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TRAK® TRL 1540V, 1840V & 2460V Lathes

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1. Item P N Title UseAs Qty 1 20982 SADDLE TRL 1840 CSS EA 1 2 20996 COVER PLATE TRL 1840 X AXIS EA 1 3 M6 1 0X12 27 SCREW BHCS STL BO EA 2 4 20981 CROSS SLIDE TRL 1840 CSS X AXIS EA 1 5 20960 YOKE TRL 1840 X AXIS EA 1 21 21978 BRACKET PT4 X AXIS DRIVE EA 1 22 M10 1 5X80 25B SCREW SHCS STL BO FULLY THD EA 4 23 21979 BRACKET MOUNTING MOTOR PT4 X AXIS DRIVE EA 1 25 M8 1 25X30 25B SCREW SHCS STL BO EA 4 28 21996 COVER ASSY PT4 X AXIS DRIVE EA 1 29 5 0 8 10 27 SCREW BHCS STL BO 13 30 20980 BED TRL 1840 CSS EA 1 34 20988 CABLE WAY EA 1 35 M6 1 0X14 25 SCREW SHCS STL BO EA 2 36 20987 CONNECTOR CABLE WAY EA 1 37 M6 1 0X20 25B SCREW SHCS STL BO EA 8 39 M6 70B WASHER FLAT USS STL BO EA 8 40 22521 FITTING LIGUID TIGHT 3 8 NPT EA 1 Item P N Title UseAs Qty 7 20984 BALLSCREW X AXIS 1 1 8 5 16 18X1 25 SCREW SHCS STL BO 4 9 16300 BEARING HOUSING EA 1 10 23930 BEARING ANGULAR CONTACT 7204 BECBP SET 1 11 15885 RING BEARING HOUSING EA 1 12 M6 1 0X25 25B SCREW SHCS STL BO EA 4 13 16314 NUT CLAMP X AXIS EA 1 14 10 32X3 4 25B SCREW SHCS STL BO EA 1 15 16350 FERRULE SPROCKET EA 1 16 16983 1 PULLEY SOLID 44 TEETH W O GUIDES EA 1 17 W02 LOCKWASHER EA 1 18 NT02 NUT LOCK EA 1 20 500 5 15 BELT 1 24 8 70 5 USS STL BO 4 25 8 1 25 30 25B SCREW SHCS STL BO EA 4 27 8
2. 114 21234 114 SOCKET HEAD SCREW M12X55L 2 115 21234 115 ADJUSTING BLOCK EA 2 116 21234 116 POSITIONING PIN EA 2 117 21234 117 HEADSTOCK NAME PLATE EA 2 118 21234 118 REVIT 2X5L EA 16 119 21234 119 OIL SIGHT GLASS EA 2 121 21234 121 COLLAR EA 2 122 21234 122 DOUBLE ROUND HEAD KEY 5X5X20L EA 2 123 21234 123 BALLBEARING DEEP GROOVE 6006ZZ EA 4 124 21234 124 INTERNAL RING EA 2 125 21234 125 SYNCHRONOUS BELT 270L050 EA 2 126 21234 126 SYNCHRONOUS PULLEY EA 2 127 21234 127 DOUBLE ROUND HEAD KEY 5X5X20L EA 2 128 21234 128 WASHER 8 5 30 3 EA 2 129 21234 129 SPRING WASHER 8 EA 2 130 21234 130 SOCKET HEAD CAP SCREW M8 X25L EA 2 131 21234 131 SHAFT EA 2 132 21234 132 EXTERNAL RING EA 2 133 21234 133 BRACKET EA 2 134 21234 134 SOCKET HEAD CAP SCREW M10 X30L EA 4 135 21234 135 FLAT WASHER 10 EA 4 136 21234 136 SPEED CODER EA 2 137 21234 137 SOCKET HEAD CAP SCREW M5X25L EA 4 138 21234 138 SPRING WASHER M5 EA 4 139 21037 01 BEARING CAP EA 1 140 21037 02 GEAR SHAFT EA 1 141 21037 03 SLEEVE EA 1 142 21037 04 GEAR EA 1 143 21037 05 GEAR EA 1 144 6003 2NSE BALLBEARING DEEP GROOVE EA 2 150 21234 150 POSITION CHECK ROD EA 1 151 21234 151 SOCKET HEAD SET SCREW 8 X8L EA 1 152 21234 152 COMPRESSION SPRING EA 1 153 21234 153 STEEL BALL 1 4 EA 1 154 21234 154 OIL SEAL TC20X35X7 EA 1 155 21234 155 SET SCREW M6X8L EA 1 156 21234 156 TOUCH BLOCK EA 1 157 21037 HEADST
3. 3 9 8 9 9 h 3 2 HEADSTOCK OIL PUMP 19 1 NOT USED ON 1540V LATHE joss D 838 2 3 4 3 6 5 100980 Figure 4 1 Electrical Cabinet 49 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual C Electrical Cabinet Parts List tem PIN Tite CT ses Qty 24084 2460V AC DRIVE 15 HP VECTOR 3 22027220 SERVO POWERBLOK 220V 1 EA 2 4 22028220 CAPBLOKMODULE PT4 22V 6 22082 MODULE ASSY VL ENCODER INTERFACE 22065 2 MODULE ASSY PT4 EB SPI N AUX I F LATHE 8 NA 21893 25 FUSE 500 VOLT SLO BLO TYPE 9 22164 FAN PT4 ENCLOSURE 22656 GUARD FAN 22653 HANDLE OPERATING MECHANISM 22552 FILTER PT4 ELECTRICS BOX EU o 22654 1 BREAKER 220 VOLT 50 AMP 1540 21893 2 FUSE 500 VOLT SLO BLO TYPE not used 1540 2460 28 22026 40 FUSE CLASS J TIME DELAY AJ T 40 AMP 1540 22026 60 CLASS J TIME DELAY AJ T 40 AMP 2460 30 22758 2460V 4 ID 2460V 22758 1540V 4 ID 1540V i00980 1 4 6 1 Power Module The purpose of the power module is to fuse and distribute 220 V 3 phase power to the drive module assembly Also 220 V single phase power is input into the transformer to pr
4. 51 Hexagon Socket Screw M5x10L 11 52 24 0729 End Cover 5541 1 53 Socket Head Screw M8x20L 2 54 Flat Washer M8 2 55 Spring Washer M8 2 56 77USA 0307 Switch Seat 5541 1 57 Socket Head Screw M6x20L 2 NBNS543 BO2D12 58 22551 1 Switch Limit 61 12 10 1 59 Socket Head Cap Screw M6x16L 2 60 Flat Washer M6 2 61 Spring Washer M6 2 62 77USA 0698 Cam 5541 2 63 24 0207 X Axis Transmission Box FC30 1 64 Cross Recessed Head Screw M6x16L 6 65 25200 6 Wiper Bedway Right Rear Rubber 63 0362 1 66 25200 7 Wiper Bedway Left Rear Rubber 63 0363 1 67 Socket Head Cap Screw M6x25L 2 68 Spring Washer M6 2 BNS543 BO2D12 69 Micro Switch 61 12 10 1 70 Socket Head Cap Screw M6x16L 2 71 Flat Washer M6 2 72 Spring Washer M6 2 73 87 0714 Cam 5541 1 74 25200 4 Wiper Bedway Left Front Rubber 63 0360 1 75 25200 5 Wiper Bedway Right Front Rubber 63 0361 1 76 Cross Recessed Head Screw M6x16L 6 77 87 0715 Cam SS41 2 78 Socket Head Cap Screw M5x16L 4 79 Flat Washer M6 4 80 Spring Washer M6 4 81 Socket Head Cap Screw M6x16L 4 82 Flat Washer M6 4 83 Spring Washer M6 4 84 24 0723 Operation Box 5541 1 85 24 0724 Operation Box Cover 5541 1 86 Hexagon Socket Screw M5x6L 8 87 77USA 0311 Apron FC25 1 88 77USA 0605_ Ballscrew Cover 5541 1 89 Cover Round Hole 30 1 90 N04 Lock Nut S45C N04 L 20x16UNF 1 91 W04 Lock Washer W04 1 Bearing Ball Double Row 92 22446 Angular Contact 2204E 2RSITN9 1 9
5. You can verify the bit pattern below by getting a voltmeter and seeing if a 5 volt signal is present when a bit reads 1 in the above table For example if the indexer is physically on tool 3 bits 1 and 2 should read 5 volts and bits 3 and 4 should read 0 volts This procedure is best done when checking the inputs 1 through 4 above with the outputs 107 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual measure bit with your voltmeter you will need to do the following For example for bit 1 place you meter across Q3 on the PLC and a ground point 6 2 4 3 Motor Driver Settings Please see the following drawing for an illustration of how the pots are to be adjusted on the motor driver board in the cable breakout box The flat part of the pot should be in the location shown in the figure below Customer service may require a visual inspection of these settings Also please verify the position of 2 switches on the motor drive board CAUTION Do not adjust any of these settings This may cause the indexer to not run correctly or not run at all and will void the warranty of the hardware 108 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual DOPDBOOWS ESE 25405460 lU o 8 7 ses MUST B
6. 4 64 77 0620 Shaft 155614 65 Deep Groove Ball Bearing s6000zz 4 66 77USA 060125 Cam 541211 67 Micro Switch Lor OM Sg 68 77USA 0672 CoverPlate 541412101 69 87 0726 CovrPlte sa 211 70 77B 0698 54 11 71 SocketHeadCapScew 2 72 0610 CoverPate 150101 73 25050 4 Carrier cabe 80454200 1 74 24 0728 XAxisMotorCovr 542101 75 24 729 EndCover 15411 76 870730 Bracet 0 F20 101 77 77USA 0307 Micro Switch 51421011 18 SocketHeadcapScrew M832L 2 79 22551 1 Switch Limit BNS543B03D12 1 80 87 0738 _ CamSettingSeat 54 11 81 Socket Head Cap Screw 2 8 sd FlatWasher 1 M8 2 83 SocketHeadcapScew 2 84 Flat Washer M6 2 85 77USA 0698 Cam 5541 1 86 22683 Switch Door 1 101171 119 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual 8888 Ah ni Le e Af i01175 eee 2 yi 5 20066 299 de OG T Y V Pe i 5 SK PUN MIA al 2 mr qs S 56158 AU lt B 9 S 9 9 2 G0 9 E Figure 7 5 2460V Headstock Drawing 120 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Insta
7. 7 29 1540 Bed amp Carriage Figure 7 30 1540 Bed amp 160 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Parts List Bed amp Carriage Item P N Mfr P N Title UseAs Qty 1 23337 1 24 0227 00 CROSS SLIDE WAY COVER FRONT EA 1 2 M6 1 0X16 10Z SCREW PH PHIL STL ZINC EA 6 3 23337 3 24 0220 00 WAY WIPER FRONT RUBBER EA 1 4 23337 4 24 0222 00 WIPER PLATE EA 1 5 23337 5 24 0223 00 SADDLE COVER EA 1 7 M8 1 25X30 25B SCREW SHCS STL BO EA 8 8 23337 8 77USA 0213 00 X AXIS YOKE EA 1 9 M8 1 25X40 25B SCREW SHCS STL BO EA 4 10 23337 10 P7 O RING EA 1 12 23337 12 24 0218 00 KEY EA 1 13 M5 0 8X16 25B SCREW SHCS STL BO EA 1 14 23337 14 24 0221 00 WAY WIPER REAR RUBBER EA 1 15 M6 1 0X25 10B SCREW PH PHIL STL BO EA 6 16 23337 16 24 0228 00 CROSS SLIDE WAY COVER REAR EA 1 18 22714 66 24 0728 X AXIS MOTOR COVER EA 6 20 M5 0 8X25 25B SCREW SHCS STL BO EA 4 21 M8 73B WASHER SPLIT LOCK STL BO EA 12 22 23337 22 24 0208 00 X AXIS MOTOR ADAPTER EA 1 26 23337 26 24 0314 01 GIB BLOCK FRONT EA 1 27 23337 27 50 0325 00 ADJUSTMENT SCREW EA 4 28 23337 28 24 0313 01 GIB EA 1 29 23337 29 24 0315 01 GIB BLOCK BACK EA 1 41 M8 1 25X16 25B SCREW SHCS STL BO EA 2 42 M8 70B WASHER FLAT US
8. NEN to the LCD Remove fuse and check continuity Computer Pendant failed See Computer Pendant Section 4 3 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 Liquid 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 Code 81 press each key on the pendant The screen will display keypad that signifies if a key is working 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 again If the problem goes away and then re appears when the RSG is plugged in replace the RSG Poor cable connections from the Re seat cable connectors by pulling out and pushing Computer Module to the Distribution back in Board and from the Distribution Board to the Keyboard Electromagnetic interference has Especially suspected if the RS232 cable is run near entered through the RS232 cable if any electrical conduit If the problem is chronic connected especial
9. 2 REQ 620322 EA 6 49 2271449 240713 UPPER DOOR GUIDE EA 1 item P N MrPN Title Use Qty 50 2271450 7 67 SPACR 8 51 227M4 51 770028 SAER T 4 52 2274 522 7 66 EA 4 56 10 15548 NUT ACORNBIKOX _ EA 4 87 29714575 770620 iE b 58 2271458 60072 TAPER ROLLER BEARING EA 4 59 2271459 24043 TOUCHBLOCK EA 1 60 20643 1 177519 LIMIT SWITCH DOOR LIMIT EA 1 61 2271461 7740672 COVERPLATE 1 62 2271462 778 0698 X ZAXISTOUCH BLOCK EA 1 64 227444 7740610 EA 1 65 22714 65 80X45SA150000L WIRE PROTECTOR EA 1 66 22714 66 24 0728 XAXIS MOTOR COVER Ea 1 67 2271467 24079 ENDCOVR EA 1 68 2271468 240730 BRACKET EA 1 69 22714 69 24 0307 MICRO SWITCH SEAT EA 1 70 M8 1 25X12 25B 7 SCREWSHCSSTLBO 4 71 2512 LIMITSWITCHASSY PTALEFT EA 1 74 808 WASHERKHLATUSSSTLBO EA 2 76 M670 WASHER FLAT USS STL BO_ EA 2 la e a ps pi ji pi 78 2511 LIMITSWITCHASSY PTA RIGHT EA 1 79 22712 TAIL STOCK 1540V EA 1 80 22170 SPINDLE ASSY EA 1 22714 153 Southwestern Industries Inc TRAK TRL 1540 1840V 2460V
10. 11 12 13 14 15 16 17 18 WARNING Use only chucks that are rated to the maximum RPM of the lathe Do not operate this machine before the machines corresponding Programming Operating and Care Manuals have been studied and understood Read and study this TRAK TRL V Safety Installation Maintenance Service amp Parts List Manual Be certain that every operator understands the operation and safety requirements of this machine before servicing Do not run the machine without knowing the function of every control key button knob or handle Ask your supervisor or a qualified instructor for help when needed Protect your eyes Wear approved safety glasses with side shields at all times Don t get caught in moving parts Before operating the machine remove all jewelry including watches and rings neckties and any loose fitting clothing Keep your hair away from moving parts Wear adequate safety headgear Protect your feet Wear safety shoes with oil resistant anti skid soles and steel toes Take off gloves before you start the machine Gloves are easily caught in moving parts Remove all tools wrenches chuck keys etc from the machine before you start Loose items can become dangerous flying projectiles Never operate any machine tool after consuming alcoholic beverages or taking strong medications or while using non prescription drugs Protect your hands Stop the machine spindle and ensure th
11. 39 2271239 50 0526 00 FLAT WASHER 1 a a EA 1 Le unes suc xs a 41 27241 24052800 0 EA 1 42 27242 24052800 CLAMPINGBLOCK EA 2 43 2271243 1 24053000 BEDWAYWIPER FA 2 MeloXi6 108 SCREW PH PHILSTLBO EA 4 m gt Se 157 Southwestern Industries Inc TRAK TRL 1540 1840V 2460V 8 ProtoTRAK VL CNC Safety Installation Maintenance Service 8 Parts List Manual 46 2271246 24053200 BEDWAYWIPER EA 2 47 M 10X510 SCREWPH PHHILSTLBO EA 4 48 2271244 24 0533 00 BEDWAY WIPER PLATE _ V EA 2 item PIN MPN JUseAs Qty 49 2271 49 50053400 j sETSCREW 2 52 2271252 X O2GLG RIVET 2x5LG 1 EA 4 60 2271260 500113800 EA 1 101008 158 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual 101007 1 7 27 1540 Bed amp Carriage Figure 7 28 1540V Bed amp Carriage 159 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual 8988 6996 GG 09 6 EN 63 69924 101007 3
12. Figure 5 11 1840V amp 2460V Headstock Taper Adjustment 1540 Machine 1 2 Remove the headstock sheet metal cover Loosen the bolts holding the headstock splash guard This should be fine if the adjustments are minor Loosen the 4 bolts that hold the headstock down to the lathe bed Use the adjusting screws to pivot the headstock in or out When facing the encoder side of the headstock the right screw on the adjusting bracket will push the headstock away from you while the left screw will pull the headstock toward you After the necessary adjustments are made tighten the 4 bolts that hold the headstock in place Be careful when tightening these bolts that the headstock does not move Replace the sheet metal cover 86 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual PUSHER SCREW PUSHER SCREW Figure 5 12 1540 Headstock Taper Adjustment 5 1 16 Spindle Bearing Preload 1840V amp 2460V Only 1 Run the lathe for 10 minutes to insure the bearings are lubricated and slightly warmed Run the lathe at 500 RPM Stop lathe and set the gearbox in neutral between low and high gears Using the torque wrench measure the spindle rolling torque The acceptable range of rolling torque is around 10 15 in lb Note that the torque required to start breaking away torque the spindles rotation will be higher
13. The following codes are used for programming and operating the lube pump To get to any of these codes go to Service Codes press E and press the code you wish to view 4 8 5 1 Code 300 Lube Pump Switch This code acts as a switch to turn the lube pump on for the programmed time set in Code 302 4 8 5 2 Code 301 Set Lube Pump cycle time This code sets the interval time between lube cycles 4 8 5 3 Code 302 Set Lube Pump discharge time This code sets the lube pumps discharge time 61 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 5 0 Procedures for Replacements amp Maintenance 5 1 Replacements 5 1 1 Servo Motor Replacement WARNING Do not work with the Servo Motors unless the power is disconnected from the machine The servomotors are run by 220 VAC There is possibility of death by electrocution Turn off power to the machine Remove the necessary sheet metal covers to get access to the motor Remove the power and encoder cable from the motor The motor is bolted in place with 4 M6 SHCS The motor is bolted to an adapter plate Remove the motor from the adapter plate before sending back to SWI Use the adapter plate on the replacement motor uisu Oe Ras nea CAUTI ON Replacement motors will not come with adapter plates See Figure 10 for an illustration of the motor and adapter plate
14. 2 Mark and remove motor electrical leads 3 Because of the weight and size of the spindle motor and the restricted working space extreme caution should be used in sliding the motor from its mounting plate 4 Loosen the belt tension See section above 5 The motor is secured with four screws to a flange plate See the figure above 5 1 11 X Axis Ball Screw Removal 1 Unplug or remove all power from the lathe 2 Access to the X axis ball screw is gained by removing the back cover in the chip guard and removing the X axis motor cover Remove the motor Remove all items on the right end of the ball screw See Figure 5 6 amp 5 7 Unbolt the ballscrew nut from the yoke OP The X ball screw is removed through the exposed hole when the cross slide is removed 71 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 100977 Al VEO LT 191219 A jl fi NN RRR RAA x px Or f Ff LZ Ny AA de zi SiGe eo ON RER Figure 5 6 X Axis Drive Train 1540V amp 1840 72 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service 8 Parts List Manual X Axis Drive Train Parts List 1540V 1840
15. 51 52 53 55 54 SN AC A1 C M2 MA 1 100989 OUTPUT POWER TO SPINDLE MOTOR 10 HP 220V 3 PHASE ESI EEH 1 2 3 4 5 7 10 11 12 13 14 15 POWER FROM FUSE BLOCK TO BRAKE RESISTOR TO GROUND BAR 100989 SPINDLE DRIVE Figure 5 3 Spindle Drive TO SPINDLE AUX MODULE ASSY Note 2460 AC drive looks slightly different 66 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 5 1 4 Computer Module Replacement 1 Turn power off to the machine and control 2 Unplug all the connectors on the pendant arm side of the pendant 3 Remove 4 screws on the right side of the unit and 2 screws on the left side of the unit The module is now free to slide toward the right side of the pendant 4 Slide the computer module a few inches and stop Pulling the computer module too far will damage the LCD cable 5 Now reach from the pendant arm side of the unit inside and remove the 37 pin LCD cable 6 Now slide the module about way out of the pendant sheet metal 7 Remove the ground stud from the side of the computer module 8 Next remove the 37 and 9 pin connectors from the top of the computer module 9 Lastly slide the unit completely out of the sheet metal 10 Follow the instructions in reverse order when reinstalling the new computer module 11 Make sure the connectors are fu
16. 6 1 5 Indexer Encoder Re Alignment This procedure is necessary only if the indexer does not return to a true home position after initializing with Service Code 147 If the encoder is misaligned the turret will consistently be off by some angle In order to perform the operation it may be necessary to use two people One will adjust the encoder while the other watches the strobe 2 light inside the black box on top of the chip enclosure If the encoder is misaligned a LED labeled strobe 2 will be lit 1 Remove the 4 screws that hold the back cover onto the indexer The encoder is mounted to the far right of the indexer if you are at the front of the machine and facing it Please refer to the Dorian manual that is included with the machine for an illustration 2 If initialization does not work attempt to index the indexer until it sits in a true position A true position means the tool stations are parallel to the crosslide This can be done by reversing the air lines on the indexer Reverse the blue and red air lines and then use a breaker bar or piece of square stock to rotate the turret manually to a true position Make sure to reverse the air lines back when complete It will be obvious when the indexer is back to a true position The indexer moves in approximately 15 increments 3 Using an allen wrench loosen the set screw holding the encoder onto the shaft 4 Rotate the encoder with the allen wrench until the strobe 2 light turns off i
17. 6 31 87 0618 Headstock Chuck Guard 5441 1 32 SocetHeadCapScrewv M1000L 3 33 22714 26 Tube Lamp 1 23341 Bult Worklight 34 87 0701 _ RearProtectionGuard 5541 11 35 2 044 j sa f 1 36 23255 jump Colant 2 1 37 24 0742 PumpSet j sa C 1 38 87 0675 Right Stand Casting 1 Fc25 C 1 39 25 07 CoolantTank sm _ 1 40 870734 ChpTay sa C 1 41 87 0732 FrontConnecionPlte 5541 1 42 870705 Cover d g9g1 O 1 118 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 43 87 0735 Support Bracket SS41 1 44 87 0712 _ ProtetonCor 1 ssi C 1 46 87 0724 Operation Box Cover 5541 1 47 HexagonSocketScew 8 48 240714 ConnectionTube SS 1 49 24071 Cover S S4 1 KR52 SL 240703 ples sk __ 1 1 52 Socket Head Cap Screw 1 M6 d6e 9 53 77A 0615 UpperRollerSetting Base 5541 3 54 Retaining Ring 1571 3 55 774064 Shaft 50 13 56 DeepGrooveBallBearing 46203272 3 57 870713 UpprDor sa 1 58 77 0027 Spcer 50 1 4 59 77068 Spcer soc 2 60 7 66 Roller CT sc 2 61 SocketHeadcapScrew 1 5 62 87 0725 LowerGuideWay sec 1 63 DomedCapSrew
18. 8 22728 060 0759 OILSEAL EA 1 pao 2023 Bys 10 27210 23 0112 00 WASHER 210 5X254xX2 EA 2 2121 24 0502 00 JTAIISTOCKBAE 1 12 270212 50 0503 00 SLEEVE TAILSTOCKBARREL EA 1 Ce ILI TEED NUT 22712 13 14 22712 14 50 0505 01 SHCS M610x22 EA 4 RK KII FEED SCREW IMPERIAL 22712 15 16 2271216 6X6X20LG DOUBLE ROUND HEAD KEY _ EA 1 SCREW SOCSET STL BO CUP EA 1 221218 500508390 BRACKET F 1 719 MelO0Go 8 SREWSHCESTLEO ea 4 INDIVIDUAL BEARING 22712 21 22 2122 50051000 DIALIMPERIAL FA 1 23 2271223 500510 HANDWHEEL EA 1 24 27224 50031100 jLOCKSCREW 1 0 1 1 0 EA 1 25 2271225 50055300 WASHER 1 1 1 1 1 EA 1 Los 22226 eoa a 27 27227 50 0515 00 LOCKING BLOCK L EA 1 28 2271228 5005600 CIAMPINGBLOK EA 1 29 2271229 50051700 LOCKINGROD 1 1 1 EA 1 30 270250 50 0518 00 EA 1 31 2271 31 50 0519 00 1 1 1 1 0 EA 1 33 2271233 50052100 ECCENTNICCOUAR EA 1 34 22712 34 064046 SPRINGPIN EA 1 35 2271235 50 0522 00 ADJUSTING BLOCK EA 1 36 2271236 502052300 FLAT WASHER 1 EA 1 3 272537 50052400 FLATWASHER EA 1 38 2271238 50 0525 00 COMPRESSION WASHER EA 1
19. BOLT STEADY REST TO MACHINE AND INSPECT TO MAKE SURE 5 WEY YI PIN 24 08 5 9 7 18 1540 Steady Rest 146 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual A ag 9 TE FEE 101006 1 8989890 Figure 7 19 1540V Overall Machine 147 Southwestern Industries Inc TRAK TRL 1540 1840V 2460V 8 ProtoTRAK VL CNC Safety Installation Maintenance Service 8 Parts List Manual 78 28 Q 2223 09 2 Figure 7 20 1540V Overall Machine 148 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual O0 Xe Figure 7 21 1540V Overall Machine 149 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Figure 7 22 1540V Overall Machine 150 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 89 l mo NE NE NS c 5 S 8 gt n J mM 151 Southwestern Industries Inc TRAK TRL 1540V 1840 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service am
20. Fuse blown in pendant Remove fuse and check continuit present See Electrical Section 4 6 Electrical Section 4 6 Out coming 110VAC from Transformer is too high too low or not present Transformer See Electrical Section 4 6 Out coming 110VAC from Power Strip istoo Using a Voltmeter check the out coming 110VAC from the high too low or not present Power Strip See Electrical Section 4 6 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 6 the Pendant 110VAC Power Cable to the Pendant See Electrical Section 4 6 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 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 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 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 Measure
21. Iv Lifting Moving the Machine 12 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 1540V 1840V 2460V machines weigh approximately 4100 4500 and 7300 165 respectively Proper equipment of sufficient capacity must be used when lifting and or moving the machine To lift the machine remove the chip pan Place the forks of the forklift at least 32 apart as shown in the figure below Be certain to lift the lathe toward the headstock Figure 2 4 Lifting the Lathe 1540V 1840V amp 2460V 13 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Do not attempt to lift this machine with a forklift having less than 10000 Ib capacity for the 1540V 1840V and 15000 Ib for the 2460V The shipping weight of the machine including electronics is 4650 5170 and 8000 Ibs respectively for the 1540V 1840V and 2460V Do not remove the skid from the machine until it is brought to its final position especially if the machine is to be moved on rollers Once the skid has been removed place the machine in position on top of the four 4 for rest pads for the 1540V six 6 rest pads for the 1840V and eight 8 rest pads for the 2460V For proper operation the machine should be set on a substanti
22. SOCKET HEAD CAP SCREW M8 X30L EA 2 18 22714 31 PUMP BRACKET EA 1 19 23265 _ COOLANT PUMP 1 8HP EA 1 20 21239 20 SPRING WASHER M6 EA 0 21 21239 21 SOCKET HEAD CAP SCREW M6X16L EA 4 22 21239 22 SOCKET HEAD CAP SCREW M16 X50L EA 4 23 21239 23 LUBE PUMP HEADSTOCK EA 1 24 23973 BELT SET SPINDLE MOTOR EA 1 25 21239 25 SPINDLE MOTOR EA 1 27 22157 32 BRAKE RESISTOR EA 1 28 21239 28 MAIN ELECTRIC SWITCH EA 1 29 21239 29 CABLE CARRIER METAL EA 1 30 21239 30 MOVING DOOR GLASS EA 1 31 21239 31 MOTOR PULLEY SPINDLE EA 1 32 22291 1 LUBRICATION PUMP WAY EA 1 33 21239 33 FILTER 1 100993 ITEMS 23 33 FIGURE 133 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Figure 7 13 1840V Splash Guard amp Cover 134 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Parts List 1840 Splash Guard amp Cover Item P N DESCRI PTI ON Qty 12 21241 12 PROTECT COVER FRONT 1 13 21241 13 SOCKET HEAD SCREW M6X10L 5 14 21241 14 SLIDE WAY 1 15 21241 15 ROUND SCREW M5X6L 20 16 21241 16 ROUND SCREW M6X10L 5 17 21241 17 _ PLATE Z AXIS MOTOR 1 18 21241 18 END COVER 1 19 21241 19 PROTECTOR PLATE 1 20 21241 20 O R
23. SOCKET HEAD SET SCREW M6X8L EA 18 34 21234 034 BALLBEARING DEEP GROOVE 6305 EA 3 35 21234 035 BEARING PLUG EA 3 36 21234 036 O RING 655 3 38 21234 038 BALLBEARING DEEP GROOVE 6205 EA 3 39 21234 039 SPACER 6 41 24934 CLUSTER GRAR 6 SHAFT ASS Y 1840 1 42 21234 042 GEAR EA 3 43 21234 043 SPACER EA 6 44 21234 044 WASHER EA 3 45 21234 045 ROD EA 3 46 21234 046 PACKING EA 3 47 21234 047 BEARING PLUG EA 3 48 21234 048 SOCKET HEAD CAP SCREW M6X12L EA 9 49 21234 049 BEARING COVER EA 3 50 21234 050 O RING P52 EA 3 51 21234 051 SOCKET HEAD CAP SCREW M6X12L EA 9 52 21234 052 PACKING EA 3 138 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 53 21234 053 BALLBEARING DEEP GROOVE 6206 EA 3 54 21234 157 NPUT SHAFT 77U 0131 02 EA 3 55 21234 055 GEAR EA 3 56 21234 056 DOUBLE ROUND HEAD KEY 8X8X50L EA 3 57 21234 057 BALLBEARING DEEP GROOVE 6207 EA 3 58 21234 058 RETAINING RING EA 3 59 21234 059 ELBOW EA 3 60 21234 060 DRAIN PLUG EA 3 69 21234 069 COVER EA 3 70 21234 070 SOCKET HEAD CAP SCREW M6X20L EA 9 72 21234 072 OIL SEAL TC38X55X8 EA 3 73 21234 073 SPACER EA 3 76 21234 076 PULLEY EA 3 71 21234 077 DOUBLE ROUND HEAD KEY 10X8X50L EA 3 78 21234 07
24. 1 35 186251 COMPRESSIONNUT EA Ti 36 106254 COMPRESSION SLEEVE EA 1 40 M61052 NULHEXSTLLAN EA 4 41 8 1 25 20 25B SCREW SHCS STLLBO EA 4 42 1 4738 WASHER SPLITLOCKSTL BO EA 4 100978 80 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual LLLLOI Xe E E E 8 amp 9 7 2 OOO 9 E 9 6 Figure 5 10 Z Axis Drive Train 2460V 81 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual Z Axis Drive Train Parts List 2460V Item Parts No Description Material Specifications Q ty 1 Socket Head Cap Screw M8x30L 6 2 25200 1 Wiper Bedway Front Rubber 87 0244 1 3 Hexagon Socket Screw M6x16L 4 4 77USA 0213 Nut Seat FC25 1 5 Socket Head Screw M8x30L 4 6 O Ring P7 1 7 20984 X Axis Ballscrew 5 415 124 0211 1 8 25200 2 Wiper Bedway Rear Rubber 87 0245 1 9 Hexagon Socket Screw M6x20L 4 10 87 0228 Rear Cover Plate 5541 1 11 24 0728 5 Motor Cover Plate SS41 1 12 21994 Motor X Axis 1 13 Socket Head Cap
25. 1 25 25 25B SCREW SHCS STL BO EA 4 31 98481A090 KEY WOODRUFF 404 1 8 X 1 2 EA 1 32 7204 AVH NILOS RING 7204 EA 1 33 1 4 73B WASHER SPLIT LOCK STL BO EA 4 38 93501A030 WASHER SERRATED EA 4 40 M8 1 25X20 25B SCREW SHCS STL BO EA 1 i00977 73 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 101178 DETAIL D DETAIL B Figure 5 7 X Axis Drive Train 2460V 74 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual X Axis Drive Train Parts List 2460 Item Parts No Description Material Specifications Q ty 1 Socket Head Cap Screw M8x30L 6 2 25200 1 Wiper Bedway Front Rubber 87 0244 1 3 Hexagon Socket Screw M6x16L 4 4 77USA 0213 Nut Seat FC25 1 5 Socket Head Screw M8x30L 4 6 O Ring 7 1 7 20984 X Axis Ballscrew SCM415 24 0211 1 8 25200 2 Wiper Bedway Rear Rubber 87 0245 1 9 Hexagon Socket Screw M6x20L 4 10 87 0228 Rear Cover Plate 5541 1 11 24 0728 X Axis Motor Cover Plate SS41 1 12 21994 Motor X Axis 1 13 Socket Head Cap Screw M8x25L 4 14 Spring Washer M8 4 15 24 0208 Motor Plate S20C 1 16 Symchronous Pulley Alum
26. 2 limit switch cables on the original axis then it could be the auxiliary module or computer auxiliary module in the electrics box module See below Auxiliary or Computer Module failure Turn off all power to the machine Use two paper clips to jumper connector pins 1 amp 6 together and 5 amp 9 together on the Auxiliary module for the limit switch port in question Next turn on all power to the machine This will verify whether or not the Auxiliary Module and the Computer Module are working properly If there is still a failure look at the Product listed under Configuration Values Mode Setup Service Codes A Software Version More This Product represents the type of configuration for the machine type The Product should read 1540 or 2460 The Machine I D Key located on the Auxiliary Module configures the system according to machine 33 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual type If the Computer Module reads the correct Product then the Computer Module is good and the Auxiliary Module is bad However if the Computer Module reads the incorrect Product then the Computer Module is bad and the Auxiliary Module is good Of course this is all under the assumption that the Auxiliary Module has the correct Machine I D Key 3 4 Problem with the Measurements 3 4 1 X amp Z Axis Measurem
27. 27011 i01180 Figure 7 8 2460V Tailstock Assembly 126 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 9 2 8 E 99 8 8 1181 7 9 2460 Tailstock Assembly 127 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual SECTION 101182 Figure 7 10 2460V Tailstock Assembly 128 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V 8 ProtoTRAK VL CNC Safety Installation Maintenance Service 8 Parts List Manual Parts List 2460V Tailstock Assembly Item Parts No Description Material Specification Qty 1 63 0501 00 Tailstock Body FC 25 1 2 Hexagon Head Screw M10x80L 2 3 Washer SS41B D M10 2 4 Socket Head Set Screw M12x16L 2 5 Socket Head Set Screw M12x25L 1 6 Socket Head Set Screw M8x16L 1 7 Socket Head Set Screw M6x30L 1 8 Socket Head Cap Screw M6x30L 4 9 Ball Cup 01 4 2 10 75 90 8 1 11 Parallel Pin 010 901 1 12 Parallel Pin 10x60L 1 13 Parallel Pin 10x100L 14 63 0502 00 Tailstock Base FC 25 1 15 63 0503 00 Quill S 45C 1 16 25026 Feed Nut
28. 8 ProtoTRAK VL CNC Safety Installation Maintenance Service 8 Parts List Manual 69 05 B 01008 1 22712 L S p 57 39 36 40 en LAHES w Pecan 12 D 9 3 4 2 9 9 Q9 2 6 9 E f Figure 7 24 1540V Tailstock Assembly 154 Southwestern Industries Inc TRAK TRL 1540V 1840 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manua 22712 Figure 7 25 1540V Tailstock Assembly 155 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual i PODS 9 9 S FEN ti A _ TES hee es ame aa Figure 7 26 1540V Tailstock Assembly 156 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Parts List 1540V Tailstock Assembly item P N MrPN Tie e UseAs Qty 1 22721 24050100 TALSTOCKBODY EA 1 2 10 5 6028 7 j SCREW SHCS STLBO EA 2 3 12 1 75 16 25B 7 SCREWSHCS STLBO EA 2 4 MI2175X0525B SCREW SHCS STL BO 1 1 EA 1 5 2725 10 4006 STRAIGHTPN EA 1 6 M6 1 0x1040B 1 1 SCREW SOCSET STL BO CUP EA 1 7 M amp 125X10408 7 SCREW SOCSET STL BO CUP EA 1
29. Check belt tension 25 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 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 Possible Cause Check This The home positions or tools are not set See the Controls Programming Operations and Care correctl manual Bad Motor Encoder See Motor diagnostics Section 4 4 3 2 2 Slow Down Axis The axis slows down and moves at a feedrate that is lower than rapid or than the programmed feedrate 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 set too low The factory default is set at 0 005 Perform Code 12
30. If torque is out of tolerance Remove the spindle belt cover You will then need to remove a bearing cover to gain access to the spindle adjusting nut Loosen the three setscrews on the spindle adjusting nut before tightening or loosening Figure 34 Torque too low Lock the spindle in low gear With a spanner wrench tighten the adjusting nut Return the speed selection lever to the neutral position Measure the rolling torque and repeat until 10 15 in Ib of rolling torque is achieved Tighten the three setscrews to retain the adjustment Torque too high Lock the spindle in gear With a spanner wrench loosen the adjusting nut two full turns Place an aluminum block over the end of the spindle and with a hammer drive the spindle forward until it is loose Near zero rolling torque With a spanner wrench tighten the adjusting nut Return the speed selection lever to the neutral position Measure the rolling torque and repeat until 10 15 in Ib of rolling torque is achieved Tighten the three setscrews to retain the adjustment 87 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 5 1 17 Aligning Tailstock to Spindle If there is taper appearing on the workpiece while machining by using the tailstock the tailstock will need to be realigned to the spindle Follow the steps below 1 Inserta gage bar between the spindle and tailstock a
31. Parts List Manual X ON N i00978 SECTION A A 119 4042 3 TOS THREADS EXTEND PAST NUT Figure 5 9 Z Axis Drive Train 1540V amp 1840V 79 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Z Axis Drive Train Parts List 1540V amp 1840 Item P N seas Qty 2 12 1 75 35 25B 5 5 5 5 1 0 1 EA 4 26 12 1 75 45 25 SCREW SHCS STLLBO EA 4 27 20962 HOUSING TAILSTOCK BEARING FA 1 30 20999 COVER TRL2460ZAXS EA 1 31 20980 BED TRL2460cC55 EA 1 LOCKWASHER 6 LOCKWASHER Cd 16983 1 PULLEY SOLID 44 TEETH W O GUIDES 8 9 E 16452 CLAMP X Y amp ZAXIS EA EA EA m gt 10 32 3 4 25B SCREW SHCS STL BO EA M8 1 25X35 25B SCREW SHCS STL BO EA 16295 1 HOUSING BEARING Z AXIS 1 14 23940 BEARING SET ANGULAR CONTACT SET 1 7205 BECBP 7205 AVH NILOS RING 7205 15759 WASHER 1 4 HARD BLK OX 1 8THK EA 8 19 23054 STUD M6 1 0X40 FULLY THREADED CLASS 4 6 8 1 25 30 25B SCREW SHCS STL BO 23 22446 BEARING SELF ALIGNING 2204 E EA 1 2RSITN9 24 044 LOCKWASHR 1 NO LOCKNUI E sss d dn 29 984814090 KEY WOODRUFF 404 8 2 EA 1 34 185210 CONTROLUNITCSA 5 _ EA
32. So if your problem is occurring on both axes its source is probably somewhere else 43 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 4 4 1 Motor Alignment Routine This service code needs to be performed each time the ProtoTRAK is turned on new software is installed or motors have been replaced The control will boot up automatically to this screen Press the Check System key and follow instructions on screen WARNING It is important that there are no obstructions on any axis before running this code If there is an obstruction then use the electronic handwheels to slowly move the machine away from the obstruction Each axis will move approximately 1 during this routine The handwheels will not move at the normal feedrates during this routine Failure to move each axis away from an obstruction will cause a crash Code 203 1540V amp 1840V only calculates the relative position between the motor poles on the stator and the magnets on the rotor through the use of the motor encoder Code 204 is used on the 2460V The alignment is set by reading the index off of the motor encoder 4 4 2 Cable Connections Check the motor cable connections on the motor side as well as the servo side Make sure the threaded connectors on the motor side are fully threaded in place The connectors should thread down about 7 to 8 turns for b
33. Tailstock Quill Travel 6 6 1 4 12 2 speed Quill Diameter 2 3 8 2 95 3 5 Quill Taper Hole MT 4 MT 5 MT 5 Spindle Motor H P 10 10 15 Voltage 220 220 220 Amps Full Load 47 36 59 Phase Hz 3 60 3 60 3 60 Dimensions Net Inches L x W x H lbs 89 x 53 x 70 4100 91 x 53 x 70 4500 113 x 58 x 74 7300 Ship Inches L x W x H lbs 90 x 55 x 73 4650 97 x 58 x 72 5170 117 x 59 x 77 8000 Other Coolant Pump Motor H P 1 8 1 8 1 8 Spindle Motor Brake Dynamic Braking Way Surface Hardness 400 450 HB Headstock Lubrication Grease Oil Bath Oil Bath Options Tooling Kit 3A or 1 6 2 5 8 D1 6 12 01 8 5 Collet Closer A2 5 D Camlock n a Indexer Option 3 4 8 Position 3 4 8 Position 1 8 position 3 4 4 position 3 4 4 Position 1 4 position Gang Tooling No maintenance grease cartridge 9 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 2 3 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 leveling pads and screws for the machine can be found in the toolbox Loosen and remove 4 scr
34. Tool 2 and the indexer went to Tool Station 3 To fix this problem re initialize the system by choosing Service Code 147 Fault 86 Indexer Power Problem This message will appear if the power is interrupted to the indexer It could indicate that no power or low power is getting to the indexer Fault 87 Indexer Air Pressure Problem This message will appear if the air pressure sensor jumper is faulty on the black cable breakout box on top of the lathe Fault 88 Indexer Not Initialized This message will appear if the indexer does not know its present position An example of this would be if the turret stops in the middle of a tool change An interruption of power or air may cause this fault Pressing the E stop button can also cause this problem if the tool is not in a known position Initialize with Service Code 147 Fault 89 Indexer Time Out This message appears if the indexer does not get to position after a few seconds This may be caused by an internal problem inside the indexer such as a broken gear or jammed component Very low air pressure may also cause this fault It should take no longer than 2 or 3 seconds for the indexer 6 2 4 Troubleshooting the Cable Breakout Box The following describes the inputs and outputs from the PLC used to run the 4 tool indexer 6 2 4 1 PLC Inputs There are 8 inputs to the PLC 7 of which are used for the 4 tool indexer For inputs 1 through 4 the corresponding LED light will be on depen
35. Z Axis Drive Train 2460V 1840V amp 2460V Headstock Taper Adjustment 1540V Headstock Taper Adjustment Tailstock Adjustment Spindle Motor Wiring 1540V Headstock Cartridge Removal X Axis Gib Z Axis Gib Calibration Set Up Headstock Oil Removal 1540V amp 2460V Tailstock Lubrication Indexer Mounting Indexer Cable Routing Motor Drive Adjustments amp PLC Inputs amp Outputs Indexer Mounting 1540V amp 2460V 4 Tool Indexer Cable Routing Drawings amp Parts Lists 2460V Overall Machine Drawing 2460V Overall Machine Drawing 2460V Overall Machine Drawing 2460V Overall Machine Drawing 2460V Headstock Drawing 2460V Headstock Drawing 2460V Carriage Side View 2460V Tailstock Assembly 2460V Tailstock Assembly 2460V Tailstock Assembly 1840V Bed and Chip Pan page 1840V Splash Guard amp Cover 1840V Headstock Assembly 1840V Headstock Assembly 1840V Tailstock Assembly 1540V Spindle Encoder Drive Assembly 1540V Steady Rest 1540V Overall Machine 1540V Overall Machine 1540V Overall Machine 1540V Overall Machine 1540V Overall Machine 1540V Tailstock Assembly 1540V Tailstock Assembly 1540V Tailstock Assembly 1540V Bed amp Carriage 1540V Bed amp Carriage 1540V Bed amp Carriage 1540V Bed amp Carriage 114 TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Fig Fig Fig Fig Fig Fig Fig Fig Fig 7 31 Lathe Apro
36. and rear of the saddle Figure 5 17 Z Axis Gib 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 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 5 2 2 1 Calibration NOTE Calibration usually is only done after replacing a computer module or adjusting the drive train 1 Recheck machine level and adjust as necessary 2 Press the SERV CODE soft key 3 Input 123 on the keyboard then press the INC SET key 4 Input the X key to tell the control the x axis is being calibrated 5 Place the 0001 indicator in the spindle and set up the metric standard on the cross slide Make sure the standard is parallel to the cross slide by using a combination square Ensure that the standard is set up so that the readings will 93 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual taken with the cross slide extended towards the operator moving towards the motor end of the X axis 6 When the indicator is zeroed at the beginning of the
37. bearing housings NOTE The bearing housing and spacer rings are matched sets keep them together 5 With the motor and drives removed inspect the ball screw ball nut and yoke for the potential problems shown in the chart below CAUTI ON Unlike a leadscrew do not unscrew the ball screw from its nut This will destroy the ball screw 41 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Potential Problem Check By Bad ball screw e Visual inspection of the ball nut if the nylon seal is broken or deformed if contamination has visibly entered the ball nut or if balls are out of the ball nut replace the ball screw e Cranking the ball screw through a significant part of its travel If it jams feel loose or has rough spots replace the ball screw e Dial indicator on a vertical flat of the ball screw indicates backlash between the ball screw and ball nut Ball nut not e Inspection for space between the head of the bolt and the ball nut i e the retaining tightened to the bolt has bottomed out in its thread and is not securing the ball nut to the yoke oke properl Yoke loose in the Inspection for any motion of the yoke or looseness in the Yoke mounting screws carriage e Visual inspection Pump the oil and ensure that it flows evenly to the ways ball screws and cross slide Z Ball screws not e Manually turn the ba
38. bed To take a reading off the level longitudinally place the level at each of the four 4 corners of the bedways Figure 2 5 Positions B amp C To take a reading off the level transversely place it on top of 7500 parallels at each end of the bedways Figure 2 5 Positions A amp D 14 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 2 5 Leveling 100193 Using the four 4 interior leveling screws see Figure 2 5 on the lathe base level the bedways longitudinally within 0008 over the total length and transversely within 0005 inches After leveling with the four 4 interior leveling screws bring the two 2 exterior leveling screws see Figures 2 1 2 2 amp 2 3 into contact with the leveling pads using care not to disturb the level The 1540V lathe only has 4 leveling screws For a newly installed machine check the level once every week Once the foundation is rigid enough then check it once per month 2 10 Electrical Connection The 1540V 1840V amp 2460V Lathes can only be configured for 208 240 volt 3 phase electricity To run at 440V you will need a step down transformer from 440V to 220V and rated at a minimum of 20 KVA for the 1540V and 1840V and 23 KVA for the 2460V DANGER Be certain that 200 volt electricity typical range 208 240V is used only with a machine labeled 220 volts at
39. below See figure 5 4 1 Turn off power to the machine 2 the right side of the pendant above the floppy drive remove the 2 screws holding the hard drive in place 3 Slide the unit toward you Be careful not to pull it too far since a cable will restrict its travel 4 Unplug the 40 pin hard drive cable and 4 pin power cable from the connector board Lastly remove the hard drive assembly The entire assembly will be replaced which includes the hard drive connector board and associated sheet metal 5 When reinstalling the 40 pin cable make sure you plug it in correctly The tab on the cable should match the opening cut out in the male connector 6 Slide the unit back into place and fasten the 2 screws Note the new hard drive will have all of the necessary software installed already CAUTION It is a good idea to back up your hard drive from time to time via a network or floppy disk If your hard drive needs to be replaced you will loose all of your programs See your programming manual for instruction on how to do this 5 1 6 Electronic Handwheels amp J ogstick There are 2 electronic handwheels on the lathes and 1 jogstick to move the carriage quickly into position Each unit is replaced as an assembly Disconnect the handwheels and jogstick from the apron cable 5 1 7 Cable Routing in Electrics Box Each cable on this machine is labeled to help identify where it is used The lower section of the electrics box has
40. does not exceed its travel and crash 5 2 4 2 Z Axis Limit Switch Stop Installation amp Aqjustment The limit switch stops for the Z axis are mounted on the side of the bed at the headstock side and attached by a bracket to the tailstock for the positive direction Each limit switch stop must be set to a specific distance from the headstock and tailstock to maximize travel and simultaneously prevent serious damage to the machine in the event of a crash The limit switch bracket and stops contains slotted holes which allow for side to side positioning adjustments of the limit switch assembly Procedure for setting Z limit switch 1 Slowly move the carriage to the front of the spindle with the handwheel until you are approximately 3 4 from the spindle CAUTION The limit switch must be triggered a minimum of 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 250 ipm 98 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 2 Lock the stop in place and make sure when you hit the stop the switch is triggered and the carriage comes to rest before hitting the spindle Make sure you have adjusted the stop far enough away to prevent a crash WARNING The Z axis limit switch at the headstock end is set to prevent crashe
41. encoder module e Umbilical 1 and 2 at the pendant e Check the servo driver connections at the pendant and also at the servo driver 44 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 4 4 5 Moving Problem from One Axis to Another Another way to troubleshoot a problem with a particular axis is to swap parts from 1 axis to another to see if the problem moves If the problem moves then that component is faulty See the example below Symptom X Axis will not move and faults This particular problem can happen because of any of following reasons bad motor servo driver power cable 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 Z motors Has problem moved to Z axis If yes replace motor If no the motor is not the problem Switch X and Z encoder cables on encoder module and X and Z servo driver cables at the computer module This runs the Z motor with the X port on the compute
42. for machine considerations especially X gib adjustments and leveling See Gib Adjustments Section 5 2 1 2 Do the following special service codes e Code 12 this is a procedure that helps the control adjust to the friction characteristics unique to the machine Write down the resulting values from the display If your problem is control related check to see if this procedure has resolved the problem 3 The torque required to manual turn the X and Z axis ballscrews should be between 10 to 15 in lbs These values should be consistent in both directions and along all areas of the axis travel Values that differ from that of above may correspond to misaligned ball screws The following steps take you in logical sequence through the assemblies If the step doesn t isolate or resolve the problem it will be necessary to disassemble the indicated item and move to the next step See Figures 5 4 and 5 6 in Section 5 0 1 Ensure that the screws that hold the bearing housing in place are not loose 2 Ensure that the Clamp Nut is secured The following applies to the clamp nut When loosening make sure to back out the 10 32 screw from the clamp nut 3 When tightening snug the 10 32 screw to keep the clamp nut from spreading tighten it again after the clamp nut is tight 4 Take out the angular contact bearings in the X amp Z axis and inspect them They should roll smoothly and be lightly greased If not replace them The Z axis has 2
43. lathes There is 1 1 amp fuse in the pendant 13 fuses in the electrical cabinet and 1 fuse in the lube pump 53 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual check fuses 1 Use Volt Ohmmeter select OHM or 2 Remove the fuse completely from the pendant display or computer module 3 Place a lead of the meter on each end of the fuse e Agood fuse reads 0 zero or close to it e bad fuse reads Open or Infinity or OL overload 4 6 6 2 Fuse Indicator Lights The power strip and spindle auxiliary module have LED lights on them to signify that 110 V power is reaching the components If these lights are off check up stream to see if some other fuses are blown Within the spindle auxiliary module there are also 3 LED s that come on when the lube pump indexer and coolant pump outlets are activated The indexer light should always be on unless there is an E stop pressed The lube and coolant pumps lights are on only when these devices are programmed to run If they do not come on when they should check the fuse next to the light 4 7 Door amp Gear Switch The 1540V 1840V and 2460V machines use a door interlock switch to verify to the control that the door is closed in various modes of operation This switch is wired normally open but is forced closed when the door is closed during CNC run mode There shou
44. machine The servo drivers are run by 220 VAC There is possibility of death by electrocution 4 5 3 Servo Driver Fault Codes Each servo driver has an LED display that indicates fault and status conditions On power up before communication with the servo drivers is established any fault code may be present Once communication is established the LED should read 0 In addition cycling the power clears the fault if the condition is no longer true The decimal point of the Seven Segment LED display for the Semipower and MTS servo drive modules will turn on when the servomotor is active Also the Seven Segment LED display for both the Semipower and MTS servo drive modules will display a 0 when the servomotor is active providing there are no errors Therefore when the Seven Segment LED display shows a zero the decimal point is on no error conditions exist the servo drive module is enabled then the motor will be energized and servoing 46 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual However when the servomotors are not active the Semipower servo drive module will display a 0 with no decimal point and the MTS servo drive module will display a 2 with no decimal point When the servomotors are not active the 2 displayed on the MTS servo drive module does not mean that there is a Watchdog timer timeout fault This is j
45. modules These voltages are set in the hardware This code may only be present if the machine was mistakenly wired for 440 volts Code B DC logic power supply fault This error code b can be attributed to poor grounding practices Assuming that there is not a hardware failure in the power drive module look at the ground connection between the motor frame and the power drive module A poor connection here can generate enough noise to cause this power supply to droop Codes C D E and F not used As stated above in the motor section one way to troubleshoot a faulty servo driver is to swap components with a problem free axis and see if the problem moves Switching the power cable and encoder cable for the faulty axis with a good axis can do this If the problem moves to the other axis and clears up from the original axis replace the Servo Driver WARNING Do not work with the Servo Driver unless the power is disconnected from the machine The servo drivers are run by 220 There is possibility of death by electrocution 48 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 4 6 Electrical electrical box is broken down into 4 different modules power module drive module auxiliary module and encoder module See Figure 4 1 for an illustration of the box layout See figures 7 33 through 7 37 for cable diagrams
46. of the gib interfere with their free movement and cause a decrease in the accuracy and or performance of the machine due to excessive friction 5 2 1 1 Cross Slide Gib Adjustment 1 Remove the yoke bolts from the top of the cross slide and slide it back and forth and feel for any looseness in the system If it is loose tighten up the adjusting screws NOTE Adjustments should be made where the gibs are worn the worst 2 Turn the X axis ball screw with a torque wrench and measure the torque The torque should be less than 15 in Ib and consistent over the travel of the X axis If the measurement is higher than this then loosen the gib Make sure the cross slide is aligned properly One easy way to check for this is to remove the yoke bolts and see if the yoke springs back into position Misalignment is also evident if the torque is higher when the yoke is up against the rear bearing housing Figure 5 16 X Axis Gib 92 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 5 2 1 2 Z Axis Gib Adjustment 1 Mount a dial indicator on the Z axis ways and locate on top of the carriage 2 Lift the carriage up to measure the amount of play The dial indicator should not move more than 0 001 If it moves more tighten the gibs Make sure not to over tighten the gibs 3 This procedure with the dial indicator will need to be done in the front
47. oil lines See Lubrication section X Gib not making good contact Pull gibs out and mark with a blue die to check where the gibs are making contact It is recommended that the gibs uniformly contact at least 80 of the surface Binding or looseness in the Drive Train Check Repeatability using the Repeatability and Positional Accuracy procedure Check the torque reading of the Drive Train Step by step carefully inspect the Drive Train for any binding or looseness It may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Z Section 4 2 Axis Motor belt too tight Loosen belt Misalignment of ball screw See Mechanical Drive Train X Z Section 4 2 27 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC 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 Screen saver has been activated Press any key to turn back on All LED keys on pendant will blink when the screen saver is on Press any key to deactivate Hitting this key will not activate any feature on the control The system has shut down Turn the power switch off check the computer pendant fuses and cable connections See Electrical Section 4 8 Poor cable connection from Computer Module to LCD Liquid Crystal Display
48. on boot up screen It can also be accessed through Service Code 203 for the 1540V and 1840V and code 204 for the 2460 This must be done initially before the machine can be moved Use the handwheels first to move the the lube pump eee should be visible on all the way surfaces O 13 Position the saddle and tailstock to the center of the bed for leveling Check the level of the machine The machine should be level to within 0 0008 longitudinally and 0 0005 transversely Even though it is the responsibility of the customer make any adjustments if necessary er barrel in and out to ensure proper function Pere 1840V amp 2460V only shift the headstock in low and high gear and verify the control recognizes each gear To run the spindle a maximum RPM must be set in SETUP mode 17 Open and close the door and verify the door switch is functional The control should display a message of DOOR OPEN in DRO mode when the door is open and it should disappear when the door is closed O 18 Make sure the X and Z electronic handwheels and jogstick are functional Check to make sure that the E Stop buttons on the pendant and door for the 1540V and 1840V and pendant and apron for the 2460V are functioning correctly O 20 Perform Service Code 12 Feed Forward Constant O 21 Perform Service Code 123 to calibrate the X and Z axis using a 150mm standard O 22 Perform Se
49. servo drive The capacitor mounts to the top of the drive Use this capacitor with the replacement servo driver 9 The servo driver then mounts to the aluminum extrusion with 4 screws CRITICAL After replacing a servo driver make sure to secure the bottom right hand screw of the drive that includes a ground cable to the heat sink and the ground cable to the side of the heat sink Also make sure that the heat sink is grounded to the ground bar on the power panel Failure to do this may cause a good servo driver to not work properly See Figure 5 2 for an illustration of the wiring of the servo drive 63 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual SP SPINDLE DRIVE TO BRAKE RESISTOR POWER FROM FUSE BLOCK TO GROUND BAR OUTPUT POWER TO SPINDLE TO SPINDLE MOTOR A 10 HP 220V 3 PHASE TO X DRIVE TO GROUND BAR X AXIS MOTOR 220V 3 PHASE 21775 TO Z DRIVE TO Z AXIS MOTOR 220V 3 PHASE 21775 Figure 5 2 Drive Module FAN 100988 64 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V 8 ProtoTRAK VL CNC Safety Installation Maintenance Service 8 Parts List Manual 5 1 3 AC Spindle Drive Replacement WARNING Do not work with the AC drive unless the power is disconnected from the machine The AC drive is run by 220 There is possibility of death by electrocut
50. 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 holds 1 44 MB 29 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 3 3 6 System Will Not Turn Boot Up Nothing happens when the switch is turned on or the system does not boot up Possible Cause Check This Main Disconnect switch is off Check the Main Disconnect switch Pendant On Off switch is Off Check the Pendant On Off switch Fuse blown in pendant or the 2 Remove fuse and check continuity Is the power strip light on transformer fuses not present See Electrical Section 4 6 Section 4 6 too high too low or not present Transformer See Electrical Section 4 6 too high too low or not present Strip See Electrical Section 4 6 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 6 to the Pendant 110VAC Power Cable to the Pendant See Electrical Section 4 6 Hard 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 wi
51. standard press the INC SET key 7 Move the cross slide towards the motor side of the x axis until the indicator zeros on the end of the standard Input 300 on the keyboard 8 If the calibration was successful the screen will return to the set up screen 9 Press the SERV CODE soft key 10 Input 123 the keyboard then press the INC SET key 11 Press the Z key to tell the control that the z axis is being calibrated 12 Setup the metric standard on the Z axis ways 13 Setup the magnetic base and 0001 indicator on the cross slide 14 When the indicator is zeroed at the beginning of the standard press the INC SET key 15 Move the saddle towards the chuck until the indicator zeros on the end of the standard then press the INC SET key 16 Input 150 on the keyboard 17 If the calibration is successful the screen will change to the set up screen SPINOLE USE SHORTEST POSSIBLE DIAL ROD DIAL INDICATOR MACHINE TABLE Figure 5 18 Macr Calibration Set Up 5 2 2 2 Backlash Compensation Code 127 Calculate X or Z Backlash Constant Every mechanical system has at least a little backlash or lost motion It is produced by the small amount of play between the gibs and ways and mostly by the accumulative bending or elasticity of all the parts of the drive train under load The backlash constant is factory set but may need to be adjusted periodically 94 Southwestern Industries Inc TRAK TRL
52. the motor and at the electrics box on the back of the column WARNING 440 Volts will damage expensive electrical components if machine is wired by mistake as 440 volts These components are not covered under warranty The circuit breaker for the machine should be a minimum of 60 amps for the 1540V and 60 amps for the 1840V and the 2460V 15 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual DANGER The 208 240 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 The 208 240 volts wires to the machine through the electrical box located on the back of the column The wire enters the main on off switch through a hole on the top of the box The ground wire should be connected at the top or bottom of the breaker bracket DANGER qualified electrician should wire the 208 240 volt 3 Southwestern Industries recommends the machine be earth grounded by driving a copper rod into the ground It is the responsibility of the customer to install this rod 2 10 1 Phase Converters For those machines that will be run with a phase converter it must be a CNC rated rotary type rather than a static phase converters CNC rated rotary phase converters allow for varying loads in the system A CNC
53. tool Never start the machine including the rotation of the spindle if the tool is in contact with the part 22 Don t use dull or damaged cutting tools They break easily and may become airborne Inspect the sharpness of the edges and the integrity of cutting tools and their holders 23 Large overhangs on cutting tools when not required result in accidents and damaged parts 24 Prevent fires When machining certain materials magnesium etc the chips and dust are highly flammable Obtain special instruction from your supervisor before machining these materials 25 Prevent fires Keep flammable materials and fluids away from the machine and hot flying chips 26 Never change gears when the spindle is rotating 27 Do not rotate the spindle by hand unless the Red Emergency Stop button is pressed 5 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 2 0 Installation Read understand this entire installation section before beginning the installation procedure 2 1 Floor Plan Layout amp Space Requirements 1540V 1840V amp 2460V 1 18 13 148 100483 4 Figure 2 1 2460 V Lathe 6 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 78 74 Figure 2 2 1540V Lathe 7 Southweste
54. ways This increased friction may lead to part inaccuracies and decreased life expectancies of your ball screws and way surfaces 2460 only Make sure the oil pump for the headstock is working properly at the start of each day Check periodically the site glass for the headstock oil The site glass is located under the spindle cover Lack of lubrication in the headstock can lead to increased wear of the gear train as well as premature wearing or failure of the spindle bearings Oil flows to the site glass only when the spindle is on 39 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 4 1 4 Machining Set Up The machining set up itself is always something that can greatly influence the performance of the lathe The following are some things to keep in mind Problems With Can Contribute To Feed and Speeds spindle rpm Poor finish See below Excessive speeds and feeds can break cutting tools or wear out too fast Tooling Poor finish Using the wrong cutter for an application Parts incorrect Cutting too deep Part dimensions incorrect Driving and cutting forces cause deflections since no material is totally rigid Poor finish decrease the life of the cutter The following is a list of common machining problems and some possible solutions Problem Check or Try This Poor surface finish Dull tool Reduce f
55. 0 1 22 25100 11 Snap Ring 5135 1 23 Retaining Ring 517 1 24 Double Round Head Key 4x4x20L 1 25 25100 15 Encoder 545 87 0126 1 26 25100 16 Spacer 5541 87 0144 1 27 25100 17 5 5541 87 0145 1 28 6003 2RS Groove Ball Bearing 6003 2 29 25 0142 Bearing Cover FC20 1 30 25100 18 Seal 22 35 6 1 31 25100 19 Shaft Encoder 545 87 0143 1 32 Socket Head Screw M6x16L 3 33 87 0111 Gasket 1 34 25100 17 JTaper Roller Bearing 32026X 1 35 25100 13 Lock Nut YSF130x2 0 69 0146 1 36 25100 14 Bearing Front FC20 87 0112 1 37 Socket Head Cap Screw M6x20L 6 38 Socket Head Cap Screw M6x16L 4 39 O Ring G95 1 40 25100 22 _ Deep Groove Ball Bearing 6309 1 41 87 0118 Collar 5541 1 42 87 0119 Bearing Cover FC20 1 43 25100 34 Gasket 88 0125 1 44 25100 33 Bearing Cover FC20 87 0122 1 45 25100 29 nput Shaft SCM415 187 0121 1 46 2510 36 Lock Nut 07 1 47 25100 37 Washer AW07 1 48 25100 35 Key Double Round Head 14x9x70L 1 49 25100 32 Oil Seal 45 65 10 T 122 TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Southwestern Industries Inc 50 25100 38 Pulley FC20 88 0149B 1 51 25100 22 _ Deep Groove Ball Bearing
56. 1 95 22714 35 24 0712 BALL SCREW COVER EA 1 96 23337 96 030 1 100 23337 100 77USA 0308 00 BEARING HOUSING TAILSTOCK EA 1 101 12 1 75 16 25B SCREW SHCS STL BO EA 4 102 M12 73B WASHER SPLIT LOCK STL BO EA 4 103 23337 103 24 0316 00 WIPPER RIGHT RUBBER EA 1 106 M5 0 8X12 12B SCREW FH PHIL STL BO EA 3 107 23337 107 24 0727 01 CABLE WAY EA 1 108 23337 108 24 0224 01 LIMIT SWITCH COVER EA 1 109 M6 1 0X10 27B SCREW BHCS STL BO EA 9 110 23337 110 24 0217 00 X AXIS GIB EA 1 111 23337 111 17 0321 00 ADJUSTMENT SCREW EA 2 112 23337 112 5541 FRONT COVER EA 1 114 23337 114 24 0215 02 CROSS SLIDE EA 1 115 23337 115 24 0201 01 SADDLE EA 1 116 12 1 75 70 25B SCREW SHCS STL BO EA 4 117 6 1 0 16 10B SCREW PH PHIL STL BO EA 3 118 23337 118 24 0317 00 WIPPER LEFT RUBBER EA 1 i01007 162 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 100518 Figure 7 31 Lathe Apron Assembly 1540V 1840V amp 2460V Parts List Lathe Apron Assembly Item P N Title Qty 1 20082 2 ELECTRONIC HANDWHEEL X AXIS TRL 1 2 20082 3 ELECTRONIC HANDWHEEL Z AXIS TRL 1 3 20295 OGSTICK ASSY 1 4 21046 HOUSING 6 PANEL 55 HANDWHEEL VER 11 0 5 M4 0 7X16 25B_ISCREW SHCS STL BO 3 6 M6 1 0X12 25B SCREW SHCS STL BO 8 7 30889 HANDLE REVOLVI NG 2 100518 163 Southwestern Industries Inc TR
57. 1 and B2 The reading across these terminals should be approximately 16 ohms for the 1540V amp 1840V and 11 ohms for the 2460V If the ohmmeter displays an overload then the resistor is bad or there is a bad connection Each individual resistor should measure 32 33 ohms 4 6 3 Spindle Auxiliary Module This module is located on the lower left side of the electrical cabinet above the encoder module See Figure 4 1 This list below describes what takes place through each connection e LPT Parallel Port From Pendant Controls the Auxiliary Module from the Pendant Its primary function is to control the limit switches coolant pump lube pump and spindle signals 51 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual e Machine I D Key Port Configures the slave software according to the machine type This key tells the control what type of machine it is If this key is not present the machine will not boot up correctly e Spindle Control Port From Pendant nterfaces signals such as Run Off Stop FWD REV and E Stop from the Pendant to the spindle auxiliary module e Spindle Control Port To PC7 Spindle Drive Interfaces signals such as Run Stop FWD REV Overload and E Stop from the spindle auxiliary module to the Spindle Drive e Euro Relay Port not used on lathes e Indexer Port An auxiliary function that uses Logic s
58. 123629 CLAMPINGBLOCK 1 30 2123630 LOCKIIGROD 1 1 31 2123631 SHIFTINGROD 1 32 2123632 FLAT WASHER 2 33 2123633 FLAT WASHER 2 34 21236 34 COMPRESSION SPRING Ea 2 35 2123635 FLAT WASHER j EA 3 36 21236 56 HEXAGON SCREW M20X160L EA 1 37 21236 37 CLAMPING BLOCK FA 2 38 21236 58 HEXAGON NUT M20xP2 0 1 39 2123639 BEDWAYWIPER 1 2 40 2123640 BEDWAY WIPER PLATE J 2 41 21236 41 CROSS RECESS HEAD SCREW M6X16L EA 8 42 2123642 BEDWAYWIPER 1 EA 2 43 2123643 BEDWAYWIPERPIATE 2 SS 20 301501RNOBG 20 51 E sq qd 46 2123646 FEED SCREW IMPERIAL 1 47 2123647 THRUST BEARING 51104 1 EA 2 52 21236 52 SOCKET HEAD CAP SCREW M6X16L EA 4 84 21236 84 HEXAGONSCREWM20XI25L Ea 1 N 142 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual 86 2123686 ECCENTRIC COLLAR EA 1 Item PIN 1 Qty 4 21286700 SHARD gt T 90 2123690 LEVR 1 143 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRA
59. 15 to 25 minutes prior to cutting the test bar at 500 RPM Load an approximately 2 dia aluminum bar into the spindle chuck Load a standard right hand face and turning tool into a tool block Align and lock the tool block onto the tool post Set the depth of cut to a maximum of 002 Set the spindle to an acceptable speed for turning the test piece A speed range from 650 to 950 RPM is recommended 2 16 Measurement of the Test Part Tools Required e Micrometers with 0001 graduations Using a calibrated O D micrometer with 0001 graduations measure and record the generated dimension at a 6 00 spacing The acceptable measurement of parallelism of spindle axis to carriage movement taper of test piece is 0008 in 6 If the taper measured is not acceptable re machine the test part and or check and adjust the level of the machine or adjust the headstock 2 1 0008 TAPER ON DIA IN 6 00 100196 meni o o olo 9 g Figure 2 9 Test Part 21 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 2 17 Mounting of A2 5 Chuck The 1540V lathe has an A2 5 spindle and requires a chuck of this type Use the following procedure to mount this style chuck Bolt the chuck adapt
60. 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 1 Seta 0001 inch dial indicator in the spindle and touch off on a block or the vise along the direction X or Z you wish to check or set the backlash constant 2 on the ProtoTRAK and at the Main Menu follow the procedure below precisely Hn a Pres MODE 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 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 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 0 otherwise start over e Whatever number appears on the sc
61. 2 52 63 0533 00 Bedway Wiper Plate SS41PL 2 53 50 0534 00 Stud 2 54 50 0536 00 Set Over Indicating Chart 1 55 50 0537 00 Indicator 1 56 Button Head Rivet Q2x5L 4 57 63 01118 00 Center SK5 MT 4 1 58 50 0431 00 Handle ABS 1 59 50 0166 00 5 1 60 50 01138 00 Knob ABS 1 61 25021 Feed Screw Imperial S45C D 63 0507B 00 1 62 25023 Thrust Bearing 51104 2 63 80 0541 00 Lock Nut 1 64 Lock Washer AW04 1 65 66 80 0508 00 1 67 Ball Cup 01 4 1 68 Socket Head Screw M6x16L 4 69 63 0539 00 Speed Change Box 1 70 Ball Cup 01 4 1 71 Socket Head Set Screw M6x10L 1 72 Socket Head Cap Screw M6x20L 4 73 80 0540 00 Socket Head Cap Screw 4 74 80 0542 00 Gear 1 5 44 1 75 80 0543 00 Shaft 1 1 75 40 76 80 0544 00 Gear 1 5 22 1 77 Dry Bearing 17x 19x15L 2 78 80 0545 00 Gear Shaft M1 75x16 1 79 Dry Bearing 12xO14x15L 1 80 25022 Thrust Bearing 80 0545 00 1 97 EUM 2 2 81 80 0546 00 Speed Change Box Cover 1 82 80 0547 00 Shifting Block 1 83 63 0548 00 Shaft 1 84 Spring Pin 4 251 1 85 Double Round Head Key 5x5x15L 1 86 Socket Head Set Screw M5x20L 1 87 80 0551 00 Indicator ACP 1 88 Button Head Rivet Q2x5L 2 89 90 80 0552 00 Setting Plate 1 91 Counter Sunk Flat Screw M5x8L 2 92 28 0229 00 Shifting Arm 1 93 17 0504 00 2 Socket Button Head Screw 530 M8x20L 1 94 50 0167 00 Washer 1 95 50 0246 01 Feed Selector Knob 1 96 Socket Head Set Screw M8x8L 1 97 Co
62. 271427 2460739 PTE a EA Ps 28 2271428 2407001 REARPROTECTION GUARD EA 1 29 2271429 24033 ENDCOVER CT EA 1 30 2271430 4074 CHPTRAY 5 1 31 227431 24042 PUMP BRACKET EA 1 32 225 JPUMPCOLANTIBHP EA 1 33 2271433 24041 REAR COVER EA 1 34 2271434 24005 COVER PLATE EA 1 35 2271435 240712 BALLSCREWCOVER EA 1 36 2271436 24 0723 OPERATIONBOX 1 LEST p 229 9 37 7240724 38 2271438 24021 RIGHTMOVINGDOR EA 1 39 2271439 24022 SAFETY GLASS EA 1 40 227440 24010 CABLE CARRIER EA 1 4 2741 240211 COVER EA 1 42 227442 80X45SS2000L WIREPROTECTOR A EA 1 43 227443 240703 EA 1 44 M6 1 0X1625B SCREW SHCS STLBO 18 45 2271445 778 0615 SETTINGBASE EA 6 46 27446 57 RETAININGRING EA 6 47 2224 4 4 SHAFT 6 152 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual 48 rvs 77
63. 3 77USA 0307 Nut Seat FC20 1 94 Socket Head Cap Screw M12x50L 4 95 Spring Washer M12 4 96 77USA 0316 Bedway Wiper Right Rubber 1 97 Cross Recessed Head Screw M6x16L 3 98 Rod S45C 1 99 87 0727 Support Bracket 5541 1 100 97 0716 Cross Slide Cover 5541 1 83 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 101 Hexagon Socket Screw M6x10L 5 102 25200 3 Gib X Axis FC30 87 2017 1 103 17 0321 Adjusting Screw S30C 2 104 Socket Head Cap Screw M8x25L 4 105 87 0215 Cross Slide FC25 1 106 87 0201 Saddle FC25 1 107 Socket Head Cap Screw M12x90L 4 108 Cross Recessed Head Screw M6x16L 3 109 77A 0317 Bedway Wiper Left Rubber 1 110 23983 Ballscrew Z Axis 5 415 77 0310 1 111 7205 AVH Ring Nilos AVH7205 1 112 23940 Bearing Set Angular Contact 7205 BECBP 2 113 Spacer 545 1 114 16295 1 Housing Bearing S45C 1 115 Socket Head Cap Screw M8x25L 4 116 16314 Nut Clamp S45C 19x16UNF 1 117 16350 Ferrule Brass 1 118 16983 1 Pulley Ballscrew 1 119 984814090 Woodruff Key 3 1 8 x1 2 1 120 W01 Lock Wsaher W01 0012 1 121 N01 Lock Nut N01 O 12x32UNF 1 122 Socket Head Cap Screw M8x25L 4 123 Spring Washer M8 4 124 Socket Head Cap Screw 10 32x3 4 1 125 Socket Head Cap Screw M12x35L 4 126 Spring W
64. 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 4 6 3 7 Code 319 Error Log This code when turned on captures the commands that were sent to the servo system It includes items such as positioning commands errors stop and go commands etc It may be helpful for identifying problems between programmed commands and executed commands To turn on the error log press the F6 softkey The page forward and backward keys allow you to scroll through the file one page at a time The data forward and data backward keys allow you to scroll through the file one line at a time The data bottom key takes you to the bottom of the file and then changes to data top which will take you back to the top The file will capture data until the file reaches a size of approximately 600 Kb At this time the file is saved to a backup file and the original file is cl
65. 460 HEADSTOCK 2 2 2500 R P M 137 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Parts List 1840V Headstock Assembly Item P N Title Use As Qty 1 21234 001 HEADSTOCK CASTING EA 4 21234 002 SPINDLE 01 6 EA 4 3 21234 003 SLEEVE EA 4 4 21234 004 CENTER EA 4 5 21234 005 BEARING COVER FRONT D1 6 EA 4 6 21234 006 SOCKET HEAD CAP SCREW M6X30L EA 24 7 21234 007 PACKING EA 4 8 21234 008 TAPER ROLLER BEARING 32017XC P5 EA 4 9 21234 009 SPACER EA 4 10 21234 010 DOUBLE ROUND HEAD KEY 10X8X105L EA 4 11 21234 011 LOW SPEED GEAR EA 4 12 21234 012 SPACER EA 4 13 21234 013 HIGH SPEED GEAR EA 4 14 21234 014 LOCKING NUT EA 4 15 21234 015 TAPER ROLLER BEARING 32016XC P5 EA 4 16 21234 016 LOCKING NUT EA 4 17 21234 017 RETAINING RING STW75 EA 4 18 21234 018 TAPER ROLLER BEARING 6015 EA 4 19 21234 019 DOUBLE ROUND HEAD KEY 8X7X18L EA 8 22 21234 022 PACKING EA 3 23 21234 023 BEARING COVER REAR EA 3 24 21234 024 SOCKET HEAD CAP SCREW M6X16L EA 12 25 21234 025 SPACER EA 12 26 21234 026 SYNCHRONOUS BELT EA 3 27 21234 027 DYNAMIC BALANCING COLLAR EA 3 28 21234 028 SOCKET HEAD SET SCREW M8X8L EA 6 29 21234 029 DYNAMIC BALANCING BLOCK EA 9 30 21234 030
66. 6309 2 52 Socket Head Cap Screw M6x16L 4 53 25100 42 O Ring P24 1 54 25100 41 Seat Pump 5541 50 01131 1 55 25100 39 Oil Manual LPO1AM2 1 56 Spring Washer M6 3 57 Socket Head Cap Screw M6x55L 3 58 25100 40 Gear Oil Pump UMC 1 87 0125 1 59 Set Screw M5x16L 2 60 25100 31 Spacer 5541 87 0124 1 61 25100 28 Gear SCM415 187 0120 1 62 25100 30 Key Double Round Head 14x9x70L 1 63 25100 22 Bearing Deep Groove Ball 6309 1 64 25100 27 Gear SCM415 87 0117 1 65 25100 24 Bearing Deep Groove Ball 6012 1 66 25110 Cluster Gear amp Shaft Ass y 1 68 25100 20 O Ring G95 1 70 25100 21 Bearing Plug FC20 87 0113 1 71 25100 22 Bearing Deep Groove Ball 6309 1 72 25100 44 Spped Jaw 2 87 0130 1 13 Retaining Ring 516 1 74 17 0629 Plug SS41 2 75 25100 45 Swing Arm FC20 87 0129 1 76 Spring Pin 5x30L 2 77 25100 43 _ Shaft SS41 87 0128 1 78 Oil Plug PT 3 4 1 79 65 0177 Speed Changing Shaft s45C 1 80 82 0152 Quadrant Gear FC20 1 81 Steel Ball 1 4 1 82 Socket Head Set Screw M8x16L 1 83 77A 0133 Speed Changing Knob FC20 1 84 Cross Recessed Head Head Screw M5x12L 2 85 65 0193 Sleeve 5541 1 86 50 0167 Washer 5541 1 87 65 0174 Indicator ALP 1 88 17 0542 Screw S30C 1 89 Socket Head Cap Screw MS820A 1 90 Double Round Head Key 5x5x15L 1 91 Socket Head Set Screw M8x8L 1 92 Compression Spring p 6x o 0 8x30L 1 93 Steel Ball o 1 4 1 94 O Ring P24 1 95 O Ring P12 1 96 Socket Head Cap Screw M12x55L 1 97 50 01114 Adju
67. 8 LOCKING NUT 04 EA 3 79 21234 079 WASHER 04 EA 3 80 21234 080 CAM EA 18 81 21234 081 DETENT SPRING EA 18 82 21234 082 DETENT SCREW EA 18 83 21234 083 CAM STUD EA 18 84 21234 084 SOCKET HEAD CAP SCREW 3 8 16UNCX16L EA 18 85 21234 085 DRIVING PLATE EA 3 86 21234 086 DRIVING COLLAR EA 3 87 21234 087 SOCKET HEAD CAP SCREW M12X25L EA 3 88 21234 088 DRIVING PIN EA 6 89 21234 089 SHIFTING ARM EA 3 90 21234 090 PLUG EA 6 92 21234 092 SHIFTING FORK EA 2 93 21234 093 CHANGE SPEED SHAFT EA 2 94 21234 094 SLEEVE 2 95 21234 095 STEEL BALL 1 4 2 96 21234 096 COMPRESSION SPRING 6X 0 8X30L EA 2 97 21234 097 SOCKET HEAD SET SCREW M8X8L EA 2 98 21234 098 DOUBLE ROUND HEAD KEY 5X15L EA 2 99 21234 099 SCREW EA 2 100 21234 100 WASHER EA 4 101 21234 101 O RING P24 EA 2 102 21234 102 SOCKET HEAD SET SCREW M5X12L EA 4 103 21234 103 KNOB EA 2 105 21234 105 SOCKET HEAD SET SCREW M8X8L EA 4 106 21234 106 STEEL BALL EA 2 107 21234 107 QUADRANT GEAR EA 2 108 21234 108 SPRING PIN 5X30L EA 4 109 21234 109 CHANGE SPEED ROD EA 2 110 21234 110 PACKING EA 2 111 21234 111 HEADSTOCK COVER EA 2 112 21234 112 SOCKET HEAD CAP SCREW M8X30L EA 12 113 21234 113 SOCKET HEAD CAP SCREW M12X25L EA 2 139 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual
68. 9 to check or change this value See Service Codes section Values lower than 0 005 may reduce the feedrate Incoming AC voltage is inadequate Perform Code 100 See Service Codes Section 4 9 and Electrical Section 4 6 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 proper and Z axis Gib adjustment procedures Binding in the Drive Train Check Repeatability using the Repeatability and Positional Accuracy procedure Check the torque reading of the Drive Train Step by step carefully inspect the Drive Train for any binding It may be necessary to disassemble and then reassemble the Drive Train See Mechanical Drive Train X Z Section 4 2 Servo Drive failure See Servo Drive Section 4 5 Motor failure See Motor Section 4 4 26 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 3 2 3 Axis Motor Motion 15 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 12 Feed Forward Constant e Code 127 Measure s the backlash i
69. AK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Figure 7 32 Pendant Bracket Kit 1540V 1840V amp 2460V 164 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Parts List Pendant Bracket Kit Item UseAs Qty 2 2473 SWIVEL PLATE BASE 2460V 1540V WEY Yl 1 121963 MOTRIN if P 2777 SONEA uci i BAG E on 5 2244 SWIVEL PLATE 2460V 1540V WEY YI _ EA 1 6 22484 PENDANT BRACKET 2460V 1540V_ EA 1 8 15759 WASHER 1 4 HARD BLK OX 1 8 THK__ EA 9 1 4 20 1 2 278 5 5 5180 EA KNOB MODIFIED 1 100979 165 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual AUXILIARY MODULE DIAGRAM i01001 ae ae SEI mm BG f SA h To Q Figure 7 33 Auxiliary Module Diagram i01001 166 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual POWER DIAGRAM EN 220V 3 PHASE 9 INPUT POWER X amp Z AXIS DRIVE FUSES 25 AMP TRANSFORMER TRANSFORMER 220V SINGLE PHASE INPUT HEAD S
70. E IN THIS POSITION DETAIL A NO 00 No 00 UU lel Ano 000 5 5 6 3 Motor Driver Adjustments amp PLC I nputs and Outputs 109 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual FOR PARTS LIST SEE SEPARATE SIZE SHEET i23700 XX SHT 1 REPLACE SCREW WITH ITEM 23 amp 24 USE M240 SHCS FOR 1540 MACHINES TO BOLT INDEXER 8 TOFASTEN INDEXER BASE TO CROSSLIDE PIN 900744176 BASE TO CROSSLIDE LSE M100 SHCS FOR 1840 MACHINES TO BOLT BASE TO CROSSLICE AA USE HAUTS THAT COME WITH 3840 OFICINA TOOL POST A USE EXISTINGHOLES FROM CABLE WAY COVER USE CNLY ON 1540 MACHINES INDEXER MUST BE INBETWEEN TOOLS TO MOUNT 8 REMOVE INDEXER Figure 6 4 Indexer Mounting 1540V 1840V amp 2460V 110 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual TOO SHT3 1 4 TOOL INDEXER COMPONENTS 111 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V 8 ProtoTRAK VL CNC Safety Installation Maintenance Service 8 Parts List Manual Figure 6 5 4 Tool Indexer Cable Routing 112 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 4 Tool Indexer Spa
71. Faulty E Stop switch Check the cable connections from the computer module to the E Stop switch Check the E Stop switch for functionality Bad Computer Module Assuming that the E Stop Switch and cable to the Computer Module are good if the E Stop button is depressed and no message is displayed on the screen then replace the pendant Bad spindle auxiliary module Replace module Bad spindle control cable This cable runs from the computer module to the auxiliary module 3 3 11 Motor Alignment Routine Does Not Work Properly The Motor Alignment Routine Code 203 1540V amp 1840V only calculates the relative position between the motor poles on the stator and the magnets on the rotor through the use of the motor encoder Once the stator and rotor are aligned the encoder s absolute zero is set The routine also distinguishes which type of motor is being used on the machine The routine can last up to 30 seconds After 30 seconds the routine will under go a Time out If the motor alignment routine fails to work properly a message should appear on the display prompting the user that the motor alignment routine has failed Each axis moves less than 1 during routine The 2460V uses service code 204 to align the servo motors This routine looks for the index pulse on the motor encoder and aligns the motor to this location Possible Cause Check This Gib locks are on or Unlock gib locks and measure the torque on each axis It should mechanically
72. Figure 5 1 Motor Assembly P N 21994 i00764 62 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 5 1 2 Servo Driver Replacement WARNING Do not work with the Servo Drivers unless the power is disconnected from the machine The servo drivers are run by 220 VAC There is possibility of death by electrocution 1 Turn off power to the machine 2 Open up the electrical cabinet 3 Remove the bracket that holds the cable in place Remove the servo driver cable from the front of the servo driver 4 Remove the power cable that runs to the servomotor This includes the 3 3 phase wires and a ground wire on the side of the aluminum extrusion In order for the servomotor to move in the same direction as it did before you replaced it you must put the wires back in the same terminals T1 uses the red wire T2 uses the white wire and T3 uses the black wire 5 Remove the black wires from servo driver labeled L1 L2 and L3 These wires feed power into the servo drivers 6 Remove the wires that run between each servo driver They are labeled B B and IR Once again make sure to put them back into their proper terminals 7 Z drive remove the small red cable that runs to the fan at the bottom of the extrusion This cable provides power to the fan 8 the Z servo drive make sure to unplug the capacitor from the
73. From there it is reduced to 24V by a power supply in the black box and reduced to12V in the white box by a transformer If there is a power problem you will need to back track to find out where the power is being interrupted If voltage drops outside of the 20 28 volts range in the black box this message could also appear To make sure power is getting to the white box verify that the green light on the side of the box is illuminated If it is not check the fuse next to the light e Fault 87 Indexer Air Pressure Problem This message will appear if the air pressure sensor senses low air or no air pressure The recommended air pressure for the indexer is 80 psi The air pressure should be at least 70 psi and no more than 150 psi for the indexer to work correctly Do not exceed 150 psi This will void the warranty on the indexer Check to make sure the air regulator is set to at least 80 psi e Fault 88 Indexer Not Initialized This message will appear if the indexer does not know its present position An example of this would be if the turret stops in the middle of a tool change An interruption of power or air may cause this fault Pressing the E stop button can also cause this problem if the tool is not in a known position Initialize with Service Code 147 e Fault 89 Indexer Time Out This message appears if the indexer does not get to position after a few seconds This may be caused by an internal problem inside the indexer such as a broken gea
74. ING 6250 1 21 21241 21 PLATE 1 22 21241 22 0 6210 1 23 21241 23 SOCKET HEAD SCREW M5X10L 6 24 21241 24 PLATE 1 25 21241 25 _ ROUND SCREW M5X6L 4 26 21241 26 6 4 27 21241 27 WASHER 6 4 28 21241 28 TUBE 1 29 21241 29 ROUND SCREW M5X6L 4 30 21241 30 SUPPORTING PLATE 1 31 21241 31 ROUND SCREW M5X6L 4 32 21241 32 ROUND SCREW M6X16L 4 33 21241 33 REAR PROTECTOR COVER 1 34 21241 34 ROUND SCREW M5X6L 16 35 23341 WORK LIGHT BULB 1 36 21241 36 DOOR HANDLE 2 100994 135 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 100995 7 Jis iis L2 1314 m1 _______ Cluster Gear u Current Position Low Gear LITE High Gear Spindie cs 7 ss s 8 nis rss ed FO Left Position High Gear Uv 5 3 d 7 as 2 ie FON N J HE L Esp os N 18 81 1 L ye hes Ae E r 09 4 et 5 ja gt im AF S t 2 A gt E e T EE 28 27 e Figure 7 14 1840V Headstock Assembly 136 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 7 15 100
75. Imperial BC2 63 0505 00 1 17 Socket Head Cap Screw M6x12L 4 18 63 0507 00 Feed Screw Imperial S45C D 1 19 Double Round Head Key 6x6x20L 1 20 Socket Head Set Screw M5x20L 1 21 50 0508 00 Bracket 1 22 Ball Cup 01 4 1 23 Thrust Bearing 51104 2 24 50 0510 00 Dial Imperial FC 20 1 25 50 0511 00 Handwheel FC 20 1 26 50 0513 00 Washer SS41B D 1 27 17 0504 00 2 Socket Button Head Screw 1 28 50 0538 00 Pad Piece 1 29 50 03111 00 Screw 1 30 27013 Guide Pin 63 0514 00 1 31 63 0515 00 Lock Nut 1 32 63 0516 00 Lock Sleeve 1 33 63 0517 00 Lock Rod 545C D 1 34 50 0518 00 Lever 5541 1 35 63 0519 00 Shaft 1 36 63 0520 00 Lever 1 37 50 0521 00 Collar 1 38 Spring Pin 06 401 1 39 50 0522 00 Adjusting Block 1 40 50 0523 00 Washer 1 41 50 0524 00 Washer 1 42 50 0525 00 Compression Spring 1 43 50 0526 00 Washer 2 44 63 0527A 00 Hexagon Head Screw 1 45 63 0528 00 Clamping Block 1 46 63 0527 00 Hexagon Head Screw 1 47 Nut M20xP2 5 1 48 25025 Wiper Bedway 50 0362 00 2 129 TRAK TRL 1540 1840 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual Southwestern Industries Inc 49 50 0363 00 Bedway Wiper Plate SS41PL 2 50 Cross Recessed Head Screw M6x16L 4 51 25024 Wiper Bedway 63 0532 00
76. K VL Safety Installation Maintenance Service amp Parts List Manual VV NOILOAS xz EL SY SI 0 WALI ONISNOH OL 1244534 NI SNUALLWdl 310H 9 WALL 30 NOLLV LNAIHO IN ASIMYSHLO SS3 ND 83 ON 1540V Spindle Encoder Drive Assembly Figure 7 17 144 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Parts List 1540V Spindle Encoder Drive Assembly 1 2225 HOUSING SPINDLE ENCODER DRIVE EA 1 2 6003285 BEARING SWI P N2104 EA 2 4 0 2103906 SNARRING o 5 2203 SHAFT SPINDLE ENCODER DRIVE EA 1 6 2103701 ADAPTOR ENCODRMOUNING EA 1 7 M6 1 0X1525B SCREW SHCSSTL BO 3 8 222 2 _ E 1 9 2204 SPROCKETASSY SPINDLE ENCODER DRIVE EA 1 10 510066 RETAININGRING 17mm EA 1 12 8708 WASHER FLATUSS STLBO 1 1 FA 2 13 8 1 25 30 25B SCREW SHCS STLBO 2 100985 gt gt 145 Southwestern Industries Inc TRAK TRL 1540V 1840 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual FITS BETWEEN THE SADDLE WINGS OF THE CARRIAGE 3 CLAMP ROLLERS ONTO TAILSTOCK BARREL AND VERIFY THEY ARE CENTERED 4 INSPECT FOR RUST OR OTHER SIGNS OF DAMAGE 2
77. L CNC Safety Installation Maintenance Service amp Parts List Manual 100992 SHEET 2 ALTER REGULATOR SET AT 80 PSI REF Figure 6 2 Indexer Cable Routing 104 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Dorian ndexer Spare Parts List Item PIN 4 216152 INDEXER ASSY MODIFIEDDORIAN 1IN 6 21630 INTERFACE BOX DORIAN WHITE 6 2 4 Tool Indexer Option 6 2 1 Field Installation I nstructions 1 Turn power on to the machine 2 Goto SETUP mode under TOOL GROUPS to verify the indexer softkey is activated Then press the INDEXER key to activate the indexer It will turn gray when activated 3 Run service code 147 to initialize the indexer 4 Goto DRO mode and press TOOL and enter a number from 1 to 8 The indexer should move to this tool number The tool number on the indexer is found on top of each tool 5 To verify the indexer is working properly run a program with all 4 tools To run the program enter a home position in Setup Mode Make sure you set the X and Z absolute zero position 12 to 18 inches from the chuck Set the home position to X 3 and Z 3 Run a program and make sure the indexer moves to the correct tool stations programmed Verify that the indexer positions to each tool station If there is a problem refer to the troubleshooting section 6 2 2 Remov
78. OCK ASSY MODIFICATIONS EA 1 100995 140 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 9 G9 9 9 9 9 SEG 0 OO MOWOO 3 GO 100996 7 16 1840V Tailstock Assembly 141 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Parts List 1840V Tailstock Assembly PIN _ Hide 21236 01 TAILSTOCK BODY Item 4 21236 04 SOCKET HEAD SET SCREW M12X16L_ 6 21236 06 SOCKET HEAD SET SCREW MO XIOL EA 8 21236 08 OILSEALTC75X90X8 EA 9 21236 09 STRAIGHT PIN 10X85L EA EA EA 12 21236 12 TAILSTOCKBASE 1 f C 15 2123615 FEEDSCREWNUTIMPERIAL _ EA 1 16 21236 16 SOCKET HEAD CAP SCREW M6X12L EA 4 17 2123617 DOUBLE ROUND HEAD KEY 6x6x20L_ EA 1 18 2123618 SOCKET HEAD SET SCREW M5x20L_ EA 1 20 2123620 16 1 21 212621 i 222 0 2123622 WASHER SN 23 21234 099 SCREW amp SET SCREW ASSEMBLY EA 1 4 21233624 CENTER 25 2123625 PAD BRASS 1 26 21236 26 ROUNDSCREW 1 GET ANA Ee 28 2123628 LOCKINGBLOCK 1 29 2
79. OTOR JUNCTION BOX SPINDLE FAN TERMINAL BLOCK WRE TOFAN 220V A CONFIGURATION MOTOR JUNCTION BOX GROUND SCREW JUMPERS SPINDLE FAN TERMINAL BLOCK Figure 5 14 Spindle Motor 1840 MOTOR JUNCTION BOX 00991 Wiring 89 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual 5 1 19 Spindle Cartridge Replacement 1540 Only see Figure 5 15 The spindle and bearings on the 1540 lathe are to be replaced as an assembly The spindle and bearings are encased within a cartridge that bolts to the headstock Problems with the spindle or bearings are to be solved by replacing the entire cartridge Remove the headstock sheet metal cover Remove the spindle encoder belt Remove the chuck guard from the headstock splash shield Loosen the spindle motor and remove belt from spindle to headstock pulley Remove headstock splash shield for easier access to the cartridge ya spa Pa Remove the rear clamping plate from the headstock casting Item 3 This can be done by removing 8 M6 SHCS and 6 M8 SHCS This will allow the spindle assembly to easily slide through the opening of the casting This plate may be left on but it makes it more difficult to remove the cartridge If it is left on the M6 SHCS will still need to be removed 7 Remove the 6 M12 SHCS that hold the front of the cartridge to t
80. RL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual SERVO DRIVE SYSTEM i00794 1 vu emm s s T SMOOTHS OUT THE RIPPLE OF THE OUTPUT SIGNAL VOLTS CAPACITOR 6 SDC PWM INPUTS Z AXIS DRIVE VOLTS DB B 11 12 TIME 220 VAC 3 PHASE OUTPUT INCREASE FREQUENCY TO 120 Hz TO INCREASE MOTOR SPEED l VOLTS VOLTS 220 VAC 3 PHASE INPUT DECREASE FREQUENCY TO 30 Hz CONSTANT FREQUENCY 60 Hz TO DECREASE MOTOR SPEED Figure 7 38 100794 1 Drive Output 171 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 22071 144 22555 15 OR 2X 22071 198 FOR 2460 3x 22556 15 m 22081 x Dy LI 9 22074 15 LIH 22070 144 OR 22070 198 FOR 2460 x ff 16593 gt i S TD B 8 22443 item 7 Qty 1 2207415 CABLE ASSY PT4PENDANT TO SEMIPOWER CONTROL 3 CABLE ASSY PT4 UMBILICAL EB TO PENDANT CABLE ASSY PT4 PARALEL PORT EB TO PENDANT 2 220 22 1 CABLE 55 4 TO MOTOR ENCODER CABLE ASSY PT4 MOTOR PWR 22292 CABLE ASSY PT4 POWER d 55 5 CABLE ASSY PT4 ELECTRICS BOX FAN CABLE ASSY
81. S STL BO EA 8 44 23337 44 24 0738 BRACKET EA 1 45 M10 1 5X90 25B SCREW SHCS STL BO FULLY THD EA 4 46 M6 1 0X10 25B SCREW SHCS STL BO EA 2 47 M6 70B WASHER FLAT USS STL BO EA 16 48 M6 73B WASHER SPLIT LOCK STL BO EA 16 49 23337 49 24 0698 BRACKET EA 1 53 M6 1 0X20 25B SCREW SHCS STL BO EA 44 56 23337 56 24 0730 BRACKET CABLE CARRIER EA 1 57 23337 57 88X45SAX1350L CABLE CARRIER EA 1 58 M5 0 8X10 10B SCREW PH PHIL STL BO EA 17 59 23337 59 24 0729 END COVER EA 1 60 8 1 25 20 25B SCREW SHCS STL BO EA 2 63 23337 63 24 0307 MICRO SWITCH SEAT EA 1 65 22551 1 LIMIT SWITCH ASSY PT4 RIGHT EA 2 66 M6 1 0X16 25B SCREW SHCS STL BO EA 22 69 23337 69 24 0697 00 Z AXIS STOPPER EA 1 70 23337 70 24 0207 01 MOTOR MOUNTING BRACKET EA 1 72 23337 72 24 0337 00 REAR WIPER RIGHT RUBBER EA 1 73 23337 73 24 0336 00 REAR WIPER LEFT RUBBER EA 1 77 23337 77 24 0226 01 X AXIS STOPPER EA 1 161 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 79 6 1 0 25 25 SCREW SHCS STL BO EA 2 81 23337 81 24 0334 00 FRONT WIPER LEFT RUBBER EA 2 82 23337 82 24 0335 00 FRONT WIPER RIGHT RUBBER EA 1 84 23337 84 24 0225 00 X AXIS STOPPER EA 1 91 22714 36 24 0723 OPERATION BOX EA 1 92 22714 37 24 0724 COVER EA 1 93 M5 0 8X6 10B SCREW PH PHIL STL BO EA 8 94 23337 94 24 0311 00 YOKE EA
82. SPINDLE ENCODER CABLE 55 4 TO SPINDLE FAN CABLE ASSY PT4 APRON 22443 CABLE ASSY PT4 VUVM 15 PIN SPINDLE CONTROL CABLE COOLANT PUMP 5 5 22291 CABLE LUBE PUMP 225511 UMIT SWITCH ASSY PTA RIGHT 225512 UMIT SWITCH ASSY PT4 LEFT 22584 CABLE ASSY DOOR LIMIT SWITCH CABLE ASSY GEAR LIMIT SWITCH 22600 CABLE ASSY PT4 E STOP CABLE 55 4 EB TO MOTOR ENCODER 2460 CABLE ASSY PT4 EB TO MOTOR PWR 2460 16 7 01002 101002 Figure 7 39 Cable Set 172 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Miscellaneous Service Parts Part Description Machine used on 1 22683 Door Interlock Switch 1540V 2 22714 26 Light Assembly 1540V 3 23341 Bulb 4 23343 Spindle Motor 1540V 5 22714 7 Window left door 1540V 6 22714 39 Window right door 1540V 7 23337 10 Crosslide gib 5 1540V 8 23337 28 Carriage gib Z axis 1540V 9 21050 3G Crosslide gib X axis 1840V 10 21050 3F Carriage gib Z axis 1840V 11 22680 Gear Switch 1840V 12 22654 Breaker 60 amp 13 22653 Breaker operator 14 21239 25 Spindle Motor 1840V 173 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual Southwestern Industries Inc
83. Screw M8x25L 4 14 Spring Washer M8 4 15 24 0208 Motor Plate S20C 1 16 Symchronous Pulley Aluminum 1 17 500 5M 15 Belt X Axis 1 18 Socket Head Cap Screw M8x25L 8 19 77A 0202 _ Lock Block FC25 1 20 50 0325 Adjusting Screw 530 4 21 21050 3 Gib Z Axis FC25 77 0218 1 22 77A 0216 _ Lock Block FC25 1 23 7204 AVH Ring Nilos 1 24 23930 Bearing Set Angular Contact 7204BECBP 2 25 15885 Spacer 545 1 26 16300 Bearing Housing S45C 1 27 16314 Nut Clamp S45C L 19x16UNF 1 28 16350 Ferrule Brass 1 29 984814090 Key Woodruff 3 1 8 x1 2 1 30 16983 1 Pulley Ballscrew 1 31 W02 Lock Washer W02 O 15 1 32 NT02 Lock Nut N02 01 15x32UNF 1 33 Socket Head Cap Screw 10 32x3 4 1 34 Socket Head Cap Screw M8x16L 2 35 Flat Washer M8 2 36 Spring Washer M8 2 37 87 0738 Clamping Block 5541 1 38 Socket Head Screw M10x90L 4 39 Socket Head Cap Screw M6x10L 2 40 Flat Washer M6 2 41 Spring Washer M6 2 42 77USA 0698 Cam 5541 1 43 Socket Head Screw M8x30L 4 44 Flat Washer M8 4 45 Spring Washer M8 4 46 Socket Head Cap Screw M6x20L 4 47 Flat Washer M6 2 48 Spring Washer M6 4 49 87 0730 Bracket FC20 1 50 Wire Protector 88x45ax1850L 1 82 TRAK TRL 1540V 1840V 2460V ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Southwestern Industries Inc
84. T slots Be careful the indexer weighs approximately 80 Ibs To re install the indexer follow these steps in reverse order Make sure you install the riser block at least 2 from the front of the cross slide not the front bracket Failure to do this will cause the indexer to hit the sliding door when the cross slide is all the way toward the operator 100 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 6 1 3 Troubleshooting the I ndexer The following fault messages will appear on the screen when there is a problem with the indexer There are also LED s in the black box on top of the chip guard that may be helpful when troubleshooting the indexer Please refer to that section below e Fault 85 Impossible Tool Position This message will appear if the indexer goes to a tool number that you did not select For example the operator chose Tool 2 and the indexer went to Tool Station 6 To fix this problem re initialize the system by choosing Service Code 147 If this does not solve the problem refer to the LED troubleshooting section e Fault 86 Indexer Power Problem This message will appear if the power is interrupted to the indexer It could indicate that no power or low power is getting to the indexer The black box on top of the chip enclosure receives 115V power from the main electrical cabinet and sends it to the white box
85. TOCK OIL PUMP FUSES 2 AMP 1840 ONLY mmi n SPINDLE DRIVE FUSES 40 AMP 896 GROUND FROM W ENCODER IF GROUND BAR MAIN DISCONNECT SWITCH 220V 3 PHASE jC LAMP TUBE 21241 28 VV GROUND FROM X AXIS amp SPINDLE DRIVE 22081 PENDANT 22328 2 SPINDLE MOTOR 10 HP 220V 3 PHASE DOOR FANS 110V Figure 7 34 Power Diagram i01000 167 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual i T 5 aa ENCODER DIAGRAM 100999 MODULE ASSY PT4 ENCODER 22068 2 Figure 7 35 Encoder Diagram i00999 168 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual SPINDLE DRIVE SYSTEM 100998 A BRIA BRAKE m Ll B RESISTOR BI I 7 RESISTOR SPINDLE DRIVE FUSES 40 IL 13 3 220652 MODULE ASSY PT4 EB SPIWAUX 7 36 Spindle Drive System i00998 169 Southwestern Industries Inc TRAK TRL 1540V 1840 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual SERVO DRIVE SYSTEM i00997 3 lt Figure 7 37 see Servo Drive System i00997 170 Southwestern Industries Inc TRAK T
86. TRAK TRL 1540V 1840V amp 2460V Lathes Safety Installation Maintenance Service amp Parts List Manual Service Manual for Non Current Lathe Products Document P N 24970 Version 062211 Covering Machine Models Covering Non current Control Models TRAK TRL 1540V e ProtoTRAK VL TRL 1840V TRAK TRL 2460V Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 USA 310 608 4422 F 310 764 2668 Service Department 800 367 3165 e mail sales southwesternindustries com service southwesternindustries com web southwesternindustries com Copyright 2007 Southwestern Industries Inc Allrights reserved No 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 Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 5610 Phn 310 608 4422 Fax 310 764 2668 Service Departmen
87. 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 Product Factory Labor New TRAK Any EXCHANGE Unit The warranty period starts on the date of the invoice to the original purchaser from Southwestern Industries Inc SWI or their authorized distributor If a unit under warranty fails it will be repaired or exchanged at our option for a properly functioning unit in similar or better condition Such repairs or exchanges will be made FOB Factory Los Angeles or the location of our nearest factory representative or authorized distributor Disclaimers of Warranties e This warranty is expressly in lieu of any other warranties express or implied including any implied warranty of merchantability or fitness for a particular purpose and of any other obligations or liability on the part of SWI or any producing entity if different e Warranty repairs exchanges do not cover incidental costs such as installation labor freight etc e SWI is not responsible for consequential damages from use or misuse of any of its products e TRAK products are precision mechanical electromechanical measurement systems and must be given the reasonable care that these types of instruments require e Replacement of chip scrapers and wipers is the responsibility of the customer Consequently the warranty does not apply if
88. To reduce the relief area when threading up to a shoulder the spindle speed should be reduced as much as possible The slower the speed of the spindle the closer the cutting tool can come to the end of the programmed thread before it pulls out and retracts If a nut must be turned all the way up to a shoulder machine a relief area behind the last thread NOTE No machine can thread up to a shoulder and instantaneously pull out Do the following service codes and procedures e Codel12 Determines the feed forward constant for the axis motors Code 133 Spindle encoder test 3 1 5 1 Cross Threading Threaded parts are cross threaded after completion of the threading event Possible Cause Check This Looseness in the Gib Gib adjustment See Gib Adjustment Section 5 2 1 Looseness in the drive train The drive train Diagnostics See Mechanical Drive Train X Z Section 4 2 Failure of the spindle encoder Replace spindle encoder Run service code 133 to check if the encoder See Spindle Encoder replacement Section counts 5 1 8 3 1 5 2 Not Threading The machine will not cut a thread at all Possible Cause Check This Spindle speed too fast Slow down spindle speed Failure of the spindle encoder Replace spindle encoder Run service code 133 to check if the encoder See Spindle Encoder replacement Section counts 5 1 8 Broken or slipping encoder coupling Check and replace as necessar Broken or loose belt on 1540V lathe only
89. V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 3 5 3 Spindle Runs Backwards The spindle motor runs in the opposite direction The spindle should always spin in the clockwise direction when the forward key on the pendant is pressed Possible Cause Check This 3 Phase wires backwards Need to switch any 2 of the 3 wires either coming out of the Spindle Drive T1 T2 and T3 or going into the Spindle Motor U V and W Caution Be sure to shut off all power to the machine before attempting to switch any wires 3 5 4 Excess Gearbox Noise 1840V amp 2460V Only Gearbox noise is louder than normal Take note of the gear where the noise is most noticeable Remove the gearbox lid and try to isolate where the noise is coming from Possible Cause Check This pump is run off a gear in the headstock Move the shift lever in and out Turn off spindle and mating properly put back in gear Adjust the gear cluster in question to make sure it is mating properly Spindle bearing not being lubricated properly worn bearing bearings preload should be approximately 10 15 in Ibs 3 5 5 Headstock is Leaking Oil 1840V amp 2460V Only A Form A Gasket sealant should be use to seal any leaking areas Make sure the sealant fills the leaking area thoroughly Sealant must cure for 24 hours for best results 3 5 5 1 Leaking Oil from Rear of Gearbox Possible Cause Check This Leaki
90. V 8 ProtoTRAK VL CNC Safety Installation Maintenance Service 8 Parts List Manual Parts List 2460V Machine Parts List Item Parts No Description Material Specification 1 87 0707 ElectricalControlBoxDoor 551 1 2 240748 Switchset sa C 1 3 240735 ProtetionCovr ssa 1 4 87 0706 Electrical Control 5541 111 5 87 0728 SuppotPlte 5541 1 6 87 0704 Protection Gard 1 ssa C 1 7 87 727 Safetypor 5654 C 1 8 250505 SafetyGlas 87072727 1 9 2124136 Rubber 2 10 87 0711 ZAxisMotorCovrPlate 5541 1 11 87 0709 _ Front ProtetinGuad 54 2 1 12 Motor M 1 25050 2 3R 11M 2000 25050 3 13 87 064 Left Stand Casting Fc5 C 1 14 87 606 Brakt C C rr 1 15 SocktHeadCapSrew M245 4 16 Aa JjSpigWaher M2 4 17 87 0677 Shat C sc C 1 18 87 0678 MotoPate FC25 C 1 19 50 0681 Adjusting Washer ssa 2 20 50 0682 Adjusing Washer 5541 2 21 Adjusting Screw 1 545 M2025x175L 1 22 Hexagonnut _ MOS 3 23 87 0708 4 sa C 1 24 87 0733 Endcovr sa 1 25 1 26 87 0731 Cover C sa C 1 27 87 0617 Anti Leaking Guard 5541 C 1 28 peo 1 22 ORing 110200 1 30 x SocketHeadcapScew
91. al floor capable of supporting the weight safely For the location of the bolt holes size and recommended mounting see Figures 2 1 2 2 amp 2 3 2 8 Cleaning 1 Remove rust protective coating from the machine before moving any slideways 2 The coating is best removed with clean dry rags Do not use a cleaning solution that may damage the rubber way scrapers plastic parts or paint WARNING Do not use gasoline or other flammable cleaning agents for cleaning the machine 3 It may be necessary to move back and forward and left and right the carriage and cross slide CAUTION Never move any of the above parts over ways that were not previously cleaned Serious damage to the TURCITE surface of slideways can occur 4 certain the carriage cross slide and spindle move freely and smoothly over their entire length 2 9 Leveling The precision and durability of the lathe depends on it being leveled properly Final inspection can be done only when the machine has been correctly leveled After the machine is in position on top of the 8 6 4 rest pads it must be leveled by the use of the 8 6 4 leveling bolts It is important that the lathe be level in order to produce accurate work It may be necessary to lag bolt the machine in order to eliminate a small amount of twist NOTE The use of a precision level having a minimum accuracy of 0005 over 10 0 will be required Move the saddle and tailstock to the center of the
92. an area where the extra slack in the cables can be stored There is a cover that covers up all of the cables 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 3 220 volt servo motor cables and 6 110 volt power cables for the pendant spindle motor fan work light coolant pump lube pump and spindle auxiliary module The logic cables are used to carry signals between modules handwheels encoders etc The power cables have been placed on the right side of the electrics box when facing from the back of the machine and the logic cables have been routed to the left side of the box Mixing of the power and logic cables may cause noise from the power cables to interrupt the signals in the logic cables This can lead to intermittent axis faults or repeatability problems 69 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 5 1 8 Spindle Encoder Replacement 1 2 3 4 5 Unplug or remove all power from the lathe Remove the spindle cover to gain access to the encoder Loosen setscrews on flexible coupling and the bolts that hold the encoder on Slide the encoder off The spindle encoder assembly is only available as a complete unit Do not disassemble Note on the 1540 make sure the belt between the spindle and encod
93. and if the encoders are counting e Code 132 Electronic handwheel test Code 131 Manual DRO test Possible Cause Check This Electronic handwheel failure Each handwheel should count 0 100 amp 0 020 respectively for Z and X in fine mode and 0 400 amp 0 100 in course mode Servo driver failure Check the LED status on the axis in question See Servo driver Section 4 5 Motor Encoder not counting See Motor diagnostics Computer Pendant failure See Computer Pendant diagnostics 3 4 4 X amp 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 cross slide moves toward the operator e Z axis carriage moves toward tailstock 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 amp Z Axis Electric Handwheels Count in Wrong Direction The Electric Handwheels count in the wrong direction The positive directions for each Electric Handwheel are e X axis Electric Handwheel turns counterclockwise e Z axis Electric Handwheel turns clockwise Do the following service code and procedures e Code 308 Reverse X axis Handwheel Direction e Code 310 Reverse Z axis Handwheel Direction 35 Southwestern I
94. are located at the top left corner of each of servo drive module Next check for any loose wiring connections to the servo drive modules and to the CapBlok WARNING Make sure to first turn the power off and unplug the machine Wait about 10 minutes or so for the CapBlok to discharge Use a voltmeter to verify the voltage between terminals B and B are safe before handling 4 5 2 Servo Driver Cooling Fan The PowerBlok drive modules in the electric box are temperature dependent See Fault Code 5 Substrate over temperature Therefore SWI has mounted the servo drive modules to a heat sink to help transfer heat away by means of convection On the bottom of the aluminum extrusion that the servos mount to sits a 12 VDC fan that cools the servo system The temperature of the system must be above 131 F for the fan to turn on The 12 volt signal will only be present when the temperature reaches 131 F The fan will turn off when the temperature reaches 122 F If you see a Code 5 on one of the servos check to see that this fan is operational The Z servo driver powers the fan If the fan is not working check to see that 12 VDC is coming out of the Z servo driver by checking across the 2 pins on the servo driver If there is 12 volts then the fan is bad otherwise the servo driver is bad An alternative solution may be to swap the X and Z servo drivers WARNING Do not work with the Servo Driver unless the power is disconnected from the
95. are off and all the cables are plugged in then the computer module is probably the problem e Umbilical 1 amp Umbilical 2 Ports To Pendant The lathes have 2 motor encoder signals which are communicated between the Encoder module and the Pendant by use of 2 Umbilical cables The X signal is communicated through umbilical 1 and the Z motor signal is transferred through umbilical 2 e Electric Hand Wheel Port To Pendant Communication for X amp Z Hand Wheel and jogstick logic signals between the Pendant and the Encoder module X amp Z Electric Hand Wheel amp J ogstick Ports This port is used to receive logic signals from of the X and Z Electric Hand Wheels and jogstick X amp Z Motor Encoder Ports These ports are used to receive logic signals from each of the XYZ Motor Encoders 52 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 4 6 5 Cable Connections The lathe machines use 15 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 WARNING Do not plug and unplug connectors with the system power on This may cause damage
96. asher M12 4 127 400 5M 15 Belt Z Axis 1 128 24 0304 Z Axis Motor Seat FC30 1 129 Pulley 1 130 Socket Head Cap Screw M6x25L 4 131 Flat Washer M6 4 132 Spring Washer M6 4 133 24 0306 Z Axis Motor Plate S20C 1 134 21994 Motor Z Axis 1 135 87 0229 Front Cover Plate 5541 1 84 TRAK TRL 1540 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual Southwestern Industries Inc 5 1 14 Align Z Axis Ball Screw Assembly See Figure 5 9 or 5 10 1 Recheck machine level Adjust as necessary 2 Move carriage to middle of travel 3 Loosen headstock bearing housing and mounting bracket and loosen tailstock bearing housing Snug but do not tighten the yoke mounting bolts Move the ball screw manually and move the carriage to the tail stock end Tighten the yoke this will align it vertically Tighten the tailstock bearing housing Loosen the yoke and retighten to realign ball horizontally Oe CO vel SOM OE d Using a 3 8 socket extension move the carriage to the headstock 10 Tighten the Z axis housing 11 Tighten the bearing housing 12 Turn the ball screw manually with the 3 8 socket extension and move the carriage to the middle of the travel 13 Loosen the yoke mounting bolts to readjust the apron plate after the bearings have been tightened 14 Retighten the yoke 15 Move the ball screw manually and move the carriage through the entire length o
97. at the CNC control is in the STOP mode e Before changing tools e Before changing parts e Before you clear away the chips oil or coolant Always use a chip scraper or brush e Before you make an adjustment to the part chuck coolant nozzle or take measurements e Before you open safeguards protective shields etc Never reach for the part tool or fixture around a safeguard Protect your eyes and the machine as well Don t use a compressed air hose to remove the chips or clean the machine oil coolant etc Stop and disconnect the power to the machine before you change belts pulley gears etc Keep work area well lighted Ask for additional light if needed Do not lean on the machine while it is running Prevent slippage Keep the work area dry and clean Remove the chips oil coolant and obstacles of any kind around the machine Avoid getting pinched in places where the spindle carriage cross slide or sliding door create pinch points while in motion Securely clamp and properly locate the workpiece in the chuck or in the fixture Use proper tool holding equipment 4 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 19 Use correct cutting parameters speed feed and depth of cut order to prevent tool breakage 20 Use proper cutting tools for the job 21 Prevent damage to the workpiece or the cutting
98. aterial before running the machine If the TRAK TRL 1840V amp 2460V has a chuck mounted to the spindle make sure the cam locks are tight and the chuck jaws are engaged onto themselves or a piece of material before running the machine If the chuck was not purchased from SWI check to make sure the chuck is rated for the maximum rpm of the machine If it is not do not run the machine above the chuck s maximum rated rpm If the chuck s rpm rate is unknown do not run the chuck over 1000 rpm The chucks purchased from SWI are rated for the machine s maximum rpm 2 6 ProtoTRAK VL Control Hardware 2 axis CNC 2 axis DRO 266 PC based processor 64 MB of RAM A C Servo Motors rated at 704 in oz continuous torque for X and Z axes Precision ground ballscrews in the carriage and cross slide to ensure smooth accurate contours without backlash Feedrate override of programmed feedrate and rapid Programmable Spindle Speed Speed override of programmed spindle speed Polycarbonate sealed membrane and gasket sealed control enclosure to lock out contamination 10 color LCD for clear presentation of prompts status information and part graphics RS232 port for interface to computers Modular design simplifies service and maximizes uptime 10 GB minimum hard drive Single floppy disk drive for additional part program storage Limit switches for the X and Z axes that are installed to prevent crashes Electronic handwheels on the X and Z axes
99. ays wipe off with a clean rag any accumulation of old oil grease or dirt that might get into a part being lubricated Do not mix detergent type automotive oil or multi purpose oils with the regular grade of S A E No 30 lubricating oil 5 2 4 X amp Z Limit Switch Adjustments 5 2 4 1 X Axis Limit Switch Stop Installation amp Adjustment The limit switch stops for the X axis are mounted to the side of the crosslide They are slotted for adjustment front to back Each limit switch stop must be set to a specific distance from the end of the crosslide 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 The switch is mounted to the carriage The switch as well as the stops are covered by a sheet metal cover Procedure for setting X limit switch 1 Loosen the stops on each side of the crosslide 2 Slowly move the crosslide to the extremes of travel 3 In DRO mode set X 0 ABS CAUTION The limit switch must be triggered a minimum of 32 before the machine reaches its travel limits in both directions This allows sufficient room for the servomotors to stop when the limit switch is hit at 250 ipm 4 Using the DRO display back the table off 1 2 5 Tighten the stops in place 6 Jog the table at 250ipm to each side and verify that the limit switches are working properly Also make sure that the table
100. be drained and flushed after the first 150 hours of operation small percentage of kerosene may be added to the gearbox to flush out dirt and sediment Operate the machine for several minutes without load so that the flushing oil can circulate through the reservoir and remove the dirt The flushing oil must then be drained and new oil added Do not flush with solvents that will soften the paint Thereafter the oil should be flushed and drained every 1500 2000 hours of operation 2 D 100514 5 19 Headstock Oil Removal 96 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual CROSS SLIDE OIL G ROVE TO CROSS SLIDE TOZBALL SCREW OILINLET FRONT aa TO V WAY Figure 5 20 1540V 1840V amp 2460V Way Lubrication 5 2 3 2 Tailstock Three oilers located on top of the spindle housing lubricate the spindle and screw bedways on which the tailstock slides should be cleaned and oiled freguently 100494 Oil ball es if epee eS ae Figure 5 21 Tailstock Lubrication 97 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 5 2 3 3 Miscellaneous Information For all oilers on the machine use medium S A E NO 30 machine oil Before filling reservoirs or oil cups alw
101. cedure 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 Z 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 Machine s feet not equally supporting weight See Leveling Section 2 9 Improper tooling Work piece not properly supported speeds too fast Feeds too slow See Machine Tool amp Setup Section 4 1 X gib too tight or loose See Gib Adjustment Section 5 2 1 Loose bearing problem Looseness in the spindle bearings Adjust spindle preload Ball screw misalignment See Mechanical Drive Train X Z Section 4 2 See Spindle Bearing Preload Section 5 1 16 1840V amp 2460 See Section 5 1 19 for 1540V 23 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 3 1 2 Turning Diameters Out of Round Parts are not round within 0004 TIR for 1840V amp 2460V and 0 0002 for the 1540V Runout for the spindle is best measured by using a 0001 dial indicator and mounting to the inside taper of the spindle Rotate the spindle a
102. chips have been allowed to enter the mechanism e Accidental damage beyond the control of SWI is not covered by the warranty Thus the warranty does not apply if an instrument has been abused dropped hit disassembled or opened e Improper installation by or at the direction of the customer in such a way that the product consequently fails is considered to be beyond the control of the manufacturer and outside the scope of the warranty
103. cket is fastened down Make sure cable clips into female portion on the top and bottom Sometimes the clips tend to stick Overlay failure keys on pendant Certain buttons on overlay do not work Do code 81 to verify each key beeps Low voltage to pendant or current spikes 1 amp fuse in pendant blows Pendant will not turn on Slave board not functioning Machine will not run If under Code 33 it says Firmware Edge or Demo it means the slave board is not functioning 4 3 1 Checking Floppy Drive by Formatting a Disk Find a new disk and install in floppy drive Install 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 Sy Dp d pr 4 4 Motor Diagnostics The Motor subsystem is comprised of 2 parts The Motor Encoder and the Motor The motors are powered by 3 phase AC 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 220 VAC There is possibility of death by electrocution Rarely do both the X and Z motor servo systems fail at the same time and in the same way
104. d Cover 5541 1 53 Socket Head Cap Screw M8x20L 2 54 Flat Washer M8 2 55 Spring Washer M8 2 56 77USA 0307 Switch Seat 5541 1 57 Socket Head Screw M6x20L 2 NBNS543 BO2D12 58 22551 1 Switch Limit 61 12 10 1 59 Socket Head Cap Screw M6x16L 2 60 Flat Washer M6 2 61 Spring Washer M6 2 62 77USA 0698 Cam SS41 2 63 24 0207 X Axis Transmission Box FC30 1 64 Cross Recessed Head Screw M6x16L 6 65 25200 6 Wiper Bedway Right Rear Rubber 63 0362 1 66 25200 7 Wiper Bedway Left Rear Rubber 63 0363 1 67 Socket Head Cap Screw M6x25L 2 68 Spring Washer M6 2 BNS543 BO2D12 69 Micro Switch 61 12 10 1 70 Socket Head Cap Screw M6x16L 2 71 Flat Washer M6 2 72 Spring Washer M6 2 73 87 0714 Cam SS41 1 74 25200 4 Wiper Bedway Left Front Rubber 63 0360 1 75 25200 5 Wiper Bedway Right Front Rubber 63 0361 1 76 Cross Recessed Head Screw M6x16L 6 77 87 0715 Cam SS41 2 78 Socket Head Cap Screw M5x16L 4 79 Flat Washer M6 4 80 Spring Washer M6 4 81 Socket Head Cap Screw M6x16L 4 82 Flat Washer M6 4 83 Spring Washer M6 4 84 24 0723 Operation Box ss41 1 85 24 0724 Operation Box Cover 5541 1 86 Socket Screw M5x6L 8 87 77USA 0311 Apron FC25 1 88 77USA 0605 Ballscrew Cover SS41 1 89 Cover Round Hole O 30 1 90 N04 Lock Nut 545 N04 0O 20x16UNF 1 91 W04 Lock Washer W04 1 Bearing Ball Double Row 92 22446 Angular Contact 2204E 2RSITN9 1 93 77USA 0307 NutSeat FC20 1 94 Socket Head Cap Screw M12x50L 4 95 Spring Wash
105. de 128 0 001 2 0 0016 Code 12 000005 2 000006 000005 2 000006 Code 100 352 7 2 325 2 X 350 1 Z 333 1 55 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service 8 Parts List Manual 4 8 1 6 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 Please perform alignment routine afterwards 4 8 1 7 CODE 317 Update Slave Software Load upgrade disk in floppy drive and press this service code New software will automatically download and control will reboot Please perform alignment routine afterwards 4 8 1 8 CODE 318 Activate Converters or Options See programming and operating manual 4 8 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 8 2 1 CODE 12 Feed Forward Constant The Code 12 procedure helps the control learn the friction characteristics of the machine by sending a graduated series of motor signals and observing the results The process takes less than 30 seconds to run It is both a diagnostic routine that displays values and a routine that sets the parameters of the control for the particular machine The Code 12 is used for diagnosing and resolving e Problems wi
106. ding on which tool is in position In other words when the indexer is locked for tool 1 the I1 LED on the PLC will be lit For inputs 5 6 and 7 the LED light for these will only be on for a second or so when a new command is sent to the PLC from the control A change of tool in DRO mode or within a program will cause these lights to come on See further below for which lights will come on when changing tools 11 Turret proximity sensor position 1 12 Turret proximity sensor position 2 Turret proximity sensor position 3 14 Turret proximity sensor position 4 15 Select 1 16 Select 2 17 Select 3 18 not used 11 14 is from the 4 tool indexer identifies turret position 15 17 is from SWI control identifies index command The 3 select lines gives us 8 possible incremental moves as follows A few examples have also been given 106 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 1 tool select 1 and 2 For example if you command the indexer to move 1 tool position like from tool 2 to 3 you will see the select 1 and 2 lights come on briefly 2 tools select 2 3 tools select1 For example if you command the indexer to move 3 tool positions like from 1 to 4 you will see the select 1 light come on briefly 4 tools select 1 2 and 3 tool stays where it is 1 tool select2 and 3 2 too
107. 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 Onthe Pendant display go into the Service Codes and input the Code 100 3 The conversation line will say SELECT AXIS Inputthe axis Either X or Z 4 n the conversation line it will say WHICH DIRECTION PLUS e f you want to run in the plus direction press INC SET e f you want to run in the minus direction press then INC SET 5 In the conversation line it will say PRESS GO Press Go after you are sure that the machine will not crash in the direction and axis that you have specified 6 Afterward the screen will display values next to the DRO position axes Your input Display Data displayed X u Z u EA EES the maximum feedrate attained Your input E Z the maximum feedrate attained 57 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Your input nothing should be 0 GGE HS Z the maximum feedrate attained Your input nothing should be 0 2 42 the maximum feedrate attained Interpretation of the resulting values displayed The values for the encoder displays should be in the range of 4 0000 to 6 5000 The feedrate should be a minimum of 300 ipm Shops with higher voltages will see higher values Values for voltag
108. e Take special precautions with chucks that have four or more jaws and unbalanced parts Do not shift headstock gears while spindle or motor is running 101162 101161 220 Volts Safety amp Information Labels Used On The TRAK TRL 1540V 1840V amp 2460V Lathe It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels 2 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual o L60_ Hz SOUTH K DEES or 2615 HOMESTEAD RANCHO DOMINGUEZ CA 90220 5 ELECTRICAL RATINGS yosi aes C PHASE Hz FLA OF LARGEST MOTOR AMPS SHORT CIRCUIT INTERRUPT AMPS ELECTRICAL DRAWING CNC CONTROL ELECTRICAL RATINGS IF APPLICABLE VOLTS 8 JAMPS MACHINE ONLY MADE IN i00774 Safety amp Information Labels Used On The TRAK TRL 1540 1840V amp 2460V Lathe It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels Power Requirements at 220 Volts 3 phase 60 HZ Model Full load Amp of Machine Full load Amp of Largest Motor 1540V 47 33 1840V 36 33 2460V 59 45 3 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 1 3 Safety Precautions em
109. e 4 6 5 Cable Connections 4 6 6 Checking A C Voltage 4 7 Door amp Gear Switch 4 8 Service Codes 4 8 1 Software Codes 4 8 2 Machine Set Up Codes 4 8 3 Diagnostic Codes TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 5 0 5 1 5 2 6 0 6 1 6 2 4 8 4 4 8 5 Operator Defaults Options Codes Lube Pump Codes Procedures for Replacements amp Maintenance Replacements 5 11 Servo Motor Replacement 5 1 2 Servo Drive Replacement 5 1 3 AC Spindle Drive Replacement 5 1 4 Computer Module Replacement 5 1 5 Hard Drive Replacement 5 1 6 Electronic Handwheels amp J ogstick 5 1 7 Cable Routing in Electrics Box 5 1 8 Spindle Encoder Replacement 5 1 9 Spindle Drive Belt Tightening Replacement Spindle Motor Removal X Axis Ball Screw Removal Installing Angular Contact Bearings Z Axis Ball Screw Removal Align Z Axis Ball Screw Assembly 1840V amp 2460V Headstock Taper Adjustment 1540V Headstock Taper Adjustment Aligning Tailstock to Spindle Spindle Motor Wiring Spindle Cartridge Replacement 1540V Only Maintenance 5 2 1 Adjustments 5 2 2 Calibration amp Backlash Constants 5 2 3 Lubrication 5 2 4 X amp Z Limit Switch Adjustments 62 Indexer Options Dorian Indexer Option 6 1 Field Installation Instructions 6 1 2 Removing the Indexer from the Lathe Troubleshooting the Indexer Troubleshooting from LED s in Black Box Inde
110. eared 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 8 3 8 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 8 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 8 4 1 Code 66 Default Metric This code causes the control to turn on in the metric mode 4 6 4 2 Code 67 Default English This code causes the control to turn on in the English mode 60 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 4 8 4 3 Code 79 This turns the beeper to the control keys 4 10 4 4 Code 80 Beeper Off This turns off the beeper to the control keys 4 8 4 5 Code 129 Arc Accuracy When the VL control operates at high feedrates it may create small part machining errors as it g
111. eedrate Increase spindle speed Use a higher rake angle tool Make sure tool is not dull or chipped Use proper grade of cutting tool Use coolant Check to see if tools are on the centerline Long workpieces out of round Use a follow or steady rest Excessive chatter 4 1 4 1 Tool bit improperly ground or not on center Avoid extreme negative rake inserts Tool overhang too great tool deflection Improper feeds and speeds X gib loose See Gib Adjustment Section 5 2 1 Work improperly supported Machine tool out of level See Leveling Procedures Section 2 9 Spindle Speeds Spindle speeds are influenced by a number of variables 4 1 4 2 Material Rigidity of the Machine Setup Coolant Insert geometry and material of insert Depth of cut Feedrates Factors that affect feedrates Depth of cut Design or type of insert Sharpness of the insert Workpiece material Type of finish or accuracy required 40 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 4 2 Mechanical Drive Train X Z Indications e Troubleshooting instructions indicate that the drive train is potentially the problem and other more easily checked variables have been exhausted e Roughness looseness tightness or jamming movement in the carriage or cross slide e Carriage walk up due to Z ball screw misalignment 1 Check
112. ents Do Not Repeat With a dial indicator mounted to the spindle touch off a fixed surface either in the X or Z 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 Expected repeatability numbers should be 0 0005 or less Possible Cause Check This Check for any looseness in the setup See Machine Tool amp Setup Section 4 1 Check the adjustment of the X and Z axis Gibs using the X and Z axis Gib adjustment procedures X and Z axis Drive Trains 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 Z Section 4 2 Encoder Disk or Reader Head on Swap the motor in question with a known good motor motor are loose For example swap the X axis motor with the Z 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 3 4 2 amp Z Axis Measurements Are Not Accurate Measurements repeat but with a dial indicator mounted to the spindle traversing the length of a gage block or so
113. er M12 4 96 77USA 0316 Bedway Wiper Right Rubber 1 97 Cross Recessed Head Screw M6x16L 3 98 Rod S45C 1 99 87 0727 Support Bracket 5541 1 100 97 0716 Cross Slide Cover 5541 1 76 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 101 Hexagon Socket Screw M6x10L 5 102 25200 3 Gib X Axis FC30 87 2017 1 103 17 0321 Adjusting Screw S30C 2 104 Socket Head Cap Screw M8x25L 4 105 87 0215 Cross Slide FC25 1 106 87 0201 Saddle FC25 1 107 Socket Head Cap Screw M12x90L 4 108 Cross Recessed Head Screw M6x16L 3 109 77 0317 Bedway Wiper Left Rubber 1 110 23983 Ballscrew Z Axis SCM415 77A 0310A 1 111 7205 AVH Ring Nilos AVH7205 1 112 23940 Bearing Set Angular Contact 7205 BECBP 2 113 Spacer 545 1 114 16295 1 Housing Bearing S45C 1 115 Socket Head Cap Screw M8x25L 4 116 16314 Nut Clamp S45C 19x16UNF 1 117 16350 Ferrule Brass 1 118 16983 1 Pulley Ballscrew 1 119 98481A090 Woodruff Key 3 1 8 x1 2 1 120 W01 Lock Wsaher W01 00112 1 121 N01 Lock Nut N01 O 12x32UNF 1 122 Socket Head Cap Screw M8x25L 4 123 Spring Washer M8 4 124 Socket Head Cap Screw 10 32x3 4 1 125 Socket Head Cap Screw M12x35L 4 126 Spring Washer M12 4 127 400 5M 15 Belt Z Axis 1 128 24 0304 Z Axis Motor Seat FC30 1 129 Pull
114. er bracket is properly fastened 5 1 9 Spindle Drive Belt Tightening Replacement The spindle drive motor is located inside the base pedestal underneath the headstock Access is gained by opening the upper cover on the headstock and removing the lower access panel on the pedestal When removing the belt loosen the top nut and raise motor with the bottom nut until the belt is loose To tighten the spindle belt loosen the bottom nut A under the motor bracket and use the top nut B to tighten the belt See the figure below Make sure the tension on the belt is such that there is no slippage when the lathe is started at its maximum speed The belt tension can be checked by pulling on one of the belts in the center of its travel with a scale until you reach 15 165 on the scale At this point the deflection of the belt relative to the other belt should be no more than 1 2 If the deflection is more than 1 2 tighten the belt Belt tension should be checked frequently during the first days of operation and periodically thereafter Keep the pulleys and belt clean and free of any foreign material to ensure long life and maximum traction T s i00491 Figure 5 5 Spindle Motor Belt Adjustment 70 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 5 1 10 Spindle Motor Removal 1 Unplug or remove all power from the lathe
115. er module or hard drive has been replaced 4 8 1 4 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 This code is used when a computer module or hard drive needs to be replaced This stores the configuration file from the hard drive to the floppy disk It is a good idea to do this code after the machine is initially setup so these values can be saved and used in the future If the computer or hard drive fails then you will not have the ability to save the configuration file and the machine will need to be re setup when the computer or hard drive is replaced Note All machines will have copy of the configuration file in the back of the electric s cabinet 4 8 1 5 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 1540V displays machine ID key of machine Lube pump cycle time 60 minutes Lube pump discharge time 15 seconds Motor encoder calibration constants X 242 0411 7 242 0342 These numbers above are typical numbers for the calibration constants Arc accuracy 0 005 Limit switches on or off Spindle on or off during run On or Off Co
116. er plate to the spindle with 4 M10 X 50 SHCS The adaptor is orientated by the key on the spindle Then bolt the chuck to the adaptor plate with 3 M8 x 70 SHCS The chucks SWI provides are self aligning and need no adjustment 22 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 3 0 Troubleshooting Symptom Use this section to begin the process of resolving a service problem Each problem type is described in a few words and then more fully described in an explanatory paragraph Following this is a chart that directs in the most logical steps 3 1 Problems Relating to Machining Results 3 1 1 Poor Finish Poor finish can be caused by a number of variables including speeds feeds tooling machine setup and chatter Do the following Service Codes e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 12 Feed Forward Constant Code 127 Measures backlash in the system e Code 128 Enter backlash compensation Possible Cause Check This 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 X amp Z axis Drive Trains are loose Check Repeatability using the Repeatability and Positional Accuracy pro
117. es from 7 to 9 Typical torque values on machines that have the ball screw aligned and the gibs adjusted to 56 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual specification should be between 10 to 15 in lbs Divide the X axis values by 2 and apply the torque values from above The feed forward gain can be adjusted manually by pressing the manual button Choose the axis you would like to change and then enter values in the positive and negative direction to adjust Adjusting the gain can help solve circularity problems Default values can be set by pressing the Reset button The manual feature should only be used in extreme cases where the AUTO routine did not solve the problem Manual adjusts above 9 may lead to servo related problems 4 8 2 2 CODE 100 Axis Open Loop Test Code 100 procedure is used to diagnose problems with the configuration of the system the encoders and incoming A C voltage IMPORTANT SAFETY NOTICE During this procedure the designated axis will be given a command to move at maximum 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
118. es in the 208 V range will see values somewhere around 325 to 350 Shops with voltages around 240 V may see values the 400 ipm range e Ifthe feedrate is very different on the same axis for and then the torque on the axis that is tested is may be higher than 15 in lbs Typical torque values on machines that have the ball screw aligned and the gibs adjusted to specification should be between 10 to 15 in Ibs This will produce code 100 values within 50 ipm in the positive and negative directions Machines that have an axis torque of 20 in Ibs may see a deviation of 75 ipm If the code 100 values exceed this deviation then the axis torque is too high Align the ball screw or adjust the gibs e fthe feedrate is less than 300 ipm and consistent in both directions check the incoming AC voltage 4 8 2 3 CODE 123 Calibration See Section 5 22 for a further explanation of this code 4 8 2 4 CODE 127 Set X or Z Backlash Constant See Section 5 22 for a further explanation of this code 4 8 2 5 CODE 128 Input Backlash Constant Code 128 allows you to enter the backlash values for each axis It displays the value after it enters This code is only used on machines with motor encoders only 4 8 2 6 CODE 203 or 204 Brushless Motor Alignment This service code needs to be performed each time the ProtoTRAK is turned on new software is installed or axis motors have been replaced The control will boot up automatically to this screen P
119. et could cause intermittent problems Make sure there is a hardware option key plugged into the parallel port of the pendant This key activates any converters or options ordered The part number for this key is 22648 The key must be programmed according to the type of machine it is on and the options ordered CAUTION Make sure the main power switch is turned off on the back of the electrical cabinet before plugging in the cables 18 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 2 7 Pendant Cable Connections Left Side ELECTRIC HANDWHEEL UMBILICAL 2 100761 1 HARD DRIVE FLOPPY DRIVE Figure 2 8 MOUSE Pendant 1 AMP FUSE Right Side KEYBOARD AC ON OFF RSG 19 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 2 14 Lubrication 1540V 1840 2460V auto lube system provides centralized automatic lubrication for the carriage cross slide and ballscrews The lube pump has a 2 liter reservoir filled with Mobil Vactra Oil No 2 CAUTION Oil that is too heavy and viscous such as 50W or 90W oil can clog oil line tubing Do not mix detergent type automotive or multi purpose oils with the Mobil Vactra Oil No 2 used in this application The lube pump has electronic
120. eter Low voltage to hard drive or slave board Can cause the system to lock up and the hard drive to act abnormally Check voltage to power cable at hard drive module with voltmeter It should be 4 8 volts and above Lower values than this can cause problems Possible problems Can lead to 42 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Hard drive failure If the hard drive fails the system will not boot up or operate It will need to be replaced All programs and machine configurations will be lost Make sure to back up your hard drive from time to time Only the hard drive module will need to be replaced 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 instructions below LCD backlight burns out Check all cable connections to LCD distribution board and computer module Make sure the power is turned off before doing so Faulty E stop switch It can be stuck open or closed pressed If it is stuck closed the pendant will need to be replaced because the user will have no way to get rid of the message If it is open it will allow the machine to still operate but it will be unsafe for the user The pendant will still need to be replaced Axis faults on screen Servo driver cables at pendant are loose Make sure cable connection bra
121. ews for the 1540 6 screws for the 1840V and 8 screws for the 2460V and the 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 4 Shortages Inventory Checklist Machine check model and serial number Leveling pads and screws 4 each for 1540V 6 each for the 1840V and 8 each for 2460V Pendant Display 22328 2 Kert Pendant Cable Cover 22401 t Toolbox with various tools 1540V 1840V amp 2460V Safety Operation amp Programming Manual P N 24492 1540V 1840V amp 2460V Safety Installation Maintenance Service amp Parts List Manual P N 24970 In case of shortages contact the representative from whom you purchased the machine 10 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V 8 ProtoTRAK VL CNC Safety Installation Maintenance Service 8 Parts List Manual 2 5 Installation Instructions amp Checklist Installer Use this checklist to assure a complete set up of the 1540V 1840V or 2460V O 1 Shutoff power to the machine ooo Visually inspect the 220 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 O 3 Clean the machine if needed and remove any
122. ey 1 130 Socket Head Cap Screw M6x25L 4 131 Flat Washer M6 4 132 Spring Washer M6 4 133 24 0306 Z Axis Motor Plate S20C 1 134 21994 Motor Z Axis 1 135 87 0229 Front Cover Plate 5541 1 77 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual BEARING HOUSING EARING RING Figure 5 8 Angular Contact Bearings 5 1 12 Installing Angular Contact Bearings 1 On the inner of the angular contact bearings the thin walls face each other 2 50 ft lb torque is needed to tighten the clamp nut See the figure above 5 1 13 Z Axis Ball Screw Removal 1 Unplug or remove all power from the lathe 2 The Z axis ball screw is attached to the lathe in three places a The left end where the Z axis motor the pulley the clamp and the pair of angular contact bearings are mounted b Behind the apron assembly where the ball nut is attached to the yoke and the oil line is located c The right end where the floating bearing is located 3 Access to the left end is gained by removing the sheet metal panel below the headstock nameplate 4 Access to the ball nut and the yoke is gained by removing the apron assembly 5 For easy assess to the ball screw remove the ball screw cover 78 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp
123. f the Z axis Pay special attention to the areas near the headstock tailstock and in the middle of the travel If there is any binding or rough spots the alignment procedure must be repeated The axis should feel equally free throughout the entire range 16 Using a torque wrench measure the torque to move the z axis at each end and in the middle of the axis travel The torque reading should be a maximum of 10 15 in Ib 5 1 15 Headstock Taper Adjustment The headstock may be adjusted to remove turning a taper if the taper is caused by a lack of parallelism of the spindle to the bed ways Ensure that the level of the bed is correct prior to any headstock adjustments 1840V amp 2460 Machine To adjust the headstock alignment loosen the four socket head cap screws that attach the headstock housing to the bed Using the adjusting screw located at the rear of the headstock see figure 5 11 adjust the headstock position in the direction necessary to remove the taper Note that the headstock will pivot about a pin located between the two front attaching screws Tighten the attaching screws and test for taper To access the front two cap screws the front cover guard will have to be removed 85 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Headstock fixing screw i00488 Headstock fixing screw Adjusting screw
124. g problem Looseness in the spindle bearings See Mechanical Drive Train X Z 4 2 See Spindle Bearing Preload Section 5 1 16 1840V amp 2460V onl Headstock and or tailstock See Adjust Headstock for Taper Section 5 1 15 not aligned To adjust tailstock from side to side adjust grub screw See Section 5 1 17 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 Parts should be round within 0004 TIR on 1840V amp 2460V and 0 0002 on 1540V e The acceptable measurement of parallelism of spindle axis to carriage movement is 0008 over 6 inches 24 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 3 1 4 1 Every Part Has the Same Error Possible Cause Check This Programming Error Programmed dimensions not correct Check absolute and incremental values Machine amp Setup Related See Machine Tool amp Setup 4 1 3 1 4 2 Errors are Random or Accumulate Size over the Part Run Possible Cause Check This Machining Setup See Machine Tool amp Setup 4 1 Looseness in the Drive Train ball nut loose in See Mechanical Drive Train X Z 4 2 yoke split nut loose yoke loose 3 1 5 Threading Problems Threads can be cut with and an unlimited number of pitches and up to 10 leads
125. ght side of the lube pump while the lube pump is activated To activate the lube pump use Service Code 300 CAUTI ON Failure to properly lubricate the lathe will result in the premature failure of ball screws and sliding surfaces 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 1540V 1840V or 2460V lathe way surfaces and ballscrews The settings for the lube pump can be viewed by doing the following press Service Codes press A software press Code 313 This screen lists the values programmed for the cycle time and discharge time 20 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 2 14 3 1840V amp 2460 Headstock Oil Reservoirs Before turning on the spindle check to make sure the headstock oil reservoir is full site glass is located under the spindle cover The reservoir holds approximately 3 gallons If low fill the site level with Mobil DTE 24 or equivalent oil through the plug located on the headstock cover 2 15 Cutting the Test Part See Figure 2 9 Tools Required e Chuck Tool Post eTool Block eTool Holder right hand face and turn type In order to accurately machine the test part the gears and bearings in the headstock must be properly warmed and preloaded This is accomplished by running the spindle for
126. he headstock Once these are remove the cartridge should slide out of the headstock This assembly weighs over 100 Ibs please get additional help to remove the cartridge 8 Slide the new cartridge into the casting Make sure to place the drain holes pointed down towards the floor when mounting This will allow any coolant that makes it in between the spindle and cartridge to drain out 9 Reverse the steps to install the new cartridge 90 Southwestern Industries Inc TRAK TRL 1540V 1840 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 8600 NOLLO3S 1540 Headstock Cartridge Removal Figure 5 15 91 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 1540 Headstock Cartridge Parts List Item PIN Tte UseAs Qty 2 2170 SPINDLE ASSY 1540V LATHE PT4 EA 1 4 M6 1 0X2025B SCREW SHCS STL OO 8 5 M8 125X3525B SCREW SHCS STLBO EA 6 12 1 75 35 25B SCREW SHCS STL OO 6 8 23359 BELT HEADSTOCKASSY 1540v E 1 9 1673 SPINDLEENCODERASY 1 EA 1 100983 5 2 Maintenance 5 2 1 Adjustments objective of adjusting the 0105 is to eliminate as much play the table saddle ram sliding surfaces as possible without having the tightness
127. hielding of the servo driver cable that runs from the pendant to the servo driver This problem should never be evident on the machine Code 7 Substrate temp sensor fault f the substrate temperature sensor fails the power drive module will display an error code of 7 This is a hardware failure The servo drive module must be replaced 47 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Code 8 Control Mode fault f the servo controller is not properly configured to control a power drive module in PWM mode or there is a cabling error the module will display an error code of 8 This problem should never be evident on the machine Code 9 DC link under voltage The power drive module will report under voltage conditions If an under voltage condition exists the power drive module will shut down the output and report fault condition 9 The under voltage trip point is 170VDC for 230VAC power drive modules These voltages are set in the hardware Check the DC voltage across the terminals labeled B and B At 230 volts the DC voltage should be approximately 300 VDC Code DC link over voltage The power drive module will report over voltage conditions If an over voltage condition exists the power drive module will shut down the output and report fault condition A The over voltage trip point is 450VDC for 230VAC power drive
128. ignals to operate the indexer XZ Limit Switch Ports Logic signals from limit switches These signals are also direction specific e Door Guard Port feeds signal back to control from door switch e Coolant Pump Outlet An auxiliary function that uses a 110V signal to power the coolant pump This outlet uses fuse for circuit protection and an Indicating Lamp which signifies that the outlet is powered up The fuse and the Indicating Lamp are located next to the outlet e Lube Pump Outlet An auxiliary function that uses a 110V signal to power the lube pump This outlet uses a 3A fuse for circuit protection and an Indicating Lamp which signifies that the outlet is powered up The fuse and the Indicating Lamp are located next to the outlet e Auxiliary Module Power In 110V signal from the power strip to power the auxiliary module This uses a 3A fuse for circuit protection and an Indicating Lamp which signifies that the Auxiliary Module is powered up The fuse and the Indicating Lamp are located next to the incoming power cord 4 6 4 Encoder Module This module is located on the lower left side of the electrical cabinet below the spindle auxiliary module See Figure 4 1 This list below describes what takes place through each connection There are 2 LED s that signify that power is reaching this module Power reaches the encoder module through umbilical cables 1 and 2 and also the electronic hand wheel cable If these lights
129. ing the I ndexer from the Lathe 1 Turn the main power off to the machine 2 Disconnect 2 cables from the black box mounted on top of the lathe See Figure 6 5 at the end of this section for layout of cable connections Unhook the black cable from the brackets that run on top of the chip enclosure 4 Remove the cabling that goes runs across the crosslide Remove the indexer together with the mounting base from the cross slide It is fastened down with 4 socket head cap screws to the crosslide Be careful the indexer weighs approximately 70 Ibs 6 To re install the indexer follow these steps in reverse order Make sure you install the riser block at least 2 1 4 from the front of the cross slide not the front bracket Failure to do this will cause the indexer to hit the sliding door when the cross slide is all the way toward the operator 105 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 6 2 3 Troubleshooting the ndexer The following fault messages will appear on the screen when there is a problem with the indexer There are also LED s in the black box on top of the chip guard that may be helpful when troubleshooting the indexer Please refer to that section below Fault 85 Impossible Tool Position This message will appear if the indexer goes to a tool number that you did not select For example the operator chose
130. inum 1 17 500 5M 15 Belt X Axis 1 18 Socket Head Cap Screw M8x25L 8 19 77A 0202 Lock Block FC25 1 20 50 0325 Adjusting Screw S30C 4 21 21050 3F Gib Z Axis FC25 77A 0218 1 22 77A 0216 Lock Block FC25 1 23 7204 AVH Ring Nilos 1 24 23930 Bearing Set Angular Contact 7204BECBP 2 25 15885 Spacer 545 1 26 16300 Bearing Housing S45C 1 27 16314 Nut Clamp S45C L 19x16UNF 1 28 16350 Ferrule Brass 1 29 98481A090 Key Woodruff 3 1 8 x1 2 1 30 16983 1 Pulley Ballscrew 1 31 W02 Lock Washer W02 0 15 1 32 NT02 Lock Nut N02 01 15x32UNF 1 33 Socket Head Cap Screw 10 32x3 4 1 34 Socket Head Cap Screw M8x16L 2 35 Flat Washer M8 2 36 Spring Washer M8 2 37 87 0738 Clamping Block 5541 1 38 Socket Head Screw M10x90L 4 39 Socket Head Cap Screw M6x10L 2 40 Flat Washer M6 2 41 Spring Washer M6 2 42 77USA 0698 Cam 5541 1 43 Socket Head Screw M8x30L 4 44 Flat Washer M8 4 45 Spring Washer M8 4 46 Socket Head Cap Screw M6x20L 4 47 Flat Washer M6 2 48 Spring Washer M6 4 49 87 0730 Bracket FC20 1 50 Wire Protector 88x45ax1850L 1 75 TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual Southwestern Industries Inc 51 Socket Screw M5x10L 11 52 24 0729 En
131. ion 7 8 9 Turn power off to the machine Before working on this unit make sure all lights on the display are off These units have a capacitor internally that keep them powered up for a minute or so after the power is turned off Remove the display unit on the front face of the unit Also remove the lower cover on the unit to gain access to the wires Disconnect the 3 wires on the lower left side of the unit These wires bring power into the unit Remove the 2 wires labeled B1 and B2 These wires run up to the resistor Remove the 3 wires labeled T1 T2 and T3 These wires take power to the spindle motor Make sure to put these wires in the same position on the new unit T1 uses the red wire T2 uses the white wire and T3 uses the black wire Remove the ground wires from the bottom of the unit The unit bolts in place with 4 screws Follow the instructions in reverse order when reinstalling Note the replacement AC drive will have the AC drive cable 22443 or 22443 1 already wired to the drive See Figure 5 3 for an illustration of the wiring of the AC drive 65 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 17 SPINDLE SPINDLE FUNCTION PIN 154071840 ply Wa gt ij 15 AGND fe ee EAS pe Lo 5 l 6 7 AGND 8 9 SK E L 1
132. l is transformed into a direct current output signal and reconfigured to simulate a 220 VAC signal with varying frequency The servo driver takes the commands from the computer module and varies the frequency of the 220 VAC output signal thus the speed of the motor SWI uses two different brands of servo drive modules One servo drive module is manufactured by Semipower Systems and the other is manufactured by MTS Systems 45 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Although both brands of servo modules almost identical there are some subtle differences with the LED codes that are displayed 4 5 1 Cap Block Above the Z axis servo driver is a component called a cap block The cap block serves 2 purposes it filters the input signal voltages to the servo drivers and it is a current reserve for the servos In other words it acts like a battery and stores energy for the servo system When the motors are commanded to move initially they will draw power from the cap block If this component fails the servo system will not work Most likely the fuses labeled under F3 T1 T2 and T3 will be blown or there will be visible damage to the cap block itself If one suspects a CapBlok failure use a voltmeter DC mode to verify that the voltage between the terminals and B is approximately 300VDC Terminals and
133. ld be continuity between pins 1 and 6 when the switch is forced closed and no continuity when the switch is in the open position Gear Switch 1840V amp 2460V only On the 1840V amp 2460V the gearbox has 2 gear ranges See the table in section 4 6 2 on page 53 A switch is mounted under the sheet metal cover on the left side of the headstock The switch closest to the headstock casting controls high gear and the other one controls low gear If the gear shifter is in the middle of both gears neither switch will be engage and the spindle will be in neutral Both switches are wired normally closed This means the switch is open when the switch is triggered There should be no continuity between pins 1 and 6 when the high gear switch is forced closed and continuity when the switch is in the open position There should be no continuity between pins 2 and 7 when the low gear switch is forced closed and continuity when the switch is in the open position 4 8 Service Codes Service codes are broken down into the 5 following categories software machine setup diagnostics user options defaults and lubrication pump control All Service Codes are accessed in the SET UP Mode by pressing the soft key for SERV CODES The service codes can be found under one of the headings listed on the main screen Press the heading you want to access the code in question If you know code you want press the CODE softkey and it will take you directly to the code i
134. le the machine to once again jog Do the following service code and procedures e Code 312 Toggles limit switches on off this will turn the limit switches on or off This is a temporary fix for the problem and allows the user to run the machine until a replacement part can be installed If the limit switches are turned off and a problem occurs because of a crash this will not be covered under warranty Possible Cause Check This Limit Switches are triggered Reset the Limit Switches using the procedures described above Poor Limit Switch Cable connection Check for any pins that are loose pushed in or bent Verify that there is a good connection between the cable and the Auxiliary Module Limit Switch failure Turn off all power to the machine For the positive direction check for continuity between pins 1 and 6 on the Limit Switch cable connector You should hear a continuous beep from your Multi meter By hand manually depress the plunger on the limit switch responsible for when the table saddle or ram is moving in the positive direction The beep from your Multi meter should stop beeping This means the Limit Switch is triggering properly for the positive direction For the negative direction repeat the same procedure as described above using pins 5 and 9 on the Limit Switch cable connector Does the limit switch problem move to the other axis If it does Try this then the switch is most likely the problem If it stays with the Switch
135. ll screw through the length of its travel Pay particular attention aligned to the movement near the headstock the middle and the tailstock 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 See Z Ball Screw Removal Section 5 1 13 X Ball Screw Removal Section 5 1 11 Aligning Z Ball Screw Section 5 1 14 4 3 Computer Pendant Diagnostics The pendant consists of 3 separate modules the computer module hard drive module and the sheet metal and LCD screen 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 Possible problems Can lead to Poor cable connections There are 9 cable connections 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 volts present Check with a voltm
136. llation Maintenance Service amp Parts List Manual 78 19 09 0 65 62 9 4 19 6 7 2 6 6 9 90 9 8 HE L Figure 7 6 2460V Headstock Drawing 121 101176 Southwestern Industries Inc TRAK TRL 1540V 1840 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Parts List 2460 Headstock Parts List Item Parts No Description Material Specifications Q ty 1 87 0101 Headstock Casting FC25 1 2 87 0106 Gasket 1 3 25100 2 Cover Bearing Front AC2 87 0105 1 4 Socket Head Cap Screw M6x40L 6 5 25100 3 Taper Roller Bearing 32028X 1 6 25100 4 Spacer 545 87 0107 1 7 25100 5 Gear 0 Low Main Shaft SCM415 87 0108 1 8 25100 6 Key Double Round Head 16x10x125 1 9 25100 7 Gear High Main Shaft SCM415 87 0109 1 10 25100 8 Lock Nut YSF140x2 0 69 0147 1 11 87 0127 Detent Screw 545 M10x16L 6 12 69 01110 0 5 21 6 13 50 01111 Detent Spring SWP 6 14 69 01117 Center Sleeve SK2 1 15 63 01118 Center SK5 1 16 25100 1 Spindle SCM440 87 0102 1 17 63 01122A Back Plate for 3 J aw Chuck FC20 10 1 18 63 01119 Lock Stud SCM21 6 19 Socket Head Cap Screw 5 16 18UNCx16L 6 20 25100 9 Key Double Round Head 8x7x20L 1 21 25100 10 Gear Encoder Main Shaft 545 87 011
137. lly seated before bolting the unit back in place Note if the hard drive is functional you may want to remove the hard drive and install it in the new computer module See the instructions in Section 5 1 5 See figure 5 4 67 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual GALLVWNO tidaaida quvH 65827 2 19200 86822 TINON JANA quvH rLd ASSV 6s7zc t Levee 3 1gvO AVMLMSIG GYVH Pld WWLAW 133HS 96 72 SSNA AS l xovus 7 13 133HS 16277 z FINGOW smlhndWoo FANG GUVH PLd ASSV Od 66272 l pzglz 09222 QNNOYD v c4Scc d 8VO S6 ayog NOLLNENYLSIG OL FINGOW YALNdNOD 1 622 3 1HvVO 4015 9 OL GYVOd NOLLNENYLSIG Glee FEV YALdVdV OL 3 INGOW YALNdNOO Replacement ive Figure 5 4 Computer Module amp Hard Dr Description Pendant Assembly VL Pendant W Out Computer Part 22328 2 24200 2 68 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 5 1 5 Hard Drive Replacement The hard drive is located inside of the computer module It has been designed so it can be easily replaced in the field without replacing the entire computer module Follow the instructions
138. ls select 1 and 3 For example if you command the indexer to move from tool 4 to tool 2 you will see the select 1 and 3 lights come on briefly 3 tools select 3 don t move nothing active come on this means no commands were sent therefore no lights The following table reflects the description above 1 2 Tools 3 Tools 4 Tools 1 Tool 2 Tools 3 Tools SELECT 1 1 0 1 1 0 1 0 0 SELECT 2 1 1 0 1 1 0 0 0 SELECT 3 0 0 0 1 1 1 1 0 6 2 4 2 1 PLC Outputs There are 6 outputs from the PLC to the 4 tool indexer Q1 Motor on fwd direction This light will be on when the indexer motor is running forward Q2 Motor on rev direction This light will be on when the indexer motor is running reverse See the table below for the bit patterns for corresponding tools Q3 Bit 1 Q4 Bit 2 Q5 Bit 3 Q6 Bit 4 Q1 amp Q2 goes to the motor driver PCB Q3 Q6 goes to SWI control identifies position feedback to control The following table reflects the meaning of the bit signals back to the control Keep in mind that the 4 tool indexer reports back up to 4 absolute positions to the PLC and the PLC will output up to 8 absolute positions back to the control ITEM TOOL1 TOOL 2 TOOL3 TOOL 4 TOOL 5 TOOL 6 TOOL 7 TOOL 8 BIT1 1 0 1 0 1 0 1 0 2 0 1 1 0 0 1 1 0 BIT 0 0 0 1 1 1 1 0 4 0 0 0 0 0 0 0 1
139. ly if intermittent remove the cable for a while to see if there is a difference 28 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 3 3 4 Fault X or Z The program run or jogging operation is interrupted with a Fault Message on the display Do the following Service Codes and procedures e Code 33 Software Identification This is needed if you call SWI Customer Service e Code 12 Feed Forward Constant e Code 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting Possible Cause Check This Servo cables at pendant switched around Make sure during an installation the X Y and Z servo cables at the pendant are in the correct ports X and Z axis Gibs are adjusted extremely tight Check the adjustment of the X and Z axis Gibs using the X and Z axis Gib adjustment procedures See X and Z axis Gib Adjustments Section 5 2 1 See Mechanical Drive Train X Z Section 4 2 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
140. machines can only be wired for 220 volts 440 volts will ruin electrical components the machine These components will not be covered under warranty Possible Cause Check This Wrong voltage Check the voltage to the machine before and after the Spindle Drive Fuse Block F2 with a Voltmeter Also check the voltage to the Spindle Drive L1 L2 and L3 Check each of the 3 fuses in the Spindle Drive Fuse Block F2 for is blown continuity with Ohmmeter See Electrical Connection Check all the wiring connections to the Main Disconnect Switch Spindle Drive Fuse Block Spindle Drive and Spindle Motor See Electrical Connection Defective cables or poor cable Check the Spindle Control cable and cable connection between the connections Auxiliary Module and the Spindle Drive Check the Spindle Control cable and cable connection between the Pendant and the Auxiliary Module See Electrical Connection on the Spindle Motor wiring jumper configuration for 220VAC See Electrical wiring section Spindle Drive may be in Local Mode On the Spindle Drive push the DSPL button until LO RE lights up and can not be run from the Pendant Use the Up and Down arrow keys to choose between Lo Local Run Spindle Motor from Spindle Drive or rE Remote Run Spindle Motor from the Pendant Spindle Drive contains incorrect Contact customer service parameters and is not programmed correctl 36 Southwestern Industries Inc TRAK TRL 1540
141. me 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 touch off a fixed surface either in the X 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 34 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 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 15 Not Counting The DRO for one axis is not counting when an axis is moved Often times if this is the case the axis will fault See Section 4 4 3 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
142. memory which acts as an internal clock to keep track of the running time of the axis motor Even when the spindle is turned off the lube pumps internal clock will not reset The interval between pump cycles is based on axis motor movement time 2 14 1 Lube Pump Operation The pumping output can be regulated electronically to control the Interval Time between pumping cycles and the Discharge Time of each pumping cycle The pump can also be run manually through a key found under service codes The following describes the steps used to program the lube pumps Interval and Discharge times Setting Interval Time Service Code 301 Press Mode Set up Service Codes C Machine Setup Code 301 and then enter the desired Interval time in minutes Setting Discharge Time Service Code 302 Press Mode Set up Service Codes C Machine Setup Code 302 and then enter the desired Discharge time in seconds Tomanually Pump Oil Service Code 300 Press Mode Set up Service Codes press E and then press Code 300 Lubrication Pump Switch The pump will pump oil for the amount of time programmed in Code 302 The spindle does not need to be turned on 2 14 2 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 ri
143. ments Are Not Repeating Section 3 4 1 e See Measurements Are Not Accurate Section 3 4 2 3 3 10 E Stop Error The E Stop cuts power to the Coolant pump and Lube pump by de energizing a relay which is internally hard wired inside the Auxiliary Module The signal that is responsible for de energizing the relay comes down from the Computer Module to the Auxiliary Module through the Spindle Control cable Furthermore the Auxiliary Module sends a signal to the Spindle Drive causing the Spindle Drive to command a Servo to Stop 31 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual which cuts power to the Spindle Motor This signal is sent from the Auxiliary Module to the Spindle Drive through the Spindle Drive cable In Addition when the E Stop is activated the Computer Module sends a Servo to Stop command to each of the X and Z Drive Modules This cuts the power to the X and Z axis Servomotors These signals are fed down from the Computer Module to the X and Z Drive Modules through the X and Z Drive Module cables Check the X and Z axis Drive Modules for fault messages 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 Check the E Stop button and the cable connection from the E Stop button to the Computer Module Possible Cause Check This
144. mpression Spring 6xG0 8x30L 1 130 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 98 Steel Ball 01 4 1 09 27046 Clamping Block Rear 63 0529 00 1 100 63 0549 00 Spacer 1 i01180 131 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 100466 7 12 1840V Bed and Chip Pan 132 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Parts List 1840V Bed 6 Chip Pan Item P N Title UseAs Qty 1 21239 01 COVER 2 21239 02 OIL SIGHT GLASS 2 3 21239 03 ROUND SCREW M5X10L EA 12 4 21239 04 SOCKET HEAD CAP SCREW M5X10L EA 12 5 20980 1840 CSS EA 0 6 21239 06 END COVER EA 1 7 21239 07 ROUND SCREW M6X8L EA 4 8 21239 08 SPRING WASHER M16 EA 6 9 21239 09 SOCKET HEAD CAP SCREW M16 X60L EA 6 10 21239 10 TRAY 1 11 21239 11 ADJUSTING SCREW EA 6 12 21239 12 LOCKING NUT EA 6 13 21239 13 INSTALLATION BLOCK EA 6 14 21239 14 STAND EA 1 15 21239 15 HEXAGON NUT M8 EA 2 16 21239 16 SPRING WASHER M8 EA 2 17 21239 17
145. ms not Saved Properly 3 3 6 System Will Not Turn On or Boot Up 3 3 7 System Reboots by Itself 3 3 8 System Shuts Off 3 3 9 Will Not Hold Calibration 3 3 10 E Stop Error 3 3 11 Motor Alignment Routine Does Not Work Properly 3 3 12 Limit Switch Error 3 4 Problem with the Measurements 3 4 1 X 8 Z Axis Measurements Do Not Repeat 3 4 2 X amp Z Axis Measurements Are Not Accurate 3 4 3 The DRO is not Counting 3 448 X amp Z Axis DRO Counting in Wrong Direction 3 4 5 X amp Z Axis Electric Handwheels Count in Wrong Direction 3 5 Problems with the Machine Tool 3 5 1 Spindle Stalls or Turns Off During Machining 3 5 2 Spindle Motor Hums or Will Not Run 3 5 3 Spindle Runs Backwards 3 5 4 Excess Gearbox Noise 2460V Only 3 5 5 Headstock is Leaking Oil 2460V Only 3 5 6 Tailstock Barrel is Stiff 4 0 Diagnostics 4 1 The Machine Tool amp Set Up 39 4 1 1 Leveling 4 1 2 A Special Word About the X amp Z Gib 4 1 3 Lubrication 4 1 4 Machining Set Up 4 2 The Mechanical Drive Train X Z 4 3 Computer Pendant Diagnostics 4 4 Motor Diagnostics 4 4 1 Motor Alignment Routine 4 4 2 Cable Connections 4 4 3 Check the Motor Encoders 4 4 4 Encoder Counts to Pendant 4 4 5 Moving Problem from One Axis to Another 4 5 Servo Drivers 4 5 1 Cap Block 4 5 2 Servo Driver Cooling Fan 4 5 3 Servo Driver Fault Codes 4 6 Electrical 4 6 1 Power Module 4 6 2 Drive Module 4 6 3 Spindle Auxiliary Module 4 6 4 Modul
146. n time frame A shorted motor may cause this Install a known good motor on this servo drive and see if the problem still exists Code 4 IGBT Saturation Fault Normally a fault code of 4 is a symptom of poor system grounding If the fault can not be cleared by turning the power off and then back on to the power drive module the fault may indicate a hardware failure with the power drive module This means the power drive module will need to be replaced providing that the system grounding checks out to be good Code 5 Substrate over temperature The substrate temperature is monitored by the hardware of the power drive module If the temperature exceeds 92 degrees Celsius or 197 6 degrees Fahrenheit the power drive module will stop operating and report fault condition 5 The power of the 12VDC fan is controlled internally by the power drive module The power to the fan is cycled on and off automatically based on the measurement of the substrate temperature Code 6 PWM frequency fault f the PWM frequency exceeds 10 5kHz the power drive module will display an error code of 6 This means that the parameter associated with the power output of the power drive module may have to be set correctly within the servo control addition a 6 fault can also be a symptom of poor grounding or PWM command signal shielding Make sure that the motor and the AC power ground are both tied to the Power drive module heat sink Also check the routing and s
147. n Assembly 7 32 Pendant Bracket Kit 7 33 Auxiliary Module Diagram 7 34 Power Diagram 7 35 Encoder Diagram 7 36 Spindle Drive System 7 37 Servo Drive System 7 38 Servo Drive Output 71 39 Cable Set TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 1 0 Safety Specifications The safe operation of the TRAK TRL 1540V 1840V and 2460V lathe depends on proper use and the precautions taken by each operator 1 1 1 2 Read and study the machine s corresponding Safety Programming Operating and Care Manual Be certain that every operator understands the operation and safety reguirements of this machine before its use Read and study the TRAK TRL 1540V 1840V 2460V Safety Installation Maintenance Service amp Parts List Manual Be certain that every operator understands the operation and safety reguirements of this machine before servicing Always wear safety glasses and safety shoes Always stop the spindle and check to ensure the CNC control is in the stop mode before changing or adjusting the tool or workpiece Never wear gloves rings watches long sleeves neckties jewelry or other loose items when operating or around the machine Use adequate point of operation safeguarding It is the responsibility of the employer to provide and ensure point of operation safeguarding per ANSI B11 6 2001 Safety Publications Refer to and study the f
148. n question Press CODE enter the number you want press SET 4 8 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 54 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Note If you 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 8 1 1 CODE 33 Software ID The Code 33 is the software identification procedure The two types of software in the control include Software Version the version of the system you have installed 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 4 8 1 2 CODE 37 RS232 Baud Rate This code sets the baud rate for RS232 applications The recommended baud rate is 9600 The following baud rates can be chosen 4800 9600 19200 38400 57600 115200 4 8 1 3 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 comput
149. n the program enter a home position in Setup Mode Make sure you set the X and Z absolute zero position 12 to 18 inches from the chuck Set the home position to X 3 and Z 3 Run a program and make sure the indexer moves to the correct tool stations programmed Verify that the indexer positions to each tool station If there is a problem refer to the troubleshooting section 6 1 2 Removing the I ndexer from the Lathe 1 2 3 Turn the main power off to the machine Unhook the air line from the air regulator Disconnect 2 air lines and 2 electrical lines The 2 air lines need to be disconnected at the white box that is mounted on the top of the chip enclosure The fittings are the quick disconnect type where you push in on the connector and pull the air lines loose One electrical cable needs to be removed from the white electrical box and one cable from the black electrical box Allfour connections to the indexer are inside a flexible black conduit See Figure 6 2 at the end of this section for layout of cable connections Unhook the black cable from the brackets that run on top of the chip enclosure Remove the cabling that goes runs across the crosslide Remove the indexer from the cross slide It is fastened down with 6 socket head cap screws to the riser block Remove the riser block from the cross slide You may want to remove the indexer and riser block assembled together but it may be difficult to slide the whole thing out of the
150. n the black box Carefully tighten down the setscrew making sure not to move the encoder If the encoder moves the number in the box will disappear and it will be necessary to re align the encoder 5 Reassemble the unit 6 1 6 Indexer Maintenance Dorian recommends that the indexer be lubricated twice a year after the first year The worm and worm gear should be lubricated with quality lithium based grease every 6 months after the first year Remove the side cover top cover and stepper motor and grease the gears When re mounting make sure the O ring and side seal are intact so that no coolant can enter the turret Refer to the Dorian manual that is supplied with each machine for more information and drawings 6 1 7 Warranty I ssues Dorian warrants the Dorian Indexer for 1 year If it is determined that there is a problem with the indexer it will need to be sent back to Dorian for repair Please refer to the Dorian manual that was shipped with the indexer Control problems are warranted by Southwestern Industries Inc for 1 year 102 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual FOR PARTS LIST SEE SEPARATE A SIZE SHEET 5 x I 5 i d I n Figure 6 1 Indexer Mounting 103 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK V
151. n the system e Code 128 Enter backlash compensation e 100 Axis open loop test Used to check the maximum feedrate of an axis and if the encoders are counting Possible Cause Check This X and Z axis Gibs are not adjusted Check the adjustment of the X and Z axis Gibs using the properl X and Z axis Gib adjustment procedures Calibration or Backlash problem Recalibrate the machine Reset the Backlash Check Repeatability and Positional Accuracy See Calibration 8 Backlash Constants section Binding in the Drive Train Check Repeatability using the Repeatability and Positional Accuracy procedure Check the torgue 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 Z Section 4 2 3 2 4 Vibration in Motion While axis is moving there is vibration or noise coming from the X or Z axis Do the following Service Codes and procedures e Code 12 Feed Forward Constant e Code 127 Measure s the backlash in the system e Code 128 Enter backlash compensation Possible Cause Check This Too much backlash entered in Code 128 Recheck the machines backlash 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
152. nd Wheel Direction This service code reverses the direction of the Z hand wheel 4 8 2 9 Code 311 Run Machine with Spindle Off This service code toggles this function on or off It defaults to off from the factory which means the spindle must be on for a program to run If it is on and you forget to turn the spindle on the tool will move to Z rapid and wait for the spindle to come on This function will be needed if you are running a repeatability program with an indicator in the spindle Make sure this feature is on when cutting parts 4 8 2 10 Code 312 Toggle Limit Switches On Off This service code toggles the limit switches on or off Code 313 also displays which state the limit switches are in 4 8 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 8 3 1 Code 54 Program Continuous Run This Code runs a program continuously without stopping for tool change 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 INC SET The program run will start automatically 3 Press STOP to stop and GO to continue 4 8 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 pre
153. nd measure the indicator movement NOTE 2460V The typical geared head engine lathe is not capable of more precise diameters Careful adjustments to this turning machine will insure to maintain this accuracy Better accuracy should not be expected from a lathe of this class Do the following service code and procedures Possible Cause Check This Tooling problem Improper tooling workpiece not properly supported See Machine Tool amp Setup Section 4 1 Loose bearing problem Looseness in the spindle bearings See Mechanical Drive Train X Z Section 4 2 Spindle bearing not preloaded correctly Reseat bearing and preload See Adjust Spindle Bearing Preload Section 5 1 16 1840V amp 2460V only 3 1 3 Cutting Taper Parts are considered to be cutting on a taper if there is a difference in diameter of more than 0008 over 6 inches This is best measured by using a 0001 micrometer Do the following service code and procedure e Code 12 Determines the feed forward constant for the axis motors Possible Cause Check This Machine set up problem Machine not leveled properly See Leveling Section 2 9 Tooling problem Improper tooling Work piece not properly supported Use steady rest or follow rest reduce overhang from chuck headstock or tailstock Looseness in the gib or Gib adjustment misalignment of ball screw See Gib Adjustment Section 5 2 1 See Z Ball screw Alignment Section 5 1 14 Loose bearin
154. ndustries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 3 5 Problems with the Machine 3 5 1 Spindle Stalls or Turns Off During Machining During machining the spindle turns off and loses power First check incoming voltage and connections 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 Motor drive Belt is slipping Check the alignment condition and tension of the Drive Belt Cut more than the machine is capable Check speeds feeds and depth of cut Spindle Drive Thermal Overload Relay IOUT Current Out located on the Spindle Drive When the Overload has tripped 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 parameters Contact correct Customer Service for assistance 3 5 2 Spindle Motor Hums or Will Not Run The spindle motor makes a constant humming noise during operation or will not turn on Note
155. ng from behind belt drive pulley Replace shaft seal o rings or gaskets Oil leaking from behind the spindle Remove spindle encoder and check seal encoder Oil leaking from the rear bearing Make sure the rear backing plate is mounted correctly assembly There should be a tapped hole located at the 12 o clock position If the tapped hole is located at the 6 o clock position the seal will leak 3 5 5 2 Leaking Oil From Front of Gearbox Check This Oil leaking from seal between lid and Remove gearbox lid and reseal Thoroughly clean lid gearbox before resealing Make sure the front backing plate matches up with the seal behind the cover 37 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 3 5 6 Tailstock Barrel is Stiff The tailstock barrel is stiff or not smooth moving through its travel The tailstock barrel subassembly jams inside the tailstock Possible Cause Check This Misalignment of tailstock housing Realign bearing housing and tailstock screw Loosen screw support and realign Too much grease Disassemble and remove excess grease Vernier Dial is binding or rubbing on Remove dial and machine off a couple of thousandths screw support or shim 38 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 4 0 Diag
156. nostics This section explains the diagnostic procedures used to isolate service problems 4 1 The Machine Tool amp Set Up 4 1 1 Leveling Leveling is one of the most important aspects of setting up the machine properly Improper leveling can lead to a variety of machining problems The machine should be level to within 0008 longitudinally and 0005 transversely See Leveling Procedures Section 2 9 4 1 2 A Special Word About the X amp Z Gib The X gib is vital to the performance of your lathe Gibs should be 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 The Z gib is used to keep the carriage firmly planted down to the ways There are two Z gibs one located on each way 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 lathe At the beginning of each day manually supply oil to the way surfaces by doing Service Code 300 Lack of lubrication can lead to a variety of problems with your machine motion due to increased friction in the sliding
157. oduce 110 V single phase power to the power strip The power strip has 6 110 V outlets that supply power to the pendant spindle auxiliary module spindle motor fan electrical box fans and a work light One outlet is used as a spare There is a LED light on the power strip that indicates it is getting 110V power If this is out check its fuse followed by the fuses for the transformer The power module has 3 40 amp fuses 1540V amp 1840V or 3 60 amp fuses 2460V to protect the spindle AC drive and 3 25 amp fuses to protect the X and Z servo drivers It also has 2 6 amp fuses for the transformer The power module also has a ground bar where all of the panels are grounded The 1840V has an additional 2 fuses rated at 2 amps to protect the headstock oil pump 50 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 4 6 2 Drive Module The drive module consists of 2 servo drivers for X and Z an AC drive to control the spindle and a fan to cool the servo drivers An explanation for the servo drivers can be found in the servo driver section 4 6 2 1 AC Spindle Motor Drive The AC drive varies the frequency of the power to change the speed of the motor The lower the frequency the lower the spindle RPM and the higher the frequency the higher the RPM The frequency range for the 1540V 1840V amp 2460V machines are shown below The corre
158. oes 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 0 005 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 lathe moves You may adjust the maximum following error to a value as small as 0001 inch However the smaller the value the slower the feedrate around corners To input a new Following Error use the following procedure Follow the instructions on the screen and input the Following Error value from 0001 to 0100 and press INC SET 4 8 4 6 Code 323 RS232 Com Port This code switches between COM ports for RS232 applications 4 8 4 7 Code 143 Toggle Tool Change Spindle Mode This code allows the spindle to stay on at tool changes when turned to the ON position 4 10 4 8 Code 147 Initialize Indexer This code is to be used on machines with indexers only It will reinitialize reset the indexer if the unit is in the wrong position This type of situation may occur if the E stop is pressed while the unit is rotating to a new tool position This code will also need to be run for example if the indexer is in tool position 4 and the control thinks it is in some other tool position 4 8 5 Lube Pump Codes
159. ollowing publications for assistance in enhancing the safe use of this machine Safety Reguirements for Manual Turning Machines with or without Automatic Control ANSI B11 6 2001 Available from the American National Standards Institute 1819 L Street N W Washington D C 20036 Concepts And Technigues Of Machine Safeguarding OSHA Publication Number 3067 Available from The Publication Office 5 U S Department of Labor 200 Constitution Avenue NW Washington DC 20210 other regulations specific to the State in which the machine is installed Danger Warning Caution and Note Labels and Notices As Used In This Manual DANGER Immediate hazards that w result in severe personal injury or death Danger labels on the machine are red in color WARNING Hazards or unsafe practices that could result in severe personal injury and or damage to the equipment Warning labels on the machine are gold in color CAUTI ON Hazards or unsafe practices that could result in minor personal injury or equipment product damage Caution labels on the machine are gold in color NOTE Call attention to specific issues requiring special attention or understanding 1 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual at a higher RPM than rated by the chuck manufacturer Set the maximum RPM limit in the ProtoTRAK SET UP mod
160. one axis has very be less than 20 in lbs high torque Servo driver failure See servo driver diagnostics Section 4 5 Motor failure See motor diagnostics Section 4 4 Check servo drive cables at pendant and servo drives 3 3 12 Limit Switch Error Limit switches are installed on the carriage and cross slide to prevent serious damage to the machine in the event of a crash Each individual limit switch has two separate plungers One plunger is responsible for triggering in the positive direction while the other plunger is responsible for triggering in the negative direction The limit switch will trigger when carriage or cross slide moves past the available travel the event a limit switch is triggered the following error message will be displayed 32 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Critical Error 5252 Limit Switch Active The X axis Limit Switch is activated Use the Hand Wheels to Move off the Switch When this happens the control will not allow the operator to continue to manually move the carriage or cross slide in the same direction To return the machine to its normal state of operation perform the following procedure 1 Use the electronic hand wheel to move the carriage or cross slide off the limit switch 2 Press the Mode or Return key to reset the control 3 Press the DRO key to enab
161. oth the motor power cable and motor encoder cable On the servo side make sure the 3 phase wires are plugged properly into the servo driver The wires should be placed into the servo driver from left to right with the red wire on the left and the black wire on the right Failure to put the correct color wire into the correct port may cause the motor to run in the wrong direction Make sure none of the wires are crimped on the insulation instead of the fork connector Also verify each motor cable ground wire is fastened to the side of the aluminum heat sink which the servos are mounted on Check the connection of the motor encoder cable on the encoder module 4 4 3 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 Run Service Code 131 This will display on the DRO if the motor encoder is counting If this number does not move then 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 4 4 4 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
162. p Parts List Manual Parts List 1540V Overall Machine PIN MPN Tte Qty 1 22741 24007 X ELECTRICAL CONTROL BOXDOOR EA 1 221 2742 77A04 SWITCHSENT EA 1 3 227143 274 035 ELECTRICAL CONTROLBOX EA 1 4 2744 24 0706 _ ELECTRICAL CONTROLBOX EA 1 5 227145 240704 EA 1 6 227146 24019 LEFT MOVINGDOOR EA 1 7 0 207147 240720 SATY GASS 15811 8 2124136 06103 DOORHANDEE EA 1 9 22149 240709 FRONT PROTECTIONGUARD EA 1 10 2123924 2R 11M 1950__ BELT SPINDLEMOTOR EA 2 Ji 2 2406074 STAND EA 12 227412 240676 BRACKET TEA 1 4 7 IE 14 22714 14 2406 78 MOTOR PLATE EA 1 15 27445 50 0680 ADJUSTING WASHER EA 2 16 22714316 50 0682 _ ADJUSTING WASHER 1 EA 2 17 M2025X2 ADJUSTMENTSCREW __ EA 1 18 M2025508 NUFHEXSTILBO EA 3 19 2271419 24070 SETTING PLATE EA 1 20 2271420 24031 _ COVER PLATE EA 1 21 2271421 2406 COVER PLATE EA 1 22 27422 24016 ANT LEAKINGCOVER EA 1 23 2272423 G20 CT EA 1 24 2271424 650 EA 1 25 6 1 0 12 258 7 SCREWSHCS STE BO EA 15 26 2271426 AWS5I5DB 1 52 5 2
163. r Jog the X and the Z axis should move Has the problem moved to the Y axis If yes the X port on the computer is the problem replace the pendant The signal is not getting from the computer to the servo driver and on to the motor If no the X servo driver is most likely the problem It could also be a problem with the servo driver cable that runs from the pendant to the servo driver or the power cable from the servo driver to the X motor Switch X and Z motor power cables at the servo driver switch X and Z motor encoder cables on encoder module Jog the Z axis key and the X axis will move Jog the X axis key and the Z will move This allows the X motor to be run with the Z servo driver and Z port on the computer module and the Z motor to be run with the X servo driver and X port on the computer Has the problem moved to the Z axis If yes then it is the X servo driver replace this component This also proves that there are no problems with any of the cables 4 5 Servo Drivers The servo drivers are located in the electrics box on the lower right side They are positioned from top to bottom as X and Z Indications e Problems moving just one axis The axis faults out on the screen Servo Types e Xand Z servos are identical Objective e Isolate the problem to the particular Servo Driver The input signal to each servo driver is 220 VAC 3 phase power Inside the servo driver this input signa
164. r or jammed component Very low air pressure may also cause this fault It should take no longer than 2 or 3 seconds for the indexer 6 1 4 Troubleshooting from LED s in Black Box Inside the black box which is mounted on top of the chip enclosure there is an LED that signifies indexer position It reads numbers from 1 to 8 There are also directional LED s to signify how far and in what direction the indexer is told to rotate by the control Remove the lid from the box in order to see the LED s The number in the black box should correspond to the tool number of the indexer If these numbers are different re initialize the indexer with Service Code 147 The directional LED s will be helpful in verifying that the command from the control is getting to the black box and to the indexer If the command is getting to the black box but not the indexer there is a problem with the indexer For example if you command the indexer to move from Tool 1 to Tool 3 the LED for 90 should light up for a second When facing the indexer the rotation of the turret in a CW direction signifies a negative move and a CCW move signifies a positive move Since the indexer takes the shortest path between tool changes it can only move 45 90 135 in the positive direction and 45 90 135 in the negative direction 101 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual
165. rated phase converter also regulates the new leg created so it does not end up being too high or low of a voltage The electrical load on the machine will vary based on the type of cut taken and the speed of the motor Static phase converters can only be used on machines with a non varying load The phase converter for the 1540V should be rated for 25 to 30 KVA the 1840V machines should be rated for 20 to 25 KVA and the 2460V machines should be rated for 30 to 35 KVA Please contact your local phase converter distributor for precise sizing Machine Type Phase Converter Size Site Prep FLA 220V Recommended Range 1540V 25 30 47 1840V 20 25 35 2460V 30 35 59 16 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual CUSTOMER POWER PROVIDE STRAIN RELIEF I i00986 Figure 2 6 Wiring the 1540V 1840V amp 2460V 2 11 Air Connection The 1540V 1840V amp 2460V machines have an air hookup in the rear of the machine only if they come with a Dorian indexer option The air regulator is set to 90 psi at the factory for the indexer unit 2 12 Mounting the Display Pendant The ProtoTRAK VL display pendant mounts to the top of the sliding doors and is held to an L bracket with 4 socket head cap screws Make sure the pendant rotates freely from side to side Make all of the cable connections to
166. re Parts List Item P N Title 1 23720 CABINET ASSY 4 TOOL INDEXER 2 23719 MOTOR 55 4 TOOL INDEXER 3 23718 1 INDEXER ASSY MODIFICATION 4 TOOL INDEXER 1 4 23718 3 4 INDEXER ASSY MODIFICATION 4 TOOL INDEXER 3 4 5 23771 M10 T HANDLE 3 4 4 TOOL INDEXER 6 23771 M12 T HANDLE 1 4 TOOL INDEXER 7 23872 SOUARE HEAD SCREW M10 3 4 4 TOOL INDEXER 8 23873 SQUARE HEAD SCREW M12 1 4 TOOL INDEXER 113 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 7 0 Drawings amp Parts Lists 101171 Ire ij Figure 7 1 2460V Overall Machine Drawing 114 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 101172 Figure 7 2 2460V Overall Machine Drawing 115 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 101170 2721 2018 18 17 15 19 Figure 7 3 2460V Overall Machine Drawing 116 Southwestern Industries Inc TRAK TRL 1540 1840V 2460V 8 ProtoTRAK VL CNC Safety Installation Maintenance Service 8 Parts List Manual 101169 Figure 7 4 2460V Overall Machine Drawing 117 Southwestern Industries Inc TRAK TRL 1540 1840V 2460
167. reen 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 Be sure not to enter too much backlash on any given axis Too much backlash in the system may cause bi directional repeatability problems or axis motor searching 5 2 3 Lubrication 5 2 3 1 1840V amp 2460V Headstock Lubrication An oil pump provides lubrication for an even distribution of oil to all the gears and bearings in the headstock One of the oil lines pumps oil to a site glass located on the 95 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual headstock Periodically check to see that oil is flowing Oil flows to this site glass only when the spindle is running The plug to drain the headstock is located under the spindle cover towards the bottom of the casting See the figure below Oil can be added to the reservoir by a plug in the top of the headstock cover or by removing the cover and pouring it into the headstock There is a level site glass located under the spindle cover The headstock reservoir holds approximately 3 gallons Fill the headstock with Mobil DTE 24 oil or an equivalent grade The headstock gearbox oil must
168. remaining grease O 4 Mount the pendant on top of the sliding door Make sure the pendant swivels and slides easily 5 Make and check all the proper electrical connections from the pendant to the electric box See the pendant and electric box wiring diagrams Be sure to mount the cable cover to the left side of the pendant along with the servo cable bracket to ensure the cables stay place Note the servo drive cables plug into the top and bottom connector the middle connector is not used on the lathe 1540V 1840V amp 2460V O 6 Slide the door or doors back and forth to make sure it slides smoothly UU O 7 Remove the protective plastic covers from the headstock and the windows on the sliding doors Turn on the power to the machine and to the pendant Make sure that the 220V line is plugged in Check the voltage coming out of the transformer across the 115V and OV taps The acceptable range is between 110V and 130V Adjust taps as necessary See section 4 6 6 for instructions carriage away from any obstructions Total movement will be approximately 1 in all directions See Section 4 4 1 10 On the 2460 verify oil is reaching the site glass Oil is only flowing when the spindle is on Also make sure the coolant pump is rotating in the correct direction en Lubricate all the way surfaces and the ball screws Under service codes press code 300 to operate Perform motor alignment routine Press Check System key
169. ress the Check System key and follow instructions on screen WARNING It is important that there are no obstructions on any axis before running this code If there is an obstruction then use the electronic handwheels to slowly move the machine away from the obstruction Each axis will move approximately 1 during this routine The handwheels will not move at the normal feedrates during this routine Failure to move each axis away from an obstruction will cause a crash 1840V amp 1540V Only The Motor Alignment Routine Code 203 calculates the relative position between the motor poles on the stator and the magnets on the rotor through the use of the motor encoder Once the stator and rotor are aligned the encoder s absolute zero is set The routine also distinguishes which type of motor is being used on the machine The routine can last up to 30 seconds After 30 seconds the routine will under 58 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual go a Time out If the motor alignment routine fails to work properly a message should appear on the display prompting the user that the motor alignment routine has failed or glass scale on or off The 2460V Lathe uses Code 204 to align the motors 4 8 2 7 Code 308 Reverse X Hand Whee Direction This service code reverses the direction of the X hand wheel 4 8 2 8 Code 310 Reverse Z Ha
170. rn Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 100483 1 Figure 2 3 1840V Lathe 2 2 Lathe Specifications Capacity 1540V 1840V 2460V Height of Centers 8 9 11 5 Distance Between Centers 40 40 1 4 60 Swing Over Bed 157 18 24 Swing Over Saddle Wings 15 17 24 Swing Over Cross Slide 6 5 8 9 14 5 Cross Slide Travel 11 13 12 5 Tool Section Max 1 1 1 4 Coolant 12 gal 13 gal 15 gal Oil Pump Way Lubrication 2 liter 2 liter 2 liter Oil Reservoir Headstock None 3 5 gal 3 gal Bed Width 12 5 8 14 32 15 75 Height 12 5 8 13 3 8 12 5 8 Headstock 8 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Spindle Nose A2 5 D1 6 D1 8 Spindle Through Hole 21 8 2 36 4 09 Spindle Taper MT 6 MT 6 MT 8 Taper in Reduction Sleeve MT 4 MT 4 MT 5 Spindle Diameter Front 3 15 3 35 5 51 Bearing Number of Bearings 5 3 2 Bearing Class Radial Runout P2 ABEC 9 5 5 Number of Spindle Speed 1 2 2 Ranges Spindle Speed Range RPM 150 4000 80 850 250 2500 40 670 100 1800 ID Thread on End of Spindle N A M62 X 2MM Pitch M106 5 X 1 5MM Pitch
171. rvice Code 127 and 128 to manually calculate the backlash for the X and Z axis 23 Check for positional accuracy and repeatability on the X and Z axis using programs X LATHE REPEAT PT4 Z LATHE REPEAT PT4 respectively Positioning and repeatability values should be less than or to 0 0005 Programs can be found on hard drive under the PT4 folder followed by the SWI TEST PROGRAMS folder Note the door must be closed to run these programs 11 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual Perform Service Code 100 both directions for the X Z axis to verify that the feed rate shown on the display is at least 300 ipm 1540 run the spindle at various speeds throughout the 150 to 4000 RPM range ME 5255 31 0 should be in the ON position in DRO to test O 27 Check to make sure the limit switches are functioning properly O Cut the test part to check for taper Measure the test bar and make any machine adjustments If unacceptable taper is found re check the level before attempting to adjust the headstock O 129 Wipe down the machine prior to leaving CAUTI ON If the TRL 1540V has a chuck mounted to the spindle make sure the chuck is mounted properly to the spindle and also make sure the chuck jaws are engaged onto themselves or a piece of m
172. s into the spindle It is not adjusted for the various chuck or collet closer combinations 3 Perform a similar adjustment at the tailstock end of the bed Make sure the carriage does not hit the tailstock when the limit switch is triggered at maximum feedrate At the tailstock end there is slight adjustment up and down and more adjustment side to side 99 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual 6 0 Indexer Options 6 1 Dorian I ndexer Option 6 1 1 Field Installation I nstructions 1 2 Turn power to the machine Verify air has been hooked up to the machine The air regulator is mounted to the bottom left of the electrical cabinet Make sure the on off switch on the white box on top of the chip guard is turned on When it is on a green light will be illuminated Go to SETUP mode under TOOL GROUPS to verify the indexer softkey is activated Then press the INDEXER key to activate the indexer It will turn gray when activated Go to DRO mode and press TOOL and enter a number from 1 to 8 The indexer should move to this tool number The tool number on the indexer is found right above the tool slot If the tool in the control and on the indexer is in the wrong position enter Service Code 147 to re initialize the indexer To verify the indexer is working properly run a program with all 8 tools To ru
173. sponding RPM s for each machine are listed in the table below Note that the 1840V amp 2460V have a low and high gear while the 1540V has only 1 speed range 1540V Spindle RPM 1840V Spindle RPM 2460V Spindle RPM Frequency Frequency Frequency 150 7 5 Hz Low Gear 80 High 250 Low Gear 40 High 100 10 5 Hz 8 Hz 4000 200 Hz Low Gear 850 High 2500 Low Gear 670 High 1800 106 Hz 145 Hz 4 6 2 2 Braking Resistors The braking mechanism for the spindle motor is non mechanical The braking effect is caused by the AC drive sending a current that produces a set magnetic field This set field will oppose the motion of the motor and bring the motor to a stop The energy generated through braking is dissipated by 2 1540V amp 1840V or 3 2460V brake resistors and mounted to the top of the electrical cabinet The motor is set to brake in 3 4 seconds for the 1540 amp 1840 and 6 seconds for the 2460 Chucks larger than 12 may require the braking parameter N22 to be adjusted to a higher value WARNING The resistor becomes very hot during braking Before working around this area be sure braking has not occurred in the last 10 minutes Note the values in the AC drive are programmed at the factory and should never be adjusted without approval If there is a problem with the braking of the system the resistor can be checked with an ohmmeter Remove the cover of the AC spindle drive and locate terminals B
174. ss 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 8 3 3 Code 131 Manual DRO A manual diagnostic routine to check the motor encoder and table encoders Turn the X hand wheel to display the encoder readings This code will display the actual DRO counts and the raw encoder counts before the calibration and backlash factors have been factors into the counts 59 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 4 8 3 4 Code 132 Electronic Hand Wheel Test Turn the X 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 4000 for Z and 0 1000 for X in course and 0 100 amp 0 020 for fine mode 4 8 3 5 Code 133 Spindle Encoder Test Turn the spindle or run the spindle at low RPM s The display should show the counts from the spindle encoder It should count to 360 on the Z display and then reset Each time it resets it displays the number in the X display area 4 6 3 6 Code
175. sting Block 5541 1 98 Socket Head Screw M12x25L 1 99 87 0131 Indicator ALP 1 100 Rivet 2x5L 8 101 50 01145 Oil Sight Glass HE30 1 102 50 01146 il Sight Glass HFTX22 1 103 87 0104 Gasket 1 104 87 0103 Headstock Cover FC20 1 123 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL Safety Installation Maintenance Service amp Parts List Manual 105 Socket Head Screw M8x20L 6 106 77U 0152 Position Rack S45C 1 107 Oil Seal 20 35 7 1 108 Set Screw M6xP1 0x8L 1 109 77A 0153 Cam S20C 2 110 22680 Switch Gear 2 101175 124 Southwestern Industries Inc TRAK TRL 1540V 1840 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 64110 3r3N01193S Figure 7 7 2460V Carriage Side View See page 78 for Parts List X Axis Drive Train 125 Southwestern Industries Inc TRAK TRL 1540V 1840 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual SECTION 23 2x 2 2X 4X 2X Q1 D 9 9 5 6 6 6260 09 63 69 9 69 6 29 G PO TAI M s WWE GO SSK OT Es AS LLC E 696 60 AT NERA AN 14 CD 1 i N Th 5 li I pre gee E A KT n1 TEN U SSA L 80999999 2X 2X FOR REPLACEMENT SEE
176. t Phn 800 367 3165 Fax 310 886 8029 Table of Contents 1 0 Safety Specifications 1 1 Safety Publications 1 1 2 Danger Warning Caution and Note Labels and Notices Used in this Manual 1 3 Safety Precautions 2 0 Installation 2 1 Floor Plan Layout amp Space Requirements 1540V 1840V amp 2460V 6 2 2 Lathe Specifications 2 3 Uncrating 2 4 Shortages Inventory Checklist 2 5 Installation Instructions amp Checklist 2 6 ProtoTRAK VL Control Hardware 2 7 Lifting and or Moving the Machine 2 8 Cleaning 2 9 Leveling 2 10 Electrical Connection 2 10 1 Phase Converters 2 11 Air Connection 2 12 Mounting the Display Pendant 2 13 Cable Interconnections 2 14 Lubrication 2 14 1 Lube Pump Operation 2 14 2 Factory Default Values 2 14 3 1840V amp 2460V Headstock Oil Reservoir 2 15 Cutting the Test Part 2 16 Measurement of the Test Part 2 17 Mounting the A2 5 Chuck 3 0 Troubleshooting by Symptom 3 1 Problems Relating to Machining Results 23 3 11 Poor Finish 3 12 Turning Diameters Out of Round 3 1 3 Cutting Taper 3 14 Parts Have Incorrect Dimensions 3 1 5 Threading Problems 3 2 Problems Regarding the Motion of the Machine 3 2 1 Run Away Axis 3 2 2 Slow Down Axis 3 2 3 Axis Motor Motion is not Smooth 3 2 4 Vibration in Motion 3 3 Problems Relating to the Operation of the Control 3 3 1 Display Blanks 3 32 Bad Picture on the Display 3 3 3 Keyboard Lockup 3 34 Fault X or Z 3 3 5 Problems Reading the Floppy Disk Progra
177. th machine motion e Machined parts come out bad especially poor finish Note Code 12 routine will set the parameters for the particular machine and its particular situation If the machine changes its friction characteristic the Feed Forward Constant should change too or the system will not servo properly Whenever gibs are adjusted or a heavy workpiece has been added to the table you should run a Code 12 When the heavy workpiece is removed Code 12 should be run again Steps 1 Position the table and addle the center of travel Note You will lose your DRO position reference Go into the Service Codes and input the Code 12 Press Auto 4 The system will run the routine automatically and then display values on the position readout Explanation Typical values should be between 2 02 and 8 08 are considered normal for the Z axis and 10 to 18 for the X axis Higher values indicate excessive friction in the system Lower values indicate a loose system and may mean a gib adjustment is necessary The value 2 02 means the friction is a factor of 2 in one direction and 2 in the other direction The values should be within 3 of each other in both directions A value of 6 08 would still be considered normal Machines with axis torques from 8 to 12 in lbs can expect values in the 4 to 6 range Machines with torques from 13 to 17 in Ibs can expect values from 5 to 7 and machines with a torque range from 18 to 22 in lbs can expect valu
178. th the Hard Drive you will see Detecting IDE Primary Master Toshiba MK6014MAP If the Mother Board of the Computer Module is not communicating with the Hard Drive you will see Detecting IDE Primary Master None Also check the wiring connection between the Hard 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 or not present See Electrical Section 4 6 is too high too low or not present Transformer See Electrical Section 4 6 Out coming 110VAC from Power Strip is Using a Voltmeter check the out coming 110VAC from the too high too low or not present Power Strip See Electrical Section 4 6 to the Pendant 110VAC Power Cable to the Pendant See Electrical Section 4 6 Poor wiring and cable connections Check for any loose wiring Also check the 110VAC Power Cable AD connection from the 110VAC Power Strip to the Pendant See Electrical Section 4 6 Computer Pendant failed See Computer Pendant diagnostics Section 4 3 30 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 3 3 8 System Shuts Off During operation the system shuts off and will not turn back on Possible Cause Check This
179. the left side of the pendant and cover these cables with the cable cover provided with the machine Also make sure to fasten the servo cables with the bracket provided 2 13 Cable I nterconnections cable interconnections are made at the factory except for those connecting to the pendant display There are a total of 8 cables that need to be connected to the pendant See Section 7 for a complete illustration of cable interconnections for all components 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 Each cable is labeled with a sticker Use the key on the pendant to match up 17 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual the connectors with the correct port parallel port will key plugged into this port The monitor port RS232 and network ports will be left empty during installation Make sure there is sufficient slack in the cables for when the pendant is rotated about the pendant arm The following drawing describes all of the cable connections to the pendant Make sure to plug the servo cables into the X and Z ports on the pendant The Y axis port is left empty These cables also have a bracket that is used to fasten the cable securely to the pendant Failure to install this brack
180. 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 the screws are tightened on each of the connectors 4 6 6 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 110V to 130V Note systems running consistently close to the high or low values may have problems when normal voltage fluctuations push the voltage out of the acceptable range Our system is shipped out assuming the customers shop has 220 V power The transformer secondary tap is set on 115 volts Measure the voltage coming out of the transformer by placing the voltmeter across the 115 V and 0 V taps If this measurement is above 120 volts then move the tap from 115 V to 110 V If the reading is low 110 V or below then change the tap from 115 V to 124 V Input power to the machine that is 230 V or above will cause the 110 voltage to be high and voltage that is 208 V or below typically causes 110 voltage to be low WARNI NG Turn the main power off before changing the taps on the transformer Failure to do this can possibly cause death by electrocution 4 6 6 1 Checking Fuses There are 15 fuses that make up the system on these
181. ttach a base of a dial indicator to the saddle apply the needle of the indicator to the surface of the bar then move the saddle through the longitudinal travel Take the measurement of its maximum difference from end to end for later adjustment Release the 4 bolts labeled A in the drawing Release the screw labeled B Adjust screw C until the tailstock is aligned with the spindle Tighten up the locking nuts A 100515 Figure 5 13 Tailstock Adjustment 5 1 18 Spindle Motor Wiring The 1540V 1840V amp 2460V spindle motors are wired for 220 volts low voltage configuration The wiring consists of 3 phase power for the motor and 110 V power for the spindle motor fan Please see the motor junction box diagram for wiring information Each junction box contains 6 terminals Make sure to hook up the wires in the same terminals after the replacement motor is installed Failure to do so may run the motor in the wrong direction The spindle motor fan wires are also found in the junction box There is 1 hot wire 1 neutral wire and 1 ground wire It does not matter which wires are connected to the hot and neutral wires All grounds from each cable are connected to either of the screws in the junction box 88 Southwestern Industries Inc TRAK TRL 1540V 1840V 2460V amp ProtoTRAK VL CNC Safety Installation Maintenance Service amp Parts List Manual 1540 MOTOR JUNCTION BOX M
182. ust the way SWI has configured the MTS servo drive module for this particular application It is completely normal to see a 2 with no decimal point displayed on the MTS servo drive module when the servomotors are not active Note always check for errors when the servo drivers are active This takes place in DRO and RUN mode The codes are as follows Code 0 No Fault Code 1 Over current This over current error is due to current conditions that exceed the thermal rating of the internal components inside the power drive module This feature does not protect the motor Sudden faults are high feedrates may cause this condition Code 2 Watchdog timer timeout This timeout error can primarily be attributed to electrical noise or mechanical disconnection which interrupts the timing of the motor current data which is sent back to the controller every 4 times per PWM cycle Check all cable connections from pendant to servo driver Code 3 Motor Short Ground Short The power drive module is protected from short circuit and ground fault conditions by automatically shutting down without damage to any internal components The power drive module shall stop operating when either the ground or phase current reaches approximately 5 times the current rating of the inverter or brake IGBT However an over current fault may be reported instead of a short circuit ground fault in the case that the short circuit trip point is not reached within a certai
183. xer Encoder Re Alignment 6 1 6 Indexer Maintenance 6 1 7 Warranty Issues 4 Tool Indexer Option 6 2 1 Field Installation Instructions 6 2 2 Removing the Indexer from the Lathe Troubleshooting the Indexer Troubleshooting the Cable Breakout Box 100 6 1 3 6 1 4 6 1 5 6 2 3 6 2 4 Figure List Fig Fig Fig Fig Fig Fig Fig 2 2 2 2 2 2 2 1 2 3 4 5 6 7 2460V Lathe 1540V Lathe 1840V Lathe Lifting the Lathe 1540V amp 2640V Leveling Wiring the 1540V amp 2640V Pendant Cable Connection Left Side Fig 2 8 Fig 4 1 Fig 5 1 Fig 5 2 Fig 5 3 Fig 5 4 Fig 5 5 Fig 5 6 Fig 5 7 Fig 5 8 Fig 5 9 Fig 5 10 Fig 5 11 Fig 5 12 Fig 5 13 Fig 5 14 Fig 5 15 Fig 5 16 Fig 5 17 Fig 5 18 Fig 5 19 Fig 5 20 Fig 5 21 Fig 6 1 Fig 6 2 Fig 6 3 Fig 6 4 Fig 6 5 7 0 Fig 7 1 Fig 7 2 Fig 7 3 Fig 7 4 Fig 7 5 Fig 7 6 Fig 7 7 Fig 7 8 Fig 7 9 Fig 7 10 Fig 7 12 Fig 7 13 Fig 7 14 Fig 7 15 Fig 7 16 Fig 7 17 Fig 7 18 Fig 7 19 Fig 7 20 Fig 7 21 Fig 7 22 Fig 7 23 Fig 7 24 Fig 7 25 Fig 7 26 Fig 7 27 Fig 7 28 Fig 7 29 Fig 7 30 Pendant Right Side Electrical Cabinet Motor Assembly Drive Module A C Spindle Drive Computer Module amp Hard Drive Replacement Spindle Motor Belt Replacement X Axis Drive Train 1540V X Axis Drive Train 2460V Angular Contact Bearing Z Axis Drive Train 1540V amp 1840V

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