haas HS- 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

HS-Series Service Manual 96-9010 English June 1998

• 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 qualied
and knowledgeable about the processes.

• Only authorized personnel with the proper training and certication 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

June 1998

TROUBLESHOOTING

COMMON ABBREVIATIONS USED IN HAAS MACHINES

AC Alternating Current
AMP Ampere
APC Automatic Pallet Changer
APL Automatic Parts Loader
ASCII American Standard Code for Information Interchange
ATC Automatic Tool Changer
ATC FWD Automatic Tool Change Forward
ATC REV Automatic Tool Changer Reverse
BHCS Button Head Cap Screw
CB Circuit Breaker
CC Cubic Centimeter
CCW Counter Clock Wise
CNC Computerized Numeric Control
CNCR SPINDLE Concurrent Spindle with axis motion
CRC Cyclic Redundancy Check Digit
CRT Cathode Ray Tube
CW Clock Wise
DB Draw Bar
DC Direct Current
DGNOS Diagnostic
DIR Directory
DNC Direct Numerical Control
ENA CNVR Enable Conveyor
EOB End Of Block
EOF End Of File
EPROM Erasable Programmable Read Only Memory
E-Stop Emergency Stop
FHCS Flat Head Cap Screw
FT Foot
FU Fuse
FWD Forward
GA Gauge
HHB Hex Head Bolts
HP Horse Power
HS Horizontal Series Of Machining Centers
ID Inside Diameter
IN Inch
IOPCB Input Output Printed Circuit Board
LB Pound
LED Light Emitting Diode
LO CLNT Low Coolant
LOW AIR PR Low Air Pressure
LVPS Low Voltage Power Supply
MCD RLY BRD M-Code Relay Board
MDI Manual Data Input
MEM Memory
M-FIN M-Code Finished
MM Millimeter
MOCON Motor Control
MOTIF Motor Interface
MSG Message
NC Numerical Control

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TROUBLESHOOTING

NC Normally Closed
NO Normally Open
OD Outside Diameter
OPER Operator
PARAM Parameter
PCB Printed Circuit Board
PGM Program
POR Power On Reset
POSIT Positions
PROG Program
PSI Pounds Per Square Inch
PWM Pulse Width Modulation
RAM Random Access Memory
REPT RIG TAP Repeat Rigid Tap
RET Return
REV CNVR Reverse Conveyor
RJH Remote Jog Handle
RPDBDN Rotary Pallet Draw Bar Down
RPDBUP Rotary Pallet Draw Bar Up
RPM Revolutions Per Minute
S Spindle Speed
SDIST Servo Distribution PCB
SFM Surface Feet Per Minute
SHCS Socket Head Cap Screw
SIO Serial Input/Output
SKBIF Serial Key Board Inter Face PCB
SP Spindle
T Tool Number
TC Tool Changer
TIR Total Indicated Runout
TNC Tool Nose Compensation
TRP Tool Release Piston
TS Tail Stock
TSC Through The Spindle Coolant
VF Vertical Mill (very first)
VF-E Vertical Mill- Extended
VMC Vertical Machining Center

June 1998

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TROUBLESHOOTING

1. 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 problems 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
Operation - 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, dont expect the machine to correct the
fault. Dont suspect machine accuracy if the vise bends the part. Dont claim hole mis-positioning if you dont
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 doesnt turn, remember that the spindle is connected to the gear box, which 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 MOCON, which is driven by the processor. The moral here is dont replace the spindle drive if the belt
is broken. Find the problem first; dont just replace the easiest part to get to.

DONT TINKER WITH THE MACHINE

There are hundreds of parameters, wires, switches, etc., that you can change in this machine. Dont 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
processors board. First, you have to download all parameters, remove a dozen connectors, replace the board,
reconnect and reload, and if you make one mistake or bend one tiny pin it WONT 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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TROUBLESHOOTING

1.1 GENERAL MACHINE OPERATION

M ACHINE N OT R UNNING

´ Machine cannot be powered on

l Check input voltage to machine (see "Electrical Service").
l Check main circuit breaker at top right of electrical cabinet; switch must be at the on position.
l Check overvoltage fuses (see "Electrical Service").
l Check wiring to POWER OFF button on front control panel.
l Check wiring to AUTO OFF relay to IOPCB.
l Check connection between 24V transformer and K1 contactor.
l Replace IOPCB (see "Electrical Service").
l Replace POWER PCB (see "Electrical Service").

´ 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 Check connection between 24V transformer and K1 contactor.
l Replace IOPCB (see "Electrical Service").
l Check Parameter 57 for Power Off at E-STOP.
l Replace MOTIF or MOCON PCB (see "Electrical Service").

June 1998

´ 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 Close doors and Zero Return machine (possible bad monitor).
l Check video cable (760) from VIDEO PCB to CRT.
l Check for lights on the processor.
l Replace CRT (see "Electrical Service").

´ Any LED on Microprocessor PCB goes out (except HALT)

l Replace Microprocessor PCB (see "Electrical Service").
l Replace VIDEO PCB (see "Electrical Service").
l Replace MOTIF PCB (see "Electrical Service").

´ Machine turns on, CRT works, but keyboard keys do not work

l Check keyboard cable (700) from VIDEO to KBIF PCB.
l Replace keypad (see "Electrical Service").
l Replace KBIF PCB (see "Electrical Service").

´ Constant E-Stop Condition (will not reset)

l Check Hydraulic counterbalance pressure, low pressure switches and cabling.

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TROUBLESHOOTING

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. Vibrations also need
to be distinguished from noise such as a bad bearing. 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 jogging the axis with the hand wheel

l The HAAS control uses very high gain accelerations curves. This 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

l 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 spindle head or from an axis. Isolate the source of vibration per "Spindle", "Servo
Motors/Lead Screws", and "Gearbox and Spindle Motor" sections.

A CCURACY

Before you complain of an accuracy problem, please make sure you follow these simple dos and donts:

l Ensure that the machine has been sufficiently warmed up before cutting parts. This will eliminate

mispositioning errors caused by thermal growth of the leadscrews (see "Thermal Growth" section).

l Dont ever use a wiggler test indicator for linear dimensions. They measure in an arc and have

sine/cosine errors over larger distances.

l Dont use magnetic bases as accurate test stops. The high accel/decel of the axis can cause them

to move.

l Dont attach magnetic base to the sheet metal of the machine.
l Don't mount the magnetic base on the spindle dogs.
l Dont check for accuracy/repeatability using an indicator with a long extension.
l Ensure that test indicators and stops are absolutely rigid and mounted to machined casting surfaces

(e.g. spindle head casting, spindle nose, or the table).

l Don't rapid to position when checking accuracy. The indicator may get bumped and give an

inaccurate reading. For best results, feed to position at 5-10 inches per minute.

l Check a suspected error with another indicator or method for verification.
l Ensure that the indicator is parallel to the axis being checked to avoid tangential reading errors.
l Center drill holes before using jobber length drills if accuracy is questioned.
l Once machining practices have been eliminated as the source of the problem, determine specifically

what the machine is doing wrong.

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TROUBLESHOOTING

´ Machine will not interpolate a round hole.

l Check that the machine is level (see "Installation" section).
l Check for backlash ("Servo Motors/Leadscrews" section).

´ Bored holes do not go straight through the workpiece.

l Check that the machine is level (see "Installation" section).
l Check for squareness in the Z axis.

´ Machine bores holes out-of-round.

l Check that the machine is level (see "Installation" section).
l Check the sweep of the machine (see "Spindle Sweep Adjustment" section).

´ Bored holes are out of round or out of position.

l Check for thermal growth of the leadscrew (see "Thermal Growth" section).
l The spindle is not parallel to the Z axis. Check the sweep of the machine (see "Spindle Sweep

Adjustment")

´ Machine mis-positions holes.

l Check for thermal growth of the leadscrew (see "Thermal Growth" section).
l Check that the machine is level (see "Installation" section).
l Check for backlash (see "Servo Motors/Leadscrews" section).
l Check the squareness of the X axis to the Y axis.

June 1998

´ Machine leaves large steps when using a shell mill.

l Check that the machine is level (see "Installation" section).
l Check the sweep of the machine (see "Spindle Sweep Adjustment" section).
l Cutter diameter too large for depth of cut.

FINISH

´ Machining yields a poor finish

l Check for gearbox vibration. This is the most common cause of a poor finish.
l Check for backlash ("Accuracy/Backlash")
l Check the condition of the tooling and the spindle.
l Check for spindle failure.
l Check the condition of the axis motors.
l Check that the machine is level (See the Installation Manual).

´ Poor Y-axis finish

Check the hydraulic counterbalance system pressure. If pressure is low, check for:

l abnormal noises from counterbalance system
l oil leaks (esp. at fittings and at filter at top of cylinder)
l bound cylinder

T HERMAL G ROWTH

A possible source of accuracy and positioning errors is thermal growth of the leadscrew. As the machine
warms up, the leadscrews expand in all three linear axes, causing accuracy and positioning errors, or
inaccurate boring depths. This is especially critical in jobs that require high accuracy, machining multiple
parts in one setup, or machining one part with multiple setups.

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TROUBLESHOOTING

Note: The leadscrew will always expand away from the motor end.

VERIFY THERMAL GROWTH

There are a number of ways to verify the problem. The following procedure will verify thermal growth of the
X-axis leadscrew in a machine that has not been warmed up:

1. Home the machine. In MDI mode, press POSIT and PAGE DOWN to the OPER page.

2. Jog to an offset location on the table (example: X-15.0" Y-8.0" ). Select the X axis and press the

ORIGIN key to zero it. Select the Y axis and zero it.

3. Press the OFSET key, then scroll down to G110 (or any unused offset). Cursor to X and press PART
ZERO SET twice. This will set X0, Y0 at this position.

4. Enter the following program. It will start at the new zero position, rapid 10 inches in the X direction,
feed the final .25 inches at 10 inches/min., and then repeat the X movement.

G00 G90 G110 X0 Y0;
X10.0;
G01 X10.25 F10. ;
M99;

5. In order to set up the indicator, run the program in SINGLE BLOCK mode, and stop it when X is at

10.25". Set the magnetic base on the table, with the indicator tip touching the spindle housing in the
X-axis, and zero it.

6. Exit SINGLE BLOCK mode, and run the program for a few minutes. Enter SINGLE BLOCK mode again,
stop the program when X is at 10.25", and take a final reading on the indicator. If the problem is
thermal growth, the indicator will show a difference in the X position.

Note: Ensure the indicator setup is correct as described in "Accuracy" section. Errors in
setup are common, and often incorrectly appear to be thermal growth.

7. A similar program can be written to test for thermal growth in the Y and Z axes, if necessary.

SOLUTIONS

Since there are many variables that affect thermal growth, such as the ambient temperature of the shop and
program feed rates, it is difficult to give one solution for all problems.

Thermal growth problems can generally be eliminated by running a warm-up program for approximately 20
minutes before machining parts. The most effective warm-up is to run the current program, at an offset Z
position above the part or table, with the spindle "cutting air". This will allow the leadscrews to warm up to
the correct temperature and stabilize. Once the machine is at temperature, the leadscrews won't expand any
further, unless they're allowed to cool down. A warm-up program should be run after each time the machine
is left idle.

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TROUBLESHOOTING

1.2 SPINDLE

N OT T URNING

´ Spindle not turning

l If there are any alarms, refer to "Alarms" section.
l Check that the spindle turns freely when machine is off.
l If motor turns but spindle does not, see "Spindle Drive Belts" and "Transmission" sections.
l Command spindle to turn at 1800 RPM and check spindle drive display. If display blinks bb, check

spindle orientation switch ("Spindle Orientation"). If spindle drive does not light the RUN LED,
check forward/reverse commands from IOPCB ("Electrical Service").

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 ("Electrical Service").
l If spindle is still not turning, replace spindle drive ("Electrical Service").
l Check for rotation of the gearbox. If the gearbox operates, check the drive belts ("Spindle Drive Belts").
l Disconnect the drive belts. If the spindle will not turn, it is seized and must be replaced ("Spindle").

Note: Before installing a replacement spindle, the cause of the previous failure must be
determined.

NOISE

June 1998

Most noises attributed to the spindle actually lie in the gearbox or drive belt of the machine. Isolate the
sources of noise as follows:

´ Excessive noise coming from the spindle head area

First determine if the noise is related to the RPM of the motor or the RPM of the spindle. For example: If
the noise appears at 2000 RPM in high gear, listen for a similar noise at 500 RPM in low gear. If the same
noise persists, the problem lies within the gearbox. If the noise disappears, the problem could be either the
gearbox or the spindle, and further testing is necessary.

Note: The gear ratio is 1:1.25 in high gear, and 3.2:1 in low gear.

l Check the drive belts' tension.

Ø If the noise persists, turn the drive belts over on the pulleys. If the noise is significantly different,

the belts are at fault. Replace the belts ("Spindle Drive Belts").

Ø If the noise does not change, remove the belts and go on to the next step.

l Run the gearbox with the drive belts disconnected. If the noise persists, the problem lies with the

gearbox.

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.

To break in a spindle, run the following program (it will take approximately 6 hours):

S300 M03 S4000 M03 S7500 M03
M97 P6G4 M97 P6040 M97 P6040
S1000 M03 S4500 M03 M99
M97 P6040 M97 P6040 N6040

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TROUBLESHOOTING

S1500 M03 S5000 M03 G04 P900.
M97 P6040 M97 P6040 M05
S2000 M03 S5500 M03 G04 P900.
M97 P6040 M97 P6040 G04 P900.
S2500 M03 S6000 M03 M99
M97 P6040 M97 P6040
S3000 M03 S6500 M03
M97 P6040 M97 P6040
S3500 M03 S7000 M03

M97 P6040 M97 P6040
This program will step the spindle speed from 300 RPM up to 7500 RPM at regular intervals of time, stop the
spindle and allow it to cool to room temperature, then restart it so the temperature can be monitored.

l Check the drive belt tension. Belts that are too tight will cause heating of the top bearing

in the spindle housing.

l If at any time during this procedure the spindle temperature rises above 150 degrees, start

the procedure over from the beginning. If the spindle temperature rises above 150 degrees
a second time, it has failed and must be replaced.

S TALLING / LOW T ORQUE

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, and run very hot and very loud. Investigate machining problems
before concluding that the problem exists with the spindle or spindle drive.

SPINDLE D RIVE

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 100oC, 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 deceleration

rate or reduce the frequency of spindle speed changes.

ORIENTATION

´ Spindle loses correct orientation

Non Vector Drive

l Check alarm history, looking for spindle overload and axis overcurrent alarms. These alarms mean

the machine is not being properly operated.

l Check the orientation ring for tightness. Ensure the shaft on which the ring mounts is clean and is free

of grease and oil.

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 shot pin on the gearbox for binding, damage, and proper operation. Replace it if it is

damaged.

l Check the switch on the shot pin against the Diagnostic display. Replace the switch if it is found to be

faulty.

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TROUBLESHOOTING

Vector Drive

l Check alarm history. Look for Spindle Z Fault, or Spindle Reference Missing alarms. If these alarms exist,

there may be a defective spindle encoder, or a broken ground or shield connection.

l Check parameters.
l Check for a mechanical slip at the contact points of all components between the spindle encoder.

TOOLS STICKING IN TAPER

´ Tool sticking in the taper keeps ATC from pulling the tool out, 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). It may also occur due to
heavy milling, milling with long tooling, or cuts with heavy vibration. If sticking only
occurs during these situations, no service is necessary.

l Check the condition of the 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 key on the keypad. If sticking is
observed, the deflection is not caused by improper ATC adjustment, but is a problem in the spindle head
of the machine.

l Ensure the spindle is not running too hot.

June 1998

1.3 SERVO MOTORS / LEAD SCREWS

NOT O PERATING

All problems that are caused by servo motor failures should register an alarm. Check the alarm history to
determine the problems cause before any action is taken.

´ Servo motor is not functioning

l Check the power cable from electrical cabinet to ensure connection is tight.
l Encoder is faulty or contaminated (Alarms 139-142, 153-156, 165-168, 182-185). Replace motor

assembly on brushless machines, replace the encoder on brush machine.

l Open circuit in motor (Alarms 139-142, 153-156, 182-185). Replace motor assembly ("Axis Motor

Removal / Installation").

l Motor has overheated, resulting in damage to the interior components (Alarms 135-138, 176). Replace

motor assembly ("Axis Motor Removal/Installation").

l Wiring is broken, shorted, or missing shield (Alarms 153-156, 175, 182-185).
l Motor has overheated; no damage to the interior components. "Overheat" alarm has been triggered.

After a thorough check of motor (DO NOT DISASSEMBLE!), take necessary steps to eliminate the
problem and alarm to resume operation. If motor is still inoperable, replace motor assembly ("Axis
Motor Removal/Installation").

l Check for broken or loose coupling between the servo motor and the lead screw. Replace or repair the

coupling ("Axis Motor Removal/Installation")

l Check for a damaged lead screw, and replace if necessary ("Lead Screw Removal and Installation"

section).

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TROUBLESHOOTING

Note: If a lead screw fails, it is most often due to a failed bearing sleeve. When replac­ing the lead screw in an older machine, always replace the bearing sleeve with the
current angular contact bearing sleeve ("Bearing Sleeve Removal and Installation"
section).

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 problems 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("Axis Motor Removal/Installation" section).

l Noise is caused by bearings. Rolling, grinding sound is heard coming from the motor. If bearings

are making a consistently loud sound, replace the bearing sleeve.

´ Lead screw noise

l Ensure oil is getting to the lead screw through the lubrication system (See Air and Oil Diagram). Check

for a plugged metering valve.

l Check for damage to the bearing sleeve.

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 to
the lead screw shaft where the bearing sleeve is mounted.

Ø 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. If incorrect, perform alignment procedure in "Lead Screw"

section.

l 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.

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TROUBLESHOOTING

A CCURACY / BACKLASH

Accuracy complaints are usually related to tooling, programming, or fixturing problems. Eliminate these
possibilities before working on the machine.

´ Poor 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 (brush motors only).

l Check parameters for that axis.
l Check for backlash in the lead screw as outlined below:

INITIAL PREPARATION -

Turn the machine ON. Zero return the machine and jog the column to the approximate center of its travel in
the X and Y directions. Move the Z-axis to it's full travel forward.

CHECKING X-AXIS:

1. Set up a dial indicator and base on the mill table as shown in Fig. 1-1.

June 1998

12

Figure 1-1. 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:

l Zero the dial indicator.
l Press the MDI key on the control panel.
l Press the HANDLE JOG key on the control panel.

The Distance to go display in the lower right hand corner of the screen 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 (+) X

direction. Jog back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.

4. Repeat Step 3 in the negative (-) direction.

TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD NOT EXCEED
.0002.

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TROUBLESHOOTING

An alternate method for checking backlash is to place the dial indicator as shown in Fig. 1-1 and manually
push the mill column to the left and right while listening for a 'clunk'. The dial indicator should return to zero
after releasing the column.

Note: The servo motors must be on to check backlash by this method.

5. If backlash is found, refer to "Backlash - Possible Causes" in this section.

CHECKING Y-AXIS:

1. Set up a dial indicator and base on the mill table as shown in Fig. 1-2.

Figure 1-2. 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:

l Zero the dial indicator.
l Press the MDI key on the control panel.
l Press the HANDLE JOG key on the control panel.

The Distance to go display in the lower right hand corner of the screen 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 3 in the negative (-) direction.

TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD NOT EXCEED
.0002.

An alternate method for checking backlash is to place the dial indicator as shown in Fig. 3-2 and manually
push up and down on the spindle head while listening for a 'clunk'. The dial indicator should return to zero
after releasing the spindle head.

Note: The servo motors must be on to check backlash by this method.

5. If backlash is found, refer to "Backlash - Possible Causes" in this section.

96-9010

13

TROUBLESHOOTING

CHECKING Z-AXIS:

1. Set up a dial indicator and base on the mill table as shown in Fig. 1-3.

Figure 1-3. Dial indicator in position to check Z-axis.

June 1998

2. Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows:

l Zero the dial indicator.
l Press the MDI key on the control panel.
l Press the HANDLE JOG key on the control panel.

The Distance to go display in the lower right hand corner of the screen 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 (+) Z

direction. Jog back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.

4. Repeat Step 3 in the negative (-) direction.

An alternate method for checking backlash is to place the dial indicator as shown in Fig. 1-3 and manually
push the column forward and back while listening for a clunk. The dial indicator should return to zero after
releasing the column.

Note: The servo motors must be on to check backlash by this method.

5. If backlash is found, refer to "Backlash - Possible Causes" in this section.

BACKLASH - POSSIBLE CAUSES:

If backlash is found in the system, check for the following possible causes:

l Loose SHCS attaching the ball nut to the nut housing. Tighten the SHCS as described in "Mechanical

Service" section.

l Loose SHCS attaching the nut housing to the column, head, or saddle, depending on the axis. Tighten

the SHCS as described in "Mechanical Service".

l Loose clamp nut on the bearing sleeve. Tighten the SHCS on the clamp nut.
l Loose motor coupling. Tighten as described in "Mechanical Service".
l Broken or loose flex plates on the motor coupling.

14

Note: The coupling cannot be serviced in the field and must be replaced as a unit if it is
found to be defective.

96-9010

June 1998

TROUBLESHOOTING

l Loose SHCS attaching the bearing sleeve to the motor housing or top of column. Tighten as described

in "Lead Screw" section.

l Defective thrust bearings in the bearing sleeve. Replace the bearing sleeve as outlined in "Bearing

Sleeve" section.

l Loose SHCS attaching the axis motor to the motor housing. If the SHCS are found to be loose, inspect

the motor for damage. If none is found, tighten as described in "Axis Motor" section. If damage is found,
replace the motor.

l Incorrect backlash compensation number in Parameter 13, 27, or 41.
l Worn lead screw.

V IBRATION

´ 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. If needed, replace the DRIVER PCB ("Electrical Service").

l Check all parameters of the suspected axis against the parameters as shipped with the machine. If there

are any differences, correct them 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, replace.

O VERHEATING

´ 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 users

application for excessive load or high duty cycle. Check the lead screw for binding ("Accuracy/Backlash"
section). If the motor is binding by itself, replace in accordance with "Axis Motor" section.

F OLLOWING E RROR

´ Following error alarms occur on one or more axes sporadically

l Check DC bus voltage on "Diagnostics" page 2. Verify this voltage on the drive cards in the control panel.

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 for shorts.
l Replace driver card ("Electrical Service").
l Replace servo motor ("Axis Motor").

96-9010

15

TROUBLESHOOTING

1.4 AUTOMATIC TOOL CHANGER

DEFLECTION

Deflection is usually caused by ATC misalignment, and sometimes caused by damaged or poor quality tooling,
a 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 adjustment of the Y offset (Parameter 211).
l Check to see if the carousel is set correctly ("Tool Changer Alignment" section in Mechanical Service).
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 1/4" before the tool holder
is seated in the taper. Replace the drawbar.

´ Tool holder sticking in the spindle taper accompanied by a popping noise as the tool holder

pops out of the spindle taper

June 1998

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. It may also occur in cuts
with heavy vibration. If sticking occurs only during these circumstances, no service is
necessary.

l Check the condition of the customers tooling, verifying the taper on the tool holder 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. See "Spindle" section
for spindle cartridge replacement.

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 key on the keypad. If sticking is
observed, the deflection is not caused by improper ATC adjustment, but is a problem in the spindle head
of the machine. See "Spindle" section for spindle cartridge replacement.

´ During a tool change, ATC appears to be pulled in; no popping noises

l Check the adjustment of the Y offset (Parameter 211).

Note: If the offset 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 key

is pressed. If they do not move freely, the ATC will be pushed out about 1/4" before the tool holder is
seated in the taper. Replace the drawbar.

´ Tool holders twist against extractor fork during a tool change

l Check the alignment of the ATC in the Z axis ("Tool Changer Alignment" section in Mechanical Service).
l Check rotational alignment (Parameter 215).

16

96-9010

June 1998

TROUBLESHOOTING

´ Tool holders spin at all pockets of the ATC

l ATC is rotationally misaligned. Check the CAROUSEL OFFSET (Parameter 215). Realign the ATC

("Automatic Tool Changer")

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.

´ Tool holders spin only at certain pockets of the ATC

l Check all of the extractor forks to ensure they are centered in the pocket of the ATC. Also, check the

alignment and CAROUSEL OFFSET (Parameter 215). See "Extractor Fork Replacement", if necessary.

Note: If the ATC shows the problem as described here, each extractor fork must be
checked and centered to eliminate the possiblilty of the ATC being aligned against an
incorrectly-centered fork.

CRASHING

Crashing of the ATC is usually a result of operator error. The most common ATC crashes are outlined as
follows:

´ ATC properly deposits a tool holder in the spindle, but the tools are dropped onto the

machine table or Z-axis way cover

l Inspect the balls and the Belleville springs in the drawbar. See appropriate section and replace drawbar.

´ The part or fixture on the mill table crashes into long tooling or into the ATC itself during a

tool change

l Inspect the pocket involved in the crash for damage and replace parts as necessary.
l The machine will normally home the Z-axis as part of the tool change sequence. Check Parameter 209

bit "TC Z NO HOME", and ensure it is set to zero.

´ The part or fixture on the mill table crashes into long tooling or into the ATC itself when

machining

l Either reposition the tools to remove the interference, or program the carousel to rotate long tooling

out of the way of the part (USE THIS ONLY AS A LAST RESORT). CAUTION! If the carousel has to be
programmed to rotate long tools clear of the part, the correct carousel position must be programmed
back in before a tool change can be executed.

Note: If these crashes occur, thoroughly inspect the ATC for damage. Pay close
attention to the extractor forks and the sliding covers on the ATC carousel. See the
appropriate section for extractor fork replacement.

96-9010

D AMAGED EXTRACTORS

Damage to the ATC is caused by either very hard or repeated crashes.

´ ATC extractor forks are damaged

l Check the condition of the extractor mounting holes in the carousel. If the threads are damaged, they

must be repaired or the carousel replaced. See appropriate section for extractor fork replacement.

17

TROUBLESHOOTING

SPINDLE OPERATION

´ ATC out of orientation with the spindle. Incorrect spindle orientation will cause the ATC

to crash, and Alarm 113 to be generated.

l Check the orientation of the spindle.

´ ATC will not run

l Check to be sure that the tool changer has been defined as a Horizontal (Parameter 209, bit "HORIZON

TAL" is set to 1.)

l In all cases where the tool changer will not run, an alarm is generated to indicate either a tool changer

in/out problem or an auxiliary axis problem. These alarms will occur either on an attempt to change
tools (ATC FWD) or zero return the machine (AUTO ALL AXES). Use the appropriate alarm to select one
of the following problems:

´ ATC carousel will not rotate. Carousel motor is getting power.

l Command a tool change, and feel for power being applied to the servo motor.

Ø If power is applied, but the carousel does not turn, check for binding between the servo motor

and the reducer ("Automatic Tool Changer" section). Check for a damaged servo motor or
bound reducer.

June 1998

Note: Do not attempt to repair the motor or to further isolate the problem in the motor.

´ ATC carousel will not rotate; servo motor is not getting power

l Command a tool change, and feel for power being applied to the turret motor.
l Check for power supply to the tool changer single axis control (auxiliary axis control).
l Check for proper operation of the auxiliary axis control board.

1.5 GEARBOX AND SPINDLE MOTOR

The gearbox cannot be serviced in the field and must be replaced as a unit. NEVER remove a motor from the
gearbox on an HS-Series mill, as this will damage the gearbox and void the warranty.

NOISE

When investigating complaints of gearbox noise, also refer to "Spindle" troubleshooting section. Gearboxes
can be damaged by failed air solenoids, gearshift cylinders, or bearings, resulting in noisy operation. While
gearbox vibration can cause a poor finish on a workpiece, noisy gearbox operation may not.

´ Excessive or unusual noise coming from the gearbox.

Operate the machine in both high and low gears. Monitor the gearbox for noise in both gear positions, and
determine if the pitch of the noise varies with the motor or the output shaft speed.

18

Ø If the noise only occurs in one gear throughout the entire RPM range of that gear position, the

problem lies with the gearbox, and it must be replaced ("Transmission" section).

Ø If the noise occurs in both gear positions, disconnect the drive belt and repeat the previous step.

If the noise persists, the gearbox is damaged and must be replaced ("Transmission" section).

Ø With the drive belt disconnected, run the machine at 1000 RPM in high gear. Command a change

of direction and listen for a banging noise in the gearbox as the machine slows to zero RPM and
speeds back up to 1000 RPM in reverse. If the noise occurs, the motor has failed and the gearbox
must be replaced.

96-9010

June 1998

TROUBLESHOOTING

GEARS WILL N OT CHANGE

´ Machine will not execute a gear change.

Note: Whenever a gear change problem occurs, an alarm will also occur. Refer to the
ALARMS section to diagnose each problem before working on the machine.

l Check air supply pressure. If pressure is too low, the gears will not change.
l Check the air solenoid assembly on the solenoid bracket. If the solenoid operates properly and the limit

switches on the gearbox operate properly, the problem lies with the gear change piston. Replace the
gearbox ("Transmission").

l Check contactor CB4.

LOW PRESSURE ALARM

´ Alarm 179 (Low Pressure Transmission Oil) has been triggered.

l Check for low oil supply in reservoir.
l Check that pump motor is running.
l Check for an air leak in the suction side of the pump.
l Check for a bad pressure sensor.
l Check for a broken or damaged cable.
l Check for a worn pump head.

96-9010

19

TROUBLESHOOTING

1. 6 PALLET CHANGER

June 1998

ALARM

180

PALLET NOT CLAMPED

Intended to keep the operator
from machining on a pallet that
is unclamped.

1001

INDEX ST UNLOCKED

Index station not in correct po­sition for a pallet change.

1002

PALLET LOCKED DOWN

Pallets did not lift even
though the main drawbar
is fully unscrewed.

POSSIBLE CAUSES

 Pallet change sequence interrupted by RESET,

FEED HOLD, E-STOP, or POWER OFF before
complete. Then, with the pallet not fully
clamped, an attempt was made to run the

spindle.

o

 Load station not in 0

 Indexing handle jammed down.
 Load station switch:

l unplugged
l defective

 Load station drawbar motor:

l unplugged
l not getting power
l broken shaft
l broken idler in gear train
l carbon buildup on brushes

 Load station floating nut assembly spinning,

not allowing drawbar to thread out of the pallet
nut, due to:

l damaged load station drawbar threads
l contamination of floating nut assembly
l weak springs in floating nut assembly

position.

COURSE OF ACTION

 Execute an M50 command (pallet change) in

MDI mode, ensuring the sequence is completed
this time.

 Orient the load station, then execute an M50

command (pallet change)

 Free indexing handle.
 Ensure switch is plugged in. If so, replace.

 Replace motor if necessary. Check resistors on

I/O board. Check M22 relay contacts on I/O
board.

 Replace damaged component. Check drawbar

threads. Check pallet nut threads.

1003

PALLETS JAMMED

Pallet changer did not rotate,
rotate fast enough, or lower

fast enough.

 Load station drawbar motor I/O board:

l relays have failed (M22)
l circuit resistors have failed (M22 output)

 Missing spring stack and/or nylon thrust

washers on load station drawbar.

 Lift cylinder Up/Down limit switches installed

incorrectly or plugged in incorrectly.

 Supply air pressure too low to lift pallets.

 Weight on pallet changer exceeds system

capability.

 Obstruction to H-frame or pallet rotation
 CW/CCW limit switches unplugged or reversed

on mounts

 Air lines disconnected or reversed on cylinder
 CW/CCW air solenoids not functioning or

disconnected

 Air pressure too low to rotate load

 Too much air pressure on lift cylinder causing

excessive resistance to rotation

 No signal from I/O PCB Pallet CW/CCW

 Replace I/O board.

 Install spring stack and/or nylon thrust washers.

Check motor integrity.

 Reinstall limit switches.

 Check all hoses and solenoid valve connections,

and system air pressure is adequate.

 Check system pressure. If correct, lessen the

load on pallet changer.

 Check for physical obstructions.
 Ensure discrete inputs RP CW and RP CCW on

the Diagnostics page are correct (correct one
reads "1" while other reads "0").

 Replace if necessary.
 Replace if necessary.

 Check supply air pressure. Check all air hoses

and fittings. Check for failed pallet rotate
cylinder.

 Lower supply air pressure at solenoid.

 Check connectors / wiring. Replace I/O board

if necessary.

20

96-9010

June 1998

TROUBLESHOOTING

CW/CCW SWITCH ILLEGAL

1004

CONDITION

Limit switches erroneously
indicate that the pallet changer
is rotated fully CW and CCW

at the same time.

1007

UP/DOWN SWITCH ILLEGAL

CONDITION

Limit switches erroneously
indicate that the pallet changer
is fully lifted and lowered at
the same time.

1008

MAIN DRAWBAR LOCKED IN

UP POSITION

The main drawbar will not
unclamp the pallet.

 CW/CCW limit switch:

l defective
l erroneously tripped (by foreign object,etc.)

 UP/DOWN limit switch:

l defective
l erroneously tripped (by foreign object,etc.)
l wired incorrectly

 Main drawbar and/or pallet nut are damaged
 Main drawbar up limit switch:

l unplugged
l defective

 Main drawbar motor:

l unplugged
l broken output shaft at snap ring groove
l failure
l gear train failure

 Ensure discrete inputs RP CW and RP CCW on

the Diagnostics page are correct (correct one
reads "1" while other reads "0"). The failed switch
will be the one not tripped when alarm occurs.
Check for physical obstructions.

 Ensure discrete inputs RP UP and RP DN on the

Diagnostics page are correct (correct one reads
"1" while other reads "0"). The failed switch will
be the one not tripped when alarm occurs. Check
for physical obstructions.

 Replace damaged component
 Ensure discrete inputs RPDBDN and RPDBUP on

the Diagnostics page are correct (both read "1"
when main drawbar is up, and both read "0" when
main drawbar if down). Replace switch if
necessary.

 Replace motor or gear train components if

necessary.

1009

MAIN DRAWBAR LOCKED

IN DOWN POSITION

The main drawbar will not
clamp the pallet.

 Clutch failure: reverse drive pin spring in clutch

hub has failed to push the pin out due to:

l dust contamination
l broken spring

 Broken drive belt between motor and drawbar
 Power supply relays (I/O board) failure (M21)

 Current limit circuit is set incorrectly (esp. if

replaced I/O board)

 Main drawbar down limit switch:

l unplugged
l defective

 Main drawbar floating nut assembly spinning,

not allowing drawbar to thread into the pallet
nut, due to:

l damaged main drawbar threads
l contamination of floating nut assembly

 Main drawbar motor:

l unplugged
l broken output shaft at snap ring groove
l failure
l gear train failure

 Clutch failure: loss of torque
 Broken drive belt between motor and drawbar
 Contamination of drawbar splines preventing

free motion

 Bearing sleeve bearings seized due to

contamination

 Power supply relays (I/O board) failure

 Replace clutch assembly

 Replace drive belt
 If power supply relay has failed, replace. If motor

directional relay, replace I/O board.

 Set current limit circuit correctly

 Ensure discrete inputs RPDBDN and RPDBUP on

the Diagnostics page are correct (both read "1"
when main drawbar is up, and both read "0" when
main drawbar is down). Replace switch if
necessary.

 Replace damaged component

 Replace motor or gear train components if

necessary.

 Replace clutch assembly
 Replace drive belt
 Replace drawbar and bearing sleeve assembly.

Check for V-seals. Identify source of
contamination.

 Replace bearing sleeve assembly. Check for V-

seals. Identify source of contamination.

 If power supply relay has failed, replace. If motor

directional relay, replace I/O board.

96-9010

21

TROUBLESHOOTING

June 1998

MAIN DRAWBAR SWITCH

1010

ILLEGAL CONDITION

Limit switches erroneously
indicate that drawbar has
tripped the down switch, but
not the up switch.

1011

MAIN DRAWBAR

UNCLAMP TIMEOUT

Main drawbar has unscrewed
from pallet nut, but reached
the down position too slowly.

 Main drawbar up/down limit switches:

l mounted in reversed positions
l plugged into wrong connectors

on solenoid mounting bracket

l defective

 Main drawbar floating nut assembly spinning,

not allowing drawbar to thread down, due to:

l damaged main drawbar threads
l contamination of floating nut assembly
l weak springs in floating nut assembly

 Main drawbar motor:

l unplugged
l broken output shaft at snap ring groove
l failure
l gear train failure (unlikely)

 Clutch failure: loss of torque
 Broken drive belt between motor and drawbar
 Power supply relays (I/O board) failure

 Current limit circuit is set incorrectly

 Ensure discrete inputs RPDBDN and RPDBUP on

the Diagnostics page are correct (both read "1"
when main drawbar is up, and both read "0" when
main drawbar is down). Replace switch if
necessary.

 Replaced damaged component. Check drawbar

threads. Check pallet nut threads.

 Replace motor or gear train components if

necessary.

 Replace clutch assembly
 Replace drive belt
 Replace I/O board

 Set current limit circuit correctly

1012
MAIN DRAWBAR
CLAMP TIMEOUT

Main drawbar started to travel
upward, but reached the up

position too slowly.

1119

(NO ALARM NAME)

 Main drawbar floating nut assembly spinning,

not allowing drawbar to thread into the pallet
nut, due to:

l damaged main drawbar threads
l contamination of floating nut assembly
l weak springs in floating nut assembly

 Main drawbar motor:

l unplugged
l broken output shaft at snap ring groove
l failure
l gear train failure (unlikely)

 Clutch failure: loss of torque

 Broken drive belt between motor and drawbar
 Current limit circuit is set incorrectly (esp. if

replaced I/O board)

 Power supply relays (I/O board) failure (M21)

 Corrupted pallet changer macro

 Replaced damaged component. Check drawbar

threads. Check pallet nut threads.

 Replace motor or gear train components if

necessary.

 Clutch failure will usually be apparent from

the clamp force and cut quality. Replace
clutch assembly.

 Replace drive belt
 Set current limit circuit correctly

 If power supply relay has failed, replace. If motor

directional relay, replace I/O board.

 Reload macro

PALLET DOES NOT SIT

CORRECTLY ON

INDEXING PINS

22

 H-frame out of alignment
 Hardstops not adjusted correctly
 Excess weight causes the pallet to go out of

alignment

 Refer to "H-frame alignment" section
 Refer to "Pallet Rotation Hardstop Adjustment"
 Check the load on the pallet changer. If it

exceeds the weight capacity, reduce the loads.

96-9010

June 1998

TROUBLESHOOTING

EXECUTION OF AN M50
RESULTS IN A "RUNNING"
MESSAGE, BUT NOTHING

HAPPENS, AND NO ALARM IS

GENERATED.

 Load station not properly oriented or, if M36 is

being used, PART READY light not pressed.

 Pallet changer macro program was loaded

before MACROS were enabled, or while Setting
23, "9xxxx PROGS EDIT LOCK", was ON.

 Ensure load station is properly oriented. If an

M36 is being used, press the flashing PART
READY light on the front switch box.

 Press RESET. Go to Setting 74, "9xxxx PROGS

TRACE", and turn it on. From MDI, execute an
M50. If the program is executing very rapidly,
but nothing is happening, turn off Setting 74 and
reload the 09000 macro.

96-9010

23

TROUBLESHOOTING

1.7 THROUGH THE SPINDLE COOLANT

Note: Abrasive swarf from grinding or ceramic machining operations will cause heavy
wear of TSC coolant pump, coolant tip and drawbar. This is not covered by warranty on
new machines. Notify HAAS Service Dept. if machine is being used for this application.

C OOLANT O VERFLOW

To begin troubleshooting, check the alarm history to determine the problems cause before any action is
taken.

´ Coolant pouring out of spindle head

l Check the customer's tooling for through holes in the pull stud, holder and tool.
l Check the purge and drain lines connected to the seal housing are intact. If not replace with (58-2010)

5/32" OD nylon tubing.

l Check for TSC seal failure. If failure is found, replace the seal housing(30-3298). Refer to the

appropriate steps in"TSC-Tool Release Piston Replacement" section for procedure.

l Check pre-charge pressure in accordance with TSC "Pressure Regulator Adjustment' section and reset

if necessary. Low pre-charge pressure can cause coolant to dump into the spindle head.

l Ensure the coolant pump relief valve has not been tampered with (yellow paint band is intact). Check

the coolant pump pressure (should be 300 psi for high pressure TSC and 140 psi for old style TSC), with
a standard (non-TSC) tool holder in spindle. If pump pressure is above 310 psi for high pressure TSC or
above 140 psi for old style TSC, reset the pump relief valve in accordance with the "Setting TSC Pump Relief
Valve".

June 1998

´ Excessive coolant flow out of drain line
´ Pulsating flow through tool and drain line

l Check pre-charge pressure in accordance with TSC "Pressure Regulator Adjustment" section. Reset

precharge pressure if necessary. Low pre-charge pressure will cause heavy or pulsating flow from the
drain line. Check main air pressure regulator for 85 psi. A higher supply pressure will reduce precharge
pressure. Lower supply pressure will increase precharge pressure.

l Ensure the coolant pump relief valve has not been tampered with (yellow paint band is intact). Check

the coolant pump pressure (should be 300 psi for high pressure TSC and 140 psi for old style TSC), with
a standard tool holder in spindle. If pump pressure is above 310 psi for high pressure TSC or above 140
psi for old style TSC, reset the pump relief valve in accordance with the "Setting TSC Pump Relief Valve".

L OW C OOLANT

´ Alarm 151, "Low Thru Spindle Coolant"

l Check coolant tank level. Check for slow coolant drainage from the machine enclosure.
l Check the filter and intake strainer for any clogging. Read filter gauges with TSC running with no tool in

spindle. Check coolant lines for any clogging or kinking. Clean or replace as needed.

l Check for overheating TSC pump motor. Single phase motors have a built in thermal cut-out. Three phase

motors have a thermal circuit that will interrupt power to the relay coil.

l If received at start-up, check that the breaker hasn't tripped and that the pump is turning. Check the

electrical continuity of cables.

l Check for pressure switch failure (refer to "Testing the Coolant Pressure Switch" section), and replace

if necessary. Check the electrical continuity of the switch cable and the control function by monitoring
the "LO CLNT" bit on the Diagnostics page (0 = pressure on, 1= pressure off). Shorting the leads should
cause the bit to switch from 1 to 0. Check this before replacing the pressure switch. Leaking switches
can give intermittant alarms.

l Check pump pressure with no tool in the spindle. If the pressure is less than 60 psi, replace the pump.

24

96-9010

June 1998

TROUBLESHOOTING

l May be generated if another machine alarm occurs during TSC operation.
l For the old TSC system, if the drawbar was replaced, check that the hole through the drawbar is 0.156

dia and not 0.190 dia. Replace the drawbar with the correct one if it is 0.190 dia.

COOLANT TIP WEAR

The carbide coolant tip should last for the life of the machine. The old bronze coolant
tip should be checked every 1000 hours of TSC operation.

´ Coolant tip is wearing quickly and needs frequent replacement.

l Check the filtration system and that the coolant is not contaminated.
l Check pre-charge pressure (refer to the TSC Pressure Regulator Adjustment" section). Heavy wear

will occur if this pressure is too high.

l Main air supply below 85 psi can cause excessive pre-charge pressure and heavy coolant tip wear.

Note: Abrasive swarf from grinding or ceramic machining operations will cause heavy
wear of TSC coolant pump, coolant tip and drawbar. This is not covered by warranty on
new machines. Notify HAAS Service Dept. if machine is being used for this application.

P RE-CHARGE F AILURE

´ Alarm 198, "Precharge Failure"

Note: This alarm only applies to the TSC system.

l Check for broken or disconnected pre-charge air line, and replace if necessary.
l Check if the "Tool Clamped" limit switch is sticking, and replace if necessary.

l Check the "Tool Clamped" limit switch adjustment (refer to "Tool Clamp/Unclamp Switch Adjustment").
l Check for low pre-charge pressure (refer to "Pressure Regulator Adjustment" section).
l Check pre-charge solenoid for proper operation.
l May be generated if another machine alarm occurs during TSC operation.

1.8 HYDRAULIC COUNTERBALANCE

M ECHANICAL D IAGNOSIS

Important! Hydraulic counterbalance oil is dyed red for easier recognition.

´ Noise in the system

l Slight moan or creaking at slow speeds is normal for rubber seals
l While Y-axis is in motion a whistle sound at tank location is normal fluid flow.
l Verify cylinder is seated correctly in counterbore. If not then reseat the cylinder.
l Bumping or grinding noise indicates a mechanical cylinder failure. Replace cylinder assembly.
l Look for galling and wear on cylinder shaft. If so replace the cylinder assembly.

96-9010

´ System is not holding pressure and/or has an E-STOP (Alarm 107) that cannot be

reset.

Check for accurate pressure readings. If low then the following items need to be checked:

l Check for leaks at all cylinder fittings. If leaking then replace cylinder assembly.
l Remove the rear panel of the machine and look for any red oil pooled at the bottom of the column.

If so, then fittings or seals could be damaged. Replace cylinder assembly.

l Remove cylinder vent fitting. If there is red oil inside the vent cavity then the cylinder

assembly needs replacement.

l Check for leaks at all hydraulic tank fittings. If leaking then tank assembly needs replacement.

25

TROUBLESHOOTING

´ Over Current alarms

l Pressure is set too high
l Pressure is set too low
l Too much oil has been added. (Insufficient gas volume causes large pressure rise)
l Hydraulic cylinder is binding or is misaligned. Replace cylinder assembly.
l Length of replacement cylinder incorrect.

´ Over Current / Following errors

l Pressure is set too high
l Pressure is set too low
l Too much oil has been added. (Insufficient gas volume causes large pressure rise)
l Hydraulic cylinder is binding or is misaligned. Replace cylinder assembly.
l Length of replacement cylinder incorrect.

1.9 ELECTRICAL TROUBLESHOOTING

CAUTION! Before working on any electrical components, power off the machine and wait
approximately 10 minutes. This will allow the high voltage power on the brushless amplifiers
to be discharged.

June 1998

ELECTRICAL ALARMS

´ Axis Drive Fault Alarm

l Blown amplifier - indicated by a light at bottom of amplifier when power is on. Replace amplifier.
l Amplifier or MOCON is noise sensitive. If this is the case, the alarm can be cleared and the axis will

run normally for a while.

To check an amplifier, switch the motor leads and control cables between the amplifier and the one
next to it. If the same problem occurs with the other axis, the amplifier must be replaced. If the
problem stays on the same axis, either the MOCON or control cable. The problem could also be the
axis motor itself, with leads either shorted to each other or to ground, which is very rare.

l Amplifier faulting out for valid reason, such as overtemp, overvoltage, or +/-12 volt undervoltage

condition. This usually results from running a servo intensive program, or unadjusted 12 volt power
supply. Replace amplifier.

Overvoltage could occur if regen load is not coming on, but this does not usually happen. The
problem could also be the axis motor itself, with leads either shorted to each other or to ground,
which is very rare.

´ Axis Overload

l The fuse function built into the MOCON has been overloaded, due to a lot of motor accel/decels, or

hitting a hard stop with the axis. This safety function protects the amplifier and motor, so find the
cause and correct it. If the current program is the cause, change the program. If the axis hits a hard
stop, the travel limits may be set wrong.

´ Phasing Error

l The MOCON did not receive the proper phasing information from the motors. DO NOT RESET the

26

machine if this alarm occurs. Power the machine down and back up. If the problem persists, it is
probably a broken wire or faulty MOCON connectors.

96-9010

June 1998

TROUBLESHOOTING

´ Servo Error Too Large

l This alarms occurs when the difference between the commanded axis position and the actual

position becomes larger than the maximum that is set in the parameter.

This condition occurs when the amplifier is blown, is not receiving the commands, or the 320 volt
power source is dead. If the MOCON is not sending the correct commands to the amplifier, it is
probably due to a broken wire, or a PHASING ERROR that was generated.

´ Axis Z Fault or Z Channel Missing

l During a self-test, the number of encoder counts was found to be incorrect. This is usually caused

by a noisy environment, and not a bad encoder. Check all shields and grounds on the encoder cables
and the motor leads that come into the amplifiers. An alarm for one axis can be caused by a bad
grounding on the motor leads of another axis.

´ Axis Cable Fault

l During a self-test, the encoder cable signals were found to be invalid. This alarm is usually caused

by a bad cable, or a bad connection on the motor encoder connectors. Check the cable for any
breaks, and the encoder connectors at the motor controller board. Machine noise can also cause
this alarm, although it is less common.

´ Alarm 101, "MOCON Comm. Failure"

l During a self-test of communications between the MOCON and main processor, the main processor

does not respond, and is suspected to be dead. This alarm is generated and the servos are stopped.
Check all ribbon cable connections, and all grounding. Machine noise can also cause this alarm,
although it is less common.

´ Alarm 157, "MOCON Watchdog Fault"

l The self-test of the MOCON has failed. Replace the MOCON.

P ROCESSOR S TACK D IAGNOSTIC

(DISCONNECT CABLES FROM A NORMAL OPERATING SYSTEM)

´ Remove low voltage cable from Video & Keyboard PCB

l Processors LED's are normal
l Runs fine and the CRT is Normal
l No keypad beep

´ Remove the Data & or Address buss from the Video & Keyboard PCB

l Processors LED's Normal - then Run goes out

´ Remove the Data & or Address buss from the Micro Processor PCB

l Processors LED's - CRT and Run are out

96-9010

27

TROUBLESHOOTING

K EYBOARD D IAGNOSTIC

Note: Refer to the "Cable Locations" section of this manual for a drawing of the Key­board Interface PCB.

June 1998

28

The following is an example of how to troubleshoot the keypad:

NOTE: Keypad Diodes 1-24 correspond to chart numbers 1-24

Example

1. Pressing the RESET button will cause diodes 1 and 17 to conduct.

l With the POWER OFF read across diode 1.
l A typical reading is between .400-.700 ohms, note your reading.

2. Press and hold the RESET button. If the diode is conducting, the reading should drop about .03 ohms.

l (If your reading was .486 and it dropped to .460, for a difference of .026; the diode is good)
l The same will hold true for diode 17 in this example. If the reading stays the same or there is no

change, the diode is not conducting. Pull P2 and read between pins 1 and 17.

l Press and hold <RESET>. The meter should read a short (0 ohms) if not the keypad is bad.

96-9010

June 1998

ALARMS

2. ALARMS

Any time an alarm is present, the lower right hand corner of the screen 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 are displayed and the RESET must be used to see the rest. The presence of any alarm will prevent the
operator from starting a program.

The ALARMS DISPLAY can be selected at any time by pressing the ALARM MESGS button. When there are no alarms,
the display will show NO ALARM. If there are any alarms, they will be listed with the most recent alarm at the bottom
of the list. The CURSOR and PAGE UP and PAGE DOWN buttons can be used to move through a large number of alarms.
The CURSOR right and left buttons can be used to turn on and off the ALARM history display.

Note that 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. See the editing topic for those errors.

The following alarm list shows the alarm numbers, the text displayed along with the alarm, and a detailed description
of the alarm, what can cause it, when it can happen, and how to correct it.

Alarm number and text: Possible causes:

101 MOCON Comm. Failure During a self-test of communications between the MOCON and main

processor, the main processor does not respond, and is suspected to be
dead. Check cable connections and grounding.

102 Servos Off 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 EMER
GENCY STOP, motor faults, tool changer problems, or power fail.

103 X Servo Error Too much load or speed on X-axis motor. The difference between the
Too Large 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. This alarm
can be caused by problems with the driver, motor, or the slide being run
into the mechanical stops.

104 Y Servo Error same as 103.

Too Large

105 Z Servo Error same as 103.

Too Large

106 A Servo Error same as 103.

Too Large

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 alarm will also be generated if there is a low pressure condition in the
hydraulic counterbalance system. In this case, the alarm will not reset until
the condition has been corrected.

96-9010 29

ALARMS

108 X 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.

109 Y Servo Overload same as 108.
110 Z Servo Overload same as 108.
111 A Servo Overload same as 108.

112 No Interrupt Electronics fault. Call your dealer.

113 Shuttle In Fault During a tool change, the carousel did not move out all the way. This alarm

can be caused by anything that stops motion of the carousel. Parameters
62 and 63 can adjust the time-out times.

114 Shuttle Out Fault During a tool change, the carousel did not move in (retract) all the way.

This alarm can be caused by anything that stops motion of the carousel.
Parameters 62 and 63 can adjust the time-out times.

115 Turret Rotate Fault Vertical mills only. Tool carousel motor not in position.

June 1998

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.

117 Spindle High Gear Fault Gearbox did not shift into high gear. During a change to high gear, the

spindle is rotated slowly while air pressure is used to move the gears but
the high gear sensor was not detected in time. Parameters 67, 70 and 75
can adjust the time-out times. Check the air pressure, the solenoids circuit
breaker CB4, and the spindle drive.

118 Spindle Low Gear Fault Gearbox did not shift into low gear. During a change to low gear, the spindle

is rotated slowly while air pressure is used to move the gears but the low
gear sensor was not detected in time. Parameters 67, 70 and 75 can adjust
the time-out times. Check the air pressure, the solenoids circuit breaker
CB4, and the spindle drive.

119 Over Voltage Incoming line voltage is above maximum. 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.

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 that
the regulator is set at 85 PSI.

121 Low Lub or Way lube is low or empty or there is no lube pressure or too high a

Low Pressure pressure. Check tank at rear of mill and below control cabinet. Also check

the connector on the side of the control cabinet. Check that the lube lines
are not blocked.

30 96-9010

June 1998

ALARMS

122 Control Overheat The control internal temperature is above 150 degrees 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.

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.

124 Low Battery Memory batteries need replacing within 30 days. This alarm is only generated at

power on and indicates that the 3.3 volt Lithium battery is below 2.5 volts. If this
is not corrected within about 30 days, you may lose your stored programs,
parameters, offsets, and settings.

125 Shuttle fault Tool carousel not initialized at power on, CYCLE START or spindle motion com

mand. This means that the tool carousel was not fully retracted to the Out position.

126 Gear Fault Gearshifter is out of position when a command is given to rotate the spindle. This

means that the two speed gear box is not in either high or low gear but is somewhere
in between. Check the air pressure, the solenoids circuit breaker CB4, and the
spindle drive.

127 No Turret Mark Vertical mills only. Tool carousel motor not in position.

129 M Fin Fault M-Fin was active at power on. Check the wiring to your M code interfaces. This test

is only performed at power-on.

130 Tool Unclamped The tool appeared to be unclamped during spindle orientation, a gear change, a

speed change, or TSC start-up. The alarm will also be generated if the tool
release piston is energized during Power Up. This can be caused by a fault in the
air solenoids, relays on the I/O assembly, the drawbar assembly, or in the wiring.

131 Tool Not Clamped 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.

132 Power Down Failure Machine did not turn off when an automatic power-down was commanded. Check

wiring to POWIF card on power supply assembly, relays on the IO assembly, and
the main contactor K1.

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.

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 drawbar
assembly.

135 X Motor Over Heat Servo motor overheat. The temperature sensor in the motor indicates

over 150 degrees F. This can be caused by an extended overload of the
motor such as leaving the slide at the stops for several minutes.

96-9010 31

ALARMS

136 Y Motor Over Heat same as 135.
137 Z Motor Over Heat same as 135.
138 A Motor Over Heat same as 135.

139 X 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.

140 Y Motor Z Fault same as 139.
141 Z Motor Z Fault same as 139.
142 A Motor Z Fault same as 139.

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 Time-out- Time allocated for use prior to payment exceeded. Call your dealer.

Call Your Dealer

145 X 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.

June 1998

146 Y Limit Switch same as 145
147 Z Limit Switch same as 145

148 A Limit Switch Normally disabled for rotary axis.

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 Tool changer not at home and Z is not either at machine home. If RESET,

Interlocked 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.

151 Low Thru Spindle For Through the Spindle Coolant option only. This alarm will shut off the spindle,

Coolant feed, and pump all at once. Check for low coolant tank level, any filter or intake

strainer clogging, or for any kinked or clogged coolant lines.

152 Self Test Fail Control has detected an electronics fault. 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 Broken wires or encoder contamination. All servos are turned off. This

Ch Missing can also be caused by loose connectors at P1-P4.

154 Y-axis Z same as 153.

Ch Missing

32 96-9010

June 1998

ALARMS

155 Z-axis Z same as 153.

Ch Missing

156 A-axis Z same as 153.

Ch Missing

157 MOCON Watchdog The self-test of the MOCON has failed. Replace the MOCON.

Fault

158 Video/Keyboard Internal circuit board problem. The VIDEO PCB in the processor stack is

PCB Failure tested at power-on. This could also be caused by a short in the front

panel membrane keypad. Call your dealer.

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.

160 Low Voltage The line voltage to control is too low. This alarm occurs when the AC

line voltage drops below 190 when wired for 230 volts or drops below
165 when wired for 208 volts.

161 X-Axis Drive Fault Current in X servo motor beyond limit. 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.

162 Y-Axis Drive Fault same as 161.
163 Z-Axis Drive Fault same as 161.
164 A-Axis Drive Fault same as 161.

165 X Zero Ret This alarm will occur if the home/limit switches move or are misadjusted.

Margin Too Small This alarm 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.

166 Y Zero Ret Same as 165.

Margin Too Small

167 Z Zero Ret Same as 165.

Margin Too Small

168 A Zero Ret Not normally enabled for A-axis.

Margin Too Small

169 Spindle Direction Problem with rigid tapping hardware. The spindle started turning in the

Fault wrong direction.

170 Phase Loss Problem with incoming line voltage between legs L1 and L2. This usually

indicates that there was a transient loss of input power to the machine.

171 UNUSED

96-9010 33

ALARMS

17 2 UNUSED

173 Spindle Ref The Z channel pulse from the spindle encoder is missing for rigid tapping

Signal Missing synchronization.

174 Tool Load Exceeded The tool load monitor option is selected and the maximum load for a tool

was exceeded in a feed. This alarm can only occur if the tool load monitor
function is installed in your machine.

175 Ground Fault A ground fault condition was detected in the 115V AC supply. This can

Detected be caused by a short to ground in any of the servo motors, the tool

change motors, the fans, or the oil pump.

176 Overheat Shutdown An overheat condition persisted for 4.5 minutes and caused an

automatic shutdown.

177 Overvoltage Shutdown An overvoltage condition persisted for 4.5 minutes and caused an

automatic shutdown.

178 Divide by Zero Software Error; Call your dealer.

179 Low Pressure Spindle coolant oil is low or low pressure condition in lines.

Transmission Oil

June 1998

180 Pallet Not Clamped The pallet change sequence was not completed for some reason (press

ing E-STOP, RESET, or FEED HOLD), and an attempt was made to run the
spindle.

182 X Cable Fault Cable from X-axis encoder does not have valid differential signals.

183 Y Cable Fault Same as 182.
184 Z Cable Fault Same as 182.
185 A Cable Fault Same as 182.

186 Spindle Not Turning Status from spindle drive indicates it is not at speed when expected.

187 B Servo Error Too Large Same as 103.
188 B Servo Overload Same as 108.
189 B Motor Overheat Same as 135.
190 B Motor Z Fault Same as 139.
191 B Limit Switch Same as 148.
192 B Axis Z Ch Missing Same as 153.
193 B Axis Drive Fault Same as 161.

194 B Zero Ret Margin Same as 168.

Too Small

195 B Cable Fault Same as 182.

196 Coolant Spigot Failure Vertical mills only.

197 100 Hours Unpaid Bill Call your dealer.

34 96-9010

June 1998

ALARMS

198 Precharge Failure During Through the Spindle Coolant operation, the precharge failed for

greater than 0.1 seconds. It will shut off the feed, spindle and pump all
at once. If received, check all air lines and the air supply pressure.

199 Negative RPM A negative spindle RPM was sensed.

201 Parameter CRC Error Parameters lost maybe by low battery. Check for a low battery and low

battery alarm.

202 Setting CRC Error Settings lost maybe by low battery. Check for a low battery and low

battery alarm.

203 Lead Screw CRC Error Lead screw compensation tables lost maybe by low battery. Check for

CRC Error low battery and low battery alarm.

204 Offset CRC Error Offsets lost maybe by low battery. Check for a low battery and low battery

alarm.

205 Programs CRC Error Users program lost maybe by low battery. Check for a low battery and

low battery alarm.

206 Internal Program Error Possible corrupted program. Save all programs to floppy disk, delete all,

then reload. Check for a low battery and low battery alarm.

207 Queue Advance Error Software Error; Call your dealer.

208 Queue Allocation Error Software Error; Call your dealer.

209 Queue Cutter Software Error; Call your dealer.

Comp Error

210 Insufficient Memory Not enough memory to store users program. Check the space available

in the LIST PROG mode and possibly delete some programs.

211 Odd Prog Block Possible corrupted program. Save all programs to floppy disk, delete all,

then reload.

212 Program Integrity Error Possible corrupted program. Save all programs to floppy disk, delete all,

then reload. Check for a low battery and low battery alarm.

213 Program RAM CRC Error Electronics fault; Call your dealer.

214 No. of Programs Indicates that the number of programs disagrees with the internal

Changed variable that keeps count of the loaded programs. Call your dealer.

215 Free Memory PTR Indicates the amount of memory used by the programs counted in the

Changed system disagrees with the variable that points to free memory. Call your

dealer.

217 X Axis Phasing Error Error occured in phasing initialization of brushless motor. This can be

caused by a bad encoder, or a cabling error.

218 Y Axis Phasing Error Same as above.

96-9010 35

ALARMS

219 Z Axis Phasing Error Same as above.
220 A Axis Phasing Error Same as above.
221 B Axis Phasing Error Same as above.
222 C Axis Phasing Error Same as above.
223 Door Lock Failure In machines equipped with safety interlocks, this alarm occurs when the

control senses the door is open but it is locked. Check the door lock circuit.

224 X Transition Fault Illegal transition of count pulses in X axis. 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 the MOCON or MOTIF PCB.

225 Y Transition Fault Same as above.
226 Z Transition Fault Same as above.
227 A Transition Fault Same as above.
228 B Transition Fault Same as above.
229 C Transition Fault Same as above.

231 Jog Handle Transition Same as 224.

Fault

232 Spindle Transition Fault Same as 224.

June 1998

233 Jog Handle Cable Fault Cable from jog handle encoder does not have valid differential signals.

234 Spindle Enc. Cable Fault Cable from spindle encoder does not have valid differential signals.

235 Spindle Z Fault Same as 139.

236 Spindle Motor Overload This alarm is generated in machines equipped with a Haas vector drive, if the

spindle motor becomes overloaded.

237 Spindle Following Error The error between the commanded spindle speed and the actual speed has

exceeded the maximum allowable (as set in Parameter 184).

240 Empty Prog or No EOB DNC program not found, or no end of program found.

241 Invalid Code RS-232 load bad. Data was stored as comment. Check the program being

received.

242 No End Check input file for a number that has too many digits.

243 Bad Number Data entered is not a number.

244 Missing ) Comment must end with a " ) ".

245 Unknown Code Check input line or data from RS-232. This alarm can occur while editing

data into a program or loading from RS-232.

246 String Too Long Input line is too long. The data entry line must be shortened.

247 Cursor Data Base Error Software Error; Call your dealer.

248 Number Range Error Number entry is out of range.

36 96-9010

June 1998

ALARMS

249 Prog Data Possible corrupted program. Save all programs to floppy disk, delete all,

Begins Odd then reload.

250 Program Data Error Same as 249.
251 Prog Data Struct Error Same as 249.
252 Memory Overflow Same as 249.

253 Electronics Overheat The control box temperature has exceeded 145 degrees F. This can be

caused by an electronics problem, high room temperature, or clogged air
filter.

254 Spindle Overheat This alarm is only generated in machines equipped with a Haas vector

drive. The spindle temperature sensor sensed a high temperature for greater
than 1.5 seconds.

257 Program Data Error Same as 249.

258 Invalid DPRNT Format Macro DPRNT statement not structured properly.

259 Bad Language Version Call your dealer.

260 Bad Language CRC Indicates FLASH memory has been corrupted or damaged.

261 Rotary CRC Error Rotary table saved parameters (used by Settings 30, 78) have a CRC error.

Indicates a loss of memory - call your dealer.

262 Parameter CRC Missing RS-232 or floppy read of parameter had no CRC when loading from floppy

or RS-232.

263 Lead Screw CRC Missing Lead screw compensation tables have no CRC when loading from floppy or

RS-232.

264 Rotary CRC Missing Rotary table parameters have no CRC when loading from floppy or RS-232.

265 Macro Variable File Macro variable file has a CRC error. Indicates a loss of memory.

CRC Error Call your dealer.

267 Tool Door Out of Position Alarm will be generated during a tool change when parameter 278 TL DR

SWITCH is set to1, and the tool carousel air door switch indicates that the
door is open after it was commanded to be closed, or closed after it was
commanded to be open.

268 DOOR OPEN @M95 START Generated whenever an M95 (Sleep Mode) is encountered and the door is

open. The door must be closed in order to start sleep mode.

270 C Servo Error Too Large Same as 103.
271 C Servo Overload Same as 108.
272 C Motor Overheat Same as 135.
273 C Motor Z Fault Same as 139.
274 C Limit Switch Same as 145.
275 C Axis Z Ch Missing Same as 153.
276 C Axis Drive Fault Same as 161.

96-9010 37

ALARMS

277 C Zero Ret Margin Same as 165.

Too Small

278 C Cable Fault Same as 182.

291 Low Air Volume/Pressure An automatic tool change was not completed due to insufficient volume or

During ATC pressure of compressed air. Check air supply line.

302 Invalid R In G02 or G03 Check your geometry. R must be less than or equal to half the distance from

start to end within an accuracy of 0.0010 inches.

303 Invalid X, Y, or Z In Check your geometry.

G02 or G03

304 Invalid I, J, or K In Check your geometry. Radius at start must match radius at end of arc

G02 or G03 within 0.0010 inches.

305 Invalid Q In Q in a canned cycle must be greater than zero.

Canned Cycle

306 Invalid I, J, K, or Q In I, J, K, and Q in a canned cycle must be greater than zero.

Canned Cycle

June 1998

307 Subroutine Subprogram nesting is limited to nine levels. Simplify your program.

Nesting Too Deep

309 Exceeded Max Feed Rate Use a lower feed rate.

310 Invalid G Code G code not defined and is not a macro call.

311 Unknown Code Possible corruption of memory by low battery. Call your dealer.

312 Program End End of subroutine reached before M99. Need an M99 to return from sub-

routine.

313 No P Code In M97, Must put subprogram number in P code.

M98, or G65

314 Subprogram or Macro Check that a subroutine is in memory or that a macro is defined.

Not In Memory

315 Invalid P Code In The P code must be the name of a program stored in memory without a

M97, M98 or M99 decimal point for M98 and must be a valid N number for M99.

316 X Over Travel Range X-axis will exceed stored stroke limits. This is a parameter in negative

direction and is machine zero in the positive direction. This will only
occur during the operation of a user's program.

317 Y Over Travel Range same as 316.
318 Z Over Travel Range same as 316.

319 A Over Travel Range Not normally possible with A-axis.

320 No Feed Rate Specified Must have a valid F code for interpolation functions.

38 96-9010

June 1998

ALARMS

321 Auto Off Alarm A fault turned off the servos automatically; occurs in debug mode only.

322 Sub Prog Without M99 Add an M99 code to the end of program called as a subroutine.

324 Delay Time Range Error P code in G04 is greater than or equal to 1000 seconds (over 999999

milliseconds).

325 Queue Full Control problem; call your dealer.

326 G04 Without P Code Put a Pn.n for seconds or a Pn for milliseconds.

327 No Loop For M L code not used here. Remove L Code.

Code Except M97, M98

328 Invalid Tool Number Tool number must be between 1 and the value in Parameter 65.

329 Undefined M Code That M code is not defined and is not a macro call.

330 Undefined Macro Call Macro name O90nn not in memory. A macro call definition is in

parameters and was accessed by user program but that macro was not
loaded into memory.

331 Range Error Number too large.

332 H and T This alarm is generated when Setting 15 is turned ON and an H code

Not Matched number in a running program does not match the tool number in the

spindle. Correct the Hn codes, select the right tool, or turn off Setting 15.

333 X-axis Disabled Parameters have disabled this axis. Not normally possible.

334 Y-axis Disabled same as 333.
335 Z-axis Disabled same as 333.

336 A-axis Disabled An attempt was made to program the A-axis while it was disabled

(DISABLED bit in Parameter 43 set to 1).

337 Line Referenced By Subprogram is not in memory, or P code is incorrect.

P, Not Found

338 Invalid IJK and XYZ There is a problem with circle definition; check your geometry.

in G02 or G03

339 Multiple Codes Only one M, X, Y, Z, A, Q, etc. allowed in any block or two G codes in the

same group.

340 Cutter Comp Begin Select cutter compensation earlier. Cutter comp. must begin on a linear

With G02 or G03 move.

341 Cutter Comp End Disable cutter comp later.

With G02 or G03

342 Cutter Comp Path Geometry not possible. Check your geometry.

Too Small

96-9010 39

ALARMS

343 Display Queue A block exists that is too long for displaying queue. Shorten title block.

Record Full

344 Cutter Comp With Cutter comp only allowed in XY plane (G17).

G18 and G19

345 Diff Step Ratio Parameters 5 and 19 must be same value.

On G17 Plane

346 Diff Step Ratio Parameters 5 and 33 must be same value.

On G18 Plane

347 Diff Step Ratio Parameters 19 and 33 must be same value.

On G19 Plane

348 Motion Not Allowed This alarm is generated if the mill is in Inverse Time Feed mode, and a

In G93 Mode G12, G13, G70, G71, G72, G150, or any Group 9 motion command is
issued.

349 Prog Stop W/O Cutter Compensation has been cancelled without an exit move. Potential

Cancel Cutter Comp damage to part.

June 1998

350 Cutter Comp Look There are too many non-movement blocks between motions when cutter

Ahead Error comp is being used. Remove some intervening blocks.

351 Invalid P Code In a block with G103 (Block Lookahead Limit), a value between 0 and 15

must be used for the P code.

352 Aux Axis Power Off Aux B, C, U, V, or W axis indicate servo off. Check auxiliary axes.

Status from control was OFF.

353 Aux Axis No Home A ZERO RET has not been done yet on the aux axes. Check auxiliary axes.

Status from control was LOSS.

354 Aux Axis Aux axes not responding. Check auxiliary axes and RS-232 connections.

Disconnected

355 Aux Axis Position Mismatch between machine and aux axes position. Check aux axes and

Mismatch interfaces. Make sure no manual inputs occur to aux axes.

356 Aux Axis Travel Limit Aux axes are attempting to travel past their limits.

357 Aux Axis Disabled Aux axes are disabled.

358 Multiple Aux Axis Can only move one auxiliary axis at a time.

359 Invalid I, J, or K In G12 Check your geometry.

or G13

360 Tool Changer Disabled Tool changer disabled by bit in Parameter 57. Not a normal condition.

361 Gear Change Disabled Gear change disabled by bit in Parameter 57. Not a normal condition.

362 Tool Usage Alarm Tool life limit was reached. To continue, reset the usage count in the

Current Commands display and press RESET.

40 96-9010

June 1998

ALARMS

363 Coolant Locked Off Override is off and program tried to turn on coolant.

364 No Circ Interp Only rapid or feed is allowed with aux axes.

Aux Axis

367 Cutter Comp G01 cannot be done with tool size.

Interference

368 Groove Too Small Tool too big to enter cut.

369 Tool Too Big Use a smaller tool for cut.

370 Pocket Definition Check geometry for G150.

Error

371 Invalid I, J, K, OR Q Check G150.

372 Tool Change In Tool change not allowed while canned cycle is active.

Canned Cycle

373 Invalid Code in DNC A code found in a DNC program could not be interpreted because of

restrictions to DNC.

374 Missing XYZA in G31 skip function requires an X, Y, Z, or A move.

G31 or G36

375 Missing Z or H in G37 G37 automatic tool length measurement function requires H code, Z value,

and tool offset enabled. X, Y, and A values not allowed.

376 No Cutter Comp In Skip Skip G31 and G37 functions cannot be used with cutter compensation.

377 No Skip in Graph/Sim Graphics mode cannot simulate skip function.

378 Skip Signal Found Skip signal check code was included but skip was found when it was not

expected.

379 Skip Signal Not Found Skip signal check code was included but skip was not found when it was

expected.

380 X, Y, A, or G49 G37 may only specify Z-axis and must have tool offset defined.

Not Allowed in G37

381 G43 or G44 Not Auto work offset probing must be done without tool offset.

Allowed in G36 or G136

382 D Code Required in G35 A Dnn code is required in G35 in order to store the measured tool

diameter.

383 Inch Is Not Selected G20 was specified but settings have selected metric input.

384 Metric Is Not Selected G21 was specified but settings have selected inches.

385 Invalid L, P, or R G10 was used to changes offsets but L, P, or R code is missing or

Code In G10 invalid.

96-9010 41

ALARMS

386 Invalid Address Format An address A..Z was used improperly.

387 Cutter Comp Not If block buffering has been limited, Cutter comp cannot be used.

Allowed With G103

388 Cutter Comp Not Coordinates cannot be altered while cutter comp is active. Move G10

Allowed With G10 outside of cutter comp enablement.

389 G17, G18, G19 Planes of rotation cannot be changed while rotation is enabled.

Illegal in G68

390 No Spindle Speed S code has not been encountered. Add an S code.

391 Feature Disabled An attempt was made to use a control feature not enabled by a

parameter bit. Set the parameter bit to 1.

392 B Axis Disabled Same as 336.

393 Invalid Motion In Rigid Tapping can only be in the Z minus G74 or G84 direction.

G74 or G84 Make sure that the distance from the initial position to the commanded Z

depth is in the minus direction.

June 1998

394 B Over Travel Range Same as 316.

395 No G107 Rotary Axis A rotary axis must be specified in order to perform cylindrical mapping

Specified (G107).

396 Invalid G107 Rotary The rotary axis specified is not a valid axis, or has been disabled.

Axis Specified

397 Aux Axis In G93 Block This alarm is generated if a G-code block specifies any form of interpolated

motion that involves BOTH one or more of the regular axes (X, Y, Z, A, B,
etc...) AND one or more of the auxiliary axes (C, U, V, W).

398 Aux Axis Servo Off Aux. axis servo shut off due to a fault.

403 RS-232 Too Many Progs Cannot have more than 200 programs in memory.

404 RS-232 No Program Need name in programs when receiving ALL; otherwise has no way to

Name store them.

405 RS-232 Illegal Prog Check files being loaded. Program name must be Onnnn and must be

Name at beginning of a block.

406 RS-232 Missing Code A receive found bad data. Check your program. The program will be

stored but the bad data is turned into a comment.

407 RS-232 Invalid Code Check your program. The program will be stored but the bad data is

turned into a comment.

408 RS-232 Number Range Check your program. The program will be stored but the bad data is

Error turned into a comment.

42 96-9010

June 1998

ALARMS

409 RS-232 Invalid N Code Bad Parameter or Setting data. User was loading settings or parameters

and something was wrong with the data.

410 RS-232 Invalid V Code Bad parameter or setting data. User was loading settings or parameters

and something was wrong with the data.

411 RS-232 Empty Program Check your program. Between % and % there was no program found.

412 RS-232 Unexpected Check your program. An ASCII EOF code was found in the input data

End of Input before program receive was complete. This is a decimal code 26.

413 RS-232 Load Program received doesnt fit. Check the space available in the LIST PROG

Insufficient Memory mode and possibly delete some programs.

414 RS-232 Buffer Overflow Data sent too fast to CNC. This alarm is not normally possible as this

control can keep up with even 38400 bits per second.

415 RS-232 Overrun Data sent too fast to CNC. This alarm is not normally possible as this

control can keep up with as much as 38400 bits per second.

416 RS-232 Parity Error Data received by CNC has bad parity. Check parity settings, number of

data bits and speed. Also check your wiring.

417 RS-232 Framing Error Data received was garbled and proper framing bits were not found. One

or more characters of the data will be lost. Check parity settings,
number of data bits and speed.

418 RS-232 Break Break condition while receiving. The sending device set the line to a

break condition. This might also be caused by a simple break in the
cable.

419 Invalid Function A code found on input of a DNC program could not be interpreted.

For DNC

42 0 Program Number The O code in the program being loaded did not match the O code

Mismatch entered at the keyboard. Warning only.

429 Flpy Dir Insufficient Floppy memory was almost full when an attempt was made to read the

Memory floppy directory.

430 Floppy Unexpected Check your program. An ASCII EOF code was found in the input data

End of Input before program receive was complete. This is a decimal code 26.

431 Floppy No Prog Need name in programs when receiving ALL; otherwise has no way to

Name store them.

432 Floppy Illegal Prog Check files being loaded. Program must be Onnnn and must be at the

Name beginning of a block.

433 Floppy Empty Prog Check your program. Between % and % there was no program found.

Name

434 Floppy Load Insufficient Program received doesn't fit. Check the space available in the LIST

Memory PROG mode and possibly delete some programs.

96-9010 43

ALARMS

435 Floppy Abort Could not read disk.

436 Floppy File Not Found Could not find floppy file.

501 Too Many Assignments Only one assignment = is allowed per block. Divide block in error into

In One Block multiple blocks.

502 [ Or = Not First Term An expression element was found where it was not preceded by [ or

In Expressn =, that start expressions.

503 Illegal Macro Variable A macro variable number was used that is not supported by this control,

Reference use another variable.

504 Unbalanced Paren. In Unbalanced brackets, [ or ], were found in an expression. Add or

Expression delete a bracket.

505 Value Stack Error The macro expression value stack pointer is in error. Call your dealer.

506 Operand Stack Error The macro expression operand stack pointer is in error. Call your dealer.

507 Too Few Operands On An expression operand found too few operands on the expression stack.

Stack Call your dealer.

June 1998

508 Division By Zero A division in a macro expression attempted to divide by zero.

Re-configure expression.

509 Illegal Macro See "Macros" section for valid variables.

Variable Use

510 Illegal Operator or See "Macros" section for valid operators.

Function Use

511 Unbalanced Right Number of right brackets not equal to the number of left brackets.

Brackets

512 Illegal Assignment Use Attempted to write to a read-only macro variable.

513 Var. Ref. Not Allowed Alphabetic addresses N and O cannot be combined with macro variables.

With N Or O Do not declare N#1, etc.

514 Illegal Macro Address A macro variable was used incorrectly with an alpha address. Same as

Reference 513.

515 Too Many Conditionals Only one conditional expression is allowed in any WHILE or IF-THEN

In a Block block.

516 Illegal Conditional A conditional expression was found outside of an IF-THEN, WHILE,

Or No Then or M99 block.

517 Exprsn. Not Allowed A macro expression cannot be concatenated to N or O. Do not declare

With N Or O O[#1], etc.

518 Illegal Macro Exprsn An alpha address with expression, such as A[#1+#2], evaluated

Reference incorrectly. Same as 517.w

44 96-9010

June 1998

ALARMS

519 Term Expected In the evaluation of a macro expression an operand was expected and

not found.

520 Operator Expected In the evaluation of a macro expression an operator was expected and

not found.

521 Illegal Functional An illegal value was passed to a function, such as SQRT[ or ASIN[.

Parameter

522 Illegal Assignment A variable was referenced for writing. The variable referenced is read

Var Or Value only.

523 Conditional Reqd THEN was encountered and a conditional statement was not processed

Prior To THEN in the same block.

524 END Found With No An END was encountered without encountering a previous matching

Matching DO DO. DO-END numbers must agree.

525 Var. Ref. Illegal Variable cannot be read during axis movement.

During Movement

526 Command Found On A G-code command was found on a WHILE-DO or END macro block.

DO/END Line Move the G-code to a separate block.

527 = Not Expected Or Only one Assignment is allowed per block, or a THEN statement is missing.

THEN Required

528 Parameter Precedes On G65 lines all parameters must follow the G65 G-code. Place

G65 parameters after G65.

529 Illegal G65 Parameter The addresses G, L, N, O, and P cannot be used to pass parameters.

530 Too Many I, J, or Ks Only 10 occurrences of I, J, or K can occur in a G65 subroutine call.

In G65 Reduce the I, J, or K count.

531 Macro Nesting Too Only four levels of macro nesting can occur. Reduce the amount of

Deep nested G65 calls.

532 Unknown Code In Macro syntax is not allowed in a pocket pattern subroutine.

Pocket Pattern

533 Macro Variable A conditional expression evaluated to an UNDEFINED value, i.e. #0.

Undefined Return True or False.

534 DO Or END Already Multiple use of a DO that has not been closed by and END in the same

In Use subroutine. Use another DO number.

535 Illegal DPRNT A DPRNT statement has been formatted improperly, or DPRNT does

Statement not begin block.

536 Command Found On A G-code was included on a DPRNT block. Make two separate blocks.

DPRNT Line

96-9010 45

ALARMS

537 RS-232 Abort While a DPRNT statement was executing, the RS-232 communications

On DPRNT failed.

538 Matching END Not A WHILE-DO statement does not contain a matching END statement.

Found Add the proper END statement.

539 Illegal Goto Expression after "GOTO" not valid.

540 Macro Syntax A section of code was interpreted by the control where macro statement

Not Allowed syntax is not permitted.

613 Command Not Allowed A command (M96, for example) in the highlighted block cannot be

In Cutter Comp. executed while cutter comp. is invoked.

End Of List

Note: Alarms 1000-1999 are user defined by macro programs.

THE FOLLOWING ALARMS APPLY ONLY TO THE HS-1RP:

June 1998

1001 Index St Unlocked The index station is not in the correct orientation for a pallet change.

1002 Pallet Locked Down The pallet did not begin to lift within two seconds of command, or did not

complete lifting within six seconds.

1003 Pallets Jammed The lift cylinder has not moved from the clockwise position within three

seconds, or has not reached the counter clockwise position within twelve
seconds.

1004 CW/CCW Switch One or both of the switches that sense the rotational position of the pallet

Illegal Condition changer has failed it's self-test.

1007 Up/Down Switch One or both of the switches that sense the lifted/lowered position of the

Illegal Condition pallet changer has failed it's self-test.

1008 Main Drawbar Locked The main drawbar will not disengage from the pallet nut.

In Up Position

1009 Main Drawbar Locked The main drawbar will not move upward to the pallet nut.

In Down Position

1010 Main Drawbar Switch One or both of the switches that sense the up/down position of the main

Illegal Condition drawbar has failed it's self-test.

1011 Main Drawbar Unclamp The main drawbar has disengaged from the pallet nut, but did not reach

Timeout the main drawbar down switch.

1012 Main Drawbar Clamp The main drawbar has begun to travel upward, but did not reach the fully

Timeout raised position within 15 seconds.

46 96-9010

June 1998

MECHANICAL SERVICE

3. MECHANICAL SERVICE

RECOMMENDED TORQUE VALUES FOR MACHINE FASTENERS

The following chart should be used as a reference guide for torquing machine fasteners where specified.

DIAMETER TORQUE

1/4 - 20 15 ft. lb.
5/16 - 18 30 ft. lb.
3/8 - 16 50 ft. lb.
M10 - 100 50 ft. lb.
M12 - 65 100 ft. lb.
1/2 - 13 80 ft. lb.
3/4 - 10 275 ft. lb.
1 - 8 450 ft. lb.

3.1 WAY COVERS

UPPER Y-AXIS WAY COVER

REMOVAL-

1. Handle jog the X-axis to center of travel. Handle jog the Y-axis down fully.

2. POWER OFF the machine.

3. Remove the left and right intermediate shields (five SHCS each) at the top of the Y-axis (behind the tool
changer cover).

4. Remove the four SHCS that attach the upper way cover to the vertical guides.

5. Remove the seven SHCS that the attach the way cover to the spindle head.

6. Lift the bottom of the way cover to collapse it. Lift the cover up until it is above the top of the column.
Pull up on one side of the way cover and slip it out from between the vertical guide and the tool changer.

INSTALLATION-

1. To install a new upper Y-axis way cover, strap both ends with nylon tie wraps (through the holes in the
end mounting plates that are closest to the leaves of the cover) while the cover is fully collapsed. Ensure
that the slots are aligned.

2. Carefully install cover into Y-axis vertical guides without damaging cover or guides. Once the cover is in
place, cut and remove the tie-wraps.

96-9010

3. Install the four SHCS at the top of the way cover. Slide the bottom of the way cover up and down to ensure
it moves freely. Also, pull each leaf of the cover gently away from the column to be certain the tabs are in
the guide slots.

4. Install the left and right intermediate shields at the top of the way cover with five SHCS each.

5. Install the bottom seven SHCS and tighten evenly.

47

MECHANICAL SERVICE

LOWER Y-AXIS WAY COVER

REMOVAL-

1. Zero return all axes.

2. POWER OFF the machine.

3. Remove the seven SHCS that attach the top of the lower Y-axis way cover to the spindle head casting.
Collapse the way cover down fully.

4. Remove the X-axis chip guard (seven SHCS) that is directly below the lower Y-axis way cover.

5. Remove the four SHCS that attach the bottom of the way cover to the left and right vertical guides.

6. Remove the way cover from the bottom.

INSTALLATION-

1. To install a new lower Y-axis way cover, strap both ends with nylon tie wraps (through the holes in the
end mounting plates that are closest to the leaves of the cover) while the cover is fully collapsed.
Ensure that the slots are aligned.

2. Carefully install cover into Y-axis vertical guides without damaging cover or guides. Once the cover is in
place, cut and remove the tie-wraps.

June 1998

3. Install the four SHCS at the bottom of the way cover, and tighten evenly.

4. Attach the top of the way cover to the spindle head casting with seven SHCS. Slide the bottom of the way
cover up and down to ensure it moves freely. Also, pull each leaf of the cover gently away from the column
to be certain the tabs are in the guide slots.

5. Replace the X-axis chip guard and attach with seven SHCS.

48

96-9010

June 1998

MECHANICAL SERVICE

3.2 TOOL RELEASE PISTON (TRP)

TOOL RELEASE PISTON R EPLACEMENT

TOOLS REQUIRED

ü 2.5" diameter, 2.5' long steel tube ü TRP alignment tool, TSC (T-1519)
ü Magnetic base indicators (2)

REMOVAL-

1. Remove the rear enclosure panel (seven SHCS).

2. IMPORTANT! Jog the X-axis all the way to the operator side of the machine. Place the steel tube through
the 3" diameter holes (second from bottom ) on either side of the column. Ensure the tube passes completely
through the column and extends out an equal distance from each side. This tube will prevent the spindle head
from falling in the event of an accident.

3. Jog the Y-axis down until the bottom of the motor is approximately 1/2" above the steel tube.

4. If machine is equipped with Through the Spindle Coolant (TSC), place a tool holder in the spindle.

5. POWER OFF the machine.

6. Disconnect the main air supply at the lube/air panel.

7. Remove the seven SHCS attaching the lower Y-axis way cover to the spindle head casting, and collapse
it downward. It is easiest to reach the TRP from the front side of the machine.

8. Disconnect the air lines at the tool unclamp solenoid and precharge line. If machine is equipped with TSC,
also remove the precharge air hose and coolant hose from the tool release spring.

Figure 3-1. TRP assembly.

96-9010

8. Disconnect clamp/unclamp cables (quick disconnect and solenoid wiring located on the solenoid bracket
on top of the transmission).

9. Remove the two SHCS and two HHB holding the tool release piston assembly to the head casting.

10. Remove the entire tool release piston assembly.

Note: Step 11 applies only to machines with TSC.

49

MECHANICAL SERVICE

11. Remove the seal housing from the tool release piston.

Figure 3-2. TSC tool release piston.

June 1998

INSTALLATION-

1. Ensure spindle, drawbar and spindle drive belt are properly in place.

2. Loosely reinstall the tool release piston with two SHCS at the bottom and two HHB (with spacer) at the
top.

3. Reconnect clamp/unclamp cables (quick disconnect and solenoid wiring located on the solenoid bracket).

4. Reconnect air lines at the tool unclamp solenoid and precharge line. If machine is equipped with TSC, also
reconnect the precharge air hose and coolant hose.

5. If machine is equipped with TSC, install the coolant hose (3/8" diameter x 27" long plastic tubing) and
precharge line.

6. Refer to the Tool Clamp/Unclamp Switch Adjustment section to verify the tool clamp/unclamp switch
has been properly adjusted and the drawbar height properly set.

Note: Steps 7 through 13 apply only to machines with TSC. Steps 9-11 apply only to
those machines that have a modified TSC Housing, starting with mach. serial number

50250.

7. Install the seal housing on the tool release piston (use Loctite on the screws). Connect the 5/32" drain
line to the lower connector of the seal housing. The drain line connector should point toward the bottom
of the machine. Connect the purge line to the top connector of the seal housing.

50

96-9010

June 1998

MECHANICAL SERVICE

Figure 3-3. Purge line routing.

Note: The drain line must run straight through the cable tie loop on the transmission,
and must not interfere with the pulley or belts.

8. Allow the bore of the seal housing to rest on the drawbar. Tighten the TRP mounting screws slightly. If
you are working on a TSC system without a modified housing go to Step 12.

96-9010

Figure 3-4. TSC Alignment Tool.

51

MECHANICAL SERVICE

Steps 9-11 apply to machines with modified TSC housing. If not applicable, skip to Step 12.

9. Place the alignment tool (T-1519) on top of the drawbar with the pins facing the TRP.

10. Lift the TRP assembly slightly and push the pins into the TSC Housing.

11. Finish tightening the four SHCS that mount the TRP to the Spindlehead. Go to step 14.

12. Jog the spindle head upward. Place two magnetic bases on the column below the TRP. Set their indicators
on opposite ends of the bottom face of the TRP housing. Set both indicator dials to zero.

13. Carefully move the TRP upward a distance of 0.005 on each indicator.

14. Tighten down the two mounting SHCS and two HHB alternately until all are completely tight.

15. Slide the lower Y-axis way cover up into place and tighten the seven SHCS.

16 IMPORTANT! Remove the steel tube from the column. CAUTION! This step must be followed or the
machine will be seriously damaged.

17. Replace the rear enclosure panel with seven SHCS.

June 1998

S ETTING PRE-CHARGE

CAUTION! Do not perform this procedure on machines equipped with Through the Spindle
Coolant (TSC). It will damage the machine. Refer to the "TSC Adjustments" section.

1. POWER ON the machine.

2. Remove the rear enclosure panel (seven SHCS).

3. Turn the air pressure regulator down (located on top of the transmission) to zero (0). The knob must be
pulled out to unlock before adjusting.

Note: At "0" pressure on the pre-charge regulator, the adjustment knob is out as far as it
will turn.

52

Figure 3-5. Air pressure regulator adjustment knob.

96-9010

June 1998

MECHANICAL SERVICE

4. Go to "Parameters" page of CRT and ensure PRE-CHARGE DELAY is set to 300. If not, set it at this time.

5. Press the TOOL RELEASE button on control panel. A banging noise will be heard as the tool release piston
contacts the drawbar.

6. Turn the air pressure regulator ½ turn in. Execute a tool change and listen for the banging noise. If it
is heard, repeat this step until no noise is heard. There should be no noise with or without a tool in the
spindle.

CAUTION! Only increase the pressure to the point where tool changes become obviously
quiet. Any further pressure increases are not beneficial. Excessive pressure to the pre­charge system will cause damage to the tool changer and tooling in the machine.

96-9010

53

MECHANICAL SERVICE

3.3 SPINDLE DRIVE BELTS

Please read this section in its entirety before attempting to replace the drive belts.

TOOLS REQUIRED

ü 2.5" diameter, 2.5' long steel tube
ü Lift fixture (T-1491)
ü Belt tensioning fixture (T-1511)

BELT REMOVAL

Note: For easier belt removal, place transmission in high gear (M42) before beginning.

Note: When servicing drive belts, always replace BOTH belts.

1. Remove the rear enclosure panel (seven SHCS).

2. IMPORTANT! Jog the X-axis all the way to the operator side of the machine. Place the steel tube through
the 3" diameter holes (second from bottom ) on either side of the column. Ensure the tube passes completely
through the column and extends out an equal distance from each side. This tube will prevent the spindle head
from falling in the event of an accident.

June 1998

3. Jog the Y-axis down until the bottom of the motor is approximately 1/2" above the steel tube.

4. Remove the tool release piston assembly in accordance with "Tool Release Piston Assembly Removal".

5. Remove the steel tube, and jog the Y-axis down to where the six transmission mounting SHCS can be
accessed.

6. Slightly loosen and hand tighten each of the six transmission mounting SHCS, one at a time.

7. Move the transmission down (if it is not already) by shaking it from the back of the motor, until there is
slack in the spindle drive belts. Remove the belts from the spindle and drive pulleys.

Note: DO NOT bend or kink the belts in any way; damage to the fibers in the belt may
result, and it will fail soon after installation.

BELT INSTALLATION

1. From the rear of the machine, install the new belts onto the top (drive) pulley. From the front of the machine,
place the belts on the bottom pulley.

Note: Be careful not to damage the inside of the belts.

54

96-9010

June 1998

MECHANICAL SERVICE

Figure 3-6. Spindle drive belt replacement.

2. Install the tool release piston assembly in accordance with appropriate section, and reconnect all switches
and air lines.

3. Loosen the top two transmission mounting SHCS about 1-1/2 turns.

4. Refer to the "Belt Tension" section and tension the belts.

5. Reset the spindle orientation in accordance with the appropriate section.

Note: The following step is necessary only if the spindle or transmission was ex­changed prior to belt replacement.

6. Double-check the spindle sweep to assure that nothing has moved during the previous steps. If sweep
is within tolerance, continue; if not, sweep must be readjusted.

Note: Drive belt tension must be adjusted after every installation.

7. Slide the lower Y-axis way cover up into place and tighten the seven SHCS.

8. IMPORTANT! Remove the steel tube from the column. CAUTION! This step must be followed or the machine
will be seriously damaged.

96-9010

9. Replace the rear enclosure panel (seven SHCS).

55

MECHANICAL SERVICE

BELT TENSION ADJUSTMENT

Note: The drive belt's tension should be adjusted after every service on the transmission
or spindle of the machine.

1. Place the lift fixture onto the transmission (Figure 3-7). Attach to the motor mounting plate with two SHCS.

2. Place the two bars (3/4" diameter) of the belt tensioning fixture through the top two holes (1" diameter)
in the column. Set the fixture plate in place on the two bars, with the eyeholes facing downward.

3. Hook the three springs into the eyeholes of the fixture plate. Jog the Y-axis up into place, then hook the
other end of the springs into the eyebolts of the lift fixture.

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Figure 3-7. Belt tensioning fixture shown in place.

4. Jog the Y-axis down until the spring hooks are just touching the top of the eyebolts on the lift fixture.

5. Zero the POSITION display screen in the control. Jog the Y-axis down exactly 8.5 inches. Monitor the screen
to verify the position. The belt is correctly tensioned.

Note: A belt that is correctly tensioned will whine slightly, and requires approximately 12
hours of break-in time.

6. Tighten down the six transmission mounting SHCS, beginning with the bottom two.

7. Run the spindle at various speeds and listen for any unusual noise or vibration. If there are any problems,
examine the belts for damage, and replace if necessary.

CAUTION! Ensure all parts of the belt tensioning fixture and transmission lift fixture are
removed before running the machine. Serious machine damage could occur if any of these
are left on the machine.

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MECHANICAL SERVICE

3.4 SPINDLE

TOOLS REQUIRED

ü 2.5" diameter, 2.5' long steel tube

S PINDLE CARTRIDGE

REMOVAL-

1. Remove the rear enclosure panel (seven SHCS).

2. IMPORTANT! Jog the X-axis all the way to the operator side of the machine. Place the steel tube through
the 3" diameter holes (second from bottom ) on either side of the column. Ensure the tube passes completely
through the column and extends out an equal distance from each side. This tube will prevent the spindle head
from falling in the event of an accident.

3. Jog the Y-axis down until the bottom of the motor is approximately 1/2" above the steel tube.

4. Remove tool release piston assembly in accordance with appropriate section.

5. Remove spindle drive belts in accordance with appropriate section.

6. Remove quick disconnect air line (1/4" O.D., 3/16" I.D.) at back side of spindle cartridge.

7. Remove the six SHCS that mount the spindle to head casting.

8. Slide the spindle out from the front side of machine.

INSTALLATION-

1. Inspect the mating surface for high spots on the spindle and spindle head casting before installing spindle.

2. Increase the air pressure to clear out any contamination in the lubrication line. Once the line is cleaned
out, return pressure to 3 psi.

3. Carefully install new spindle into bored sleeve of head casting. Apply grease to the inside of the through
bore in the spindle head (see Figure 3-8).

NOTE: Spindle is a grease-packed cartridge.

CAUTION! The spindle nose has a drain hole at the front and should be pointed down.

4. Evenly tighten the six mounting SHCS on the front side of the spindle in a cross pattern until all bolts are
completely tight.

5. Install spindle drive belts in accordance with appropriate section.

6. Connect the air line at the rear of the spindle cartridge. Check the pressure gauge at the rear of the lube/
air panel. It should be 3 psi.

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7. Install the tool release piston assembly in accordance with appropriate section. Adjust for proper tool
push and switch settings.

8. Reset spindle orientation and check the tool changer adjustment.

9. Refer to the "Spindle - Overheating" section of "Troubleshooting" and run the spindle break-in program.
Verify that spindle temperatures are acceptable.

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MECHANICAL SERVICE

June 1998

Figure 3-8. Spindle cartridge.

10. IMPORTANT! Remove the steel tube from the column. CAUTION! This step must be followed or the
machine will be seriously damaged.

11. Replace the rear enclosure panel with seven SHCS.

SPINDLE ORIENTATION

1. Remove the rear enclosure panel (seven SHCS).

2. In MDI mode, press the ORIENT SPINDLE key.

3. Loosen the four SHCS on the orientation ring (Figure 3-9). Remove two of these screws and insert them
into the two threaded holes in the ring. Evenly tighten these two screws until the taper lock is broken free
from the shaft.

4. Remove the two screws and place them into their original holes. Tighten them finger tight, then 1/2 turn
more. Ensure that the orientation ring is snug, but not tight.

5. Set up a magnetic base with a 0.0005" indicator on the table. Zero the indicator on the spindle dogs parallel
to the Y-axis travel.

6. Jog the spindle dogs across the indicator and note the indicator reading. The spindle dogs should be
parallel to the Y axis within 0.010". If the reading is acceptable, skip to Step 8.

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Note: There is a 0.015"-0.030" backlash in the spindle system when it is oriented. Be
certain to compensate for this backlash when performing this adjustment.

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MECHANICAL SERVICE

Figure 3-9. Rear view of spindle orientation components.

7. Using an open end wrench, rotate the spindle until the appropriate alignment is attained. If the spindle
is very difficult to rotate, STOP and return to Step 3.

8. Tighten the orientation screws evenly to 15 ft-lbs. Verify that spindle alignment has not changed.

Note: It is vital that the screws be tightened evenly. If not, the top of the orientation ring
will run out and the ring will slip.

9. Make at least 100 tool changes to test the spindle orientation.

10. If the spindle is found to be out of alignment, check all tool changer alignments.

11. Replace the rear enclosure panel with seven SHCS.

SPINDLE SWEEP A DJUSTMENT

Note: The machine must be properly leveled for the spindle sweep adjustment to be
accurate.

1. Place an indicator on the table and insert a 6" tool bar into the spindle.

2. Jog the Z-axis while indicating the bottom, and then the side, of the test bar. The readings must be within

0.0005/10" in both the Y/Z and X/Z planes, as stated in the inspection report supplied with the machine.

3. Shim the spindle, if necessary, to correct the spindle sweep to specifications. Recheck spindle sweep.

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MECHANICAL SERVICE

ORIENTATION - VECTOR DRIVE

1. Place the machine in low gear.

2. Adjust Parameter 257, "SPINDL ORIENT OFSET", until the spindle dogs are parallel to the X-axis.
Ensure that the dogs are within 0.030" using a dial indicator. See Figure 3-10.

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Figure 3-10

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MECHANICAL SERVICE

3.5 DRAWBAR REPLACEMENT

TOOLS REQUIRED

ü 2.5" diameter, 2.5' long steel tube

REMOVAL-

1. Remove the rear enclosure panel (seven SHCS).

2. IMPORTANT! Jog the X-axis all the way to the operator side of the machine. Place the steel tube

through the 3" diameter holes (second from bottom ) on either side of the column. Ensure the tube
passes completely through the column and extends out an equal distance from each side. This tube will
prevent the spindle head from falling in the event of an accident.

3. Jog the Y-axis down until the bottom of the motor is approximately 1/2" above the steel tube.

4. Place an empty tool holder in the spindle.

5. Remove the tool release piston in accordance with the appropriate section.

6. Remove the snap ring from the top of the spindle shaft.

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Figure 3-11. Snap ring removal.

7. Remove the tool holder from the spindle.

8. Remove the spindle in accordance with the "Spindle Cartridge" section.

9. Remove the drawbar from the spindle assembly.

INSTALLATION-

1. Thoroughly coat the replacement drawbar with grease, including the end of the shaft where the four holding

balls are located.

2. Insert four new balls in the replacement drawbar and insert into the spindle shaft. Be sure that, as the shaft

is installed, the balls do not fall out of the bores in the drawbar.

NOTE: Carefully inspect the inside of the spindle shaft, where the end of the drawbar
rides, for galling or burrs. If it is damaged, the spindle must be replaced.

3. Install the spindle cartridge. Reinstall the tool release piston in accordance with the appropriate section.

4. Install a tool holder without a cutter into the spindle taper.

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MECHANICAL SERVICE

5. Remove the tool release piston.

6. Install the snap ring on the spindle shaft.

7. Reinstall the tool release piston.

8. Complete installation of the spindle.

9. Refer to the appropriate sections and set the drawbar height, and clamp and unclamp switches.

NOTE: Step 10 must be followed or damage to the Automatic Tool Changer will result.

10. Set the spindle orientation.

11. IMPORTANT! Remove the steel tube from the column. CAUTION! This step must be followed or the

machine will be seriously damaged.

12. Replace the rear enclosure panel with seven SHCS.

13. Test-run the machine and adjust the ATC as necessary.

June 1998

3.6 TOOL CLAMP/UNCLAMP SWITCH ADJUSTMENT

TOOLS REQUIRED

ü Right angle plate ü Flexible ruler
ü Machined aluminum block (2"x4"x4") ü 1" diameter pipe or pry bar

T OOL CLAMP/UNCLAMP SWITCH A DJUSTMENT - INITIAL P REPARATION

1. Remove the rear enclosure panel (seven SHCS). Disconnect the lower Y-axis way cover from the bottom

of the spindle head and collapse it downward.

2. Secure the right angle plate in place on the table.

3. Place a sheet of paper on the table for protection, then place the machined block of aluminum against the

right angle plate.

4. POWER ON the machine.

5. Insert an empty tool holder into the spindle taper.

6. Go to HANDLE JOG mode. Choose Z-axis and set the jog increments to .01.

7. Jog the Z-axis in the negative (-) direction until the tool holder is approximately .03" from the block. At

this point, stop jogging and press the TOOL RELEASE button (top left). The tool holder will come out of the
taper.

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8. The clearance from the tool holder to the block should be zero (0). To accomplish this, set the jog

increments to .001 and jog in the negative (-) Z direction a few increments at a time. Between these moves,
push the TOOL RELEASE button and feel for movement by placing your finger between the tool holder and
the spindle. Do this until no movement is felt. You are now at zero (0).

Note: Do not jog too far in the negative (-) direction! This will cause overcurrent in the Z­axis.

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MECHANICAL SERVICE

SETTING D RAWBAR H EIGHT

1. Press the MDI key and turn the jog handle to zero (0).

2. Press HANDLE JOG and set the increments to .01. Jog the Z-axis in the positive (+) direction .100".

3. Press and hold the TOOL RELEASE button, and try to move the block by hand. The block should be tight

at .100" and loose at .110". If it moves at .100", jog the Z-axis in the negative (-) direction one increment at
a time. Press the TOOL RELEASE button and check for movement between increments until the block is tight.

Note: The increments jogged in the Z negative (-) direction are the amount of shim
washers that must be added to the tool release bolt (or coolant tip for TSC). Refer to the
"Shim Washers" section.

If the block is tight at .110", move the Z-axis in the positive (+) direction one increment at a time. Press the
TOOL RELEASE button and check movement between increments until the block is loose.

Note: The increments jogged in the Z positive (+) direction are the amount of shim
washers that must be removed from the tool release bolt (or coolant tip for TSC). Refer
to the "Shim Washers" section.

SHIM W ASHERS

1. To add or subtract shim washers, remove the tool release piston assembly in accordance with the "Tool

Release Piston" section.

Note: Shims may need replacement when the spindle cartridge, tool release piston
assembly, or drawbar is replaced.

2. Remove the tool release bolt. If the machine is equipped with TSC, loosen the three set screws and remove

the coolant tip.

3. Add or subtract the required number of shim washers (from previous section).

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Figure 3-12 Shim location (without TSC). Figure 3-13. Shim location (with TSC).

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MECHANICAL SERVICE

4. Put a drop of serviceable (blue) Loctite® on the threads of the tool release bolt and install. If replacing

tool release coolant tip, put a drop of Loctite® on the threads of the three set screws before installing.

5. Install the tool release piston assembly and recheck settings. If within specifications, continue; if not,

readjust.

LOWER (UNCLAMP) SWITCH

1. Push the PARAM/DGNOS button (top center) twice. You are now in diagnostics mode. Look at the bottom

left corner of the page and you should see DB OPN 0 (tool unclamped) and directly under that, DB CLS 1 (tool
clamped). If not, push PAGE DOWN until you do. A "1" means that particular switch is being tripped. A "0"
means it is not being tripped.

2. With the tool holder resting on the block and set at zero ("Setting Drawbar Height" section), jog Z-axis in

the positive (+) direction .06.

3. Press the tool release button and hold it. DB OPN should change from a "0" to a "1". If it does not, slightly

loosen the two ¼-20 x ½" SHCS holding the unclamp switch bracket (switch on right) to the tool release
assembly.

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64

Figure 3-14. Tool release piston assembly.

4. While activating tool release, tap unclamp switch assembly towards spring retainer until it just trips. Switch

must trip at .060 +/- .010.

THIS ADJUSTMENT IS VERY IMPORTANT FOR PROPER TOOL CHANGER OPERATION, AND MUST
BE PROPERLY SET!

5. Check the adjustment by setting the jog handle at .06 and activating the tool release. The DB OPN signal

should be a "1". If the adjustment is not correct, adjust until it is within specifications. You may have to readjust
the switch several times. Set jog handle at 0.050 and activate tool release DB OPN signal should be a "0".

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MECHANICAL SERVICE

UPPER (CLAMP) SWITCH

CAUTION! Remove the tool holder from the spindle before performing the upper (CLAMP)
switch adjustment. Failure to remove it could result in damage to the tool holder, the mill
table, or cause severe personal injury.

6. Place a shim (approximately .020 thick), or the flexible ruler, between the tool release piston adjustment

bolt and the drawbar. For TSC equipped machines, this step must be done with the seal housing removed.

7. Move the tool release piston in so the shim is pressed against the drawbar. This can be done in one of

the following two ways:

Ø Using the pipe or pry bar as a lever, carefully push on the piston until it contacts the drawbar and

the shim is held in place. Push the piston down until it contacts the drawbar and the shim is held in
place. Monitor the "Tool Unclmp" status in the Diagnostics display.

IMPORTANT! Use extreme care when performing this procedure on TSC equipped
machines, or the pipe fitting will break off the top of the TRP shaft.

Ø If the machine is equipped with the "MACROS" option: in MDI, program #1120=1 and execute. This

will energize the pre-charge solenoid, bringing the TRP in contact with the drawbar (no prying is
necessary). To de-energize the solenoid, press RESET.

8. While the tool release piston is against the shim, move the switch bracket all the way in and check for "Tool

Unclmp" status on the CRT (DB OPN=0, DB CLS=0), and tighten the bracket bolts. If not, move the switch out
until "Tool Unclmp" status appears on the CRT and then tighten the bolts.

9. Check the switch several times. This is done by moving the piston in and out to ensure that the "Tool

Unclmp" status appears when the piston makes contact with the shim and drawbar, and does not appear when
it is in the retracted position. "Tool Unclmp" status appears on the screen as (DB OPN=0, DB CLS=0).

Note: For TSC equipped machines refer to "Tool Release Piston Replacement" section
for proper installation and alignment of seal housing.

10. Replace the rear enclosure panel with seven SHCS. Replace the lower Y-axis way cover in accordance

with the appropriate section.

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MECHANICAL SERVICE

3.7 TRANSMISSION

Please read this section in its entirety before attempting to remove or replace the
transmission.

TOOLS REQUIRED

ü Transmission removal kit, includes:

l transmission removal fixture (T-1482)
l transmission lift fixture (T-1491)

ü Chain hoist

REMOVAL-

1. Remove the rear enclosure panel (seven SHCS).

2. Press RESET. Jog the Z-axis all the way back, and the X-axis to the center of it's travel. This will allow

easier access to the motor from the rear of the machine.

3. IMPORTANT! Jog the X-axis all the way to the operator side of the machine. Jog the Y-axis all the way

up. Place the steel tube through the 3" diameter holes (second from bottom ) on either side of the column.
Ensure the tube passes completely through the column and extends out an equal distance from each side.
This tube will prevent the spindle head from falling in the event of an accident.

June 1998

4. Jog the Y-axis down until the bottom of the motor is approximately 1/2" above the steel tube. EMERGENCY

STOP the machine.

5. Loosen (but DO NOT REMOVE) the six SHCS holding the transmission to the spindle head. Gently shake

the motor from the back to make sure there is slack between the spindle drive belts and pulleys.

6. Remove the seven SHCS that attach the lower Y-axis way cover to the spindle head, and collapse it

downward. It is easiest to reach the tool release piston and motor wires through the front of the machine.

7. Remove the two SHCS and two HHB that hold the tool release piston to the head casting, but DO NOT

disconnect the air hoses and switches.

8. Remove both spindle drive belts. Replace the tool release piston and hand tighten the two SHCS and two

HHB.

9. IMPORTANT! Remove the steel tube from the column. CAUTION! This step must be followed or the machine

will be seriously damaged.

10. Press RESET. Jog the Z-axis all the way back, and the X-axis to the center of it's travel. This will allow

easier access to the motor from the rear of the machine.

11. Jog the Y-axis until the two lower holes in the column and the corresponding holes in the spindle head

are aligned (at approx. Y=16.25"). Place two of the original shipping lockbolts (5/8-11 x 4" SHCS) through
the two holes and snug tighten. CAUTION! This step must be followed to keep the spindle head from moving
during service. If this is not done, serious injury could occur.

66

12. POWER OFF the machine and disconnect the main air line.

13. Disconnect all electrical lines and air lines from the transmission solenoid bracket.

Note: The motor wires can be disconnected from the front of the machine.

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MECHANICAL SERVICE

Disconnect the electrical and oil lines from the oil pump. Plug the oil lines to prevent contamination. Most
of the lines should be marked and identified. If not marked, do so as it is removed.

If machine is equipped with the Through the Spindle Coolant option, remove the pressure regulator, check
valve assembly, and bracket from the old transmission, so they can be installed later on the new transmission.

14. Place the lift fixture onto the transmission (Figure 3-15). Attach to the motor mounting plate with two

SHCS (1/2-13 x 1-1/4).

Figure 3-15. Transmission lift fixture.

15. Secure the transmission removal fixture support bracket to the back of the column with four SHCS.

16. Assemble the support arms (3) of the transmission removal fixture by placing a thrust washer at the

bottom of each joint and inserting the dowel pins from the top side (Figure 7-2). Grease the joints to ensure
smooth arm movement.

17. Hook the chain hoist onto the transmission removal fixture, then attach the chain's hook onto the

center eyebolt of the lift fixture.

18. Remove ALL slack in the hoist's chain, then remove the six transmission mounting SHCS. CAUTION! The

transmission might swing out when the mounting screws are removed, so hold it in place and carefully swing
the transmission out of the back of the machine. Lower the transmission to the ground or a pallet.

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MECHANICAL SERVICE

June 1998

Figure 3-16. Transmission removal fixture and chain hoist.

INSTALLATION-

1. If machine is equipped with Through the Spindle Coolant option, reinstall the pressure regulator, check

valve assembly, and bracket onto the new transmission.

2. Remove the lift fixture from the old transmission and place it on the new transmission.

3. Hook the chain hoist onto the transmission removal fixture, then attach the chain's hook onto the center

eyebolt of the lift fixture.

4. Hoist the transmission into place. Only lift the transmission high enough to clear the enclosure and to

swing into place.

5. Grease the rubber vibration isolators on the new transmission with general purpose grease.

6. Lift the new transmission up close to the spindle head, and secure it with six SHCS. Make sure the

transmission is all the way down in the clearance holes. Tighten the two top transmission mounting SHCS.

7. Remove the transmission lift fixture from the transmission, and the transmission removal fixture from the

column.

8. IMPORTANT! Isolate the three motor wires, which are to be connected later. This keeps the wires from

getting shorted out.

68

9. Reconnect all electrical and fluid lines. Replace any leaking or kinked lines at this time, if necessary.

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MECHANICAL SERVICE

10. IMPORTANT! Remove the two shipping lockbolts from the column and spindle head.

CAUTION! Serious machine damage will occur if the axes are moved with the lockbolts in
place.

11. Zero return the machine. Jog the Y-axis all the way up.

12. IMPORTANT! Insert the steel tube in place through the column, as described in the "Removal" section.

Connect the three motor wires and the ground wire to the motor.

13. Remove the tool release piston in accordance with the appropriate section.

14. Install the drive belts in accordance with the "Spindle Drive Belts - Belt Installation" section.

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Figure 3-17. Drive belt replacement (after transmission replacement).

15. IMPORTANT! Remove the steel tube from the column. CAUTION! This step must be followed or the

machine will be seriously damaged.

16. Replace the rear enclosure panel with seven SHCS. Slide the lower Y-axis way cover into place and replace

the seven SHCS.

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MECHANICAL SERVICE

3.8 TOOL CHANGER ASSEMBLY

CT-EXTRACTOR REPLACEMENT

REMOVAL -

1. Zero return all axes and remove any tooling.

2. Rotate the carousel into position by pressing M39 T_ (Enter the tool position number that needs

replacement.)

3. Jog the Y-axis down, away from the tool changer.

4. POWER OFF the machine.

5. Retract the carousel door and clamp open. CAUTION! The door spring is under high tension.

6. Remove one SHCS that fastens the extractor to the carousel. CAUTION! The extractor spring is under high

compression. Once it is removed, one extractor and the spring should come out. Remove the other SHCS
to remove the extractor clip and block.

June 1998

Figure 3-18. C-T Extractor Assembly.

INSTALLATION-

Assembly Parts:

(2) extractor clips
(2) extractor sleeves
(2) screws and (2) washers
(1) extractor block
(1) compression spring

NOTE: Be sure to check for proper extractor assembly orientation.

7. Insert sleeve into pivot hole of each extractor and assemble each extractor with a SHCS and hard washer

(round edge facing head of screw). Before mounting the assembly to the carousel, apply a small amount of
semi-permanent Loctite® to each screw, then thread the screws just a few turns.

8. Place one end of the spring onto the top notch of the extractor and pivot the opposite extractor until both

ends are firmly seated.

9. Evenly tighten the extractor screws to the carousel housing.

10. Verify the extractor assembly is properly oriented for the tool type.

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MECHANICAL SERVICE

CAROUSEL MOTOR

REMOVAL-

1. POWER OFF the machine.

2. Disconnect the carousel wire harness at carousel motor junction box.

3. Remove the four bolts mounting motor to carousel reduction transmission.

Figure 3-19. Tool changer carousel motor.

4. Motor output shaft locates on a keyway and will pull directly out.

INSTALLATION-

5. Line up keyway with output shaft and slide motor into place.

6. Tighten the four motor mounting bolts to the carousel transmission box.

7. Reconnect the wire harness to the carousel motor.

8. Check that the carousel indexing alignment is correct by doing a ZERO RET / AUTO ALL AXES. Adjust the

rotational offset, Parameter 215, according to the "Tool Changer Alignment" section.

T OOL C HANGER D OOR

REMOVAL-

1. Disconnect the air supply to the machine.

2. Disconnect the door spring.

3. Remove the rubber bumper and door return spring from the back side of the carousel cover.

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4. Remove the air door cylinder swivel mount from the cylinder front mount.

NOTE: The air door cylinder is under spring tension.

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MECHANICAL SERVICE

5. Remove the cylinder front mount from the door, being careful not to lose the small spring or nylon door

slider.

6. Rotate the trap door clockwise past the "closed" position. Continue rotating and gently pull down on the

door. It will slide down once it has been rotated far enough.

INSTALLATION-

1. Clean the washer contact surface of the tool changer cover, and apply a thin coat of grease.

2. With the door rotated to the right slightly, lift the door up between the carousel cover and the tool changer

front plate, making sure the door nylon washer is between the door and the cover.

3. With the door in the up position, rotate the door counterclockwise past it's normal "closed" position to

it's normal "open" position to assure smooth operation.

4. Replace the rubber bumper on the back side of the carousel cover.

5. Apply a small coat of grease to the inside of the carousel cover, just above the door opening. Also apply

grease to the nylon door slider and small spring.

6. Install the cylinder front mount, being sure the nylon door slider and spring are in place.

June 1998

7. Install the cylinder swivel mount onto the cylinder front mount.

8. Install the door return spring on the back of the carousel.

9. Check for smooth operation and adjust the air door regulator (located on top of the tool changer) to assure

adequate opening of the door.

T OOL C HANGER C AROUSEL R EPLACEMENT

REMOVAL-

1. Center the X-axis. Jog the Y-axis all the way down.

2. Manually open the tool changer door and brace it open.

3. Turn off the three circuit breakers on the Power PCB.

Note: This allows no power to the motors and keeps the lights on.

CAUTION! Make sure that fingers are clear of carousel while performing the following:

4. Press the carousel "IN" solenoid and hold it while someone places a 4 x 4 to hold the carousel in the "IN"

position.

72

5. With the 4x4 in place and all fingers clear, release the "IN" solenoid.

6. Remove the four SHCS that mount the gearbox to the top mounting plate. (Fig. 3-20 #1)

7. Tilt the motor forward and remove the belt.

8. Remove the four SHCS that secure the (2) switch brackets and place them clear of the large pulley (Fig.

3-20, #2).

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June 1998

MECHANICAL SERVICE

CAUTION! Make sure that fingers are clear of carousel while performing the following:

9. While someone holds the 4x4 (fingers clear), press the turret "IN" solenoid and hold while the 4x4 is

removed.

10. After the 4x4 is removed, release the "IN" solenoid.

11. Remove the six SHCS that mount the clyinder cap to the carousel. (Fig. 3-20, #3)

12. Remove the hex nut that attaches the shock absorber to the cylinder cap (Fig 3-20, #5)

13. Remove the cylinder cap.

14. Remove the six SHCS that attach the locking cap to the shaft assembly(Fig 3-20, #6)

15. Slide the carousel assembly off.

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Figure 3-20. Carousel replacement.

INSTALLATION-

1. Grease the tool changer shaft.

2. Ensure the drive belt is in place before installing the carousel. Slide the carousel assembly on the shaft.

3. Place the belt on the drive pulley.

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MECHANICAL SERVICE

4. Install the locking cap. (Fig. 3-20, #6)

5. Install the cylinder cap. Pull the shaft of the shock absorber through the front hole of the cylinder cap.

6. Install the shock absorber nut. (Fig. 3-20, #5)

7. Install the six SHCS that attach the cylinder cap to the carousel.(Fig. 3-20, #3)

CAUTION! Make sure that fingers are clear of turret while performing the following:

8. Carefully press the turret "IN" solenoid and hold while someone places a 4x4 to hold the turret in the "IN"

position.

9. With the 4x4 in place and all fingers clear, release the "IN" solenoid.

10. Install the switch bracket and four SHCS. (Fig. 3-20, #2)

11. Tilt the motor forward and mount the belt to the pulley.

12. Install the four SHCS that mount the gearbox to the top mounting plate. (Fig. 3-20, #1)

June 1998

13. While someone holds the 4x4 (fingers clear), press the turret "IN" solenoid and remove the 4 x 4.

14. Release the "IN" solenoid.

15. Turn the three circuit breakers on the Power PCB back on.

16. Go to the next section and perform all aligment procedures under Tool Changer Alignment.

T OOL C HANGER A LIGNMENT P ROCEDURES

Carousel In/Out Procedure:

1. Check that the main air regulator is set at 85 psi.

2. Zero return all axes.

3. In MDI mode, type "T1" and press ATC FWD. Turn Setting 7 off.

4. Select the ALARM page. Type "debug" and press the WRITE key.

5. Press the ORIENT SPINDLE key.

NOTE: Ensure the tool pushout switch adjustment for tool clamp/unclamp adjustment
has been completed.

74

6. Manually open and secure the air door.

7. In HANDLE JOG mode, select the Y axis. Slowly move the Y axis up towards the spindle until the extractor

on station #1 is close to engaging the tool holder.

8. Ensure that the tool carousel in/out adjustment is correct by checking the centerline of the tool extractor

groove in reference to the extractor centerline.

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Figure 3-21. Tool Changer IN/OUT adjustment nut

NOTE: Do not loosen the 1/4" nut located at center. Tighten the 1/2" locknut without turning
the adjustment screw.

Adjustments are made by loosening the 1/2" locknut located at the nose of the actuation cylinder, and turning
the setscrew clockwise or counterclockwise.

NOTE: Do not loosen the 1/4" nut located at center. Tighten the 1/2" locknut without
turning the adjustment screw.

9. After completing the carousel adjustment, the switch adjustments for carousel in/out must be done.

NOTE: On the Diagnostics page, TC OUT must be 1 and TC IN must be 0.

SETTING PARAMETER 215

IF YOUR MACHINE IS OPERATING WITH 9.20 SOFTWARE OR LATER SKIP TO STEP 15.

10. Loosen the two 1/4" SHCS on top of the switch bracket, inside the tool carousel. Adjust the bracket until

the TC OUT switch reads 1. Manually override the shuttle solenoid to shuttle out the carousel and release
it. The TC OUT switch must always trip.

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11. Manually override the shuttle solenoid to bring the shuttle out. Check that the TC IN switch trips to 1

and the TC OUT switch trips to 0.

NOTE: Verify the tool changer is empty for the next step.

12. Jog the spindle (with tool holder) towards the tool changer. When the tool changer extractor is close

to engaging the tool holder, confirm that the carousel rotation is in line with the tool side-to-side engagement.

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MECHANICAL SERVICE

If the carousel is too far in the clockwise direction, Parameter 215, "Carousel Offset", must be set to a
lower value. Increase the value if the carousel is too far counterclockwise.

On machines before software version 9.14, the carousel offset number must not be 15,000 or an even multiple
of it (30,000; 45,000; etc.). This is because 15,000 (9,000 for HS-2) is the exact distance between pockets.
Machines with software version 9.14 or later do allow the use of these numbers.

NOTE: The ZERO RET key must be pressed EVERY TIME Parameter 215 is changed.

13. Jog the Y-axis up slowly until the extractors have fully engaged the tool, ensuring that the spindle

orientation is still correct. Ensure the extractor is fully engaged, but not overloading the servo motor.

NOTE: There should be a small amount of clearance to prevent the extractor from
knocking when the Y-axis moves into position. Parameter 211, "Y-Axis Tool Change
Offset", will adjust this distance.

14. IMPORTANT! Once you have completed this procedure, type "debug" on the ALARMS page, then press

the WRITE key to exit. Turn Setting 7 on.

15. Press "POWER UP RESTART", the tool changer will align to tool number #1.

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STEPS 15-21 OF THIS PROCEDURE ARE FOR SETTING PARAMETER 215 AND ONLY APPLY TO
MACHINES OPERATING WITH 9.20 SOFTWARE OR LATER.

16. Go to parameter 215 and set it to zero

17. Enter "DEBUG" mode and go to the POSITION page and page up to "POS RAW-DAT" SCREEN.

18. ENTER "W" and HANDLE JOG

19. Slowly turn the jog handle and observe how the carousel rotates as a normal axis. Be careful not to turn

the jog handle too fast or else the carousel will begin to oscillate.

20. The screen will display a "CO" and a number. This stands for C)arousel O)ffset.

21. Rotate the carousel to tool ZERO (on the HS-1 this is pocket #24, HS-2 is #40) This number is then entered

in Parameter 215.

22. Press "POWER UP RESTART" and the tool changer will align to tool #1.

SETTING PARAMETER 211

Note: For machines equipped with macros: In MDI Mode type #1126=1 (air door open),
but do not execute the program yet.

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For machines not equipped with macros, manually open the toolchanger air door.

1. Go to the alarms page and enter DEBUG Mode.

2. Execute the MDI program to open the air door.

3. Orient the spindle.

4. Manually load a tool into the spindle.

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5. Slowly jog the Y-axis up past the HOME position, into the tool change position.

6. Visually watch for the tool carousel fingers to expand over the tool and close in around it.

7. Continue jogging up slowly just until the tool applies slight pressure upwards on the carousel.

8. Go to the POSITION DISPLAY and page up to "POS-RAW DAT" page and read the actual Y-axis position.

9. Enter the number from the Y-axis from the actual position then put in Parameter 211. The controls default

setting is 780000.

10. Handle jog down past the home switch into the normal operating envelope.

11. Exit DEBUG.

12. In MDI execute a tool change by pressing ATC FWD.

13. Note the reaction of the carousel as the tool enters the extractor fingers:

If the carousel deflects up then decrease the number in Parameter 211.
If the tool deflects down as it enters the carousel then decrease the number in Parameter 211.
If the tool deflects up as it is pulled out of the spindle by the carousel, then decrease the number
in Parameter 211.

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MECHANICAL SERVICE

SIDE MOUNT TOOL CHANGER ALIGNMENT (HS-2RP)

1. Remove the tool changers shipping retainer bolt. Refer to Figure 3-22.

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Figure 3-22.

2. There are four tool changer cable connectors that must be plugged in before the tool changer is

operable.

Cables shipped in the tool changer enclosure include:

Cable 1 ( Carousel Drive Motor Cable). The cable is encased in flexible conduit and supplied

with an amphenol connector. This cable must be routed around the back of the machine
under the apron and connected to the Tool Changer connector on the side of the
control panel.

Cable 2 (Shuttle Motor Drive Cable). The cable is routed around the back of the machine

and is supplied with a connector bracket, found at the right rear corner of the machine
behind an access panel. The connector bracket is labeled TC IN/OUT for this cable
connector.

Cable 3 (Shuttle-In ) TC IN, #820B / Cable 4 (Shuttle-Out) TC OUT, #820 limit switch

cables. The connections for these cables are located near the base of the tool changer.
The wiring for the connectors are located behind the side apron, near the tool changers
base support tube. Remove the factory-installed shuttle out jumper, before plugging
the shuttle-out connector on the tool changer to its matching connector from the
machine.

78

NOTE: Keep the shuttle-out jumper, as it will be used later in the tool changer
alignment procedures.

3. POWER-UP the machine.

4. Press the RESET button to clear the alarm message.

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5. Press the ZERO RET and then the AUTO ALL AXES button. The machine will move the spindle to its

home position (Zero X, Y, Z, A and W).

6. Go to the SETTINGS screen. Cursor to Setting 51, DOOR HOLD OVERRIDE. Toggle the DOOR

HOLD OVERRIDE to ON. With the setting toggled to ON, press the WRITE/ENTER button to
enter this value into the control. With this setting set to ON the operator side door can be open
during the next steps without generating an alarm.

7. Command the shuttle door to open. Move to the MDI screen. Enter value #1126="1" from the

keypad, then press INSERT. Press RESET and then CYCLE START. The tool changer door will open.

8. Move to the SETTING screen. Cursor to Setting (7) PARAMETER LOCK. Toggle the

PARAMETER LOCK to OFF, then press the WRITE/ENTER button to enter this value.

9. Press the E-STOP button.

10. Go to the PARAMETER screen, cursor to Parameter 215. This parameter controls the position of

the zero pocket for the tool changer carousel. Record the value for this parameter, set the Param­eter to zero by entering 0 and press the WRITE/ENTER button.

NOTE: Check Parameter Settings after all procedures have been completed and
machine POWER-UP/RE-START(ed).

11. Enter DEBUG Mode. Move to the POS-RAW DAT screen.

12. The lower right hand area of the screen will display CO and a number. The C)arousel O)ffset

number will be used to orient the tool changer carousels rotational position. Turn the E-STOP off
and press the RESET button three times to clear the alarm message(s).

13. Enter W and then press the HANDLE/JOG button. Slowly turn the HANDLE/JOG control in ½

turn increments and observe the rotation of the carousel. The carousel will alternate between
counterclockwise and clockwise motion but will eventually stop. Continue to rotate the carousel until
tool pocket #40 (designated ZERO tool) is at or near the three oclock position.

14. Install two ¼-20 x 2 in. shoulder bolts into threaded holes on the face of the carousel as shown in

Figure 3-23. Place a 48" bubble level or a flat bar with a torpedo level across the two shoulder bolts.

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Figure 3-23.

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MECHANICAL SERVICE

15. Continue to handle jog the tool changers carousel to achieve a level condition. Record the Carou-

sel Offset number given on the POS-RAW DAT screen. Move to the PARAMETER screen. Enter the
recorded Carousel Offset value into PARAMETER 215.

16. Remove the leveling tools.

17. Command shuttle door to close. Move to the MDI screen. Cursor to number 1, enter 0 from

the keypad and press the ALTER button. Press RESET and then CYCLE START. The tool changer door
will close.

18. Press the ZERO RET button and then the AUTO ALL AXES button. The machine will move to its

home position (zero X, Y, Z, A and Tool Changer Carousel).

19. Press the POWER UP RESTART button and the tool changer will align to tool #1.

20. Command Shuttle Door to open, again. Move to the MDI screen. Cursor to the number 0, enter

1 from the keypad and press the ALTER button. Press RESET and then CYCLE START. The tool changer
door will open.

21. Press the E-STOP button.

22. Disconnect the TC IN limit switch connector (#820B) and the TC OUT limit switch connector (#820)

located at the base of the tool changer. Re-install the previously removed jumper into the TC IN con­nector on the wiring coming from the machine-side.

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23. Disconnect the tool changers shuttle motor cable connector, behind the rear access panel on the

control box side of the machine. See Figure 3-24.

24. The next step requires the tool changer carousel to be manually shuttled into the machine enclo-

sure. To shuttle the carousel out, its shuttle arm must be fully rotated. First, reach in through the tool
changer's window, push up on the cam follower bolt (as shown in Figure 3-25.) and then move the carou­sel to its fully extended position in the enclosure. Verify that it is fully extended by inspecting the location
of the cam follower bolt. The cam follower bolt should bottom out at the end of the guide slot.

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Figure 3-24. Figure 3-25.

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25. Next, move to PARAMETERS screen. Record the values for the Settings #210 (X-axis), #211 (Y-

axis) and #64 (Z-axis). After recording the values for these Parameters, enter "0" for their values.

26. Go to ALARMS page, enter DEBUG from the keypad and press WRITE/ENTER. Move to the POSI-

TION screen to enter the POS-RAW DAT screen.

27. Handle jog the X, Y and Z axes as necessary to place the spindle centerline inline with the centerline

of the tool changers extractor fingers. Align the spindle centerline with the center of the tool changers
fingers in the X , Y plane only.

NOTE: As an alignment aid, a 2.325" diameter disk mounted into a tool holder may
be used (Refer to Figure 3-26). Handle jog as necessary to bring the disk in line
with the center of the tool changers fingers.

Figure 3-26.

28. Record the values in the ACTUAL column for the position of the X and Y-axes given on the POS-

RAW DAT screen.

Enter the position value for the X-axis in Parameter 210.

NOTE: this number is entered without the decimal point and must be the same sign
as that given on the POS-RAW DAT screen. For example 0.7094 would be entered
as 7094, and 278.8854 would be 2788854.

Enter the position value for the Y-Axis in Parameter 211.

29. Align the Z-axis. Line up the finger groove in the tool holder with the extractor fingers on the

carousel. Handle jog the spindle in +Z direction (towards the rear of the machine). Then handle jog
the -X direction (towards the control panel). Stop when it is clear that the tool holder groove can be
jogged towards the front of the machine without hitting the extractor fingers.

NOTE: It should not be necessary to move the Y-axis during this exercise.

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30. Handle Jog the spindle in the -Z direction (towards the front of the machine) and align the tool

changer's fingers with the groove in the tool holder. Handle jog the spindle in the +X direction (to­wards the tool changer) and slowly move the tool holder into the extractor fingers. STOP AND RE-
ALIGN IF ANY MISALIGNMENT IS FOUND. Continue to move the tool holder into the fingers until the
drive notch on the side of the tool holder is approximately 0.050 in. from bottoming out on the carousels
alignment key. Refer to Figure 3-27.

31. Record the values for the position of the Z-axis given on the POS-RAW DAT screen.

Enter the position value for the Z-Axis in Parameter 64.

32. Move the spindle in the X direction to extract the tool holder from the tool changers extractor

fingers. Jog the spindle as necessary to move it clear of the tool changer. Remove the tool holder
from the spindle.

33. Manually pull the carousel out of the machine enclosure, into its retracted position.

34. Close the tool changer door. Press MDI/DNC, move to PROGRAM screen. Toggle the cursor to the

number 1 after the equal sign. Enter 0 and press ALTER button. Next press RESET and CYCLE START.
The tool changer door will close.

35. Press ZERO RET button and then AUTO ALL AXES button, to move the machine spindle to its home

position.

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36. Remove the jumper installed in the TCIN limit switch connector (#820B) at the base of the tool

changer and reconnect the previously disconnected limit switch cables.

37. POWER OFF, then POWER ON the machine. Press RESET button to clear any alarm messages.

NOTE: Verify all Parameter Value(s) have been recorded.

38. Press the ZERO RET and then AUTO ALL AXES button.

39. Install a tool holder into the spindle. See Figure 3-27.

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Figure 3-27.

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MECHANICAL SERVICE

40. Press the MDI/DNC button, then ATC FORWARD button. Repeat step 22, to manually move the

carousel into the machine enclosure.

NOTE: The spindle will move to its tool change position and the machine will fault-out
and display a SHUTTLE FAULT ALARM. This is due to the shuttle motor cable
disconnection.

Move the carousel into the tool holder and verify that proper extractor finger alignment has been
made. (Repeat steps 23 through 30 as necessary to align the tool changer extractor fingers to the
tool holder.)

43. Once alignment has been verified, pull the tool changer carousel out of the enclosure, close the

shuttle door and reconnect the shuttle motor cable connector at the rear of the machine.

44. Press the MDI/DNC button and then press the ATC FORWARD button to verify proper operation of

the tool changer.

45. Go to the SETTING 7, toggle PARAMETER LOCK to ON . With the setting toggled to ON, press

WRITE/ENTER button to enter this value.

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MECHANICAL SERVICE

3.9 AXIS MOTOR

Please read this section in its entirety before attempting to remove or replace the axis
motors.

X-AXIS M OTOR

REMOVAL-

1. Power ON the machine. Zero return all axes and put machine in HANDLE JOG mode.

2. Jog the Y-axis to the bottom of it's travel. Jog the X-axis away from the motor.

3. Remove the rear enclosure panel (seven SHCS).

4. POWER OFF the machine.

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84

Figure 3-28. X-axis motor and lead screw assembly.

5. On the top of the motor housing, remove the four BHCS and remove the cover plate.

6. Loosen the SHCS on the motor coupling at the lead screw.

7. On the motor housing, loosen the four SHCS and remove the motor from the housing.

8. Disconnect all wiring from the motor and remove.

INSTALLATION-

1. Inspect the motor coupling and replace it if required. Visually inspect the flex plates to ensure they

are parallel to the coupling halves. Slide the new coupling onto the motor shaft until the coupling half
is flush to the end of the shaft.

NOTE: The slot in the locking collar must be positioned 45 degrees between the bolt hole
pattern of the coupler. If improperly aligned, the coupler will not have enough clamping
force on the leads screw or motor shaft. Refer to diagram in coupling replacement
section.

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MECHANICAL SERVICE

2. Reconnect all wiring to the motor.

3. Align the key on the motor shaft. Slide the motor into the motor housing, inserting the end of the

lead screw into the motor coupling.

4. Reinstall and tighten down the four SHCS that hold the motor to the housing.

5. Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite® on the screw

before inserting.)

6. Replace the cover plate and fasten with four BHCS.

7. Replace the rear enclosure panel with seven SHCS.

8. Check for backlash in the X-axis lead screw ("Troubleshooting" section) or noisy operation, and grid

offset.

Y-AXIS M OTOR

REMOVAL-

1. Power ON the machine. Zero return all axes and put machine in HANDLE JOG mode.

2. Remove the rear enclosure panel (seven SHCS).

3. Jog the X-axis until the Y-axis lead screw can be easily accessed from the rear.

4. Jog the Y-axis until the two upper holes in the column and the corresponding holes in the spindle head

are aligned. Place two of the original shipping lockbolts (5/8-11 x 4" SHCS) through the two holes and tighten.
CAUTION! This step must be followed to keep the spindle head from moving during service. If this is not done,
serious injury could occur.

5. POWER OFF the machine.

6. Loosen the four SHCS and remove the upper bellows guide from the X-axis way bellows supports so the

motor can be pulled up from the motor mount.

7. Loosen the SHCS on the motor coupling at the lead screw.

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Figure 3-29. Y-axis motor and coupling.

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MECHANICAL SERVICE

8. Loosen the four SHCS and remove the motor from the motor mount.

9. Disconnect all wiring from the motor.

10. Remove the motor.

INSTALLATION-

1. Inspect the motor coupling and replace it if required. Visually inspect the flex plates to ensure they are

parallel to the coupling halves. Slide the new coupling onto the motor shaft until the coupling half is flush
to the end of the shaft.

NOTE: The slot in the locking collar must be positioned 45 degrees between the bolt
hole pattern of the coupler. If improperly aligned, the coupler will not have enough
clamping force on the leads screw or motor shaft. Refer to diagram in Coupling
Replacement section.

2. Reconnect all wiring to the motor.

3. Align the key on the motor shaft. Slide the motor into the motor housing, inserting the end of the lead

screw into the motor coupling.

4. Reinstall and tighten down the four SHCS that hold the motor to the housing.

June 1998

5. Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite® on the screw

before inserting.)

6. CAUTION! Remove the shipping lockbolts from the column and spindle head. Failure to remove these

will cause severe damage to the machine.

7. Replace the rear enclosure panel with seven SHCS.

8. Check for backlash in the Y-axis lead screw (Troubleshooting section) or noisy operation.

9. Check that Parameter 211, "Y-Axis Tool Change Offset", is set correctly, and adjust if necessary.

10. Check the grid offset after the new motor has been installed.

Z-AXIS MOTOR

REMOVAL-

1. Power ON the machine. Zero return all axes and put machine in HANDLE JOG mode.

2. Jog the Y-axis to the bottom of it's travel. Jog the Z-axis all the way towards the back of the machine.

3. Remove the thirteen SHCS that attach the Z-axis way cover to the table, and collapse it back towards the

saddle.

4. POWER OFF the machine.

86

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MECHANICAL SERVICE

Figure 3-30. Z-axis motor and lead screw assembly.

5. On the motor mount, loosen the four BHCS and remove the cover plate.

6. Loosen the SHCS on the motor coupling at the lead screw.

7. Loosen the four SHCS and remove the motor from the mount.

8. Disconnect all wiring from the motor and remove.

INSTALLATION-

1. Inspect the motor coupling and replace it if required. Visually inspect the flex plates to ensure they are

parallel to the coupling halves. Slide the new coupling onto the motor shaft until the coupling half is flush
to the end of the shaft.

NOTE: The slot in the locking collar must be positioned 45 degrees between the bolt
hole pattern of the coupler. If improperly aligned, the coupler will not have enough
clamping force on the leads screw or motor shaft. Refer to diagram in Coupling
Replacement section.

2. Reconnect all wiring to the motor.

3. Align the key on the motor shaft. Slide the motor into the motor housing, inserting the end of the lead

screw into the motor coupling.

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4. Reinstall and tighten down the four SHCS that hold the motor to the housing.

5. Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite® on the screw

before inserting.)

6. Replace the cover plate and fasten with four BHCS.

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MECHANICAL SERVICE

7. Replace the Z-axis way cover with thirteen SHCS.

8. Check for backlash in the Z-axis lead screw ("Troubleshooting" section) or noisy operation.

9. Check the grid offset after the new motor has been changed.

C OUPLING R EPLACEMENT

REMOVAL-

1. Remove the axis motor in accordance with "Axis Motor Removal/Installation" section.

NOTE: It will not be necessary at this time to completely remove the motor. Do not
disconnect the electrical components.

2. Completely loosen the two SHCS on the two coupling clamp rings and remove the coupling.

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88

Figure 3-31. Motor coupling components.

INSTALLATION-

3. Slide the new coupling onto the motor shaft until the coupling half is flush to the end of the shaft.

NOTE: The slot in the locking collar must be positioned 45 degrees between the bolt
hole pattern of the coupler. If improperly aligned, the coupler will not have enough
clamping force on the leads screw or motor shaft.

4. Tighten the two SHCS on the coupling's clamp ring. Before tightening, add one drop of blue Loctite®

to each screw.

5. Reinstall the axis motor.

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MECHANICAL SERVICE

3.10 BEARING SLEEVE

Please read this section in its entirety before attempting to remove or replace the bearing
sleeve.

X-A XIS BEARING SLEEVE

REMOVAL-

1. POWER ON the machine. Zero return all axes and put the machine in HANDLE JOG mode.

2. Remove the rear enclosure panel (seven SHCS).

3. Jog the Y-axis to the bottom of it's travel. Jog X-axis away from bearing support.

4. POWER OFF the machine.

5. Remove the hardstop bracket from bearing support end.

6. Remove the clampnut.

7. Manually screw the column over in order to access the motor.

CAUTION! Do not screw the column too far over since the hardstops are removed!

8. Remove the X-axis motor in accordance with "X-Axis Motor - Removal".

9. Remove the coupling.

NOTE: The motor's electrical connections do not need to be removed for this operation.
After removing the motor from the motor mount, set it aside.

10. Loosen the SHCS on the clamp nut at the motor end of the lead screw, and remove the clamp nut.

11. Loosen the six SHCS and remove the bearing sleeve from the motor mount. Push on the column or the

opposite end of the lead screw to loosen.

CAUTION! Do not pry the bearing sleeve away from the housing. Damage to the sleeve,
bearing, motor housing or lead screw will result.

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Figure 3-32. Bearing sleeve mounting location.

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MECHANICAL SERVICE

INSTALLATION-

1. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free

of dirt, burrs, grease, or other contaminants.

CAUTION! Mating surfaces must be clean or misalignment may occur, seriously affecting
the proper operation of the machine.

2. With the column all the way to the left, place the bearing sleeve in the motor mount. It may be necessary

to align the bearings in the sleeve to facilitate mounting on the lead screw.

3. Install the six SHCS on the bearing sleeve, and torque to 15 ft-lbs. (Place a drop of blue Loctite on each

of the SHCS before inserting.)

4. Manually screw the column over in order to access the bearing support.

CAUTION! Do not screw the column too far over since the hardstops are removed!

Screw the clamp nut on the bearing support end of the lead screw two or three turns, but do not tighten.

5. Screw the clamp nut on the motor end of the lead screw two or three turns, but do not tighten.

June 1998

6. Loosen all of the SHCS on the bearing sleeve approximately 1/4 turn, then torque to 15 ft-lbs. DO

NOT SKIP THIS STEP. It ensures the lead screw is installed and runs parallel and flat to the linear guides
and the saddle.

7. Tighten the lead screw against the clamp nuts as follows:

Ø Tighten the clamp nut on the motor housing end of the lead screw to 15 ft-lbs.
Ø Tighten the SHCS on the clamp nut.
Ø Place a spanner nut over the clamp nut on the support bearing end of the lead screw and slowly

tighten to 4 inch-lbs. Remove the spanner nut.

Ø Tighten the SHCS on the clamp nut with Loctite, and mark it with yellow marking paint.

8. Reinstall and tighten the hard stop on the bearing support.

9. Reinstall the X-axis motor as described in "X-Axis Motor - Installation".

10. Check for backlash in the X-axis lead screw ("Troubleshooting" section), or noisy operation.

11. Replace the rear panel enclosure with seven SHCS.

Y-AXIS BEARING S LEEVE

REMOVAL-

1. POWER ON the machine. Zero return all axes and put machine in HANDLE JOG mode.

90

2. Remove the seven SHCS attaching the lower Y-axis way cover to the head casting, and collapse it downward

in order to access the support bearing.

3. Remove the rear enclosure panel (seven SHCS).

4. Jog the X-axis until the Y-axis lead screw can be easily accessed from the rear.

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MECHANICAL SERVICE

5. Jog the Y-axis until the two upper holes in the column and the corresponding holes in the spindle head

are aligned. Place two of the original shipping lockbolts (5/8-11 x 4" SHCS) through the two holes and tighten.

CAUTION! This step must be followed to keep the spindle head from crashing down during
service. If this is not done, serious injury could occur.

6. POWER OFF the machine.

7. Remove the axis motor in accordance with "Y-Axis Motor - Removal".

8. Loosen the SHCS and remove the clamp nut on the lead screw bearing plate end.

Figure 3-33. Y-axis lead screw bearing support end clamp nut.

9. Loosen the SHCS and remove the clamp nut on the motor end of the lead screw.

10. Loosen the six SHCS and remove the bearing sleeve from the top of the column.

CAUTION! Do not pry the bearing sleeve away from the top of the column. Damage to the
sleeve, bearing, top of column or lead screw will result.

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MECHANICAL SERVICE

Figure 3-34. Y-axis lead screw motor end clamp nut and bearing sleeve.

INSTALLATION-

1. Ensure all mating surfaces on the bearing sleeve, motor housing, top of column, and ball nut are free of

dirt, burrs, grease, or other contaminants.

June 1998

CAUTION! Mating surfaces must be clean or misalignment may occur, seriously affecting the
proper operation of the machine.

2. Install the bearing sleeve on top of the column with six SHCS. (Place a drop of blue Loctite on each of

the SHCS before inserting.) Tighten down to 15 ft-lbs. It may be necessary to align the bearings in the sleeve
to facilitate mounting on the lead screw.

3. Screw the clamp nut on the motor end of the lead screw two or three turns, but do not tighten.

4. Loosen all of the SHCS on the bearing sleeve approximately 1/4 turn, then torque to 15 ft-lbs. DO NOT

SKIP THIS STEP. It ensures the lead screw is installed and runs parallel and flat to the linear guides and the
saddle.

5. The following sequence is important to ensure proper installation of the lead screw:

Ø Tighten the clamp nut, hand tight, against the bearing sleeve.
Ø Install the shaft lock onto the bearing support end of the leadscrew. This will keep the

lead screw from turning while torquing the clamp nut.

Ø Place a spanner wrench on the clamp nut at the motor end of the assembly.
Ø Torque the clamp nut against the bearing sleeve to 15 FT-LBS.
Ø Remove the shaft lock.
Ø With a T-handle wrench hand tighten the clamp nut screw and mark with yellow paint.
Ø Screw the clamp nut against the bearing at the bearing support end, hand tight. Tighten the

clamp nut another 1/8. (If you have a torque screwdriver, torque the clamp nut to 4 IN-LBS.)

Ø With a T-handle wrench hand tighten the clamp nut screw and mark with yellow paint.

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6. Reinstall the axis motor in accordance with "Y-Axis Motor - Installation".

7. Replace the lower Y-axis way cover and attach it to the head casting with seven SHCS.

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MECHANICAL SERVICE

8. CAUTION! Remove the shipping lockbolts from the column and spindle head. Failure to remove these will

cause severe damage to the machine.

9. Check for backlash in the lead screw (Troubleshooting section), or noisy operation.

10. Replace the rear enclosure panel with seven SHCS.

Z-AXIS B EARING SLEEVE

REMOVAL-

1. POWER ON the machine. Zero return all axes and put the machine in HANDLE JOG mode.

2. Jog the Y-axis to the bottom of it's travel. Jog the Z-axis all the way towards the back of the machine.

3. Remove the thirteen SHCS that attach the Z-axis way cover to the table, and collapse it towards the saddle.

4. Remove the rear enclosure panel (seven SHCS).

5. POWER OFF the machine.

6. Remove the Z-axis motor in accordance with "Z-Axis Motor - Removal".

NOTE: The motor's electrical connections do not need to be removed for this operation.
After removing the motor from the mount, set it to one side.

7. Loosen the SHCS on the clamp nut at the motor end of the lead screw, and remove the clamp nut.

8. Pry open the sheet metal bracket, and remove the hard stop from the lead screw support bearing end

of the lead screw.

9. Loosen the SHCS on the clamp nut at the bearing support end, and remove the clamp nut.

10. Loosen the six SHCS and remove the bearing sleeve from the motor mount (Fig. 10-1). Push on the

opposite end of the lead screw to loosen.

CAUTION! Do not pry the bearing sleeve away from the housing. Damage to the sleeve,
bearing, motor housing or lead screw will result.

INSTALLATION-

1. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt,

burrs, grease, or other contaminants.

CAUTION! Mating surfaces must be clean or misalignment may occur, seriously affecting
the proper operation of the machine.

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2. Place the bearing sleeve in the motor mount. It may be necessary to align the bearings in the sleeve to

facilitate mounting on the lead screw.

3. Install and tighten the six SHCS on the bearing sleeve. (Place a drop of blue Loctite on each of the

SHCS before inserting.) Torque to 15 ft-lbs.

4. Screw the clamp nut on the bearing support end of the lead screw two or three turns, but do not tighten,

and temporarily place the hard stop over the bearing support.

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MECHANICAL SERVICE

5. Loosen all of the SHCS on the bearing sleeve approximately 1/4 turn, then torque to 15 ft-lbs. DO NOT

SKIP THIS STEP. It ensures the lead screw is installed and runs parallel and flat to the linear guides and the
saddle.

6. The following sequence is important to ensure proper installation of the lead screw:

Ø Tighten the clamp nut, hand tight, against the bearing sleeve.
Ø Install the shaft lock onto the bearing support end of the leadscrew. This will keep the

lead screw from turning while torquing the clamp nut.

Ø Place a spanner wrench on the clamp nut at the motor end of the assembly.
Ø Torque the clamp nut against the bearing sleeve to 15 FT-LBS.
Ø Remove the shaft lock.
Ø With a T-handle wrench hand tighten the clamp nut screw and mark with yellow paint.
Ø Screw the clamp nut against the bearing at the bearing support end, hand tight. Tighten the

clamp nut another 1/8. (If you have a torque screwdriver, torque the clamp nut to 4 IN-LBS.)

Ø With a T-handle wrench hand tighten the clamp nut screw and mark with yellow paint.

7. Reinstall and tighten the hard stop.

8. Reinstall the Z-axis motor as described in "Z-Axis Motor - Installation".

9. Check for backlash in the Z-axis lead screw ("Troubleshooting" section), or noisy operation.

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10. Replace the rear panel enclosure with seven SHCS.

11. Replace the Z-axis way cover, and attach it to the table with thirteen SHCS.

3.11 LEAD SCREW

Please read this section in its entirety before attempting to remove or replace the lead
screws.

TOOLS REQUIRED:

ü Torque wrench
ü Spanner nut

X-AXIS LEAD SCREW

REMOVAL-

1. Turn the machine ON. Zero return all axes and put the machine in HANDLE JOG mode.

2. Remove the rear enclosure panel.

3. Jog the Y-axis to the bottom of it's travel. Jog the X-axis all the way towards the control.

4. POWER OFF the machine.

5. Remove the hardstop and locknut from the bearing support.

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6. Remove the five SHCS that secure the nut housing to the lead screw nut.

7. Remove the oil line from the lead screw nut.

8. Rotate the nut on the lead screw, in order to move the nut near the bearing support end of the leadscrew.

9. Temporarily replace the hardstop bearing support and push the column all the way away from the control

box.

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10. Remove the X-axis motor and bearing sleeve in accordance with appropriate sections.

11. Push column towards the control box.

CAUTION! Do not move the column too far over since the hardstops are removed!

12. Pull the lead screw toward control box side, out of the bearing in the bearing support.

13. Lift the lead screw up, forward, and to the side of the machine until the motor end of the lead screw is

free. Carefully remove the lead screw.

INSTALLATION-

1. Ensure all mating on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt, burrs,

grease, or other contaminants.

CAUTION! Mating surfaces must be clean or misalignment may occur, seriously affecting
the proper operation of the machine.

2. Hold the lead screw vertically with the motor end down and the nut near the support end (top).

3. Hold the lead screw at the left side of the machine near the front of the saddle and lower into place,

rotating the leadscrew into position.

CAUTION! Be careful not to bump or scratch lead screw against column, saddle or bellows
support.

4. Once in position, gently push the bearing support end of the lead screw into the bearing in the bearing
support.

5. Replace the bearing pack.

6. Rotate the nut.

7. Rotate the leadscrew nut so it goes into the nut housing and start the five SHCS that secure the leadscrew
nut to the nut housing. Do not tighten.

8. Reattach the oil line to the lead screw nut.

9. Replace the X-axis motor in accordance with the appropriate section.

10. With the lead screw secured in place, torque the five SHCS from the nut to the nut housing to 15 ft-lbs.

11. The following sequence is important to ensure proper installation of the lead screw:

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Ø Tighten the clamp nut, hand tight, on the motor end.
Ø Install and tighten clamp nut on bearing support. Ensure the nut does not touch the support

bearing.

Ø Install the shaft lock onto the bearing support end of the leadscrew. This will keep the lead screw

from turning while torquing the clamp nut.

Ø Place a spanner wrench on the clamp nut at the motor end of the assembly.
Ø Torque the clamp nut against the bearing sleeve to 15 FT-LBS.

NOTE: The 40/50 mm leadscrew clamp nut should be torqued to 50 FT-LBS.

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MECHANICAL SERVICE

Ø With a T-handle wrench hand tighten the clamp nut screw and mark with yellow paint.
Ø Remove the shaft lock.
Ø Loosen the clamp nut screw and clamp nut at the bearing support end and tighten to 4 IN-LBS.

against the bearing. Retighten the clamp screw.

12. Replace the bearing support end hard stop.

13. POWER ON the machine.

14. Rotate the leadscrew by hand to assure free movement.

15. Jog the X-axis to the left end of travel and check for free movement.

NOTE: During assembly, the leadscrew is tested for a maximum rotational torque of 12
in-lbs.

20. Replace the rear enclosure panel (seven SHCS).

Y-AXIS L EAD SCREW

REMOVAL-

1. POWER ON the machine. Zero return all axes and put machine in HANDLE JOG mode.

June 1998

2. Remove the seven SHCS attaching the upper Y-axis way cover to the head casting, collapse it upward,

and tie-wrap it in place.

3. Jog the Y-axis all the way down, resting on the hard stop. Jog the X-axis to the center of travel so the lead

screw can be easily accessed from the rear.

4. POWER OFF the machine.

5. Remove the rear enclosure panel (seven SHCS).

6. Remove the axis motor in accordance with "Y-Axis Motor - Removal".

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MECHANICAL SERVICE

Figure 3-35. Y-axis lead screw and motor assembly (from rear).

7. Remove the SHCS securing the hood to the machine. Unplug the service light and gently move the hood

forward approximately one foot.

NOTE: It is not necessary to fully remove the hood from the machine.

8. Remove the seven SHCS attaching the lower Y-axis way cover to the head casting, and collapse it downward.

9. Loosen the SHCS and remove the clamp nut on the lead screw bearing plate end.

10. Loosen the SHCS and remove the clamp nut on the motor end of the lead screw.

11. Disconnect the oil line from the ball nut.

12. Loosen the six SHCS and remove the bearing sleeve from the top of the column.

13. Remove the five SHCS on the ball nut flange. Remove the ball nut from the ball nut housing by manually

screwing the nut up the lead screw.

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MECHANICAL SERVICE

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Figure 3-36. Y-axis lead screw bearing support end clamp nut.

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Figure 3-37. Y-axis lead screw motor end clamp nut and bearing sleeve.

14. Remove the lead screw from the column by lifting it out of the bearing support, pulling the lower end

of the lead screw out the front of the column (over the top of the spindle head), and lowering the motor end
out of the top of the column.

15. Remove the hard stop from the old lead screw for use on the new lead screw.

INSTALLATION-

1. Place the hard stop on the new lead screw, so the hard stop is at the top of the column and the flange

of the lead screw is mounted on the upper side of the nut housing.

2. Manually turn the ball nut up the lead screw until it will be possible to install the nut into the nut

housing (about halfway).

3. Insert the motor end of the lead screw through the upper bearing support hole. Lift the bottom of

the lead screw over the spindle head, then lower the lead screw, guiding the bearing support end of the screw
into the bearing.

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NOTE: Correct alignment is critical to sliding the ball screw into the bearing. Binding
will not occur if it is guided carefully and correctly into the bearing.

4. Place the bearing sleeve onto the lead screw and attach it to the top of the column with the six SHCS. Torque

the SHCS to 15 ft-lbs.

5. Loosely screw the clamp nut on the bearing plate end of the lead screw.

6. Orient the ball nut so the oil line can be connected, then turn the lead screw by hand to pull the ball nut

flange down until it contacts the nut housing.

7. Insert the five SHCS that hold the ball nut to the ball nut housing, but do not tighten completely.

8. Loosely install the clamp nut on the motor end of the lead screw.

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Figure 3-38. Y-axis lead screw motor.

9. Hand-turn the lead screw to move the spindle motor up and down, to assure free movement of the lead

screw.

10. Torque the five SHCS that hold the ball nut to the nut housing to 15 ft-lbs.

11. The following sequence is important to ensure proper installation of the lead screw:

Ø Tighten the clamp nut, hand tight, on the motor end.
Ø Install and tighten clamp nut on bearing support. Ensure the nut does not touch the support

bearing.

Ø Install the shaft lock onto the bearing support end of the leadscrew. This will keep the lead screw

from turning while torquing the clamp nut.

Ø Place a spanner wrench on the clamp nut at the motor end of the assembly.
Ø Torque the clamp nut against the bearing sleeve to 15 FT-LBS.

Note: The 40/50 mm leadscrew clamp nut should be torqued to 50 FT-LBS.

Ø With a T-handle wrench hand tighten the clamp nut screw and mark with yellow paint.
Ø Remove the shaft lock.
Ø Loosen the clamp nut screw and clamp nut at the bearing support end and tighten to 4 IN-LBS.

against the bearing. Retighten the clamp screw.

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