haas VF- 96-7045 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

VF-Series Service Manual 96-7045 English November 26 1993

• 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

VF Series Service Manual

TROUBLESHOOTING

This section is intended for use in determining the solution to a known problem. Solutions given are
intended to give the individual servicing the CNC a pattern to follow in, first, determining the 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 computer. 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, reload and reconnect, 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.

HAAS AUTOMATION, INC. 96-7045 VF SERIES SERVICE MANUAL

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VF Series Service Manual

1. General Machine Operation

1.1

MACHINE NOT RUNNING

PROBLEM:

? Machine cannot be powered on.

SOLUTION:

· Check input voltage to machine (Section 2,
Electrical Service).

· Check main circuit breaker at top right of
electrical cabinet; switch must be at the on
position.

· Check overvoltage fuses (Section 3.1,
Electrical Service).

· Check wiring to POWER OFF button on
front control panel.

· Check wiring to AUTO OFF relay to IOPCB.

· Replace IOPCB (Section 4.3, Electrical

Service).

· Replace POWER PCB (Section 4.4, Electrical
Service).

PROBLEM:

? Machine can be powered on, but turns off

by itself.

SOLUTION:

· Check settings #1 and #2 for Auto Off
Timer or Off at M30.

· Check alarm history for OVERVOLTAGE or
OVERHEAT shutdown.

· Check AC power supply lines for
intermittent supply.

· Check wiring to POWER OFF button on
front control panel.

· Replace IOPCB (Section 4.3, Electrical Service).

· Replace MOTIF PCB (Section 4.1, Electrical

Service).

PROBLEM:

? Machine turns on, keyboard beeps, but no

CRT display.

SOLUTION:

· Check for green POWER LED at front of CRT.

· Check for power connections to CRT from

IOPCB.

· Check video cable (760) from VIDEO PCB
to CRT.

· Replace CRT (Section 5.1, Electrical Service).

PROBLEM:

? Any LED on Microprocessor PCB goes out

(except HALT).

SOLUTION:

· Replace Microprocessor PCB (Section 4.1,
Electrical Service).

· Replace VIDEO PCB (Section 4.1, Electrical
Service).

· Replace MOTIF PCB (Section 4.1, Electrical
Service).

PROBLEM:

? Machine turns on, CRT works, but no keyboard

keys work.

SOLUTION:

· Check keyboard cable (700) from VIDEO to
KBIF PCB.

· Replace keypad (Section 5.5, Electrical
Service).

· Replace KBIF PCB (Section 4.6, Electrical
Service).

· Check Parameter 57 for Power Off at E-STOP.

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VF Series Service Manual

1.2

perceptions varying among individuals, making
it difficult to determine in mild cases if there is
an actual problem. Because the VF Series uses
a gear head, it will be noisier than a direct drive
or belt system. 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.
We will assume that vibrations would be some­thing that could be felt by putting your hand on
the spindle covers. One crude method of mea­surement would be to take an indicator on a
magnetic base extended 10 inches between the
table and spindle housing and observe the
reading of the indicator. A reading of more than
.001 would indicate excessive vibration. The two
common sources of noise are the spindle and
axis drives.

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.

(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.

PROBLEM:

? Machine vibrates while spindle is on and is

SOLUTION:

VIBRATION

Vibration is a subjective evaluation with

Most complaints about vibration, accuracy,

These symptoms will not occur individually

not cutting. Sometimes only at specific
RPM.

· If the spindle alone causes vibration of the
machine this is usually caused by the belt/
pulley drive system. This occurs because
a pulley is either out of balance, misaligned,
or belt tension is incorrect. It is extremely
important that when servicing the spindle
transmission that pulleys are checked for
runout. Balance is almost impossible to
check except by trial and error. This method
can be accomplished by putting additional
washers under one of the allen bolts of the
locking collar and observing the effect. By
moving from bolt to bolt you should see
better or worse results and take action

accordingly. Vibrations at different speeds
are usually caused by all of the above
except that harmonics are in play. If the
problem is severe and cannot simply be
corrected, you may have to consider
replacing the gearbox and spindle with
factory-balanced units.

PROBLEM:

? Machine vibrates while jogging the axis

with the hand wheel.

SOLUTION:

· 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.

PROBLEM:

? The machine vibrates excessively in a cut.

SOLUTION:

· This is a tough one to call because
machining practices come into play.
Generally speaking, the least rigid element
of a cut is the tool because it is the smallest
part. Any cutter will vibrate if pushed
beyond its tensile strength. In order to
eliminate the machine as the source of the
problem, you need to check the spindle and
the backlash of the axes as described in
the following sections. Once machining
practices have been eliminated as the
source of vibration, observe the machine in
both operation and cutting air. Move the
axes (individually) without the spindle
turning and then turn the spindle without
moving the axes. Isolate whether the
vibration comes from the headstock or
from an axis. Isolate the source of vibration
per Sections 2.2, 3.2, and Section 6.

1.3

lem, please make sure you follow these simple
dos and donts.

ACCURACY

Before you complain of an accuracy prob-

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

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VF Series Service Manual

and have sine/cosine errors over larger
distances.

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

· Dont attach test points to the sheet metal
of the spindle head or table.

· Dont check for thermal growth with an
indicator on a long extension magnetic base.

· Do insure that test indicators and stops are
absolutely rigid and mounted to machined
casting surfaces.

· Do check a suspected error with another
indicator or method for verification.

· Do ensure that the indicator is parallel to the
axis being checked to avoid tangential
reading errors.

· Do center drill holes before using jobber
length drills if accuracy is questioned.

Once machining practices have been elimi­nated as the source of the problem, determine
specifically what the machine is doing wrong.

PROBLEM:

? Machine will not interpolate a round hole.

SOLUTION:

· Check the levelness of the machine (See
the Installation Manual).

PROBLEM:

? Bored holes are out of round, or you bore

a hole at a given X/Y position and then
check at the same location using a test
indicator and it indicates you are out of
position.

SOLUTION:

· The spindle is not parallel to the Z axis.
Check the spindle sweep to the table and
the squareness of the Z axis with a cylinder
square. If available use a spindle master
bar and indicate the spindle to the Z axis.

PROBLEM:

? Machine mis-positions holes.

SOLUTION:

· Check the levelness of the machine (See
the Installation Manual).

· Check for backlash (Section 3.3).

· Check the squareness of the X axis to the

Y axis.

PROBLEM:

? Machine leaves large steps when using a

shell mill.

SOLUTION:

· Check for backlash (Section 3.3).

PROBLEM:

? Bored holes do not go straight through the

workpiece.

SOLUTION:

· Check the levelness of the machine (See
the Installation Manual).

· Check for squareness in the Z axis.

PROBLEM:

? Machine bores holes out-of-round.

SOLUTION:

· Check the levelness of the machine (See
the Installation Manual).

· Check the sweep of the machine (Section 5.3,
Mechanical Service).

HAAS AUTOMATION, INC. 96-7045 VF SERIES SERVICE MANUAL

· Check the levelness of the machine (See
the Installation Manual).

· Check the sweep of the machine (Section

5.3, Mechanical Service).

· Cutter diameter too large for depth of cut.

1.4

PROBLEM:

? Machining yields a poor finish.

SOLUTION:

FINISH

· Check for backlash (Section 3.3).

· Check the condition of the tooling and the

spindle (Section 2).

5

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2. Spindle

VF Series Service Manual

2.1

PROBLEM:

? Spindle not turning.

SOLUTION:

2.2

ally lie in the motor/gearbox or drive belt of the
machine. Isolate the sources of noise as follows:

NOT TURNING

· If there are any alarms, see Section 6.

· Check that the spindle turns freely when

machine is off.

· If motor turns but spindle does not, see
Sections 3 and 9, Mechanical Service.

· Command spindle to turn on 1800 RPM
and check spindle drive display. If display
blinks "bb" , check spindle orientation
switch (Section 7, Mechanical Service). If
spindle drive does not light the RUN LED,
check forward/reverse commands from
IOPCB (Section 4.3, Electrical Service).

· Check the wiring of analog speed command
from MOTIF PCB to spindle drive (cable 720).

· If spindle is still not turning, replace MOTIF
PCB (Section 4.1, Electrical Service).

· If spindle is still not turning, replace spindle
drive (Section 5, Mechanical Service).

· Check for rotation of the gearbox (VF-1,
VF-2, VF-3) or the motor (VF-0). If the
motor or gearbox operates, check the
drive belt (Section 3, Mechanical Service).

· Disconnect the drive belt. If the spindle
will not turn, it is seized and must be
replaced (Section 5, Mechanical Service).
NOTE: Before using the replacement
spindle, the cause of the previous failure
must be determined.

NOISE

Most noises attributed to the spindle actu-

SOLUTION:

· On VF-1, VF-2, and VF-3 models, 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 with the gearbox.
If the noise disappears, the problem could
be either the gearbox or the spindle, and
further testing is necessary.

· Check the alignment of the pulleys to the
belt. Correct as necessary (Sections 3 and
4, Mechanical Service).

· Remove the head covers and check the
machine's drive belt tension (Section 3.3,
Mechanical Service).
> If the noise persists, turn the drive belt
over on the pulleys. If the noise is
significantly different, the belt is at fault.
Replace the belt
(Section 3, Mechanical Service).
> If the noise does not change, remove
the belt and go on to the next step.

· Check the pulleys for excessive runout
(more than 0.003" axial or radial).

· Run the motor (VF-0) or the gearbox (VF-1,
VF-2, VF-3) with the drive belt disconnected.
If the noise persists, the problem lies with
the gearbox/motor. If it disappears, go on
to the next step.

· Check for the correct amount of lubrication
to the spindle bearings (1-2 cc every two
hours) in an air mist-lubricated spindle.
> If the spindle is not getting lubrication,
correct the problem per the lube and air
diagram at the back of this manual and
replace the spindle (Section 5, Mechanical
Service).
> If the spindle is getting lubrication, re
place the spindle (Section 5, Mechanical
Service).

PROBLEM:

? Excessive noise coming from the spindle

head area.

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VF Series Service Manual

2.3

ing, 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.

ously 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.

OVERHEATING

When investigating complaints of overheat-

A machine that runs at high RPM continu-

To break in a spindle, do the following:

· Run the spindle at 300 RPM for at least
two (2) hours.

· Increase the spindle speed to 1000 RPM
for 20 minutes.

· Increase the spindle speed to 3000 RPM
for 20 minutes.

2.4

STALLING/LOW TORQUE

Generally, complaints of stalling or low
torque relate to incorrect tooling or machining
practices. A spindle that is tending to seize will
yield a poor finish machining, run very hot and
very loud. Investigate machining problems
before concluding the problem exists with the
spindle or spindle drive.

It is important to consider what horsepower
and torque is available in various speed ranges
of the spindle. If your machine is a VF-1 or VF-2
(with a transmission), the following horsepower
and torque are available in low gear:

SPEED (RPM) TORQUE (ft-lb) HORSEPOWER

0-100 45-90 less than 2

100-500 90 3 to 7.5

500-1250 90-35 7.5

1250-1840 35-25 7.5 to 5

· Increase the spindle speed to 7000 RPM
for 20 minutes.

· Stop the spindle and allow to cool to
room temperature.

· Turn the spindle on to 7000 RPM and
monitor the temperature inside the
spindle taper at 15-minute intervals
until the temperature drops off, then
stabilizes. This will take about two (2)
hours.

· Temperatures of about 140° are
possible at the end of this test.

If the spindle fails this test, check the

following:

· Check for correct amount of lubrication
(1-2 cc every two hours). NOTE: Over
lubrication is a common source of over­heating. Check the oil flow carefully.

· Check the drive belt tension (Section 3,
Mechanical Service). Too-tight belts
will cause heating of the top bearing in
the spindle housing.

· Ensure that the correct oil is being
used (Lubrication Chart, page 131).

If your machine is a VF-0 (no transmission) or a
VF-1 or VF-2 and you are in high gear, the
following are available:

SPEED (RPM) TORQUE (ft-lb) HORSEPOWER

0-400 11-22 less than 2

400-2000 22 3 to 7.5
2000-5000 22-9 7.5
5000-7500 9-6 7.5 to 5

If your machine is a VF-3, the following horse­power and torque are available in low gear:

SPEED (RPM) TORQUE (ft-lb) HORSEPOWER

0-125 60-120 less than 3

125-625 120 4 to 10

625-1550 120-45 10
1550-1840 45-32 10 to 7

If your machine is a VF-3 and you are in high
gear, the following are available:

SPEED (RPM) TORQUE (ft-lb) HORSEPOWER

0-600 15-30 less than 3

600-2500 30 4 to 10
2500-6250 30-11 10
6250-7500 11-9 10 to 7

If you still have spindle torque problems and
there is no mechanical cause such as binding or
friction in the transmission or spindle, the motor
or spindle drive are the cause. The first choice

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VF Series Service Manual

for replacement is the spindle drive. If there is
still a problem, the entire motor/transmission
assembly must be replaced.

2.5

PROBLEM:

? Spindle loses correct orientation.

SOLUTION:

ORIENTATION

· Check alarm history, looking for spindle
overload and axis overcurrent alarms.
These alarms indicate the machine is not
being properly operated.

· Check the orientation ring for tightness
(Section 7, Mechanical Service). Ensure
the shaft on which the ring mounts is free
of grease.

· Check the orientation ring for cracks near
the bolt holes or near the balancing holes.
> If there are cracks, replace the ring
(Section 7, Mechanical Service).
> If there are no cracks, remove the drive
belt (Section 3, Mechanical Service) and
verify that the pulley on the transmission
output shaft is tight. On most machines,
there is no key on the transmission pulley.

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

heavy milling. If sticking only occurs during
these situations, no service is necessary.

SOLUTION:

· Check the condition of the customer's
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.

· 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 Section 5,
Mechanical Service, for spindle cartridge
replacement.

· Duplicate the cutting conditions under
which the deflection occurs, but do not
execute an automatic tool change. Try
instead to release the tool using the tool
release button on the front of the spindle
head. If sticking is observed, the deflection
is not caused by improper ATC adjustment,
but is a problem in the spindle head on the
machine. See Section 5, Mechanical
Service, for spindle cartridge replacement.

· Ensure the spindle is not running too hot
(Section 2.3).

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

2.6

TOOLS STICKING IN TAPER

PROBLEM:

? Tool sticking in the taper causes ATC to be

pulled up; accompanied by a popping noise
as the tool holder pops out of the spindle
taper.
NOTE: This problem may occur after
loading a cold tool into a hot spindle (a
result of thermal expansion of the tool
holder inside the spindle taper), or after

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3. Servo Motors/ Lead Screws

There is very little that a user might do to repair a servo motor. Problems with servo motors may
include open-circuited motor, shorted winding of motor, motor shorted to case, water (coolant) in motor,
or overheat damage to motor. None of these can be fixed by the user so the motor must be replaced.
All of the above problems would generate alarms identifying one of the servo motors as having failed.
These alarms are 103-106 (following error too large), 108-111 (servo overload), 135-138 (overheat), 139­142 (Z channel fault), 153-156 (Z channel missing), and 161-164 (overcurrent).

Attached to each DC servo motor, there is an incremental encoder that is 2000 lines per revolution.
These encoders also supply a Z channel pulse once per revolution. The encoders and Z channel are
continuously monitored to ensure the number of pulses matches for each revolution of the motor. If the
encoders become contaminated, these pulse counts will be wrong and an alarm will be generated. This
ensures that the data from the encoders is reliable. There can never be a loss of servo position due to
accumulated encoder errors. The alarms generated will indicate that either the Z pulse occurred and the
encoder pulse was wrong or, after one and one half motor revolutions, the Z pulse did not occur.

Encoders' faults can be caused by contamination of the encoder or by a wiring problem. If the
encoder is contaminated, it must be replaced. Wiring problems may be a broken wire, shorted wire, or
missing shield. All wires to the encoder are enclosed in their own shielded cable. In addition, all power
wires to the motor are enclosed in a separately shielded cable. Failure of either of these shields may
cause noise in the encoder circuits and result in the encoder fault alarms.

Never connect or disconnect the servo motor cables with the control powered as this will cause an
apparent encoder fault.

The servo motor encoders are differential line drivers. This means that the A, B, and Z signals are
transmitted to the control as signal pairs. A cable test is performed on these signals to ensure the
differential pair are always present.

3.1

motor failures should also register an alarm.
Check the alarm history to determine the
problem's cause before any action is taken.

PROBLEM:

? Servo motor is not functioning.

SOLUTION:

NOT OPERATING

All problems that are caused by servo

· Check the power cable from rear electrical
cabinet to ensure connection is tight.

· Encoder is faulty or contaminated (Alarms
139-142, 153-156, 165-168, 182-185).

Replace motor assembly (Section 10,
Mechanical Service).

· Open circuit in motor (Alarms 139-142,
153-156, 182-185). Replace motor assembly

(Section 10, Mechanical Service).

· Motor has overheated, resulting in damage
to the interior components (Alarms
135-138, 176). Replace motor assembly
(Section 10, Mechanical Service).

· Wiring is broken, shorted, or missing
shield (Alarms 153-156, 175,
182-185).

· Dust in the motor from brushes has
shorted out the motor (Alarms 153-156,
175, 182-185). Replace motor assembly
(Section 10, Mechanical Service).

· Motor has overheated; no damage to the
interior components. OVERHEAT alarm
has been triggered. After thorough check
of motor (DO NOT DISASSEMBLE!), take
necessary steps to eliminate the problem
and alarm to resume operation. If motor is
still inoperable, replace motor assembly
(Section 10, Mechanical Service).

(Cont'd)

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VF Series Service Manual

3.1

· Check for broken or loose coupling between

· Check for a broken lead screw. If cracked

3.2

lack of lubrication and is usually accompanied
by heating. Other causes are misalignment,
bearing sleeve damage, or ball nut damage.
Check the alarm history of the machine and look
for axis overcurrent and following error alarms.
NOTE: Do not replace lead screws or bearing
sleeves without due consideration; they are
extremely durable and reliable. Verify that
customer complaints are not due to tooling,
programming, or fixturing problems.

PROBLEM:

? Servo motor noise.

(Cont'd)

the servo motor and the lead screw.
Replace or repair the coupling (Section

10.4, Mechanical Service).

or broken, replace (Section 10, Mechanical
Service).
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 (Section 12, Mechanical
Service).

NOISE

Lead screw noise is usually caused by a

PROBLEM:

? Lead screw noise.

SOLUTION:

· Ensure oil is getting to the lead screw
through the lubrication system (See Air
and Oil Diagrams, pages 129 & 130). Look
for a plugged metering valve.

· Check for damage to the bearing sleeve.

· Check the pre-load on old-style bearing

sleeves (Section 12, Mechanical Service).
NOTE: The current angular contact design
sleeve has a fixed pre-load; it cannot be
adjusted.

· 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 (Section 12,
Mechanical Service). Be certain to check
for damage to the lead screw shaft where
the bearing sleeve is mounted.
> If the noise persists, the lead screw is
damaged and must be replaced (Section
11, Mechanical Service). When replacing
the lead screw in an older machine, always
replace the bearing sleeve with the current
angular contact design bearing sleeve
(Section 12, Mechanical Service).

SOLUTION:

· Disconnect the servo motor from the lead
screw and rotate by hand. If the noise
persists, replace the motor assembly
(Section 10, Mechanical Service).

· Noise is caused by motor brushes. No
problems will occur and noise should
eventually go away.

· Noise is caused by bearings. Rolling,
grinding sound is heard coming from the
motor. ENSURE NOISE IS NOT COMING
FROM THE BRUSHES. If bearings are
making a consistently loud sound, replace
the bearing sleeve (Section 12, Mechanical
Service).

VF SERIES SERVICE MANUAL 96-7045 Publication Date: November 26, 1993

12

· Check the lead screw for misalignment.
If incorrect, align as outlined in Section 11,
Mechanical Service.

Misalignment in the lead screw itself
will tend to cause the lead screw to

i

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.

tighten up and make excessive noise
at both ends of the travel. The ball
nut may get hot.

VF Series Service Manual

3.3

tooling, programming, or fixturing problems.
Eliminate these possibilities before working on
the machine.

PROBLEM:

? Poor mill table-positioning accuracy.

SOLUTION:

ACCURACY/BACKLASH

Accuracy complaints are usually related to

· 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 (Sections 10, 11,
Mechanical Service).

· Check for backlash in the lead screw as
outlined below:

INITIAL PREPARATION -

Turn the VMC ON. ZERO RET the machine and
move the mill table to the approximate center of
its travel in the X and Y directions. Move the
spindle head to approximate center of the Z-axis
travel, also.

control panel. The "Distance to go" display
on the lower right hand corner should read:

X=0 Y=0 Z=0

3. Set the rate of travel to .001 on the control
panel and jog the machine .010 in the positive
(+) X direction. Jog back to zero (0) on the
display. The dial indicator should read zero (0)
± .0001.

4. Repeat step three in the negative (-) direction.

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

An alternate method for checking backlash
is to place the dial indicator as shown in Fig. 3-1
and manually push on the mill table in both
directions. The dial indicator should return to
zero after releasing the table.
NOTE: The servos must be on to check back­lash by this method.

CHECKING Y-AXIS:

1. Set up a dial indicator and base on the mill
table as shown in Fig. 3-2.

CHECKING X-AXIS:

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

Fig. 3-1 Dial indicator in position to check X-axis.

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

- Zero the dial indicator.

- Press the MDI button on the control panel.

- Press the HANDLE JOG button on the

Fig. 3-2 Dial indicator in position to check Y-axis.

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

- Zero the dial indicator.

- Press the MDI button on the control panel.

- Press the HANDLE JOG button on the

(Cont'd)

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VF Series Service Manual

3.3

3. Set the rate of travel to .001 on the control
panel and jog the machine .010 in the positive
(+) Y direction. Jog back to zero (0) on the display.
The dial indicator should read zero (0) ± .0001.

4. Repeat step three in the negative (-) direction.

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

is to place the dial indicator as shown in Fig. 3-2
and manually push on the mill table in both
directions. The dial indicator should return to
zero after releasing the table.
NOTE: The servos must be on to check back­lash by this method.

(Cont'd)

control panel. The "Distance to go" display
on the lower right hand corner should read:

X=0 Y=0 Z=0

An alternate method for checking backlash

> If backlash is found in the system,

check for the following possible causes:

· Loose SHCS attaching the ball nut to the nut
housing. Tighten the SHCS as described
in Section 11, Mechanical Service.

· Loose SHCS attaching the nut housing to
the mill table, spindle head, or saddle,
depending on the axis. Tighten the SHCS
as described in Section 11, Mechanical
Service.

· Loose clamp nut on the bearing sleeve.
Tighten the SHCS on the clamp nut.

· Loose motor coupling. Tighten as described
in Section 10.4, Mechanical Service.

· Broken or loose flex plates on the motor
coupling.
(NOTE: The coupling cannot be serviced
in the field and must be replaced as a
unit if it is found to be defective. See
Section 10.4, Mechanical Service.)

CHECKING Z-AXIS:

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

2. Manually push up and down on the spindle
head while listening for a 'clunk'. Also, watch for
any rapid change in the dial indicator. Either of
these indicate possible backlash.

NOTE: Servos must be on to check for backlash
in the Z-axis.

NOTE: Do not mistake deflection for backlash in
the system.

· Loose SHCS attaching the bearing sleeve
to the motor housing. Tighten as described
in Section 12, Mechanical Service.

· Defective thrust bearings in the bearing
sleeve. Replace the bearing sleeve as
outlined in Section 12, Mechanical Service.

· Loose SHCS attaching the axis motor to
the motor housing. If the SHCS are
found to be loose, inspect the motor for
damage and if none is found, tighten as
described in Section 10, Mechanical
Service. If damage is found, replace the
motor (Section 10, Mechanical Service.)

· Incorrect backlash compensation number
in the parameter in the machine. Check
Parameters 13, 27, and 41.

· Worn lead screw. Replace as outlined in
Section 11, Mechanical Service.

3.4

PROBLEM:

? Excessive servo motor vibration.

Fig. 3-3 Dial indicator in position to check Z-axis.

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VIBRATION

VF Series Service Manual

SOLUTION:

· 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 (Section 4.2, Electrical Service).

· Check all Parameters of the suspected
axis against the Parameters as shipped
with the machine. If there are any
differences, correct those and determine
how the Parameters were changed.
PARAMETER LOCK should normally be on.

· 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 chassis. If the
motor is open or shorted, replace (Section
10, Mechanical Service).

SOLUTION:

· Check DC bus voltage on diagnostics
page #2. If it is at the low side of the
recommended voltages, change the
transformer tap to the next lower voltage
group as explained in the Installation
Manual.

· Check motor wiring.

· Replace driver card (Section 4.2, Electrical

Service).

· Replace servo motor (Section 10, Mechanical
Service).

3.5

PROBLEM:

? Servo motor overheating.

SOLUTION:

3.6

OVERHEATING

· 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).

· 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 (Section 3.3). If
the motor is binding by itself, replace
(Section 10, Mechanical Service).

FOLLOWING ERROR

PROBLEM:

? Following error alarms occur on one or

more axes sporadically.

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VF Series Service Manual

4. Automatic Tool Changer

Before any of the following checks are made, you must first ensure the spindle orientation, drawbar
height, and the tool clamp/unclamp switch adjustments are correct. Refer to Section 6, Mechanical

Service, before proceeding.

4.1

aged drawbar. Before beginning any trouble­shooting, observe the direction of the ATC
deflection.

PROBLEM:

? During a tool change, ATC appears to be

SOLUTION:

DEFLECTION

Deflection is usually caused by ATC
misalignment, and sometimes caused

i

pushed down.

· Check to see if pull studs on the tool

· Check the adjustment of the "Z" offset

· Check Parameters 71, 72, and 143 against

· Ensure the tool holders are held firmly in

· Ensure the balls on the drawbar move

by damaged or poor quality tooling, a
damaged spindle taper, or a dam-

holder are correct and tight.

(Parameter 64, Section 8, Mechanical
Service). NOTE: If the offset is incorrect,
a tool changer crash has occurred, and a
thorough inspection of the ATC is necessary
at this time.

the values that are in the documentation
sent with the machine.

place by the extractor forks.

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 down about ¼" before the tool
holder is seated in the taper, resulting in
damage to the roller bolts on the ATC
shuttle. Replace drawbar (Section 5.3,
Mechanical Service).

out of the spindle taper.
NOTE: This problem may occur after loading
a cold tool into a hot spindle (a result of
thermal expansion of the tool holder inside
the spindle taper), or after heavy milling. If
sticking occurs only during these
circumstances, no service is necessary.

SOLUTION:

· 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.

· 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 Section 5,
Mechanical Service, for spindle cartridge
replacement.

· Duplicate the cutting conditions under
which the deflection occurs, but do not
execute an automatic tool change. Try
instead to release the tool using the tool
release button on the front of the spindle
head. If sticking is observed, the deflection
is not caused by improper ATC adjustment,
but is a problem in the spindle head on the
machine. See Section 5, Mechanical
Service, for spindle cartridge replacement.

PROBLEM:

? During a tool change, ATC appears to be

pulled up; no popping noises.

SOLUTION:

PROBLEM:

? Tool holder sticking in the spindle taper

causes the ATC to be pulled up as the
spindle head is traveling up after depositing
the tool holder in the carousel; accompanied
by a popping noise as the tool holder pops

HAAS AUTOMATION, INC. 96-7045 VF SERIES SERVICE MANUAL

· Check the adjustment of the "Z" offset
(Parameter 64, Section 8, Mechanical
Service). NOTE: If the offset is incorrect,
a tool changer crash has occurred, and a
thorough inspection of the ATC is necessary
at this time.

(Cont'd)

17

VF Series Service Manual

4.1

(Cont'd)

· Ensure the roller bolts on the shuttle of
the ATC are tight against the v-guides on
the ATC holding arm. If the lower right
roller bolt is loose against the v-guide, the
upper right bolt is probably bent. See the
following section (ATC Crashing) or Section

14.2, Mechanical Service, for roller bolt
replacement.
NOTE: Bent roller bolts are a symptom of
another problem with the ATC. Repair the
bent roller bolt and then isolate the ATC
problem.

· Check Parameter 71 against the values
that are in the documentation sent with
the machine.

· 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 down about ¼" before the tool
holder is seated in the taper, resulting in
damage to the roller bolts on the ATC
shuttle. Replace drawbar (Section 5.3,
Mechanical Service).

SOLUTION:

· Check all the extractor forks to ensure they
are centered in the pocket of the ATC. Also,
see above. See Section 14.6, Mechanical
Service, for extractor fork replacement.
NOTE: If the ATC shows the problem as
described here, each extractor fork must
be checked and centered to eliminate the
possibility of the ATC being aligned against
an incorrectly-centered fork.

4.2

operator error. The most common ATC crashes
are outlined as follows:

PROBLEM:

? Shuttle crashes into spindle when a tool

SOLUTION:

CRASHING

Crashing of the ATC is usually a result of

change is commanded (tool holder is in the
pocket facing the spindle head).

· Rotate the carousel to an empty pocket.
Refer to the Programming and Operation
manual for correct operation.

PROBLEM:

? Tool holders twist against extractor fork

during a tool change.

SOLUTION:

· Check the alignment of the ATC in the X
and Y axes (Section 14.3, Mechanical
Service).

PROBLEM:

? Tool holders spin at all pockets of the ATC

when the ATC shuttle retracts.

SOLUTION:

· ATC is misaligned in the "Y" axis. Realign
ATC (Section 14.3, Mechanical Service).
NOTE: Observe the direction the tool
holder rotates, as this will be the direction
in which the "Y" axis of the ATC needs to
be moved.

PROBLEM:

? Tool holders spin only at certain pockets of

the ATC when the ATC shuttle retracts.

NOTE: This crash is fairly common

i

command the ATC to an empty pocket before
the machine will operate correctly. Repeated
crashes of this type can damage the I/O board,
the slip clutch, and the shuttle motor in the ATC.

PROBLEM:

? Spindle crashes into top of the tool holder

SOLUTION:

· Check all of the extractor forks on the

and is a result of operator error. If
the ATC is stopped in the middle of
tool change cycle, the operator must

after a turret rotation during a tool change.
When the spindle head moves down over
the top of the tool holder during a tool
change, the pull stud will bind inside the
drawbar bore of the spindle, forcing the ATC
down, bending the upper right roller bolt on
the ATC shuttle or completely breaking it off.
Tool holder is not held correctly in the
extractor fork, possibly held only in one side
of the extractor and at an odd angle.

ATC. Replace, if needed (Section 14.6,
Mechanical Service).

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PROBLEM:

? Spindle crashes into top of the tool holder

after a turret rotation during a tool change.
The balls in the drawbar do not move freely,
causing the ATC to be forced down far
enough to bend the upper right roller bolt or
completely break it off.

SOLUTION:

· Ensure the balls on the drawbar move
freely in the holes in the drawbar when the
tool release button is pressed. If this
failure occurs, check all of the extractor
forks on the ATC for damage and repair the
spindle drawbar. See Section 14.1 for ATC
shuttle replacement, Section 5.3,
Mechanical Service, for drawbar
replacement, and 14.2, Mechanical Service,
for extractor fork replacement.

PROBLEM:

? ATC properly deposits a tool holder in the

spindle, but the tools are dropped onto the
machine table when the shuttle retracts.

SOLUTION:

· Inspect the balls and the Belleville springs
in the drawbar. See Section 5.3, Mechanical
Service, for drawbar replacement.

PROBLEM:

? The part or fixture on the mill table crashes

into long tooling or into the ATC itself during
a tool change.

SOLUTION:

· Program the machine to move the part out
of the way of the ATC. Inspect the pocket
involved in the crash for damage and
replace parts as necessary.

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, the sliding
covers on the ATC carousel, and the roller
bolts on the ATC shuttle. See Section 14.2,
Mechanical Service for extractor fork
replacement and Section 14.7, Mechanical
Service, for sliding door replacement.

4.3

very hard or repeated crashes.

PROBLEM:

? ATC shuttle is broken off of the holding plate.

SOLUTION:

PROBLEM:

? ATC extractor forks are damaged after

SOLUTION:

BREAKAGE

Breakage of the ATC is caused by either

· Carefully inspect the bosses on the shuttle
casting (where the roller bolts mount) for
damage to the threads or cracks. If any of
the bosses are cracked, replace the casting.
Realign the tool changer after repairing
the machine (Section 14, Mechanical
Service).

breakage.

· Check the condition of the mounting holes
in the carousel. If the threads are damaged,
they must be repaired or the carousel
replaced. See Section 14.6, Mechanical
Service, for extractor fork replacement.

PROBLEM:

? The part or fixture on the mill table crashes

into long tooling or into the ATC itself when
machining.

SOLUTION:

· 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

HAAS AUTOMATION, INC. 96-7045 VF SERIES SERVICE MANUAL

4.4

observe the ATC in operation and look for the
following:

PROBLEM:

? ATC makes noise as the shuttle moves.

NOISY OPERATION

To isolate noise(s) in the ATC, carefully

(Cont'd)

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VF Series Service Manual

4.4

SOLUTION:

PROBLEM:

? ATC makes noise during carousel rotation.

SOLUTION:

(Cont'd)

· Check the adjustment of the roller bolts on
the ATC (Section 14.2, Mechanical Service).
Loose roller bolts can cause the ATC to
make a clunking noise when the shuttle is
commanded to move. Tight roller bolts
can cause the shuttle motor to labor
excessively, possibly damaging the motor
or the I/O board. In this case, the shuttle
may also move too slowly.

· Check for damage to the trap door on the
ATC cover. See Section 14.11, Mechanical
Service, for trap door replacement.

· Check for missing plastic riders on the
ATC shutter. See Section 14.11, Mechanical
Service, for shutter replacement.

· Ensure the guide pin mounted to the
holding plate is not bent and does not
scrape the ATC cover during movement.
See Section 14.11, Mechanical service,
for guide pin replacement.

· Listen for damage to the gear train in the
shuttle motor. If the motor is found to be
the source of the noise, replace the motor
(Section 14.8, Mechanical Service). DO
NOT try to repair the motor or to further
isolate the noise in the motor.

· Check to ensure the Geneva driver on the
turret motor is tight and properly adjusted
(Section 14.8, Mechanical Service). If the
Geneva driver is found to be loose, check
for damage to the Geneva star. Any
roughness in the slots will require that it
be replaced (Section 14.10, Mechanical
Service).

· Check the adjustment of the Geneva driver
in relation to the Geneva star (Section 14.10,
Mechanical Service). If the adjustment is
too loose, the carousel will vibrate heavily
and make a loud clanking noise during
carousel rotation. If the adjustment is too
tight, the turret motor will labor excessively
and the carousel may appear to move
erratically. NOTE: If the turret motor

adjustment is tight for extended periods,
the turret motor, Geneva star, and the I/O
board may be damaged. If the adjustment
of the Geneva star appears tight at some
pockets and loose at others, the problem
lies with the Geneva star. Check the
concentricity of the star relative to the
bearing housing on the carousel assembly.
If the concentricity of the star is proven to
within specification and the problem still
persists, the Geneva star must be replaced
(Section 14.10, Mechanical Service).

· Ensure the screws holding the turret
motor to the mounting plate are tight
(Section 14.9, Mechanical Service).

· Ensure the screws attaching the motor
mounting plate to the shuttle casting are
tight.

· Check for excessive noise in the gear train
of the turret motor. See Section 14.9,
Mechanical Service, for turret motor
replacement.
NOTE: If the motor is found to be the
source of noise, replace the motor assembly
(motor, mounting plate, and Geneva driver).
DO NOT attempt to repair the motor or to
further isolate the problem in the motor.

4.5

SPINDLE ORIENTATION

A switch is used to sense when the pin drops
in to lock the spindle. When the pin drops the
switch opens, indicating orientation is complete.
The normally-closed side of this switch is wired
to the spindle drive and commands it into the
COAST STOP condition. This is done to make
sure that the spindle motor is not powered when
the pin is locking the spindle.
If, during a tool change, the dogs on the spindle
shaft do not align with the keys on the ATC
carousel, the spindle orientation may be at fault.
The orientation of the spindle is as follows:

1) If the spindle is turning, it is commanded
to stop,

2) Pause until spindle is stopped,

3) Spindle orientation speed is commanded
forward,

4) Pause until spindle is at orientation
speed,

5) Command spindle lock air solenoid active,

6) Pause until spindle locked status is
active and stable,

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VF Series Service Manual

7) If not locked after time-out time, alarm
and stop.

PROBLEM:

? ATC out of orientation with the spindle.

Incorrect spindle orientation will cause the
ATC to crash as the shuttle moves. Alarm
113 will be generated.

SOLUTION:

· Check the orientation of the machine
(Section 7, Mechanical Service).

4.6

run, an alarm is generated to indicate either a
shuttle in/out problem or a turret rotation problem.
These alarms will occur either on an attempt to
change tools (ATC FWD) or ZERO RETURN the
machine (AUTO ALL AXES). Use the appropri­ate alarm to select one of the problems following:

ATC WILL NOT RUN

In all cases where the tool changer will not

PROBLEM:

? ATC shuttle will not move; shuttle is not

getting power (Command a tool change and
feel for power being applied to the shuttle
motor).

SOLUTION:

· Check that the TC IN/TC OUT LED on the
I/O PCB is illuminated when a tool change
takes place.
> If the LED lights, check the fuse FU5
on the POWER PCB. Otherwise, replace
the I/O PCB (Section 4.3, Electrical Service).
> If the LED does not light, check cables
510 and 520.

PROBLEM:

? ATC turret will not rotate; turret motor is

getting power (command a tool change and
feel for power being applied to the turret
motor).

SOLUTION:

PROBLEM:

? ATC shuttle will not move; shuttle is getting

power (Command a tool change and feel for
power being applied to the shuttle motor).

SOLUTION:

· Disconnect the slip clutch arm from the
ATC shuttle and ensure the shuttle can
move freely. If not, see Sections 14.1,

14.3, and 14.4, Mechanical Service, for
shuttle adjustment.

· Command a tool change with the shuttle
disconnected.
> If the shuttle cycles, check the slip clutch
on the ATC. See Section 14.8, Mechanical
Service, for slip clutch replacement.
NOTE: The slip clutch should move the
shuttle with a fair amount of force, but not
so much that the shuttle cannot be made
to slip when holding it back by hand. If
the slip clutch is frozen, replace it. It
cannot be rebuilt in the field.
> If the shuttle does not cycle, the motor
has failed and must be replaced. Turn the
motor by hand and feel for binding in the
gear train in the motor. See Section 14.8,
Mechanical Service.
NOTE: The motor uses a large amount of
gear reduction and should be hard to turn
by hand.

· If power is applied but the output shaft
on the motor does not turn, check for
binding between the turret motor assembly
and the Geneva star (Section 14.9, Mechanical
Service). Check for damage to the Geneva
star or the Geneva driver. See Section

14.10, Mechanical Service, for Geneva
star replacement, and 14.9 for turret
motor replacement. Check for a broken
turret motor (See Section 14.9, Mechanical
Service for turret motor replacement).
NOTE: Do not attempt to repair the motor
or to further isolate the problem in the
motor.

PROBLEM:

? ATC turret will not rotate; turret motor is

not getting power (command a tool change
and feel for power being applied to the
turret motor).

SOLUTION:

· Check that the TC CW/ TC CCW LED on
the I/O PCB is illuminated when a tool
change takes place.
> If the LED lights, check the fuse FU5
on the POWER PCB. Otherwise, replace
the I/O PCB (Section 4.3, Electrical Service).
> If the LED does not light, check cables
510 and 520.

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VF Series Service Manual

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 a VF-1, VF-2, or VF-3 gearbox as this will damage the gearbox and void the warranty.

5.1

noise, also refer to Section 2 (Spindle Trouble­shooting). Gearboxes can be damaged by
failed air solenoids, gearshift cylinders, or
bearings, resulting in noisy operation. It is not
likely that poor finish on a workpiece can be
attributed to a bad gearbox.

PROBLEM:

? Excessive or unusual noise coming from the

SOLUTION:

NOISE

When investigating complaints of gearbox

gearbox and/or spindle motor.

· Operate the machine in both high and low
gears. Monitor the gearbox for noise in
both gear positions and if the pitch of the
noise varies with the motor or the output
shaft speed.
> 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 (Section
9, Mechanical Service).
> 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
(Section 9, Mechanical Service).
> 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 (Section 9,
Mechanical Service).

NOTE: Whenever a gear change problem
occurs, an alarm will also occur. Refer to
the ALARMS section (Section 6) to diagnose
each problem before working on the
machine.

When a gear change is performed, the

following sequence of events occurs:

1) If the spindle is turning, it is commanded
to stop,

2) Pause until spindle is stopped,

3) Gear change spindle speed is
commanded forward,

4) Pause until spindle is at speed,

5) Command high or low gear solenoid
active,

6) Pause until in new gear or reversal time,

7) Alarm and stop if max gear change time
elapsed,

8) If not in new gear, reverse spindle
direction, go 8,

9) Turn off high and low gear solenoids.

SOLUTION:

· Check the air solenoid assembly on the
solenoid bracket (rear of gearbox). 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 (Section 9,
Mechanical Service).

· Check contactor CB4.

5.3

PROBLEM:

? Alarm 179 (Low Pressure Spindle Coolant)

CORRECTING ALARMS

has been triggered.

5.2

PROBLEM:

? Machine will not execute a gear change.

HAAS AUTOMATION, INC. 96-7045 VF SERIES SERVICE MANUAL

GEARS WILL NOT CHANGE

SOLUTION:

· Check for low oil supply in reservoir.

· Check to see that pump motor is running.

(Cont'd)

23

VF Series Service Manual

5.3

· Check for an air leak in the suction side of

· Check for a bad pressure sensor.

· Check for a broken or damaged cable.

· Check for a worn pump head.

(Cont'd)

the pump.

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6. Alarms / Diagnostics

Any time an alarm is present, the lower right hand corner will have a blinking "ALARM." Push the
ALARM display key to view the current alarm. All alarms are displayed with a reference number and a
complete description. If the RESET key is pressed, one alarm will be removed from the list of alarms. If
there are more than 18 alarms, only the last 18 will be displayed and the CURSOR DOWN key must be
used to see the rest. The presence of any alarm will prevent the operator from starting a program.

Note that the tool changer alarms can be easily corrected by first correcting any mechanical problem,
pressing RESET until the alarms are clear, selecting ZERO RET mode, and selecting AUTO ALL AXES.
Some messages are displayed while editing to tell the operator what is wrong, but these are not alarms.

The following list shows the alarm number and the cause of the alarm. Please refer to this list
before resuming normal operation when an alarm occurs.

102 SERVOS OFF

This is not an alarm; but indicates that the servo motors are off, the tool changer is dis­abled, the coolant pump is off, and the spindle motor is stopped. Caused by EMERGENCY
STOP, motor faults, tool changer problems, or power fail.; check for other causes.

103 X FOLLOWING ERROR TOO LARGE
104 Y FOLLOWING ERROR TOO LARGE
105 Z FOLLOWING ERROR TOO LARGE
106 A FOLLOWING ERROR TOO LARGE

These alarms can be caused by power problems, motor problems, driver problems, the
slide being run into the mechanical stops, or excessive axis load. The difference between
the motor position and the commanded position has exceeded a parameter. The motor
may also be stalled, disconnected, or the driver failed. The servos will be turned off and a
RESET must be done to restart. See Section 2, Electrical Service, to check line voltage
adjustments. See Section 3.1, Electrical Service, check the servo motors, servo drivers,
and ball screw adjustment.

107 EMERGENCY OFF

EMERGENCY STOP button was pressed. Servos are also turned off. After the E-STOP is
released, the RESET button must be pressed at least twice to correct this; once to clear
the E-STOP alarm and once to clear the Servo Off alarm. This is an operator-initiated
condition. If you do not know why it occurred, check wiring to emergency stop circuit.

108 X SERVO OVERLOAD
109 Y SERVO OVERLOAD
110 Z SERVO OVERLOAD
111 A SERVO OVERLOAD

Excessive load on X-axis motor. This can occur if the load on the motor over a period of
several seconds or even minutes is large enough to exceed the continuous rating of the
motor. The servos will be turned off when this occurs. This can be caused by running into
the mechanical stops but not much past them. It can also be caused by anything that
causes a very high load on the motors. See Section 3.1, Electrical Service, to check the
servo motors, servo drivers, and ball screw adjustment.

112 NO INTERRUPT

This alarm can be caused by electrical interference or an electronics problem. See
Section 4.1, Electrical Service, to replace Microprocessor and Motor Interface PCB's.

(Cont'd)

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6.

113 SHUTTLE IN FAULT
114 SHUTTLE OUT FAULT

115 TURRET ROTATE FAULT

116 SPINDLE ORIENTATION FAULT

(Cont'd)

Tool changer not completely to right or left. During a tool changer operation the tool in/out
shuttle failed to get to the in or out position. Parameters 62 and 63 can adjust the time­out times. This alarm can be caused by anything that jams the motion of the slide or by the
presence of a tool in the pocket facing the spindle. A loss of power to the tool changer
can also cause this, so check fuse FU5 and relays 1-8, 2-1, and 2-2. See Section 4 for
troubleshooting of the tool changer.

Tool carousel motor not in position. During a tool changer operation the tool turret failed to
start moving or failed to stop at the right position. Parameters 60 and 61 can adjust the
time-out times. This alarm can be caused by anything that jams the rotation of the turret. A
loss of power to the tool changer can also cause this, so check fuse FU5 and relays 1-8,
2-3, and 2-4. See Section 4 for troubleshooting of the tool changer.

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. See Section 4.5 to
troubleshoot spindle orientation.

117 SPINDLE HIGH GEAR FAULT
118 SPINDLE LOW GEAR FAULT

Gearbox did not shift into high or low gear. During a gear change, the spindle is rotated
slowly while air pressure is used to move the gears but the high/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. See Section 5 for
troubleshooting of gear change problems.

119 OVER VOLTAGE

Incoming line voltage is above maximum (about 255V when wired for 240 or 235 when
wired for 208). The servos will be turned off and the spindle, tool changer, and coolant
pump will stop. If this condition remains for 4.5 minutes, an automatic shutdown will
begin. This can also be caused by an electronic problem. See Section 2, Electrical
Service, to check line voltage adjustment taps. See Section 4.2, Electrical Service, to
replace SDIST PCB. Also check that servo regen load resistor is installed (cable 920).

120 LOW AIR PRESSURE

Air pressure dropped below 80 PSI for a period defined by Parameter 76. Check your
incoming air pressure for at least 100 PSI and ensure the regulator is set at 85 PSI. If this
is not caused by low air pressure, check pressure sensor at spindle head and wiring back
to IOPCB. Check Parameter 76, which is used to delay the low air alarm condition for
short outages. Air blast during tool change can cause your air supply to drop pressure;
monitor the pressure drop during a tool unclamp.

121 LOW LUB OR LOW PRESSURE

Way lube is low or empty or there is no lube pressure or too high a pressure. Check tank at
rear of mill and below control cabinet. Also check connector P5 on the side of the control
cabinet. Check that the lube lines are not blocked. This can be caused by failure of the
pump to provide pressure, failure of the lube pressure sensor, a wiring error, or a param­eter error. See Air and Oil Line Diagrams (p.133) to check level switch and pressure
switch (cable 960).

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122 CONTROL OVER HEAT

The control internal temperature is above 150° F. This can be caused by almost anything
in the control overheating. But is usually caused by overheat of the two regen resistors for
servos and spindle drive. This alarm will also turn off the servos, spindle drive, coolant
pump, and tool changer. One common cause of this overheat condition is an input line
voltage too high. If this condition remains for 4.5 minutes, an automatic shutdown will
begin. It is also caused by incorrect transformer tapping, SDIST PCB problem, or Spindle
Drive problem. See Section 2, Electrical Service, to check line voltage adjustment taps.
See Section 4.2, Electrical Service, to replace SDIST PCB. See Section 2.3 to check the
spindle drive.

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. See Section 2.3 for check of the Spindle Drive. Front of Drive indicates type of
problem. If not a Drive problem, check wiring to IOPCB (cable 780).

124 LOW BATTERY

Memory batteries need replacing within 30 days. This alarm is only generated at POWER
ON and indicates that the 3.3V Lithium battery is below 2.5V. If this is not corrected within
about 30 days, stored programs, parameters, offsets, and settings may be lost. See
Section 4.1, Electrical Service, for replacement of Microprocessor PCB or battery.

VF Series Service Manual

125 SHUTTLE FAULT

Tool shuttle not initialized at power on, CYCLE START or spindle motion command. This
means that the tool shuttle was not fully retracted to the out position. See Section 4 for
tool changer problem.

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. See
Section 5 for gear change problem.

127 NO TURRET MARK

Tool carousel motor not in position. The turret motor only stops in one position indicated
by a switch and cam on the Geneva mechanism. This alarm is only generated at POWER
ON. The AUTO ALL AXES button will correct this but be sure that the pocket facing the
spindle afterwards does not contain a tool. See Section 4 for tool changer problem.

128 TOOL IN TURRET

Pocket opposite spindle has tool in it. This alarm is not implemented.

129 M FIN FAULT

This indicates an external M-code wiring error was detected at power-on. Check your
wiring to the M-FIN signal or see Section 4.3, Electrical Service, for replacement of the
IOPCB.

130 TOOL UNCLAMPED
131 TOOL NOT CLAMPED

Tool release piston is energized at power up, or, tool release piston is not Home. This is a
possible fault in the air solenoids, relays on the IO Assembly, the draw bar assembly, or
wiring. See Sections 2.6 and 4.1 for tool clamp/unclamp problems.

(Cont'd)

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VF Series Service Manual

6.

132 POWER DOWN FAILURE

133 SPINDLE LOCKED

134 TOOL CLAMP FAULT

135 X MOTOR OVER HEAT
136 Y MOTOR OVER HEAT
137 Z MOTOR OVER HEAT
138 A MOTOR OVER HEAT

(Cont'd)

The control attempted to shut-off and could not. The auto-off relay on the IOPCB did not
open the main contactor circuit. Check the wiring from IOPCB to POWER PCB. See
Section 4.3, Electrical Service, for IOPCB replacement.

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. See Section 2.5 for spindle orientation checks. Check for correct function of the
shot pin.

Tool did not release from spindle when commanded. Check air pressure and solenoid
circuit breaker CB4. Can also be caused by misadjustment of draw bar assembly. See
Sections 2.6 and 4.1 for tool clamp/unclamp problems.

Servo motor overheat. The temperature sensor in the motor indicates over 150°F. This can
be caused by an extended overload of the motor such as leaving the slide at the stops for
several minutes. See Section 3 for check of servo motors and ball screws. A parameter or
a wiring error can also cause this alarm.

139 X MOTOR Z FAULT
140 Y MOTOR Z FAULT
141 Z MOTOR Z FAULT
142 A MOTOR Z FAULT

Encoder marker pulse count failure. This alarm usually indicates that the encoder has
been damaged and encoder position data is unreliable. This can also be caused by loose
connectors at P1-P4. See Section 3.1 for check of motor/encoder and wiring. This is
usually an encoder or wiring error. It can also be caused by the MOTIF PCB. See Section

4.1, Electrical Service, for replacement of MOTIF PCB.

143 SPINDLE NOT LOCKED

Shot pin not fully engaged when a tool change operation is being performed. Check air
pressure and solenoid circuit breaker CB4. This can also be caused by a fault in the
sense switch that detects the position of the lock pin. See Section 2.5 for spindle orienta­tion checks.

144 TIMEOUT - CALL YOUR DEALER

Time allocated for use prior to payment exceeded. Not a mechanical or electrical problem.

145 X LIMIT SWITCH
146 Y LIMIT SWITCH
147 Z LIMIT SWITCH
148 A LIMIT SWITCH

Axis hit limit switch or switch disconnected. This is not normally possible as the stored
stroke limits will stop the slides before they hit the limit switches. Check the wiring to the
limit switches and connector P5 at the side of the main cabinet. Can also be caused by a
loose encoder shaft at the back of the motor or coupling of motor to the screw. See Sec­tion 7, Electrical Service, to replace limit switches.

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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. See
Section 4.3, Electrical Service, for IOPCB replacement or Section 2 for Spindle Drive
problem.

150 Z AND TOOL INTERLOCKED

Tool changer not at home and Z is neither at machine home or above tool. If RESET, E-STOP,
or POWER OFF occurs during tool change, Z-axis motion and tool changer motion may not
be safe. Check the position of the tool changer and remove the tool if possible. Re-initialize
with the AUTO ALL AXES button but be sure that the pocket facing the spindle afterwards
does not contain a tool. Indicates a dangerous condition with the position of the Z axis
and the tool changer. It is usually preceded by an alarm related to the tool changer. See
Section 4 for troubleshooting of tool changer.

151 LOW COOLANT

If the low coolant sensor is installed, this indicates low coolant level in the coolant tank
outside of the enclosure. Check coolant level and sensor in tank.

152 SELF TEST FAIL

This can be caused by an electronics problem or electrical interference. All motors and
solenoids are shut down. This is most likely caused by a fault of the processor board
stack at the top left of the control. Call your dealer. See Section 4.1, Electrical Service,
for replacement of MOTIF PCB.

VF Series Service Manual

153 X AXIS Z CH MISSING
154 Y AXIS Z CH MISSING
155 Z AXIS Z CH MISSING
156 A AXIS Z CH MISSING

These alarms indicate a problem with the servo axis encoder. All servos are turned off. It
can also be caused by wiring errors, electronics problems, encoder contamination, pa­rameter errors, or by loose connectors at P1-P4.. See Section 9, Mechanical Service, for
replacement of motor/encoder. See Section 4.1, Electrical Service, for replacement of
MOTIF PCB.

157 MOTOR INTERFACE PCB FAILURE

Internal circuit board problem. The MOTIF PCB in the processor stack is tested at POWER
ON. See Section 4.1, Electrical Service, for replacement of MOTIF PCB.

158 VIDEO/KEYBOARD PCB FAILURE

Internal circuit board problem. The VIDEO PCB in the processor stack is tested at POWER
ON. This could also be caused by a short in the front panel membrane keypad. See Sec­tion 5.5, Electrical Service, for replacement of keypad. See Section 4.1, Electrical Ser­vice, for replacement of VIDEO PCB.

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. See Section 5.5, Electrical
Service, for replacement of keypad. This can also be caused by a bad cable 700. Be
sure the problem is not in the cable before replacing keypad.

160 LOW VOLTAGE

This can be caused by a line voltage problem, a transformer tap problem, or an electronic
problem. Cable 980 can cause this problem. See Section 4.1, Electrical Service, to
replace MOTIF PCB or SDIST PCB.

(Cont'd)

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