ProtoTRAK KMX K3 Knee Mill & Retrofit

Transcription

1 ProtoTRAK KMX K Knee Mill & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual Document: P/N 9777 Version: 7 65 Homestead Place Rancho Dominguez, CA USA T F Service Department: sales@trakmt.com service@trakmt.com web:

2 Copyright 07, All rights are reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, mechanical, photocopying, recording or otherwise, without the prior written permission of Southwestern Industries, Inc. While every effort has been made to include all the information required for the purposes of this guide, 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.

3 Table of Contents.0 Safety Safety Publications... Danger, Warning, Caution, and Note Labels & Notices As Used In This Manual... Safety Precautions Installation Floor Plan, Layout & Space Requirements K... 6 Uncrating... 8 Shortages: Inventory Checklist... 8 Installation Instructions & Checklist... 9 Machine Specifications... 0 Maximum Work Capacities ProtoTRAK KMX Control Hardware Basic System Specifications Lifting and/or Moving the Machine... 5 Cleaning... 7 Leveling: Leveling Tolerance is.0005 / Electrical Connection... 9 Air Connection - Optional... Mounting the Display Pendant... Cable Interconnections....5 Lubrication Manual Lubrication Parts List Knee Mill Lubrication (Figure 9) Head Lubrication Troubleshooting by Symptom Problems Relating to Machining Results Poor Finish Circles Out of Round...7. Problems Regarding the Motion of the Machine Run Away Axis Axis Will Not Jog...9. Problems Relating to the Operation of the Control... 9 i

4 .. Fault X or Y KMX Pendant Troubleshooting LED s Service Codes Software... Machine Set-Up... Diagnostic Codes... 4 Operator Defaults/Options... 5 CODE : Hysteresis... 5 CODE : Feed Forward Constant... 6 CODE 97: Set Positive Motor Encoder Direction... 6 CODE 00: Axis Open Loop Test... 7 CODE : X, Y, Z And Quill Calibration Using Part Measurements... 8 CODE : X, Y, Z and Quill Calibration Maintenance Gib Adjustments Table Gib Adjustment, X-Axis Saddle Side Gib Adjustment, Y-Axis Saddle Bottom Gib Adjustment, Y-Axis Head Rotational and Tramming To Rotate the Head Side to Side: Tramming the Head Back to Front Adjustment Introduction to Self-Service When You Have a Service Problem Communication with the SWI Customer Service Group Replacements Exchange Program Return Authorization (RA) Number Figures and Parts Lists Drawings SYSTEM DIAGRAM-KMX NEW MACHINES & UPGRADES PENDANT ARM KIT-TOP MOUNT-KMX-K PENDANT ARM KIT-TOP MOUNT-KMX RETROFIT XX DRIVE KIT X-AXIS-SM ii

5 PARTS LIST FOR DRIVE KIT X-AXIS-SM XX DRIVE KIT-SPORT Y-AXIS PARTS LIST FOR DRIVE KIT-SPORT - Y-AXIS BRACKET ASSY-BP SER I Z AXIS - SWI GS BRACKET ASSY-Z AXIS EASSON GLASS SCALE XX DRIVE KIT - Z AXIS HARDWARE KIT MX Z-AXIS-BP XX Z AXIS BALL SCREW - BASEPLATE, BEARING HOUSING & COVERS ASSY PARTS LIST FOR Z-AXIS BALLSCREW- BASEPLATE- BEARING HOUSING & COVERS ASSY ELECTRONIC HANDWHEELKIT- KNEE MILL-X & Y AXIS POWER DRAWBAR OPTION K, K-R AIR REGULATOR ASSY - DPMV - FILTER iii

6 .0 Safety The safe operation of the TRAK K Mills depends on its proper use and the precautions taken by each operator. Read and study this manual and the ProtoTRAK KMX Programming, Operating, and Care Manual. Be certain every operator understands the operation and safety requirements of this machine before its use. Always wear safety glasses and safety shoes. Always stop the spindle and check to ensure the CNC control is in the stop mode before changing or adjusting the tool or workpiece. 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 OSHA Milling Machine. Safety Publications Refer to and study the following publications for assistance in enhancing the safe use of this machine. Safety Requirements for Manual Milling, Drilling and Boring Machines with or without Automatic Control (ANSI B.8-00). Available from The American National Standards Institute, 89 L Street N.W., Washington D.C. 006 Concepts And Techniques Of Machine Safeguarding (OSHA Publication Number 067). Available from The Publication Office - O.S.H.A., U.S. Department of Labor, 00 Constitution Avenue, NW, Washington, DC 00.. Danger, Warning, Caution, and Note Labels & Notices As Used In This Manual DANGER - Immediate hazards that will result in severe personal injury or death. Danger labels on the machine are red in color. WARNING - Hazards or unsafe practices which could result in severe personal injury and/or damage to the equipment. Warning labels on the machine are orange in color. CAUTION - Hazards or unsafe practices, which could result in minor personal injury or equipment/product damage. Caution labels on the machine are yellow in color. NOTE - Call attention to specific issues requiring special attention or understanding.

7 Safety & Information Labels Used On The TRAK K Milling Machines It is forbidden by OSHA regulations and by law to deface, destroy or remove any of these labels

8 Safety & Information Labels Used On The TRAK K Milling Machines It is forbidden by OSHA regulations and by law to deface, destroy or remove any of these labels Power Requirements at 0 and 440 Volts, -phase 60 Hz KMX K Overload Setting - 0 V Overload Setting V FLA of Largest Motor at 0 V FLA of Largest Motor at 440 V FLA of Machine at 0 V FLA of Machine at 440 V Vari-speed Head 8.5 A 4.5 A 8.5 A 4.5 A 8.5 A 4.5 A

9 . Safety Precautions. Do not operate this machine before the TRAK K Mill Installation, Maintenance, Service and Parts List Manual, and ProtoTRAK KMX Programming, Operating & Care Manual have been studied and understood.. Do not run this machine without knowing the function of every control key, button, knob, or handle. Ask your supervisor or a qualified instructor for help when needed.. Protect your eyes. Wear approved safety glasses (with side shields) at all times. 4. Don't get caught in moving parts. Before operating this machine remove all jewelry including watches and rings, neckties, and any loose-fitting clothing. 5. Keep your hair away from moving parts. Wear adequate safety headgear. 6. Protect your feet. Wear safety shoes with oil-resistant, anti-skid soles, and steel toes. 7. Take off gloves before you start the machine. Gloves are easily caught in moving parts. 8. Remove all tools (wrenches, chuck keys, etc.) from the machine before you start. Loose items can become dangerous flying projectiles. 9. Never operate a milling machine after consuming alcoholic beverages, or taking strong medication, or while using non-prescription drugs. 0. Protect your hands. Stop the machine spindle and ensure that the CNC control is in the stop mode: Before changing tools Before changing parts Before you clear away the chips, oil or coolant. Always use a chip scraper or brush Before you make an adjustment to the part, fixture, coolant nozzle or take measurements 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 compressed air to remove the chips or clean the machine.. Disconnect power to the machine before you change belts, pulley, and gears.. Keep work areas well lighted. Ask for additional light if needed. 4. Do not lean on the machine while it is running. 5. Prevent slippage. Keep the work area dry and clean. Remove the chips, oil, coolant and obstacles of any kind around the machine. 6. Avoid getting pinched in places where the table, saddle or spindle head create "pinch points" while in motion. 7. Securely clamp and properly locate the workpiece in the vise, on the table, or in the fixture. Use stop blocks to prevent objects from flying loose. Use proper holding clamping attachments and position them clear of the tool path. 4

10 8. Use correct cutting parameters (speed, feed, depth, and width of cut) in order to prevent tool breakage. 9. Use proper cutting tools for the job. Pay attention to the rotation of the spindle: Left hand tool for counterclockwise rotation of spindle, and right hand tool for clockwise rotation of spindle. 0. After an emergency stop, always turn the FORWARD/REVERSE switch to "Off" (STOP) before releasing or resetting the E-Stop.. Prevent damage to the workpiece or the cutting tool. Never start the machine (including the rotation of the spindle) if the tool is in contact with the part.. Check the direction (+ or -) of movement of the table, saddle, and quill when using the jog or power feed or ram out.. Don't use dull or damaged cutting tools. They break easily and become airborne. Inspect the sharpness of the edges, and the integrity of cutting tools and their holders. Use proper length for the tool. 4. Large overhang on cutting tools when not required result in accidents and damaged parts. 5. Handwheels must have the crank folded inside when using CNC programmed machining or rapid feeds, power feed or jog. 6. Prevent fires. When machining certain materials (magnesium, etc.) the chips and dust are highly flammable. Obtain special instruction from you supervisor before machining these materials. Keep flammable materials and fluids away from the machine and hot, flying chips. 7. Changing the speed of rotation of the spindle must be done while the rotation is on. It is recommended to stop and start the spindle at a low rate of speed. 8. Interlocked table guards may be purchased from if deemed necessary by the user. 5

11 .0 Installation Read and understand this entire installation section before beginning the installation procedure. Figure Machine Footprints. Floor Plan, Layout & Space Requirements K K Weight (approximate) net 800 lbs Weight (approximate) shipping 00 lbs Pallet Size 6 x 6 A Overall width 0 B Overall length 70 C Base width 4. D Width between leveling screws.9 E Distance between leveling screws 9.7 F Base length 8.8 6

12 Figure Overall Dimensions K Table Size 0 x 50 T-Slots (number x width) x 5/8 Dimension G 87 Dimension G Min 65 Dimension H Min 64 Dimension H Max 78 Dimension I Min 8 Dimension I Max 49 Dimension J Max 7 Dimension K 69 7

13 . Uncrating. Carefully remove the wood crate and protective packaging, paying attention not to scratch, damage, or mar any parts of the machine. Remove the cardboard boxes with the PENDANT DISPLAY (handle carefully) and the box containing the TOOL BOX. The leveling pads and screws for the machine can be found in the toolbox. The Y way covers are shipped in a separate tube. Loosen and remove 4 screws and nuts holding the machine to the wood pallet. 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. Shortages: Inventory Checklist Machine (check model and serial number) Manual drawbar with washer Leveling pads (FC4), screws (FC) and leveling nuts (FC) (4 each) Pendant Display with four M6 SHCS screws for mounting Pendant Arm assembled to the column Toolbox with various tools ProtoTRAK KMX Safety, Operation & Programming Manual (P/N 98) TRAK K KMX Knee Mill & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual (P/N 9777) Way covers K front of saddle Way covers K rear of saddle In case of shortages, contact the representative from whom you purchased the machine. 8

14 .4 Installation Instructions & Checklist Installer: Use this checklist to assure a complete set-up of the K or KMX or -axis retrofit or upgrade.. Shut off power to the machine.. Visually inspect the 0 or 440V wiring going into the electrical panel. Visually verify the wiring is correct per our wiring diagram. Make sure a strain relief is being used where the wiring enters the cabinet. Have the customer repair any wiring discrepancies. Measure the 0 volt or 440 volt and 0 volt input power to make sure it is within specification. If not, notify customer and report on service report.. Clean the machine if needed and remove any remaining grease. 4. Unlock the table, saddle, and knee gib locks. 5. Mount the pendant to the pendant arm using (4) M6 socket head cap screws. 6. Make and check all the proper electrical connections from the pendant to the electric box. See drawing 989 at rear of manual. 7. On retrofits, place the nameplate serial # plate (94) on the pendant arm. This serial # plate is the main system # for that machine. Place the serial # plate using drive screws to the front of the pendant arm near the pivot point of the arm. Use a #6 drill bit for drive screws. See drawing at the rear of the manual. 8. On retrofits and TRAK knee mills make sure to plug in the machine ID key on the pendant. 9. Turn on the power to the machine and to the pendant. 0. Load software from our website. The pendant may or may not have the latest software loaded. (Retrofits only.). Lubricate all the way surfaces and the ball screws.. Jog the table and saddle back and forth until the way surfaces are well lubricated. Oil should be visible on all the way surfaces.. Check the level of the machine. The machine should be level to within " front to back and " side to side. Even though it is the responsibility of the customer, make any adjustments if necessary. 4. Check tram on head and adjust as necessary. 5. Turn on features like glass scales, limit switches and electronic handwheels via service codes 04, 05, (8) and Jog each axis. If you see a fault, you may need to reverse the direction the glass scales via service codes and. 7. If the motors are running the wrong direction, perform service code Check to make sure that the E-Stop button is functioning correctly and turns off power to the axis motors. On SWI machines make sure the spindle turns off as well. On retrofits we do not interface with the spindle. 9. Check and adjust gibs as required. 0. Perform Service Code, Feed Forward Constant.. Perform Service Code 00 in both directions for the X and Y and make sure the feedrate is at least 0 ipm. Note code 00 on the Z axis does not work on axis knee mills.. Perform Service Code to automatically calculate the backlash for the X and Y-axis of glass scale machines. Perform Service Code to calibrate the X and Y-axis using a 50mm standard. If you do not have a precision standard, cut part and measure and enter a calibration factor in service code. 4. Perform Service Code 8 to enter backlash for the X and Y-axis of single feedback machines 9

15 (i.e. motor encoder only). 5. Check for positional accuracy and repeatability on the X and Y-axis using programs SWI Test programs.pt4 and.pt4 respectively. Positioning and repeatability values should be less than or = to Perform Service Code and quill softkey to calibrate the Z-axis quill ( axis knee mills) or press Z axis to calibrate the rd axis on axis knee mills using a 75mm or standard. If you do not have a precision standard, cut part and measure and enter a calibration factor in service code. 7. Perform Service Code 8 to enter backlash for the Z-axis. Applies to axis systems only Check for positional accuracy and repeatability on the Z-axis using SWI test program.pt4 Positioning and repeatability values should be less than or = to for the quill and 0.00 or so for the axis knee mill quill. If using a standard, the Z repeat program will need to be modified to use vs 75 mm. 9. If the machine or retrofit came with an auxiliary function option, then use accessory key on pendant and make sure the coolant pump and/or solenoid for the mister fires. The accessory key should be in the ON position to test coolant pump or solenoid. The control should be in DRO mode. Make sure air is hooked up to the machine during the test. If the machine has a separate coolant pump switch mounted to the pendant, then turn this on and off to test. 0. Perform service code 50 and enter machine serial number. The pendant serial number should be set at the factory.. If the machine has a power drawbar option, check to make sure that the tools load and unload properly. N/A to retrofits.. Wipe down the machine prior to leaving. Machine Specifications Specifications K Movement and ranges (X, Y, Z axis) x 6 x 6 Quill Travel (maximum) 5 Quill Diameter 86 mm Spindle Taper R8 Speed Range RPM Spindle to Column 8 to Quill Feeds Per Revolution of Spindle.005/.00/.006 (Not applicable on three axis) Head Tilt +/- 90 Head Swivel +/- 45 Spindle Motor Power HP Voltage 0/440 V Phase/Cycle phase/60 Hz Current- Non Spindle Control 8.5/4.5 amps Current Spindle Control amps Maximum Weight of Workpiece 850 lbs Coolant Capacity 9 gallons.6 Maximum Work Capacities 0

16 K Drilling Mild Steel (-axis manual feed) ¼ Tapping Mild Steel Milling (metal removal rate/mild steel) ½ inch /min Drilling (-axis systems) ½ Maximum work capacities are dependent on a lot of variables that cannot be controlled by the machine manufacturer. Each one of the following will have an impact on the above numbers: speeds, feeds, cutter, cutter sharpness, material, setup, coolant and machine adjustments. The numbers above assume all conditions are optimal and may be higher or lower depending on material composition..7 ProtoTRAK KMX Control Hardware ProtoTRAK KMX CNC Specifications The list below summarizes the features and specifications..7. Basic System Specifications Control Hardware Digital Servo Amplifiers custom designed for ProtoTRAK operation D.C. Servo Motors rated at 80 in-oz. continuous torque are twice that required Precision Ball Screws in the table and saddle Modular Design simplifies service and maximized uptime 5V/60HZ/0 amps Feedrate Override of programmed feedrate and rapid Polycarbonate Sealed Membrane Keypad to lock out contamination 9.0 Color LCD USB port for interface with a storage device Rugged Industrial PC Glass Scale on quill for Z-axis readout Software Diameter Cutter Compensation allows programming of the part rather than the center of the tool path Circular interpolation makes arcs and any size hole easy to do with standard tools Linear Interpolation to machine lines at any angle Conrad provides automatic corner radius programming with one data input Incremental and Absolute programming can even be mixed within an event Error Messages to identify programming mistakes Fault Messages for system self-diagnostics Parts Graphics display Look a single button press to view graphics during programming Math Help for finding points in a prompted format with graphical representation of prompts Machine Tool Error Compensation and Backlash Compensation custom set on mill after installation Selectable Inch/mm measurement readout

17 Jog of X and Y from to 00 inches per minute Selectable or -axis operation AGE Auto Geometry Engine Programmed Canned Cycles Posn/Drill single point Bolt Hole series of points evenly spaced around a circle Mill straight line in any direction Arc any portion of a circle Pocket a rectangle, circle or irregular and all the material inside, includes finish cut Profile a perimeter of a rectangle, circle or irregular shape, includes finish cut Repeat, Rotation, Mirror of programmed events with or without offset Options Remote Stop/Go (RSG) switch USB thumb drive for program storage and transfer. Offline programming system DXF and Parasolid programming on Offline

18 Figure - Knee Mill Component Identification Item Part Number Description K 089 Spindle Motor 975- KMX Pendant 566 Y-Axis Handwheel (Saddle) X-Axis Handwheel (Table) X, Y or Z Motor Servo driver Cable Breakout Box , -6, -9 Y Axis Ballscrew depends on machine, K uses , -4, -48, -54 X Axis Ballscrew depends on machine, K uses 48

19 Figure 4 - Knee Mill Rear View Item Part Number K Description 0V= V=0676 Electrical Box Cable Breakout Box (optional) 900 Lube Pump Electrical box (if have tableguard option) 4

20 .8 Lifting and/or Moving the Machine CAUTION! The K machine weighs approximately 800 lbs. Proper equipment of sufficient capacity must be used when lifting and/or moving the machine. (See Figure 5 to Prepare the Mill before Lifting):. Using a steel cable with protective sleeving (min /4 diameter) or a -ton sling, position sling loops on machine as shown in Figure 5.. Use cardboard pieces or other suitable protective sheets on both sides of the machine to prevent scratching.. Remove the 4 nuts and screws holding the machine to the wood skid. 4. Lift the machine (the machine should lift approximately level). 5. Insert the 4 screws for leveling pads in their place in the bed. 6. Place the machine in its location (see floor plan and bed footprint drawing), carefully positioning each leveling pad under each leveling screw. 7. Remove the lifting cable or sling and all protective cardboard. 5

21 Figure 5 - Lifting the Machine 6

22 .9 Cleaning. Remove rust protective coating from the machine before moving any slideways (table, saddle, knee, etc.).. 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.. It may be necessary to move back and forward, left and right, and up and down the table, saddle and the ram. Always release the clamp levers (two in front of the table, one underneath the saddle on each side, and two ram lockbolts on the right side of the column) before attempting to move the above parts. 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 Be certain the table, saddle and spindle move freely and smoothly over their entire length. Leveling: Leveling Tolerance is.0005 /0. Set the machine on its 4 leveling pads on a solid, level floor prepared in accordance with the state and local rules for machine tool installation.. Put one or two precision Spirit Levels or Electronic Levels in the center of the table in the positions illustrated in Figure 6.. Adjust the 4 corner leveling screws on their pads until the machine is level to.0005 in/0 in. 4. If the machine must be anchored to the floor, follow the general instruction for installing machine tools and use for leveling any well-known methods: shims, etc.). 5. If the machine must be installed on vibration mounts/pads (rubber, commercially available leveling and vibration mounts, etc.) follow the instructions delivered with the mounts/pads, ordering them to satisfy the load of the machine and the maximum weight of the work piece. 6. When machine is correctly level, lock the adjusting screws in place with their hex nuts. 7

23 Figure 6 - Placement of Levels Item P/N Title FC LEVEL SCREW FC LOCK HEX NUT FC4 LEVELING PAD i008 Figure 7 - Leveling Screws 8

24 . Electrical Connection The TRAK K Knee Mill can be configured for 0 or 440 volt phase electricity. These machines also require a 0V power source to power the control. DANGER! Be certain that 00-volt electricity (typical range 08 40V) is used only with a machine labeled 0 volts at the motor and at the electrics box on the back of the column. Be certain that 400-volt electricity (typical range V) is used only with a machine labeled 440 volts at the motor and at the electrics box on the back of the column. DANGER! The 0 or 440-volt line must originate from a dedicated and independent fused box with a manual shut-off lever. It is the responsibility of the purchaser to supply a wired box that meets all local codes and regulations. Incoming 0 or 440-volt power connects to the machine through the electrical box located on the back of the column. The power cable enters the black box through a hole on the top of the box. DANGER! Only a qualified electrician should wire the 0 or 440-volt -phase electricity. To convert a K machine from 0 to 440 volt power or vice versa things must happen: spindle motor must be rewired (see diagram below), overload relay must be set to 8.5 amps for 0 V and 4.5 for 440 volts and the voltage stickers on the electric s box must be replaced. 9

25 Figure 7. Spindle Motor Rewiring 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. 0

26 Figure 8 - Wiring K Not for Retrofit Part Number Description K 0V & 440V = 0676 Electrical Box 0V & 440V = 48- Overload 46 Contactor (Qty = ) (Reverse or Forward) NOTE: If equipped with Table Guard Option, the Electrical Box the P/N is

27 . Air Connection - Optional..4 The K mill machines have an air hookup in the rear of the machine if the machine has a power drawbar or auxiliary function option. Auxiliary function options are only found on axis mills. If the machine has a power drawbar option then the machine will include an air regulator, air manifold and an oiler. The air fitting is ¼ NPT. Within the manifold there is an additional air line port in case the user wants to hook up an air line to clean chips. Remove the plug to gain access to this port. If the machine has an auxiliary function option then the machine will include an air solenoid. The air regulator is set to 90 psi at the factory for the power drawbar unit and solenoid. See a drawing at the rear of the manual for more information on the power drawbar unit. The air comes in through the manifold, and then into the air regulator that tees off into an oiler for the power drawbar unit and into an air solenoid. The solenoid is used for a misting system the user may install later on this machine. There is a ¼ quick disconnect air fitting on the solenoid where the mister air hose can be plugged into. See drawing 80- at rear of manual for a drawing of this assembly. The air requirement for the power drawbar option is 7.5 SCFM or.5 CFM at 90 psi. Mounting the Display Pendant The ProtoTRAK KMX display pendant mounts to the pendant arm with four M6 SHCS. There is a locating screw on the pendant arm to help align the pendant with the mounting holes. CAUTION! The locating screw in the arm is used for positioning. Keep a hold of the pendant until the screws are fastened. If the pendant arm rotates too freely, remove the painted cap on the bracket attached to the column and tighten the hex nut to adjust it. Replace the cap. See Drawing at rear of manual. Cable Interconnections All cable interconnections are made at the factory except for those connecting to the pendant display. See Drawing 989 at rear of manual for all cable interconnections. Find the configuration that pertains to your application. With the main power to the machine turned off, plug in the connectors that are bundled on the pendant arm. Each cable mates to only one connector on the pendant display back panel. Use the key on the pendant to match up the connectors with the correct port. Make sure there is sufficient slack in the cables for when the pendant is rotated about the pendant arm. The worst case is when the pendant is all the way forward toward

28 the operator. The following drawing describes all of the cable connections to the pendant. Make sure the machine ID key is plugged into the machine or it will not run CAUTION! Make sure the main power is turned off on the back of the electrical cabinet before plugging in the cables..5 Lubrication CAUTION! Failure to properly lubricate the mill will result in the premature failure of bearings, sliding surfaces & ballscrews.5. Manual Lubrication The TRAK mill X & Y way surfaces and ball screws need to be manually lubricated. The Manual Lube automatically discharges about 4ml of oil every plunge.. At the beginning of each day, manually pull the pump handle. Note: If the machine has been sitting for a long while, run the machine through the full length of its travel to ensure lubrication reaches all surfaces.. At the beginning of each day, check the oil level in the system. If low, fill with Mobil Vactra Oil No. or equivalent. CAUTION! Failure to manually activate the pump at the beginning of each day and allowing the pump to run dry may cause severe damage to the TRAK mill way surfaces and ball screws.

29 Figure 9 - Knee Mill Lubrication 4

30 .5. Parts List Knee Mill Lubrication (Figure 9) Item P/N Title Qty 900 HAND OILER 900 ALUMINUM PIPE ELBOW T-JOINT - 4 HOLES- M8 X CONNECTOR REGULATING DISTRIBUTOR FLEXIBLE TUBE - inches SCREW NUT - M8 X.0 MALE SCREW NUT - PD /8-9MM SCREW - M5 X 0 mm LG 8 90 SCREW NUT - M8 X.0 FEMALE 90 ADAPTER 90 SLEVE - 4. mm I.D. 8 i Head Lubrication Once Each Week: Add SAE 0 or 0W oil to the side cup on the head. This will provide lubrication to the quill. Twice a Month: Apply drops of oil in upper cup on front of head with SAE 0 oil. This feed supplies oil to the feed cradle for the power quill feed to keep the grease pliable. If oil is not added, the grease on the feed cradle will thicken and this makes it difficult to engage the power quill feed. WARNING! Do not overfill this oil cup as excess oil could wash down into the upper spindle bearings and wash away the grease. 5

31 Every Four Months:. Apply a good grade of general-purpose grease through the grease fittings on the back of the head. This grease lubricates the Low range gear set and the feed change gears respectively.. Lubricate vari-disk on spindle motor by means of grease fitting on motor shaft. 6

32 .0 Troubleshooting by Symptom Use this section to begin the process of resolving a service problem. Each symptom type is described in a few words and then more fully described in an explanatory paragraph. Following this is a chart that directs in the most logical steps. Problems Relating to Machining Results.. Poor Finish The part finish is marred with scallops or is very rough. Do the following Service Codes and document values: Code Software Identification. This is needed if you call SWI Customer Service. Code Measures backlash in the system (Only used on Dual Feedback systems) Code Feed Forward Constant Code 8 Enter backlash compensation (for Z-axis on three-axis systems; not used on Dual Feedback systems) Possible Cause Too much backlash entered for code 8 or calculated with code. Machine Tool & Setup problem Table, Saddle, or Knee Locks are locked Inadequate or no Lubrication to Ballscrews and Way surfaces X, Y, and knee Gibs are not adjusted properly X & Y-axis Drive Trains are loose Way surfaces are pocked, scarred, or excessively worn.. Circles Out of Round Check This Verify nothing is mechanically loose and the backlash values are not higher than what physically is in the system. Check for any looseness in the setup (Tool, Tool holder, Part, Vise, or Fixture). Check the condition and type of cutter being used, type of material, RPM and Feedrate, etc. Make sure the Table and Saddle Locks are unlocked. Never use gib locks with a CNC machine. Make sure all the Way surfaces are getting proper lubrication. If not, check to make sure that the lube pump is functioning properly. Also check for any pinched or blocked oil lines. Check the adjustment of the X and Y gibs. See X and Y Gib Adjustments in Section 5.. 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. Visually check the condition of all the Way surfaces. For 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. Circles are not round within 0.00 TIR over.0 DIA. This is best measured by placing a dial indicator in the quill and sweeping around the part. 7

33 Note: The typical slideway-milling machine is not capable of achieving more precise results although careful adjustments to a new milling machine may produce better results. If more precise circles are required, then it is recommended to use a precision boring head/boring bar. Do the following Service Codes and document values: Code Software Identification. This is needed if you call SWI Customer Service. Code Measures backlash in the system (Only used on Dual Feedback systems) Code Feed Forward Constant. Code 8 Enter backlash compensation. Possible Cause Torque values on X and Y-axis are too high. Machine Tool and Setup problem Machine not level Head is not Trammed X and Y Gibs are not adjusted properly Calibration or Backlash problem Glass Scale problem X & Y-axis Drive Trains are loose Head Bolts are loose. Check This Make sure torque is lower than 0 in-lbs. Normal values for a machine that is aligned and adjusted properly should be between 0 and 5 in-lbs. Make sure torque is consistent across axis travel. Check for any looseness in the setup (Tool, Tool holder, Part, Vise, or Fixture). Verify that the machine is level to specification. Verify that the Head is Trammed to specification. See Tramming the Head Sec 5.. Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures. Recalibrate the machine. Reset the Backlash. Check Repeatability and Positional Accuracy. Make sure that the Glass Scale is installed correctly according to the Glass Scale Installation procedures. Check for any loose brackets or misalignment etc. Also, check to make sure the Glass Scale assemblies are functioning correctly. 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. Verify that all the head bolts are tight. 50 lbs. Problems Regarding the Motion of the Machine.. 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: Code Software Identification. This is needed if you call SWI Customer Service. 8

34 Code 00 Axis open loop test. Used to check the maximum feedrate of an axis and if the encoders are counting properly. Code Manual DRO turn handwheels to check motor encoder counts vs glass scale counts Possible Cause Motor encoder versus glass scale encoders are counting in opposite directions The home positions or tools are not set correctly and hence the machine moves to location that is surprising to the operator. The Glass Scale is not reading. Bad Motor Encoder Motor has failed.. Axis Will Not Jog Check This This would be apparent during a new install or when a pendant/computer module is replaced. Run service code or 00 to confirm this is your problem. If it is your problem run services codes for the X axis or for Y axis. See the Controls Programming, Operations and Care manual. Turn off glass scale and see if faulting goes away Run service code. If the motor is not counting, check the connection. Swap motor with other axis and replace motor as necessary The system powers up but will not respond to the jog command. Generally when this happens, you will see a fault on one of the axis. See section... Do the following Service Codes and procedures: Possible Cause E-Stop is pressed in Servo Drive failure Code Software Identification. This is needed if you call SWI Customer Service. Code 00 Axis open loop test. Used to check the maximum feedrate of an axis and if the encoders are counting. Motor has failed Poor cable or wiring connections Computer/Pendant failed. Check This Check E-Stop. Especially if both axes will not jog Especially, if only one axis will not jog. Swap the axis motors to see if problem stay with motor or with the pendant. Swap motor with other axis and replace motor as necessary See Electrical Connection per drawing 989 at rear of manual If the motor appears good and you have power, then the pendant and/or computer module may need to be replaced. Problems Relating to the Operation of the Control.. Fault X or Y The program run or jogging operation is interrupted with a Fault Message on the display. Do the following Service Codes and procedures: 9

35 Code Software Identification. This is needed if you call SWI Customer Service. Code 00 Axis open loop test. Used to check the maximum feedrate of an axis and if the encoders are counting. Code Manual DRO turn handwheels to check motor encoder counts vs glass scale counts Possible Cause Motor encoder versus glass scale encoders are counting in opposite directions Cable connection problems Table and Saddle Locks are locked X and Y Gibs are adjusted extremely tight Binding or looseness in the Drive Train Incoming electrical power Motor encoder or glass scale not working properly Motor or Servo Drive failure Pendant/computer module failure Check This This would be apparent during a new install or when a pendant/computer module is replaced. Run service code or 00 to confirm this is your problem. If it is your problem run services codes for the X axis or for Y axis. Check all cable connections. See drawing 989 at rear of manual. Make sure the Table and Saddle Locks are unlocked. High torque on any axis may cause faulting problems. Check the adjustment of the X and Y Gibs using the X and Y Gib adjustment procedures. Inspect drive trains Incoming voltage too low. Should be 05 volts and above. Run service code or 00. Swap motor from one axis to another and see if problem stays or follows motor. If problem does not follow motor, then replace computer module. 0

36 .4 KMX Pendant Troubleshooting LED s The following LED s are found on the back of the KMX pendant and may be useful when troubleshooting with our customer service department. 4VDC VDC 5 VDC 5-VDC.VDC RSG DOOR SW DOOR SW DOOR LOCK DOOR LOCK K00-FB K0-FB K00-OUT K0-OUT K00-FAULT K0-FAULT WDT- FAULT SPARE SPDL EN BUTTON PRESS LED 4VDC VDC 5VDC 5-VDC.VDC Description 4VDC power LCD power External 5VDC power CPU Power Apps board logic power If one or more LED s above are not on, there is a power problem on the pendant and the pendant/computer module will most likely need to be replaced. Check power connector and reboot to see if this solves the problem. RSG DOOR SW DOOR SW DOOR LOCK DOOR LOCK RSG button state indicator. ON = Button Pressed. Each press of the RSG button should turn this LED on and off. Door guard switch indicator. ON = Switch Closed. Switch closed means tableguard doors are physically closed. The door switches are wired normally closed. Not used on USA machines. Not used on USA machines. Not used on USA machines. The 4 LED s below should be on when the e stop is not pressed and you are in DRO mode. If one or more of these LED s are off in this condition, then there is an internal problem with the pendant/computer module and the pendant will most likely need to be replaced. K00-FB K00 relay feedback indicator. ON when K00 contacts are closed. K0-FB K0 relay feedback indicator. ON when K00 and K0 contacts are closed. K00-OUT K00 relay command indicator. ON when system is commanding K00 contacts to close. K0-OUT K0 relay command indicator. ON when system is commanding K0 contacts to close. The K00 and K0 fault LED s below will be on when relays K00 or K0 are in an unexpected condition. Confirm the E stop button is not pressed or Euro bypass connector jumper is missing or loose. If you still see this condition, then there is an internal fault inside of the pendant and the pendant/computer module will most likely need to be replaced. K00-FAULT K00 relay fault indicator. ON = Fault Detected. K0-FAULT K00 relay fault indicator. ON = Fault Detected.

37 LED WDT-FAULT SPARE SPDL EN BUTTON PRESS Description Watchdog fault indicator. Slow blink ( sec on/ sec off) = Normal operation. Fast blink (5 time/sec) = Watchdog fault occurred. If this occurs, reboot to see if the problem is solved. If not, the pendant/computer module will most likely need to be replaced. Unused. Spindle enable indicator. ON = Spindle Enabled. Should be on when in DRO or RUN modes, which allow you to turn on the spindle. ON when any overlay button is pressed. This verifies all overlay keys are recognized. Service code 8 can also be used.

38 4.0 Service Codes The following is a list of service codes used on the KMX control system. The Service Codes are divided into logical categories. The table below is a quick summary of the service codes. More detailed information can be found below. All Service Codes are accessed in the SET-UP Mode by pressing the soft key for SERV CODES. The service codes can be found under one of the headings listed on the main screen. Press the heading you want to access the code in question. If you know code # you want press the CODE # softkey and it will take you directly to the code in question. Press CODE #, enter the number you want, press SET. 4. Software Code Description Comment Software, Firmware and PLC versions Displays current software versions and system settings. 4 Load configuration file from USB thumb drive To load configuration files from a USB thumb drive to the KMX control. Follow the directions 4 Save configuration file to USB thumb drive on the screen. To save the configuration files for reloading later. When a computer replacement is necessary, saving the settings to a thumb drive for reloading them later is highly desirable. Follow the directions on the screen. 6 Update Software Runs the routine that copies new software from a USB thumb drive device to the ProtoTRAK system. Use this routine to install new ProtoTRAK software. 4. Machine Set-Up Hysterisis Measures the backlash between motor encoders and glass scales. Feed Forward Constant Measures the friction characteristic of the machine. 97 Axis Configuration It allows the user to set the positive direction for each axis. Axis Calibration Using Offset This is a scale factor (one per axis) that is defined as the length of the part programmed divided by the physical dimension of the actual part measured. It is less than for a part that was cut too big and greater than for a part that was cut too small. Calibration Mode Use to calibrate the KMX control with a standard 8 Backlash Calibration Constant Use to load backlash compensation for each axis.

39 04 Toggle X Glass Scale On or Turn on or off Off 05 Toggle Y Glass Scale On or Turn on or off Off 08 Reverse X EHW Direction Change direction of EHW on X axis 09 Reverse Y EHW Direction Change direction of EHW on Y axis Toggle Limit Switches On or Turns limit switches on or off Off Reverse Y Position Sensor Reverse the direction of the glass scale Reverse X Position Sensor Reverse the direction of the glass scale 5 Reverse Quill Position Sensor Reverse the quill glass scale. Service code 97 should do the same. 8 Toggle Limit Switches from Tells software which style limit switch is present. to input 50 Turn EHW On or Off Turns the EHW option on or off since EHW are optional. 400 Update Foreign Language MLS File Used to update the software language table. Please contact your distributor for available 50 Set Pendant and Machine Serial Numbers 4. Diagnostic Codes Program, Configuration File, Log Back up languages and for more information. Service code to record pendant and machine serial numbers. A warning will be given to user until this requirement is met. The following service code captures all important data from the OP machine. This includes the users program, configuration files, message log, fault log etc. This is meant to be used to help us solve problems that may pertain to our software. This file can then be ed to our service department. 54 Continuous Run Mode Cycles through the program in current memory. 8 Program Panel Keyboard Test Gives a tone feedback to a button push and highlights the button. 00 Open Loop Test Run an axis at rapid speed for second to check encoders Manual DRO Turns off servos so you can check encoders. Turn handwheel to compare motor encoder counts vs glass scale counts. Electronic Handwheel Test Test the EHW signals. One revolution of hand wheel should read when in fine mode and in course mode 4

40 9 Message Log Logs the machine as it runs. It captures all key presses, error messages and data as the machine runs. It is saved automatically with service code. 0 Fault Log A log that captures all faults and error messages. 6 Error Message Display Displays error messages on screen 7 Display Memory Check Displays memory availability of various devices 4 Test Light Indicator Turns on and off some test lights used for troubleshooting. 4.4 Operator Defaults/Options 66 Metric Boot Up Default To have the ProtoTRAK open up in mm measurement. 67 English Boot Up Default To have the ProtoTRAK open up in inch measurement. 79 Turn On Beeper Turn the beeper on when pressing keys on either of the front panels 80 Turn Off Beeper Turns the beeper off when pressing keys 40 Step Over for Pockets and Allows user to set step over distances Face Mill 45 Set Part Program Location Sets the location of part program storage between a USB device and to a network The following explains some of the service codes in more detail. 4.5 CODE : Hysteresis Note: This code is use only for systems with Glass Scales on the table and saddle. The Code service routine checks the readings of the motor encoder against the glass scale encoder. It is a measurement of how much motor motion is necessary to create table or saddle motion. This test helps us to look at two things: Play: How much backlash must be taken up when motion is reversed. Friction: How much the mechanical components must be "torqued up" in order to break the friction and create motion. The Code procedure is very useful and will help in diagnosing all types of motion and performance problems.. Position the table and saddle in the center of travel. Note: You will lose your DRO position reference.. Go into the Service Codes and input Code.. The system will run the checking routine automatically and then display the values in the position readout. 5

41 Explanation: As an overall measure of the system hysteresis, we are looking for the X and Y values to be less than.004". A value greater than this indicates a problem with either excessive friction or play that may affect the finish or accuracy of machined parts. CODE : Feed Forward Constant The Code 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 0 to 45 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 is used for diagnosing and resolving: Problems with machine motion. Machined parts come out bad especially poor finish. Note: Code 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. When the heavy workpiece is removed, Code should be run again. 4. Position the table and addle in the center of travel. Note: You will lose your DRO position reference. 5. Go into the Service Codes and input the Code. 6. Press Auto 7. The system will run the routine automatically and then display values on the position readout. Explanation: Typical values should be between 8.08 and. are considered normal for each axis. Higher values indicate excessive friction in the system. Lower values indicate a loose system and may mean a gib adjustment is necessary. Value 8.08 means the friction is a factor of 8 in one direction, and 8 in the other direction. The values should be within or 4 of each other in both directions. A value of 8.0 would still be considered normal. CODE 97: Set Positive Motor Encoder Direction This procedure sets the Plus and Minus motion for the Motor encoders. It may be necessary to perform this procedure after a new installation or after installing a new Computer Module. STEPS:. Center the table and saddle and position the quill about halfway down.. Go into Service Codes and input Code 97.. Very carefully, move the table, the saddle and the quill in the positive direction, approximately inch for each axis. Positive motion is: X - table moves to the left (so the tool moves to the right relative to the workpiece) 6

42 4.8 Y - saddle moves toward the front (so the tool moves up relative to the workpiece). Z the head moves up (DPM machines) Z - the quill moves up. If you do not move correctly from the beginning, repeat the procedure. 4. Press INC SET to signal the procedure is complete. Note on axis PT (old style) knee mills, if the motor encoder and ballscrew encoder are counting backwards then you may need to run service code 5 to reverse the ballscrew encoder. CODE 00: Axis Open Loop Test Code 00 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 second in the direction you choose. Avoid crashes by making sure the quill is out of the way and by starting with the table and saddle centered. MAKE SURE THAT NO ONE IS STANDING IN THE WAY OF THE TABLE OR SADDLE! Note: You will lose the DRO reference position. This procedure is to be run for each axis that is servo-driven, and for both the plus and minus direction for each axis.. Center the table and saddle and raise the head. Make sure the gib locks are released.. On the Pendant display, go into the Service Codes and input the Code 00.. The conversation line will say: SELECT AXIS. Input the axis. Either X or Y. Please note, code 00 does not work on the Z axis of axis knee mills. 4. In the conversation line it will say WHICH DIRECTION? PLUS. If you want to run in the plus direction, press INC SET. If you want to run in the minus direction, press +/-, then INC SET 5. In the conversation line it will say PRESS GO. Press Go after you are sure that the machine will not crash in the direction and axis that you have specified. 6. Afterward the screen will display values next to the DRO position axes. The table below assumes machine has secondary feedback. Machines with motor encoders only will display the reading next to the axis in question. Your input Display Data displayed. X + X Motor encoder reading Y nothing (should be 0) Z Table encoder reading Feedrate the maximum feedrate attained 7

43 Your input X Motor encoder reading X - Y nothing (should be 0) Z Table encoder reading Feedrate the maximum feedrate attained 4.9 Your input X nothing (should be 0) Y + Y Motor encoder reading Z Table encoder reading Feedrate the maximum feedrate attained Your input X nothing (should be 0) Y - Y Motor encoder reading Z Table encoder reading Feedrate the maximum feedrate attained Interpretation of the resulting values displayed: The values for the encoder displays should be in the range of.0000 to.0000 for the X and Y motor. If the motor encoder or glass scale reading is not within this value, then the one that is out of specification may be the problem. If one of the encoders is not reading then it will need to be replaced. The feedrate should be a minimum of 0 ipm for the X and Y axis. If the feedrate is less than 0 ipm and inconsistent in both directions, check the incoming AC voltage and mechanics of the drive train. CODE : X, Y, Z And Quill Calibration Using Part Measurements This service code can be used to calibrate each axis if you do not have a precision standard which is used when calibrating with service code. Service code allows you to apply a scale factor (one per axis) that is defined as the length of the part programmed divided by the physical dimension of the actual part measured. It is less than for a part that was cut too big and greater than for a part that was cut too small. The values are limited between.99 and.0. If the user enters a number outside that range, limit the number and prompt the user that the value was limited. An example of how a user might use this service code. This would be used if you did not have a precision standard like our FST s carry. The user could cut a square and then measure the length along the X axis. For example, let s say the user measure He would then take.0000/.9985 and enter into service code for the X axis. This service code allows up to 8 digits to be entered after the decimal point. For your quill scale calibration, machine a reference plane and set your DRO Z readout to 0. Use the DRO to position the quill or axis knee mill Z axis down to some number, for example Machine some material away from a corner so it will be easy to measure the difference between your reference plane and your new plane. 8

44 4.0 To calculate your offset with a.0000 difference in position, measure the actual amount machined and compare it with For example, if your measurement showed the difference between the reference plane and the machined plane is , calculate the offset: Z calibration offset = DRO actual = = Once you have calculated your values, use Service Code to enter them. CODE : X, Y, Z and Quill Calibration Calibration is used teach the machine a known distance. We typically calibrate our machines over a 50 mm distance. There is no limit to how far you can calibrate the machine. On axis knee mills, press the Quill button to calibrate the quill sensor. On axis knee mills, press the Z button to calibrate the Z motor.. Set-up a gauge block or standard and indicate it parallel to the axis you are calibrating. Note: Put the display in Inch or mm to match your gage block. Recommended gage blocks are: X and Y -- 50mm or 6 Z mm or. Set a indicator in the spindle and move it up to one side of the gage block or standard.. Go to setup mode, go to section B and press CODE. 4. Select the axis you want to calibrate X or Y. For the quill press the F key labeled QUILL. 5. Follow the instructions on the screen to complete calibration. Figure - Calibration Set-Up 9

45 5.0 Maintenance 5. Gib Adjustments The objective of adjusting the gibs is to eliminate as much play in the table and saddle sliding surfaces as possible without having the tightness of the gib interfere with their free movement and cause a decrease in the accuracy and/or performance of the machine due to excessive friction. 5.. Table Gib Adjustment, X-Axis See Figure.. Clean all chips, dirt and excess oil from the table and saddle.. Center the saddle on the bed ways.. Move the table fully to the left side of the saddle. Note: For machines that have excessive wear in the center of the table way, it will be necessary to center the table on the saddle. The resulting adjustment of the gib will be compromised to account for the varying clearance from the center to the ends of the table. 4. Attach a.000 dial indicator with a magnetic base to the left front of the saddle. Place the indicator stylus on the front surface of the table as close to the indicator base as possible. 40

46 Figure - Table Gib Adjustment 5. Move the left end of the table back and forth and note the amount of movement on the dial indicator. Adjust the X-axis gib until the registered movement is To adjust the gib for excessive clearance: Loosen the gib lock screw on the right end of the saddle. Estimate the amount of gib lock screw adjustment required, and tighten the gib lock screw on the left end of the saddle. Tighten the gib lock screw on the right end of the saddle to lock the give in place, and recheck. Repeat as necessary. To adjust the gib for too small of a clearance: Loosen the gib lock screw on the left end of the saddle. Estimate the amount of gib lock screw adjustment required, and tighten the gib lock screw on the right end of the saddle. Tighten the gib lock screw on the left end of the saddle to lock the gib in place, and recheck. Repeat as necessary. 4

47 Figure - Table Gib Screw 5.. Saddle Side Gib Adjustment, Y-Axis See Figure 4.. Clean all chips, dirt and excess oil from the table and saddle.. Center the saddle on the bed ways.. Move the table fully to the left side of the saddle. 4. Remove the chip wiper guard and chip wiper from the front and rear of the left side box way. 4

48 Figure 4 - Saddle Side Gib Adjustment 5. Attach a.000 dial indicator with a magnetic base to the left front of the saddle. Place the indicator stylus on the edge of the large box way. 6. Move the left end of the table back and forth and note the amount of movement on the dial indicator. Adjust the Y-axis side gib until the registered movement is To adjust the gib for excessive clearance: Loosen the gib lock screw on the back of the saddle. Estimate the amount of gib lock screw adjustment required, and tighten the gib lock screw on the front of the saddle. Tighten the gib lock screw on the back end of the saddle to lock the gib in place, and recheck. Repeat as necessary To adjust the gib for too small of a clearance: Loosen the gib lock screw on the front of the saddle. Estimate the amount of gib lock screw adjustment required, and tighten the gib lock screw on the back of the saddle. Tighten the gib lock screw on the front of the saddle to lock the gib in place, and recheck. Repeat as necessary. 7. Replace the front and rear chip wiper, and chip wiper guard. 4

49 5.. Saddle Bottom Gib Adjustment, Y-Axis See Figure 5.. Clean all chips, dirt and excess oil from the table and saddle.. Center the saddle on the bed ways.. Move the table fully to the left side of the saddle. 4. Attach a.000 dial indicator with a magnetic base to the left front of the saddle. Place the indicator stylus on the top surface of the box way. 5. Lift the end of the table up and note the amount of movement on the dial indicator. Adjust the Y-axis left bottom gib until the registered movement is Move the table fully to the right. 7. Reposition the indicator to the right front of the saddle. 8. Lift the right end of the table up and note the amount of movement on the dial indicator. Adjust the Y-axis right bottom gib until the registered movement is To adjust the gib for excessive clearance: Loosen the gib lock screw on the back of the saddle. Estimate the amount of gib lock screw adjustment required, and tighten the gib lock screw on the front of the saddle. Tighten the gib lock screw on the back end of the saddle to lock the gib in place, and recheck. Repeat as necessary. To adjust the gib for too small of a clearance: Loosen the gib lock screw on the front of the saddle. Estimate the amount of gib lock screw adjustment required and tighten the gib lock screw on the back of the saddle. Tighten the gib lock screw on the front of the saddle to lock the gib in place, and recheck. Repeat as necessary. Figure 5 - Saddle Bottom Gib Adjustment 44

50 5. Head Rotational and Tramming The TRAK knee head is free to rotate up to 90 degrees to the right or left. The K can also rotate 45 front to back. 5.. To Rotate the Head Side to Side:. Loosen the four locknuts.. Rotate the head with the adjusting worm shaft. When rotating to greater than a 45 angle, support head by hand.. Tighten the locknuts. Snug each locknut, then lightly tighten each locknut, then fully tighten each locknut in a crisscross pattern. 4. Use the method shown in the figure below and a parallel bar to square the head to the table. 5.. Tramming the Head The purpose of tramming the head is make sure the head is perpendicular to the top of the table from both side to side and back to front. Side to side tolerance 0.00 Side-to-Side Alignment. Make sure the machine is level.. Make sure the table has been clean. Mount a dial indicator in a tool holder and mount in the quill.. Adjust the Y-axis so that the spindle is in the center of the table. 4. Adjust the Knee so that the dial indicator will reach the table. 5. Move the dial indicator to 6 o clock position and adjust the face so the needle is zero. 6. Do a series of sweeps from 9 o clock to o clock and check for the repeatability of the setup. 7. If the head is out of tram from side to side then loosen the 4 head bolts and rotate the head with the worm shaft. 8. Once the head has been trammed, tighten the 4 heads bolts. Be careful not to move the head while tightening. Tighten the bolts in a criss-cross pattern. Torque = 50 ft-lbs. 45

51 5.. Back to Front Adjustment Figure 6 - Tramming of Head. Make sure the table has been clean.. Mount a dial indicator in a tool holder and mount in the quill.. Adjust the Y-axis so that the spindle is in the center of the table. 4. Adjust the knee so that the dial indicator will reach the table and lock the clamps on the knee. 5. Move the dial indicator to 6 o clock position and adjust the face so the needle is zero. 6. Do a series of sweeps from 6 o clock to o clock and check for the repeatability of the setup. The head should be trammed as close as possibility to ± Loosen the three bolts and adjust the tram with the bolt mounted on the top of the ram. Once the head has been trammed tighten the three bolts. Be careful not to move the head while tightening. Tighten the bolts a little at a time. (Note: the head should droop down rather than up because tool pressure will take care of the extra ) 46

52 6.0 Introduction to Self-Service The objective of this section of the manual is to allow the user of the ProtoTRAK Control to resolve the majority of potential service problems. This manual assumes that the user is not experienced with CNC troubleshooting and repairs. Special tools are not required for the procedures described in the manual. Please see Sections for basic troubleshooting sections of the manual. 6. When You Have a Service Problem SWI recommends that you consult this manual or our web site first. Often it will be possible for you to resolve the problem yourself or isolate the problem to a particular cause. Your next step is to contact the SWI Customer Service Group for assistance. 6.. Communication with the SWI Customer Service Group 6. SWI Service Department Direct Line: (800) Web Address This phone line rings directly into the SWI Customer Service Group. If a Customer Service Representative (CSR) is not available within the first few of minutes, your call is transferred into our voice mail system. Our voice mail is continuously monitored. If you have an emergency, indicate this in your message. Our Service Voice Mail box number is 555. SWI Service Department Direct Fax number (0) Customer Service Group hours: Monday - Friday 7:00 AM to 4:0 PM Pacific Time. SWI observes a normal holiday schedule. Replacements 6.. Exchange Program SWI keeps in stock the major subassemblies required to resolve service problems. With very few exceptions, the part needed to resolve any given service problem is on the shelf and ready to ship. A little bit of troubleshooting on your part means that we can get the right part to you fast. After replacing the failed unit with the replacement unit, simply put the failed unit in the same box that the replacement part came in and ship it back to us via UPS ground service. This unique Exchange program gives our customers access to re-built like-new subassemblies that have been brought up to current design revisions and go through the same QC procedures as our new products. These high-quality replacement units are available at a fraction of the price of a new subassembly. 47

53 6.. Return Authorization (RA) Number All shipments of replacement parts are accomplished through our Return Authorization (RA) system. At the same time the CSR is diagnosing the problem and ordering the part, they will issue an RA number that will allow us to efficiently process the return part. 48

54 7.0 Figures and Parts Lists Figure 7- K - Top Housing Assembly 49

55 Parts List - K -Head Top Assembly (Figure 7) Item P/N Title Qty GEAR HOUSING ASSY HI-LOW SHIFT CLUTCH ASSY HI-LOW SHIFT ASSY 4 VS FRU-K-SOCKET CAP SCREW M6-P.0x5L PULLY PINION ASSY 6 VS64 FRU-K-BULL GEAR PINION BEARING CAP 7 VS9 FRU-K-SCREW M5-P0.8x5L 8 VS7 FRU-K-KEY 5x55L 9 VS6 FRU-K-TIMING BELT PULLEY 0 VS6 FRU-K-WASHER Ø 5/8 VS6 FRU-K-JAM NUT 5/8-NC LOWER VARI-DISC DRIVE ASSY VS6 FRU-K-BELT /8"-#5 4 VS4- FRU-K-SCREW M8-P.5x8L 5 VS5 FRU-K-KEY 8x7x60L 6 VS4 FRU-K-BELT UPPER VARI ASSY-DISC DRIVE-R8 8 VS FRU-K-BELT HOUSING 9 VS7 FRU-K-SOCKET CAP SCREW M8-P.5x5L 0 VS FRU-K-TOP BEARING CAP VS- FRU-K-WAVE WASHER VS5 BEARING-DEEP GROVE-6007V VS9 FRU-K-SCREW- SOC HD CAP M6-P.0x8L SPEED CHANGE HANDWHEEL-ASSY-R8 5 VS07 FRU-K-SCREW- SOC HD CAP M6-P.0x5L 9 VS FRU-K-MOTOR PULLEY COVER 0 VS04 FRU-K-COPPER CHIP(REQ.) VS FRU-K-SCREW- FLAT HD PHILIP M5-P0.8x0L VS FRU-K-STUD Ø 7/6-00L VS96 FRU-K-JAM NUT /8"-6NC 4 VS0 FRU-K-VENTILATOR(REQ.) 5 VS6 FRU-K-SCREW- SOC HD CAP M6-P.0x0L 6 VS54 FRU-K-HANDLE FIX BLOCK 7 VS55 FRU-K-SET SCREW 8 VS56 FRU-K-BRAKE LOCK HANDLE 9 VS57 FRU-K-BAKELITE BALL HANDLE 40 OIL- FRU-K-OIL CUP FRU-SK/SK-BEARING SPACER 4 VS5- FRU-K-NUT SPINDLE MOTOR ASSY-K & K-HP () 44 VS0 FRU-K-WASHER- FLAT Ø 0. (4) 45 VS FRU-K-SOC HD SCREW- /8-6NCxL (4) i

56 Figure 8- K - Gear Housing & Parts List Item P/N Title Qty VS8 FRU-K-GEAR HOUSING VS FRU-K-GUIDE SPRING VS FRU-K-SPRING GUIDE PIN i0778-5

57 Figure 9 - K - Hi-Low Shift Clutch Sub-Assembly 5

58 Parts List High-Low Shift Clutch Item P/N Title Qty VS75 FRU-K-BEARING SLEEVE VS77 FRU-K-BALL BEARING ( REQ.) 6908ZZ VS78 FRU-K-BEARING SPACER 4 VS79 FRU-K-BEARING SPACER 5 VS80 FRU-K-SNAP RING R-65 6 VS7 FRU-K-SPLINED GEAR HUB 7 VS7 FRU-K-KEY 8x7x0L 8 VS74 FRU-K-SPINDLE BULL GEAR 9 VS4 FRU-K-WASHER 0 VS5 FRU-K-EXTERNAL TOOTH WASHER Ø 40 VS8 FRU-K-LOCK WASHER Ø 9/6-8NC VS76 FRU-K-RING 087 BEARING SPACER ASSY () i0778- Figure 0 - K - Hi-Low Shift 5

59 Parts List - Hi-Low Shift Item P/N Title Qty VS89 FRU-K-HI-LOW DETENT PLATE VS87 FRU-K-CLUTCH GEAR SHAFT VS9 FRU-K-HI-LOW PINION BLOCK 4 VS9 FRU-K-SPRING 5 VS90 FRU-K-HI-LOW DETENT PLUNGER 6 VS94 FRU-K-HI-LOW SHAFT CRANK 7 VS88 FRU-K-PIN Ø X9L 8 VS9 FRU-K-SCREW M5-P0.8x5L 9 VS9- FRU-K-SET SCREW M5-P0.8x5L 0 VS9- FRU-K-WASHER- FLAT Ø VS57 FRU-K-BAKELITE BALL HANDLE VS6 FRU-K-WASHER- FLAT Ø M5 408 HI/LOW SHAFT ASSY () i

60 Figure - K - Pulley Pinion & Parts List Parts List - K Pulley Pinion Item P/N DESCRIPTION Qty VS67 FRU-K-BULL GEAR PINION COUNTER SHAFT VS69 FRU-K-KEY 5X5X8L VS66 FRU-K-BULL GEAR PINION 4 AK8 BEARING-DEEP GROOVE-60ZZ 5 VS FRU-K-SOCKET SET SCREW M6-P.0x6L BEARING-DEEP GROOVE-SET ()-60ZZ () i

61 Figure - K - Lower Vari-Disc Drive (assembly not available, order parts separately) 56

62 Parts List K/K Lower Vari-Disc Drive (Figure ) Item P/N Title Qty VS50 FRU-K-BELT HOUSING BASE VS59 FRU-K-BRAKE BLOCK VS58 FRU-K-TURNING BLOCK SHAFT 4 VS0 FRU-K-RETAINING RING Ø 7 5 VS5 FRU-K-SET SCREW M6-.0X6L 6 VS5 FRU-K-BRAKE LOCK BUSHING 7 VS5 FRU-K-BRAKE LOCK SHAFT 8 VS5- FRU-K-BRAKE LOCK PIN DIA X 5/8"L 9 VS47 FRU-K-BRAKE SHOE 0 VS48 FRU-K-BRAKE SHOE PIVOT SLEEVE VS7 FRU-K-SOCKET CAP SCREW M6-P.0x5L VS7- FRU-K-WASHER Ø 6 VS7- FRU-K-NUT M6-P.0 4 VS49 FRU-K-BRAKE SPRING 5 VS FRU-K-WASHER DIA. 4 6 VS0 FRU-K-SCREW-PAN HEAD PHILIP 5-40NC 4 7 VS46 FRU-K-BRAKE BEARING CAP 8 VS4- FRU-K-BALL BEARING 600ZZ 9 VS4 FRU-K-SOCKET CAP SCREW M5-0.8xL 4 0 VS45 FRU-K-STATIONARY DRIVEN VARIDISC VS70 FRU-K-SPINDLE PULLY ASSY VS00 FRU-K-SPINDLE PULLY SPACER VS7 FRU-K-KEY 8x7x0L 4 VS97 FRU-K-SNAP RING Ø 40 5 VS50- FRU-K-DUST COVER 6 VS50- FRU-K-SCREW-FH-PH-STL-BO M6-.0X6L BRAKE SHOE ASSY () i

63 Figure - K - Upper Vari-Disc Drive Sub-Assy 58

64 Parts List K Upper Vari-Disc Drive Sub-Assy VS4 FRU-K-SPINDLE PULLEY BEARING HOUSING 464 BEARING-DEEP GROVE-60ZZ VS44 FRU-K-ADJUSTABLE-DRIVEN VARIDISC 4 VS6 FRU-K-SPEED CHANGE PLATE 5 VS8 FRU-K-PIVOT SLEEVE Ø 5 6 VS7 FRU-K-WASHER M5 P0.8X0L 7 VS FRU-K-SCREW-SHCS M5-0.8X0L 8 VS9 FRU-K-SPEED CHANGE PLATE PIVOT STUD 9 VS4 FRU-K-WASHER Ø 8. 0 VS40 FRU-K-ROLL PIN Øx5L VS5 FRU-K-ADJUSTMENT NUT VS4 FRU-K-CHAIN END STUD VS FRU-K-CHAIN FRONT SCREW M4-P0.7x5L 4 VS7 FRU-K-SNAP RING Ø 5 5 FVS96 JAM NUT /8-6NC BEARING HOUSING ASS'Y - K/K () 7 46 VARIDISC ASSY-ADJUSTABLE () i

65 Figure 4 - K - Speed Change Handwheel & Parts List Item P/N DESCRIPTION Qty VS6 SPEED CHANGE HOUSING VS0 BEARING SELF LUBRICATING VS SPEED CHANGER GEAR 4 VS SPEED CHANGE CHAIN DRUM 5 VS WORM 7 VS5 SPEED CHANGE SHAFT 8 VS40 ROLL PIN Øx5L 9 VS4 COPPER BUSHING 0 VS4- WASHER-WAVE VS7 SPEED CHANGE HANDWHEEL VS8 FULL DOG SOCKET SET SCREW M6-P.0x0L VS8 HANDLE /8-6NC 4 VS CHAIN #0X VS- DOWEL PIN Øx5L 6 VS0 SPEED CHANGE STUD 7 VS6- SPEED DIAL 8 VS95 NUT-ACORN 5/6-8 NC 9 VS6- NAME PLATE 0 VS9 SCREW-DRIVE 4 M5-0.8X4 40B SCREW-SOC SET-STL-BO-CUP M5-0.8X5 40B SCREW-SOC SET-STL-BO-CUP i

66 Figure 5 - K - Spindle Motor & Parts List Item P/N Title Qty VS0 FRU-K-MOTOR HP VS- FRU-K-KEY 6x6x45L VS FRU-K-STATIONARY MOTOR VARIDISC 4 VS6 FRU-K-BUSHING 5 VS5 FRU-K-ADJUSTABLE MOTOR VARIDISC ASSY. 6 VS6- FRU-K-KEY 7x7x50L 7 VS8 FRU-K-SPRING FOR VARIDISC MOTOR SHAFT 8 VS9 FRU-K-ADJUSTABLE VARIDISC SPRING COLLAR 9 VS0 FRU-K-SCREW- SOC HD CAP M8-P.5x0L 0 95 VARIDISC ASSY-ADJUSTABLE MOTOR () i089 6

67 Figure 6- K - Lower Head Assembly 6

68 Parts List K Lower Head Assembly (Figure 6) Item P/N Title Qty K-B5- FRU-K-HANDWHEEL HANDLE (AVAILABLE ONLY IN ASSY. 085) K-B FRU-K-HAND WHEEL CLUTCH K-B7 FRU-K-ROLL PIN Øx5L 4 K-B0 FRU-K-CAM ROD 5 K-B08 FRU-K-SOCKET SET SCREW M6-P.0x8L 6 K-B9- FRU-K-ROLL PIN Øx0L 7 K-B0- FRU-K-CAM ROD PIN Ø6x5L 8 K-B07 FRU-K-CAP SCREW M6-P.0x5L 9 K-B06 FRU-K-FEED TRIP BRACKET OVERLOAD CLUTCH TRIP ASSY K-B7 FRU-K-SOCKET SET SCREW M6-P.0x0L K-B0 FRU-K-CHEM BLACKED LOCKNUT M6-P.0 K-B99 FRU-K-CLUTCH ARM COVER 4 M5-0.8X50 5B SCREW-SHCS-STL-BO QUILL FEED SELECTOR ASSY 6 K-B67 FRU-K-CAP SCREW M6-P.0x8L 4 7 K-B9 FRU-K-CLUSTER GEAR KEY xx45l 8 K-B7 FRU-K-CLUSTER GEAR SHAFT UPPER BEARING 9 K-B8 FRU-K-CLUSTER GEARS ASSEMBLY 0 K-B94 FRU-K-SNAP RING 95 DOWEL PIN Ø 4 K-B FRU-K-BEVEL GEAR THRUST SPACER K-B FRU-K-BEVEL GEAR BEARING K-B FRU-K-CLUSTER GEAR SHAFT 660BB WORM GEAR CRADLE ASSY 5 K-B8 FRU-K-WORM GEAR CRADLE THROW-OUT 6 K-B9 FRU-K-SHIFT SLEEVE 7 K-B5 FRU-K-CAP SCREW(REQ.) M5-P0.8xL 8 K-B0 FRU-K-GEAR SHIFT PLUNGER 9 K-B FRU-K-COMPRESSION SPRING 0 K-B FRU-K-ROLL PIN Øx0L K-B FRU-K-SHIFT CRANK K-B86 FRU-K-WORM GEAR 4 K-B8 FRU-K-QUILL SKIRT 5 K-B89- FRU-K-ADJ WORM SHAFT SET SCREW M6-P.0x6L 6 K-B4 FRU-K-BUSHING 7 K-B87 FRU-K-KEY 4x4x8L 8 K-B89 FRU-K-ADJ WORM SHAFT 9 K-B7 FRU-K-KEY xx0l 40 K-B78 FRU-K-CLOCK SPRING(CLOCK SPRING ASSY.) 6

69 4 K-B77 FRU-K-SPRING COVER 4 K-B69 FRU-K-RD.HEAD SCREW(REQ.) M5-P0.8x5L 4 K-B70 FRU-K-ROLL PIN 44 K-B75- FRU-K-SET SCREW M8-P.5x6L 45 K-B75- FRU-K-COMPRESSION SPRING 46 K-B75- FRU-K-STEEL BALL 47 K-B76 FRU-K-PINION SHAFT HUB SLEEVE 48 K-B75 FRU-K-RACK FEED HANDLE HUB 49 K-B7 FRU-K-PINION SHAFT HUB SCREW SPINDLE ASSY-K/K 5 VS09 DRAWBAR-R8-MANUAL 5 VS09- FRU-K-SPACER 5 K-B9 FRU-K-BLACK PLASTIC BALL HANDLES 54 K-B90 FRU-K-PINION SHAFT HUB HANDLE 55 K-B48 FRU-K-QUILL LOCK SLEEVE 56 K-B48- FRU-K-COMPRESSION SPRING 57 K-B5 FRU-K-QUILL LOCK SLEEVE TAPPED 58 KB-0 FRU-K-INDICATOR ROD SCREW 59 K-B49 FRU-K-LOCK HANDLE 60 KB-0 FRU-K-INDICATOR ROD 6 K-B64 FRU-K-QUILL STOP MICRO-SCREW 6 K-B60 FRU-K-SNAP RING Ø6 6 K-B4- FRU-K-FEED TRIP PLUNGER NUT M40-P K-B4- FRU-K-FEED TRIP PLUNGER SOC SET SCREW M4-P0.7x0L 65 K-B45 FRU-K-FEED TRIP LEVER 66 K-B4 FRU-K-FEED TRIP PLUNGER 67 K-B85 FRU-K-REVERSE TRIP BALL LEVER SCREW 68 K-B44 FRU-K-SOCKET SET SCREW 69 K-B8 FRU-K-REVERSE TRIP BALL LEVER 70 K-B6 FRU-K-QUILL MICRO-STOP NUT 7 K-B6 FRU-K-MICROMETER NUT 7 K-B FRU-K-TRIP PLUNGER BUSHING 7 K-B84 FRU-K-FEED REVERSE TRIP PLUNGER 74 K-B FRU-K-TRIP PLUNGER 75 K-B0 FRU-K-COMPRESSION SPRING 76 K-B58 FRU-K-CHEM BLACKED RD.HD.SCREWS( REQ.) M5-P0.8x8L 77 K-B8 FRU-K-CAM ROD SLEEVE ASSY 78 K-B59 FRU-K-MICROMETER SCALE 79 KB-00 FRU-K-SCREW- SOC HD /8-4NFx5L 80 K-B6 FRU-K-QUILL STOP KNOB FEED REVERSE CLUTCH ASSY 64

70 8 OIL- FRU-K-OIL CUP 8 K-B09 FRU-K-KEY xx0l 84 K-B7- FRU-K-WORM GEAR SET SCREW M6-P.0x8L 85 K-B88- FRU-K-COMPRESSION SPRING 86 K-B89 FRU-K-OVERLOAD CLUTCH LEVER SPRING PLUNGER QUILL PINION SHAFT ASSY-R8 88 K-B67 FRU-K-KEY 5x5x5L 89 K-B7- FRU-K-SET SCREW M6-P.0x8L 90 K-B4 FRU-K-NEEDLE BEARING BA66 BEARING SIZE KO-BA66Z 9 K-B9 FRU-K-QUILL HOUSING 9 K-B04 FRU-K-TRIP HANDLE 9 K-B05 FRU-K-BLACK PLASTIC BALL 94 K-B5- FRU-K-HANDWHEEL SPRING PIN Øxx0L 95 K-B5 FRU-K-HANDWHEEL 96 K-B FRU-K-REVERSE KNOB 97 K-B00 FRU-K-CAP SET SCREW M5-P0.8x5L SCALE-HEAD ROTATION-R POINTER SCALE DRIVE SCREW-SCALE FRU-SK/SK-HANDWHEEL ASSY () FRU-SK/SK-FEED REVERSE KNOB ASSY () TRIP HANDLE ASSEMBLY (INCLUDES PLASTIC BALL) () FRU-SK/SK-FEED TRIP ASSY () QUILL MICRO NUT & SCREW ASSY () CLOCK SPRING ASSEMBLY (SPRING & COVER) () FRU-SK/SK-FEED HANDLE ASSY (QUILL HANDLE) () FRU-SK/SK-QUILL LOCK SLEEVE ASSY () 09 K-B4 FRU-K-QUILL 0 K-B50- STRAIGHT LOWER CLAMP K-B5 FELT OIL STRAINER K-B50- STRAINER UPPER CLAMP K-B9 SCREW-PH-HD-M5-0.8X8L 4 M5-0.8X5 40B SCREW-SOC SET-STL-BO-CUP i

71 Figure 7 - K - Worm Gear Cradle & Parts List Item P/N Title Qty K-B7 FRU-K-WORM GEAR CRADLE K-B07 FRU-K-WORM GEAR SPACER K-B08 FRU-K-FEED DRIVEWORM GEAR 4 K-B05 FRU-K-WORM CRADLE BUSHING 5 K-B04 FRU-K-FEED WORM GEAR SHAFT SLEEVE 6 K-B09 FRU-K-FEED DRIVE WORM GEAR SHAFT 7 K-B FRU-K-KEY xx5l 8 K-B0 FRU-K-WORM SHAFT KEY xx8l 9 K-B0 FRU-K-FEED BEVEL PINION 0 K-B0 FRU-K-BEVEL PINION WASHER Ø 5 K-B0 FRU-K-SOC.HD.SCREW M5-P0.8x0L K-B6 FRU-K-FEED DRIVING GEAR K-B6- FRU-K-KEY xx8l 4 K-B5 FRU-K-FEED REVERSE BEVEL GEAR 5 K-B FRU-K-WASHER Ø 6, OD 6 K-B4 FRU-K-SOC HD SCREW M6-P.0x5L 7 K-B7 FRU-K-KEY xx0l 8 K-B40 FRU-K-FEED DRIVE GEAR 9 K-B6 FRU-K-FEED ENGAGE PIN 0 K-B06 FRU-K-SETSCREW M6-P.0x6L i

72 Figure 8 - K - Quill Feed Selector & Parts List Item P/N Title Qty K-B66 FRU-K-CLUSTER GEAR COVER K-B64 FRU-K-CLUSTER GEAR SHAFT CRANK K-B70 FRU-K-SHIFT CRANK 4 K-B69 FRU-K-SPRING Ø x 0L 5 K-B68 FRU-K-GEAR SHIFT PLUNGER 6 K-B7 FRU-K-SHIFT KNOB-5/6-8NC 7 K-B7 FRU-K-ROLL PIN Ø x 0L 8 K-B6 FRU-K-FEED GEAR SHIFT FORK 9 K-B65 FRU-K-SHAFT 0 K-B6 FRU-K-CAP SET SCREW M5-P0.8x5L 807 SCALE-QUILL SELECTOR DRIVE SCREW-SCALE i

73 Figure 9 - K - Quill Pinion Shaft & Parts List Item P/N Title UseAs Qty K-B66 QUILL PINION SHAFT EA 5706 BUSHING KIT-PINION SHAFT-R8 EA K-B9 WASHER EA 4 K-B9 OVERLOAD CLUTCH WORM GEAR EA 5 K-B9 OVERLOAD CLUTCH RING EA 6 K-B9- SCREW SOC HD CAP M4-P0.7x5L EA 7 K-B94 SNAP RING 95 DOWEL PIN Ø 4 EA 8 K-B68 SCREW PIN EA () i

74 Figure 0 - K - Overload Clutch Trip & Parts List Item P/N Title Qty K-B8 FRU-K-OVERLOAD CLUTCH SLEEVE K-B8- FRU-K-KEY 5x8xL K-B80 FRU-K-OVERLOAD CLUTCH 4 K-B79 FRU-K-SAFETY CLUTCH SPRING 5 K-B78 FRU-K-OVERLOAD CLUTCH LOCKNUT 6 K-B76 FRU-K-SOCKET SET SCREW M6-P.0x8L 7 K-B75 FRU-K-CLUTCH RING 8 K-B97 FRU-K-OVERLOAD CLUTCH WASHER 9 K-B98 FRU-K-SNAP RING Ø 0 0 K-B96 FRU-K-OVERLOAD CLUTCH TRIP LEVER K-B74 FRU-K-CLUTCH RING PIN (REQ.) K-B77 FRU-K-BRASS PLUG i

75 Figure - K - Feed Reverse Clutch & Parts List Item P/N Title Qty K-B57 FRU-K-FEED WORM SHAFT K-B47 FRU-K-FEED WORM SHAFT THRUST WASHER K-B44 FRU-K-FEED WORM SHAFT BUSHING 4 K-B4 FRU-K-WORM 5 K-B59 FRU-K-PIN Ø xl 6 K-B49 FRU-K-FEED REVERSE BEVEL GEAR 7 K-B48 FRU-K-BUSHING 8 K-B6 FRU-K-KEY xx5l 9 K-B50 FRU-K-FEED REVERSE CLUTCH 0 K-B56 FRU-K-PIN Ø x9l K-B5 FRU-K-FEED REVERSE BEVEL GEAR K-B5 FRU-K-BUSHING K-B55 FRU-K-REVERSE CLUTCH ROD i

76 Figure - K - Spindle Assembly & Parts List Item P/N Title Qty K-B7 SPINDLE R8 K-B4 SPINDLE DIRT SHIELD 088 BEARING-ANGULAR CONTACT-U/SET()-707 P4 4 K-B6 BEARING SPACER-SMALL 5 K-B7 BEARING SPACER-LARGE 7 K-B NOSE-PIECE 8 K-B SLEEVE 9 K-B BEARING-DEEP GROVE-606ZZ 0 K-B0 BEARING LOCK WASHER Ø 0 K-B9 SPINDLE BEARING LOCK NUT- Ø0-0N K-B50- STRAIGHT LOWER CLAMP () K-B5 FELT OIL STRAINER () 4 K-B50- STRAINER UPPER CLAMP () 5 K-B9 SCREW-PH-HD-M5-0.8X8L () BEARING SPACER SET () i086 7

77 Figure - K Base Machine 7

78 Parts List K Base Machine (Reference Only)(Figure ) Item P/N Title Qty C0 FRU-K-QUILL HOUSING ADJ.GEAR C0 FRU-K-RAM ADAPTER C04 FRU-K-NUT 4 C06 FRU-K-VERTICAL ADJUSTING WORM 5 C07 FRU-K-WORM THRUST WASHER(REQ.) 6 C08 FRU-K-VERTICAL ADJUSTING WORM SHAFT 7 C09 FRU-K-WORM KEY 8 C0 FRU-K-RAM 9 C FRU-K-SOCKET CAP SCREW(REQ.) 0 C4 FRU-K-ROLL DOWEL PIN C5 FRU-K-ANGLE PLATE C6 FRU-K-ROUND HD DRIVE SCREW(5REQ.) 5 C7 FRU-K-ADAPTER PIVOT PIN 4 C8 FRU-K-CHAMFERED & HARDENED WASHER(7REQ.) 7 5 C9 FRU-K-ADAPTER LOCKING BOLT(REQ.) 6 C FRU-K-TABLE 4" OR 48" 7 C FRU-K-STOP PIECE T-BOLT(REQ.) 8 C FRU-K-TABLE STOP PIECE(REQ.) 9 C FRU-K-HEX NUT(REQ.) 0 C7 FRU-K-TABLE LOCK BOLT HANDLE C8 FRU-K-SADDLE LOCK BOLT C9 FRU-K-SADDLE LOCK PLUNGER C40 FRU-K-SOCKET HD CAP SCREW(REQ.) 4 C4 FRU-K-GIB ADJUSTING SCREW(REQ.) 5 C4 FRU-K-TABLE STOP BRACKET 6 C4 FRU-K-SADDLE/TABLE GIB 7 C44 WIPER-FRONT/REAR-K 8 C46 FRU-K-TABLE LOCK PLUNGER 9 C47 FRU-K-TABLE LOCK BOLT 0 C48 FRU-K-TABLE LOCK BOLT HANDLE C49 FRU-K-SADDLE/KNEE GIB C50 FRU-K-SADDLE KNEE WIPER PLATE(4REQ.) 4 C5 FRU-K-OVAL HEAD SCREW(8REQ.) 8 4 C5- FRU-K-LEFT HAND COLUMN WIPER HOLDER 5 C5 FRU-K-SADDLE 6 C54- WIPER-CHIP-LEFT KNEE-K 7 C55 FRU-K-KNEE/COLUMN GIB 8 C56 FRU-K-ALLEN CAP SCREW(REQ.) 9 C57- FRU-K-RIGHT HAND COLUMN WIPER HOLDER 7

79 40 C58- WIPER-CHIP-RIGHT KNEE-K 4 C59 FRU-K-CHIP GUARDS-UPPER 4 C60 FRU-K-CHIP GUARDS-MIDDLE 4 C6 FRU-K-CHIP GUARDS-LOWER 44 C6 FRU-K-KNEE 45 C64 FRU-K-STOP SCREW 46 C65 FRU-K-KNEE LOCK SHAFT ASSEMBLY 47 C69 FRU-K-KNEE LOCK PLUNGER 48 C7 FRU-K-KNEE BINDER PLUG(PLASTIC) 49 C7 FRU-K-DOG POINT SET SCREW 50 C7 FRU-K-SET SCREW 5 C74 FRU-K-JAM NUT 5 C75 FRU-K-KEY 5 C76 FRU-K-WASHER 54 C77 FRU-K-BEVEL GEAR 55 C79 FRU-K-SEALED BALL BEARING 56 C80 FRU-K-BEARING RETAINER RING 57 C8 FRU-K-SOCKET HEAD CAP SCREW 58 C8 FRU-K-ELEVATING SCREW ASSEMBLY 59 C8 FRU-K-HANDLE 60 C84 FRU-K-ELEVATING CRANK 6 C85 FRU-K-GEARSHAFT CLUTCH INSERT 6 C86 FRU-K-DIAL LOCK NUT 6 C87 FRU-K-DIAL WITH 00 GRADUATIONS 64 C88 FRU-K-DIAL HOLDER 65 C89 FRU-K-SOCKET HEAD CAP SCREW 66 C90 FRU-K-BEARING RETAINING RING 67 C9 FRU-K-GREASE SEALED BEARING 68 C9 FRU-K-BEARING CAP 69 C9 FRU-K-KEY 70 C94 FRU-K-ELEVATING SHAFT FOR " KNEE 7 C95 FRU-K-GREASE SEALED BEARING 7 C96 FRU-K-BEVEL PINION 7 C97 FRU-K-SET SCREW 74 C98 FRU-K-COLUMN 75 C99 FRU-K-WASHER 76 C0 FRU-K-SOCKET HEAD CAP SCREW 77 C0 FRU-K-PEDESTAL 78 C04 FRU-K-ELEVATING SCREW NUT 79 C05 FRU-K-SOCKET HEAD CAP SCREW 80 C8 FRU-K-SPIDER 74

80 8 C0 FRU-K-RAM PINION 8 C FRU-K-RAM PINION HANDLE 84 C FRU-K-PLASTIC BALL 85 C FRU-K-CHAMFERED HARDENED WASHER 86 C4 FRU-K-TURRET 87 C5 FRU-K-GIB SCREW NUT 88 C6 FRU-K-GIB SCREW 89 C7 FRU-K-LOCK BAR 90 C8 FRU-K-SCREW 9 C9 FRU-K-LOCKING BOLT 9 C0 FRU-K-RAM PINION SCREW 9 C FRU-K-RAM/TURRET GIB FRU-SK/SK-STOP PIECE T-BOLT ASSY () FRU-SK/SK-TABLE LOCK HANDLE () FRU-SK/SK-KNEE LOCK HANDLE & SHAFT () FRU-SK/SK-KNEE CRANK HANDLE ASSY () CHIP GUARD SET K/K () 99 FC CAP SCREW 00 FC NUT 0 FC4 MACHINE MAT 0 C EYEBOLT 0 C05 INTERNAL SET SCREW 04 C00 GIB LOCK 05 C45 WIPER-FRONT/REAR-K 06 C9 GIB ADJUSTMENT SCREW 07 C4 GIB-LEFT 08 C5 BRACKET-LEFT 09 C6 GIB-RIGHT 0 C7 BRACKET-RIGHT C66 M6-.0X6L 4 C78 /4-0X.0 4 i

81 Figure 4 - K - Transformer Option 0V &440V 76

82 Figure 5 - K -Transformer Options 0V & 77

83 Parts List - K - Transformer Options Item P/N Title 40-M0D SAFETY SWITCH - 0A - 600VAC - MODIFIED ENCLOSURE ASSY-TRANSFORMER OPTION-0V ENCLOSURE ASSY-TRANSFORMER OPTION-440V CABLE ASSY-SAFETY SWITCH/XFMR MODULE-DPM 8 5/6-8X/ 5B SCREW-SHCS-STL-BO 9 5/6 70B FLAT WASHER 5/6 0 M6-.0X0 5B SCREW-SHCS-STL-BO M6 70B WASHER-FLAT USS-STL-BO LABEL-FUSE CHART REPLACEMENT-0V LABEL-FUSE CHART REPLACEMENT-440V FUSE-TIME DELAY-5 AMPS-0V FUSE-TIME DELAY-0 AMPS-440V i

84 8.0 Drawings SYSTEM DIAGRAM-KMX NEW MACHINES & 8. UPGRADES PENDANT ARM KIT-TOP MOUNT-KMX-K PENDANT ARM KIT-TOP MOUNT-KMX 8.4 RETROFIT 055-XX DRIVE KIT X-AXIS-SM PARTS LIST FOR DRIVE KIT X-AXIS-SM XX DRIVE KIT-SPORT Y-AXIS PARTS LIST FOR DRIVE KIT-SPORT - Y-AXIS BRACKET ASSY-BP SER I Z AXIS - SWI GS BRACKET ASSY-Z AXIS EASSON GLASS SCALE XX DRIVE KIT - Z AXIS HARDWARE KIT MX Z-AXIS-BP XX Z AXIS BALL SCREW - BASEPLATE, BEARING HOUSING & COVERS ASSY PARTS LIST FOR Z-AXIS BALLSCREW- BASEPLATE- BEARING HOUSING & COVERS ASSY ELECTRONIC HANDWHEELKIT- KNEE MILL-X & 8.5 Y AXIS POWER DRAWBAR OPTION K, K-R AIR REGULATOR ASSY - DPMV - FILTER 79

85 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTHWESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CONSENT OF SOUTHWESTERN INDUSTRIES. SOUTHWESTERN INDUSTRIES, INC. 06 ALL RIGHT RESERVED DPM/DPM5 UPGRADE WITH CABLE BREAKOUT BOX MONITORING BYPASS JUMPER REVISIONS REV DESCRIPTION ECN DATE DFT A PRODUCTION RELEASE /8/6 RM B (C7) DELETED /4/7 AC LG C (B4)(4B5) 856 WAS: 856 EXISTING CABLE. SHEET /9/7 AC LG TITLE:... NON SWI MACHINES; WAS:... BREAKOUT BOX. ENG LG D USB USB NETWORK 750 EXISTING CABLE WHEN REPLACING ORDER 608- (NO LONGER NEEDED) D X-MOTOR Z-SCALE UMB UMB TEST PORT Y-MOTOR EURO E-STOP TABLE GUARD MACH ID KMX PENDANT Z-MOTOR AC SPDL EN UPGRADE-AUX 70-0 C CBB PWR RSG SPDL SW-BOX UPGRADE SW-BOX } (NO LONGER NEEDED) C AC INLET GND 975--LB Rev A TO KMX PENDANT 9808 Y EHW (EXISTING CABLE) AUX. FUNCTIONS FROM KMX PENDANT ADAPTER CABLES DPM5/B5 ONLY X EHW Y EHW X SENSOR Y SENSOR B 9808 X EHW DUAL INPUT LIMIT SWITCH X LIMIT SW Y LIMIT SW UMBILICAL Z LIMIT SW UMBILICAL X LIMIT Y LIMIT Z LIMIT FWD/REV SWITCH B X SPEED SENSOR 4 Y SPEED SENSOR Z SPEED SENSOR INDEXER EURO SPINDLE ENABLE/ COOLANT INPUT LIMIT SWITCH UPGRADES USE THESE EXISTING ELECTRICAL CABINET WITH RELAY MODULE 7009 A INPUT POWER COOLANT 4 NOTES: (UNLESS OTHERWISE SPECIFIED). A 8 7 POWER FUSE A GND LABEL P/N REV 6 NOT USED ON THIS UPGRADE. AUX FUNCTIONS PART OF RELAY MODULE X & Y MOTORS REQUIRE MOTOR EXTENSION CABLE (760) TO REACH PENDANT. CONNECTORS NOT USED 4 CONNECTORS NOT USED ON USA MACHINES 5 4 DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH - - DRAWN BY ENGINEER CHECKER FE APPROVALS RM LG LG DATE 0//6 THIRD ANGLE PROJECTION SCALE: SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SYSTEM DIAGRAM-KMX NEW MACHINES & UPGRADES SIZE CODE IDENT. NO. DWG NO. REV D C SHEET OF 6

86 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTHWESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CONSENT OF SOUTHWESTERN INDUSTRIES. SOUTHWESTERN INDUSTRIES, INC. 06 ALL RIGHT RESERVED DPM UPGRADE NO CABLE BREAKOUT BOX MONITORING BYPASS JUMPER REVISIONS REV DESCRIPTION ECN DATE DFT A PRODUCTION RELEASE /8/6 RM B (C7) DELETED /4/7 AC LG C (B4)(4B5) 856 WAS: 856 EXISTING CABLE. SHEET /9/7 AC LG TITLE:... NON SWI MACHINES; WAS:... BREAKOUT BOX. ENG LG D USB USB NETWORK 750 EXISTING CABLE WHEN REPLACING ORDER 608- (NO LONGER NEEDED) D X-MOTOR Z-SCALE UMB UMB TEST PORT Y-MOTOR EURO E-STOP TABLE GUARD MACH ID KMX PENDANT Z-MOTOR AC SPDL EN UPGRADE-AUX 70-0 C CBB PWR RSG SPDL SW-BOX UPGRADE SW-BOX } (NO LONGER NEEDED) C AC INLET GND 975--LB Rev A TO KMX PENDANT 7000 (EXISTING CABLE) AUX. FUNCTIONS FROM KMX PENDANT B FWD/REV SWITCH B X Y X-GLASS SCALE Y-GLASS SCALE EXISTING ELECTRICAL CABINET WITH RELAY MODULE 7009 A A NOTES: (UNLESS OTHERWISE SPECIFIED). X & Y MOTORS REQUIRE MOTOR EXTENSION CABLE (760) TO REACH PENDANT. CONNECTORS NOT USED DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH - - DRAWN BY ENGINEER CHECKER FE APPROVALS RM LG LG DATE 0//6 THIRD ANGLE PROJECTION SCALE: SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SYSTEM DIAGRAM-KMX NEW MACHINES & UPGRADES SIZE CODE IDENT. NO. DWG NO. REV D C SHEET OF 6

87 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTHWESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CONSENT OF SOUTHWESTERN INDUSTRIES. SOUTHWESTERN INDUSTRIES, INC. 06 ALL RIGHT RESERVED TRM,B/B5 UPGRADE AXIS & AXIS KNEE MILL UPGRADE WITH CABLE BREAKOUT BOX-SWI MACHINES REVISIONS REV DESCRIPTION ECN DATE DFT A PRODUCTION RELEASE /8/6 RM B (C7) DELETED /4/7 AC LG C (B4)(4B5) 856 WAS: 856 EXISTING CABLE. SHEET /9/7 AC LG TITLE:... NON SWI MACHINES; WAS:... BREAKOUT BOX. ENG LG D MONITORING BYPASS JUMPER AMP FUSE D USB USB NETWORK AMP X-MOTOR Z-SCALE UMB UMB FUSE AUX # TEST PORT AUX # Y-MOTOR EURO E-STOP KMX PENDANT 5 VOLTS TABLE GUARD MACH ID Z-MOTOR AC SPDL EN UPGRADE-AUX AC IN C CBB PWR AC INLET GND RSG SPDL SW-BOX UPGRADE SW-BOX 975--LB Rev A 608 POWER CABLE COMPUTER LUBE PUMP C 9808 Y EHW ADAPTER CABLES DPM5/B5 ONLY X EHW Y EHW X SENSOR Y SENSOR E-STOP B 9808 X EHW DUAL INPUT LIMIT SWITCH X LIMIT SW Y LIMIT SW Z LIMIT SW X SPEED SENSOR UMBILICAL UMBILICAL X LIMIT Y LIMIT Z LIMIT INPUT LIMIT SWITCH UPGRADES USE THESE FWD/REV SWITCH SPINDLE CONTROL B 4 Y SPEED SENSOR NOTES: (UNLESS OTHERWISE SPECIFIED). A Z SPEED SENSOR INPUT POWER COOLANT INDEXER EURO SPINDLE ENABLE/ COOLANT Z+ X & Y MOTORS REQUIRE MOTOR EXTENSION CABLE (760) TO REACH PENDANT. CONNECTORS NOT USED 4 CONNECTORS NOT USED ON USA MACHINES 5 USE ON AXIS KNEE MILL WITH Z ELECTRONIC HANDWHEEL 8 PT STYLE AXIS KNEE MILL BALLSCREW ENCODER PLUGS HERE A POWER FUSE A GND LABEL P/N REV Z- 9 CABLE 658- ONLY NEEDED IF CUSTOMER ORDERS AUX FUNCTION OPTION DIMENSIONS ARE IN INCHES APPROVALS DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' DRAWN BY FRACTIONS = ±/8 FINISH = 5 RMS ENGINEER REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES CHECKER DIMENSIONING PER ASME Y4.5 MATERIAL FE FINISH - - RM LG LG DATE 0//6 THIRD ANGLE PROJECTION SCALE: SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SYSTEM DIAGRAM-KMX NEW MACHINES & UPGRADES SIZE CODE IDENT. NO. DWG NO. REV D C SHEET OF 6

88 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTHWESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CONSENT OF SOUTHWESTERN INDUSTRIES. SOUTHWESTERN INDUSTRIES, INC. 06 ALL RIGHT RESERVED TRM,B UPGRADE AXIS & AXIS KNEE MILL UPGRADE NO CABLE BREAKOUT BOX-SWI MACHINES REVISIONS REV DESCRIPTION ECN DATE DFT A PRODUCTION RELEASE /8/6 RM B (C7) DELETED /4/7 AC LG C (B4)(4B5) 856 WAS: 856 EXISTING CABLE. SHEET /9/7 AC LG TITLE:... NON SWI MACHINES; WAS:... BREAKOUT BOX. ENG LG D 8 USB USB MONITORING BYPASS JUMPER NETWORK AMP FUSE D X-MOTOR Z-SCALE UMB UMB 5-AMP TEST PORT FUSE AUX # C Y-MOTOR Z-MOTOR CBB PWR EURO E-STOP TABLE GUARD MACH ID AC SPDL EN RSG AC INLET GND KMX PENDANT UPGRADE-AUX SPDL SW-BOX UPGRADE SW-BOX 975--LB Rev A POWER CABLE Z+ Z VOLTS AC IN AUX # COMPUTER LUBE PUMP C 856 E-STOP B EXISTING PART FWD/REV SWICTH SPINDLE CONTROL B X Y X-GLASS SCALE Y-GLASS SCALE A NOTES: (UNLESS OTHERWISE SPECIFIED). ON B, X & Y MOTORS REQUIRE MOTOR EXTENSION CABLE (760) TO REACH PENDANT. A CONNECTORS NOT USED 5 USE ON AXIZ KNE MILL WITH Z ELECTRONIC HANDWHEEL 8 PT STYLE AXIS KNEE MILL BALLSCREW ENCODER PLUGS HERE DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH - - DRAWN BY ENGINEER CHECKER FE APPROVALS RM LG LG DATE 0//6 THIRD ANGLE PROJECTION SCALE: SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SYSTEM DIAGRAM-KMX NEW MACHINES & UPGRADES SIZE CODE IDENT. NO. DWG NO. REV D C SHEET 4 OF 6

89 D 8 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTHWESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CONSENT OF SOUTHWESTERN INDUSTRIES. SOUTHWESTERN INDUSTRIES, INC. 06 ALL RIGHT RESERVED KMX AXIS RETRO OR UPGRADE NO CABLE BREAKOUT BOX-NON SWI MACHINES KMX AXIS RETRO OR UPGRADE NO CABLE BREAKOUT BOX-NON SWI MACHINES 4 5 REVISIONS REV DESCRIPTION ECN DATE DFT A PRODUCTION RELEASE /8/6 RM B (C7) DELETED /4/7 AC LG C (B4)(4B5) 856 WAS: 856 EXISTING CABLE. SHEET /9/7 AC LG TITLE:... NON SWI MACHINES; WAS:... BREAKOUT BOX. ENG LG D USB USB NETWORK 986 C X-MOTOR Z-SCALE UMB UMB Z+ C TEST PORT 5 Z- Y-MOTOR EURO E-STOP Z-MOTOR TABLE GUARD AC SPDL EN MACH ID KMX PENDANT UPGRADE-AUX MONITORING BYPASS JUMPER B CBB PWR AC INLET GND RSG SPDL SW-BOX UPGRADE SW-BOX B 975--LB Rev A 608 PLUG INTO WALL OUTLET A NOTES: (UNLESS OTHERWISE SPECIFIED). CONNECTORS NOT USED A 5 USE ON AXIS KNEE MILL WITH Z ELECTRONIC HANDWHEEL X Y 6 CABLE NEEDED IF USER ORDERS CLASS SCALE OPTION AND NO CABLE BREAKOUT BOX 7 ELECTRICAL BOX AND FWD/REV SWITCH PART OF MACHINE AND NOT PROVIDED BY SWI 8 PT STYLE AXIS KNEE MILL BALLSCREW ENCODER PLUGS HERE X-GLASS SCALE 5 Y-GLASS SCALE 4 DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH - - DRAWN BY ENGINEER CHECKER FE APPROVALS RM LG LG DATE 0//6 THIRD ANGLE PROJECTION SCALE: SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SYSTEM DIAGRAM-KMX NEW MACHINES & UPGRADES SIZE CODE IDENT. NO. DWG NO. REV D C SHEET 5 OF 6

90 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTHWESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CONSENT OF SOUTHWESTERN INDUSTRIES. SOUTHWESTERN INDUSTRIES, INC. 06 ALL RIGHT RESERVED REVISIONS REV DESCRIPTION ECN DATE DFT A PRODUCTION RELEASE /8/6 RM B (C7) DELETED /4/7 AC LG C (B4)(4B5) 856 WAS: 856 EXISTING CABLE. SHEET /9/7 AC LG TITLE:... NON SWI MACHINES; WAS:... BREAKOUT BOX. ENG LG D MONITORING BYPASS JUMPER D USB USB NETWORK 585 X-MOTOR Z-SCALE UMB UMB TEST PORT Y-MOTOR EURO E-STOP TABLE GUARD MACH ID KMX PENDANT Z-MOTOR AC SPDL EN UPGRADE-AUX CBB PWR RSG SPDL SW-BOX UPGRADE SW-BOX C AC INLET GND C 975--LB Rev A KMX AXIS RETRO OR UPGRADE W/ CABLE BREAKOUT BOX-NON SWI MACHINES KMX AXIS RETRO OR UPGRADE W/ CABLE BREAKOUT BOX-NON SWI MACHINES 608 PLUG INTO WALL OUTLET X EHW Y EHW X SENSOR Y SENSOR B B DUAL INPUT LIMIT SWITCH X LIMIT SW Y LIMIT SW Z LIMIT SW X SPEED SENSOR UMBILICAL UMBILICAL X LIMIT Y LIMIT Z LIMIT INPUT LIMIT SWITCH UPGRADES USE THESE 4 Y SPEED SENSOR Z SPEED SENSOR INDEXER EURO SPINDLE ENABLE/ COOLANT Z+ NOTES: (UNLESS OTHERWISE SPECIFIED). CONNECTORS NOT USED 4 CONNECTORS NOT USED IN USA MACHINES A INPUT POWER COOLANT 987 Z- 5 USE ON AXIS KNEE MILL WITH Z ELECTRONIC HANDWHEEL 8 PT STYLE AXIS KNEE MILL BALLSCREW ENCODER PLUGS HERE 9 CABLE 658- ONLY NEEDED IF CUSTOMER ORDERS AUX FUNCTION OPTION A GND POWER FUSE A LABEL P/N REV DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH - - DRAWN BY ENGINEER CHECKER FE APPROVALS RM LG LG DATE 0//6 THIRD ANGLE PROJECTION SCALE: SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SYSTEM DIAGRAM-KMX NEW MACHINES & UPGRADES SIZE CODE IDENT. NO. DWG NO. REV D C SHEET 6 OF 6

91 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTHWESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CONSENT OF SOUTHWESTERN INDUSTRIES. SOUTHWESTERN INDUSTRIES, INC. 06 ALL RIGHT RESERVED REVISIONS REV DESCRIPTION ECN DATE DFT ENG A PRODUCTION RELEASE /07/6 CC DM B ITEM 4 WAS: M6-.0X0 5B. 46 //6 Sal DM C ITEM 9 WAS: 97K CC LG D Orientation of Belleville Washers D 4X X USB USB NETWORK X-MOTOR Z-SCALE UMB UMB TEST PORT Y-MOTOR EURO E-STOP 6 C KMX PENDANT TABLE GUARD Z-MOTOR AC SPDL EN MACH ID UPGRADE-AUX 4X C CBB PWR RSG SPDL SW-BOX UPGRADE SW-BOX AC INLET GND B 4X 5 4X X 5 4X B X 4X 8 7 4X A A NOTES: (UNLESS OTHERWISE SPECIFIED). FOR CLARITY THREE ADDITIONAL CABLE TIES (ITEM ) ARE NOT SHOWN DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH DRAWN BY ENGINEER CHECKER FE APPROVALS CJC DSM DSM DATE THIRD ANGLE PROJECTION TITLE SIZE CODE IDENT. NO. DWG NO. REV D SCALE: SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA PENDANT ARM KIT-TOP MOUNT-KMX-K : SHEET OF C

92 Parts List for Assembly P/N: Printed // PENDANT ARM KIT-TOP MOUNT-KMX, K Type Revision PL C Dwg Size Product D KMX Status R Engineer DM Date 4/0/06 Planner Code By CJC Comm Code Item P/N Title Detail Qty UseAs Rev Stat Type Mfr PENDANT ARM ASSY-KMX EA A R PL 5896 CAP-PENDANT EA C R DWG 6797 RAM SUPPORT MACHINED EA A R PL PLATE-LEVELING EA R DWG CABLE TIE MOUNT 4 EA - R DWG LB LABEL-PENDANT-KMX EA A R DWG 968 CABLE TIE-PLASTIC 8 IN LONG (TCA) 4 EA - R DWG /6X 80P PIN-DOWEL-STL-PLAIN 4 EA R PS 0 5/8-8X5 / 4B SCREW-HEX HD-STL-BO EA R PS /4-0X6 4P SCREW-HEX HD-STL-PLAIN EA R PS /4-0X/4 40B SCREW-SOC SET-STL-BO-CUP 4 EA R PS /4-0 X /8 7B SCREW-BHCS-STL-BO 4 EA A R PS 4 M6-.0X5 5B SCREW-SHCS-STL-BO 4 EA A R PS 0 5/8-8 57Z NUT-NYLON LOCK-JAM-STL-ZINC EA R PS 5 5/8 70P WASHER-FLAT USS-STL-PLAIN EA R PS 6 /4 7P WASHER-FLAT SAE-STL-PLAIN EA R PS WASHER-BELLEVILLE SPRING LK-SERRATED.64 ID x.74 OD x.04 THK-/4 or M6 4 EA D R DWG 8 M6 70B WASHER-FLAT USS-STL-BO 4 EA - R PS WASHER-BELLEVILLE SPRING LK.60 ID x.875 OD x.086 THK EA B R DWG SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

93 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTHWESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CONSENT OF SOUTHWESTERN INDUSTRIES. SOUTHWESTERN INDUSTRIES, INC. 06 ALL RIGHT RESERVED REVISIONS REV DESCRIPTION ECN DATE DFT ENG A PRODUCTION RELEASE /07/6 CC DM B ITEM 4 WAS: M6-.0X0 5B. 46 //6 Sal DM C ITEM 9 WAS: 97K CC LG D Orientation of Belleville Washers D 4 4X 0 9 X 6 X-MOTOR Y-MOTOR USB USB Z-SCALE UMB UMB EURO E-STOP NETWORK TEST PORT C KMX PENDANT TABLE GUARD Z-MOTOR AC SPDL EN CBB PWR MACH ID RSG UPGRADE-AUX SPDL SW-BOX UPGRADE SW-BOX 4X C AC INLET GND Southwestern Industries 65 Homestead Pl. Rancho Dominguez, Ca. 900 SYSTEM S/N B 4X 5 4X 0 X X 5 4X B X Southwestern Industries 65 Homestead Pl. Rancho Dominguez, Ca X 8 7 4X SYSTEM S/N A NOTES: (UNLESS OTHERWISE SPECIFIED). FOR S/N SEE ES-74. A DRILL HOLES USE # 7 DRILL BIT, FASTEN NAME PLATE (ITEM 0) WITH 4X /8 4J DRIVE SCREWS (ITEM ). BOLT & WASHER COMBINATION MAY VARY DEPENDING ON THE UNIT BEING REVISED 4 THREE ADDITIONAL CABLE TIES (ITEM ) ARE NOT BEING SHOWN ON DRAWING DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH 9775-CSTG DRAWN BY ENGINEER CHECKER FE APPROVALS CJC DSM DSM DATE THIRD ANGLE PROJECTION TITLE SIZE CODE IDENT. NO. DWG NO. REV D SCALE: SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA PENDANT ARM KIT-TOP MOUNT-KMX RETROFIT : SHEET OF C

94 Parts List for Assembly P/N: Printed // PENDANT ARM KIT-TOP MOUNT-KMX RETROFIT Type Revision PL C Dwg Size Product D Status R Engineer DM Date 4/0/06 Planner Code By CC Comm Code Item P/N Title Detail Qty UseAs Rev Stat Type Mfr PENDANT ARM ASSY-KMX EA A R PL 5896 CAP-PENDANT EA C R DWG 6797 RAM SUPPORT MACHINED EA A R PL PLATE-LEVELING EA R DWG CABLE TIE MOUNT 4 EA - R DWG LB LABEL-PENDANT-KMX EA A R DWG 0 94 NAMEPLATE-SYSTEM S/N EA - R DWG 968 CABLE TIE-PLASTIC 8 IN LONG (TCA) 4 EA - R DWG /6X 80P PIN-DOWEL-STL-PLAIN 4 EA R PS 4X/8 4J SCREW-DRIVE-4-SS EA A R PS 0 5/8-8X5 / 4B SCREW-HEX HD-STL-BO EA R PS /4-0X6 4P SCREW-HEX HD-STL-PLAIN EA R PS /4-0X/4 40B SCREW-SOC SET-STL-BO-CUP 4 EA R PS /4-0 X /8 7B SCREW-BHCS-STL-BO 4 EA A R PS 4 M6-.0X5 5B SCREW-SHCS-STL-BO 4 EA A R PS 5 /-X6 4P SCREW-HEX HD-STL-PLAIN EA R PS 6 5/8-X6 4P SCREW-HEX HD-STL-PLAIN EA R PS 7 M0-.5X50 4P SCREW-HEX HD-STL-PLAIN EA R PS 0 5/8-8 57Z NUT-NYLON LOCK-JAM-STL-ZINC EA R PS 5 5/8 70P WASHER-FLAT USS-STL-PLAIN EA R PS 6 /4 7P WASHER-FLAT SAE-STL-PLAIN EA R PS SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

95 Parts List for Assembly P/N: PENDANT ARM KIT-TOP MOUNT-KMX RETROFIT Rev C Printed //07 Item P/N Title Detail Qty UseAs Rev Stat Type Mfr WASHER-BELLEVILLE SPRING LK-SERRATED.64 ID x.74 OD x.04 THK-/4 or M6 4 EA D R DWG 8 M6 70B WASHER-FLAT USS-STL-BO 4 EA - R PS WASHER-BELLEVILLE SPRING LK.60 ID x.875 OD x.086 THK EA B R DWG 40 / 70P WASHER-FLAT USS-STL-PLAIN EA R PS 4 M0 70P WASHER-FLAT USS-STL-PLAIN EA A R PS DOC PENDANT ARM KIT-TOP MOUNT-KMX RETROFIT EA A R DOC SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

96 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTH- WESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CON- SENT OF SOUTHWESTERN INDUSTRIES. BEARING HOUSING REVISIONS REV DESCRIPTION ECN DATE APPRV G ITEM 8 REF WAS: /4/0 LG H ADDED ITEMS 56, 57, & /6/ LG J ADDED ITEM 6(M0-.5X0 5B), DETAIL A & B. DELETED NOTE 8 WAS: M0X0 (4) PLCS REQ'D LG D (096) BALL BEARING 7 D 4 4 C X DIAL HOLDER FIBER SPACER VERNIER DIAL DIAL LOCK NUT REF C X 5 A DETAIL B 5 B REF X ( ) B B DETAIL A 7 BEARING 008 IS FOUND IN HARDWARE KIT 694 FOR DPME.(D) A 6 SHIM TO ENSURE SUFFICIENT THREADS TO MOUNT HANDWHEEL. SHIM QTY SHOULD BE CONSISTENT FROM MACHINE TO MACHINE.(C-) 5. 4 SHIM AS NEEDED TO ENSURE MIN VERNIER DIAL GAP.(C,D) (REF) A USE LOCTITE 7 FOR SET SCREWS. SEE ES-95 FOR APPLICATION PROCEDURE.(A) INSTALL WOODRUFF KEY (ITEM 5) PRIOR TO INSTALLING DRIVE HOUSING (ITEM ).(B5) THESE ITEMS ARE SUPPLIED WITH MACHINE.(C,D-4) NOTES: (UNLESS OTHERWISE SPECIFIED) FOR PARTS LIST SEE SEPARATE "A" SIZE SHEET DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH DRAWN BY ENGINEER MFE FE APPROVALS JRS DATE TITLE SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SIZE CODE IDENT. NO. DWG NO. REV D 068 : 4 SCALE: DRIVE KIT- X AXIS-SM 055-XX SHEET OF J

97 Parts List for Assembly P/N: 055- Printed // DRIVE KIT-X AXIS SM Type Revision PL J Dwg Size Product PL PT4 Status R Engineer SPG REV ECN SIGN DATE H 45 LG /5/4 J 4468 LG..5 Date By 6/9/996 JM Planner Code Comm Code 0 MANUF Item P/N Title Detail Qty UseAs Rev Stat Type 56 DRIVE HOUSING EA C R DWG COVER X-AXIS DRIVE HOUSING-MX EA C R DWG 5 56 COVER-BACK X AXIS HOUSING EA - R DWG HANDWHEEL ASSY w/ FOLD-AWAY HANDLE EA E R PL 8 56 BEARING HOUSING ASSY-X AXIS EA - R PL STOP-STEEL-X AXIS EA D R DWG 566 SEAL-BEARING HOUSING EA A R DWG 698- PULLEY-SOLID 44 TEETH W/O GUIDES EA C R DWG 645 NUT CLAMP-X, Y, & Z AXIS EA E R DWG FERRULE-SPROCKET-DRIVE KIT EA - R DWG A090 KEY WOODRUFF #404-/8 X / EA - R PS SPACER-CNC X AXIS HANDLE.00" THICK 5 EA B R DWG M-5 BELT - TIMING 5MM POWERGRIP EA R PS 0 07 BEARING-ANGULAR CONTACT-704 EA D R DWG 477- SPACER -.00" THICK EA B R DWG SPACER -.050" THICK EA B R DWG 4 8-X/8 5B SCREW-SHCS-STL-BO 6 EA R PS 4 5/6-8X 5B SCREW-SHCS-STL-BO EA R PS 4 /8-6X / 5B SCREW-SHCS-STL-BO 4 EA R PS 46 /4-0X 4B SCREW-HEX HD-STL-BO 7 EA R PS SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

98 Parts List for Assembly P/N: 055- DRIVE KIT-X AXIS SM 055- Rev J Printed //05 Item P/N Title Detail Qty UseAs Rev Stat Type 47 8-X/8 0B SCREW-RH-PHIL-STL-BO EA R PS 48 0-X/4 5B SCREW-SHCS-STL-BO EA R PS 49 /-0 5Z NUT-HEX JAM-STL-ZINC EA R PS WASHER-/4 HARD BLK OX /8 THK 7 EA - R DWG 5 /8 70P WASHER-FLAT USS-STL-BO 4 EA R PS 55 / 75Z WASHER-EXT TOOTH-STL-ZINC EA R PS 56 / 66Z WASHER-FLAT-NARROW-ANSI TYPE B EA - R PS 6 M0-.5X0 5B SCREW-SHCS-STL-BO 4 EA R PS SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

99 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTH- WESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CON- SENT OF SOUTHWESTERN INDUSTRIES. REVISIONS REV DESCRIPTION ECN DATE APPRV J ITEM: 4 REF WAS: 60 04/4/0 LG K ADDED ITEMS 5 & /6/ LG L ADDED ITEMS 7, 7 & /5/4 LG D D (BALLSCREW) C 4X 4X 4X 4X 5 OR 9 OR 8 OR 0 4X 4X 4X 6 OR 4 OR Ref (609) 5 C X 40 B 5 8 X X X (096) B 4 4X NOTES: UNLESS OTHERWISE SPECIFIED. USED ON K & K4 (C) X 4X SHIM AS NEEDED TO INSURE MIN. VERNIER DIAL GAP. SHIM SHOULD BE CONSISTENT FROM MACHINE TO MACHINE (B5, B6). A INSTALL WOODRUFF KEY (ITEM 0) PRIOR TO MOTOR BRACKET (ITEM 6) (C). A 4 WASHERS OPTIONAL IF NEED ADDITIONAL BRACKET ALIGNMENT. WASHER MUST BE USED WHEN USING M8 HARDWARE TO FASTEN BRACKET. ALWAYS USE ITEM WHEN POSSIBLE (C4). 5. MAX ROLLING TORQUE = 5 IN/LBS. MUST BE WITHIN IN/LBS FRONT, MIDDLE, BACK. 6 TORQUE CLAMPNUT (ITEM 5) TO 50 FT/LBS (C4). 7. INSTALL MOTOR COVER (ITEM 5) BEFORE BRACKET COVET (ITEM ) AFTER MOTOR. 8 USE VERNIER THAT COMES WITH THE MACHINE (B6) DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH - - SEE SEPARATE "A" SIZE SHEET FOR PARTS LIST DRAWN BY ENGINEER APPROVAL APPROVAL APPROVALS JRS SPG DATE -6-6 /9/0 TITLE SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SIZE CODE IDENT. NO. DWG NO. REV D 068 : SCALE: DRIVE KIT-SPORT Y-AXIS 08-XX SHEET OF L

100 Parts List for Assembly P/N: 08- Printed /5/ DRIVE KIT-PT4-Y AXIS Type Revision PL J Dwg Size Product D PT4 Status R Engineer SPG REV ECN DATE SIGN G LG H 60 0/0/0 LG J 45 /5/4 LG Date By /9/00 SPG Planner Code Comm Code 0 MANUF Item P/N Title Detail Qty UseAs Rev Stat Type Mfr Mfr P/N 566 SEAL-BEARING HOUSING EA A R DWG 07 BEARING-ANGULAR CONTACT-704 EA D R DWG BEARING HOUSING ASSY-LARGE FLANGE-Y AXIS EA A R PL NUT CLAMP-X, Y, Z AXIS EA D R DWG 6 06 MOTOR BRACKET-KNEE MILLS-40 DEGR EA E R DWG PULLEY-SOLID 44 TEETH W/O GUIDES EA C R DWG FERRULE-SPROCKET-DRIVE EA - R DWG M-5 BELT - TIMING 5MM POWERGRIP (Y AXIS) EA R PS 06 COVER-SPORT 40 DEGREE EA B R DWG 567- DIAL HOLDER EA G R DWG 586 DIAL NUT EA A R DWG WASHER-TAB EA A R DWG HANDWHEEL ASSY WITH FOLD-AWAY HANDLE EA E R PL 6 / 66Z WASHER-FLAT-NARROW-ANSI TYPE B EA - R PS 7 / 75Z WASHER-EXT TOOTH-STL-ZINC EA R PS 8 /-0 5Z NUT-HEX JAM-STL-ZINC EA R PS 9 0-X/4 5B SCREW-SHCS-STL-BO EA R PS 0 /8-6X / 5B SCREW-SHCS-STL-BO 4 EA R PS 08 WASHER-.75X.94X.0-STL 4 EA - R DWG /4-0X 4B SCREW-HEX HD-STL-BO 4 EA R PS SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

101 Parts List for Assembly P/N: 08- DRIVE KIT-PT4-Y AXIS 08- Rev J Printed /5/04 Item P/N Title Detail Qty UseAs Rev Stat Type Mfr Mfr P/N 5759 WASHER-/4 HARD BLK OX /8 THK 4 EA - R DWG 4 6-X/8 0B SCREW-PH-PHIL-STL-BO 8 EA R PS 5 4 SHEET METAL ASSY-MOTOR COVER-COOLANT EA - R PL 6 0-X 5B SCREW-SHCS-STL-BO EA R PS 7 0 7B WASHER-SPLIT LOCK-STL-BO EA R PS A090 KEY WOODRUFF #404-/8 X / EA R PS 477- SPACER -.00" THICK EA B R DWG 0 SPACER Y-AXIS- BALLSCREW EA R DWG /4-0X/8 0B SCREW-PH-PHIL-STL-BO EA 0 R PS B WASHER-FLAT USS-STL-BO EA R PS SPACER-CNC X AXIS HANDLE.00" THICK EA B R DWG SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

102 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTH- WESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CON- SENT OF SOUTHWESTERN INDUSTRIES. REVISIONS REV DESCRIPTION ECN DATE APPRV - ORIGINAL RELEASE LG A ADDED: ITEMS 0 & 7. DELETED NOTES &. 45 7/7/4 LG 7 X ( ) X X X X 4 NOTES: (UNLESS OTHERWISE SPECIFIED).. REFER TO 800- FOR INSTALLATION INSTRUCTIONS. DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH DRAWN BY ENGINEER CHECKER FE APPROVALS SAL DATE NC 8//0 NC THIRD ANGLE PROJECTION TITLE 5/8/0 BRACKET ASSY-BP SER I Z 7/7/4 SIZE CODE IDENT. NO. DWG NO. REV B 068 SCALE: SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA AXIS-SWI GS 4.6 lbm 809- SHEET OF A

103 Parts List for Assembly P/N: 809- Printed 7/7/ BRACKET ASSY-BP SER I Z AXIS-SWI GS REPLACES 808-, BP SER I Type Revision Status PL A R Dwg Size Product Engineer B PT4 SPG Date 5/7/0 Planner Code By NC Comm Code SCALES Item P/N Title Detail Qty UseAs Rev Stat Type Mfr Mfr P/N 809- BLOCK-UPPER MOUNT-GLASS SCALE-BP EA - R DWG 809- BLOCK-LOWER MOUNT-GLASS SCALE-BP EA - R DWG BLOCK-READER HEAD-GLASS SCALE-BP EA - R DWG ADAPTER-Z-AXIS GLASS SCALE EA B R DWG ADAPTER-Z-AXIS GLASS SCALE-LARGE EA A R DWG 0-X /4 5B SCREW-SHCS-STL-BO EA R PS 4 6-X/ 40B SCREW-SOC SET-STL-BO-CUP 4 EA - R PS 5 M5-0.8X5 5B SCREW-SHCS-STL-BO EA A R PS 6 /4-8X/8 5B SCREW-SHCS-STL-BO EA R PS 7 0-X/4 5B SCREW-SHCS-STL-BO EA R PS 6 /6X/ 8B SPRING PIN EA R PS WASHER - BELLEVILLE SPRING LOCK 0 OR M5 - SERRATED EA - R PS M5 70B WASHER-FLAT USS-STL-BO EA R PS SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

104 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTH- WESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CON- SENT OF SOUTHWESTERN INDUSTRIES. REVISIONS REV DESCRIPTION ECN DATE APPRV - ORIGINAL RELEASE NC A REVISED (M5 WASHER)X LOCATIONS 47 0/8/ NC B REVISED: ITEM QTY 4 WAS: & NOTE /07/4 LG C ADDED NOTE. ITEM 7 WAS: 0 70B. 448 //5 LG 7 5 X 5 0 X (Z AXIS GLASS SCALE) (M5 WASHER) X (PART OF HEAD) X X X NOTES: (UNLESS OTHERWISE SPECIFIED).. REFER TO ES-58 FOR INSTALLATION INSTRUCTIONS. M5-0.8x0mm SHCS HARDWARE COMES WITH EASSON GLASS SCALE KIT. FOR PARTS LIST SEE SEPARATE "A" SIZE SHEET UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES. TOLERANCES: DECIMALS.X = ±..XX = ±.0.XXX = ±.005 ANGLES ±0 0' MATERIAL FINISH - - FRACTIONS ±/64 5 RMS DRAWN BY CHECKER APPROVAL APPROVAL APPROVALS NC DATE 6.5. SAL 7/07/4 TITLE SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SIZE CODE IDENT. NO. DWG NO. REV C 068 : SCALE: BRACKET ASSY-Z AXIS EASSON GLASS SCALE SHEET OF C

105 Parts List for Assembly P/N: Printed // BRACKET ASSY-Z AXIS-EASSON GLASS SCALE Type Revision PL C Dwg Size Product C PT4 Status R Engineer JW Date 7/6/0 Planner Code 0 By NC Comm Code MANUF Item P/N Title Detail Qty UseAs Rev Stat Type Mfr Mfr P/N 0550 PLATE-MOUNTING-Z-AXIS ARM EA F R DWG 055- MOUNTING PLATE- Z AXIS GLASS SCALE EA - R DWG 0548 ADAPTER-Z-AXIS GLASS SCALE-Ø.57 EA B R DWG ADAPTER PLATE- Z AXIS GLASS SCALE EA - R DWG 5 0-X/4 5B SCREW-SHCS-STL-BO 4 EA R PS 6 0-X /4 5B SCREW-SHCS-STL-BO 5 EA R PS 7 M5 70B WASHER-FLAT USS-STL-BO EA R PS 8 /6X/ 8B SPRING PIN EA R PS 9 /4-8X/8 5B SCREW-SHCS-STL-BO EA R PS 0 M5-0.8X0 5B SCREW-SHCS-STL-BO NON STOCKABLE () EA - R PS WASHER - BELLEVILLE SPRING LOCK 0 OR M5 - SERRATED 4 EA - R PS SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

106 8 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTH- WESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CON- SENT OF SOUTHWESTERN INDUSTRIES ZONE REVISIONS REV DESCRIPTION ECN DATE APPRV - ORIGINAL RELEASE JG A ADD ITEMS 4 & 4 84 JG B ADD SHIM JG C UPDATE ITEM IN DWG JG D D 45 SWI LOGO XX MOTOR ASSY-USA 785 MOTOR ASSY-EURO C C 4X X B B X 8 X A NOTES: (UNLESS OTHERWISE SPECIFIED). COVER 4 NOT SHOWN. REFER TO HARDWARE KIT DWG 608-XX TO IDENTIFY A PARTS MARKED WITH ITEM NUMBERS: ETC. SEE DWG 4468 FOR HOW TO REWORK QUILL FOR ITEM 44/ NEXT ASSY APPLICATION Z AXIS USED ON DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH - - APPROVALS DRAWN BY ENGINEER MFE FE JRS JG DATE THIRD ANGLE PROJECTION TITLE SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SIZE CODE IDENT. NO. DWG NO. REV D 068 : SCALE: DRIVE KIT - Z AXIS 5000-XX SHEET OF C

107 Parts List for Assembly P/N: 608- Printed /0/ HARDWARE KIT MX Z-AXIS-BP Type Revision PL F Dwg Size Product C PT4 Status R Engineer MZ REV ECN DATE SIGN A 04 8/5/9 SPG B 047 /0/9 FM C 0479 /6/94 SPG D /4/94 SPG E //94 SPG F JG Date By 4/7/99 FM Part Type Comm Code MANUF Item P/N Title Detail Mfr Mfr P/N UseAs Qty 65 BRACKET BALLNUT-MACHINED (FORK) EA SCREW /8-4 BRKT BALLNUT MOUNTING EA 9 60 POSITIONER LOCATOR EA 6- COUPLING SOCKET HEAD EA 6- JACKSCREW NUT /---/- EA 7 64 NUT LEVELING /4-6 EA 8 66 SCREW HEX HD EA A06 WASHER-FINISHED FLAT-CASE HARDENED STL EA 0 /4-6 5Z NUT-HEX JAM-STL-ZINC-GRADE EA 49 WASHER-LOWER BOLT EA WASHER-/4 HARD BLK OX /8 THK EA 4 8 /4-0 56Z NUT-NYLON LOCK-STL-ZINC EA 0 /-X / 5B SCREW-SHCS-STL-BO PJ EA /4-0X /4 5B SCREW-SHCS-STL-BO EA /4-0X/4 5B SCREW-SHCS-STL-BO EA 4 /4-0X/8 40B SCREW-SOC SET-STL-BO-CUP EA 5 /8-6 50B NUT-HEX-STL-BO EA 6 /8 70P WASHER-FLAT USS-STL-BO EA 7 /8 7B WASHER-SPLIT LOCK-STL-BO EA SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

108 Parts List for Assembly P/N: 608- HARDWARE KIT MX Z-AXIS-BP 608- Rev F Printed /0/005 Item P/N Title Detail Mfr Mfr P/N UseAs Qty 4 /4-0X /4 5B SCREW-SHCS-STL-BO EA 4 SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

109 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTH- WESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CON- SENT OF SOUTHWESTERN INDUSTRIES. X X 4 REVISIONS REV DESCRIPTION ECN DATE APPRV C ADDED NOTE 09 5//06 JG D ADDED ITEM 0 &, CABLE CLAMP & M6 70B WASHER 09 //07 TM E ADDED NOTE 4 & 5. REVISED PICTORIAL /9/7 LG D 6 D X X 8 Z+ C 0 C 5 Z- 6 4X 5 4X B 8X 7 B NOTES: (UNLESS OTHERWISE SPECIFIED). SHIM (ITEM 9) OPTIONAL. A CABLE CLAMP GOES AROUD TOP WIRE ONLY A SEE PAGE FOR WASHER AND CLAMP PICTURES FOR PART LIST SEE SEPARATE "A" SIZE SHEET 4 ON KMX: THIS CABLE IS REQUIRED ONLY IF A CABLE BREAKOUT BOX IS PRESENT. 5 CONNECT TO CABLE BREAKOUT BOX ON SMX & Z AXIS SCALE PORT ON KMX PENDANT DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH - - APPROVALS DRAWN BY ENGINEER CHECKER FE JRS JG DATE THIRD ANGLE PROJECTION TITLE SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SIZE CODE IDENT. NO. DWG NO. REV D 068 : SCALE: Z AXIS BALL SCREW - BASEPLATE, BEARING HOUSING & COVERS ASSY 40-XX SHEET OF E

110 NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTH- WESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CON- SENT OF SOUTHWESTERN INDUSTRIES. REVISIONS REV DESCRIPTION ECN DATE APPRV C ADDED NOTE 09 5//06 JG D ADDED ITEM 0 &, CABLE CLAMP & M6 70B WASHER 09 //07 TM E ADDED NOTE 4 & 5. REVISED PICTORIAL /9/7 LG D D C C B B A A DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH - - APPROVALS DRAWN BY ENGINEER CHECKER FE JRS JG DATE THIRD ANGLE PROJECTION TITLE SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SIZE CODE IDENT. NO. DWG NO. REV D 068 : SCALE: Z AXIS BALL SCREW - BASEPLATE, BEARING HOUSING & COVERS ASSY 40-XX SHEET OF E

111 Parts List for Assembly P/N: 40-6 Printed 6/9/ Z AXIS BALLSCREW-BASEPLATE-BEARING HOUSING & COVERS ASSY Type Revision Status PL A R Dwg Size Product Engineer D Z AXIS LG REV ECN DFT ENG DATE A 4655 Sal LG 06/8/7 Date By 4//07 LG Planner Code Comm Code Item P/N Title Detail Qty UseAs Rev Stat Type Mfr Mfr P/N 47 BRACKET-SERVO MOTOR EA - R DWG 4 COVER - FRONT EA A R DWG 4 COVER-LATERAL EA A R DWG BASE PLATE ASSY EA B R PL BALLSCREW MODULE Z-AXIS EA B R PL ELEC HANDWHEEL ASSY-Z AXIS-DPMV EA K R PL M-5 BELT-TIMING EA R PS CABLE ASSY-ADAPTOR TO COMP EA C R PL LIMIT SWITCH ASSY-Z AXIS-KMX EA A R PL 0 5/6-8X /4 5B SCREW-SHCS-STL-BO EA - R PS 0-X/8 B SCREW-PH-PHIL-EXT SEMS-STL-BO 8 EA - R PS 4 BRACKET-LIMIT SWITCH EA - R DWG K PLUG-BLK EA - R PS 5 0-X/ 5B SCREW-SHCS-STL-BO 4 EA - R PS B WASHER-FLAT USS-STL-BO 4 EA A R PS 7 60 PLATE CENTERING EA R DWG 8 /4-0X 5B SCREW-SHCS-STL-BO EA A R PS CABLE CLAMP-NYLON-/4" EA - R DWG M6 70B WASHER-FLAT USS-STL-BO EA - R PS 987 CABLE ASSY-6 COND-ADAPTOR-DB5 TO DB9 EA A R PL SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

112 D NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTH- WESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CON- SENT OF SOUTHWESTERN INDUSTRIES. REVISIONS REV DESCRIPTION ECN DATE APPRV - ORIGINAL RELEASE LG A ADD ITEM :89-DOC LG B ADD ASS'Y NOTES, SHTS & JE C CHG ITEM : 987 WAS LG D CHG QTY ITEM : WAS. ADD NOTE LG E ADD ITEM -0 IN BOM.0.07 LG F ADDED ITEMS, TO BOM. ADDED NOTE LG G EXTENSIVELY REVISED. FOR PREVIOUS CONDITION SEE REV F LT H ITEM 0 QTY (6) WAS: LG D C 7 M0x0 (4X) REF 4 EXISTING 9 EXISTING END CAP 8 M0x0 (4X) BALL BEARING - REUSE SPACERS DIAL HOLDER FIBER SPACER VERNIER DIAL DIAL NUT C 0 X REF ELECTRONIC HANDWHEEL OPTION KNEE MILL X - AXIS REMOVE 6 7 B NOTES: UNLESS OTHERWISE SPECIFIED. RECORD ROLLING TORQUE PLCS BEFORE DISASSEMBLING.. ALIGN RIGHT SIDE OF TABLE WITH SADDLE. STANDARD KNEE MILL X - AXIS ALL PARTS TO BE REMOVED FOR INSTALLATION OF ELECTRONIC HANDWHEEL OPTION EXCEPT BALL BEARING. B. REMOVE PARTS PER DRAWING. 4 INSTALL PARTS PER DRAWING. 5. ALIGN BRACKET TO MAINTAIN SAME TORQUE. 6 RETURN TO STOCK: 566 (HANDWHEEL ASSY), 5057 (SHAFT EXTENSION). (C) 7 RETURN TO BINS: 654 (DIAL HOLDER), 586 (DIAL NUT), 65 (VERNIER DIAL). (B) 8 RETURN TO DPMS BIN FOR REUSE ON DPMS. (C) A 9 ON K USE BUSHING 987 (ITEM ) ON X AND Y. ON K AND K4 USE BUSHING 99- (ITEM ) ON X AND BUSHING 987 (ITEM ) ON Y. (C5, C7) A 0. APPLY LABELS (ITEM & ) TO HANDWHEEL (ITEM ) ON CABLE AT THE CONNECTOR END. 8 (SEE SHEET FOR ADDITIONAL NOTES) (ITEM ) IS PART OF BALLSCREW EXTENSION KIT FOR PARTS LIST SEE SEPARATE "A" SIZE SHEET DIMENSIONS ARE IN MILLIMETERS -4 ±0.00, 4-6 ±0.05, 6-6 ±0.050, 6-50 ±0.070, ±0.00, ±0.00 REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONS PER ASME Y4.5 MATERIAL FINISH DRAWN BY ENGINEER MFE FE APPROVALS JJ LG DATE TITLE SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SIZE CODE IDENT. NO. DWG NO. REV D 068 : SCALE: ELECTRONIC HANDWHEEL- KIT-KNEE MILL-X & Y AXIS 89 H SHEET OF

113 D D 5 X X 9 4 C C 0 X REF ALL PARTS TO BE REMOVED FOR INSTALLATION OF ELECTRONIC HANDWHEEL OPTION ELECTRONIC HANDWHEEL OPT KNEE MILL Y - AXIS B B STANDARD KNEE MILL Y - AXIS A. INSTALL OPTION PER DRAWING. A RETURN TO STOCK: 566 (HANDWHEEL ASSY). (C4) RETURN TO BIN:65 (VERNIER DIAL), 567- (DIAL HOLDER), & 586 (DIAL NUT). (C4) FOR PARTS LIST SEE SEPARATE "A" SIZE SHEET DIMENSIONS ARE IN MILLIMETERS -4 ±0.00, 4-6 ±0.05, 6-6 ±0.050, 6-50 ±0.070, ±0.00, ±0.00 REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONS PER ASME Y4.5 MATERIAL FINISH DRAWN BY ENGINEER MFE FE APPROVALS JJ LG DATE TITLE SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SIZE CODE IDENT. NO. DWG NO. REV D 068 : SCALE: ELECTRONIC HANDWHEEL- KIT-KNEE MILL-X & Y AXIS 89 H SHEET OF

114 Parts List for Assembly P/N: 89 Printed 4/0/07 89 ELECTRONIC HANDWHEEL KIT-KNEE MILL-X & Y AXIS Type Revision Status PL H R Dwg Size Product Engineer D K-MILL LG Date /0/004 Planner Code By JJ Comm Code Item P/N Title Detail Qty UseAs Rev Stat Type Mfr 946 ELEC HANDWHEEL-X & Y AXIS EA K R PL 99- BUSHING - BALL SCREW.5 LG. EA C R DWG 987 BUSHING-Y-AXIS EA B R DWG SPACER-CNC X AXIS HANDLE.00" THICK EA B R DWG BRACKET - WAY COVER FRONT Y-AXIS DRIVE EA F R DWG SPACER ANGLED 0 DEGREE Y-AXIS EA E R PL 7 78 SPACER 45 - MACHINED EA C R DWG 8 /4-0X5/8 6B SCREW-FHCS-STL-BO EA R PS 9 M6-.0X5 5B SCREW-SHCS-STL-BO 4 EA A R PS 0 M6-.0X75 5B SCREW-SHCS-STL-BO (6) EA - R PS BUSHING () EA L R DWG 89-DOC ELECTRONIC HANDWHEEL KIT - KNEE MILL EA - R DOC 566 HANDWHEEL ASSY w/ FOLD-AWAY HANDLE - EA E R PL WASHER-TAB - EA A R DWG END CAP-X AXIS FC006 - EA A R DWG FRU-DPM-DIAL HOLDER DPM X-AXIS - EA R DWG DIAL HOLDER - EA G R DWG 8 65 VERNIER DIAL - EA - R DWG PJ DIAL NUT - EA A R DWG EXTENSION-SHAFT - EA G R DWG LABEL-TEXT-WHITE-.00W x.47h EHW X EA AD R DWG SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

115 Parts List for Assembly P/N: 89 ELECTRONIC HANDWHEEL KIT-KNEE MILL-X & Y AXIS 89 Rev H Printed 4/0/07 Item P/N Title Detail Qty UseAs Rev Stat Type Mfr LABEL-TEXT-WHITE-.00W x.47h EHW Y EA AD R DWG SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE, RANCHO DOMINGUEZ, CA Fax Page of

116 D OUT IN MUFFLER IS ON THE RIGHT SIDE OF MACHINE USE POWER DRAWBAR CHECKING TOOL TO VERIFY THAT THE DRAWBAR SHOULDER HEIGHT IS BETWEEN.050 &.075 LOWER THAN BEARING HOUSING OR WASHER (ITEM,,) REVISIONS REV DESCRIPTION ECN DATE APPRV E ADDED: SHT -, NOTES -4, ITEMS,,,4,5,,4,7,0. ITEM 0 & 0 WAS: ITEMS 7 & 6. DELETED ITEM 8 WAS: /4 7B QTY LG F ITEM WAS: 6987; ITEM WAS: LG NOTE WAS: WASHERS (ITEMS & )MAY BE SWAPPED IN G ORDER TO OBTAIN THE REQUIRED SHOULDER HEIGHT //7 PM ADDED ITEM. D X X 0 X C C 6.5 X X 6X B B REF BEARING HOUSING 5 (4X) 4 (X) 7 (4X) PART OF ITEM NOTES: (UNLESS OTHERWISE SPECIFIED). A ADD WASHERS / SHIMS (ITEMS, & ) AS REQUIRED IN ORDER TO OBTAIN PROPER SPACING OF.050" TO.075" GAP BETWEEN BOTTOM OF POWER DRAWBAR / AIR GUN AND TOP OF SHOULDER ON POWER DRAWBAR WHEN QUILL IS FULLY RETRACTED, USING CHECKING TOOL TO MEASURE. THIS PROVIDES 7/6" OF ENGAGEMENT OF DRAWBAR. ADJUST OILER (PART OF ITEM ) TO FEED ONE DROP OF OIL EVERY ACTIVATIONS. TO PRIME THE OILER TURN ON THE AIR, FILL OILER / FULL AND PRESS THE IN OR OUT BUTTON ON POWER DRAWBAR CONTROLLER 40 TO 60 TIMES AND TURN KNOB UNTIL DROP OF OIL DROPS INSIDE OILER. USE SOLENOID BRACKET (PART OF ITEM 4) AS TEMPLATE TAPPING TWO M6- HOLES, MOUNT AIR REGULATOR (ITEM 4) USING HARDWARE (M6-x5 SHCS) PROVIDED WITH AIR REGULATOR. 4. NOSEPIECE 58-4 (PART OF ITEM ) IS TO BE RECYCLED (X) (X) PART OF ITEM DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH APPROVALS DRAWN BY ENGINEER MFE FE CJC LG DATE 0/0/5 THIRD ANGLE PROJECTION SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SIZE CODE IDENT. NO. DWG NO. REV D SCALE: NOTICE: THIS DESIGN WAS ORIGINATED BY AND EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OWNED BY SOUTH- WESTERN INDUSTRIES. IT IS DISCLOSED IN CONFIDENCE FOR A SPECIFIC PURPOSE AND THE RECIPIENT HEREOF AGREES NOT TO MAKE ANY REPRODUCTION, DISCLOSURE OR OTHER USE OF THIS INFORMATION WITHOUT THE WRITTEN CON- SENT OF SOUTHWESTERN INDUSTRIES. POWER DRAWBAR OPTION- K,K-R G SHEET OF A

117 IN TO UNIT OUT TO UNIT D D POWER DRAWBAR AIR FLOW DIAGRAM C Left Side of Head C IN TO UNIT OUT TO UNIT AIR LINE TO OILER B AIR LINE TO OILER B A Left Rear of Ram A DIMENSIONS ARE IN INCHES DEC..X = ±.,.XX = ±.0,.XXX = ±.005, ANGLES.XX = ±0 0' FRACTIONS = ±/8 FINISH = 5 RMS REMOVE ALL SHARP EDGES MASK ALL TAPPED HOLES DIMENSIONING PER ASME Y4.5 MATERIAL FINISH APPROVALS DRAWN BY ENGINEER MFE FE CJC LG DATE 0/0/5 THIRD ANGLE PROJECTION SOUTHWESTERN INDUSTRIES, INC. 65 HOMESTEAD PLACE RANCHO DOMINGUEZ, CA SIZE CODE IDENT. NO. DWG NO. REV D SCALE: POWER DRAWBAR OPTION- K,K-R G SHEET OF