steel sharp e Coolant Flood coolant Cool Tool or Kerosene Mount vise and indicate the back jaw parallel to the table within 0005 2 Clamp material in vice with a minimum of 800 above the vise jaws Load in the Euclid block program from the ProtoTRAK SM flash drive it is part number euclid PT4 It is found under the PT4 folder followed by the SWI TEST PROGRAMS folder Use an edge finder to set Absolute 0 on X and Y Absolute zero is the front left corner of the block as viewed from in front of the machine Load the 750

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