haas 96-9010 Service Manual
Haas Technical Publications
Manual_Archive_Cover_Page Rev A
any other party automatically voids the factory warranty.
June 6, 2013
HAAS SERVICE AND OPERATOR MANUAL ARCHIVE
Horizontal Service Manual 96-9010 English October 10 1994
• This content is for illustrative purposes.
• Historic machine Service Manuals are posted here to provide information for Haas machine owners.
• Publications are intended for use only with machines built at the time of original publication.
• As machine designs change the content of these publications can become obsolete.
• You should not do mechanical or electrical machine repairs or service procedures unless you are qualied
and knowledgeable about the processes.
• Only authorized personnel with the proper training and certication should do many repair procedures.
WARNING: Some mechanical and electrical service procedures can be
extremely dangerous or life-threatening.
Know your skill level and abilities.
All information herein is provided as a courtesy for Haas machine owners
for reference and illustrative purposes only. Haas Automation cannot be held
responsible for repairs you perform. Only those services and repairs that are
provided by authorized Haas Factory Outlet distributors are guaranteed.
Only an authorized Haas Factory Outlet distributor should service or repair a
Haas machine that is protected by the original factory warranty. Servicing by
HORIZONTAL
TROUBLESHOOTING
SERVICE MANUAL
TROUBLESHOOTING
This section is intended for use in determining the solution to a known problem. Solutions given are intended
to give the individual servicing the CNC a pattern to follow in, first, determining the problems source and,
second, solving the problem.
The troubleshooting tips are organized in this section according to the area of the CNC that may be giving sign
of a problem. (Ex.: Out-of round circles in drilling will be found under the heading General Machine Opera-
tion - Accuracy).
If the problem you are experiencing cannot be found under the heading you expect, please try several other
possible headings. If the problem is still not found, contact Haas Automation for further details.
BEFORE YOU BEGIN:
USE COMMON SENSE
Many problems are easily overcome by correctly evaluating the situation. All machine operations are composed of a program, tools, and tooling. You must look at all three before blaming one as the fault area. If a
bored hole is chattering because of an overextended boring bar, dont expect the machine to correct the fault.
Dont suspect machine accuracy if the vise bends the part. Dont claim hole mis-positioning if you dont first
center-drill the hole.
FIND THE PROBLEM FIRST
Many mechanics tear into things before they understand the problem, hoping that it will appear as they go. We
know this from the fact that more than half of all warranty returned parts are in good working order. If the
spindle doesnt turn, remember that the spindle is connected to the spindle motor, which is driven by the
spindle drive, which is connected to the I/O BOARD, which is driven by the computer. The moral here is dont
replace the spindle drive if the belt is broken. Find the problem first; dont just replace the easiest part to get
to.
DONT TINKER WITH THE MACHINE
There are hundreds of parameters, wires, switches, etc., that you can change in this machine. Dont start
randomly changing parts and parameters. Remember, there is a good chance that if you change something,
you will incorrectly install it or break something else in the process. Consider for a moment changing the
processors board. First, you have to download all parameters, remove a dozen connectors, replace the board,
reload and reconnect, and if you make one mistake or bend one tiny pin it WONT WORK. You always need to
consider the risk of accidentally damaging the machine anytime you work on it. It is cheap insurance to
double-check a suspect part before physically changing it. The less work you do on the machine the better.
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HORIZONTAL
TROUBLESHOOTING
SERVICE MANUAL
MACHINE OPERATION
1. MACHINE OPERATION
1.1 MACHINE NOT RUNNING
´ MACHINE CANNOT BE POWERED ON.
l Check input voltage to machine
l Check main circuit breaker at top right of electrical cabinet;switch must be at the on position.
l Check overvoltage fuses
l Check wiring to POWER OFF button on front control panel.
l Check wiring to AUTO OFF relay to IOPCB.
l Replace IOPCB
l Replace POWER PCB
´ MACHINE CAN BE POWERED ON, BUT TURNS OFF BY ITSELF.
l Check settings #1 and #2 for Auto Off Timer or Off at M30.
l Check alarm history for OVERVOLTAGE or OVERHEAT shutdown.
l Check AC power supply lines for intermittent supply.
l Check wiring to POWER OFF button on front control panel.
l Replace IOPCB
l Check Parameter 57 for Power Off at E-STOP.
l Replace MOTIF PCB
´ MACHINE TURNS ON, KEYBOARD BEEPS, BUT NO CRT DISPLAY.
l Check for green POWER LED at front of CRT.
l Check for power connections to CRT from IOPCB.
l Check video cable (760) from VIDEO PCB to CRT.
l Replace CRT
´ ANY LED ON MICROPROCESSOR PCB GOES OUT (EXCEPT HALT).
l Replace Microprocessor PCB
l Replace VIDEO PCB
l Replace MOTIF PCB
´ MACHINE TURNS ON, CRT WORKS, BUT KEYBOARD KEYS DO NOT WORK.
l Check keyboard cable (700) from VIDEO to KBIF PCB.
l Replace keypad
l Replace KBIF PCB
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HORIZONTAL
MACHINE OPERATION
SERVICE MANUAL
TROUBLESHOOTING
1.2 VIBRATION
Vibration is a subjective evaluation with perceptions varying among individuals, making it difficult to determine
in mild cases if there is an actual problem. In obvious cases, it is a matter of determining the source which
is not easy, since all parts rotate together and sound can be transferred readily.Therefore vibration noises
need to be distinguished from other noises such as those coming from a bad bearing. We will assume that
vibrations would be something that could be felt by putting your hand on the spindle covers. One crude
method of measurement would be to take an indicator on a magnetic base extended 10 inches between the
table and spindle housing and observe the reading of the indicator. A reading of more than .001 would indicate
excessive vibration. The two common sources of noise are the spindle and axis drives.Most complaints about
vibration, accuracy, and finish can be attributed to incorrect machining practices such as poor quality or
damaged tooling, incorrect speeds or feeds, or poor fixturing. Before concluding that the machine is not
working properly, ensure that good machining practices are being observed. These symptoms will not occur
individually (Ex. A machine with backlash may vibrate heavily, yielding a bad finish.). Put all of the symptoms
together to arrive at an accurate picture of the problem.
´ MACHINE VIBRATES WHILE SPINDLE IS ON AND IS NOT CUTTING. SOMETIMES ONLY AT
SPECIFIC RPM.
If the spindle alone causes vibration of the machine this is usually caused by the belt/pulley drive system. This
occurs because a pulley is either out of balance, misaligned or belt tension is incorrect. It is extremely important when servicing the spindle motor, that pulleys are checked for runout. Balance is almost impossible to
check except by trial and error. This method can be accomplished by putting additional washers under one of
the allen bolts of the locking collar and observing the effect. By moving from bolt to bolt you should see better
or worse results and take action accordingly. Vibrations at different speeds are usually caused by all of the
above except that harmonics are in play.
´ MACHINE VIBRATES WHILE JOGGING THE AXIS WITH THE HAND WHEEL.
The HAAS control uses very high gain accelerations curves. The vibration as you jog is simply the servos
quickly trying to follow the handle divisions. If this is a problem, try using a smaller division on the handle. You
will notice the vibration more at individual clicks than when you are turning the handle faster. This is normal.
´ THE MACHINE VIBRATES EXCESSIVELY IN A CUT.
This is a tough one to call because machining practices come into play. Generally speaking, the least rigid
element of a cut is the tool because it is the smallest part. Any cutter will vibrate if pushed beyond its tensile
strength. In order to eliminate the machine as the source of the problem, you need to check the spindle and
the backlash of the axes as described in the following sections. Once machining practices have been eliminated as the source of vibration, observe the machine in both operation and cutting air. Move the axes
(individually) without the spindle turning and then turn the spindle without moving the axes. Isolate whether the
vibration comes from the headstock or from an axis.
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TROUBLESHOOTING
SERVICE MANUAL
MACHINE OPERATION
1.3 ACCURACY
Before you complain of an accuracy problem, please make sure you follow these simple dos and donts.
l Dont ever use a wiggler test indicator for linear dimensions. They measure in arc's and have sine/
cosine errors over larger distances.
l Dont use magnetic bases as accurate test stops. The high accel/decel of the axis can cause them to
move.
l Dont attach test points to the sheet metal of the spindle head or table.
l Dont check for thermal growth with an indicator on a long extension magnetic base.
l Do insure that test indicators and stops are absolutely rigid and mounted to machined casting surfaces.
l Do check a suspected error with another indicator or method for verification.
l Do ensure that the indicator is parallel to the axis being checked to avoid tangential reading errors.
l Do center drill holes before using jobber length drills if accuracy is questioned.
Once machining practices have been eliminated as the source of the problem, determine specifically what
the machine is doing wrong.
´ MACHINE WILL NOT INTERPOLATE A ROUND HOLE.
l Check that the machine is properly leveled.
l Check for backlash
´ BORED HOLES DO NOT GO STRAIGHT THROUGH THE WORKPIECE.
l Check that the machine is properly leveled.
l Check for squareness in the Z axis.
´ MACHINE BORES HOLES OUT-OF-ROUND.
l Check that the machine is properly leveled.
l Check the sweep of the machine
´ BOREDHOLES ARE OUT OF ROUND, OR YOU BORE A HOLE AT A GIVEN X/Y POSITION AND
THEN CHECK AT THE SAME LOCATION USING A TEST INDICATOR AND IT INDICATES YOU
ARE OUT OF POSITION.
l The spindle is not parallel to the Z axis. In order to check the effective spindle sweep, place an indicator
on the table and insert a 6" test tool bar into the spindle. Indicate below and to the side of the test bar in the
Z-Axis.
´ MACHINE MIS-POSITIONS HOLES
l Check that the machine is properly leveled.
l Check for backlash
l Check the squareness of the X axis to the Y axis.
´ MACHINE LEAVES LARGE STEPS WHEN USING A SHELL MILL.
l Check that the machine is properly leveled.
l Check the sweep of the machine
l Cutter diameter too large for depth of cut.
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HORIZONTAL
SPINDLE
SERVICE MANUAL
TROUBLESHOOTING
1.4 FINISH
´ MACHINE YIELDS A POOR FINISH
l Check for backlash
l Check the condition of the tooling and the spindle
2. SPINDLE
2.1 NOT TURNING
´ SPINDLE NOT TURNING.
l Check that the spindle turns freely when machine is off.
l Command spindle to turn on 1800 RPM and check spindle drive display. If display blinks bb, check
spindle orientation switch .
If spindle drive does not light the RUN LED,check forward/reverse commands from IOPCB.
l Check the wiring of analog speed command from MOTIF PCB to spindle drive (cable 720).
l If spindle is still not turning, replace MOTIF PCB .
l If spindle is still not turning, replace spindle drive
l Check the drive belt .
l Disconnect the drive belt. If the spindle will not turn, it is seized and must be replaced.
NOTE: Before using the replacement spindle, the cause of the previous failure must be determined.
2.2 NOISE
l Excessive noise coming from the spindle head area.
l Check the alignment of the pulleys to the belt.
l Check the machines drive belt tension.
> If the noise persists, turn the drive belt over on the pulleys. If the noise is
significantly different, the belt is at fault. Replace the belt
> If the noise does not change, remove the belt and go on to the next step.
l Check the pulleys for excessive runout (more than 0.003" axial or radial).
2.3 OVERHEATING
When investigating complaints of overheating, a temperature probe must be used to accurately check the
temperature at the top of the spindle taper. The temperature displayed in Diagnostics is not relevant.
A machine that runs at high RPM continuously will have a much warmer spindle than a machine that runs at
a lower RPM. New spindles tend to run much warmer than spindles that have already been broken in. In
order to run a valid test on a new spindle, ensure that it is properly broken in.
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HORIZONTAL
TROUBLESHOOTING
The following program should run for 24hrs to properly break in the spindle:
N100 S300 M03 G04 P900 N700 S6000 M03
G04 P900 M05 G04 P900
M05 G04 P900 M05
G04 P900 G04 P900 G04 P900
N200 S1000 M03 N500 S4000 M03 G04 P900
G04 P900 G04 P900 N800 S7500 M03
M05 M05 G04 P900
G04 P900 G04 P900 M05
N300 S2000 M03 G04 P900 G04 P900
G04 P900 N600 S5000 M03 G04 P900
M05 G04 P900 M99
G04 P900 M05
G04 P900 G04 P900
N400 S3000 M03 G04 P900
SERVICE MANUAL
2.4 STALLING/LOW TORQUE
SPINDLE
Generally, complaints of stalling or low torque relate to incorrect tooling or machining practices. A spindle
that is tending to seize will yield a poor finish machining, run very hot and very loud. Investigate machining
problems before concluding the problem exists with the spindle or spindle drive.
If you still have spindle torque problems and there is no mechanical cause such as binding or friction in the
transmission or spindle, the motor or spindle drive are the cause. The first choice for replacement is the
spindle drive. If there is still a problem, the entire motor/transmission assembly must be replaced.
2.5 SPINDLE DRIVE
Low line voltage may prevent the spindle from accelerating properly. If the spindle takes a long time to
accelerate, slows down or stays at a speed below the commanded speed with the load meter at full load, the
spindle drive and motor are overloaded. High load, low voltage, or too fast accel/decel can cause this problem.
If the spindle is accelerated and decelerated frequently, the regenerative load resistor inside the control
may heat up. If this resistor heats beyond 1000C, a thermostat will generate an overheat alarm.
If the regen load resistors are not connected or open, this could then result in an overvoltage alarm. The
overvoltage occurs because the regenerative energy being absorbed from the motor while decelerating is
turned into voltage by the spindle drive. If this problem occurs,the possible fixes are to slow the decel rate or
reduce the frequency of spindle speed changes.
2.6 ORIENTATION
´ SPINDLE LOSES CORRECT ORIENTATION.
l Check alarm history, looking for spindle overload and axis overcurrent alarms. These alarms indicate the
machine is not being properly operated.
l Check the orientation ring for tightness.
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HORIZONTAL
SPINDLE
NOTE: Ensure the shaft on which the ring mounts is free of grease.
l Check the orientation ring for cracks near the bolt holes or near the balancing holes.
> If there are cracks, replace the ring .
l Check the switch on the shot pin against the Diagnostic display.
Replace the switch if it is found to be faulty.
SERVICE MANUAL
TROUBLESHOOTING
2.7 TOOLS STICKING IN TAPER
´ TOOL STICKING IN THE TAPER CAUSES ATC TO BE PULLED ; ACCOMPANIED BY A POPPING
NOISE AS THE TOOL HOLDER POPS OUT OF THE SPINDLE TAPER.
NOTE: This problem may occur after loading a cold tool into a hot spindle (a result of thermal expan
sion of the tool holder inside the spindle taper), or after heavy milling. If sticking only occurs during
these situations, no service is necessary.
l Check the condition of the customers tooling,verifying the taper on the tooling is ground and not turned.
Look for damage to the taper caused by chips in the taper or rough handling. If the tooling is suspected,
try to duplicate the symptoms with different tooling.
l Check the condition of the spindle taper. Look for damage caused by chips or damaged tooling. Also,
look for damage such as deep gouges in the spindle taper caused by tool crashing.
l Duplicate the cutting conditions under which the deflection occurs, but do not execute an automatic tool
change. Try instead to release the tool using the tool release button on the front of the spindle head. If
sticking is observed, the deflection is not caused by improper ATC adjustment, but is a problem in the
spindle head on the machine.
l Ensure the spindle is not running too hot.
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HORIZONTAL
TROUBLESHOOTING
SERVICE MANUAL
SERVO MOTORS / LEAD SCREWS
3. SERVO MOTORS/LEAD SCREWS
3.1 GENERAL INFORMATION
There is very little that a user might do to repair a servo motor. Problems with servo motors may include opencircuited motor, shorted winding of motor, motor shorted to case, water (coolant) in motor, or overheat damage
to motor. None of these can be fixed by the user so the motor must be replaced. All of the above problems
would generate alarms identifying one of the servo motors as having failed. These alarms are 103-106 (following error too large), 108-111 (servo overload), 135-138 (overheat), 139-142 (Z channel fault), 153-156 (Z
channel missing), and 161-164 (overcurrent).
Attached to each DC servo motor, there is an incremental encoder that is 2000 lines per revolution. These
encoders also supply a Z channel pulse once per revolution. The encoders and Z channel are continuously
monitored to ensure the number of pulses matches for each revolution of the motor. If the encoders become
contaminated, these pulse counts will be wrong and an alarm will be generated. This ensures that the data
from the encoders is reliable. There can never be a loss of servo position due to accumulated encoder errors.
The alarms generated will indicate that either the Z pulse occurred and the encoder pulse was wrong or, after
one and one half motor revolutions, the Z pulse did not occur.
Encoders faults can be caused by contamination of the encoder or by a wiring problem. If the encoder is
contaminated, it must be replaced. Wiring problems may be a broken wire, shorted wire, or missing shield. All
wires to the encoder are enclosed in their own shielded cable. In addition, all power wires to the motor are
enclosed in a separately shielded cable. Failure of either of these shields may cause noise in the encoder
circuits and result in the encoder fault alarms.
Never connect or disconnect the servo motor cables with the control powered as this will cause an apparent
encoder fault.
The servo motor encoders are differential line drivers. This means that the A, B, and Z signals are transmitted to the control as signal pairs. A cable test is performed on these signals to ensure the differential pair are
always present.
SERVO DRIVE MOTORS OVERHEAT SENSE SWITCHES
Each servo motor contains a normally-open overtemperature sense thermostat. When the motor case
temperature exceeds 1500 F, an alarm will be generated and operation of the machine will stop. This alarm
should not occur under any normal operating circumstances and usually indicates that there is serious problem
with the motor or drive circuit. After September 1990, the overheat sensor was changed to normally closed.
This change is specified in the parameters.
SERVO DRIVE OVERCURRENT SENSOR
Each servo motor drive circuit contains a current limit setting and an overcurrent sense circuit. When an
overcurrent condition persists for more than 0.01 second, an alarm will be generated and operation of the
machine will stop. This current limit is presently set at 20 amps.
SERVO CHARACTERISTICS
This machine is not capable of instantly changing speed. That is, it takes some non-zero time to accelerate
and decelerate. Acceleration and deceleration in this machine have both a constant accel/decel mode and an
exponential mode. Constant acceleration is used at the beginning of a rapid move and at the end of any move
whose speed exceeds the exponential accel/decel time constant.
Constant acceleration is a type of motion when the amount of speed change over time is constant. This
constant is set by Parameters 7, 21, 35, and 49. It has units of encoder increments per second per second.
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HORIZONTAL
SERVO MOTORS / LEAD SCREWS
Exponential acceleration and deceleration is a type of motion where the speed is proportional to the distance
remaining in a programmed travel. The exponential accel/decel time constant is set by Parameters 113, 114,
115, and 116. It has units of 0.0001 seconds. The speed limit at which exponential accel/decel is not available
is defined by the relationship between Parameters 7 and 113 (for the X-axis). Thus if Parameter 7 is 1200000
steps/sec/sec and Parameter 113 is 750 (0.075 seconds);
the maximum velocity for accurate interpolation should be:
1200000 x 0.075 = 90000 steps/second
For a 2000 line encoder and 6 mm screw, this would be:
60 x 90000 / 33867 = 159 inches/minute
In the normal feed cutting mode, with G64 active, giving continuous cutter motion, deceleration of the axes
in motion begins at some distance away from the end point. If look-ahead has provided another motion, the
acceleration for that motion will begin at the same instant. This means that two motions, at right angles to each
other, will not produce a perfectly square corner. The corner will be rounded. It also means that if the two
motions are parallel or nearly parallel, there will be a smooth transition from one stroke to the next.
Rapid moves have a slightly different operation when continuous cutter mode is active. Acceleration for the
next motion is started when the axes being moved all fall within the In Position Limit Parameters 101, 102,
103, and 104. These parameters
have units of encoder steps. Rapid moves will also decelerate at the constant accel/decel limit until the speed
drops below that for exponential accel/decel (see example above giving 159 inches per minute). Parameter 57
can be used to override this.
SERVICE MANUAL
TROUBLESHOOTING
To prevent the rounding of corners, you can specify exact stop either with G09 (non-modal) or with G61
(modal). When either of these is active in a motion, all of the axes are brought to an exact stop, at zero speed,
before the next motion is started.
The tool path in a circular move (G02 or G03) is not changed by the exponential acceleration/deceleration so
there is no error introduced in the radius of the cut unless the speed exceeds that for exponential accel/decel
(see example above giving 159 inches per minute).
GROUND FAULT DETECTOR
This control has a ground fault sense circuit added to the servo drive power supply. This circuit will detect a
short to ground on any of the servo motor power leads or in the internal 115V AC power. A ground fault can be
caused by arcing brushes in the servo motors and will shut off all servo power.
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TROUBLESHOOTING
SERVICE MANUAL
SERVO MOTORS / LEAD SCREWS
3.2 NOT OPERATING
All problems that are caused by servo motor failures should also register an alarm. Check the alarm history to
determine the problems cause before any action is taken.
´ SERVO MOTOR IS NOT FUNCTIONING.
l Check the power cable from rear electrical cabinet to ensure connection is tight.
l Encoder is faulty or contaminated (Alarms 139-142, 153-156, 165-168, 182-185).
l Open circuit in motor (Alarms 139-142, 153-156, 182-185).
l Motor has overheated, resulting in damage to the interior components (Alarms 135-138, 176).
l Wiring is broken, shorted, or missing shield (Alarms 153-156, 175,182-185).
l Dust in the motor from brushes has shorted out the motor (Alarms 153-156, 175, 182-185).
l Motor has overheated; no damage to the interior components.
OVERHEAT alarm has been triggered. After thorough check of motor (DO NOT DISASSEMBLE!), take
necessary steps to eliminate the problem and alarm to resume operation.
3.3 NOISE
Lead screw noise is usually caused by a lack of lubrication and is usually accompanied by heating. Other
causes are misalignment, bearing sleeve damage, or ball nut damage. Check the alarm history of the machine
and look for axis overcurrent and following error alarms.
NOTE: Do not replace lead screws or bearing sleeves without due consideration; they are extremely
durable and reliable. Verify that customer complaints are not due to tooling, programming, or fixturing
problems.
´ SERVO MOTOR NOISE.
l Disconnect the servo motor from the lead screw and rotate by hand. If the noise persists, replace the
motor assembly
l Noise is caused by motor brushes. No problems will occur and noise should eventually go away.
l Noise is caused by bearings. Rolling, grinding sound is heard coming from the motor. ENSURE
NOISE IS NOT COMING FROM THE BRUSHES.
´ LEAD SCREW NOISE.
l Ensure oil is getting to the lead screw through the lubrication system . Look for a plugged metering
valve.
l Check for damage to the bearing sleeve.
l Check the pre-load on old-style bearing sleeves .
NOTE: The current angular contact design sleeve has a fixed pre-load; it cannot be adjusted.
l Run the axis back and forth. The motor will get very hot if the bearing sleeve is damaged. If so, turn
the axis by hand and feel for roughness in the lead screw. Loosen the clamp nuts at both ends of the
lead screw. If the symptom disappears, replace the bearing sleeve . Be certain to check for damage
the lead screw shaft where the bearing sleeve is mounted.
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HORIZONTAL
SERVO MOTORS / LEAD SCREWS
> If the noise persists, the lead screw is damaged and must be replaced. When replacing the lead
screw in an older machine, always replace the bearing sleeve with the current angular contact design
bearing sleeve.
l Check the lead screw for misalignment.
Misalignment in the lead screw itself will tend to cause the lead screw to tighten up and make excessive
noise at both ends of the travel. The ballnut may get hot. Misalignment radially at the yoke where the lead
screw ball nut mounts is indicated by heating up of the ball nut on the lead screw, and noise and tightness
throughout the travel of the lead screw. Misalignment at the yoke where the ball nut mounts is indicated by
noise and tightness at both ends of the travel of the lead screw. The ball nut may get hot.
SERVICE MANUAL
TROUBLESHOOTING
3.4 ACCURACY/BACKLASH
Accuracy complaints are usually related to tooling, programming, or fixturing problems. Eliminate these
possibilities before working on the machine.
´ POOR MILL TABLE POSITIONING ACCURACY.
l Check for a loose encoder on the servo motor. Also, ensure the key in the motor
or the lead screw is in place and the coupling is tight .
l Check for backlash in the lead screw as outlined below:
INITIAL PREPARATION -
Turn the HMC ON. ZERO RET the machine and move the mill column to the approximate center of its travel in
the X and Y directions. Move the spindle head to approximate center of the Z-axis travel, also.
CHECKING X-AXIS:
1. Set up a dial indicator and base on the mill table as shown in Fig. 3-1.
Fig. 3-1 Dial indicator in position to check X-axis.
2. Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows:
- Zero the dial indicator.
- Press the MDI button on the control panel.
- Press the HANDLE JOG button on the
control panel. The Distance to go display
on the lower right hand corner should read:
X=0 Y=0 Z=0
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TROUBLESHOOTING
3. Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) X direction.
Jog back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.
4. Repeat step three in the negative (-) direction.
TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD
NOT EXCEED .0002.
SERVICE MANUAL
SERVO MOTORS / LEAD SCREWS
CHECKING Y-AXIS:
1. Set up a dial indicator and base on the mill table as shown in Fig. 3-2.
Fig. 3-2 Dial indicator in position to check Y-axis.
2. Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows:
- Zero the dial indicator.
- Press the MDI button on the control panel.
- Press the HANDLE JOG button on the
control panel. The Distance to go display
on the lower right hand corner should read:
X=0 Y=0 Z=0
3. Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) Y direction.
Jog back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.
4. Repeat step three in the negative (-) direction.
TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD NOT
EXCEED .0002.
An alternate method used in checking backlash is to manually push up and down on the spindle head while
listening for a clunk. Also, watch for any rapid change in the dial indicator. Either of these indicate possible
backlash.
NOTE: The servos must be on to check backlash by this method.
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SERVO MOTORS / LEAD SCREWS
SERVICE MANUAL
TROUBLESHOOTING
CHECKING Z-AXIS:
1. Set up a dial indicator and base on the table as shown in Fig. 3-3.
2. An alternate method for checking backlash is to manually push the column to the left/right and push the
spindle head up/down.
NOTE: Servos must be on to check for backlash in the Z-axis.
NOTE: Do not mistake deflection for backlash in the system.
Fig. 3-3 Dial indicator in position to check Z-axis.
> If backlash is found in the system,check for the following possible causes:
l Loose SHCS attaching the ball nut to the nut housing.
l Loose SHCS attaching the nut housing to the mill table, spindle head, or saddle,
depending on the axis.
l Loose clamp nut on the bearing sleeve. Tighten the SHCS on the clamp nut.
l Loose motor coupling.
l Broken or loose flex plates on the motor coupling.
NOTE: The coupling cannot be serviced in the field and must be replaced as a unit if it is found to be
defective.
l Loose SHCS attaching the bearing sleeve to the motor housing.
l Defective thrust bearings in the bearing sleeve.
l Loose SHCS attaching the axis motor to the motor housing. If the SHCS are found to be loose, inspect
the motor for damage.
l Incorrect backlash compensation number in the parameter in the machine. Check Parameters 13, 27,
and 41.
l Worn lead screw.
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TROUBLESHOOTING
SERVICE MANUAL
SERVO MOTORS / LEAD SCREWS
3.5 VIBRATION
´ EXCESSIVE SERVO MOTOR VIBRATION.
l If no A axis is present, swap the suspected bad servo motor with the A driver and check to see if
there is a driver problem.
l Check all Parameters of the suspected axis against the Parameters as shipped with the machine. If
there are any differences, correct those and determine how the Parameters were
changed. PARAMETER LOCK should normally be ON.
l A bad motor can cause vibration if there is an open or short in the motor. A short would normally cause
a GROUND FAULT or OVERCURRENT alarm; check the ALARMS. An ohmmeter applied to the motor
leads should show between 1 and 3 ohms between leads, and over 1 megohm from leads to ground.
If the motor is open or shorted, replacement it.
´ SERVO MOTOR OVERHEATING.
l If a motor OVERHEAT alarm occurs (ALARMS 135-138), check the Parameters for an incorrect setting.
Axis flags in Parameters 1, 15, or 29 can invert the overheat switch (OVER TEMP NC).
l If the motor is actually getting hot to the touch, there is excessive load on the motor. Check the users
application for excessive load or high duty cycle.
Check the lead screw for binding.
3.6 FOLLOWING ERROR
´ FOLLOWING ERROR ALARMS OCCUR ON ONE OR MORE AXES SPORADICALLY.
l Check DC bus voltage on diagnostics page #2. If it is at the low side of the recommended voltages,
change the transformer tap to the next lower voltage group as explained in the INSTALLATION MANUAL
l Check motor wiring
l Driver card replacement.
l Servo motor replacement.
4. TOOL CHANGER
4.1 DEFLECTION
Deflection is usually caused by ATC misalignment, and sometimes caused by damaged or poor quality
tooling, damaged spindle taper, or a damaged drawbar. Before beginning any troubleshooting, observe the
direction of the ATC deflection.
´ DURING A TOOL CHANGE, ATC APPEARS TO BE PUSHED OUT.
l Check to see if pull studs on the tool holder are correct and tight.
l Check the mechanical adjustment of the Y offset
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HORIZONTAL
TOOL CHANGER
l Check Parameters 71, 72, and 143 against the values that are in the documentation sent with the
machine.
l Ensure the tool holders are held firmly in place by the extractor forks.
l Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release button is
pressed If they do not move freely, the ATC will be pushed out about ¼ before the tool holder is
seated in the taper, resulting in damage to the roller bolts on the ATC shuttle.
SERVICE MANUAL
TROUBLESHOOTING
´TOOL HOLDER STICKING IN THE SPINDLE TAPER CAUSES THE ATC TO BE PULLED IN AS
THE SPINDLE HEAD IS TRAVELING UP AFTER DEPOSITING THE TOOL HOLDER IN THE
CAROUSEL; ACCOMPANIED BY A POPPING NOISE AS THE TOOL HOLDER POPS OUT OF
THE SPINDLE TAPER.
NOTE: This problem may occur after loading a cold tool into a hot spindle (a result of thermal
expansion of the tool holder inside the spindle taper), or after heavy milling. If sticking occurs only during
these circumstances, no service is necessary.
l Check the condition of the customers tooling, verifying the taper on the tool holders ground and not
turnedLook for damage to the taper caused by chips in the taper or rough handling. If the tooling is
suspected, try to duplicate the symptoms with different tooling.
l Check the condition of the spindle taper. Look for damage caused by chips or damaged tooling. Also,
look for damage such as deep gouges in the spindle taper caused by tool crashing.
l Duplicate the cutting conditions under which the deflection occurs, but do not execute an automatic tool
change. Try instead to release the tool using the tool release button on the front of the spindle head. If
sticking is observed, the deflection is not caused by improper ATC adjustment, but is a problem in the
spindle head on the machine.
´ DURING A TOOL CHANGE, ATC APPEARS TO BE PULLED IN ; NO POPPING NOISES.
l Check the mechanical adjustment of the Y offset .
NOTE: If the adjustment is incorrect, a tool changer crash has occurred, and a thorough inspection of
the ATC is necessary at this time.
l Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release button is
pressed. If they do not move freely, the ATC will be pushed out about ¼ before the tool holder is
seated in the taper.
´ TOOL HOLDERS TWIST AGAINST EXTRACTOR FORK DURING A TOOL CHANGE.
l Check the alignment of the ATC in the X and Z axes.
l Check rotational alignment.
´ TOOL HOLDERS SPIN AT ALL POCKETS OF THE ATC
l ATC rotationally misaligned
Check the carousel offset (parameter 215)
NOTE: Observe the direction the tool holder rotates, as this will be the direction in which the X axis of
the ATC needs to be moved.
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HORIZONTAL
TROUBLESHOOTING
4.2 CRASHING
Crashing of the ATC is usually a result of operator error. The most common ATC crashes are outlined as
follows:
SERVICE MANUAL
TOOL CHANGER
´ATC PROPERLY DEPOSITS A TOOL HOLDER IN THE SPINDLE, BUT THE TOOLS ARE DROPPED
ONTO THE MACHINE TABLE.
l Inspect the balls and the Belleville springs in the drawbar.
´ THE PART OR FIXTURE ON THE MILL TABLE CRASHES INTO LONG TOOLING OR INTO THE
ATC ITSELF DURING A TOOL CHANGE.
l Check for damage to the trap door on the ATC cover.
l Check for missing plastic riders on the ATC shutter.
´ ATC OUT OF ORIENTATION WITH THE SPINDLE.
Incorrect spindle orientation will cause the ATC to crash as the shuttle moves. Alarm 113 generated.
l Check the orientation of the machine.
´ATC WILL NOT RUN
l In all cases where the tool changer will not run, an alarm is generated to indicate either a shuttle in/out
problem or a turret rotation problem. These alarms will occur either on an attempt to change tools (ATC
FWD) or ZERO RETURN the machine (AUTO ALL AXES).
´ TURRET WILL NOT ROTATE; TURRET MOTOR IS NOT GETTING POWER (COMMAND A TOOL
CHANGE AND FEEL FOR POWER BEING APPLIED TO THE TURRET MOTOR).
l Check that the TC CW/ TC CCW LED on the I/O PCB is illuminated when a toolchange takes place.
´ ATC PROPERLY DEPOSITS A TOOL HOLDER IN THE SPINDLE BUT GIVES A SHUTTLE OUT
FAULT.
l Check the shuttle in/out switch adjustment.
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HORIZONTAL
SERVICE MANUAL
TROUBLESHOOTING
10-25-94 96-9010
17
HORIZONTAL
ALARMS: 102-114
SERVICE MANUAL
ALARMS
ALARMS
Any time an alarm is present, the lower right hand corner will have a blinking ALARM. Push the ALARM
display key to view the current alarm. All alarms are displayed with a reference number and a complete
description. If the RESET key is pressed, one alarm will be removed from the list of alarms. If there are
more than 18 alarms, only the last 18 will be displayed and the CURSOR DOWN key must be used to see
the rest. The presence of any alarm will prevent the operator from starting a program.
Note that the tool changer alarms can be easily corrected by first correcting any mechanical problem,
pressing RESET until the alarms are clear, selecting ZERO RET mode, and selecting AUTO ALL AXES.
Some messages are displayed while editing to tell the operator what is wrong, but these are not alarms.
The following list shows the alarm number and the cause of the alarm. Please refer to this list before
resuming normal operation when an alarm occurs.
102 SERVOS OFF
This is not an alarm; but indicates that the servo motors are off, the tool changer is disabled, the coolant
pump is off, and the spindle motor is stopped. Caused by EMERGENCY STOP, motor faults, tool changer
problems, or power fail.; check for other causes.
103 X FOLLOWING ERROR TOO LARGE
104 Y FOLLOWING ERROR TOO LARGE
105 Z FOLLOWING ERROR TOO LARGE
106 A FOLLOWING ERROR TOO LARGE
These alarms can be caused by power problems, motor problems, driver problems, the slide being run into
the mechanical stops, or excessive axis load. The difference between the motor position and the commanded position has exceeded a parameter. The motor may also be stalled, disconnected, or the driver
failed. The servos will be turned off and a RESET must be done to restart.
107 EMERGENCY OFF
EMERGENCY STOP button was pressed. Servos are also turned off. After the E-STOP is released, the
RESET button must be pressed at least twice to correct this; once to clear the E-STOP alarm and once to
clear the Servo Off alarm. This is an operator-initiated condition. If you do not know why it occurred, check
wiring to emergency stop circuit.
108 X SERVO OVERLOAD
109 Y SERVO OVERLOAD
110 Z SERVO OVERLOAD
111 A SERVO OVERLOAD
Excessive load on X-axis motor. This can occur if the load on the motor over a period of several seconds or
even minutes is large enough to exceed the continuous rating of the motor. The servos will be turned off
when this occurs. This can be caused by running into the mechanical stops but not much past them. It can
also be caused by anything that causes a very high load on the motors.
Servo, servo driver and ball screw.
112 NO INTERRUPT
This alarm can be caused by electrical interference or an electronics problem.
113 SHUTTLE IN FAULT
114 SHUTTLE OUT FAULT
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HORIZONTAL
ALARMS
Tool changer not completely to right or left. During a tool changer operation the tool in/out shuttle failed to get to
the in or out position. Parameters 62 and 63 can adjust the time-out times. This alarm can be caused by
anything that jams the motion of the slide or by the presence of a tool in the pocket facing the spindle. A loss of
power to the tool changer can also cause this, so check fuse FU5 and relays 1-8, 2-1, and 2-2.
Tool changer operation.
115 TURRET ROTATE FAULT
Tool carousel motor not in position. During a tool changer operation the tool turret failed to start moving or failed
to stop at the right position. Parameters 60 and 61 can adjust the time-out times. This alarm can be caused by
anything that jams the rotation of the turret. A loss of power to the tool changer can also cause this, so check
fuse FU5 and relays 1-8, 2-3, and Turret operation.
116 SPINDLE ORIENTATION FAULT
Spindle did not orient correctly. During a spindle orientation function, the spindle is rotated until the lock pin
drops in; but the lock pin never dropped. Parameters 66, 70, 73, and 74 can adjust the time-out times. This can
be caused by a trip of circuit breaker CB4, a lack of air pressure, or too much friction with the orientation pin.
119 OVER VOLTAGE
Incoming line voltage is above maximum (about 255V when wired for 240 or 235 when wired for 208). The
servos will be turned off and the spindle, tool changer, and coolant pump will stop. If this condition remains for
4.5 minutes, an automatic shutdown will begin. This can also be caused by an electronic problem.
Line voltage adjustment taps.
SERVICE MANUAL
ALARMS: 115-123
120 LOW AIR PRESSURE
Air pressure dropped below 80 PSI for a period defined by Parameter 76. Check your incoming air pressure for
at least 100 PSI and ensure the regulator is set at 85 PSI. If this is not caused by low air pressure, check
pressure sensor at spindle head and wiring back to IOPCB. Check Parameter 76, which is used to delay the
low air alarm condition for short outages. Air blast during tool change can cause your air supply to drop
pressure; monitor the pressure drop during a tool unclamp.
121 LOW LUB OR LOW PRESSURE
Way lube is low or empty or there is no lube pressure or too high a pressure. Check tank at rear of mill and
below control cabinet. Also check connector P5 on the side of the control cabinet. Check that the lube lines are
not blocked. This can be caused by failure of the pump to provide pressure, failure of the lube pressure sensor,
a wiring error, or a parameter error. See Air and Oil Line Diagrams to check level switch and pressure switch
(cable 960).
122 CONTROL OVER HEAT
The control internal temperature is above 150° F. This can be caused by almost anything in the control overheating. But is usually caused by overheat of the two regen resistors for servos and spindle drive. This alarm
will also turn off the servos, spindle drive, coolant pump, and tool changer. One common cause of this overheat
condition is an input line voltage too high. If this condition remains for 4.5 minutes, an automatic shutdown will
begin. It is also caused by incorrect transformer tapping, SDIST PCB problem, or Spindle Drive problem.
123 SPINDLE DRIVE FAULT
Overheat or failure of spindle drive or motor. The exact cause is indicated in the LED window of the spindle
drive inside the control cabinet. This can be caused by a stalled motor, shorted motor, overvoltage,
undervoltage, overcurrent, overheat of motor, or drive failure. e. Front of drive indicates type of problem. If not
a Drive problem, check wiring to IOPCB (cable 780).
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19
HORIZONTAL
ALARMS: 124-138
124 LOW BATTERY
Memory batteries need replacing within 30 days. This alarm is only generated at POWER ON and indicates
that the 3.3V Lithium battery is below 2.5V. If this is not corrected within about 30 days, stored programs,
parameters, offsets, and settings may be lost.
Replacement of Microprocessor PCB or battery.
129 M FIN FAULT
This indicates an external M-code wiring error was detected at power-on. Check your wiring to the M-FIN
signal.
130 TOOL UNCLAMPED
131 TOOL NOT CLAMPED
Tool release piston is energized at power up, or, tool release piston is not Home. This is a possible fault in
the air solenoids, relays on the IO Assembly, the draw bar assembly, or wiring.
Tool clamp/unclamp problems.
132 POWER DOWN FAILURE
The control attempted to shut-off and could not. The auto-off relay on the IOPCB did not open the main
contactor circuit. Check the wiring from IOPCB to POWER PCB.
IOPCB replacement. ELECTRICAL
SERVICE MANUAL
ALARMS
133 SPINDLE LOCKED
Shot pin did not release. This is detected when spindle motion is commanded. Check the solenoid that
controls the air to the lock, relay 2-8, the wiring to the sense switch, and the switch.
Check for correct function of the shot pin.
134 TOOL CLAMP FAULT
Tool did not release from spindle when commanded. Check air pressure and solenoid circuit breaker CB4.
Can also be caused by misadjustment of draw bar assembly.
Tool clamp/unclamp problems.
135 X MOTOR OVER HEAT
136 Y MOTOR OVER HEAT
137 Z MOTOR OVER HEAT
138 A MOTOR OVER HEAT
Servo motor overheat. The temperature sensor in the motor indicates over 1500F. This can be caused by an
extended overload of the motor such as leaving the slide at the stops for several minutes.
Check of servo motors and ball screws.
A parameter or a wiring error can also cause this alarm.
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HORIZONTAL
ALARMS
139 X MOTOR Z FAULT
140 Y MOTOR Z FAULT
141 Z MOTOR Z FAULT
142 A MOTOR Z FAULT
Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and
encoder position data is unreliable. This can also be caused by loose connectors at P1-P4.
Check motor/encoder and wiring.
It can also be caused by the MOTIF PCB.
143 SPINDLE NOT LOCKED
Shot pin not fully engaged when a tool change operation is being performed. Check air pressure and
solenoid circuit breaker CB4. This can also be caused by a fault in the sense switch that detects the
position of the lock pin.
144 TIMEOUT - CALL YOUR DEALER
Time allocated for use prior to payment exceeded.
Not a mechanical or electrical problem.
145 X LIMIT SWITCH
146 Y LIMIT SWITCH
147 Z LIMIT SWITCH
148 A LIMIT SWITCH
Axis hit limit switch or switch disconnected. This is not normally possible as the stored stroke limits will
stop the slides before they hit the limit switches. Check the wiring to the limit switches and connector P5 at
the side of the main cabinet. Can also be caused by a loose encoder shaft at the back of the motor or
coupling of motor to the screw.
SERVICE MANUAL
ALARMS: 139-156
149 SPINDLE TURNING
Spindle not at zero speed for tool change. A signal from the spindle drive indicating that the spindle drive
is stopped is not present while a tool change operation is going on.
150 Z AND TOOL INTERLOCKED
Tool changer not at home and Z is neither at machine home or above tool. If RESET, E-STOP, or POWER
OFF occurs during tool change, Z-axis motion and tool changer motion may not be safe. Check the position
of the tool changer and remove the tool if possible. Re-initialize with the AUTO ALL AXES button but be sure
that the pocket facing the spindle afterwards does not contain a tool. Indicates a dangerous condition with
the position of the Z axis and the tool changer. It is usually preceded by an alarm related to the tool
changer.
Tool changer problems.
152 SELF TEST FAIL
This can be caused by an electronics problem or electrical interference. All motors and solenoids are shut
down. This is most likely caused by a fault of the processor board stack at the top left of the control. Call
your dealer.
153 X AXIS Z CH MISSING
154 Y AXIS Z CH MISSING
155 Z AXIS Z CH MISSING
156 A AXIS Z CH MISSING
These alarms indicate a problem with the servo axis encoder. All servos are turned off. It can also be
caused by wiring errors, electronics problems, encoder contamination, parameter errors, or by loose
connectors at P1-P4..
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HORIZONTAL
ALARMS: 157-169
157 MOTOR INTERFACE PCB FAILURE
Internal circuit board problem. The MOTIF PCB in the processor stack is tested at POWER ON.
158 VIDEO/KEYBOARD PCB FAILURE
Internal circuit board problem. The VIDEO PCB in the processor stack is tested at POWER ON. This could
also be caused by a short in the front panel membrane keypad.
159 KEYBOARD FAILURE
Keyboard shorted or button pressed at POWER ON. A POWER ON test of the membrane keypad has found
a shorted button. It can also be caused by a short in the cable from the main cabinet or by holding a switch
down during POWER ON.
This can also be caused by a bad cable 700.
Be sure the problem is not in the cable before replacing keypad.
160 LOW VOLTAGE
This can be caused by a line voltage problem, a transformer tap problem, or an electronic problem. Cable
980 can cause this problem.
161 X AXIS OVER CURRENT OR DRIVE FAULT
162 Y AXIS OVER CURRENT OR DRIVE FAULT
163 Z AXIS OVER CURRENT OR DRIVE FAULT
164 A AXIS OVER CURRENT OR DRIVE FAULT
These alarms indicate a problem with servo motor, the servo drive, or excessive load on servos. Possibly
caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running a short
distance into a mechanical stop. It can also be caused by a short in the motor or a short of one motor lead
to ground.
Check of servo motor and ball screw.
SERVICE MANUAL
ALARMS
165 X ZERO RET MARGIN TOO SMALL
166 Y ZERO RET MARGIN TOO SMALL
167 Z ZERO RET MARGIN TOO SMALL
168 A ZERO RET MARGIN TOO SMALL
This alarm indicates a problem with limit switches, parameters, or motor encoders for servos, and this
alarm will occur if the home/limit switches move or are misadjusted. This alarm also indicates that the zero
return position may not be consistent from one zero return to the next. The encoder Z channel signal must
occur between 1/8 and 7/8 revolution of where the home switch releases. This will not turn the servos off
but will stop the zero return operation.
If a new motor or encoder is installed, this alarm is likely before grid offset parameters are adjusted.
169 SPINDLE DIRECTION FAULT
The spindle started turning in the wrong direction. This alarm occurs only for rigid tapping. It can be
caused by a bad rigid tapping encoder, a wiring error, or a parameter error.
Installation of rigid tapping encoder.
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96-9010 10-25-94
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