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VMC 96-8100
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haas VMC 96-8100 Service Manual

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Haas Technical Publications
Manual_Archive_Cover_Page Rev A
any other party automatically voids the factory warranty.
June 6, 2013
HAAS SERVICE AND OPERATOR MANUAL ARCHIVE
VMC Service Manual 96-8100 English December 15 1994
• This content is for illustrative purposes.
• Historic machine Service Manuals are posted here to provide information for Haas machine owners.
• Publications are intended for use only with machines built at the time of original publication.
• As machine designs change the content of these publications can become obsolete.
• Only authorized personnel with the proper training and certication should do many repair procedures.
WARNING: Some mechanical and electrical service procedures can be
extremely dangerous or life-threatening. Know your skill level and abilities.
All information herein is provided as a courtesy for Haas machine owners for reference and illustrative purposes only. Haas Automation cannot be held responsible for repairs you perform. Only those services and repairs that are provided by authorized Haas Factory Outlet distributors are guaranteed.
Only an authorized Haas Factory Outlet distributor should service or repair a Haas machine that is protected by the original factory warranty. Servicing by
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Troubleshooting
SERVICE MANUAL
SERVICE TROUBLE
TROUBLESHOOTING
This section is intended for use in determining the solution to a known problem. Solutions given are intended to give the individual servicing the CNC a pattern to follow in, first, determining the problems source and, second, solving the problem.
The troubleshooting tips are organized in this section according to the area of the CNC that may be giving sign of a problem. (Ex.: Out-of round circles in drilling will be found under the heading General Machine Operation - Accuracy).
If the problem you are experiencing cannot be found under the heading you expect, please try several other possible headings. If the problem is still not found, contact Haas Automation for further details.
BEFORE YOU BEGIN:
l USE COMMON SENSE
Many problems are easily overcome by correctly evaluating the situation. All machine opera tions are composed of a program, tools, and tooling. You must look at all three before blaming one as the fault area. If a bored hole is chattering because of an overextended boring bar, dont expect the machine to correct the fault. Dont suspect machine accuracy if the vise bends the part. Dont claim hole mis-positioning if you dont first center-drill the hole.
l FIND THE PROBLEM FIRST
Many mechanics tear into things before they understand the problem, hoping that it will appear as they go. We know this from the fact that more than half of all warranty returned parts are in good working order. If the spindle doesnt turn, remember that the spindle is connected to the gear box, which is connected to the spindle motor, which is driven by the spindle drive, which is connected to the I/O BOARD, which is driven by the computer. The moral here is dont replace the spindle drive if the belt is broken. Find the problem first; dont just replace the easiest part to get to.
l DONT TINKER WITH THE MACHINE
There are hundreds of parameters, wires, switches, etc., that you can change in this machine. Dont start randomly changing parts and parameters. Remember, there is a good chance that if you change something, you will incorrectly install it or break something else in the process. Consider for a moment changing the processors board. First, you have to download all param eters, remove a dozen connectors, replace the board, reload and reconnect, and if you make one mistake or bend one tiny pin it WONT WORK. You always need to consider the risk of accidentally damaging the machine anytime you work on it. It is cheap insurance to double­check a suspect part before physically changing it. The less work you do on the machine the better.
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SERVICE TROUBLE
SERVICE MANUAL
G
eneral Machine Operation

1. GENERAL MACHINE OPERATION

1.1 MACHINE NOT RUNNING

´ Machine cannot be powered on.
l Check input voltage to machine (Section 2,Electrical Service).
l Check main circuit breaker at top right of electrical cabinet; switch must be at the on position.
l Check overvoltage fuses (Section 3.1,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 (Section 4.3, ElectricalService).
l Replace POWER PCB (Section 4.4 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 (Section 4.3, Electrical Service).
l Check Parameter 57 for Power Off at E-STOP.
l Replace MOTIF PCB (Section 4.1, 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 (Section 5.1, Electrical Service).
´ Any LED on Microprocessor PCB goes out (except HALT).
l Replace Microprocessor PCB (Section 4.1, Electrical Service).
l Replace VIDEO PCB (Section 4.1, ElectricalService).
l Replace MOTIF PCB (Section 4.1, 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 (Section 5.5, Electrical Service).
l Replace KBIF PCB (Section 4.6, Electrical Service).
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Vibration

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 be transferred readily. Vibrations also need to be distinguished from noise such as a bad bearing. We will assume that vibrations would be something that could be felt by putting your hand on the spindle covers. One crude method of mea­surement would be to take an indicator on a magnetic base extended 10 inches between the table and spindle housing and observe the reading of the indicator. A reading of more than .001 would indicate excessive vibration. The two common sources of noise are the spindle and axis drives. Most com­plaints about vibration, accuracy, and finish can be attributed to incorrect machining practices such as poor quality or damaged tooling, incorrect speeds or feeds, or poor fixturing. Before concluding that the machine is not working properly, ensure that good machining practices are being observed. These symptoms will not occur individually (Ex. A machine with backlash may vibrate heavily, yielding a bad finish.). Put all of the symptoms together to arrive at an accurate picture of the problem.
´ Machine vibrates while spindle is on and is not cutting. Sometimes only at
specific RPM.
l If the spindle alone causes vibration of the machine this is usually caused by the belt/pulley
drive system. This occurs because a pulley is either out of balance, misaligned, or belt tension is incorrect. It is extremely important that when servicing the spindle transmission that pulleys are checked for runout. Balance is almost impossible to check except by trial and error. This method can be accomplished by putting additional washers under one of the allen bolts of the locking collar and observing the effect. By moving from bolt to bolt you should see better or worse results and take action accordingly. Vibrations at different speeds are usually caused by all of the above except that harmonics are in play. If the problem is severe and cannot simply be corrected, you may have to consider replacing the gearbox and spindle with factory­balanced units.
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SERVICE TROUBLE
´ Machine vibrates while jogging the axis with the hand wheel.
l The HAAS control uses very high gain accelerations curves. This vibration as you jog is simply
the servos quickly trying to follow the handle divisions. If this is a problem, try using a smaller division on the handle. You will notice the vibration more at individual clicks than when you are turning the handle faster. This is normal.
´ The machine vibrates excessively in a cut.
l This is a tough one to call because machining practices come into play. Generally speaking, the
least rigid element of a cut is the tool because it is the smallest part. Any cutter will vibrate if pushed beyond its tensile strength. In order to eliminate the machine as the source of the problem, you need to check the spindle and the backlash of the axes as described in the following sections. Once machining practices have been eliminated as the source of vibration, observe the machine in both operation and cutting air. Move the axes (individually) without the spindle turning and then turn the spindle without moving the axes. Isolate whether the vibration comes from the headstock or from an axis. Isolate the source of vibration per Sec tions 2.2, 3.2, and Section 6.
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1.3 ACCURACY

Before you complain of an accuracy problem, please make sure you follow these simple dos and donts.
l Dont ever use a wiggler test indicator for linear dimensions. They measure in an arc and have
sine/cosine errors over larger distances.
l Dont use magnetic bases as accurate test stops. The high accel/decel of the axis can cause
them to move.
l Dont attach test points to the sheet metal of the spindle head or table.
l Dont 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.
Accuracy
´ Machine will not interpolate a round hole.
l Check the levelness of the machine (See the Installation Manual).
l Check for backlash (Section 3.3).
´ 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 (Section 5.3, Mechanical Service).
´ Bored holes are out of round, or you bore a hole at a given X/Y position and then
check at the same location using a test indicator and it indicates you are out of position.
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 (Section 3.3).
l Check the squareness of the X axis to the Y axis.
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Finish
´ 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 (Section 5.3, Mechanical Service).
l Cutter diameter too large for depth of cut.
´ Boring depth inaccurate (VF-6)
Insufficient counterbalance pressure due to:
l Hose corrupted.
l regulator bad.
l check valve bad.
l air cylinder bad.
l bound cylinder
l surge tank leak

1.4 FINISH

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SERVICE TROUBLE
´ Machining yields a poor finish.
l Check for backlash (Section 3.3).
l Check the condition of the tooling and the spindle (Section 2).
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Spindle

2. SPINDLE

2.1 NOT TURNING

´ Spindle not turning.
l If there are any alarms, see Section 6.
l Check that the spindle turns freely when machine is off.
l If motor turns but spindle does not, see Sections 3 and 9, Mechanical Service.
l Command spindle to turn at 1800 RPM and check spindle drive display. If display blinks bb,
check spindle orientation switch (Section 7, Mechanical Service). If spindle drive does not light the RUN LED, check forward/reverse commands from IOPCB (Section 4.3, Electrical Service).
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 (Section 4.1, Electrical Service).
l If spindle is still not turning, replace spindle drive (Section 5, Mechanical 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 (Section 3, Mechanical Service).
l Disconnect the drive belt. If the spindle will not turn, it is seized and must be replaced (Section
5, Mechanical Service).
NOTE: Before using the replacement spindle, the cause of the previous failure must be deter
mined.

2.2 NOISE

Most noises attributed to the spindle actually lie in the motor/gearbox or drive belt of the ma chine. Isolate the sources of noise as follows:
´ Excessive noise coming from the spindle head area.
On VF-1, VF-2, and VF-3 models, first determine if the noise is related to the RPM of the motor or the
RPM of the spindle. For example: If the noise appears at 2000 RPM in high gear, listen for a similar noise at 500 RPM in low gear. If the same noise persists, the problem lies with the gearbox. If the noise disappears, the problem could be either the gearbox or the spindle, and further testing is necessary.
l Check the alignment of the pulleys to the belt. Correct as necessary (Sections 3 and 4,
Mechanical Service).
l Remove the head covers and check the machines drive belt tension (Section 3.3, Mechanical
Service).
ØIf the noise persists, turn the drive belt over on the pulleys. If the noise is significantly different, the belt is at fault. Replace the belt (Section 3, Mechanical Service). ØIf 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 (1-2 cc every two hours) in a
an air mist-lubricated spindle.
ØIf the spindle is not getting lubrication, correct the problem per the lube and air dia gram at the back of this manual and replace the spindle (Section 5,Mechanical Service). ØIf the spindle is getting lubrication, replace the spindle (Section 5,Mechanical Service).
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Spindle

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, do the following:
l Run the spindle at 300 RPM for at least two (2) hours.
l Increase the spindle speed to 1000 RPM for 20 minutes.
l Increase the spindle speed to 3000 RPM for 20 minutes.
l Increase the spindle speed to 7000 RPM for 20 minutes.
l Stop the spindle and allow to cool to room temperature.
l Turn the spindle on to 7000 RPM and monitor the temperature inside the spindle taper at 15-
minute intervals until the temperature drops off, then stabilizes. This will take about two (2)hours.
l Temperatures of about 140
If the spindle fails this test, check the following:
l Check for correct amount of lubrication (1-2 cc every two hours).
o
are possible at the end of this test.
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SERVICE TROUBLE
NOTE: Over lubrication is a common source of overheating. Check the oil flow carefully.
l Check the drive belt tension (Section 3, Mechanical Service). Too-tight belts will cause heating
of the top bearing in the spindle housing.
l Ensure that the correct oil is being used (Lubrication Chart, page 131).
Spindle Motor Overheat Sense Switch
There is a normally closed thermal switch in the spindle motor. Should the temperature reach 210 F the switch will trigger an alarm- Spindle Drive Fault.
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SERVICE MANUAL

2.4 STALLING/LOW TORQUE

Generally, complaints of stalling or low torque relate to incorrect tooling or machining practices. A spindle that is tending to seize will yield a poor finish machining, run very hot and very loud. Investi­gate machining problems before concluding the problem exists with the spindle or spindle drive.
It is important to consider what horsepower and torque is available in various speed ranges of the spindle. If your machine is a VF-1 or VF-2 (with a transmission), the following horsepower and torque are available in low gear:
SPEED (RPM) TORQUE (ft-lb) HORSEPOWER
0-100 45-90 less than 2
100-500 90 3 to 7.5
500-1250 90-35 7.5
1250-1840 35-25 7.5 to 5
If your machine is a VF-0 (no transmission) or a VF-1 or VF-2 and you are in high gear, the following are available:
Spindle
SPEED (RPM) TORQUE (ft-lb) HORSEPOWER
0-400 11-22 less than 2
400-2000 22 3 to 7.5
2000-5000 22-9 7.5
5000-7500 9-6 7.5 to 5
If your machine is a VF-3, the following horsepower and torque are available in low gear:
SPEED (RPM) TORQUE (ft-lb) HORSEPOWER
0-125 60-120 less than 3
125-625 120 4 to 10
625-1550 120-45 10
1550-1840 45-32 10 to 7
If your machine is a VF-3 and you are in high gear, the following are available:
SPEED (RPM) TORQUE (ft-lb) HORSEPOWER
0-600 15-30 less than 3
600-2500 30 4 to 10
2500-6250 30-11 10
6250-7500 11-9 10 to 7
If you still have spindle torque problems and there is no mechanical cause such as binding or friction in the transmission or spindle, the motor or spindle drive are the cause. The first choice for replacement is the spindle drive. If there is still a problem, the entire motor/transmission assembly must be replaced.
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Spindle

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. See Section 28 for adjustment.
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

SERVICE MANUAL
SERVICE TROUBLE
´ Spindle loses correct orientation.
l Check alarm history, looking for spindle overload and axis overcurrent alarms. These alarms
indicate the machine is not being properly operated.
l Check the orientation ring for tightness (Section 7, Mechanical Service). Ensure the shaft on
which the ring mounts is free of grease.
l Check the orientation ring for cracks near the bolt holes or near the balancing holes.
> If there are cracks, replace the ring (Section 7, Mechanical Service). > If there are no cracks, remove the drive belt (Section 3, Mechanical Service) and verify that the pulley on the transmission output shaft is tight. On most machines, there is no key on the transmission pulley.
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.

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), or after heavy milling. If sticking only occurs during these situations, no service is necessary.
l Check the condition of the customers tooling, verifying the taper on the tooling is ground and
not turned. Look for damage to the taper caused by chips in the taper or rough handling. If the tooling is suspected, try to duplicate the symptoms with different tooling.
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
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SERVICE TROUBLE
crashing. See Section 5, Mechanical Service, 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 Section 5, Mechanical Service, for spindle cartridge replacement.
l Ensure the spindle is not running too hot (Section 2.3).
SERVICE MANUAL
Servos / Leadscrews

3. SERVO MOTORS / LEADSCREWS

There is very little that a user might do to repair a servo motor. Problems with servo motors may include open-circuited motor, shorted winding of motor, motor shorted to case, water (coolant) in motor, or overheat damage to motor. None of these can be fixed by the user so the motor must be replaced. All of the above problems would generate alarms identifying one of the servo motors as having failed. These alarms are 103-106 (following error too large), 108-111 (servo overload), 135-138 (overheat), 139-142 (Z channel fault), 153-156 (Z channel missing), and 161-164 (overcurrent).
Attached to each DC servo motor, there is an incremental encoder that is 2000 lines per revolution. These encoders also supply a Z channel pulse once per revolution. The encoders and Z channel are continuously monitored to ensure the number of pulses matches for each revolution of the motor. If the encoders become contaminated, these pulse counts will be wrong and an alarm will be generated. This ensures that the data from the encoders is reliable. There can never be a loss of servo position due to accumulated encoder errors. The alarms generated will indicate that either the Z pulse occurred and the encoder pulse was wrong or, after one and one half motor revolutions, the Z pulse did not occur.
Encoders faults can be caused by contamination of the encoder or by a wiring problem. If the encoder is contaminated, it must be replaced. Wiring problems may be a broken wire, shorted wire, or missing shield. All wires to the encoder are enclosed in their own shielded cable. In addition, all power wires to the motor are enclosed in a separately shielded cable. Failure of either of these shields may cause noise in the encoder circuits and result in the encoder fault alarms.
Never connect or disconnect the servo motor cables with the control powered as this will cause an apparent encoder fault.
Servo Characteristics
This machine is not capable of instantly changing speed. That is, it takes some non-zero time to accelerate and decelerate. Acceleration and deceleration in this machine have both a constant accel/ decel mode and an exponential mode. Constant acceleration is used at the beginning of a rapid move and at the end of any move whose speed exceeds the exponential accel/decel time constant.
Constant acceleration is a type of motion when the amount of speed change over time is constant. This constant is set by Parameters 7, 21, 35, and 49. It has units of encoder increments per second per second.
Exponential acceleration and deceleration is a type of motion where the speed is proportional to the
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Servos / Leadscrews
distance remaining in a programmed travel. The exponential accel/decel time constant is set by Para meters 113, 114, 115, and 116. It has units of 0.0001 seconds. The speed limit at which exponential accel/decel is not available is defined by the relationship between Parameters 7 and 113 (for the X­axis). Thus if Parameter 7 is 1200000 steps/sec/sec and Parameter 113 is 750 (0.075 seconds); the maximum velocity for accurate interpolation should be:
1200000 x 0.075 = 90000 steps/second
For a 2000 line encoder and 6 mm screw, this would be:
60 x 90000 / 33867 = 159 inches/minute
In the normal feed cutting mode, with G64 active, giving continuous cutter motion, deceleration of the axes in motion begins at some distance away from the end point. If look-ahead has provided another motion, the acceleration for that motion will begin at the same instant. This means that two motions, at right angles to each other, will not produce a perfectly square corner. The corner will be rounded. It also means that if the two motions are parallel or nearly parallel, there will be a smooth transition from one stroke to the next.
Rapid moves have a slightly different operation when continuous cutter mode is active. Accelera­tion for the next motion is started when the axes being moved all fall within the In Position Limit Pa­rameters 101, 102, 103, and 104. These parameters have units of encoder steps. Rapid moves will also decelerate at the constant accel/decel limit until the speed drops below that for exponential accel/ decel (see example above giving 159 inches per minute). Parameter 57 can be used to override this.
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To prevent the rounding of corners, you can specify exact stop either with G09 (non-modal) or with G61 (modal). When either of these is active in a motion, all of the axes are brought to an exact stop, at zero speed, before the next motion is started.
The tool path in a circular move (G02 or G03) is not changed by the exponential acceleration/ deceleration so there is no error introduced in the radius of the cut unless the speed exceeds that for exponential accel/decel (see example above giving 159 inches per minute).
The servo motor encoders are differential line drivers. This means that the A, B, and Z signals are transmitted to the control as signal pairs. A cable test is performed on these signals to ensure the differential pair are always present.
Overheat Sense Switches
Each servo motor contains a normally-open overtemperature sense thermostat. When the motor case temperature exceeds 150° F, an alarm will be generated and operation of the machine will stop. This alarm should not occur under any normal operating circumstances and usually indicates that there is serious problem with the motor or drive circuit. After September 1990, the overheat sensor was changed to normally closed. This change is specified in the parameters.
Overcurrent Sensor
Each servo motor drive circuit contains a current limit setting and an overcurrent sense circuit. When an overcurrent condition persists for more than 0.01 second, an alarm will be generated and operation of the machine will stop. This current limit is presently set at 20 amps.
Ground Fault Detector
This control has a ground fault sense circuit added to the servo drive power supply. This circuit will
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detect a short to ground on any of the servo motor power leads or in the internal 115V AC power. A ground fault can be caused by arcing brushes in the servo motors and will shut off all servo power.

3.1 NOT OPERATING

All problems that are caused by servo motor failures should also register an alarm. Check the alarm history to determine the problems cause before any action is taken.
´ Servo motor is not functioning.
l Check the power cable from 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 (Section 10, Mechanical Service).
l Open circuit in motor (Alarms 139-142, 153-156, 182-185). Replace motor assembly (Section
10 , Mechanical Service).
l Motor has overheated, resulting in damage to the interior components (Alarms 135-138, 176).
Replace motor assembly (Section 10, Mechanical Service).
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 (Section 10, Mechanical Service).
l Motor has overheated; no damage to the interior components. OVERHEAT alarm has been
triggered. After thorough check of motor (DO NOT DISASSEMBLE!), take necessary steps to eliminate the problem and alarm to resume operation. If motor is still inoperable, replace motor assembly (Section 10, Mechanical Service).
l Check for broken or loose coupling between the servo motor and the lead screw. Replace or
repair the coupling (Section 10.4, Mechanical Service)
l Check for a broken lead screw. If cracked or broken, replace (Section 10, Mechanical Service).
Servos / Leadscrews
NOTE: If a lead screw fails, it is most often due to a failed bearing sleeve. When replacing the lead
screw in an older machine, always replace the bearing sleeve with the current angular contact bearing sleeve (Section 12, Mechanical Service).

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 reliable. Verify that customer complaints are not due to tooling, programming, or fixturing problems.
´ Servo motor noise.
l Disconnect the servo motor from the lead screw and rotate by hand. If the noise persists,
replace the motor assembly (Section 10, Mechanical Service).
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. EN
SURE NOISE IS NOT COMING FROM THE BRUSHES. If bearings are making a consistently loud sound, replace the bearing sleeve (Section 12, Mechanical Service).
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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,
pages 129 & 130). Look for a plugged metering valve.
l Check for damage to the bearing sleeve.
l Check the pre-load on old-style bearing sleeves (Section 12, Mechanical Service).
NOTE: The current angular contact design sleeve has a fixed pre-load; it cannot be adjusted.
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 (Section 12, Mechanical Service). 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 (Section 11, Mechani
cal Service). When replacing the lead screw in an older machine, always replace the bearing sleeve with the current angular contact design bearing sleeve (Section 12, Mechanical Service).
l Check the lead screw for misalignment. If incorrect, align as outlined in Section 11, Mechanical
Service.
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SERVICE TROUBLE
Misalignment in the lead screw itself will tend to cause the lead screw to tighten up and make excessive noise at both ends of the travel. The ballnut may get hot. Misalignment radially at the yoke where the lead screw ball nut mounts is indicated by heating up of the ball nut on the lead screw, and noise and tightness throughout the travel of the lead screw. Misalignment at the yoke where the ball nut mounts is indicated by noise and tightness at both ends of the travel of the lead screw. The ball nut may get hot.
´ Noise in Z - Motion (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

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 (Sections 10, 11, Mechanical Service).
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l Check for backlash in the lead screw as outlined below:
SERVICE MANUAL
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.
Servos / Leadscrews
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 fol lows: - 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.
An alternate method for checking backlash is to place the dial indicator as shown in Fig. 3-1 and
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Servos / Leadscrews
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.
SERVICE MANUAL
SERVICE TROUBLE
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 fol lows: - 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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SERVICE MANUAL
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.
Servos / Leadscrews
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
Section 11, 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 Section 11, 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 Section 10.4, 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. See Section 10.4, Mechani cal Service.)
l Loose SHCS attaching the bearing sleeve to the motor housing. Tighten as described in Sec
tion12, Mechanical Service.
l Defective thrust bearings in the bearing sleeve. Replace the bearing sleeve as outlined in
Section 12, Mechanical Service.
l Loose SHCS attaching the axis motor to the motor housing. If the SHCS are found to be loose,
inspect the motor for damage and if none is found, tighten as described in Section 10, Mechani cal Service. If damage is found, replace the motor (Section 10, Mechanical Service.)
l Incorrect backlash compensation number in the parameter in the machine. Check Parameters
13, 27, and 41.
l Worn lead screw. Replace as outlined in Section 11, Mechanical Service.
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Servos / Leadscrews

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 (Section 4.2, Electrical Service).
l Check all Parameters of the suspected axis against the Parameters as shipped with the ma
chine. If there are any differences, correct those and determine how the Parameters were changed. PARAMETER LOCK should normally be on.
l A bad motor can cause vibration if there is an open or short in the motor. A short would normally
cause a GROUND FAULT or OVERCURRENT alarm; check the ALARMS. An ohmmeter applied to the motor leads should show between 1 and 3 ohms between leads, and over 1 me gohm from leads to chassis. If the motor is open or shorted, replace (Section 10, Mechanical Service).

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
users application for excessive load or high duty cycle. Check the lead screw for binding (Section 3.3). If the motor is binding by itself, replace (Section 10, Mechanical Service).
SERVICE MANUAL
SERVICE TROUBLE

3.6 FOLLOWING ERROR

´ Following error alarms occur on one or more axes sporadically.
l Check DC bus voltage on diagnostics page #2. If it is at the low side of the recommended
voltages, change the transformer tap to the next lower voltage group as explained in the Installa tion Manual.
l Check motor wiring. l Replace driver card (Section 4.2, Electrical Service). l Replace servo motor (Section 10, Mechanical
´ 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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SERVICE MANUAL
Tool Changer

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 (Parameter 64, section 8, Mechanical Service).
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. (Section 5.3, Mechanical Service)
´ Tool holder sticking in the spindle taper causes the ATC to be pulled up as the
spindle head is traveling up after depositing the tool holder in the carousel; ac companied by a popping noise as the tool holder pops out of the spindle taper.
NOTE: This problem may occur after loading a cold tool into a hot spindle (a result of thermal expansion of the tool holder inside the spindle taper), or after heavy milling. If sticking occurs only during these circumstances, no service is necessary.
l Check the condition of the customers tooling, verifying the taper on the tool holder is ground
and not turned. Look for damage to the taper caused by chips in the taper or rough handling. If the tooling is suspected, try to duplicate the symptoms with different tooling.
l Check the condition of the spindle taper. Look for damage caused by chips or damaged
tooling. Also, look for damage such as deep gouges in the spindle taper caused by tool crashing. See Section 5, Mechanical Service, for spindle cartridge replacement.
l Duplicate the cutting conditions under which the deflection occurs, but do not execute an auto
matic tool change. Try instead to release the tool using the tool release button on the front of the spindle head. If sticking is observed, the deflection is not caused by improper ATC adjustment, but is a problem in the spindle head on the machine. See Section 5, Mechanical Service, for spindle cartridge replacement.
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Tool Changer
´ During a tool change, ATC appears to be pulled up; no popping noises.
l Check the adjustment of the Z offset (Parameter 64, Section 8, Mechanical Service). NOTE: If
the offset is incorrect, a tool changer crash has occurred, and a thorough inspection of the ATC is necessary at this time.
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 Section 14.2, Mechanical Service, for roller bolt replacement. NOTE: Bent roller bolts are a symptom of another problem with the ATC. Repair the bent roller bolt and then isolate the ATC problem.
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 (Section 5.3, Mechanical Service).
´ Tool holders twist against extractor fork during a tool change.
l Check the alignment of the ATC in the X and Y axes (Section 14.3, Mechanical Service).
SERVICE MANUAL
SERVICE TROUBLE
´ Tool holders spin at all pockets of the ATC when the ATC shuttle retracts.
l ATC is misaligned in the Y axis. Realign ATC (Section 14.3, Mechanical Service). NOTE:
Observe the direction the tool holder rotates, as this will be the direction in which the Y axis of the ATC needs to be moved.
´ 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 Section 14.6, Mechanical Service, for extractor fork replacement.
NOTE: If the ATC shows the problem as described here, each extractor fork must be checked and centered to eliminate the possibility of the ATC being aligned against an incorrectly-centered fork.

4.2 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.
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SERVICE MANUAL
´ Spindle crashes into top of the tool holder after a turret rotation during a tool
change.
When the spindle head moves down over the top of the tool holder during a tool change, the pull stud will bind inside the drawbar bore of the spindle, forcing the ATC down, bending the upper right roller bolt on the ATC shuttle or completely breaking it off. Tool holder is not held correctly in the extrac­tor fork, possibly held only in one side of the extractor and at an odd angle.
l Check all of the extractor forks on the ATC. Replace, if needed (Section 14.6, Mechanical
Service).
´ Spindle crashes into top of the tool holder after a turret rotation during a tool
change.
The balls in the drawbar do not move freely, causing the ATC to be forced down far enough to bend the upper right roller bolt or completely break it off.
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. See Section 14.1 for ATC shuttle replacement, Section 5.3, Mechanical Service, for drawbar replacement, and 14.2, Mechanical Service, for extractor fork replacement.
Tool Changer
´ 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 Section 5.3, Mechanical Service,
for drawbar replacement.
´ 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.
´ 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 carou sel 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 Section 14.2, Mechanical Service for extractor fork replacement and Section 14.7, Mechanical Service, for sliding door replacement.
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Tool Changer

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 (Section 14, Mechanical Service).
´ 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 Section 14.6, Mechanical Service, for extractor fork replacement.
SERVICE MANUAL
SERVICE TROUBLE

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 (Section 14.2, Mechanical Service). Loose
roller bolts can cause the ATC to make a clunking noise when the shuttle is commanded to move. Tight roller bolts can cause the shuttle motor to labor excessively, possibly damaging the motor or the I/O board. In this case, the shuttle may also move too slowly.
l Check for damage to the trap door on the ATC cover. See Section 14.11, Mechanical Service,
for trap door replacement.
l Check for missing plastic riders on the ATC shutter. See Section 14.11, Mechanical Service, 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 Section 14.11, Mechanical service, 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 (Section 14.8, Mechanical Service). DO NOT try to repair the motor or to further isolate the noise in the motor.  ATC makes noise during carousel rotation.
l Check to ensure the Geneva driver on the turret motor is tight and properly adjusted (Section
14.8, Mechanical Service). If the Geneva driver is found to be loose, check for damage to the Geneva star. Any roughness in the slots will require that it be replaced (Section 14.10, Mechani cal Service).
l Check the adjustment of the Geneva driver in relation to the Geneva star (Section 14.10, Me
chanical Service). If the adjustment is too loose, the carousel will vibrate heavily and make a loud clanking noise during carousel rotation. If the adjustment is too tight, the turret motor will
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labor excessively and the carousel may appear to move erratically. NOTE: If the turret motor adjustment is tight for extended periods, the turret motor, Geneva star, and the I/O board may be damaged. If the adjustment of the Geneva star appears tight at some pockets and loose at others, the problem lies with the Geneva star. Check the concentricity of the star relative to the bearing housing on the carousel assembly. If the concentricity of the star is proven to within specification and the problem still persists, the Geneva star must be replaced (Section 14.10, Mechanical Service).
Ensure the screws holding the turret motor to the mounting plate are tight (Section 14.9, Mechanical Service).
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 Section 14.9, Mechanical
Service, for turret motor replacement.
NOTE: If the motor is found to be the source of noise, replace the motor assembly (motor, mounting plate, and Geneva driver).
DO NOT attempt to repair the motor or to further isolate the problem in the motor.
SERVICE MANUAL
Tool Changer

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 (Section 7, Mechanical Service).
´ ATC WILL NOT RUN
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:
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Tool Changer
´ 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, see Sections 14.1, 14.3, and 14.4, Mechanical Service, 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 Section 14.8, Mechanical Service,
for slip clutch replacement.
NOTE: The slip clutch should move the shuttle with a fair amount of force, but not so much that the shuttle cannot be made to slip when holding it back by hand. If the slip clutch is frozen, replace it. It cannot be rebuilt in the field.
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. See Section 14.8, Mechanical Service.
NOTE: The motor uses a large amount of gear reduction and should be hard to turn by hand.
SERVICE MANUAL
SERVICE TROUBLE
´ ATC shuttle will not move; shuttle is not getting power (Command a tool change
and 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. Otherwise, replace the I/O PCB
(Section 4.3, Electrical Service).
Ø If the LED does not light, check cables 510 and 520.
´ ATC turret will not rotate; turret motor is getting power (command a tool change
and 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 (Section 14.9, Mechanical Service). Check for damage to the Geneva star or the Geneva driver. See Section 14.10, Mechanical Service, for Geneva star replacement, and 14.9 for turret motor replacement. Check for a broken turret motor (See Section 14.9, Mechanical Service for turret motor replacement). NOTE: Do not at tempt to repair the motor or to further isolate the problem in the motor.
´ ATC turret will not rotate; turret motor is not getting power (command a tool
change and feel for power being applied to the turret motor).
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. Otherwise, replace the I/O PCB
(Section 4.3, Electrical Service).
Ø If the LED does not light, check cables 510 and 520.
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Gearbox / Spindle Motor

5. GEARBOX AND SPINDLE MOTOR

The gearbox cannot be serviced in the field and must be replaced as a unit. NEVER remove a motor from a VF-1, VF-2, or VF-3 gearbox as this will damage the gearbox and void the warranty.

5.1 NOISE

When investigating complaints of gearbox noise, also refer to Section 2 (Spindle Troubleshooting). Gearboxes can be damaged by failed air solenoids, gearshift cylinders, or bearings, resulting in noisy operation. It is not likely that poor finish on a workpiece can be attributed to a bad gearbox.
´ 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 (Section 9, Mechanical Service).
Ø If the noise occurs in both gear positions, disconnect the drive belt and repeat theprevious
step. If the noise persists, the gearbox is damaged and must be replaced, (Section 9, Me chanical Service).
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 (Section 9, Mechanical Service).

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 (Section 6) to diagnose each problem before working on the machine.
When a gear change is performed, the following sequence of events occurs:
1) If the spindle is turning, it is commanded to stop,
2) Pause until spindle is stopped,
3) Gear change spindle speed is commanded forward,
4) Pause until spindle is at speed,
5) Command high or low gear solenoid active,
6) Pause until in new gear or reversal time,
7) Alarm and stop if max gear change time elapsed,
8) If not in new gear, reverse spindle direction,
9) Turn off high and low gear solenoids.
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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 (Section 9, Mechanical Service).
l Check contactor CB4.
SERVICE MANUAL
SERVICE TROUBLE
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SERVICE MANUAL

Electrical

6. ELECTRICAL TROUBLE SHOOTING

6.1 WHAT CAN GO WRONG WITH LIMIT SWITCHES

If the machine is operated without connector P5, a LOW LUBE and DOOR OPEN alarm will be generated. In addition, the Home search will not stop at the limit switch and will instead run into the physical stops on each axis.
If the switch is damaged and permanently open, the zero search for that axis will move in the negative direction at about 0.5 in/min until it reaches the physical travel stops at the opposite end of travel.
If the switch is damaged and permanently closed, the zero search for that axis will move at about 10 in/min in the positive direction until it reaches the physical stops.
If the switch opens or a wire breaks after the zero search completes, an alarm is generated, the servos are turned off, and all motion stops. The control will operate as though the zero search was never performed. The RESET can be used to turn servos on but you can jog that axis only slowly.

6.2 SUPPLY VOLTAGE SENSOR

A sensor circuit on the SDIST circuit board is used to monitor the voltage applied to the control. It actually monitors the DC buss voltage developed for the servo drives. When this voltage drops below a set point, an alarm is generated. The voltage being monitored is rectified from the 115V AC second­ary of transformer T1. Cable 980 carries the analog voltage from the SDIST PCB to the MOTIF PCB.

6.3 SUPPLY VOLTAGE DISPLAY

The Diagnostic Data display page is used to display this voltage. It has a range of zero to 200V DC. If the machine is wired for 230V AC, a primary service voltage of 230V will provide a secondary voltage of about 120V; that will produce a servo buss voltage of about 168V DC.
Note that load variations on the servo motors and spindle drive will cause slight variations in this display. If the voltage varies by more than 10V under load, it indicates that the wiring to the control is dropping too much voltage and may need a larger gauge wire.

6.4 LOW VOLTAGE TRIP POINT

If this voltage drops below the following limits:
205V AC when wired for nominal 230V AC service 190V AC when wired for nominal 208V AC service
an alarm will be generated. The sensor actually converts the servo DC buss analog voltage to digital and monitors the digital value. Both alarm trip points correspond to 140V DC on the servo buss.
If one leg of the three-phase incoming power is lost, there may not be an alarm. In this case, the machine may turn off completely, the electronics may shut down, or the servos and the video monitor may shut off.
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Electrical

6.5 UNDER/OVER VOLTAGE SENSORS

An overvoltage sensor monitors the DC servo motor buss. When this voltage exceeds 185V DC, a load is applied to the servo buss. That load is called the regen load resistor. When this voltage ex­ceeds 190V DC, an alarm is generated and machine operation stops. If the voltage remains between these two values for more than a few seconds, an overtemperature alarm may be generated. That alarm is caused by an overheat of the regen resistor.
The overvoltage alarm will be generated for different input service voltages depending on how the machine is configured. The following limits apply:
260V AC when wired for nominal 230V AC service 235V AC when wired for nominal 208V AC service
It is also possible that an overvoltage condition will be detected first by the spindle drive. This would initially show only a spindle drive fault. A check of the status on the spindle drive LEDs will show what the actual alarm is.
In controls built after April 1990, there is an undervoltage sensor that monitors the voltage of all three inputs power phases. If this voltage drops below 180V AC for 208 input or drops below 200 for 230 input for any phase, an alarm will be generated. This phase sensor is built into the IOPCB circuit board in the lower left hand corner of the control.
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6.6 CORRECTING ALARMS

´ Alarm 179 (Low Pressure Spindle Coolant) 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.
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SERVICE MANUAL

Alarms

ALARMS
Any time an alarm is present, the lower right hand corner will have a blinking ALARM. Push the ALARM display key to view the current alarm. All alarms are displayed with a reference number and a complete description. If the RESET key is pressed, one alarm will be removed from the list of alarms. If there are more than 18 alarms, only the last 18 will be displayed and the CURSOR DOWN key must be used to see the rest. The presence of any alarm will prevent the operator from starting a program.
Note that the tool changer alarms can be easily corrected by first correcting any mechanical prob­lem, pressing RESET until the alarms are clear, selecting ZERO RET mode, and selecting AUTO ALL AXES. Some messages are displayed while editing to tell the operator what is wrong, but these are not alarms.
The following list shows the alarm number and the cause of the alarm. Please refer to this list before resuming normal operation when an alarm occurs.
102 SERVOS OFF
This is not an alarm; but indicates that the servo motors are off, the tool changer is disabled, the coolant pump is off, and the spindle motor is stopped. Caused by EMERGENCY STOP, motor f faults, tool changer problems, or power fail.; check for other causes.
103 X FOLLOWING ERROR TOO LARGE 104 Y FOLLOWING ERROR TOO LARGE 105 Z FOLLOWING ERROR TOO LARGE 106 A FOLLOWING ERROR TOO LARGE
These alarms can be caused by power problems, motor problems, driver problems, the slide being run into the mechanical stops, or excessive axis load. The difference between the motor position and the commanded position has exceeded a parameter. The motor may also be stalled, disconnected, or the driver failed. The servos will be turned off and a RESET must be done to restart. See Section 2, Electrical Service, to check line voltage adjustments. See Section 3.1, Electrical Service, check the servo motors, servo drivers, and ball screw adjust ment.
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 E­STOP alarm and once to clear the Servo Off alarm. This is an operator-initiated condition. If you do not know why it occurred, check wiring to emergency stop circuit.
108 X SERVO OVERLOAD 109 Y SERVO OVERLOAD 110 Z SERVO OVERLOAD 111 A SERVO OVERLOAD
Excessive load on X-axis motor. This can occur if the load on the motor over a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor. The servos will be turned off when this occurs. This can be caused by running into the me­chanical stops but not much past them. It can also be caused by anything that causes a very high load on the motors. See Section 3.1, Electrical Service, to check the servo motors, servo drivers, and ball
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screw adjustment.
112 NO INTERRUPT
This alarm can be caused by electrical interference or an electronics problem. See
Section 4.1, Electrical Service, to replace Microprocessor and Motor Interface PCBs.
113 SHUTTLE IN FAULT
114 SHUTTLE OUT FAULT
Tool changer not completely to right or left. During a tool changer operation the tool in/out shuttle failed to get to the in or out position. Parameters 62 and 63 can adjust the time-out times. This alarm can be caused by anything that jams the motion of the slide or by the presence of a tool in the pocket facing the spindle. A loss of power to the tool changer can also cause this, so check fuse FU5 and relays 1-8, 2-1, and 2-2. See Section 4 for trouble­shooting of the tool changer.
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 time­out times. This alarm can be caused by anything that jams the rotation of the turret. A loss of power to the tool changer can also cause this, so check fuse FU5 and relays 1-8, 2-3, and 2-
4. See Section 4 for troubleshooting of the tool changer.
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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. See Section 4.5 to troubleshoot spindle orientation.
117 SPINDLE HIGH GEAR FAULT 118 SPINDLE LOW GEAR FAULT
Gearbox did not shift into high or low gear. During a gear change, the spindle is rotated slowly while air pressure is used to move the gears but the high/low gear sensor was not detected in time. Parameters 67, 70 and 75 can adjust the time-out times. Check the air pressure, the solenoids circuit breaker CB4, and the spindle drive. See Section 5 for trouble­shooting of gear change problems.
119 OVER VOLTAGE
Incoming line voltage is above maximum (about 255V when wired for 240 or 235 when wired for 208). The servos will be turned off and the spindle, tool changer, and coolant pump will stop. If this condition remains for 4.5 minutes, an automatic shutdown will begin. This can also be caused by an electronic problem. See Section 2, Electrical Service, to check line voltage adjustment taps. See Section 4.2, Electrical Service, to replace SDIST PCB. Also check that servo regen load resistor is installed (cable 920).
120 LOW AIR PRESSURE
Air pressure dropped below 80 PSI for a period defined by Parameter 76. Check your incoming air pressure for at least 100 PSI and ensure the regulator is set at 85 PSI. If this is not caused by low air pressure, check pressure sensor at spindle head and wiring back to IOPCB. Check Parameter 76, which is used to delay the low air alarm condition for short
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outages. Air blast during tool change can cause your air supply to drop pressure; monitor the pressure drop during a tool unclamp.
SERVICE MANUAL
121 LOW LUB OR LOW PRESSURE
Way lube is low or empty or there is no lube pressure or too high a pressure. Check tank at rear of mill and below control cabinet. Also check connector P5 on the side of the control cabinet. Check that the lube lines are not blocked. This can be caused by failure of the pump to provide pressure, failure of the lube pressure sensor, a wiring error, or a parameter error. See Air and Oil Line Diagrams (p.133) to check level switch and pressure switch (cable 960).
122 CONTROL OVER HEAT
The control internal temperature is above 1500 F. This can be caused by almost anything in the control overheating. But is usually caused by overheat of the two regen resistors for servos and spindle drive. This alarm will also turn off the servos, spindle drive, coolant pump, and tool changer. One common cause of this overheat condition is an input line voltage too high. If this condition remains for 4.5 minutes, an automatic shutdown will begin. It is also caused by incorrect transformer tapping, SDIST PCB problem, or Spindle Drive problem. See Section 2, Electrical Service, to check line voltage adjustment taps. See Section 4.2, Electrical Service, to replace SDIST PCB. See Section 2.3 to check the spindle drive.
Alarms
123 SPINDLE DRIVE FAULT
Overheat or failure of spindle drive or motor. The exact cause is indicated in the LED window of the spindle drive inside the control cabinet. This can be caused by a stalled motor, shorted motor, overvoltage, undervoltage, overcurrent, overheat of motor, or drive failure. See Section 2.3 for check of the Spindle Drive. Front of Drive indicates type of problem. If not a Drive problem, check wiring to IOPCB (cable 780).
124 LOW BATTERY
Memory batteries need replacing within 30 days. This alarm is only generated at POWER ON and indicates that the 3.3V Lithium battery is below 2.5V. If this is not corrected within about 30 days, stored programs, parameters, offsets, and settings may be lost. See Section
4.1, Electrical Service, for replacement of Microprocessor PCB or battery.
125 SHUTTLE FAULT
Tool shuttle not initialized at power on, CYCLE START or spindle motion command. This means that the tool shuttle was not fully retracted to the out position. See Section 4 for tool changer problem.
126 GEAR FAULT
Gearshifter is out of position when a command is given to rotate the spindle. This means that the two-speed gear box is not in either high or low gear but is somewhere in between. Check the air pressure, the solenoids circuit breaker CB4, and the spindle drive. See Section 5 for gear change problem.
127 NO TURRET MARK
Tool carousel motor not in position. The turret motor only stops in one position indicated by a switch and cam on the Geneva mechanism. This alarm is only generated at POWER ON. The AUTO ALL AXES button will correct this but be sure that the pocket facing the spindle afterwards does not contain a tool. See Section 4 for tool changer problem.
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128 TOOL IN TURRET
Pocket opposite spindle has tool in it. This alarm is not implemented.
129 M FIN FAULT
This indicates an external M-code wiring error was detected at power-on. Check your wiring to the M-FIN signal or see Section 4.3, Electrical Service, for replacement of the IOPCB.
130 TOOL UNCLAMPED 131 TOOL NOT CLAMPED
Tool release piston is energized at power up, or, tool release piston is not Home. This is a possible fault in the air solenoids, relays on the IO Assembly, the draw bar assembly, or wiring. See Sections 2.6 and 4.1 for tool clamp/unclamp problems.
132 POWER DOWN FAILURE
The control attempted to shut-off and could not. The auto-off relay on the IOPCB did not open the main contactor circuit. Check the wiring from IOPCB to POWER PCB. See Section
4.3, Electrical Service, for IOPCB replacement.
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. See Section 2.5 for spindle orientation checks. Check for correct function of the shot pin.
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SERVICE TROUBLE
134 TOOL CLAMP FAULT
Tool did not release from spindle when commanded. Check air pressure and solenoid circuit breaker CB4. Can also be caused by misadjustment of draw bar assembly. See Sections 2.6 and 4.1 for tool clamp/unclamp problems.
135 X MOTOR OVER HEAT 136 Y MOTOR OVER HEAT 137 Z MOTOR OVER HEAT 138 A MOTOR OVER HEAT
Servo motor overheat. The temperature sensor in the motor indicates over 150oF. This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes. See Section 3 for check of servo motors and ball screws. A parameter or a wiring error can also cause this alarm.
139 X MOTOR Z FAULT 140 Y MOTOR Z FAULT 141 Z MOTOR Z FAULT 142 A MOTOR Z FAULT
Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose connectors at P1-P4. See Section 3.1 for check of motor/encoder and wiring. This is usually an encoder or wiring error. It can also be caused by the MOTIF PCB. See Section 4.1, Electrical Service, for replacement of MOTIF PCB.
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143 SPINDLE NOT LOCKED
Shot pin not fully engaged when a tool change operation is being performed. Check air pressure and solenoid circuit breaker CB4. This can also be caused by a fault in the sense switch that detects the position of the lock pin. See Section 2.5 for spindle orientation checks.
144 TIMEOUT - CALL YOUR DEALER
Time allocated for use prior to payment exceeded. Not a mechanical or electrical problem.
145 X LIMIT SWITCH 146 Y LIMIT SWITCH 147 Z LIMIT SWITCH 148 A LIMIT SWITCH
Axis hit limit switch or switch disconnected. This is not normally possible as the stored stroke limits will stop the slides before they hit the limit switches. Check the wiring to the limit switches and connector P5 at the side of the main cabinet. Can also be caused by a loose encoder shaft at the back of the motor or coupling of motor to the screw. See Section 7, Electrical Service, to replace limit switches.
149 SPINDLE TURNING
Spindle not at zero speed for tool change. A signal from the spindle drive indicating that the spindle drive is stopped is not present while a tool change operation is going on. See Section 4.3, Electrical Service, for IOPCB replacement or Section 2 for Spindle Drive problem.
Alarms
150 Z AND TOOL INTERLOCKED
Tool changer not at home and Z is neither at machine home or above tool. If RESET, E­STOP, or POWER OFF occurs during tool change, Z-axis motion and tool changer motion may not be safe. Check the position of the tool changer and remove the tool if possible. Re-initial­ize with the AUTO ALL AXES button but be sure that the pocket facing the spindle afterwards does not contain a tool. Indicates a dangerous condition with the position of the Z axis and the tool changer. It is usually preceded by an alarm related to the tool changer. See Section 4 for troubleshooting of tool changer.
151 LOW COOLANT
If the low coolant sensor is installed, this indicates low coolant level in the coolant tank outside of the enclosure. Check coolant level and sensor in tank.
152 SELF TEST FAIL
This can be caused by an electronics problem or electrical interference. All motors and solenoids are shut down. This is most likely caused by a fault of the processor board stack at the top left of the control. Call your dealer. See Section 4.1, Electrical Service, for replace­ment of MOTIF PCB.
153 X AXIS Z CH MISSING 154 Y AXIS Z CH MISSING 155 Z AXIS Z CH MISSING 156 A AXIS Z CH MISSING
These alarms indicate a problem with the servo axis encoder. All servos are turned off. It can also be caused by wiring errors, electronics problems, encoder contamination, parameter
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errors, or by loose connectors at P1-P4.. See Section 9, Mechanical Service, for replacement of motor/encoder. See Section 4.1, Electrical Service, for replacement of MOTIF PCB.
157 MOTOR INTERFACE PCB FAILURE
Internal circuit board problem. The MOTIF PCB in the processor stack is tested at POWER ON. See Section 4.1, Electrical Service, for replacement of MOTIF PCB.
158 VIDEO/KEYBOARD PCB FAILURE
Internal circuit board problem. The VIDEO PCB in the processor stack is tested at POWER ON. This could also be caused by a short in the front panel membrane keypad. See Section 5.5, Electrical Service, for replacement of keypad. See Section 4.1, Electrical Service, for replacement of VIDEO PCB.
159 KEYBOARD FAILURE
Keyboard shorted or button pressed at POWER ON. A POWER ON test of the membrane keypad has found a shorted button. It can also be caused by a short in the cable from the main cabinet or by holding a switch down during POWER ON. See Section 5.5, Electrical Service, for replacement of keypad. This can also be caused by a bad cable 700. Be sure the problem is not in the cable before replacing keypad.
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160 LOW VOLTAGE
This can be caused by a line voltage problem, a transformer tap problem, or an electronic problem. Cable 980 can cause this problem. See Section 4.1, Electrical Service, to replace MOTIF PCB or SDIST PCB.
161 X AXIS OVER CURRENT OR DRIVE FAULT 162 Y AXIS OVER CURRENT OR DRIVE FAULT 163 Z AXIS OVER CURRENT OR DRIVE FAULT 164 A AXIS OVER CURRENT OR DRIVE FAULT
These alarms indicate a problem with servo motor, the servo drive, or excessive load on servos. Possibly caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running a short distance into a mechanical stop. It can also be caused by a short in the motor or a short of one motor lead to ground. See Section 4.1, Electrical Service, for replacement of servo drive cards. See Section 3 for check of servo motor and ball screw.
165 X ZERO RET MARGIN TOO SMALL 166 Y ZERO RET MARGIN TOO SMALL 167 Z ZERO RET MARGIN TOO SMALL 168 A ZERO RET MARGIN TOO SMALL
This alarm indicates a problem with limit switches, parameters, or motor encoders for servos, and this alarm will occur if the home/limit switches move or are misadjusted. This alarm also indicates that the zero return position may not be consistent from one zero return to the next. The encoder Z channel signal must occur between 1/8 and 7/8 revolution of where the home switch releases. This will not turn the servos off but will stop the zero return opera­tion. See Section 16, Mechanical Service, for setting grid offset parameters. See Section 3 for checking of motor and encoder. If a new motor or encoder is installed, this alarm is likely before grid offset parameters are adjusted.
169 SPINDLE DIRECTION FAULT
The spindle started turning in the wrong direction. This alarm occurs only for rigid tapping.
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It can be caused by a bad rigid tapping encoder, a wiring error, or a parameter error. See Section 6, Electrical Service, for installation of rigid tapping encoder.
SERVICE MANUAL
170 PHASE LOSS L1-L2 171 PHASE LOSS L2-L3 172 PHASE LOSS L3-L1
These alarms indicate a problem with incoming line voltage. This usually indicates that there was a transient loss of input power to the machine. See Section 2, Electrical Service, for checking line voltage.
173 SPINDLE REF SIGNAL MISSING
The Z channel pulse from the spindle encoder is missing for hard tapping synchroniza­tion. This alarm occurs only for rigid tapping. See Section 6, Electrical Service, for installation/ check of rigid tapping encoder.
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. This is not normally a machine fault. Check the setup.
Alarms
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. If the fault occurs repeatedly, remove motors one at a time to isolate fault. If it occurs rarely, the motor in motion at the fault is the likely cause. A short of the spindle head solenoid cables can also cause this condition. See Section 9, Mechanical Service, to replace servo motors. See Section 14, Mechanical Service, to replace tool changer motors.
176 OVER HEAT SHUTDOWN
This alarm is actually caused by a previous Over Heat alarm. After 4 1/2 minutes of overheat, the control begins an automatic shutdown.
177 OVER VOLTAGE SHUTDOWN
This alarm is actually caused by a previous Over Voltage alarm. After 4 1/2 minutes of overvoltage, the control begins an automatic shutdown.
178 DIVIDE BY ZERO
Indicates an electronics or software problem. If intermittent or not consistent, see Section
4.1, Electrical Service, for replacement of Microprocessor PCB.
179 LOW PRESSURE SPINDLE COOLANT
This alarm indicates a problem with spindle cooling/transmission lubrication oil. It does not occur in a VF-0. When the spindle is in motion, the oil pump must be running to lubricate the transmission and cool the spindle. See Section 5.3 for check of oil sump, pump, and pressure sensor.
180 TOOL ARM ROTATION FAULT 181 TOOL POT POSITION FAULT
These alarms are not Implemented.
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182 X CABLE FAULT 183 Y CABLE FAULT 184 Z CABLE FAULT 185 A CABLE FAULT
Cable from axis encoder does not have valid differential signals. See Section 10, Me­chanical Service, for replacement of motor, encoder, and cabling. This can also be caused by a MOTIF PCB problem. See Section 4.1, Electrical Service, for replacement of the MOTIF PCB.
186 SPINDLE NOT TURNING
Status from spindle drive indicates that it is not turning when it is expected. See Section
4.3, Electrical Service, for IOPCB replacement or Section 2 for Spindle Drive problem.
201 PARAMETER CRC ERROR
Parameters lost maybe by low battery. Check for a low battery and low battery alarm.
202 SETTING CRC ERROR
Settings lost maybe by low battery. Check for a low battery and low battery alarm.
203 LEAD SCREW CRC ERROR
Lead screw compensation tables lost maybe by low battery. Check for CRC Error low battery and low battery alarm.
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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 PROG ERROR
Software Error.
207 QUEUE ADVANCE ERROR
Software Error.
208 QUEUE ALLOCATION ERROR
Software Error.
209 QUEUE CUTTER COMP ERROR
Software Error.
210 INSUFFICIENT MEMORY
Not enough memory to store users program. Check the space available in the LIST PROG mode and possibly delete some programs.
211 ODD PROG BLOCK
Software Error.
212 PROG INTEGRITY ERROR
Software Error.
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213 EPROM CRC ERROR
All of these alarms indicate a software or electronics problem. See Section 4.1, Electrical Service, for replacement of Microprocessor PCB.
240 EMPTY PROG OR NO EOB
Software Error.
241 INVALID CODE
RS-232 load bad. Data was stored as comment (RS-232 communications problem or RS­232 program format problem). Check the program being received. See the Programming and Operation Manual.
242 NO END
Software Error.
243 BAD NUMBER
Data entered is not a number.
244 MISSING )
Comment must end with a  ) .
Alarms
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
These alarms usually indicate an operator illegal action., such as input line too long. The data entry line must be shortened. See the Programming and Operation Manual.
247 CURSOR DATA BASE ERROR
Software Error.
248 NUMBER RANGE ERROR
Number entry is out of range.
249 PROG DATA BEGINS ODD 250 PROG DATA ERROR 251 PROG DATA STRUCT ERROR 252 MEMORY OVERFLOW 253 PROG DATA ERROR 254 PROG DATA ERROR 255 PROG DATA ERROR 256 PROG DATA ERROR 257 PROG DATA ERROR
All of these alarms indicate and RS-232 communication problem or a software or electron­ics problem. See Programming and Operation Manual for RS-232 operation. See Section 4.1, Electrical Service, for replacement of Microprocessor PCB.
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258 INVALID DPRNT FORMAT
This alarm is caused by an error in the way the programmer uses the macro DPRNT function. See the Programming and Operation Manual.
302 - 390
All of the 302 through 390 alarms are caused by programming problems in the users NC program. See the Programming and Operation Manual.
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 G02 OR G03
Check your geometry with the Help page.
304 INVALID I, J, OR K IN G02 OR G03
Check your geometry with the Help page. Radius at start must match radius at end of arc within 0.0010 inches.
305 INVALID Q IN CANNED CYCLE
Q in a canned cycle must be greater than zero.
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SERVICE TROUBLE
306 INVALID I, J, OR K IN CANNED CYCLE
I, J, and K in a canned cycle must be greater than zero.
307 SUBPROGRAM CALL NESTING TOO DEEP
Subprogram nesting is limited to nine levels. Simplify your program.
308 CANNED CYCLE NESTING TOO DEEP
Software Error.
309 MAX FEED RATE EXCEEDED
Use a lower feed rate.
310 INVALID G CODE
G code not defined and is not a macro call.
311 UNKNOWN CODE
Possible corruption of memory by low battery. Call your dealer.
312 PROGRAM END
End of subroutine reached before M99. Need an M99 to return from subroutine.
313 NO P CODE IN M98
Must put subprogram number in P code.
314 SUBPROGRAM OR MACRO NOT IN MEMORY
Check that a subroutine is in memory or that a macro is defined.
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315 INVALID P CODE IN M97, M98 OR M99
The P code must be the name of a program stored in memory without a decimal point for M98 and must be a valid N number for M99.
316 X OVER TRAVEL RANGE 317 Y OVER TRAVEL RANGE 318 Z OVER TRAVEL RANGE 319 A OVER TRAVEL RANGE
Axis will exceed stored stroke limits. This is a parameter in negative direction and is machine zero in the positive direction. This will only occur during the operation of a users program.
320 NO FEED RATE SPECIFIED
Must have a valid F code for interpolation functions.
321 AUTO OFF
A fault turned off the servos automatically; occurs in debug mode only.
324 INVALID P CODE IN G04
P code in G04 is over 1000.0 or over 9999.
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Alarms
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 LOOPING FOR M CODE EXCEPT M97, M98
L code not used here. Remove L Code.
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 Codes Not Matched
This alarm is generated when Setting 15 is turned ON and an H code 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
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334Y-axis Disabled
335 Z-axis Disabled
Parameters have disabled this axis. Not normally possible in VMC.
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.
338 Invalid IJK and XYZ in G02 or G03
There is a problem with circle definition; check your geometry.
339 Multiple Code
Only one M, X, Y, Z, A, Q, etc. allowed in any block or two G codes in the same group.
340 Cutter Comp Begins With G02 or G03
Select cutter comp earlier.
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SERVICE TROUBLE
341Cutter Comp Ends With G02 or G03
Disable cutter comp later.
342 Cutter Comp Path Too Small
Geometry not possible. Check your geometry with the Help page.
344 Cutter Comp With G18 or G19
Cutter comp only allowed in XY plane (G17).
345 Scaling Parameters Wont Allow G17
Plane Parameters 5 and 19 must be same value.
346 Scaling Parameters Wont Allow G18
Plane Parameters 5 and 33 must be same value.
347 Scaling Parameters Wont Allow G19
Plane Parameters 19 and 33 must be same value.
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 Stopped Without Cancel of Cutter Comp
Information message only. Fix or Ignore.
350 Cutter Comp Look Ahead Too Small
There are too many non-movement blocks between motions when cutter comp is being used. Remove some intervening blocks.
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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 Yet
A ZERO RET has not been done yet on the aux axes. Check auxiliary axes. Status from control was LOSS.
354 Aux Axis Not Connected
Aux axes not responding. Check auxiliary axes and RS-232 connections.
355 Aux Axis Position Lost
Mismatch between VMC and aux axes position.
Check aux axes and interfaces. Make sure no manual inputs occur to aux axes.
356 Aux Axis Travel Limit
Aux axes are attempting to travel past their limits.
357 Aux Axis Disabled
Aux axes are disabled.
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Alarms
358 Multiple Aux Axis
Can only move one auxiliary axis at a time.
359 Invalid I, J, or K In G12 or G13
Circ Pocket Milling Check your geometry with the Help page.
360 Tool Changer Disabled By Parameters
Check Parameter 57. Not a normal condition for VMC.
361 Gear Change Disabled By Parameters
Check Parameter 57. Not a normal condition for VMC.
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
Override is off and program tried to turn on coolant.
364 No Circular Interp Allowed On Aux Axis
Only rapid or feed is allowed with aux axes.
365 Cutter Comp Interference
G02 or G03 cut cannot be done with tool size.
366 Cutter Comp Interference
Tool doesnt fit inside of cut.
367 Cutter Comp Interference
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G01 cannot be done with tool size.
368 Groove Too Small
Tool too big to enter cut.
369 Tool Too Big For Cutter Comp
Use a smaller tool for cut.
370 Pocket Definition Error
Check geometry for G150.
371 Invalid I, J, K, OR Q
Check G150.
372 Tool Change In Canned Cycle
Tool change not allowed while canned cycle is active.
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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SERVICE TROUBLE
374 Missing XYZA in G31 or G36
G31 skip function requires an X, Y, Z, or A move.
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 not allowed in G37
G37 may only specify Z-axis and must have tool offset defined.
381 G43 or G44 not allowed in G36
Auto work offset probing must be done without tool offset.
382 D code required in G35
A Dnn code is required in G35 in order to store the measured tool diameter.
383 Inches Is Not Selected
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SERVICE TROUBLE
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 Code In G10
G10 was used to changes offsets but L, P, or R code is missing or invalid.
403 - 420
All of the 403 through 420 alarms are caused by communications problems with RS-232.
See the Programming and Operation Manual.
403 RS-232 Directory Full
Cannot have more than 100 programs in memory.
404 RS-232 No Program Name
Need name in programs when receiving ALL; otherwise has no way to store them.
405 RS-232 Illegal Program Name
Check files being loaded. Program name must be Onnnn and must be at beginning of a block.
VMC
SERVICE MANUAL
Alarms
406 RS-232 Missing Code
A receive found bad data. Check your program. The program will be stored but the bad data is turned into a comment.
407 RS-232 Invalid Code
Check your program. The program will be stored but the bad data is turned into a com­ment.
408 RS-232 Number Range Error
Check your program. The program will be stored but the bad data is 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 End of File
Check Your Program. An ASCII EOF code was found in the input data before program receive was complete. This is a decimal code 26.
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VMC
Alarms
413 RS-232 Insufficient Memory
Program received doesnt fit. Check the space available in the LIST PROG 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.
SERVICE MANUAL
SERVICE TROUBLE
418 RS-232
Break Break condition while receiving. The sending device set the line to a break condi­tion. This might also be caused by a simple break in the cable.
419 Invalid Function FOR DNC
A code found on input of a DNC program could not be interpreted.
501 - 538
All of the 501 through 538 alarms are caused by errors in macro programming. See the Programming and Operation Manual.
The ALARM MSGS display is the most important source of diagnostic data. At any time after the machine completes its power-up sequence, it will either perform a requested function or stop with an alarm. Refer to Section 2.5 for a complete list of alarms, their possible causes, and some corrective action.
If there is an electronics problem, the controller may not complete the power-up sequence and the CRT will remain blank. In this case, there are two sources of diagnostic data; these are the audible beeper and the LEDs on the processor PCB. If the audible beeper is alternating a ½ second beep, there is a problem with the main control program stored in EPROMs on the processor PCB. If any of the processor electronics cannot be accessed correctly, the LEDs on the processor PCB will light or not as described in Section 24.1. If the machine powers up but has a fault in one of its power supplies, it may not be possible to flag an alarm condition. If this happens, all motors will be kept off and the top left corner of the CRT will have the message:
POWER FAILURE ALARM
and all other functions of the control will be locked out.
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VMC
SERVICE TROUBLE
SERVICE MANUAL
Discrete Inputs

DIAGNOSTIC DATA

When the machine is operating normally, a second push of the PARAM/DGNOS key will select the diagnostics display page. The PAGE UP and PAGE DOWN keys are then used to select one of two different displays. These are for diagnostic purposes only and the user will not normally need them. The diagnostic data consists of 32 discrete input signals, 32 discrete output relays and several internal control signals. Each can have the value of 0 or 1. In addition, there are up to three analog data displays and an optional spindle RPM display. Their number and functions are:
DISCRETE INPUTS
# Name Description # Name Description
1 TC IN Tool Changer In 17 SP LOK Spindle Locked 2 TC OUT Tool Changer Out 18 SP FLT Spindle Drive Fault 3 T ONE At Tool One 19 SP SP* Spindle Not Stopped 4 LO CNTLow Coolant 20 SP AT* Spindle Not At Speed 11 OVERV* Not Over Voltage 27 LO PH B Low voltage in phase 2 12 LO AIR Low Air Pressure 28 LO PH C Low voltage in phase 3 13 LO LUB Low Lube Oil 29 GR FLT Ground fault 14 OVRHT* Not Over Heat 30 SKIP Skip Signal 15 DB OPN Tool Unclamped 31 spare 16 DB CLS Tool Clamped 32 spare
DISCRETE OUTPUTS
# Name Description # Name Description
1 SRV PO Servo Power On 17 M21 Spare M Functions 2 SP FOR Spindle Forward 18 M22 3 SP REV Spindle Reverse 19 K111 Spindle & T.C. Enable 4 SP RST Spindle Reset 20 K210 E-Stop Enable 5 4TH BK 4th Axis Brk Rel21 UNCLPR Unclamp pre-charge 6 COOLNT Coolant Pump 22 M26 7 AUT OF Auto Turn Off 23 5TH BK 5th Axis Brake 8 SP FAN Spind Motor Fan 24 Y160 Door Lock 9 TC IN Tool Changer In 25 spare 10 TC OUTTool Changer Out 26 spare 11 TC CW Tool Changer CW 27 spare 12 TC CCW Tool Changer CCW 28 spare 13 SP HIG Spindle High Gear 29 spare 14 SP LOW Spindle Low Gear 30 spare 15 T UNCL Tool Unclamped 31 spare 16 SP LOK Spindle Lock Cmd 32 spare
The 32 inputs are numbered the same as the 32 connections on the inputs printed circuit board. The last eight outputs are reserved for expansion by HAAS.
The second page of diagnostic data is displayed using the PAGE UP and PAGE DOWN keys. It contains:
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Inputs 2
INPUTS2
Name Description Name Description
X Z CH X-axis Z Channel X ZIRQ X-axis Z channel interrupt
Y Z CHY Axis Z Channel Y ZIRQ Y-axis Z channel interrupt Z
Z CH Z-axis Z Channel Z ZIRQ Z-axis Z channel interrupt A
Z CH A-axis Z Channel A ZIRQ A-axis Z channel interrupt
X HOME X-axis Home/Lim Switch 1K IRQ 1 kHz Interrupt
Y HOME Y-axis Home Z IRQ Z channel interrupt
Z HOME Z-axis Home SPZIRQ Spindle encoder Z interrupt
A HOME A-axis Home SELF T Self-Test Input
X OVRH X Motor OverTemp X CABL Broken cable to X encoder
Y OVRH Y Motor OverTemp Y CABL Broken cable to Y encoder
Z OVRH Z Motor OverTemp Z CABL Broken cable to Z encoder
A OVRH A Motor OverTemp A CABL Broken cable to encoder
OVC X X Drive Overcurrent spare
OVC Y Y Drive Overcurrent spare
OVC Z Z Drive Overcurrent spare
OVC A A Drive Overcurrent
AD EOC A-to-D End of Conversion
SERVICE MANUAL
SERVICE TROUBLE
ANALOG DATA
Name Description
DC BUSS DC Servo Buss Voltage SP TEMP Spindle temperature F SP LOAD Spindle load in % AUX TMP Not used SP SPEED Spindle RPM CW or CCW
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MECHANICAL SERVICE

VMC
SERVICE MANUAL
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VMC
Head Covers
SERVICE MANUAL
MECHANICAL SERVICE
1. HEAD COVERS REMOVAL AND INSTALLATION
Please read this section in its entirety before attempting to remove or replace covers.
TOOLS REQUIRED:
3 5/32" HEX WRENCH 3 CARDBOARD
REMOVAL
1. Power on the Vertical Machining Center (VMC).
Fig. 1-1 Power on/off button.
2. Zero return (ZERO RET) all axes, then handle jog to center X- and Y-axes under spindle.
Fig. 1-2 Spindle control panel.
3. Protect table surface with a piece of cardboard.
4. Remove cover panels. Remove top cover and remove the rear cover (on newer models only), then the front cover. Carefully pull the front cover from the bottom until you can disconnect the tool release cable (quick disconnect), if equipped. Place front cover aside.
5. Remove side covers one at a time. Z-axis may be jogged to make removal of screws easier. After screw removal, the side covers are removed from the top side of the enclosure.
Ø Be very careful not to run the head covers into the enclosure.
NOTE: For installation, ensure all previously removed parts have been replaced, then install in reverse order of removal.
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MECHANICAL SERVICE
HEAD COVERS
VMC
SERVICE MANUAL
Tool Release Piston
10-32 x 3/8"
SHCS
Fig. 1-3 The VF Series Machining Center
REMOVE SIDE
COVERS FROM
TOP SIDE
COVER TABLE
WITH CARDBOARD
2 . TOOL RELEASE PISTON ASSEMBLY
Please read this section in its entirety before attempting to replace tool release piston assembly.
TOOLS REQUIRED:
35/16" HEX WRENCH

2.1 REMOVAL

1. Remove cover panels from headstock area (Section 1.1).
2. Remove the four 3/8-16 x 1¾" SHCS holding the tool release piston assembly to the head cast ing.
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. (On earlier machines, the clamp/unclamp cables are located on the tool release piston assembly and must be unscrewed.)
5. Remove the tool-release air hose at the fitting noted.
6. Remove entire tool release piston assembly.
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Tool Release Piston
VMC
SERVICE MANUAL
MECHANICAL SERVICE
TOOL RELEASE
PISTON ASSEMBLY
¼
" AIR HOSE
FITTING
3/8"-16 x 1¾"
SHCS
TOOL CHANGER
HEAD
CASTING
3/8"-16 x 1¾"
SPINDLE
TRANSMISSION
SHCS
MOTOR
SHROUD
CLAMP /UNCLAMP
CABLES
3/8
" AIR
HOSE
FITTING
Fig. 2-1 VF-1 spindle and headstock area shown with covers removed.
VF-0 will have no transmission. Left: Older models Right: Newer models.
¼"
AIR
HOSE FITTING
¼"
HOSE FITTING
AIR
Fig. 2-3 Variations of the tool release piston. Left: Solenoid valve. Right: Quick exhaust valve
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MECHANICAL SERVICE
CLAMP / UNCLAMP CABLES
TOOL RELEASE PISTON ASSEMBLY
¼"
AIR
HOSE FITTING
VMC
SERVICE MANUAL
Tool Release Piston
DRIVE BELT
SPINDLE PULLEY
Fig 2-3 Mounting location for tool release piston assembly

2.2 INSTALLATION

1. Ensure drive belt has been properly replaced in accordance with the instructions in Sections
3.2 .
2. Verify spindle sweep adjustment is correct before proceeding (Section 5.3, Mechanical Ser vice). If not correct, re-shim as necessary.
3. Reinstall tool release piston assembly, tightening down the four 3/8-16 x 1¾" SHCS alternately until all are completely tight.
4. Reconnect the air hose at the applicable fitting on the tool release piston assembly.
5. Reconnect the clamp/unclamp cables to the sides of the solenoid bracket. Older models may have a screw-on attachment on the tool release piston assembly.
6. Continue with reassembly and adjustments (Sections 6-9).
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Tool Release Piston
SERVICE MANUAL

2.3 SETTING PRE-CHARGE

NOTE: This section applies only to machines having a tool release piston assembly with a pre­charge solenoid installed.
1. Remove the cover panels (Section 1, Mechanical Service). It will not be necessary to remove the rear or right side panels for this operation.
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.
MECHANICAL SERVICE
Fig. 2-4 Air pressure regulator adjustment knob.
3. Go to the PARAMETERS page of the CRT and ensure the 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 draw bar.
5. Turn the air pressure regulator ½ turn in. Execute a tool change and listen for the noise de scribed 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.
NOTE: 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.
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SERVICE MANUAL
Belt Assembly

3. BELT ASSEMBLY

Please read this section in its entirety before attempting to replace drive belt.
TOOLS REQUIRED:
3 5/16" HEX WRENCH 3 1/2" ALLEN WRENCH 3 5/8" HEX WRENCH 3 7/16" ALLEN WRENCH 3 5/32" HEX WRENCH 3 3/4" BOX-END WRENCH 3 PRY BAR 3 GATES BELT TENSION TESTER (PART #12998-F)

3.1 BELT REMOVAL

NOTE: FOR EASIER REMOVAL, PLACE TRANSMISSION IN HIGH GEAR BEFORE BEGINNING.
1. Remove cover panels from head stock area (Section 1).
2. Remove the tool release piston assembly (Section 2.1).
MOTOR
OIL LINE
DISCONNECT
INSPECTION
COVER
3/8-16 x 1"
SHCS
Fig. 3-1 Spindle head casting disconnect points
4. Lift the transmission and motor assembly to the point where the sump tank clears the center web in the spindle head casting. (It is highly recommended that you use the Haas Transmission Lift at this time.
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Belt Assembly
VMC
SERVICE MANUAL
TRANSMISSION
SHIFTER
DRIVE BELT
HEAD CASTING
Fig. 3-2 Head casting area showing belt location
MECHANICAL SERVICE
(EXCEPT VF-0)
SPINDLE
PULLEY
5. For all VMC's except VF-0, remove the six 3/8-16 x 1¼" 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.
6. For the VF-0, remove the four 3/8-16 x 1¼" 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.
7. 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.
8. 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 lower the transmission down onto the spindle head casting.
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.
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MECHANICAL SERVICE
3. Tighten the drive belt in accordance with the instructions in Section 3.3.
4. Set the Spindle orientation as described in Section 7.
NOTE: The following step is necessary only if the spindle or transmission was exchanged prior to belt replacement.
5. Double-check the spindle sweep (Section 5.4) to assure that nothing has moved during the previous steps. If sweep is within tolerance, continue; if not, sweep must be readjusted. (If this is the case, there is no need to completely disassemble the spindle assembly. Simply loosen the set screws, the spindle lock ring, and the six 3/8-16 x ¾" SHCS and re-shim as necessary.)
NOTE: Drive belt's tension must be adjusted after every installation.
SERVICE MANUAL

3.3 TENSION ADJUSTMENT

NOTE: The drive belt's tension should be adjusted after every service on the transmission or spindle on the machine.
1. Turn the machine ON. Position the spindle head casting at a level you will be able to work on the drive belt comfortably.
Belt Assembly
2. Remove the cover panels from the head stock area (Section 1).
3. Remove the tool release piston assembly (Section 2.1).
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 3/8-16 x 1¼" 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.
7. Tighten the 3/8-16 x 1¼" 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 3/8-16 x 1¼" 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.
11. Retighten the 3/8-16 x 1¼" SHCS holding the motor plate to the spindle head casting.
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VMC
Spindle Assembly
SERVICE MANUAL
MECHANICAL SERVICE

4. SPINDLE PULLEY

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.

5. SPINDLE ASSEMBLY

Please read this section in its entirety before attempting to replace spindle.
TOOLS REQUIRED:
3 1/8" HEX WRENCH 3 1/2" HEX WRENCH 3 5/16" HEX WRENCH 3 7/16" HEX WRENCH 3 3/16" ALLEN WRENCH 3 RUBBER MALLET 3 WOOD BLOCK (6" x 6" x 6") 3 SHIMS (.0005, .001, .0015, .002) 3 CARDBOARD

5.1 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 (Section 1).
3. Disconnect the air cooling tube or, on newer models, disconnect the two oil lines from the back side of the spindle, whichever is applicable. Plug the oil lines to prevent fluid from siphoning out of the transmission.
4. Remove the tool release piston assembly (Section 2.1).
5. Remove the spindle drive belt from the spindle pulley (Section 3.1). It is not possible to com pletely remove the belt at this time.
6. 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.
7. Ensure oil fill plug is inserted into oil fill hole before removing spindle or oil may spill into into the spindle cartridge.
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MECHANICAL SERVICE
VMC
SERVICE MANUAL
Spindle Assembly
OIL FILL HOLE
HEAD CASTING
Fig. 5-1 Oil injection cover and oil line disconnect.
MOTOR
DISCONNECT OIL
LINE HERE
SPINDLE
OIL INJECTION
COVER
10. With the 5/16" hex wrench, loosen approximately two turns the six 3/8-16 x ¾" SHCS holding the spindle to the underside of the head casting.
11. Place the block of wood (minimum 6" thick) on the table directly under the spindle.
SPINDLE
WOOD
BLOCK
Fig. 5-2 Position wood block under spindle.
COVERED
TABLE
12. At the panel, go to the JOG mode and choose Z-axis. Slowly jog in the negative (-) direction until spindle rests on the block, then remove the screws that were previously loosened (step 9).
13. Jog Z-axis in the positive (+) direction until spindle is half way out of the head casting.
14. Grasp spindle with one hand and continue to jog in Z in the positive (+) direction until it is com pletely free of the casting.
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VMC
Spindle Assembly

5.2 SPINDLE CARTRIDGE INSTALLATION

1. Thoroughly clean all mating surfaces of both the cartridge and the head casting, lightly stone if necessary to remove burrs or high spots.
SERVICE MANUAL
MECHANICAL SERVICE
TOOL DRAW BAR
SPINDLE PULLEY
SPINDLE HOUSING
Fig. 5-3 Spindle cartridge.
2. Place spindle on wood block making sure both spindle dogs contact the block. Align the two 10­32 holes located on the spindle lock so they are approximately 90 degrees from the front of the spindle on the right side.
FRONT
10-32 HOLES
Fig. 5-4 Underside view of spindle cartridge.
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MECHANICAL SERVICE
SERVICE MANUAL
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.
PULLEY
SPINDLE HOUSING
Fig. 5-5 Spindle cartridge alignment.
5. 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.
Spindle Assembly
Do not force it!
6. Install the six 3/8-16 x ¾" SHCS and tighten down completely.
7. Reattach the brass fitting to the oil injection cover and connect the oil line to the fitting. CAUTION! Do not over tighten the fittings when replacing on the oil injection cover. Overtighten ing will result in damage to the spindle cartridge and leaks in the spindle cooling/gearbox lubri cation system, and this damage can only be repaired at the factory.
8. Reinstall the drive belt (Section 3.2) and adjust the tension as needed (Section 3.3).
9. Reinstall the tool release piston assembly (Section 2.2).
10. Reconnect the air cooling tube or, on newer machines, the two oil lines on the back side of the spindle.
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VMC
Spindle Assembly

5.3 DRAWBAR REPLACEMENT

REMOVAL:
1. Place a tool holder with no cutter in the spindle.
2. Remove cover panels (Section 1).
3. Remove the tool release piston (Section 2.1).
4. Remove the snap ring from the top of the spindle shaft.
5. Reinstall the tool release piston (Section 2.2).
6. Remove the tool holder from the spindle.
7. Remove the spindle (Section 5.1).
8. Remove the drawbar and the distance tube from the spindle assembly.
SERVICE MANUAL
MECHANICAL SERVICE
INSTALLATION:
9. Thoroughly coat the replacement drawbar with grease, including the end of the shaft where the four holding balls are located.
10. Insert four new balls in the replacement drawbar and insert into the spindle shaft. Be sure that as the shaft is installed, the balls do not fall out of the bores in the drawbar.
NOTE: Carefully inspect the 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.
11. Install the spindle cartridge (Section 5.2, Mechanical Service). The tool release piston will have to be reinstalled at this time (Section 2.2).
12. Install a tool holder with no cutter into the spindle taper.
13. Remove the tool release piston (Section 2.1).
14. Install the snap ring on the spindle shaft.
15. Reinstall the tool release piston (Section 2.2).
16. Finish installation of the spindle (Section 5.4).
17. Set the drawbar height, clamp and unclamp switches (Section 6).
NOTE: Step 18 must be followed or damage to the ATC will result.
18. Set the spindle orientation (Section 7).
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MECHANICAL SERVICE
19. Reinstall the head covers (Section 1).
20. Test-run the machine and adjust the ATC as necessary (Sections 14.3, 14.4).
SERVICE MANUAL

5.4 SPINDLE SWEEP ADJUSTMENT

1. Loosen the two ¼-20 set screws that anchor the lock ring.
2. Using a soft metal punch, gently tap to loosen and remove the lock ring. It is a right-hand thread; turn counterclockwise.
3. 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.
4. Establish reference zero at rear of the table. Sweep the three remaining points (left, front, and right) and record the reading.
Spindle Assembly
10" DIA. CIRCLE
Fig. 5-7 Spindle sweep area.
5. Shim the spindle if necessary to correct the spindle sweep to specifications.
6. 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.
7. Reassemble VMC in reverse order (spindle pulley then drive belt). Refer to Sections 1 - 4, Me chanical Service, for correct procedures. Ensure there is at least 0.0015 gap between spindle shaft and oil injection cover. Continue with reassembly and adjustment steps (Sections 6-9).
NOTICE: The machine must be properly leveled for the spindle sweep adjustment to be accurate.
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Tool Clamp/Unclamp
6. TOOL CLAMP/UNCLAMP SWITCH ADJUSTMENT;
Shim Washer Draw Bar Height Setting
Please read this section in its entirety before adjusting clamp/unclamp switches or setting draw­bar height.
TOOLS REQUIRED:
3 MACHINED ALUMINUM BLOCK (2" x 4" x 4") 3 5/16" HEX WRENCH 3 HAMMER 3 6" FLEXIBLE RULER or .020" SHIM 3 1" DIA. PIPE (APPROX. 1' LONG)
6.1 TOOL CLAMP/UNCLAMP SWITCH ADJUSTMENT - INITIAL PREPARATION
1. Remove cover panels (Section 1).
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.
SERVICE MANUAL
MECHANICAL SERVICE
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.
ñ
Fig. 6-1 Z-axis jog increment setting (.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.
The clearance from the tool holder to the block should be zero (0).
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MECHANICAL SERVICE
Fig. 6-2 Placement of aluminum block under spindle.
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).
SERVICE MANUAL
Tool Clamp/Unclamp
Do not jog too far in the negative (-) direction or else it will cause an overcurrent in the Z-axis!

6.2 SETTING DRAWBAR HEIGHT

1. Set hand wheel to 0 by pushing MDI and turning hand wheel to zero (0).
2. Push handle jog button and set increments to .01. Jog Z-axis in the positive (+) direction .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 incre ment 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 (See Section 6.3).
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 (See Section 6.3).
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Tool Clamp/Unclamp

6.3 SHIM WASHERS

1. To add or subtract shim washers, remove tool release piston assembly (Section 2.1) from head casting.
Shims may need replacement when spindle cartridge, tool release piston assembly, or drawbar is replaced. If none have been replaced, skip to Section 6-4.
MOUNTING
BOLTS
TOOL RELEASE
LOCK BOLT
SERVICE MANUAL
MECHANICAL SERVICE
SHIM
WASHERS
Fig. 6-3 Tool release piston assembly
2. Remove tool release bolt
3. Add or subtract required shim washers (See Section 6.2 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.
¼" AIR HOSE
CONNECTION
LIMIT
SWITCHES
Fig. 6-4 Tool release piston assembly
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5. Install tool release piston assembly and recheck settings. If within specifications, continue; if not, readjust.
SERVICE MANUAL
6.4 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 (Section 6.2), jog Z-axis in the positive (+) direction .06.
3. Press 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. On earlier machines, loosen nut that holds the switch to the bracket.
Tool Clamp/Unclamp
UNCLAMP SWITCH
SPRING RETAINER
Fig. 6-5 Tool release piston assembly (cutaway).
4. While activating tool release, tap unclamp switch assembly towards spring retainer until it just trips. On earlier machines, loosen or tighten nuts accordingly. 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.
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.
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UPPER (CLAMP) SWITCH -
6. Place a shim (approximately .020 thick), or the flexible ruler, between the tool release piston and the draw bar.
DRAW BAR
SHIM
SERVICE MANUAL
MECHANICAL SERVICE
SPINDLE
CARTRIDGE
ASSEMBLY
Fig. 6-6 Placement of shim before checking switch adjustment.
7. 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.
Ú
PISTON
SHIM
HEAD CASTING
Fig. 6-7 Push piston down to hold shim in place (VF-1/2). Fig. 6-8 VF-0 tool release piston adjustment.
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8. Push down on the tool release piston again until it contacts the draw bar. Monitor the TOOL UNCLAMP light on the screen.
9. Using a hammer, lightly tap the bottom of the switch mounting bracket until the TOOL UNCLAMP light goes off. Do not tap the switch too far, only enough to trip the TOOL UNCLAMP light.
10. Tighten the switch in place. (Check for correct operation by again pushing down on the tool release piston. Hit the tool release button and hold the piston down with the pipe. The TOOL UNCLAMP light should be on. Release the pipe and the light should go off.)
SERVICE MANUAL

Spindle Orientation

7. SPINDLE ORIENTATION
Please read this section in its entirety before attempting to orient spindle.
TOOLS REQUIRED:
3 7/16" SOCKET W/RATCHET or 3/16" HEX SOCKET 3 5/32" HEX WRENCH 3 3/4" WRENCH 3 SCREWDRIVER
7.1 SPINDLE ORIENTATION:
1. Remove cover panels from head stock area (Section 1.1) and tool changer front cover.
2. On Toshiba motor only: with the 3/4" wrench, remove the three hex head bolts that hold the spindle motor to the transmission (Initiate a tool release to facilitate access to the front bolt.).
3. With a tool holder in the spindle, initiate a tool change.
STOP THE TOOL CHANGER BEFORE IT ENGAGES TOOL HOLDER BY PRESSING EMERGENCY STOP.
4. With a screwdriver, push tool changer arm so that tool changer moves towards tool holder. While doing this, turn tool holder so that keyway is aligned with the extractor key. Push arm all the way over, so that the tool changer fully engages tool holder.
5. Disconnect the air supply to the machine, pivot the spindle motor to the right side of the machine (Toshiba motor only).
6. Loosen the four ¼-20 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.
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Setting Parameter 64
ORIENTATION
THREADED
HOLES
1/4-20
BOLTS
Fig. 7-2 Top view of spindle orientation components (VF-1/VF-2). Fig. 7-3 VF-0 motor with orient ring location.
RING DETENT
7. Manually turn the orientation ring and push the shot pin until it drops into the orientation ring detent.
SERVICE MANUAL
ORIENTATION
TOSHIBA MOTOR
ELECTRIC BOX
RING
MECHANICAL SERVICE
SHOT PIN
8. Remove the two ¼" bolts and place them in their original holes. While pushing shot pin into detent, tighten the four bolts. These bolts must be tight.
9. Reconnect the air line.
10. Reset alarms and zero return the Z-axis by going into ZERO RET mode, push Z, then push ZERO SIGL AXIS to bring shuttle out and home the axis.
11. Reinstall the three hex head bolts that hold spindle motor to transmission and tighten (Toshiba motor only).

8. SETTING PARAMETER 64

Please read this section in its entirety before attempting to set Parameter 64.
SETTING PARAMETER 64: (TOOL CHANGE OFFSET)
NOTE: Parameter 7 must be "unlocked" before setting the Parameter 64.
1. WITHOUT a tool in the spindle taper, initiate a tool change and stop the tool changer using the EMERGENCY STOP button. 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 flange A of tool holder (looking directly into pocket). Move indicator to bottom right flange B of tool holder. Any difference between these flanges should be equally divided. For example: if a difference of .002 from left side to right side flange, adjust indicator dial so that indicator reads .001 when it is on either flange. This gives you the tool offset reference.
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Setting Parameter 64
TOOL
CHANGER
COVER
TABLE
TOOL
HOLDER
Fig. 8-1 Checking tool offset reference.
SPINDLE
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 the bottom left flange of the tool holder.
If spindle head is too far in the negative (-) or the positive (+) direction, go to the 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.
Fig. 8-2 Screen showing calculator.
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 Pa rameter 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).
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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.
SERVICE MANUAL
MECHANICAL SERVICE
9. SPINDLE MOTOR & TRANSMISSION
Please read this section in its entirety before attempting to remove or replace transmission.
TOOLS REQUIRED:
3 5/32" HEX WRENCH 3 5/16" HEX WRENCH 3 3/8" HEX WRENCH 3 9/16" x 3/8" DRIVE SOCKET 3 ½" DRIVE RATCHET 3 7/16" x 3/8" DRIVE SOCKET 3 RUBBER MALLET 3 ¾" x ½" DRIVE SOCKET 3 3/8" DRIVE RATCHET 3 ¾" BOX-END WRENCH 3 CARDBOARD 3 GREASE 3 ADJUSTABLE PLIERS 3 ¼" STUBBY BLADE SCREWDRIVER 3 TWO WOOD BLOCKS (6" x 6" x 6") 3 2" x 4" x 4" ALUMINUM BLOCK 3 SHIM WASHERS (.001, .0015, .002, .0005, .010)

9.1 MOTOR REMOVAL (VF-0)

1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the transmis sion. At this time, raise the Z-axis to the full up position.
2. Remove the cover panels from head stock area (Section 1).
3. Remove the tool release piston assembly (Section 2.1).
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 reas sembly.
7. Remove the two ¼-20 x ½" SHCS holding the tube to the solenoid bracket and position the tube so as to not interfere with removal of the motor. It may be necessary to tie the tube back to the Z­axis motor to keep it in place.
8. Remove the four 3/8-16 x 1" SHCS and carefully lift the spindle motor assembly off the spindle head. Take care to not damage the drive pulley during removal.
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NOTE: It is recommended that the HAAS Transmission Hoist be used in this operation (See Section
9.3 for assembly and setup).
SERVICE MANUAL
LIFTING POINTS
Spindle Motor
Figure 9-1 VF-0 with lifting eyeholes.

9.2 INSTALLATION (VF-0)

1. Carefully lower the motor assembly down to just above the spindle head casting, taking care to not 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 3/8-16 x 1" SHCS attaching the motor to the spindle head casting. Adjust the drive belt as noted in Section 3.3 before tightening down completely.
4. Set the spindle orientation as noted in Section 7.
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 tube 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.
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9.3 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.
MODIFICATION
PLATE
SERVICE MANUAL
MECHANICAL SERVICE
SPACER
½-13 X 4 ½" HHB
Fig. 9-2 Support base/mast support assembly.
MAST
2. Attach the boom modification plates to the mast using the three ½-13 x 4½" HHB, three ½" split washers, three ½-13 hex nuts, and the three spacers.
MAST SUPPORT
3/8-16 X 1 ¼"
SHCS
SUPPORT BASE
FLAT WASHERS
3/8" HEX NUTS
Fig. 9-2 Exploded view of boom modification plate components.
SPLIT WASHERS
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 surfaces 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
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boom and the rounded end of the cable guide is toward the outside. Slide the clevis pin through the hole and fasten with the 1/8" x 1" cotter pin.
C. Attach the winch base to the boom with the two 3/8-16 x 1" SHCS, two 3/8" lock wash ers, 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.
HOLE IS
TOWARD
TOP EDGE
(ROUNDED SIDE
ON OUTER EDGE)
PULLEY WHEEL
CABLE GUIDE MUST
ROTATE FREELY
Spindle Motor
BOOM
Fig. 9-3 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. Assemble the cradle as follows:
A. Attach frame C to frames A and B as shown, using two ¼-20 x ½" SHCS, two ¼" medium split washers, and two ¼-20 hex nuts. Do not over tighten the bolts ­the frame sections must slide over the transmission during removal. B. Attach the transmission stops (frame D) to frames A and B as shown, using one ¼-20 x ½" SHCS, one ¼" medium split washer, and one ¼-20 hex nut for each part. Adjust the stops as necessary and tighten securely. C. Fasten all the 5/16-18 shoulder eye bolts to the frame members with the 5/16" split washers and 5/16-18 hex nuts. Assemble as shown and tighten securely.
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SERVICE MANUAL
MECHANICAL SERVICE
EYELETS
FRAME
SPLIT WASHERS
"C"
FRAME "D"
HEX NUTS
FRAME
"B"
FRAME "A"
Fig. 9-4 Exploded view of cradle assembly.
¼-20 x ½"
SHCS

9.4 TRANSMISSION REMOVAL (VF-1/2/3/4)

1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the transmis sion. At this time, raise the Z-axis to the full up position.
2. Remove the cover panels from head stock area (Section 1).
3. Remove the tool release piston assembly (Section 2.1).
4. Remove the six 3/8-16 x 1¼" SHCS holding the transmission to the head casting. Slide the transmission forward enough to release the drive belt from the transmission and spindle pulleys.
5 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.
TUBE
OIL PUMP
SOLENOID
BRACKET
TRANSMISSION
Fig. 9-5 Solenoid bracket with all lines connected
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6. 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.
7. Remove the two ¼-20 x ½" SHCS holding the flexible tube to the solenoid bracket and position t he tube so as to not interfere with the transmission removal. It may be necessary to tie the tube back to the Z-axis motor to keep it in place.
8. Remove the protective cardboard from the mill table and install the support base assembly on the table, using the four ½-13 x 1" SHCS, four ½" flat washers, and the four T-nuts.
NOTE: 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.
Spindle Motor
Fig. 9-6 Support base/mast support assembly location.
9. 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.
BOOM
CLEVIS PINS
MAST
MODIFICATION PLATE
COTTER PINS
Fig. 9-7 Mounting boom assembly to mast.
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MECHANICAL SERVICE
BOOM
CLEVIS PINS
MAST
Fig. 9-8 Mounting boom assembly to mast.
MODIFICATION PLATE
COTTER PINS
11. Place the hoist directly over the transmission and attach the hook to the cradle's eye bolt.
Fig. 9-9 Fully assembled hoist in position
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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HOOK DIAGONALLY
ACROSS MOTOR
Fig. 9-12 Lifting position for VF-1's thru 4
Spindle Motor
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.

9.5 TRANSMISSION INSTALLATION

1. Place cradle under new transmission and lift just enough to put tension on the cables.
2. Ensure new transmission is seated securely and lift. Only lift high enough to clear the enclosure and to swing into place.
3. Slowly swing boom around to center the cradle and transmission over the spindle head.
4. Lower the transmission carefully to just above the spindle head. Place the drive belt onto the transmission pulley.
5. Lower the transmission into the spindle head, taking care not to crush or bind the drive belt as you lower.
6. Insert and tighten down the six 3/8-16 x 1¼" SHCS attaching the transmission to the spindle head. Adjust the drive belt tension as noted in Section 3.3 before tightening down completely.
7. Reattach the flexible tube to the solenoid bracket and reconnect all electrical and fluid lines. Replace any leaking lines at this time, if necessary.
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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.
SERVICE MANUAL
MECHANICAL SERVICE

10. AXIS MOTOR REMOVAL/INSTALLATION

Please read this section in its entirety before attempting to remove or replace the motors.
TOOLS REQUIRED:
3 1/8" HEX WRENCH 3 3/8" OPEN-END WRENCH 3 5/32" HEX WRENCH 3 7/16" OPEN-END WRENCH 3 ¼" HEX WRENCH 3 BLUE LOCTITE 3 PHILLIPS SCREWDRIVER 3 3/16" HEX WRENCH
10.1 X-AXIS MOTOR REMOVAL -
1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. Move the table to the far left position. Loosen the 10-32 x 3/8" SHCS and remove the right way cover.
MOTOR
MOTOR HOUSING
NUT HOUSING
LEAD SCREW
SUPPORT BEARING
Fig. 10-1 X-axis motor and components.
3. Move the table to the far right position. Loosen the 10-32 x 3/8" SHCS and remove the left way cover.
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4. Remove the side enclosure panels.
5. On the motor housing, remove the four 10-32 x 3/8" BHCS and remove the cover plate.
6. Loosen the 10-32 x ½" SHCS on the motor coupling at the lead screw.
7. Turn the machine power OFF.
8. On the motor housing, loosen the four 5/16-18 x 1¼" SHCS and remove the motor from the housing.
9. Disconnect all wiring from the motor.
INSTALLATION -
1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.
COUPLING HALVES
CLAMP
RING
Axis Motor
FLEX
PLATES
MOTOR
Fig. 10-2 Motor coupling components.
2. Reinstall 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 they are parallel to the coupling halves and 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 insert ing.)
4. Replace the cover plate and fasten with the four 10-32 x 3/8" BHCS.
5. Reinstall the way covers.
6. Reinstall the side enclosures.
7. Check for backlash in the lead screw (Section 3.3, Troubleshooting) or noisy operation.
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10.2 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 the 5/32" hex wrench, remove the 10-32 x 3/8" 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.
SERVICE MANUAL
MECHANICAL SERVICE
COVER PLATE
MOTOR HOUSING
" Y" MOTOR
NUT HOUSING
Fig. 10-3 Y-axis motor and components.
LEAD SCREW
SUPPORT BEARING
4. If the bearings are to be serviced, move the table to the rear of its travel and remove the 10-32 x 3/8" SHCS holding the front way covers to the saddle. Slide the way cover to the forward position.
REMOVING OILER AND AIR REGULATOR PANEL -
5. Turn the machine off and disconnect the compressed air.
6. Using the 3/8" open-end hex wrench, disconnect the oil line connecting the base to the lubrica tion system panel.
7. Using the 7/16" open-end hex wrench, disconnect the solenoid on the front of the panel. Discon nect 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.
9. Unplug 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 3/8-16 x ¾" SHCS
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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.
3/8-16 x 3/4" SHCS
AIR REGULATOR
Axis Motor
LUBRICATOR
Fig. 10-4 Lubricator/air regulator panel.
11. On the motor housing, remove the four 10-32 x 3/8" BHCS and remove the cover plate.
12. Loosen the 10-32 x ½" SHCS on the motor coupling at the lead screw.
13. On the motor housing, loosen the 5/16-18 x 1¼" SHCS and remove the motor from the housing.
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 they are parallel to the coupling halves and the slits in the coupling and clamp ring are in alignment. Tighten the 10-32 x ½" SHCS on the motor cou­pling 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 10-32 x 3/8" BHCS.
5. Reinstall the lube/air regulator panel in reverse order of steps 5-10.
6. Reinstall the way covers.
7. Check for backlash in the lead screw (Section 3.3, Troubleshooting) or noisy operation.
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10.3 Z-AXIS MOTOR REMOVAL -
1. Turn the machine power ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. Remove the back panel from the spindle head.
3. If the bearings are to be serviced, remove the three 10-32 x ½" SHCS attaching the Z-axis way cover to the spindle head and slide the cover to the bottom position.
SERVICE MANUAL
MECHANICAL SERVICE
MOTOR
MOTOR
HOUSING
NUT HOUSING
WAY COVER
LEAD SCREW
SUPPORT BEARING
Fig. 10-5 Z-axis motor and components
4. Lower the spindle head to its lowest position.
5. Disconnect the electrical power.
6. On the motor housing, remove the four 10-32 x 3/8" BHCS and remove the cover plate.
7. Loosen the 10-32 x ½" SHCS on the motor coupling at the lead screw.
8. On the motor housing, loosen the four 5/16-18 x 1¼" SHCS and remove the motor from the housing.
9. Unplug the z-axis connection from the control panel.
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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 they are parallel to the coupling halves and 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 10-32 x 3/8" BHCS.
5. Reconnect electrical power.
6. Reinstall the way covers.
7. Check for backlash in the lead screw (Section 3.3, Troubleshooting) or noisy operation.
Axis Motor
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10.4 COUPLING REPLACEMENT

1. Remove the axis motor (Section 9).
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.
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 (Section 10).
SERVICE MANUAL
CLAMP RING
MECHANICAL SERVICE
COUPLING HALVES
FLEX PLATES
Fig. 10-6 Motor coupling.
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11. LEAD SCREW - REMOVAL AND INSTALLATION

Please read this section in its entirety before attempting to remove or replace the lead screws.
IMPORTANT NOTICE ! ! !
Lead screws may not be replaced without also replacing the old-style bearing sleeves! These installation procedures do not account for the old-style bearing sleeves, so the bearing sleeve type should be verified before replacement.
The new bearing sleeves will have two ¼" diameter holes on the face, the older bearing sleeves will not.
TOOLS REQUIRED:
3 1/8" HEX WRENCH 3 SPANNER WRENCH 3 5/32" HEX WRENCH 3 3/8" OPEN-END WRENCH 3 ¼" HEX WRENCH 3 7/16" OPEN-END WRENCH 3 5/16" HEX WRENCH 3 PRE-LOAD FIXTURE 3 BLUE LOCTITE 3 2" x 4" WOOD BLOCK (21"-23 ½" L)
Lead Screw
11.1 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 10-32 x 3/8" SHCS and remove the chip tray from the mill table.
4. Move the table to the far right position. Loosen the 10-32 x 3/8" SHCS and remove the left way cover.
5. Move the table to the far left position. Loosen the eleven 10-32 x 3/8" SHCS and remove the right way cover.
6. Remove the hard stop from the bearing housing on the lead screw.
MOTOR
COVER PLATE
NUT HOUSING
BALL NUT
MOTOR HOUSING
LEAD SCREW
LEAD SCREW
Fig. 11-1 X-axis lead screw and components.
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7. Disconnect the oil line from the ball nut.
8. Loosen the 10-32 x ½" SHCS and remove the clamp nut on the lead screw support bearing end.
SERVICE MANUAL
MECHANICAL SERVICE
MOTOR HOUSING
MOTOR
LEAD SCREW
Fig. 11-2 Lead screw assembly.
OIL LINE
MILL TABLE
BALL NUT
9. Remove the axis motor (Section 10.1).
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 ¼-20 x 1" (or ¼-20 x ¾") 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.
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MOTOR HOUSING
Lead Screw
NUT HOUSING
Fig. 11-3 Install lead screw from right side.
BALL NUT
LEAD SCREW
3. Insert the lead screw through the nut housing and motor housing (See Fig. 11-3), taking care not to make contact with the screw threads, causing possible damage.
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.)
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.
BEARING SLEEVE
MOTOR HOUSING
Fig. 11-4 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 ¼-20 x 1" (or ¼-20 x ¾") SHCS, attaching the ball nut to the nut hous ing. (Place a drop of blue Loctite® on each of the SHCS before inserting.) Tighten down com pletely.
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Lead Screw
9. Move mill table to the far left position. ("Far left" is when the limit switch bracket touches the x­axis 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 on 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.
NOTE: For the older type bearing sleeves, set the lead screw pre-load (Section 12.1).
SERVICE MANUAL
MECHANICAL SERVICE
13. Reinstall the motor (Section 10.1).
14. Reinstall the way covers and chip tray.
15. Check for backlash in the lead screw (Section 3.3, Troubleshooting) or noisy operation.
11.2 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 (Section 10.2).
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.
5. Loosen the 10-32 x ½" SHCS on the clamp nut at the motor end, then remove the clamp nut.
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Lead Screw
MOTOR
BALL NUT
SUPPORT BEARING
Fig. 11-5 Y-axis lead screw and components.
MOTOR HOUSING
NUT HOUSING
LEAD SCREW
HARD STOP
6. 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.
7. Disconnect the oil line at the ball nut.
8. Loosen and remove the six ¼-20 x 1" 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").
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VMC
SERVICE MANUAL
MECHANICAL SERVICE
NUT HOUSING
SUPPORT
BEARING
Fig. 11-6 Pull lead screw forward around bearing support,...
LEAD SCREW
...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.
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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, SERI OUSLY 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.
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.
SERVICE MANUAL
Lead Screw
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.
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Lead Screw
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. 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.
NOTE: For the older type bearing sleeves, set the lead screw pre-load (Section 12.2).
15. Reinstall the axis motor (Section 10.2).
16. Check for backlash in the lead screw (Section 3.3, Troubleshooting) or noisy operation.
11.3 Z-AXIS LEAD SCREW REMOVAL -
VF-6 WARNING! ALWAYS BLOCK THE SPINDLE HEAD AND BLEED THE COUNTER
WEIGHT SYSTEM AIR, BEFORE SERVICING ANY Z-AXIS COMPONENTS.
SERVICE MANUAL
MECHANICAL SERVICE
1. Remove the axis motor (Section 10.3).
2. Remove the bearing sleeve (Section 12.3).
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.
NUT HOUSING
SUPPORT
BEARING
BALL NUT
LEAD SCREW
Fig. 11-7 Z-axis lead screw and components.
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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. Manually push the spindle head to the top of its travel and block it in position with the 2" x 4". Place a piece of paper between the board and table.
CAUTION: FAILURE TO BLOCK THE SPINDLE HEAD IN POSITION MAY RESULT IN A SPINDLE HEAD FREE-FALL, CAUSING DAMAGE TO THE SPINDLE HEAD AND/OR MILL TABLE, OR SERIOUS PERSONAL INJURY.
7. 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.
USE EXTREME CAUTION! DO NOT DAMAGE THE THREADS ON THE LEAD SCREW.
SERVICE MANUAL
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.
Lead Screw
CAUTION: MATING SURFACES MUST BE CLEAN OR MISALIGNMENT MAY OCCUR, SERI OUSLY 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.
Fig. 11-8 Reinstalling the lead screw.
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Lead Screw
3. Loosely screw on the clamp nut on 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 insert ing.) Tighten down completely.
5. Hand-turn the lead screw until the face of the ball nut is approximately six inches (6") from the support bearing face.
6. CAREFULLY remove the wood block and lower the spindle head until the nut housing is resting on the ball nut.
7. 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.
8. Loosen, but do not remove, the six ¼-20 x 1" SHCS attaching the bearing sleeve to the motor housing.
9. Hand-turn the lead screw until spindle head is at the top of its travel.
SERVICE MANUAL
MECHANICAL SERVICE
10. 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.
11. Loosely install the clamp nut on the motor housing end of the lead screw.
12. 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.
13. Reinstall the hard stop at the support bearing end of the lead screw.
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. 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.
NOTE: For the older type bearing sleeves, set the lead screw pre-load (Section 12.3).
15. Reinstall the axis motor (Section 10.3).
16. Check for backlash in the lead screw (Section 3.3, Troubleshooting) or noisy operation.
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Support Bearings

12. LEAD SCREW SUPPORT BEARING

Lead Screw Pre-load Adjustments
INTRODUCTION:
The lead screw test fixture is designed to adjust pre-load on the lead screw bearings in the field. When used properly, the fixture will accurately set the pre-load on the thrust bearings in the lead screw.
GENERAL DESCRIPTION:
The test fixture operates by air pressure to apply tension on the lead screw. This, in turn, pre­loads the bearings in the motor housing to optimize bearing life and minimize backlash.
NOTE: VMC's built after approximately October 1, 1992 will not need pre-load adjustments. Skip this procedure for those machines as applicable.
Please read this section in its entirety before attempting to set the pre-load.
TOOLS REQUIRED:
3 1/8" HEX WRENCH 3 SPANNER WRENCH 3 5/32" HEX WRENCH 3 3/8" OPEN-END WRENCH 3 ¼" HEX WRENCH 3 7/16" OPEN-END WRENCH 3 5/16" HEX WRENCH 3 PRE-LOAD FIXTURE

12.1 X-AXIS

1. Turn the VF-1 ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2 Remove the motor (Section 11.1).
3. Loosen the 10-32 x 3/8" SHCS on the clamp nut inside the motor housing on the lead screw and unscrew the clamp nut one turn.
4. Loosen the clamp nut on the support bearing at least four turns.
5. Slide the pre-load fixture onto the lead screw and tighten the four 5/16-18 x 1¼" SHCS attaching it to the motor housing.
6. Tighten the two 10-32 x ½" SHCS on the clamp rings on the fixture coupling.
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SERVICE MANUAL
MECHANICAL SERVICE
MILL TABLE
PRE-LOAD
FIXTURE
Fig. 12-1 Pre-load fixture in place.
MOTOR
HOUSING
7. Tighten the clamp nut on the lead screw in the motor housing with a spanner to ensure that the bearings are seated.
8. Connect compressed air to the fixture and set the air pressure to 105 psi (+0/-5 psi). Loosen the clamp nut on the lead screw on the motor housing at least four full turns.
9. Hand-tighten the clamp nut back down until it just contacts the bearing on the motor housing.
CAUTION! DO NOT TIGHTEN THE CLAMP NUT AGAINST THE BEARING.
10. Tighten the 10-32 x ½" SHCS on the clamp nut. The lead screw may need to be rotated to allow access. (To rotate the lead screw, disconnect the compressed air from the fixture and rotate the lead screw by hand. Repeat steps 9 and 10).
CAUTION! DO NOT OVER TIGHTEN THE 10-32 x ½" SHCS AS DAMAGE TO THE LEAD SCREW AND THE CLAMP NUT WILL RESULT.
11. Disconnect the compressed air supply from the fixture and remove the fixture from the motor housing.
WARNING! THE COMPRESSED AIR SUPPLY MUST BE REMOVED PRIOR TO REMOVING THE FIXTURE FROM THE MOTOR HOUSING. FAILURE TO DO SO WILL CAUSE THE CYLINDER TO RETRACT RAPIDLY, CAUSING DAMAGE TO THE FIXTURE AND PERSONAL INJURY.
REASSEMBLY-
12. Reinstall the motor (Section 11.1). 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.
13. Reconnect electric power to the machine and POWER ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
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"X" MOTOR
MOTOR HOUSING
NUT HOUSING
Fig. 12-2 X-axis motor and components.
LEAD SCREW
SUPPORT BEARING
14. Tighten the clamp nut on the lead screw support bearing on the end opposite the motor housing until it contacts the bearing, then tighten the 10-32 x ½" SHCS on the clamp nut.
CAUTION! DO NOT OVER TIGHTEN THE 10-32 x ½" SHCS AS DAMAGE TO THE LEAD SCREW AND THE CLAMP NUT WILL RESULT.
15. Reinstall the way covers.
16. Check for backlash in the lead screws (Section 3.3, Troubleshooting) or noisy operation.

12.2 Y-AXIS

1. Turn the machine power ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
COVER PLATE
"Y" MOTOR
NUT HOUSING
LEAD SCREW
SUPPORT BEARING
MOTOR HOUSING
Fig. 12-3 Y-axis motor and components.
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Support Bearings
2. Remove the motor (Section 11.2).
3. Loosen the 10-32 x 3/8" SHCS on the clamp nut inside the motor housing on the lead screw and unscrew the clamp nut one turn.
4. Loosen the 10-32 x 3/8" SHCS on the clamp nut on the support bearing. Loosen the clamp nut at least four turns.
5. Slide the pre-load fixture onto the lead screw and tighten the four 5/16-18 x 1¼" SHCS that attach it to the motor housing.
6. Tighten the two 10-32 x 3/8" SHCS on the clamp rings on the fixture coupling.
7. Tighten the clamp nut on the lead screw in the motor housing with a spanner to ensure that the bearings are seated.
8. Connect compressed air to the fixture and set the air pressure to 105 psi (+0/-5 psi). Loosen the clamp nut on the lead screw on the motor housing at least four full turns.
9. Screw the clamp nut back down until it just contacts the bearing on the motor housing.
SERVICE MANUAL
MECHANICAL SERVICE
CAUTION! DO NOT TIGHTEN THE CLAMP NUT AGAINST THE BEARING.
10. Tighten the 10-32 x 3/8" SHCS on the clamp nut. The lead screw may need to be rotated to allow access. (To rotate the lead screw, disconnect the compressed air from the fixture and rotate the lead screw by hand. Repeat steps 9 and 10).
CAUTION! DO NOT OVER TIGHTEN THE 10-32 x ½" SHCS AS DAMAGE TO THE LEAD SCREW AND CLAMP NUT WILL RESULT.
11. Disconnect the compressed air supply from the fixture and remove the fixture from the motor housing.
WARNING! THE COMPRESSED AIR SUPPLY MUST BE REMOVED PRIORTO REMOVING THE FIXTURE FROM THE MOTOR HOUSING. FAILURE TO DO SO WILL CAUSE THE CYLINDER TO RETRACT RAPIDLY CAUSING DAMAGE TO THE FIXTURE AND PERSONAL INJURY.
REASSEMBLY -
12. Reinstall the motor (Section 11.2). 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.
13. Reconnect electric power to the machine and POWER ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
14. Move the table to the rear of its travel. Tighten the clamp nut on the lead screw support bearing on the end opposite the motor housing until it just contacts the bearing , then tighten the 10-32 x ½" SHCS on the clamp nut.
CAUTION! DO NOT OVER TIGHTEN THE 10-32 x ½" SHCS AS DAMAGE TO THE LEAD SCREW AND CLAMP NUT WILL RESULT.
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15. Reinstall the way covers.
16. Check for backlash in the lead screws (Section 3.3, Troubleshooting) or noisy operation.
SERVICE MANUAL

12.3 Z-AXIS

VF-6 WARNING! ALWAYS BLOCK THE SPINDLE HEAD AND BLEED THE COUNTER
WEIGHT SYSTEM AIR, BEFORE SERVICING ANY Z-AXIS COMPONENTS.
1. Turn the machine power ON. ZERO RETURN all axes. Put the machine in HANDLE JOG mode.
2. Remove the motor (Section 11.3).
3. Loosen the 10-32 x 3/8" SHCS on the clamp nut inside the motor housing on the lead screw and unscrew the clamp nut one turn.
4. Loosen the 10-32 x 3/8" SHCS on the clamp rung on the support bearing. Loosen the clamp nut at least four turns.
Support Bearings
5. Slide the pre-load fixture onto the lead screw and tighten the four 5/16-18 x 1¼" SHCS that attach it to the motor housing.
6. Tighten the two 10-32 x 3/8" SHCS on the clamp rings on the fixture coupling.
Fig. 12-4 "Z" motor and components.
7. Tighten the clamp nut on the lead screw in the motor housing with a spanner to ensure that the bearings are seated.
8. Connect compressed air to the fixture and set the air pressure to 105 psi (+0/-5 psi). Loosen the clamp nut on the lead screw on the motor housing at least four full turns.
9. Screw the clamp nut back down until it just contacts the bearing on the motor housing.
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CAUTION! DO NOT TIGHTEN THE CLAMP NUT AGAINST THE BEARING.
10. Tighten the 10-32 x ½" SHCS on the clamp nut. The lead screw may need to be rotated to allow access. (To rotate the lead screw, disconnect the compressed air from the fixture and rotate the lead screw by hand. Repeat steps 9 and 10).
CAUTION! DO NOT OVER TIGHTEN THE 10-32 x ½" SHCS AS DAMAGE TO THE LEAD SCREW AND CLAMP NUT WILL RESULT.
11. Disconnect the compressed air supply from the fixture and remove the fixture from the motor housing.
WARNING! THE COMPRESSED AIR SUPPLY MUST BE REMOVED PRIOR TO REMOV ING THE FIXTURE FROM THE MOTOR HOUSING. FAILURE TO DO SO WILL CAUSE THE CYLINDER TO RETRACT RAPIDLY CAUSING DAMAGE TO THE FIXTURE AND PERSONAL INJURY.
REASSEMBLY -
12. Reinstall the motor (See Section 11.3). Make sure the flex plates are parallel to the coupling halves and the slits in the coupling and clamp ring are in alignment.
SERVICE MANUAL
MECHANICAL SERVICE
13. Reconnect electric power to the machine and POWER ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
14. Tighten the clamp nut on the lead screw support bearing (the end opposite the motor housing) until it just contacts the bearing, then tighten the 10-32 x ½" SHCS on the clamp nut.
CAUTION! DO NOT OVER TIGHTEN THE 10-32 x ½" SHCS AS DAMAGE TO THE LEAD SCREW AND THE CLAMP NUT WILL RESULT.
15. Reinstall the way covers.
16. Check for backlash in the lead screws (Section 3.3, Troubleshooting) or noisy operation.
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