TRAK ProtoTRAK KMX K3 Guide

ProtoTRAK®KMX
K3 Knee Mill & Retrofit
Safety, Installation, Maintenance, Service & Parts List Manual
2615 Homestead Place
Rancho Dominguez, CA 90220-5610 USA
T | 310.608.4422 |F | 310.764.2668
Service Department: 800.367.3165
e-mail: [e-mail] | [e-mail] | web: www.trakmt.com
Document: P/N 29777
Version: 091018

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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Southwestern Industries, Inc.
ProtoTRAKKMX K3 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Table of Contents
1.0 Safety ........................................................................................................1
Safety Publications................................................................................................ 11.1
Danger, Warning, Caution, and Note Labels & Notices As Used In This Manual .......... 11.2
Safety Precautions ................................................................................................ 41.3
2.0 Installation ...............................................................................................6
Floor Plan, Layout & Space Requirements –K3........................................................ 6
2.1
Uncrating ............................................................................................................. 82.2
Shortages: Inventory Checklist.............................................................................. 82.3
Installation Instructions & Checklist........................................................................ 92.4
Machine Specifications..........................................................................................102.5
Maximum Work Capacities ....................................................................................112.6
ProtoTRAK KMX Control Hardware.........................................................................112.7
2.7.1 Basic System Specifications ............................................................................11
Lifting and/or Moving the Machine.........................................................................152.8
Cleaning..............................................................................................................172.9
Leveling: Leveling Tolerance is .0005”/10” ............................................................172.10
Electrical Connection ............................................................................................192.11
Air Connection - Optional......................................................................................222.12
Mounting the Display Pendant...............................................................................222.13
Cable Interconnections.........................................................................................222.14
Lubrication ..........................................................................................................23
2.15
2.15.1 Manual Lubrication ........................................................................................23
2.15.2 Parts List –Knee Mill Lubrication (Figure 9) ......................................................25
2.15.3 Head Lubrication ...........................................................................................25
3.0 Troubleshooting by Symptom.................................................................27
Problems Relating to Machining Results .................................................................273.1
3.1.1 Poor Finish....................................................................................................27
3.1.2 Circles Out of Round......................................................................................27
Problems Regarding the Motion of the Machine ......................................................283.2
3.2.1 Run Away Axis ..............................................................................................28
3.2.2 Axis Will Not Jog ...........................................................................................29
Problems Relating to the Operation of the Control ..................................................293.3

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Southwestern Industries, Inc.
ProtoTRAKKMX K3 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
3.3.1 Fault X or Y...................................................................................................29
KMX Pendant Troubleshooting LED’s......................................................................313.4
4.0 Service Codes..........................................................................................33
Software .............................................................................................................334.1
Machine Set-Up ...................................................................................................334.2
Diagnostic Codes .................................................................................................344.3
Operator Defaults/Options ....................................................................................354.4
CODE 11: Hysteresis ...........................................................................................354.5
CODE 12: Feed Forward Constant ........................................................................364.6
CODE 97: Set Positive Motor Encoder Direction .....................................................364.7
CODE 100: Axis Open Loop Test ..........................................................................374.8
CODE 122: X, Y, Z And Quill Calibration Using Part Measurements ...........................384.9
CODE 123: X, Y, Z and Quill Calibration ................................................................394.10
5.0 Maintenance............................................................................................40
Gib Adjustments ..................................................................................................405.1
5.1.1 Table Gib Adjustment, X-Axis .........................................................................40
5.1.2 Saddle Side Gib Adjustment, Y-Axis.................................................................42
5.1.3 Saddle Bottom Gib Adjustment, Y-Axis ............................................................43
Head Rotational and Tramming.............................................................................445.2
5.2.1 To Rotate the Head Side to Side:....................................................................44
5.2.2 Tramming the Head.......................................................................................44
5.2.3 Back to Front Adjustment...............................................................................45
6.0 Introduction to Self-Service ...................................................................46
When You Have a Service Problem........................................................................466.1
6.1.1 Communication with the SWI Customer Service Group .....................................46
Replacements......................................................................................................466.2
6.2.1 Exchange Program ........................................................................................46
6.2.2 Return Authorization (RA) Number..................................................................47
7.0 Figures and Parts Lists............................................................................48
8.0 Drawings .................................................................................................78
29819 SYSTEM DIAGRAM-KMX NEW MACHINES & UPGRADES.................................788.1
29756-1 PENDANT ARM KIT-TOP MOUNT-KMX-K3..................................................788.2
29756-4 PENDANT ARM KIT-TOP MOUNT-KMX RETROFIT ......................................788.3
20255-XX DRIVE KIT –X-AXIS-SM ........................................................................788.4

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Southwestern Industries, Inc.
ProtoTRAKKMX K3 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
20255-1 PARTS LIST FOR DRIVE KIT –X-AXIS-SM .................................................788.5
23083-XX DRIVE KIT-SPORT –Y-AXIS...................................................................788.6
23083-1 PARTS LIST FOR DRIVE KIT-SPORT - Y-AXIS ............................................788.7
28092-1 BRACKET ASSY-BP SER I Z AXIS - SWI GS ................................................788.8
20586-1 BRACKET ASSY-Z AXIS EASSON GLASS SCALE ..........................................788.9
25000-XX DRIVE KIT - Z AXIS...............................................................................788.10
16208-1 HARDWARE KIT MX3 Z-AXIS-BP...............................................................788.11
24230-XX Z AXIS BALL SCREW - BASEPLATE, BEARING HOUSING & COVERS ASSY ..788.12
24230-6 PARTS LIST FOR Z-AXIS BALLSCREW- BASEPLATE- BEARING HOUSING &8.13
COVERS ASSY ..............................................................................................................78
23891 ELECTRONIC HANDWHEELKIT- KNEE MILL-X & Y AXIS.................................788.14
22580-7 POWER DRAWBAR OPTION K2, K3-R8......................................................788.15
22380-1 AIR REGULATOR ASSY - DPMV - FILTER...................................................788.16

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Southwestern Industries, Inc.
ProtoTRAKKMX K3 & Retrofit Safety, Installation, Maintenance, Service & 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 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 1910.212 - Milling
Machine.
Safety Publications
1.1
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.
Danger, Warning, Caution, and Note Labels & Notices As1.2
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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Southwestern Industries, Inc.
ProtoTRAKKMX K3 & Retrofit Safety, Installation, Maintenance, Service & 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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Southwestern Industries, Inc.
ProtoTRAKKMX K3 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Safety & Information Labels Used On The
TRAK K3 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
KMX K3
Vari-speed Head
Overload Setting - 220 V
8.5 A
Overload Setting - 440 V
4.25 A
FLA of Largest Motor at 220 V
8.5 A
FLA of Largest Motor at 440 V
4.25 A
FLA of Machine at 220 V
8.5 A
FLA of Machine at 440 V
4.25 A

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Southwestern Industries, Inc.
ProtoTRAKKMX K3 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
Safety Precautions1.3
1. 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.
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.

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Southwestern Industries, Inc.
ProtoTRAKKMX K3 & Retrofit Safety, Installation, Maintenance, Service & Parts List Manual
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.
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. Interlocked table guards may be purchased from Southwestern Industries, Inc. if
deemed necessary by the user.