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TROUBLESHOOTING
SERVICE
MANUAL
TROUBLESHOOTING
This section is intended for use in determining the solution to a known problem. Solutions given are intended to give the
individual servicing the CNC a pattern to follow in, first, determining the problems source and, second, solving the problem.
The troubleshooting tips are organized in this section according to the area of the CNC that may be giving sign of a problem.
(Ex.: Out-of round circles in drilling will be found under the heading General Machine 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, dont expect the machine to correct the fault. Dont suspect machine accuracy if the
vise bends the part. Dont claim hole mis-positioning if you dont first center-drill the hole.
FIND THE PROBLEM FIRST
Many mechanics tear into things before they understand the problem, hoping that it will appear as they go. We know this
from the fact that more than half of all warranty returned parts are in good working order. If the spindle doesnt turn,
remember that the spindle is connected to the 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 dont replace the
spindle drive if the belt is broken. Find the problem first; dont just replace the easiest part to get to.
DONT TINKER WITH THE MACHINE
There are hundreds of parameters, wires, switches, etc., that you can change in this machine. Dont start randomly changing
parts and parameters. Remember, there is a good chance that if you change something, you will incorrectly install it or break
something else in the process. Consider for a moment changing the processors board. First, you have to download all
parameters, remove a dozen connectors, replace the board, reload and reconnect, and if you make one mistake or bend one
tiny pin it WONT WORK. You always need to consider the risk of accidentally damaging the machine anytime you work on
it. It is cheap insurance to double-check a suspect part before physically changing it. The less work you do on the machine
the better.
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TROUBLESHOOTING
1. GENERAL MACHINE OPERATION
1.1 MACHINE NOT RUNNING
´ 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 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 Replace IOPCB (see "Electrical Service").
l Check Parameter 57 for Power Off at E-STOP.
l Replace MOTIF PCB (see "Electrical Service").
´ Machine turns on, keyboard beeps, but no CRT display.
l Check for green POWER LED at front of CRT.
l Check for power connections to CRT from IOPCB.
l Check video cable (760) from VIDEO PCB to CRT.
l Replace CRT (see "Electrical Service").
´ Any LED on Microprocessor PCB goes out (except HALT).
l Replace Microprocessor PCB (Section 4.1, Electrical Service).
l Replace VIDEO PCB (see "Electrical Service").
l Replace MOTIF PCB (see "Electrical Service").
´ Machine turns on, CRT works, but no keyboard keys work.
l Check keyboard cable (700) from VIDEO to KBIF PCB.
l Replace keypad (see "Electrical Service").
l Replace KBIF PCB (see "Electrical Service").
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SERVICE
1.2 VIBRATION
Vibration is a subjective evaluation with perceptions varying among individuals, making it difficult to determine in mild
cases if there is an actual problem. 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 betransferred 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. 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.
MANUAL
´ 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/Leadscrews", and "Gearbox and Spindle Motor" sections.
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1.3 ACCURACY
Before you complain of an accuracy problem, please make sure you follow these simple dos and donts.
l Dont ever use a wiggler test indicator for linear dimensions. They measure in an arc and have sine/cosine errors over
larger distances.
l Dont use magnetic bases as accurate test stops. The high accel/decel of the axis can cause them to move.
l Dont attach test points to the sheet metal of the spindle head or table.
l Dont check for thermal growth with an indicator on a long extension magnetic base.
l Do insure that test indicators and stops are absolutely rigid and mounted to machined casting surfaces.
l Do check a suspected error with another indicator or method for verification.
l Do ensure that the indicator is parallel to the axis being checked to avoid tangential reading errors.
l Do center drill holes before using jobber length drills if accuracy is questioned.
l Once machining practices have been eliminated as the source of the problem, determine specifically what the machine
is doing wrong.
´ Machine will not interpolate a round hole.
l Check the levelness of the machine (See the Installation Manual).
l Check for backlash ("Servo Motors/Leadscrews" section).
MANUAL
TROUBLESHOOTING
´ Bored holes do not go straight through the workpiece.
l Check the levelness of the machine (See the Installation Manual).
l Check for squareness in the Z axis.
´ Machine bores holes out-of-round.
l Check the levelness of the machine (See the Installation Manual).
l Check the sweep of the machine ("Spindle Sweep Adjustment").
´ Bored holes are out of round or out of postion.
l 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.
´ Machine mis-positions holes.
l Check the levelness of the machine (See the Installation Manual).
l Check for backlash ("Servo Motors/Leadscrews").
l Check the squareness of the X axis to the Y axis.
´ Machine leaves large steps when using a shell mill.
l Check the levelness of the machine (See the Installation Manual).
l Check the sweep of the machine ("Spindle Sweep Adjustment").
l Cutter diameter too large for depth of cut.
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´ Boring depth inaccurate (VF-6)
Insufficient counterbalance pressure due to:
l corrupted hose
l bad regulator
l bad check valve
l air cylinder bad
l bound cylinder
l surge tank leak
1.4 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" section)
l Check the condition of the tooling and the spindle.
l Check for spindle failure.
l Check the condition of the servo motors.
l Check the machine level.
MANUAL
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TROUBLESHOOTING
2. SPINDLE
2.1 NOT TURNING
´ 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 "Belt Assembly" and "Spindle Motor & Transmission" sections.
l Command spindle to turn at 1800 RPM and check spindle drive display. If display blinks bb, check spindle orienta
tion switch ("Spindle Orientation" section). 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 (VF-1, VF-2, VF-3) or the motor (VF-0). If the motor or gearbox operates, check the
drive belt ("Belt Assembly" section).
l Disconnect the drive belt. If the spindle will not turn, it is seized and must be replaced ("Spindle Assembly" section).
NOTE: Before using the replacement spindle, the cause of the previous failure must be determined.
2.2 NOISE
Most noises attributed to the spindle actually lie in the motor/gearbox or drive belt of the machine. Isolate the sources of
noise as follows:
´ Excessive noise coming from the spindle head area.
On VF-1 through 6 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.
l Remove the head covers and check the machines drive belt tension ("Tension Adjustment" section).
Ø 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 ("Belt Assembly" section).
Ø If the noise does not change, remove the belt and go on to the next step.
l Check the pulleys for excessive runout (more than 0.003" axial or radial).
l 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.
l Check for the correct amount of lubrication to the spindle bearings (0.5-1.0 cc every two hours) in a an air mist-
lubricated spindle.
Ø 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 ("Spindle Assembly" section).
Ø If the spindle is getting lubrication, replace the spindle ("Spindle Assembly" section).
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2.3 OVERHEATING
When investigating complaints of overheating, a temperature probe must be used to accurately check the temperature at the
top of the spindle taper. The temperature displayed in Diagnostics is not relevant. A machine that runs at high RPM
continuously will have a much warmer spindle than a machine that runs at a lower RPM. New spindles tend to run much
warmer than spindles that have already been broken in. In order to run a valid test on a new spindle, ensure that it is properly
broken in.
To break in a spindle, run the following program (it will take approximately 6 hours):
N100 S300 M03 G04 P900. N700 S6000 M03
G04 P900. M05 G04 P900.
M05 G04 P900. M05
G04 P900. G04 P900. G04 P900.
N200 S1000 M03 N500 S4000 M03 G04 P900.
G04 P900. G04 P900. N800 S7500 M03
M05 M05 G04 P900.
G04 P900. G04 P900. M05
N300 S2000 M03 G04 P900. G04 P900.
G04 P900. N600 S5000 M03 G04 P900.
M05 G04 P900. M99
G04 P900. M05
G04 P900. G04 P900.
N400 S3000 M03 G04 P900.
MANUAL
NOTE: This program will step the spindle speed from 300 RPM up to either 5000 or 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 If at any time during this procedure the spindle temperature rises above 150 degrees, start the procedure
over from the beginning.
If the spindle fails this test for any reason, check the following:
l Check for correct amount of lubrication.
NOTE: Over lubrication is a common source of overheating. Check the oil flow carefully.
l Check the drive belt tension. Too-tight belts will cause heating of the top bearing in the spindle housing.
l Ensure that the correct oil is being used (refer to "Maintenance Schedule").
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.
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2.5 SPINDLE DRIVE
Low line voltage may prevent the spindle from accelerating properly. If the spindle takes a long time to accelerate, slows
down or stays at a speed below the commanded speed with the load meter at full load, the spindle drive and motor are
overloaded. High load, low voltage, or too fast accel/decel can cause this problem.
If the spindle is accelerated and decelerated frequently, the regenerative load resistor inside the control may heat up. If this
resistor heats beyond 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 decel rate or reduce the frequency of spindle speed changes.
2.6 ORIENTATION
´ Spindle loses correct orientation.
l Check alarm history, looking for spindle overload and axis overcurrent alarms. These alarms the machine is not being
properly operated.
l Check the orientation ring for tightness. Ensure the shaft on which the ring mounts is free of grease.
l Check the orientation ring for cracks near the bolt holes or near the balancing holes.
Ø 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.
MANUAL
TROUBLESHOOTING
2.7 TOOLS STICKING IN TAPER
´ 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). 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 button on the front of the spindle head. If sticking is observed, the
deflection is not caused by improper ATC adjustment, but is a problem in the spindle head on the machine.
l Ensure the spindle is not running too hot.
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3. SERVO MOTORS / LEADSCREWS
3.1 NOT OPERATING
All problems that are caused by servo motor failures should also register an alarm. Check the alarm history to deter
mine the problems cause before any action is taken.
´ Servo motor is not functioning.
l Check the power cable from rear electrical cabinet to ensure connection is tight.
l Encoder is faulty or contaminated (Alarms 139-142, 153-156, 165-168, 182-185). Replace motor assembly
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 assem
bly ("Axis Motor Removal/Installation").
l Wiring is broken, shorted, or missing shield (Alarms 153-156, 175, 182-185).
l Dust in the motor from brushes has shorted out the motor (Alarms 153-156, 175, 182-185). Replace motor
assembly ("Axis Motor Removal/Installation").
l Motor has overheated; no damage to the interior components. OVERHEAT alarm has been triggered. After thorough
check of motor (DO NOT DISASSEMBLE!), take necessary steps to eliminate the problem and alarm to resume opera
tion. 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 broken lead screw. If cracked or broken, replace ("Lead Screw Removal and Installation" section).
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).
3.2 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 reli
able. Verify that customer complaints are not due to tooling, programming, or fixturing problems.
´ Servo motor noise.
l Disconnect the servo motor from the lead screw and rotate by hand. If the noise persists, replace the motor assembly
("Axis Motor Removal/Installation" section).
l Noise is caused by motor brushes. No problems will occur and noise should eventually go away.
l Noise is caused by bearings. Rolling, grinding sound is heard coming from the motor. ENSURE NOISE IS
NOT COMING FROM THE BRUSHES. If bearings are making a consistently loud sound, replace the bearing sleeve.
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´ Lead screw noise.
l Ensure oil is getting to the lead screw through the lubrication system (See Air and Oil Diagrams). Look 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.
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 through out 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.
MANUAL
TROUBLESHOOTING
´ Noise in Z - Motion (VF-6)
Brake won't release (leadscrew won't rotate)
l alarm not cleared
l low pressure switch blown
l brake power fuse blown
l brake power transformer blown
l brake power rectifier blown
l cabling pinched
l brake failed
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3.3 ACCURACY/BACKLASH
Accuracy complaints are usually related to tooling, programming, or fixturing problems. Eliminate these possibilities before
working on the machine.
´ Poor mill table-positioning accuracy.
l Check for a loose encoder on the servo motor. Also, ensure the key in the motor or the lead screw is in place and the
coupling is tight.
l Check for backlash in the lead screw as outlined below:
INITIAL PREPARATION -
Turn the 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.
CHECKING X-AXIS:
1. Set up a dial indicator and base on the mill table as shown in Fig. 3-1.
MANUAL
Fig. 3-1 Dial indicator in position to check X-axis.
2. Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows:
- Zero the dial indicator.
- Press the MDI button on the control panel.
- Press the HANDLE JOG button on the control panel.
The Distance to go display on the lower right hand corner should read: X=0 Y=0 Z=0
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.
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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.
MANUAL
TROUBLESHOOTING
Fig. 3-2 Dial indicator in position to check Y-axis.
2. Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows:
- Zero the dial indicator.
- Press the MDI button on the control panel.
- Press the HANDLE JOG button on the control panel.
The Distance to go display on the lower right hand corner should read: X=0 Y=0 Z=0
3. Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) Y direction. Jog
back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.
4. Repeat step three in the negative (-) direction.
TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD NOT EXCEED .0002.
An alternate method for checking backlash 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.
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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.
MANUAL
Fig. 3-3 Dial indicator in position to check Z-axis.
If backlash is found in the system, check for the following possible causes:
l Loose SHCS attaching the ball nut to the nut housing. Tighten the SHCS as described in Mechanical Service.
l Loose SHCS attaching the nut housing to the mill table, spindle 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.
(NOTE: The coupling cannot be serviced in the field and must be replaced as a unit if it is found to be defective.
l Loosen SHCS attaching the bearing sleeve to the motor housing. Tighten as described in "Lead Screw Removal and
Installation".
l Defective thrust bearings in the bearing sleeve. Replace the bearing sleeve as outlined in "Bearing Sleeve Removal and
Installation".
l Loose SHCS attaching the axis motor to the motor housing. If the SHCS are found to be loose, inspect the
motor fordamage and if none is found, tighten as described in "Axis Motor Removal/Installation". If damage is found,
replace the motor.
l Incorrect backlash compensation number in the parameter in the machine. Check Parameters 13, 27, and 41.
l Worn lead screw.
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3.4 VIBRATION
´ Excessive servo motor vibration.
l If no A axis is present, swap the suspected bad servo motor with the A driver and check to see if there is a driver
problem. If needed, replace the DRIVER PCB ("Electrical Service" section).
l Check all Parameters of the suspected axis against the Parameters as shipped with the machine. If there are any differ
ences, correct those and determine how the Parameters were changed. PARAMETER LOCK should normally be on.
l A bad motor can cause vibration if there is an open or short in the motor. A short would normally cause a GROUND
FAULT or OVERCURRENT alarm; check the ALARMS. An ohmmeter applied to the motor leads should show between 1
and 3 ohms between leads, and over 1 megohm from leads to chassis. If the motor is open or shorted, replace.
3.5 OVERHEATING
´ Servo motor overheating.
l If a motor OVERHEAT alarm occurs (ALARMS 135-138), check the Parameters for an incorrect setting. Axis flags in
Parameters 1, 15, or 29 can invert the overheat switch (OVER TEMP NC).
l If the motor is actually getting hot to the touch, there is excessive load on the motor. Check the users application for ex
cessive 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 Removal/Installation".
MANUAL
TROUBLESHOOTING
3.6 FOLLOWING ERROR
´ 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.
l Replace driver card ("Electrical Service").
l Replace servo motor ("Axis Motor Removal/Installation").
´ Z-axis motor overcurrent (VF-6)
l Brake won't release (leadscrew won't rotate)
Ø alarm not cleared
Ø low pressure switch blown
Ø brake power fuse blown
Ø brake power transformer blown
Ø brake power rectifier blown
Ø cabling pinched
Ø brake failed
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MANUAL
4. AUTOMATIC TOOL CHANGER
4.1 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 down.
l Check to see if pull studs on the tool holder are correct and tight.
l Check the adjustment of the Z offset ("Setting Parameter 64").
NOTE: If the offset is incorrect a tool changer crash has occured and a thorough inspection of the ATC is necessary at
this time.
l Check the adjustment of the Z offset check parameters 71, 72, and 143 against the values that are in the
documentation sent with the machine.
l Ensure the tool holders are held firmly in place by the extractor forks.
l Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release button is pressed. If they
do not move freely, the a ATC will be pushed down about 1/4" before the tool holder is seated in the taper, resulting in
damage to the roller bolts on the ATC shuttle. Replace the drawbar.
´ Tool holder sticking in the spindle taper causes the ATC to be pulled up as the spindle head
is traveling 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. 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 customers 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 Assembly" 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 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 the
"Spindle Assembly" section in Mechanical Service for spindle cartridge replacement.
´ During a tool change, ATC appears to be pulled up; no popping noises.
l Check the adjustment of the Z offset ("Setting Parameter 64" section). NOTE: If the offset is incorrect, a tool
changer crash has occurred, and a thorough inspection of the ATC is necessary at this time.
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l 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 "Roller Bolt Replacement", 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.
l Check Parameter 71 against the values that are in the documentation sent with the machine.
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 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.
´ Tool holders twist against extractor fork during a tool change.
l Check the alignment of the ATC in the X and Y axes ("Automatic Tool Changer Alignment" section).
´ Tool holders spin at all pockets of the ATC when the ATC shuttle retracts.
l ATC is misaligned in the Y axis. Realign ATC ("Automatic Tool Changer Alignment" section). 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.
´ Tool holders spin only at certain pockets of the ATC when the ATC shuttle retracts.
l Check all the extractor forks to ensure they are centered in the pocket of the ATC. Also, see above. See "Extractor Fork
Replacement" section, if necessary.
MANUAL
TROUBLESHOOTING
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 CRASHING
Crashing of the ATC is usually a result of operator error. The most common ATC crashes are outlined as follows:
´ Shuttle crashes into spindle when a tool change is commanded (tool holder is in
the pocket facing the spindle head).
l Rotate the carousel to an empty pocket. Refer to the Programming and Operation manual for correct operation.
NOTE: This crash is fairly common and is a result of operator error. If the ATC is stopped in the middle of tool change
cycle, the operator must 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.
´ During a tool change spindle crashes into top of the tool holder after a turret rotation.
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.
l Check all of the extractor forks on the ATC.
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´ During a tool change spindle crashes into top of the tool holder after a turret rotation.
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.
l 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.
´ ATC properly deposits a tool holder in the spindle, but the tools are dropped onto
the machine table when the shuttle retracts.
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 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.
MANUAL
´ 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, the sliding
covers on the ATC carousel, and the roller bolts on the ATC shuttle. See appropriate section for extractor fork
replacement.
4.3 BREAKAGE
Breakage of the ATC is caused by either very hard or repeated crashes.
´ ATC shuttle is broken off of the holding plate.
l 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.
´ ATC extractor forks are damaged after breakage.
l Check the condition of the 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.
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4.4 NOISY OPERATION
To isolate noise(s) in the ATC, carefully observe the ATC in operation and look for the following:
´ ATC makes noise as the shuttle moves.
l Check the adjustment of the roller bolts on the ATC ("Roller Bolt Replacement" section). 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.
l Check for damage to the trap door on the ATC cover. See appropriate section for trap door replacement.
l Check for missing plastic riders on the ATC shutter. See "ATC Trap Door Replacement" for shutter replacement.
l Ensure the guide pin mounted to the holding plate is not bent and does not scrape the ATC cover during movement. See
"ATC Trap Door Replacement" for guide pin replacement.
l 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 ("Shuttle Motor Removal" section). DO NOT try to repair the motor or to further isolate the noise in the motor.
ATC makes noise during carousel rotation.
MANUAL
TROUBLESHOOTING
l Check to ensure the Geneva driver on the turret motor is tight and properly adjusted ("Shuttle Motor Removal" section).
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 ("Geneva Star Replacement" section).
l Check the adjustment of the Geneva driver in relation to the Geneva star ("Geneva Star Replacement" section). 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
("Geneva Star Replacement" section).
l Ensure the screws holding the turret motor to the mounting plate are tight ("Turret Motor Removal" section).
l Ensure the screws attaching the motor mounting plate to the shuttle casting are tight.
l Check for excessive noise in the gear train of the turret motor. See appropriate section 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.
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SERVICE
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,
7) If not locked after time-out time, alarm and stop.
´ 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.
l Check the orientation of the machine.
MANUAL
´ ATC WILL NOT RUN
l In all cases where the tool changer will not run, an alarm is generated to indicate either a shuttle in/out problem or a
turret rotation problem. These alarms will occur either on an attempt to change tools (ATC FWD) or ZERO RETURN the
machine (AUTO ALL AXES). Use the appropriate alarm to select one of the problems following:
´ ATC shuttle will not move; shuttle is getting power (Command a tool change and feel for power
being applied to the shuttle motor).
l Disconnect the slip clutch arm from the ATC shuttle and ensure the shuttle can move freely. If not, appropriate section
for shuttle adjustment.
l Command a tool change with the shuttle disconnected.
Ø If the shuttle cycles, check the slip clutch on the ATC. See "Shuttle Installation" section 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.
Ø 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.
NOTE: The motor uses a large amount of gear reduction and should be hard to turn by hand.
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´ ATC shuttle will not move; shuttle is not getting power.
l Command a tool change feel for power being applied to the shuttle motor.
l Check that the TC IN/TC OUT LED on the I/O PCB is illuminated when a tool change takes place.
Ø If the LED lights, check the fuse FU5 on the POWER PCB or FU1 on the I/O PCB. Otherwise, replace the
I/O PCB ("Electrical Service").
Ø If the LED does not light, check cables I/O-P1-510 and I/O-P2-520.
´ ATC turret will not rotate; turret motor is getting power.
l Command a tool change feel for power being applied to the turret motor.
l 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 ("Automatic Tool Changer" section). Check for damage to the Geneva star or the Geneva driver.
Check for a broken turret motor ("Turret Motor Removal" section). NOTE: Do not attempt to repair the motor or to further
isolate the problem in the motor.
MANUAL
TROUBLESHOOTING
´ ATC turret will not rotate; turret motor is not getting power.
l Command a tool change feel for power being applied to the turret motor.
l Check that the TC CW/ TC CCW LED on the I/O PCB is illuminated when a tool change takes place.
Ø If the LED lights, check the fuse FU5 on the POWER PCB or FU1 on the I/O PCB. Otherwise, replace the
I/O PCB (Electrical Service).
Ø If the LED does not light, check cables I/o-P1-510 and I/O-P2-520.
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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-Series mill
that has a gearbox as this will damage the gearbox and void the warranty.
5.1 NOISE
When investigating complaints of gearbox noise, also refer to "Spindle" troubleshooting section. Gearboxes can be dam-
aged 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.
´ Excessive or unusual noise coming from the gearbox and/or spindle motor.
Operate the machine in both high and lowgears. 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.
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 ("Spindle Motor & 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, ("Spindle Motor & Transmission" sec
tion).
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.
5.2 GEARS WILL NOT CHANGE
´ Machine will not execute a gear change.
NOTE: Whenever a gear change problem occurs, an alarm will also occur. Refer ALARMS section 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,
9) Turn off high and low gear solenoids.
l 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 ("Spindle Motor & Transmission" section).
l Check contactor CB4.
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MANUAL
TROUBLESHOOTING
5.3 LOW PRESSURE ALARM
´ Alarm 179 (Low Pressure Transmission Oil) has been triggered.
l Check for low oil supply in reservoir.
l Check to see 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.
6. THROUGH THE SPINDLE COOLANT
6.1 COOLANT OVERFLOW
To begin troubleshooting, check the alarm history to determine the problems cause before any action is taken.
´ Coolant pouring out of spindle head covers.
l Check for seal failure. If failure is found, replace the seal (seal / housing assy. kit #93-9000). Refer to the appropriate
steps in"TSC-Tool Release Piston Replacement" section for procedure.
l Check that the TSC drain line is intact. If necessary, replace with 5/32" O.D. X 32" long nylon tubing (24" long for VF-
O/OE)
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 140 psi), with a standard tool holder in spindle. If pump pressure is above 140 psi, reset
the pump relief valve in accordance with the "Setting TSC Pump Relief Valve" section.
´ 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.
l Ensure the coolant pump relief valve has not been tampered with (yellow paint band is intact). Check the coolant pump
pressure (should be 140 psi), with a standard tool holder in spindle. If pump pressure is above 140 psi, reset pump
relief valve in accordance with "Setting Pump Relief Valve" section.
6.2 LOW COOLANT
´ Alarm 151, "Low Thru Spindle Coolant"
l Check coolant tank level. Check the filter and intake strainer for any clogging. Check coolant lines for any clogging
or kinking. Clean or replace as needed.
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.
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l Check for pressure switch failure (refer to "Testing the Coolant Pressure Switch" section), and replace if necessary.
SERVICE
Check "LO CLNT" bit in the diagnostics display (0 = pressure on, 1= pressure off).
l If the filter has been cleaned or the coolant line has been disconnected from the pump or check valve assembly, prime
the system as described in "Priming TSC System" section.
6.3 COOLANT TIP WEAR
´ 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.
6.4 PRE-CHARGE FAILURE
MANUAL
´ Alarm 198, "Precharge Failure"
NOTE: This alarm can 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.
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MANUAL
ALARMS
7. ALARMS
Any time an alarm is present, the lower right hand corner will have a blinking ALARM. Push the ALARM display key to view the
current alarm. All alarms are displayed with a reference number and a complete description. If the RESET key is pressed, one alarm
will be removed from the list of alarms. If there are more than 18 alarms, only the last 18 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.
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:
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 EMERGENCY 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.
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.
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ALARMS
SERVICE
113 Shuttle In Fault Tool changer not completely to right. During a tool changer operation
the tool in/out shuttle failed to get to the in position. Parameters 62 and 63 can adjust the time-
out times. This alarm can be caused by anything that jams the motion of the slide or by the
presence of a tool in the pocket facing the spindle. A loss of power to the tool changer can also
cause this, so check CB5 and relays 1-8, 2-1, and 2-2.
114 Shuttle Out Fault Tool changer not completely to left. During a tool change operation the tool in/out shuttle failed
to get to the out position. Parameters 62 and 63 can adjust the time-out times. This alarm can
be caused by anything that jams the motion of the slide or by the presence of a tool in the
pocket facing the spindle. A loss of power to the tool changer can also cause this, so check
CB5 and relays 1-8, 2-1, and 2-2.
115 Turret Rotate Fault Tool carousel motor not in position. During a tool changer operation the tool turret failed to
start moving or failed to stop at the right position. Parameters 60 and 61 can adjust the time-
out times. This alarm can be caused by anything that jams the rotation of the turret. A loss of
power to the tool changer can also cause this, so check CB5 and relays 1-8, 2-3, and 2-4.
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.
MANUAL
117 Spindle High Gear Fault For Vertical Mills only. 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 For Vertical Mills only. 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 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.
119 Over Voltage Incoming line voltage is above maximum (about 255 volts 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.
120 Low Air Pressure Air pressure dropped below 80 PSI for a period defined by parameter 76. Check your incom
ing 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 pressure.
Low 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.
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 resis
tors 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.
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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 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.
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 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 after
wards does not contain a tool.
MANUAL
ALARMS
128 Tool In Turret Pocket opposite spindle has tool in it. Future option not yet implemented.
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 Tool release piston is energized at power up. This is a possible fault in the air
solenoids, relays on the IO Assembly, the draw bar assembly, or 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.
136 Y Motor Over Heat same as 135.
137 Z Motor Over Heat same as 135.
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ALARMS
SERVICE
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 connec
tors 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 possibleas 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.
MANUAL
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 or above. 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 machines with Through the Spindle Coolant only. This alarm will shut off the
Coolant spindle, 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
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155 Z-axis Z same as 153.
Ch Missing
156 A-axis Z same as 153.
Ch Missing
157 Motor Interface Internal circuit board problem. The MOTIF PCB in the processor stack is
PCB Failure tested at power-on. Call your dealer.
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.
MANUAL
ALARMS
161 X-axis Over Current Current in X servo motor beyond limit. Possibly caused by a stalled or
or Drive Fault 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 Over Current same as 161.
or Drive Fault
163 Z-axis Over Current same as 161.
or Drive Fault
164 A-axis Over Current same as 161.
or Drive Fault
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 opera
tion.
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.
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ALARMS
SERVICE
170 Phase Loss L1-L2 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 Phase Loss L2-L3 Problem with incoming line voltage between legs L2 and L3.
172 Phase Loss L3-L1 Problem with incoming line voltage between legs L3 and L1.
173 Spindle Ref The Z channel pulse from the spindle encoder is missing for hard 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 Detected A ground fault condition was detected in the 115V AC supply. This can be caused by a short
to ground in any of the servo motors, the tool change motors, the fans, or the oil pump.
176 Over heat Shutdown An overheat condition persisted for 4.5 minutes and caused an automatic shutdown.
MANUAL
177 Over voltage 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
180 Tool Arm Rotation Fault For Side Mount Tool Changer, the tool exchange operation did not sense the 180 degree
rotation switch.
181 Tool Pot Position Fault For Side Mount Tool Changer, the tool pot positioning mechanism is not working.
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 error.
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.
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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 Spigot failed to achieve commanded location after two (2) attempts.
197 100 Hours Unpaid Bill Call your dealer.
198 Precharge Failure During TSC 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.
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.
MANUAL
ALARMS
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 Software Error; Call your dealer.
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 Software Error; Call your dealer.
212 Program Integrity Error Software Error; Call your dealer.
213 EPROM 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.
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ALARMS
SERVICE
216 EPROM Speed Failure Indicates that an EPROM internal driver has weakened so that data read from that EPROM may
be unreliable. 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.
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 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 PCB.
224 Y Transition Fault Same as above.
225 Z Transition Fault Same as above.
226 A Transition Fault Same as above.
227 B Transition Fault Same as above.
228 C Transition Fault Same as above.
MANUAL
231 Jog Handle Transition Same as 223.
Fault
232 Spindle Transition Fault Same as above.
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.
240 Empty Prog or No EOB Software Error; Call your dealer.
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.
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248 Number Range Error Number entry is out of range.
249 Prog Data Software Error; Call your dealer.
Begins Odd
250 Program Data Error Same as 249.
251 Prog Data Struct Error Same as 249.
252 Memory Overflow Same as 249.
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 changed. Call your dealer.
261 Rotary CRC Error Rotary table saved parameters (used by Settings 30, 78) have a CRC error. Indicates a loss of
save memory - call your dealer.
MANUAL
ALARMS
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.
302 Invalid R In G02 or G03 Check your geometry with the HELP page. 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 with the HELP page.
G02 or G03
304 Invalid I, J, or K In Check your geometry with the HELP page. Radius at start must match
G02 or G03 radius at end of arc 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
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.
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ALARMS
SERVICE
312 Program End End of subroutine reached before M99. Need an M99 to return from subroutine.
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 users 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.
MANUAL
320 No Feed Rate Specified Must have a valid F code for interpolation functions.
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 over 1000.0 or over 9999.
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 16.
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 in VF Series CNC Mill.
334 Y-axis Disabled same as 333.
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335 Z-axis Disabled same as 333.
336 A-axis Disabled Parameters have disabled this axis. Must enable A-axis to program it or remove programming
of A-axis. The A-axis can be disabled permanently by Parameter 43 or temporarily by Setting
30.
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 comp earlier.
With G02 or G03
341 Cutter Comp End Disable cutter comp later.
With G02 or G03
MANUAL
ALARMS
342 Cutter Comp Path Geometry not possible. Check your geometry with the HELP page.
Too Small
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 Illegal Spiral Motion Linear axis path is too long. For helical motions, the linear path must not be more than the
length of the circular component.
349 Prog Stop W/O Information message only. Fix or Ignore.
Cancel Cutter Comp
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 Software error. Call your dealer.
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ALARMS
SERVICE
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 DisabledAux 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 with the HELP page.
or G13
MANUAL
360 Tool Changer Disabled Check Parameter 57. Not a normal condition for VF Series CNC Mill.
361 Gear Change Disabled Check Parameter 57. Not a normal condition for VF Series CNC Mill.
362 Tool Usage Alarm Tool life limit was reached. To continue, reset the usage count in the Current Commands
display and press RESET.
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.
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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 auto offset skip 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
MANUAL
ALARMS
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.
386 Invalid Address Format An address A¼Z 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 outside of cutter comp.
Allowed With G10 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.
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ALARMS
SERVICE
394 B Over Travel Range Same as 316.
398 Aux Axis Servo Off Aux. axis servo shut off due to a fault.
403 RS-232 Too Many Progs Cannot have more than 100 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.
MANUAL
408 RS-232 Number Range Check your program. The program will be stored but the bad data is
Error turned into a comment.
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 Insufficient Program received doesnt fit. Check the space available in the LIST PROG
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.
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419 Invalid Function A code found on input of a DNC program could not be interpreted.
For DNC
420 Program Number The O code in the program being loaded did not match the O code
Mismatch entered at the keyboard. Warning only.
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
MANUAL
ALARMS
434 Floppy Insufficient Program received doesnt fit. Check the space available in the LIST
Memory PROG mode and possibly delete some programs.
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.
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
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ALARMS
SERVICE
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.
MANUAL
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.
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
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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 Ks 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.
MANUAL
ALARMS
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
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.
613 Command Not Allowed A command (M96, for example) in the highlighted block cannot be
In Cutter Comp. executed while cutter comp. is invoked.
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VF-SERIES
SERVICE
MANUAL
MECHANICAL
SERVICE
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MANUAL
MECHANICAL SERVICE
1. HEAD COVERS REMOVAL / INSTALLATION
PLEASE READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO REMOVE OR REPLACE COVERS.
REMOVAL -
1. Power on the Vertical Machining Center (VMC).
2. Zero return (ZERO RET) all axes, then HANDLE JOG to center X- and Y-axes under spindle.
3. Protect table surface with a piece of cardboard.
4. Loosen the four SHCS that attach top cover to side covers, and remove.
5. Loosen the six SHCS that attach rear cover to side covers, and remove.
6. Loosen the eight SHCS that attach front cover to side covers, then carefully remove front cover from the bottom
until you can disconnect the tool release cable (quick disconnect).
7. Loosen the seven SHCS that attach each side cover, and remove from the top side. Jog Z-axis as necessary to make
screw removal easier.
CAUTION! Be careful not to run head covers into the enclosure.
42
Fig. 1-1 View of VMC head covers.
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MECHANICAL SERVICE
SERVICE
INSTALLATION -
1. Protect table surface with a piece of cardboard.
2. Replace each side cover from the top side with seven SHCS. Jog Z-axis as necessary to make access to screws
easier.
CAUTION! Be careful not to run the head covers into the enclosure.
3. Reconnect tool release cable, if equipped, then replace front cover from the bottom and attach with eight SHCS.
4. Replace rear cover, and attach to side covers with six SHCS.
5. Replace top cover, and attach to side covers with four SHCS.
MANUAL
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2 . TOOL RELEASE PISTON ASSEMBLY
PLEASE READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO REPLACE TOOL RELEASE PISTON
ASSEMBLY.
NOTE: If machine is equipped with the TSC option, refer to the "Through the Spindle Coolant" section for TRP Assembly procedures.
2.1 REMOVAL
1. Remove cover panels from the headstock area in accordance with "Head Covers Removal and Installation".
2. Remove the four 3/8-16 x 1¾" SHCS holding the tool release piston assembly to the head casting.
3. Disconnect the air line at the lube/air panel.
4. Disconnect the clamp/unclamp cables (quick disconnect) and the assembly's solenoid wiring located on the solenoid bracket.
5. Remove the tool release air hose at the fitting shown in Fig. 2-2.
6. Remove entire tool release piston assembly.
Fig. 2-1 Spindle and headstock area shown with covers removed. VF-0 will have no transmission.
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Fig. 2-2 Tool release piston with solenoid valve.
Fig. 2-3 Mounting location for tool release piston assembly
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2.2 INSTALLATION
1. Ensure drive belt has been properly replaced as described in "Belt Assembly" section.
2. Verify spindle sweep adjustment is correct (as shown in "Spindle Assembly" section) before proceeding.
If not correct, re-shim as necessary.
3. Reinstall tool release piston assembly, tightening down the four SHCS alternately until all are completely tight.
4. Reconnect the air hoses at the applicable fittings on the tool release piston assembly.
5. Reconnect the clamp/unclamp cables to the sides of the solenoid bracket.
6. Continue with the reassembly and adjustments described later in this manual.
2.3 SETTING PRE-CHARGE
1. Remove the cover panels in accordance with "Head Covers Removal and Installation". It will not be
necessary to remove the rear or right side panels for this operation.
MANUAL
MECHANICAL SERVICE
2. Turn the air pressure regulator down 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.
Fig. 2-4 Air pressure regulator adjustment knob.
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3. Go to PARAMETERS page of CRT and ensure PRE-CHARGE DELAY is set to 200. If not, do so at this time.
4. Execute a tool change. A banging noise will be heard as the tool release piston contacts the drawbar.
5. Turn the air pressure regulator ½ turn in. Execute a tool change and listen for the noise described previously. 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 pre-charge system will cause damage to the tool changer and
tooling in the machine.
MANUAL
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3. BELT ASSEMBLY
PLEASE READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO REPLACE THE DRIVE BELT.
3.1 BELT REMOVAL
NOTE: FOR EASIER REMOVAL, PLACE TRANSMISSION IN HIGH GEAR BEFORE BEGINNING.
1. Remove cover panels from headstock area in accordance with "Head Covers Removal and Installation".
Fig. 3-1 Spindle head casting disconnect points
2. Remove tool release piston assembly in accordance with "Tool Release Piston Assembly Removal".
3. For all VMC's except VF-0, remove the six SHCS holding the transmission to the head casting and pull the transmission forward enough (½" to ¾" max.) to allow the drive belt to be pulled upward over the spindle pulley.
4. For the VF-0, remove the four SHCS holding the mounting plate to the spindle head casting. Slide the assembly
forward enough to allow the drive belt to be pulled up over the spindle pulley.
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Fig. 3-2 Head casting area showing belt location
MANUAL
5. Remove the inspection cover from the bottom of the spindle head casting and carefully slide the drive belt between
the sump tank and the web in the casting.
6. First, pull the belt up over the spindle pulley, then push the other end down to clear the shifter and pull out.
NOTE: DO NOT bend or kink the belt in any way; damage to the fibers in the belt may result, and the belt will fail soon
after installation.
3.2 BELT INSTALLATION
1. For all VMC's except VF-0 (only one belt on VF-0's), slide the replacement belt(s) under the sump tank and onto the
pulley.
NOTE: DO NOT bend or kink the belt in any way; damage to the fibers in the belt may result, and the belt will fail soon
after installation.
2. Ensuring the belt is properly seated, push the transmission back, tightening the belt. Pull belt forward from rear of
head casting. Pull belt over spindle pulley.
3. Tighten the drive belt in accordance with the following section.
4. Set the spindle orientation in accordance with appropriate section.
NOTE: The following step is necessary only if the spindle or transmission was exchanged prior to belt replacement.
5. 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.
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3.3 TENSION ADJUSTMENT
NOTE: The drive belt's tension should be adjusted after every service on the transmission or spindle of the machine.
1. Turn the machine ON. Position the spindle head casting at a level that will allow you to work on the
drive belt comfortably.
2. Remove the cover panels from the head stock area as shown in "Head Covers Removal" section.
3. Remove the tool release piston assembly in accordance with appropriate section.
4. Screw a 3/8-16 x 1¼" bolt into each of the rearmost mounting holes for the tool release piston
assembly on the spindle head casting. The bolt should protrude ½"-¾" above the casting.
VF-1, VF-2, VF-3, VF-4:
5. Loosen the six SHCS holding the transmission to the spindle head casting.
6. Place the pry bar between the transmission and the bolt in the spindle head and force the transmission back until the
belt tension is set. The belt tension should be set moderately tight. If it is set too tight, the belt will whine when the
assembly is at speed; and if it is set too loose, if will vibrate during accelerations and decelerations.
MANUAL
MECHANICAL SERVICE
7. Tighten the SHCS holding the transmission to the spindle head casting.
8. Recheck the tension and repeat steps 5-7, if necessary.
VF-0:
9. Loosen the four SHCS holding the motor plate to the spindle head casting.
10. Using the pry bar, force the motor plate back until the belt tension is set. The belt tension should be set moderately
tight. If it is set too tight, the belt will whine when the assembly is at speed; and if it is set too loose, it will vibrate during
accelerations and decelerations.
11. Retighten the SHCS holding the motor plate to the spindle head casting.
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4. SPINDLE ASSEMBLY
PLEASE READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO REPLACE SPINDLE.
IMPORTANT!
The current pulley is shrink-fitted onto the spindle and is not field-serviceable. It is identified by two threaded holes on
top of the spindle pulley. Should any attempt to remove the pulley damage the spindle or its components, the service
warranty will be voided.
If the VMC being serviced has an old style pulley and requires removal, refer to service manual 96-8100, 4/13/93 for
further assistance.
NOTE: The drive belt's tension should be adjusted after every service on the transmission or spindle of the machine.
4.1 SPINDLE CARTRIDGE REMOVAL
1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the spindle. Place the cardboard
on the mill table to protect the surface.
2. Remove cover panels from head stock area as described in "Head Covers Removal" section.
3. Remove the tool release piston assembly in accordance with appropriate section.
4. Remove the spindle drive belt from the spindle pulley as shown in previous section. It is not possible to
completely remove the belt at this time.
5. First disconnect the oil line from the fitting at the oil injection cover, then remove the brass fitting.
NOTE: When replacing a new design spindle in any vertical machine, it is important to note that the cavity
between the housing and the spindle cartridge will be filled with either oil or grease. An oil filled spindle
is identified by the oil fill hole to the left side of the spindle head near the spindle bore as viewed from the top.
6. Ensure oil plug is inserted into oil injection port of spindle before removing spindle or oil may spill into the
spindle cartridge.
7. With the 5/16" hex wrench, loosen approximately two turns the six SHCS holding the spindle to the underside of the
head casting.
8. Place the block of wood (minimum 6" thick) on the table directly under the spindle.
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Fig. 4-1 Position wood block under spindle.
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MECHANICAL SERVICE
9. At the panel, go to the JOG mode and choose Z-axis. Slowly jog in the negative (-) direction until the spindle rests
on the block, then remove the screws that were previously loosened (step 7).
10. Jog Z-axis in the positive (+) direction until spindle is half way out of the head casting.
11. Grasp spindle with one hand and continue to jog in Z in the positive (+) direction until it is completely free of the
casting.
4.2 SPINDLE CARTRIDGE INSTALLATION
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Fig. 4-2 Spindle cartridge.
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1. Thoroughly clean all mating surfaces of both the cartridge and the head casting, lightly stone if necessary to remove
burrs or high spots.
2. Place spindle on wood block making sure both spindle dogs contact the block. Align the two 10-32 holes located on
the spindle lock so they are approximately 90 degrees from the front of the spindle on the right side.
MANUAL
Fig. 4-3 Underside view of spindle cartridge.
3. Slowly jog the Z-axis in the negative (-) direction until threaded portion of spindle is inside of head casting. At this
point, align spindle to spindle bore. While performing this operation, you must make sure the spindle cartridge is
straight to the spindle bore.
Fig. 4-4 Spindle cartridge alignment.
4. If the spindle moves to one side, use a rubber mallet and/or jog in the X or Y directions to straighten it. The spindle
must go in easy. If it does not, check your alignment. Do not force it!
5. Install the six SHCS and tighten down completely.
6. Reattach the brass fitting to the oil injection cover and connect the oil line to the fitting. CAUTION! Do not
overtighten the fittings when replacing on the oil injection cover. Overtightening may result in damage to the spindle
cartridge.
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7. Fill the cavity between the housing and the spindle cartridge with oil. The oil fill hole is to the left side of the spindle
head near the spindle bore, as viewed from the top. WARNING! Never pour oil into the spindle housing.
8. Reinstall the drive belt and adjust the tension as needed.
9. Reinstall the tool release piston assembly.
10. Check the spindle sweep, as described later in this section.
NOTE: Refer to the appropriate sections and check the spindle orientation and ATC alignment.
4.3 DRAWBAR REPLACEMENT
NOTE: If machine is equipped with the TSC option, refer to the "Through the Spindle Coolant" section for the drawbar
replacement procedure.
REMOVAL -
1. Place a tool holder with no cutter in the spindle.
MANUAL
MECHANICAL SERVICE
2. Remove head cover panels as shown in "Head Covers Removal'.
3. Remove the tool release piston in accordance with appropriate section.
4. Remove the snap ring from the top of the spindle shaft.
5. Reinstall the tool release piston.
6. Remove the tool holder from the spindle.
7. Remove the spindle, as described earlier in this section.
8. Remove the drawbar and distance tube from the spindle assembly.
INSTALLATION -
9. Thoroughly coat the replacement drawbar with grease, including the end of the shaft where the four holding balls
are located.
10. If machine is equipped with Through the Spindle Coolant option, grease the O-rings.
11. 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.
CAUTION! Insert the drawbar gently so the O-rings are not damaged. DO NOT use a hammer to force it.
NOTE: Carefully inspect the spindle shaft for galling or burrs inside the spindle shaft where the end of the drawbar
rides. If it is damaged, the spindle must be replaced.
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12. Refer to appropriate section, and install the spindle cartridge. The tool release piston will have to be reinstalled at
this time.
13. Install a tool holder with no cutter into the spindle taper.
14. Remove the tool release piston.
15. Install the snap ring on the spindle shaft.
16. Reinstall the tool release piston.
17. Finish installation of the spindle, beginning with "Spindle sweep adjustment".
18. Set the drawbar height, clamp and unclamp switches, as described in the following section.
CAUTION! Step 20 must be followed or damage to the ATC will result.
19. Refer to "Spindle Orientation" and set the spindle orientation.
MANUAL
20. Reinstall the head covers.
21. Test-run the machine and perform the necessary ATC adjustments in the "Automatic Tool Changer" section.
4.4 SPINDLE SWEEP ADJUSTMENT
NOTE: The machine must be properly leveled for the spindle sweep adjustment to be accurate.
1. To check spindle sweep, place a .0005 indicator on a suitable holder, place on spindle nose and jog the Z-axis in the
negative (-) direction enough so that you can adjust the indicator to sweep a 5" radius from the center of X and Y axes'
travels. Slowly jog Z-axis in the negative (-) direction to zero out indicator.
2. Establish reference zero at rear of the table. Sweep the three remaining points (left, front, and right) and record the
reading.
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Fig. 4-5 Spindle sweep area.
3. Shim the spindle if necessary to correct the spindle sweep to specifications.
MANUAL
MECHANICAL SERVICE
4. Recheck sweep. It must be within .0005 in both X/Z and Y/Z planes, as stated in the inspection report supplied with
the VMC.
5. Replace the Tool Release Piston Assembly in accordance with the "Tool Release Piston Assembly Installation" and
"Setting Pre-Charge" sections.
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5. TOOL CLAMP/UNCLAMP SWITCH ADJUSTMENT
PLEASE READ THIS SECTION IN ITS ENTIRETY BEFORE ADJUSTING CLAMP/UNCLAMP SWITCHES OR SETTING DRAWBAR HEIGHT.
TOOLS REQUIRED:
MACHINED ALUMINUM BLOCK (2" x 4" x 4")
6" FLEXIBLE RULER or .020" SHIM
1" DIA. PIPE (APPROX. 1' LONG)
5.1 TOOL CLAMP/UNCLAMP SWITCH ADJUSTMENT - INITIAL PREPARATION
1. Remove cover panels, as described in "Head Covers Removal".
2. Place a sheet of paper under the spindle for table protection, then place a machined block of aluminum (approximately 2" x 4" x 4") on the paper.
Fig. 5-1 Placement of aluminum block under spindle.
3. Power on the VMC.
4. Insert a tool holder WITHOUT ANY TYPE OF CUTTER into the spindle taper.
5. Go to the HANDLE JOG mode. Choose Z-axis and set jog increments to .01.
6. Jog Z-axis in the negative (-) direction until the tool holder is approximately .03 from the block. At this point, stop
jogging the spindle and push the tool release button (top left). You will notice that the tool holder comes out of the
taper.
NOTE: The clearance from the tool holder to the block should be zero (0).
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7. To accomplish this, set the jog increments to .001 and jog in the negative (-) Z direction a few increments of the
hand wheel 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).
CAUTION! Do not jog too far in the negative (-) direction or else it will cause an overcurrent in the Z-axis.
5.2 SETTING DRAWBAR HEIGHT
1. Press MDI and turn hand wheel to zero (0).
2. Press HANDLE JOG button and set increments to .01. Jog Z-axis in the positive (+) direction 0.100".
3. Press and hold tool release button, grasp block and try to move it. Block should be tight at .100 and loose at .110.
If block does move at .100, jog Z-axis in the negative (-) direction one increment at a time. Push tool release button and
check for movement between increments until block is tight.
The increments jogged in the Z negative (-) direction are the amount of shim washers that must be added to the tool
release bolt (Refer to "Shim Washers" section).
MANUAL
MECHANICAL SERVICE
4. If block is tight at .110, move Z-axis in the positive (+) direction one increment at a time. Push tool release button
and check movement between increments until block is loose.
The increments jogged in the Z positive (+) direction are the amount of shim washers that must be removed from the
tool release bolt (Refer to "Shim Washers" section).
5.3 SHIM WASHERS
1. To add or subtract shim washers, remove tool release piston assembly ("Tool Release Piston" section) from head
casting.
NOTE: Shims may need replacement when spindle cartridge, tool release piston assembly, or drawbar is replaced. If
none have been replaced, skip this section.
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Fig. 5-2 Tool release piston assembly
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2. Remove tool release bolt.
3. Add or subtract required shim washers (See previous section for correct amount to add or remove).
4. Before installing tool release bolt, put a drop of serviceable (blue) Loctite® on the threads and install.
5. Install tool release piston assembly and recheck settings. If within specifications, continue; if not, readjust.
5.4 ADJUSTMENT OF SWITCHES - 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.
MANUAL
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 hand wheel at .06 and activate 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.
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Fig. 5-3 Tool release piston assembly.
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UPPER (CLAMP) SWITCH -
CAUTION! Remove the tool holder from the spindle before performing the upper (CLAMP) switch adjustment. Failure
to remove 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.
MANUAL
MECHANICAL SERVICE
Fig. 5-4 Placement of shim before checking switch adjustment.
7. Move the tool release piston down so the shim is pressed against the drawbar. This can be done in one of the two
following ways:
Ø Using the pipe as a lever, push down on the piston until it contacts the draw bar and the shim
is held in place. For the VF-0: wedge a large, flat-tip screwdriver under the cooling fins of the
motor and push the piston down.
Ø If machine is equipped with the "macros" option: set macro variable #1120 to 1. This will
energize the pre-charge solenoid.
8. While the tool release piston is down, 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.
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9. Check the switch several times. This is done by by moving the piston up and down to ensure that the "Tool Unclmp"
status appears when the piston makes contact with the shim and drawbar, and does not appear (DB OPN=0, DB
CLS=1) when it is in the retracted position.
MANUAL
Fig. 5-5 Push piston down to hold shim in place.
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6. SPINDLE ORIENTATION
PLEASE READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO ORIENT THE SPINDLE.
6.1 SPINDLE ORIENTATION
1. Remove cover panels from the head stock area ("Head Covers Removal"), and tool changer front cover.
2. In MDI mode, press the ORIENT SPINDLE button.
3. Loosen the four 1/4"-20 bolts on the orientation ring. Remove two of these bolts and insert them into the two
threaded holes on the ring. Evenly tighten these two bolts until the taper lock is broken.
4. Remove the two 1/4"-20 bolts and place them into their original holes. Tighten them finger tight, then 1/2 of a 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 dog in the X- plane.
6. Jog the indicator across the spindle dogs and note the indicator reading. The spindle dogs should be parallel to the
X axis within 0.030".
Fig. 6-1 Top view of spindle orientation components.
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Fig. 6-2 VF-0 motor with orient ring location.
MANUAL
7. 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 the adjustment.
8. Using a 5/8" 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 5.
9. Disconnect the main air line to the machine.
10. Manually turn the orientation ring and push the shot pin until it drops into the orient ring detent.
11. Tighten the orient screws (evenly) to 15 ft-lbs. Verify that spindle alignment has not changed.
NOTE: It is vital that the orient screws be tightened evenly. If not, the top of the orientation ring will run out and the ring
will slip.
NOTE: Ensure the orient ring has an adequate layer of grease around the circumference before starting operation.
12. Make at least 50 tool changes to test the spindle orientation.
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MECHANICAL SERVICE
7. SETTING PARAMETER 64 (TOOL CHANGE OFFSET)
PLEASE READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO SET PARAMETER 64.
NOTE: Parameter 7 must be "unlocked" before setting Parameter 64.
1. WITHOUT a tool in the spindle taper, initiate a tool change and stop the tool changer using the EMERGENCY STOP
button (when the Z-axis moves above the carousel, but before the carousel rotates). Insert a tool holder into the pocket
facing the spindle.
2. Using a .0005 indicator and suitable 18" mag base, zero off of bottom left edge A of tool holder (looking directly
into pocket). Move indicator to bottom right edge B of tool holder. Any difference between these edges should be
equally divided. For example: if a difference of .002 from left side to right side edge, adjust indicator dial so that
indicator reads .001 when it is on either edge. This gives you the tool offset reference.
3. Carefully (so as not to disturb relative position) move the indicator to one side. Remove tool from the tool changer
and place it in the spindle.
4. Zero return Z SIGL AXIS.
5. Carefully (so as not to disturb relative position) place indicator under spindle and indicate on bottom left edge of the
tool holder.
If spindle head is too far in the negative (-) or the positive (+) direction, go to JOG mode and choose Z-axis. Jog Z-axis
in the necessary direction until it reads zero (0).
6. Push the help button twice. This will put the machine in the calculator mode.
64
Fig. 7-1 Checking tool offset reference.
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Fig.7-2 Screen showing calculator.
MANUAL
7. Take the number in the Z-axis machine display (center left of page) and multiply it by Parameter 33, which is Z
RATIO (STEPS/INCH).
If Z-axis work display is negative (-), add the number to the number that you calculated to Parameter 64. If the number
is positive (+), subtract it from Parameter 64.
8. To insert the calculated new number, place the cursor at Parameter 64, type in new number and push write key.
ZERO RET Z-axis to initialize the new Parameter 64.
9. Recheck the offset with the indicator (Steps 1-5).
10. Insert tool holder in spindle in spindle taper and initiate a tool change.
NOTE: When the Parameter 64 is changed, the tool offsets must be reset.
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MECHANICAL SERVICE
8. SPINDLE MOTOR & TRANSMISSION
PLEASE READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO REMOVE OR REPLACE
TRANSMISSION.
NOTE: The drive belt's tension should be adjusted after every service on the transmission or spindle.
8.1 MOTOR REMOVAL (VF-0)
1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the transmission. At this time,
raise the Z-axis to the full up position.
2. Remove the cover panels from head stock area ("Head Stock Removal" section).
3. Remove the tool release piston assembly ("Tool Release Piston Assembly" section).
4. Press the POWER OFF button on the control panel and turn the main breaker off. If there is an external breaker box,
turn it off and lock it out.
5. Disconnect the air supply from the back panel of the machine.
6. Disconnect all of the electrical and pneumatic lines from the solenoid bracket on top of the spindle motor assembly.
Mark any connections that have not been previously labeled for reassembly.
7. Remove the two SHCS holding the cable carrier to the solenoid bracket and position the cable carrier so as to not
interfere with removal of the motor. It may be necessary to tie the cable carrier back to the Z-axis motor to keep it in
place.
8. If machine is equipped with Through the Spindle Coolant option, remove the pressure regulator and bracket from
the old transmission and install them on the new transmission.
9. Remove the four SHCS and carefully lift the spindle motor assembly off the spindle head. Take care to not damage
the drive pulley during removal.
NOTE: It is recommended that the HAAS Transmission Hoist be used in this operation (Refer to "Hoist Pre-Assembly",
later in this section, for assembly and setup).
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MANUAL
Figure 8-1 VF-0 with lifting eyeholes.
8.2 INSTALLATION (VF-0)
1. Carefully lower the motor assembly down to just above the spindle head casting, taking care not to damage the drive
pulley or pinch the drive belt.
2. Place the drive belt on the motor's drive pulley and lower the motor down onto the spindle head casting.
3. Insert and tighten down the four SHCS attaching the motor to the spindle head casting. Adjust the drive belt as noted
in "Belt Assembly" before tightening down completely.
4. Refer to the appropriate section and set the spindle orientation.
5. Check for proper orientation of the machine and be aware of any unusual noises or vibration that may occur because
of incorrect belt tension.
6. Reattach the cable carrier to the solenoid bracket and reconnect all electrical and fluid lines. Replace any leaking or
damaged lines at this time, if necessary.
NOTE: Ensure the orient ring has an adequate layer of grease around the circumference before starting operation.
8.3 HOIST PRE-ASSEMBLY
1. Attach the mast support to the support base, using the four 3/8-16 x 1¼" SHCS, four 3/8" flat washers, four split
washers, and the four 3/8-16 hex nuts. Ensure the bolts are securely tightened.
2. Attach the boom modification plates to the mast using the three ½-13 x 4½" HHB, three ½" split washers, three ½13 hex nuts, and the three spacers.
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Fig. 8-2 Support base/mast support assembly.
Fig. 8-3 Exploded view of boom modification plate components.
3. Assemble the boom assembly as follows:
A. Lubricate the components of the assembly:
1) Using a grease brush, apply grease to the through-hole and the side surface of the pulley wheel.
2) Wipe a thin coat of oil on the entire cable.
3) Lubricate all clevis pins with a thin layer of grease.
4) Oil all bearings on the winch and apply grease to the gear teeth.
B. Place the pulley wheel inside the cable guide and place this subassembly into the end of the
boom. Ensure the clevis pin through-hole is toward the top of the boom and the rounded end of
the cable guide is toward the outside. Slide the clevis pin through the hole and fasten with the
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1/8" x 1" cotter pin.
C. Attach the winch base to the boom with the two 3/8-16x1" SHCS, two 3/8" lock washers, and
the two 3/8" hex nuts. See owner's manual for mounting for left-or right-handed operation.
D. Feed the free end of the cable (without hook) between the pulley and cable guide and
through the inside of the boom.
VF-SERIES
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MANUAL
Fig. 8-4 Mounting cable guide and pulley wheel to boom.
E. Attach the cable to the winch as follows:
1) FOR LEFT-HAND OPERATION Pass the cable under the winch drum and through the hole in the drum flange.
Form a loop of cable and securely anchor it in place using the tie-down clasp, carriage
bolt, and hex nut. The cable must be underwound on the winch drum.
2) FOR RIGHT-HAND OPERATION Pass the cable between the frame rod and the countershaft of the winch, over the
winch drum, and through the hole in the drum flange. Form a loop of cable and
securely anchor it in place using the tie-down clasp, carriage bolt, and hex nut.
The cable must be overwound on the winch drum.
F. Ensure all hex nuts and cap nuts are securely tightened and all cotter pins are properly bent
to secure them in place. Make sure all pivots and rotation points are well-lubricated and refer to
the winch owner's manual for proper lubrication before operating.
4. Place the transmission lift fixture on top of the transmission, with the rod at each end in the two lifting eyeholes of
the transmission. Tighten the fixture onto the transmission by turning the handle at the end. NOTE: Do not overtighten.
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Fig. 8-5 View of transmission lift fixture.
8.4 TRANSMISSION REMOVAL
NOTE: This procedure is not for VF-O.
1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the transmission. At this time, raise
the Z-axis to the full up position.
2. Remove the cover panels from head stock area ("Head Covers Removal" section).
3. 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.
4. Remove the tool release piston assembly ("Tool Release Piston" section).
5. Remove the six SHCS holding the transmission to the head casting. Slide the transmission forward enough to
release the drive belt from the transmission and spindle pulleys.
6. Press the POWER OFF button on the control panel and turn the main breaker off. If there is an external breaker box,
turn it off and lock it up.
7. Disconnect all electrical lines and air lines from the transmission solenoid bracket. 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.
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Fig. 8-6 Solenoid bracket with all lines connected.
8. Remove the two SHCS holding the cable carrier to the solenoid bracket and position the cable carrier so as to not
interfere with the transmission removal. It may be necessary to tie the cable carrier back to the Z-axis motor to keep it
in place.
MANUAL
9. Remove the protective cardboard from the mill table and install the support base assembly on the table, using the
four SHCS, four ½" flat washers, and the four T-nuts.
CAUTION! Ensure the protective rubber pads on the bottom of the mounting base are in place and in good condition,
or damage to the mill table may result.
Fig. 8-7 Support base/mast support assembly location.
10. With the boom modification plate in place, insert the mast into the mast support. Using the two clevis pins, attach
the boom to the mast.
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Fig. 8-8 Mounting boom assembly to mast.
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11. Place the hoist directly over the transmission and attach the hook to the cradle's eye bolt.
12. Raise the transmission, ensuring the hoist is being lifted in the locking position, clearing the enclosures. Swing the
boom toward the front of the machine and lower onto the wood blocks.
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Fig. 8-9 Fully assembled hoist in position
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Fig. 8-10 Lifting position for VF-1 through 4.
13. For VF-1-4: Place the hoist hook in the bar's lifting eye and place the two hooks on either end of the bar into
diagonally opposite lifting holes in the motor shroud. Lift just enough to ensure the hooks are seated properly, then
carefully lift the motor and transmission assembly up enough to clear the VMC. Swing the boom toward the front of the
machine and lower onto the wood blocks.
8.5 TRANSMISSION INSTALLATION
1. If machine is equipped with Through the Spindle Coolant option, reinstall the pressure regulator, check valve
assembly, and bracket. Install two cable ties on the replacement transmission as follows:
Ø Place one cable tie around the limit switch cable.
Ø Place the second cable tie through the first one, forming a loop.
Ø Tighten the first cable tie. NOTE: The loop of the second cable tie must allow the drain line to slip through.
2. Place cradle under new transmission and lift just enough to put tension on the cables.
3. Ensure new transmission is seated securely and lift. Only lift high enough to clear the enclosure and to swing into
place.
4. Slowly swing boom around to center the cradle and transmission over the spindle head.
NOTE: Inspect the gearbox isolators to ensure the spacer is flush with the bushing on the underside of the housing.
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5. Lower the transmission carefully to just above the spindle head. Place the drive belt onto the transmission pulley.
6. Lower the transmission into the spindle head, taking care not to crush or bind the drive belt as you lower.
7. Insert and tighten down the six SHCS attaching the transmission to the spindle head. If these screws include
gearbox isolators, ensure the following:
Ø The fender washer is placed below the 3/8" black washer when screw is installed.
Ø The 3/8" fender washer is not touching the gearbox housing.
Adjust the drive belt tension as noted in "Belt Assembly" section before tightening screws down completely.
8. Reattach the cable carrier to the solenoid bracket and reconnect all electrical and fluid lines. Replace any leaking
lines at this time, if necessary.
NOTE: The hoist must be disassembled before removing from the mill table. Break down the hoist by removing the
boom assembly, then the mast. It will not be necessary to completely break down the hoist after the first assembly.
NOTE: On shot pin assemblies that do not have a hole through the shaft, ensure the positioning ring has an adequate
layer of grease around the circumference before starting operation. On those assemblies that do have a hole through
the shaft, do not grease the orient ring.
MANUAL
MECHANICAL SERVICE
9. AXIS MOTOR REMOVAL / INSTALLATION
PLEASE READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO REMOVE OR REPLACE THE MOTORS.
9.1 X-AXIS MOTOR REMOVAL -
1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
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Fig. 9-1 X-axis motor and components.
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2. Move the table to the far left position. Loosen the SHCS and remove the right way cover.
3. Move the table to the far right position. Loosen the SHCS and remove the left way cover.
4. Remove the side enclosure panels.
5. On 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. Turn the machine power OFF.
8. On the motor housing, loosen the four SHCS and remove the motor from the housing.
9. Disconnect all wiring from the motor.
INSTALLATION -
MANUAL
1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.
Fig. 9-2 Motor coupling components.
2. Reinstall and tighten down the four SHCS that hold the motor to the housing.
3. Visually inspect the flex plates to ensure they are parallel to the coupling halves and the slits in the coupling and
clamp ring are in alignment (See Fig. 9-2). Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of
blue Loctite® on the screw before inserting.)
4. Replace the cover plate and fasten with the four BHCS.
5. Move the table to the far right position. Replace the left way cover with the SHCS.
6. Move the table to the far left position. Replace the right way cover with the SHCS.
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7. Reinstall the side enclosures.
8. Check for backlash in the X-axis lead screw (Troubleshooting section) or noisy operation.
9.2 Y-AXIS MOTOR REMOVAL -
1. Turn the machine power ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. Move the table to the farthest forward position. Using a 5/32" hex wrench, remove the SHCS on the way cover at the
rear of the saddle.
3. Slide the way cover back against the machine. Remove the two roller brackets from the base. Pull the way cover
forward and off of the base.
4. If the bearings are to be serviced, move the table to the rear of its travel and remove the SHCS holding the front way
covers to the saddle. Slide the way cover to the forward position.
MANUAL
MECHANICAL SERVICE
REMOVING OILER AND AIR REGULATOR PANEL -
5. Turn the machine off and disconnect the compressed air.
6. Using a 3/8" open-end hex wrench, disconnect the oil line connecting the base to the lubrication system panel.
7. Using a 7/16" open-end hex wrench, disconnect the solenoid on the front of the panel. Disconnect the other two air
lines from the panel (quick-disconnect fittings) by hand.
8. Disconnect the three connections labeled 'limit switches' and remove the cords from the panel.
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Fig. 9-3 Y-axis motor and components.
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9. Disconnect the limit switch connection and the Y-axis connection at the side of the control panel.
10. While holding the lube/air panel assembly at the bottom edge, loosen the two SHCS and remove the panel assembly.
CAUTION! On machines with only two SHCS, remove one screw at a time. Replace the screw to hold the cabinet in
place before removing the other screw. Failure to do this will result in damage to the cabinet.
11. On the motor housing, remove the four and remove the cover plate.
12. Loosen the SHCS on the motor coupling at the lead screw.
13. On the motor housing, loosen the SHCS and remove the motor from the housing.
MANUAL
INSTALLATION -
1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.
2. Replace and tighten down the four SHCS that hold the motor to the housing.
3. Visually inspect the flex plates to ensure they are parallel to the coupling halves and the slits in the coupling and
clamp ring are in alignment. Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite®
on the screw before inserting.)
4. Replace the cover plate and fasten with the four BHCS.
5. Replace the lube system panel with the two SHCS that mount it.
6. Plug in the limit switch connection and Y-axis connection at the side of the control panel.
7. Reconnect the three connections labeled "limit switches" to the panel .
8. Reconnect the two air lines to the panel, and the solenoid to the front of the panel.
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9. Reconnect the oil line that connects the lube system panel to the base.
10. If the front way cover was removed, slide it back into position, and replace the SHCS that holds it to the saddle.
11. Move the table to the fully forward position. Replace the rear way cover.
12. Replace the two roller brackets onto the base.
13. Slide the way cover back into place, and attach to the saddle with the SHCS.
14. Check for backlash in the Y-axis lead screw (Troubleshooting section) or noisy operation.
9.3 Z-AXIS MOTOR REMOVAL -
ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH SHAFT STOP BLOCK BEFORE SERVICING ANY Z-AXIS COMPONENTS.
1. Turn the machine power ON. Zero return (ZERO RET) all axes and put the machine in HANDLE JOG mode.
MANUAL
MECHANICAL SERVICE
2. Loosen the six SHCS that attach the rear cover to the side covers, and remove from the spindle head.
NOTE: If machine is equipped with a hydraulic counterbalance, remove entire spindle head cover for VF-0/OE/1/2, VCE
500/550/700/750, or right side spindle head cover for VF-3/4, VCE 1000/1250.
3. If the bearings are to be serviced, remove the three SHCS attaching the Z-axis way cover to the spindle head and
slide the cover to the bottom position.
4. Lower the spindle head to its lowest position.
5. If the machine is equipped with a hydraulic counterbalance, install cylinder shaft stop PN 99-7502 (See Fig. 9-6).
HANDLE JOG Z-axis up until shaft stop blocks axis.
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6. Disconnect the electrical power.
7. On the motor housing, loosen the four BHCS and remove the cover plate.
MANUAL
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Fig. 9-5 Z-axis motor and components
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Fig. 9-6 Z-axis motor and components for machines equipped with hydraulic counterbalance.
8. Loosen the SHCS on the motor coupling at the lead screw.
9. On the motor housing, loosen the four SHCS and remove the motor from the housing.
10. Disconnect the Z-axis connection from the control panel.
INSTALLATION -
1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.
2. Replace and tighten down the four 5/16-18 x 1¼" SHCS that hold the motor to the housing.
3. Visually inspect the flex plates to ensure that they are parallel to the coupling halves, and that the slits in the coupling
and clamp ring are in alignment (See Fig. 10-2). Tighten the 10-32 x ½" SHCS on the motor coupling at the lead screw.
(Place a drop of blue Loctite® on the screw before inserting.)
4. Replace the cover plate and fasten with the four BHCS.
5. Reconnect electrical power.
6. Remove shaft stop, if necessary.
7. If the front way cover was removed, slide it back into position, and replace the 10-32x3/8" SHCS that holds it to the
saddle.
8. Move the table to the fully forward position. Replace the rear way cover.
9. Replace the two roller brackets onto the base.
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10. Slide the way cover back into place, and attach to the saddle with the 10-32x3/8" SHCS.
11. Check for backlash in Z-axis lead screw (Troubleshooting section), or noisy operation.
9.4 COUPLING REPLACEMENT
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 10-32 x ½" SHCS on the two coupling rings and remove the coupling.
3. For installation: Slide the new coupling onto the motor shaft until the coupling half is flush to the end of the shaft.
NOTE: Make sure that the collar split and coupling half split do not line up. Otherwise, the coupling will not be locked
tightly to the lead screw.
MANUAL
MECHANICAL SERVICE
4. Tighten the two 10-32 x ½" 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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10. LEAD SCREW REMOVAL AND INSTALLATION
Fig. 9-7 Motor coupling.
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PLEASE READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO REMOVE OR REPLACE THE LEAD SCREWS.
IMPORTANT NOTICE ! ! !
The new bearing sleeves will have two ¼" diameter holes on the face, the older bearing sleeves will not. This
procedure only applies to machines with new bearing sleeves. Contact your dealer for an older manual if your
machine is equipped with older bearing sleeves.
TOOLS REQUIRED:
SPANNER WRENCH 2" x 4" WOOD BLOCK (21"-23 ½" L)
PRE-LOAD FIXTURE BLUE LOCTITE
10.1 X-AXIS LEAD SCREW REMOVAL -
1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. Remove the side enclosures.
3. Loosen the SHCS and remove the chip tray from the mill table.
MANUAL
4. Move the table to the far right position. Loosen the SHCS and remove the left way cover.
5. Move the table to the far left position. Loosen the eleven SHCS and remove the right way cover.
6. Remove the hard stop from the bearing housing on the lead screw.
Fig. 10-1 X-axis lead screw and components.
7. Disconnect the oil line from the ball nut.
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Fig. 10-2 Lead screw assembly.
MANUAL
MECHANICAL SERVICE
8. Loosen the 10-32 x ½" SHCS and remove the clamp nut on the lead screw support bearing end.
9. Remove the axis motor in accordance with "X-Axis Motor Removal".
NOTE: The motor's electrical connections do not need to be removed for this operation. After removing motor from the
housing, set it to one side.
10. Loosen the 10-32 x ½" SHCS and remove the clamp nut on the lead screw in the motor housing.
11. Loosen the six ¼-20 x 1" SHCS and remove the bearing sleeve from the motor housing. Push on the mill table 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, OR
LEAD SCREW WILL RESULT.
12. Loosen the six SHCS and remove the lead screw from the nut housing by pushing on the lead screw at the motor
end.
INSTALLATION -
1. Center the mill table on the saddle.
2. 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.
3. Insert the lead screw through the nut housing and motor housing (See Fig. 10-3), taking care not to make contact
with the screw threads, causing possible damage.
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Fig. 10-3 Install lead screw from right side.
4. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bearings in the sleeve to
facilitate mounting on the lead screw.)
MANUAL
5. Insert the six ¼-20 x 1" SHCS, attaching the bearing sleeve to the motor housing. (Place a drop of blue Loctite® on
each of the SHCS before inserting.) Tighten down completely.
Fig. 10-4 Bearing sleeve mounting location.
6. Attach the clamp nut on the lead screw at the end opposite the motor housing. Screw on two or three turns but do
not tighten down.
7. Move mill table as far right as possible, leaving room to insert two of the six ¼-20 x 1" (or ¼-20 x ¾") SHCS, one on
either side, attaching the ball nut to the nut housing. (Place a drop of blue Loctite® on each of the SHCS before
inserting.) Tighten down completely.
CAUTION: DO NOT RUN MILL TABLE PADS PAST THE END OF THE LINEAR GUIDES! IF THIS OCCURS, CEASE ALL
OPERATIONS AND CONTACT THE MANUFACTURER AT ONCE.
8. Hand-turn the lead screw and move the mill table back to approximately center of the saddle. Install the remaining
four SHCS, attaching the ball nut to the nut housing. (Place a drop of blue Loctite® on each of the SHCS before
inserting.) Tighten down completely.
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9. Move mill table to the far left position. ("Far left" is when the limit switch bracket touches the x-axis limit switch.)
10. Loosen all of the SHCS attaching the bearing sleeve to the motor housing approximately ¼ turn and retighten
completely. DO NOT SKIP THIS STEP. It ensures the lead screw is installed and runs parallel and
flat to the linear guides and the saddle.
11. Screw the clamp nut on the end of the lead screw in the motor housing. Do not tighten down completely.
12. Tighten the lead screw against the clamp nut as follows:
Ø Tighten the clamp nut on the motor housing end of the lead screw to 15 foot-pounds.
Ø Tighten the SHCS on the clamp nut.
Ø Tighten the clamp nut on the support bearing end of the lead screw until it contacts the bearing,
then tighten further approximately 1/8 of a turn.
Ø Tighten the SHCS on the clamp nut.
13. Reinstall the motor.
MANUAL
MECHANICAL SERVICE
14. Reinstall the way covers and chip tray.
15. Check for backlash in the lead screw ("Accuracy/Backlash" section) or noisy operation.
10.2 Y-AXIS LEAD SCREW REMOVAL -
1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. Remove the motor in accordance with "Y-Axis Motor Removal".
3. Remove the hard stop from the lead screw support bearing end of the lead screw.
4. Loosen the 10-32 x ½" SHCS on the clamp nut at the bearing support end, then remove the clamp nut.
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Fig. 10-5 Y-axis lead screw and components
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5. Loosen the SHCS on the clamp nut at the motor end, then remove the clamp nut.
6. Loosen the six SHCS and remove the bearing sleeve from the motor housing. Push on the mill
table 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, OR LEAD SCREW WILL RESULT.
7. Disconnect the oil line at the ball nut.
8. Loosen and remove the six SHCS attaching the ball nut to the nut housing.
9. Hand-turn the lead screw toward the rear of the machine until the front end of the lead screw clears the
bearing by approximately six inches (6").
MANUAL
Fig. 10-6 Pull lead screw forward around bearing support,...
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...push back into the machine, then pull out forward.
10. Carefully pull the lead screw forward, to the right of the support bearing, under the front way cover until
the rear of the lead screw clears the nut housing. Shift the rear end of the lead screw to the right side of the
nut housing and move the lead screw to the rear of the machine until it clears the front way cover. Remove lead screw
from the machine.
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. Slide the motor end of the lead screw under the saddle, taking care not to damage the screw threads. Position the
lead screw to the right side of the nut housing and slide toward the rear of the machine as far as it will go.
3. Pull the lead screw forward until it is against the front way covers. Place the motor end of the lead screw through the
nut housing and push the lead screw toward the back of the machine until the ball nut is seated in the nut housing.
MANUAL
MECHANICAL SERVICE
4. Place the bearing sleeve in the motor housing. It may be necessary to align the bearings in the sleeve to facilitate
mounting on the lead screw.
5. Screw the clamp nut on the motor end of the lead screw two or three turns. Do not tighten.
6. Pull the lead screw through the lead screw support bearing and loosely install the clamp nut as on the opposite end.
NOTE: DO NOT SKIP STEPS 7-10. THESE STEPS ENSURE THE LEAD SCREW IS INSTALLED AND RUNS PARALLEL
AND FLAT TO THE LINEAR GUIDES AND THE SADDLE.
7. Install and tighten the six ¼-20 x 1" SHCS on the bearing sleeve. (Place a drop of blue Loctite® on each of the SHCS
before inserting.) Tighten down completely.
8. Hand-turn the lead screw until the table is as far forward as possible while still allowing room to install the SHCS on
the ball nut.
9. Install the two outer SHCS of the six ¼-20 x 1" (or ¾") SHCS that secure the ball nut to the nut housing. (Place a drop
of blue Loctite® on each of the SHCS before inserting.) Tighten down completely.
10. Loosen all of the SHCS on the bearing sleeve approximately ¼ turn, but do not remove.
11. Hand-turn the lead screw until it is at the rear of its travel. Retighten all six of the SHCS on the bearing sleeve.
12. Install and tighten down the four remaining ¼-20 x 1" (or ¾") SHCS that secure the ball nut to the nut housing.
(Place a drop of blue Loctite® on each of the SHCS before inserting.) Tighten down completely.
13. Reinstall the hard stop on the lead screw support bearing.
14. Tighten the lead screw against the clamp nut as follows:
Ø Tighten the clamp nut on the motor housing end of the lead screw to 15 foot-pounds.
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Ø Tighten the SHCS on the clamp nut.
Ø Tighten the clamp nut on the support bearing end of the lead screw until it contacts the bearing,
then tighten further approximately 1/8 of a turn.
Ø Tighten the SHCS on the clamp nut.
15. Reinstall the axis motor.
16. Check for backlash in the Y-axis lead screw (Troubleshooting section) or noisy operation.
10.3 Z-AXIS LEAD SCREW REMOVAL -
WARNING! ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH SHAFT STOP BLOCK. DO NOT MOVE THE SPINDLE
DURING LEAD SCREW SERVICE.
1. Remove the axis motor in accordance with "Z-Axis Motor Removal", making sure to follow all warnings included in
that procedure.
2. Remove the bearing sleeve in accordance with "Z-Axis Bearing Sleeve Removal".
MANUAL
3. Hand-turn the lead screw to move the screw up until the bottom end clears the support bearing by approximately six
inches (6").
4. Disconnect the oil line at the ball nut.
5. Loosen the six ¼-20 x 1" (or ¾") SHCS attaching the ball nut to the nut housing. Remove five of the screws.
6. Remove the last SHCS from the ball nut and lower the lead screw down and to the right of the support bearing, past
the Z-axis way cover. For the VF-6, remove the lead screw from top of column.
USE EXTREME CAUTION! DO NOT DAMAGE THE THREADS ON THE LEAD SCREW.
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Fig. 10-7 Z-axis lead screw and components.
INSTALLATION -
1. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt, burrs,
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grease, or other contaminants.
CAUTION: MATING SURFACES MUST BE CLEAN OR MISALIGNMENT MAY OCCUR, SERIOUSLY AFFECTING THE
PROPER OPERATION OF THE MACHINE.
2. Slide the lead screw up into the nut housing and gently lower it until it is resting in the support bearing.
MANUAL
Fig. 10-8 Reinstalling the lead screw.
3. Loosely screw the clamp nut onto the support bearing end of the lead screw.
4. Reinstall the bearing sleeve. (Place a drop of blue Loctite® on each of the SHCS before inserting.) Tighten down
completely.
5. Hand-turn the ball nut until it comes into contact with the nut housing mounting surface. If necessary, turn the
leadscrew to correctly position lube fitting of the ball nut.
6. Install and tighten down the two outer ¼-20 x 1" (or ¾") SHCS attaching the ball nut to the nut housing. (Place a
drop of blue Loctite® on each of the SHCS before inserting.) Tighten down completely.
7. Loosen, but do not remove, the six ¼-20 x 1" SHCS attaching the bearing sleeve to the motor housing.
8. Hand-turn the lead screw and remove the shaft stop, accessing it from the underside of the spindle head. Allow the
spindle head to move to the top of its travel.
9. Retighten the six ¼-20 x 1" SHCS attaching the bearing sleeve to the motor housing.
NOTE: DO NOT SKIP STEPS 7-10. THESE STEPS ENSURE THE LEAD SCREW IS INSTALLED AND RUNS
PARALLEL AND FLAT TO THE LINEAR GUIDES AND THE COLUMN.
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10. Loosely install the clamp nut on the motor housing end of the lead screw.
11. Install the remaining four ¼-20 x 1" (or ¾") SHCS attaching the ball nut to the nut housing. (Place a drop of blue
Loctite® on each of the SHCS before inserting.) Tighten down completely.
12. Reinstall the hard stop at the support bearing end of the lead screw.
13. Tighten the lead screw against the clamp nut as follows:
Ø Tighten the clamp nut on the motor housing end of the lead screw to 15 foot-pounds.
Ø Tighten the SHCS on the clamp nut.
Ø Tighten the clamp nut on the support bearing end of the lead screw until it contacts the bearing,
then tighten further approximately 1/8 of a turn.
Ø Tighten the SHCS on the clamp nut.
14. Reinstall cylinder shaft stop by hand-turning the lead screw.
15. Reinstall the axis motor in accordance with "Z-Axis Motor - Installation".
MANUAL
MECHANICAL SERVICE
16. Check for backlash in the Z-axis lead screw (Troubleshooting section) or noisy operation.
11. BEARING SLEEVE REMOVAL AND INSTALLATION
Please read this section in its entirety before attempting to remove or replace the bearing sleeve.
TOOLS REQUIRED:
SPANNER WRENCH WOOD BLOCK (16" L)
PRE-LOAD FIXTURE
11.1 X-AXIS BEARING SLEEVE REMOVAL -
1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
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Fig. 11-1 X-axis lead screw and components.
2. Loosen the SHCS and remove the chip tray from the mill table.
3. Remove the axis motor in accordance with "X-Axis Motor Removal".
NOTE: The motor's electrical connections do not need to be removed for this operation. After removing from the motor
housing, set it to one side.
4. Loosen the 10-32 x ½" SHCS and remove the clamp nut on the lead screw in the motor housing.
5. Loosen the six ¼-20 x 1" SHCS and remove the bearing sleeve from the motor housing. Push on the mill table 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, 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.
2. Move mill table to the far right.
3. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bearings in the sleeve to
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Fig 11-2 Lead screw assembly
MANUAL
MECHANICAL SERVICE
4. Insert the six ¼-20 x 1" SHCS, attaching the bearing sleeve to the motor housing. (Place a drop of blue Loctite® on
each of the SHCS before inserting.) Tighten down completely.
5. Start the clamp nuts on both ends of the lead screw. Do not tighten.
6. Hand-turn the mill table to the far left position.
7. Loosen the six ¼-20 x 1" SHCS attaching the bearing sleeve to the motor housing and retighten completely. DO NOT
SKIP THIS STEP. It ensures the lead screw is installed and runs parallel and flat to the linear guides and the saddle.
NOTE: For the angular contact design bearing, no pre-load is necessary. Do the following:
Ø Tighten the clamp nut on the motor housing to 15 foot-pounds.
Ø Tighten the SHCS on the clamp nut.
Ø Tighten the clamp nut on the support bearing end of the lead screw until it
contacts the bearing, then tighten further approximately 1/8 of a turn.
Ø Tighten the SHCS on the clamp nut.
9. Reinstall the axis motor in accordance with "X-Axis Motor Removal".
10. Reinstall the way covers and chip tray.
11. Check for backlash in the X-axis lead screw (Troubleshooting section) or noisy operation.
11.2 Y-AXIS BEARING SLEEVE REMOVAL -
1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. Remove the axis motor in accordance with "Y-Axis Motor Removal".
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3. Remove the hard stop from the bearing housing on the lead screw.
4. Loosen the 10-32 x ½" SHCS and remove the clamp nut from the bearing support end of the lead screw.
5. Loosen the six ¼-20 x 1" SHCS and remove the bearing sleeve from the motor housing. Push on the mill table or the
opposite end of the lead screw to loosen.
CAUTION: DO NOT PRY THE BEARING SLEEVE AWAY FROM THE MOTOR HOUSING. DAMAGE TO THE SLEEVE,
BEARING, OR THE 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.
MANUAL
2. Slide the bearing sleeve into the motor housing and start all six ¼-20 x 1" SHCS into the motor housing. (Place a
drop of blue Loctite® on each of the SHCS before inserting.)
3. Move the table to the rear of its travel.
4. Tighten the six ¼-20 x 1" SHCS that attach the bearing sleeve to the motor housing.
5. Loosely install the clamp nut on the lead screw at the motor housing end.
NOTE: For the angular contact design bearing, no pre-load is necessary (follow the procedure in "X-axis bearing sleeve"
section).
6. Reinstall the axis motor.
7. Check for backlash in the Y-axis lead screw (Troubleshooting section) or noisy operation.
11.3 Z-AXIS BEARING SLEEVE REMOVAL -
WARNING! ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH SHAFT SROP BLOCK BEFORE SERVICING ANY Z-AXIS
COMPONENTS.
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1. Turn the machine power ON. Zero return (ZERO RET) all axes and put the machine in HANDLE JOG mode.
2. Loosen the six SHCS that attach the rear cover to the side covers, and remove from the spindle head.
NOTE: If machine is equipped with a hydraulic counterbalance, remove entire spindle head cover for VF-0/OE/1/2, VCE
500/550/700/750, or right side spindle head cover for VF-3/4, VCE 1000/1250.
3. If the bearings are to be serviced, remove the three SHCS attaching the Z-axis way cover to the spindle head and
slide the cover to the bottom position.
4. Remove the hard stop from the bearing housing on the lead screw.
5. Loosen the 10-32 x ½" SHCS and remove the clamp nut from the bearing support end of the lead screw.
6. Raise the spindle head until the bottom edge is approximately sixteen inches (16") above the mill table.
7. Install cylinder shaft stop PN 99-7562. HANDLE JOG Z-axis up until shaft stop block axis.
8. Place the wood block beneath the spindle head and lower the spindle head until it is resting on the block.
MANUAL
MECHANICAL SERVICE
9. Perform Steps 6-10 of "Z-Axis Motor Removal".
NOTE: The motor's electrical connections do not need to be removed for this operation. After removing from motor
housing, set it to one side.
10. Loosen the 10-32 x ½" SHCS and remove the clamp nut from the motor housing end of the lead screw.
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Fig. 11-3 Z-axis bearing sleeve.
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11. Loosen the six ¼-20 x 1" SHCS and remove the bearing sleeve from the motor housing. Hand-turn the lead screw
in an upward direction to push the bearing sleeve out of the motor housing.
CAUTION! DO NOT PRY THE BEARING SLEEVE AWAY FROM THE MOTOR HOUSING. DAMAGE TO THE
SLEEVE, BEARING, OR THE 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.
2. Slide the bearing sleeve into the motor housing and start all six ¼-20 x 1" SHCS into the motor housing. (Place a
drop of blue Loctite® on each of the SHCS before inserting.)
3. Tighten the six ¼-20 x 1" SHCS that attach the bearing sleeve to the motor housing.
MANUAL
4. Loosely install the clamp nut on the lead screw at the motor housing end.
5. Reinstall the hard stop on the bearing housing end of the lead screw.
NOTE: For the angular contact design bearing, no pre-load is necessary. Follow the procedures as outlined in "X-Axis
Bearing Sleeve" section.
6. Reinstall the axis motor in accordance with "Z-Axis Motor-Installation".
7. Remove shaft stop.
8. Check for backlash in the Z-axis lead screw (Troubleshooting section) or noisy operation.
12. AUTOMATIC TOOL CHANGER
TOOLS REQUIRED:
½" DRIVE RATCHET HYDRAULIC JACK
10" EXTENSION (½" DRIVE) DIAL CALIPER
1-2-3 BLOCK
CARDBOARD
LEVEL, STARRET #98
TWO-JAW PULLER
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12.1 CARRIAGE CASTING REPLACEMENT
NOTE: If the carriage casting is damaged in a crash, it must be replaced. Look specifically for broken bosses where the
roller bolts mount to the casting. If the carriage casting is broken off of the holding plate but not damaged, only the
roller bolts need be replaced.
1. Turn the machine power off.
2. Remove the left side enclosure panel of the machine.
3. Disconnect all cables from the carriage casting and remove any bolts holding the ATC to the holding plate.
NOTE: If the carriage casting has been damaged, replacement is necessary; move the ATC to a bench and remove all
components from the damaged carriage casting and place in the new casting. Skip to Step 6 for replacement.
4. Place a piece of cardboard over the machine's table, and carefully lower the carriage casting (with carousel) onto
the machine table.
5. If the carriage casting has crashed and/or has been broken off of the holding plate, it should be inspected for
damage before going any further.
MANUAL
MECHANICAL SERVICE
6. Remove any damaged roller bolts from the carriage casting. Replace with new bolts.
7. With a lifting device, carefully lift the ATC assembly up and onto the holding plate.
NOTE: Ensure the cam follower on the slip clutch engages the slot on the carriage casting.
8. With the ATC assembly securely supported, install the lower roller bolts and adjust in accordance with "Roller Bolt
Replacement".
9. Repair or replace any cables damaged and adjust the ATC. Align the ATC assembly in accordance with the
following sections, and set Parameter 64 in accordance with "Spindle Motor and Transmission" section.
12.2 ROLLER BOLT REPLACEMENT
1. Remove the shuttle motor cover from the back of the machine (VF-0, VF-1, VF-2).
2. Place a support under the center of the carousel.
3. Loosen the eccentric locks on the bottom roller bolts.
CAUTION! Ensure the ATC is securely supported, otherwise it may fall when an upper roller bolt is removed.
4. Carefully remove the damaged roller bolt from the ATC shuttle and replace with a new bolt.
NOTE: REPLACE ONLY ONE ROLLER BOLT AT A TIME. Carefully inspect the v-groove rollers for roughness or damage,
and replace if necessary.
5. Tighten the eccentric locks on the bottom rollers until there is no play between the rollers and the V-guide on the ATC
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holding plate.
6. Set the tool change offset (Parameter 64) in accordance with "Spindle Orientation".
7. Verify the ATC alignment in accordance with the following section.
8. Reinstall the shuttle motor cover (VF-0, VF-1, VF-2).
12.3 AUTOMATIC TOOL CHANGER (ATC) ALIGNMENT
1. Verify that the spindle orientation is correct (Refer to appropriate section).
2. Command an automatic tool change, and press EMERGENCY STOP when the shuttle is in the full in position.
3. Verify that the spindle dog lines up to the alignment key in the ATC, in the Y plane.
NOTE: If the spindle dog and alignment key do not line up, loosen the four HHB that hold the ATC holding arm to the
column.
MANUAL
Fig. 12-1 Underside showing centering measurements.
4. Move the entire tool changer until the tool alignment key lines up with the spindle dog. Tighten the four HHB.
NOTE: Parameter 64 must be checked, and adjusted if necessary, when the ATC is aligned.
5. Make at least 50 tool changes after the alignment is complete. Verify that the tools are being picked up squarely.
12.4 SHUTTLE STROKE ADJUSTMENT -
6. Move the ATC away from the spindle and loosen the four HHBs in the ATC holding arm in the X-axis plane.
7. Push the cam follower to its full upward stroke, then push the entire ATC assembly in by pushing on the tool changer
holding plate until ATC is fully engaged on the tool holder.
8. Ensure the extractor is making full contact on the tool flange.
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Fig. 12-2 Automatic Tool Changer - Mechanical Assembly (Side View)
12.5 EXTRACTOR FORK REPLACEMENT
NOTE: Extractor forks that do not hold the tool holders firmly, or forks that are bent, must be replaced. Damage to the
ATC will result if not replaced.
1. With no tool holders in the spindle or in the ATC, command "ATC FWD" until the extractor fork needing replacement
is facing the spindle.
2. Command "ATC FWD" again, but press the EMERGENCY STOP after the spindle head lifts up off the carousel
NOTE: At this point, the shuttle should be in and the spindle should be about 4½" above the carousel.
3. Loosen the SHCS that attach the damaged extractor fork to the ATC carousel.
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