Trak Machine Tools ProtoTRAK SMX K2 Guide

ProtoTRAK®SMX
K2, K3, K4 & Retrofit
Safety, Installation, Maintenance, Service & Parts List Manual
Document: P/N 24319
Version: 082718
2615 Homestead Place
Rancho Dominguez, CA 90220-5610 USA
T | 310.608.4422 |F | 310.764.2668
Service Department: 800.367.3165
e-mail: [email protected]m | [email protected]om | web:
www.trakmt.com

Copyright 2018, Southwestern Industries, Inc. All rights are reserved. No part of this publication may be reproduced,
stored in a retrieval system, or transmitted, in any form or by any means, mechanical, photocopying, recording or
otherwise, without the prior written permission of Southwestern Industries, Inc.
While every effort has been made to include all the information required for the purposes of this guide, Southwestern
Industries, Inc. assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from
the use of the information contained in this guide.
All brand names and products are trademarks or registered trademarks of their respective holders.

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Table of Contents
1.0 Safety................................................................................................................................................................ 1
1.1 Safety Publications.......................................................................................................................................... 1
1.2 Danger, Warning, Caution, and Note Labels & Notices As Used In This Manual................................................... 1
1.3 Safety Precautions .......................................................................................................................................... 4
2.0 Installation ....................................................................................................................................................... 6
2.1 Floor Plan, Layout & Space Requirements –K2, K3 & K4 ................................................................................... 6
2.2 Uncrating ....................................................................................................................................................... 8
2.3 Shortages: Inventory Checklist ....................................................................................................................... 8
2.4 Installation Instructions & Checklist.................................................................................................................. 9
2.5 Machine Specifications .................................................................................................................................. 10
2.6 Maximum Work Capacities............................................................................................................................. 10
2.7 ProtoTRAK SMX Control Hardware .................................................................................................................. 11
2.8 Lifting and/or Moving the Machine ................................................................................................................. 14
2.9 Cleaning ....................................................................................................................................................... 16
2.10 Leveling: Leveling Tolerance is .0005”/10”................................................................................................... 16
2.11 Electrical Connection ................................................................................................................................... 18
2.11.1 Phase Converters .................................................................................................................................. 21
2.11.2 Flange Disconnect/Transformer (Optional) .............................................................................................. 21
2.12 Air Connection - Optional ............................................................................................................................. 25
2.13 Mounting the Display Pendant ..................................................................................................................... 26
2.14 Cable Interconnections ............................................................................................................................... 26
2.15 Lubrication ................................................................................................................................................. 33
2.15.1 Manual Lubrication............................................................................................................................... 33
2.15.2 Head Lubrication.................................................................................................................................. 35
2.16 ProtoTRAK SMX Euclid Block Procedure........................................................................................................ 36
3.0 Troubleshooting by Symptom ........................................................................................................................... 38
3.1 Problems Relating to Machining Results ......................................................................................................... 38
3.1.1 Poor Finish.............................................................................................................................................. 38
3.1.2 Circles Out of Round ............................................................................................................................... 38
3.1.3 Taper Cut on a Programmed Straight Line Move ....................................................................................... 39
3.1.4 Parts Have Incorrect Dimensions.............................................................................................................. 40
3.2 Problems Regarding the Motion of the Machine ............................................................................................... 41
3.2.1 Run Away Axis ....................................................................................................................................... 41
3.2.2 Slow Down Axis ..................................................................................................................................... 41
3.2.3 Axis Will Not Jog..................................................................................................................................... 42

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
3.2.4 Axis Motor Motion Is Not Smooth............................................................................................................. 42
3.2.5 Vibration in Motion .................................................................................................................................. 43
3.2.6 Searching Axis ........................................................................................................................................ 43
3.3 Problems Relating to the Operation of the Control .......................................................................................... 44
3.3.1 Display Blanks........................................................................................................................................ 44
3.3.2 Bad Picture on the Display ...................................................................................................................... 44
3.3.3 Keyboard Lockup ................................................................................................................................... 44
3.3.4 Fault X or Y ........................................................................................................................................... 44
3.3.5 Problems Reading the Floppy Disk; Programs Not Saved Properly .............................................................. 45
3.3.6 System Will Not Turn On or Boot-Up ........................................................................................................ 45
3.3.7 System Reboots by Itself ......................................................................................................................... 46
3.3.8 System Shuts Off .................................................................................................................................... 46
3.3.9 Will Not Hold Calibration......................................................................................................................... 46
3.3.10 Auxiliary Functions Not Working (Option on 3 Axis Machines Only) .......................................................... 47
3.3.11 E-Stop Error ......................................................................................................................................... 47
3.3.12 Limit Switch Error - Optional.................................................................................................................. 48
3.4 Problem with the Measurements .................................................................................................................... 48
3.4.1 X, Y and Z-Axis Measurements Do Not Repeat .......................................................................................... 48
3.4.2 X, Y, and Z-Axis Measurements Are Not Accurate ...................................................................................... 50
3.4.3 The DRO Is Not Counting ....................................................................................................................... 50
3.4.4 X, Y, and Z-Axis DRO Counting in Wrong Direction .................................................................................... 50
3.4.5 X, Y, & Z-Axis Electric Handwheels Count in Wrong Direction ..................................................................... 50
3.5 Problems with the Machine Tool .................................................................................................................... 51
3.5.1 Spindle Stalls or Turns-Off During Machining ........................................................................................... 51
3.5.2 Spindle Motor Hums or Will Not Run........................................................................................................ 51
3.5.3 Spindle Runs Backwards ......................................................................................................................... 53
3.5.4 Head Noise ............................................................................................................................................. 53
4.0 Diagnostics ..................................................................................................................................................... 55
4.1 The Machine Tool & Set-Up .......................................................................................................................... 55
4.1.1 The Milling Machine Checklist.................................................................................................................. 55
4.1.2 A Special Word About X & Y Gibs ............................................................................................................ 55
4.1.3 Lubrication............................................................................................................................................. 56
4.1.4 Machining Set-Up ................................................................................................................................... 56
4.2 The Mechanical Drive Train (X, Y) ................................................................................................................. 57
4.2.1 Keys to Ball Screw Alignment ................................................................................................................ 58
4.3 Computer/Pendant Diagnostics ...................................................................................................................... 58
4.4 Motor Diagnostics ......................................................................................................................................... 59
4.4.1 Cable Connections................................................................................................................................... 60

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
4.4.2 To Check the Motor Encoders .................................................................................................................. 60
4.4.3 Encoder Counts to Pendant...................................................................................................................... 60
4.4.4 Moving Problem from One Axis to Another................................................................................................ 60
4.5 Servo Driver................................................................................................................................................. 60
4.6 Glass Scales.................................................................................................................................................. 61
4.6.1 Alignment of scales ................................................................................................................................. 61
4.6.2 Measurements Do Not Repeat.................................................................................................................. 61
4.7 TRAK Sensors ............................................................................................................................................... 62
4.7.1 Faulting Axis.......................................................................................................................................... 62
4.7.2 Measurements Do Not Repeat.................................................................................................................. 62
4.8 Electrical ...................................................................................................................................................... 63
4.8.1 Checking A/C Voltage .............................................................................................................................. 63
4.8.2 Checking Fuses....................................................................................................................................... 63
4.8.3 Cable Breakout Box Connections.............................................................................................................. 64
4.8.4 Cable Connections .................................................................................................................................. 64
4.9 Service Codes ............................................................................................................................................... 68
4.9.1 Software Codes ...................................................................................................................................... 69
4.9.2 Machine Set-up Codes............................................................................................................................. 70
4.9.3 Diagnostic Codes. ................................................................................................................................... 72
4.9.4 Operator Defaults/Options Codes............................................................................................................. 73
5.0 Procedures for Replacements & Maintenance ..................................................................................................... 74
5.1 Replacements .............................................................................................................................................. 74
5.1.1 Servo Motor Replacement........................................................................................................................ 74
5.1.2 Servo Driver Replacement........................................................................................................................ 74
5.1.3 Computer Module and LCD/Enclosure Replacement................................................................................... 75
5.1.4 System Flash Disk Replacement............................................................................................................... 77
5.1.5 Cable Routing on Machine ....................................................................................................................... 79
5.1.6 TRAK Sensor .......................................................................................................................................... 79
5.1.7 Glass Scale Replacement......................................................................................................................... 82
5.1.8 Power Drawbar....................................................................................................................................... 86
5.1.9 Ball Screw Replacement, X-Axis (Table) ................................................................................................... 88
5.1.10 Ball Screw Replacement, Y-Axis (Saddle) ................................................................................................ 91
5.1.11 Air Solenoid Replacement –Auxiliary Function Machines Only.................................................................. 94
5.1.12 Spindle Motor Wiring............................................................................................................................. 94
5.1.13 Feed Trip Adjustment (not applicable to 3 axis controls).......................................................................... 95
5.1.14 Quill Clock Spring Replacement and Adjustment ...................................................................................... 95
5.1.15 Spindle Motor Removal and Replacement ............................................................................................... 96
5.1.16 Drive Belt Replacement ......................................................................................................................... 97

iv
TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
5.1.17 Timing Belt Replacement....................................................................................................................... 98
5.1.18 Brake Shoe Replacement....................................................................................................................... 98
5.1.19 Spindle Replacement............................................................................................................................. 99
5.2 Maintenance ............................................................................................................................................... 100
5.2.1 Gib Adjustments ................................................................................................................................... 100
5.2.2 Calibration & Backlash Constants ........................................................................................................... 103
5.2.3 Head Rotational and Tramming.............................................................................................................. 105
5.2.4 Limit Switch Option ............................................................................................................................... 107
6.0 Retrofit Installation......................................................................................................................................... 109
6.1 Installation Tools and Hardware................................................................................................................... 109
6.2 Required Tools/Hardware ........................................................................................................................... 109
6.3 Suggested Fastener Stock............................................................................................................................ 110
7.0 Installation Procedures ................................................................................................................................... 111
7.1 X and Y Ball Screw Installation..................................................................................................................... 111
7.1.1 Removing the Table and Leadscrews...................................................................................................... 111
7.1.2 X-Axis Ball Screw Installation - Part 1.................................................................................................... 113
7.1.3 Y-Axis Ball Screw Installation ................................................................................................................ 115
7.1.4 X-Axis Ball Screw Installation - Part 2 ..................................................................................................... 120
7.2 Motor/Servo Driver Installation .................................................................................................................... 124
7.2.1 X-Axis Motor/Servo Driver Installation.................................................................................................. 124
7.2.2 Y-Axis Motor and Servo Driver Installation.............................................................................................. 125
7.3 Pendant Installation..................................................................................................................................... 126
7.3.1 Pendant Arm Installation ....................................................................................................................... 126
7.3.2 Installation of the Pendant Display......................................................................................................... 127
7.4 Cable Breakout Box Mounting ...................................................................................................................... 128
7.5 Z-Axis Glass Scale Installation...................................................................................................................... 128
7.6 TRAK Sensor Installation - Optional.............................................................................................................. 130
7.6.1 X and Y Axis Sensor .............................................................................................................................. 130
7.7 X and Y Glass Scale Installation - Optional .................................................................................................... 133
7.7.1 X Axis Scale Installation......................................................................................................................... 133
7.7.2 Y Axis Scale Installation......................................................................................................................... 134
7.8 Limit Switch Installation .............................................................................................................................. 136
7.9 System Interconnection ............................................................................................................................... 138
7.9.1 ProtoTRAK SMX Basic System Configuration............................................................................................ 138
7.9.2 Cable Routing ....................................................................................................................................... 138
8.0 Z Motor/Ball Screw Assembly .......................................................................................................................... 139
8.1 Installation of the Base Plate ....................................................................................................................... 139
8.2 Installation of the Ball Screw ....................................................................................................................... 142

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
8.3 Installation of the Motor and Remaining Components.................................................................................... 142
8.4 Lagun Z Axis Cutout .................................................................................................................................... 148
9.0 Introduction to Self-Service............................................................................................................................. 149
9.1 When You Have a Service Problem ............................................................................................................... 149
9.1.1 Communication with the SWI Customer Service Group ............................................................................ 149
9.2 Replacements.......................................................................................................................................... 150
9.2.1 Exchange Program ................................................................................................................................ 150
10.0 Figures and Parts Lists.................................................................................................................................. 151
TRAK Warranty Policy............................................................................................................................................ 211

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
1.0 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 SMX 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 1910.212 - Milling Machine.
1.1 Safety Publications
Refer to and study the following publications for assistance in enhancing the safe use of this machine.
Safety Requirements for Manual Milling, Drilling and Boring Machines with or without Automatic Control
(ANSI B11.8-2001). Available from The American National Standards Institute, 1819 L Street N.W., Washington D.C.
20036
Concepts And Techniques Of Machine Safeguarding (OSHA Publication Number 3067). Available from The
Publication Office - O.S.H.A., U.S. Department of Labor, 200 Constitution Avenue, NW, Washington, DC 0210.
1.2 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.

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
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

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
Safety & Information Labels Used On The
TRAK K2, K3 & K4 Milling Machines
It is forbidden by OSHA regulations and by law to deface, destroy or remove any of these labels
Power Requirements at 220 and 440 Volts, 3-phase 60 Hz
SMX K2/K3
SMX K4
Vari-speed Head
Spindle Control
Vari-speed Head
Spindle Control
Overload Setting
220 V
8.5 A
11 A
14 A
17.5 A
Overload Setting
440 V
4.25 A
N/A
7 A
N/A
FLA of Largest Motor
at 220 V
8.5 A
11 A
14 A
17.5 A
FLA of Largest Motor
at 440 V
4.25 A
N/A
7 A
N/A
FLA of Machine at
220 V
8.5 A
11 A
14 A
17.5 A
FLA of Machine at
440 V
4.25 A
N/A
7 A
N/A

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
1.3 Safety Precautions
1. Do not operate this machine before the TRAK K Mill Installation, Maintenance, Service and Parts List Manual,
and ProtoTRAK SMX Programming, Operating & Care Manual have been studied and understood.
2. Do not run this machine without knowing the function of every control key, button, knob, or handle. Ask your
supervisor or a qualified instructor for help when needed.
3. Protect your eyes. Wear approved safety glasses (with side shields) at all times.
4. Don't get caught in moving parts. Before operating this machine remove all jewelry including watches and rings,
neckties, and any loose-fitting clothing.
5. Keep your hair away from moving parts. Wear adequate safety headgear.
6. Protect your feet. Wear safety shoes with oil-resistant, anti-skid soles, and steel toes.
7. Take off gloves before you start the machine. Gloves are easily caught in moving parts.
8. Remove all tools (wrenches, chuck keys, etc.) from the machine before you start. Loose items can become
dangerous flying projectiles.
9. Never operate a milling machine after consuming alcoholic beverages, or taking strong medication, or while
using non-prescription drugs.
10. Protect your hands. Stop the machine spindle and ensure that the CNC control is in the stop mode:
Before changing tools
Before changing parts
Before you clear away the chips, oil or coolant. Always use a chip scraper or brush
Before you make an adjustment to the part, fixture, coolant nozzle or take measurements
Before you open safeguards (protective shields, etc.). Never reach for the part, tool, or fixture around a
safeguard.
11. Protect your eyes and the machine as well. Don't use compressed air to remove the chips or clean the machine.
12. Disconnect power to the machine before you change belts, pulley, and gears.
13. Keep work areas well lighted. Ask for additional light if needed.
14. Do not lean on the machine while it is running.
15. Prevent slippage. Keep the work area dry and clean. Remove the chips, oil, coolant and obstacles of any kind
around the machine.
16. Avoid getting pinched in places where the table, saddle or spindle head create "pinch points" while in motion.
17. Securely clamp and properly locate the workpiece in the vise, on the table, or in the fixture. Use stop blocks to
prevent objects from flying loose. Use proper holding clamping attachments and position them clear of the tool
path.
18. Use correct cutting parameters (speed, feed, depth, and width of cut) in order to prevent tool breakage.
19. 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.

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
20. After an emergency stop, always turn the FORWARD/REVERSE switch to "Off" (STOP) before releasing or
resetting the E-Stop.
21. 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.
22. Check the direction (+ or -) of movement of the table, saddle, and quill when using the jog or power feed or
ram out.
23. 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.
24. Large overhang on cutting tools when not required result in accidents and damaged parts.
25. Handwheels must have the crank folded inside when using CNC programmed machining or rapid feeds, power
feed or jog.
26. 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.
27. 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.
28. For non-spindle control machines - interlocked table guards. Interlocked table guards may be purchased from
TRAK Machine Tools if deemed necessary by the user.

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
2.0 Installation
Read and understand this entire installation section before beginning the installation procedure.
2.1 Floor Plan, Layout & Space Requirements –K2, K3 & K4
Figure 1 –Machine Footprints
K2
K3
K4
Weight (approximate) net
2200 lbs
2800 lbs
3600 lbs
Weight (approximate) shipping
2500 lbs
3100 lbs
3900 lbs
Pallet Size
6’ x 6’
6’ x 6’
6’ x 6’
AOverall width
101”
103”
103”
BOverall length
66”
70”
72.5”
CBase width
24.2”
24.2”
24”
DWidth between leveling screws
21.9”
21.9”
22.8”
EDistance between leveling screws
29.1”
29.7”
33.1”
FBase length
37.4”
38.8”
42.5”

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
K2
K3
K4
Table Size
9” x 49”
10” x 50”
10” x 50”
T-Slots (number x width)
3” x 5/8”
3” x 5/8”
3” x 5/8”
Dimension G
86”
87”
92”
Dimension G Min
65”
65”
73”
Dimension H Min
56”
64”
64”
Dimension H Max
67”
78”
78”
Dimension I Min
36”
38”
36”
Dimension I Max
49”
49’
54.5
Dimension J Max
18”
17”
23”
Dimension K
69”
69”
77”
Figure 2 –Overall Dimensions

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
2.2 Uncrating
Carefully remove the wood crate and protective packaging, paying attention not to scratch, damage, or mar any parts of
the machine.
Remove the cardboard 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.
2.3 Shortages: Inventory Checklist
_____ Machine (check model and serial number)
______ Manual drawbar with washer
______ Leveling pads (FC114), screws (FC112) and leveling nuts (FC113) (4 each)
______ Pendant Display with four 1/4-20 screws for mounting
______ Pendant Arm assembled to the column
______ Toolbox with various tools
______ ProtoTRAK SMX Safety, Operation & Programming Manual (P/N 24493)
______ TRAK K2, K3, K4 & Retrofit Safety, Installation, Maintenance, Service & Parts List
Manual (P/N 24319)
______ Way covers K2 –front of saddle - 20875
______ Way covers K3 & K4 –front of saddle - 20872
______ Way covers K2 –rear of saddle - 20874
______ Way covers K3 & K4 –rear of saddle - 20871
In case of shortages, contact the representative from whom you purchased the machine.

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
2.4 Installation Instructions & Checklist
Installer: Use this checklist to assure a complete set-up of the K2, K3, K4 or SMX 2 or 3-axis retrofit.

1.
Shut off power to the machine.

2.
Visually inspect the 220 or 440V wiring going into the electrical panel. Visually verify the
wiring is correct per our wiring diagram. Make sure a strain relief is being used where the
wiring enters the cabinet. Have the customer repair any wiring discrepancies. Measure the
220 volt and 110 volt input power to make sure it is within specification. If not, notify
customer and report on service report.

3.
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) 1/4-20 x 3/4" socket head cap screws.

6.
Make and check all the proper electrical connections from the pendant to the electric box.
See the pendant and electric box wiring diagrams.

7.
On retrofits, place the nameplate serial # plate (21934) on the pendant arm. This serial #
plate is the main system # for that machine. Place the serial # plate using 2 drive screws to
the front of the pendant arm near the pivot point of the arm. Use a #36 drill bit for drive
screws. See figure 57.

8.
On retrofits and TRAK knee mills make sure to plug in the machine ID key on the top corner
of pendant before powering up the pendant. Failure to do so may cause an improper
configuration file. If this happens, go to service code 313 and load the defaults. Loading
defaults will erase any calibration factors that have been done. See pendant connection –
Figure 13.

9.
Turn on the power to the machine and to the pendant.

10.
Load master and slave software from software upgrade disk or USB. The pendant may or may
not have the latest software loaded. (Retrofits only.)

11.
Lubricate all the way surfaces and the ball screws.

12.
Jog the table and saddle back and forth until the way surfaces are well lubricated. Oil should
be visible on all the way surfaces.

13.
Check the level of the machine. The machine should be level to within 0.0005" front to back
and 0.0005" side to side. Even though it is the responsibility of the customer, make any
adjustments if necessary.

14.
Check tram on head and adjust as necessary.

15.
Check to make sure that the E-Stop button is functioning correctly. N/A to retrofits for
spindle.

16.
Perform Service Code 12, Feed Forward Constant.

17.
Perform Service Code 11 to automatically calculate the backlash for the X and Y-axis of glass
scale machines

18.
Perform Service Code 123 to calibrate the X and Y-axis using a 150mm standard.

19.
Perform Service Code 127 and 128 to manually calculate the backlash for the X and Y-axis of
single feedback machines (i.e. motor encoder only).

20.
Check for positional accuracy and repeatability on the X and Y-axis using programs XREPEAT
2 AXIS.PT4 and YREPEAT 2 AXIS.PT4 respectively. Positioning and repeatability values
should be less than or = to 0.0005”. Programs can be found on C drive under the PT4SX
folder followed by the SWI TEST PROGRAMS folder.

21.
For 2 axis machines - perform Service Code 123 and press QUILL softkey to calibrate the Z-
axis quill using a 75mm or 3” standard.

22.
For 3 axis machines - perform Service Code 123 and press Z softkey to calibrate the Z-axis
ball screw encoder using a 75mm or 3” standard.

23.
Perform Service Code 100 in both directions for the X, Y, and Z-axis to verify that the feed
rate shown on the display is at least 120 ipm.

24.
Run the spindle at various speeds in both high and low gear for 15 minutes. Verify head

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TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
shifts from high to low gear smoothly. Test quill feed and spindle brake. N/A to retrofits.

25.
Install the Y-axis front and rear way covers.

26.
Check that all other options that came with machine are installed, functioning or adjusted
properly. They included chip pan, table guard, limit switches, EHW’s, RSG, etc

27.
3 axis machines only - If machine has an auxiliary function option, then use accessory key on
pendant and make sure the coolant pump or solenoid for the mister fires. The accessory key
should be in the ON position to test coolant pump or solenoid. The control should be in DRO
mode. Make sure air is hooked up to the machine during the test. If the machine has a
separate coolant pump switch mounted on the pendant arm then turn this on and off to test.

28.
If the machine has a power drawbar option, check to make sure that the tools load and
unload properly. Verify the drawbar unit is sitting 0.050” to 0.075” above drawbar
shoulder.N/A to retrofits.

29.
Wipe down the machine prior to leaving.
2.5 Machine Specifications
Specifications
K2
K3
K4
Movement and ranges (X, Y, Z axis)
33” x 12” x 16”
32” x 16” x 16”
32” x 16 ½” x
16.5”
Quill Travel (maximum)
5”
5”
5”
Quill Diameter
86 mm
86 mm
100 mm
Spindle Taper
R8
R8
# 40 taper
Speed Range
60-4200 RPM
60-4200 RPM
70-3950 RPM
Optional Spindle Control Speed Range
Low: 40 –600
Low: 40 –600
Low: 40 –600
High: 300 –5000
High: 300 –5000
High: 300 –5000
Spindle to Column
8” to 20”
8” to 32”
7” to 31”
Quill Feeds Per Revolution of Spindle
(Not applicable on three axis)
.0015/.003/.006”
.0015/.003/.006”
.0015/.003/.006”
Head Tilt
+/- 90
+/- 90
+/- 90
Head Swivel
+/- 45
+/- 45
N/A
Spindle Motor Power
3 HP
3 HP
5 HP
Voltage
220/440 V
220/440 V
220/440 V
Machine with Optional Speed Control
220 V
220 V
220 V
Phase/Cycle
3 phase/60 Hz
3 phase/60 Hz
3 phase/60 Hz
Current- Non Spindle Control
8.5/4.3 amps
8.5/4.3 amps
14/7 amps
Current –Spindle Control
11 amps
11 amps
17.5 amps
Maximum Weight of Workpiece
750 lbs
850 lbs
850 lbs
Coolant Capacity
9 gallons
9 gallons
9 gallons
2.6 Maximum Work Capacities
K2/K3
K4
Drilling Mild Steel (2-axis manual feed)
1 ¼”
1 ½”
Tapping Mild Steel
1”
1”
Milling (metal removal rate/mild steel)
1 ½ inch3/min
2 inch3/min
Drilling (3-axis systems)
½”
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.

11
TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
2.7 ProtoTRAK SMX Control Hardware
2 or 3-axis CNC, 3-axis DRO
400 PC-based processor
256 MB of RAM
D.C. Servo Motors rated at 280 in-oz continuous torque for X, Y and Z-axes
Precision ground ballscrews in the table and saddle to ensure smooth accurate contours without backlash
Feedrate override of programmed feedrate and rapid
Polycarbonate sealed membrane and gasket sealed control enclosure to lock out contamination
10 ½" color LCD for clear presentation of prompts, status information and part graphics
Modular design simplifies service and maximizes uptime
256 MB flash drive
Single floppy disk drive for additional part program storage
Optional auxiliary function box for control of coolant pump or spray mist coolant, spindle off and a
programmable rotary table or indexer –3 axis machines only

12
TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
Figure 3 & Parts List Shown
Knee Mill Component Identification
Item
Part Number
Description
SMX K2 + K3
SMX K2 + K3
Spindle Control
SMX K4
SMX K4
Spindle Control
1
20819
24162
20820
24163
Spindle Motor
2
24000-1
SMX Pendant
3
15616
Y-Axis Handwheel (Saddle)
4
15616
X-Axis Handwheel (Table)
5
20296
X, Y or Z Motor

13
TRAK Machine Tools
Southwestern Industries, Inc.
ProtoTRAK SMX, K2, K3 & K4 & Retrofit Safety, Installation, Maintenance, Service and Parts List Manual
Figure 4 & Parts List Shown
Knee Mill Rear View
Item
Part Number
Description
SMX K2/K3
SMX K2/K3
Spindle Control
SMX K4
SMX K4
Spindle
Control
1
220V=20676
440V=20676
24060-1
220V only
220V=20676-1
440V=20676
24060-2
220V only
Electrical Box
2
24999
24999
24999
24999
Cable Breakout Box
3
24999-1
24999-1
24999-1
24999-1
Cable Breakout Box with AUX
Functions
4
9001
9001
9001
9001
Lube Pump
5
20676-2
N/A
20676-2
N/A
Electrical box
(if have tableguard option)