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    Haas Technical PublicationsManual_Archive_Cover_Page Rev A June 6, 2013•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 origi...

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    TROUBLESHOOTING1June 200396-9010 rev GCOMMON ABBREVIATIONS USED IN HAAS MACHINESACAlternating CurrentAMPAmpereAPCAutomatic Pallet ChangerAPLAutomatic Parts LoaderASCIIAmerican Standard Code for Information InterchangeATCAutomatic Tool ChangerATC FWDAutomatic Tool Changer ForwardATC REVAutomatic T...

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    TROUBLESHOOTING296-9010 rev GJune 2003LOW AIR PRLow Air PressureLVPSLow Voltage Power SupplyMBMegabyte (1 million)MCD RLY BRDM -Code Relay BoardMDIManual Data InputMEMMemoryM-FINM -code FinishedMMMilliMeterMOCONMotor ControlMOTIFMotor InterfaceMSGMessageMSHCPMetric Socket Head Cap ScrewNCNumeric...

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    TROUBLESHOOTING3June 200396-9010 rev G1. TROUBLESHOOTINGThis section is intended for use in determining the solution to a known problem. Solutions given are intended togive the individual servicing the CNC a pattern to follow in, first, determining the problem’s source and, second,solving the p...

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    TROUBLESHOOTING496-9010 rev GJune 20031.1 GENERAL MACHINE OPERATIONMACHINE NOT RUNNINGMachine cannot be powered on• Check input voltage to machine (see "Electrical Service").• Check main circuit breaker at top right of electrical cabinet; switch must be at the on position.• Check...

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    TROUBLESHOOTING5June 200396-9010 rev GVIBRATIONVibration is a subjective evaluation with perceptions varying among individuals, making it difficult to determine inmild cases if there is an actual problem. In obvious cases, it is a matter of determining the source - which isnot easy, since all par...

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    TROUBLESHOOTING696-9010 rev GJune 2003• Check a suspected error with another indicator or method for verification.• Ensure that the indicator is parallel to the axis being checked to avoid tangential reading errors.• Center drill holes before using jobber length drills if accuracy is quest...

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    TROUBLESHOOTING7June 200396-9010 rev GTHERMAL GROWTHA possible source of accuracy and positioning errors is thermal growth of the ballscrew. As the machine warmsup, the ballscrews expand in all three linear axes, causing accuracy and positioning errors, or inaccurateboring depths. This is especia...

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    TROUBLESHOOTING896-9010 rev GJune 20031.2 SPINDLENOT TURNINGSpindle not turning•If there are any alarms, refer to "Alarms" section.•Check that the spindle turns freely when machine is off.•If motor turns but spindle does not, see "Spindle Drive Belts" and "Transmis...

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    TROUBLESHOOTING9June 200396-9010 rev GOVERHEATINGWhen investigating complaints of overheating, a temperature probe must be used to accurately check thetemperature at the top of the spindle taper. The temperature displayed in Diagnostics is not relevant. A machinethat runs at high RPM continuously...

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    TROUBLESHOOTING1096-9010 rev GJune 2003N1000S7500M3;G04 P30.;S500 M3;G04 P150.;M99;N2000S10000M3;G04 P30.;S500M3;G04 P150.;M99;%•If at any time during this procedure the spindle temperature rises above 150 degrees (120 degreesfor 50 Taper), start the procedure over from the beginning and follo...

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    TROUBLESHOOTING11June 200396-9010 rev G(SET MACRO VARIABLES TO ZERO BEFORE STARTING)(LATEST REVISION OCT. 11TH, 1999)G103 P1#115= 500. (RPM INCREMENT)#116=5000. (MAX RPM)#118= 1.0IF [#117 GT 160] THEN M01 (OPTIONAL STOP)IF [#117 LT 120] THEN #118= 0.8IF [#117 LT 90] THEN #118= 0.6IF [#117 LT 60] ...

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    TROUBLESHOOTING1296-9010 rev GJune 2003Vector DriveTo properly troubleshoot the Vector Drive, use the following questions as a guide:• What alarms are generated?• When does the alarm occur?• Is the Vector Drive top fault light on?• Is there a fault light on any of the servo amplifiers?...

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    TROUBLESHOOTING13June 200396-9010 rev G8.Measure the resistance across the motor wires from phase to phase and from each phase tochassis. The meter should read .1 ohms phase-to-phase and open phase-to-chassis.If the fault occurs upon deceleration or acceleration just as the spindle reaches its sp...

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    TROUBLESHOOTING1496-9010 rev GJune 2003TOOLS STICKING IN TAPERTool sticking in the taper causes ATC to be pulled up; accompanied by a popping noise asthe tool holder pops out of the spindle taper.NOTE:This problem may occur after loading a cold tool into a hot spindle (aresult of thermal expansi...

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    TROUBLESHOOTING15June 200396-9010 rev G1.3 SERVO MOTORS / BALL SCREWSNOT OPERATINGAll problems that are caused by servo motor failures should register an alarm. Check the alarm history todetermine the problem’s cause before any action is taken.Servo motor is not functioning•Check the power ca...

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    TROUBLESHOOTING1696-9010 rev GJune 2003•Run the axis back and forth. The motor will get very hot if the bearing sleeve is damaged. If so, turnthe axis by hand and feel for roughness in the ball screw. Loosen the clamp nuts at both ends of theball screw. If the symptom disappears, replace the b...

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    TROUBLESHOOTING17June 200396-9010 rev GCHECKING X-AXIS:1.Set up a dial indicator and base on the mill table as shown in Fig. 1.3-1.Figure 1.3-1. Dial indicator in position to check X-axis.2.Set dial indicator and the “Distance to go” display in the HANDLE JOG mode to zero as follows:• Zero ...

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    TROUBLESHOOTING1896-9010 rev GJune 2003CHECKING Y-AXIS:1.Set up a dial indicator and base on the mill table as shown in Fig. 1.3-2.Figure 1.3-2. Dial indicator in position to check Y-axis.2.Set dial indicator and the “Distance to go” display in the HANDLE JOG mode to zero as follows:• Zero...

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    TROUBLESHOOTING19June 200396-9010 rev GCHECKING Z-AXIS:1.Set up a dial indicator and base on the mill table as shown in Fig. 1.3-3.Figure 1.3-3. Dial indicator in position to check Z-axis.2.Set dial indicator and the “Distance to go” display in the HANDLE JOG mode to zero as follows:• Zero ...

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    TROUBLESHOOTING2096-9010 rev GJune 2003BACKLASH - POSSIBLE CAUSES:If backlash is found in the system, check for the following possible causes:•Loose SHCS attaching the ball nut to the nut housing. Tighten the SHCS as described in "MechanicalService" section.•Loose SHCS attaching th...

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    TROUBLESHOOTING21June 200396-9010 rev G5.Index the bearing housing by one set of holes, moving clockwise. Bolt the bearing housing flangedown. Torque the bolts to 25 ft./lbs. Check the backlash in each of the four quadrants. The factoryspecification is 0.0003” to 0.0007”.If necessary, repeat ...

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    TROUBLESHOOTING2296-9010 rev GJune 2003FOLLOWING ERRORFollowing error alarms occur on one or more axes sporadically•Check DC bus voltage on "Diagnostics" page 2. Verify this voltage on the drive cards in the control panel.If it is at the low side of the recommended voltages, change t...

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    TROUBLESHOOTING23June 200396-9010 rev GContamination of the lube and/or coolant systems can be caused by a wearing Ball Screw, or by metal chipsentering the systems through open or loose way covers. Check all way covers and seals for excessive clear-ances.Machine Crash:A hard machine crash can ca...

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    TROUBLESHOOTING2496-9010 rev GJune 2003SPINDLE OPERATIONATC out of orientation with the spindle. Incorrect spindle orientation will cause the ATCto crash, and Alarm 113 to be generated.•Check the orientation of the spindle.ATC will not run•Check to be sure that the tool changer has been defi...

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    TROUBLESHOOTING25June 200396-9010 rev G1.4 PALLET CHANGER180 PALLET NOT CLAMPED Intended to keep the operator from machining on a pallet that is unclamped.This is caused by a pallet change sequence interrupted by RESET, FEED HOLD, E-STOP, or POWEROFF before complete. Then, with the pallet not ful...

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    TROUBLESHOOTING2696-9010 rev GJune 2003ORThe load station floating nut assembly is spinning, not allowing the drawbar to thread out of the palletnut, due to:•damaged load station drawbar threads,•contamination of floating nut assembly,•weak springs in the floating nut assembly.To correct t...

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    TROUBLESHOOTING27June 200396-9010 rev GThis alarm indicates the CW/CCW limit switch is:•defective,•erroneously tripped (by a foreign object, etc.).To correct this, ensure the discrete inputs RP CW and RP CCW on the Diagnostics page are correct(correct one reads “1” while the other reads ...

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    TROUBLESHOOTING2896-9010 rev GJune 2003The main drawbar DOWN limit switch is:•unplugged,•defective.To correct this, ensure the discrete inputs RPDBDN and RPDBUP on the Diagnostics page are correct(both read “1” when the main drawbar is up, and both read “0” when the main drawbar is d...

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    TROUBLESHOOTING29June 200396-9010 rev GORThe main drawbar motor:•is unplugged,•has broken the output shaft at the snap ring groove,•has failed,•has geartrain failure (unlikely).To correct this, replace the motor or geartrain components if necessary.ORThe is a clutch failure/loss of torque...

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    TROUBLESHOOTING3096-9010 rev GJune 2003ORThe hardstops are not adjusted correctly. To correct this, refer to the “Pallet Rotation Hardstop Adjust-ment” section.ORExcess weight causes the pallet to go out of alignment. To correct this, check the load on the palletchanger. If it exceeds the we...

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    TROUBLESHOOTING31June 200396-9010 rev G1.5 AUTOMATIC TOOL CHANGERDEFLECTIONDeflection 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 ofthe ATC...

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    TROUBLESHOOTING3296-9010 rev GJune 2003Tool holders spin only at certain pockets of the ATC•Check all of the extractor forks to ensure they are centered in the pocket of the ATC. Also, check thealignment and CAROUSEL OFFSET (Parameter 215). See "Extractor Fork Replacement", if necess...

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    TROUBLESHOOTING33June 200396-9010 rev G1-57Chain Motion200 Series Retrieving a new tool from the chain.300 Series Returning a tool to the chain.In the event of a tool changer related alarm. The FG state and BG state will be displayed as negative value.Entering Tool Change Recovery will clear the ...

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    TROUBLESHOOTING3496-9010 rev GJune 2003Arm slide mechanism stops early and does not reach the centerline of the spindle and/or carousel tool pocket.This is caused because the travel stop-nut on the slide shock absorber has loosened and backedoff. To correct this, readjust the shock absorber stop...

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    TROUBLESHOOTING35June 200396-9010 rev GORThis is caused because the arm is not pulled in far enough. To correct this, adjust the hydraulicpressure or arm pull-in travel stop screw.Tool holder falls out of the magazine tool pots.This is caused because the tool pocket detents are stuck or the sprin...

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    TROUBLESHOOTING3696-9010 rev GJune 20031.6 GEARBOX AND SPINDLE MOTORThe gearbox cannot be serviced in the field and must be replaced as a unit. NEVER remove a motor from thegearbox on an HS-Series mill, as this will damage the gearbox and void the warranty.NOISEWhen investigating complaints of ...

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    TROUBLESHOOTING37June 200396-9010 rev G1.7 THROUGH THE SPINDLE COOLANTNOTE:Abrasive swarf from grinding or ceramic machining operations will causeheavy wear of TSC coolant pump, coolant tip and drawbar. This is not coveredby warranty on new machines. Notify HAAS Service Department if machine isb...

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    TROUBLESHOOTING3896-9010 rev GJune 2003LOW COOLANTAlarm 151, "Low Thru Spindle Coolant"•Check coolant tank level. Check for slow coolant drainage from the machine enclosure.•Check the filter and intake strainer for any clogging. Read filter gauges with TSC running with no tool insp...

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    TROUBLESHOOTING39June 200396-9010 rev G1.8 HYDRAULIC COUNTERBALANCE020406080100120140160psiHydraulicTankPressureGaugePressureSwitchCablePressureManifoldOutletPressureSwitchFill ValveHydraulic Tank AssemblyTOP OF TRAVEL PRESSUREA reference table is listed below indicating top of travel pressure a...

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    TROUBLESHOOTING4096-9010 rev GJune 2003noitidnoCenihcaM)s(melborPelbissoPevitcerroCnoitcA,smralaenihcaM.wolgnidaererusserpskaelrednilyC-skaelgnittiF-12,smralaenihcaM,kognidaererusserp.tesertonseodmralaeruliafdraobO/I-stcatnocytridroelbacdaB-simetsysro/dnahgihootgnitteshctiwS-.eguagetaruccanioteu...

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    TROUBLESHOOTING41June 200396-9010 rev Gc)Pump new Mobil DTE-25 oil (see chart for qty.) into system using Hydraulic Hand PumpKit. (see “Hydraulic Hand Pump Instructions” below).MachineQuarts of Mobile DTE-25# of Pump StrokesVF-E-11, VR-11, HS-12 per tank93VB-1, HS-33 per tank0140d) Pressurize...

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    TROUBLESHOOTING4296-9010 rev GJune 2003MECHANICAL DIAGNOSISImportant! Hydraulic counterbalance oil is dyed red for easier recognition.Noise in the system•Slight moan or creaking at slow speeds is normal for rubber seals•While Y-axis is in motion a whistle sound at tank location is normal flu...

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    TROUBLESHOOTING43June 200396-9010 rev G1.9 ELECTRICAL TROUBLESHOOTINGCAUTION! Before working on any electrical components, power off the machine andwait approximately 10 minutes. This will allow the high voltage power onthe brushless amplifiers to be discharged.ELECTRICAL ALARMSAxis Drive Fault ...

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    TROUBLESHOOTING4496-9010 rev GJune 2003Axis Cable Fault•During a self-test, the encoder cable signals were found to be invalid. This alarm is usually causedby a bad cable, or a bad connection on the motor encoder connectors. Check the cable for anybreaks, and the encoder connectors at the moto...

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    TROUBLESHOOTING45June 200396-9010 rev GWO8Over-current limit, stalled or PCB fault. Check for binding in the tool changer gearbox. Make surethe belt is not too tight. Ohm out the motor cable, checking pins G to F (should be open), G to H(should be open), and F to H (should read between 2.5 and 5 ...

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    TROUBLESHOOTING4696-9010 rev GJune 2003KEYBOARD DIAGNOSTICThis Keyboard Grid is for machines with a Keyboard Interface only. This Keyboard Grid isnot for machines with a Serial Keyboard Interface.NOTE:Refer to the "Cable Locations" section of this manual for a drawing of theKeyboard In...

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    TROUBLESHOOTING47June 200396-9010 rev GExample1.Pressing the RESET button will cause diodes 1 and 17 to conduct.•With the POWER OFF read across diode 1. A typical reading is between .400-.700 ohms, note your reading.2.Press and hold the RESET button. If the diode is conducting, the reading shou...

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    TROUBLESHOOTING4896-9010 rev GJune 20031. Open the control panel2. Double click on the Network icon3. Select the Protocols tab.4. Highlight NWLINK IPX/SPX Compatible Transport.5. Select properties.6. Select Manual Frame Type Detection.7. Click on Add.8. Select Ethernet 802.29. Click on Add.10. C...

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    49ALARMSJune 200396-9010 rev G2. ALARMSAny time an alarm is present, the lower right hand corner of the screen will have a blinking "ALARM". Pushthe ALARM display key to view the current alarm. All alarms are displayed with a reference number and acomplete description. If the RESET key ...

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    50ALARMSJune 200396-9010 rev G109Y Servo OverloadSame as alarm 108.110Z Servo OverloadSame as alarm 108.111A Servo OverloadSame as alarm 108.112No InterruptElectronics fault. Call your dealer.113Shuttle In FaultTool changer is not completely to right. During a tool changeroperation the tool in/ou...

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    51ALARMSJune 200396-9010 rev G121Low Lube or Low PressureWay lube is low or empty or the lube pressure is too high or low.Check tank at rear of mill and below control cabinet. Also checkconnector on the side of the control cabinet. Check that the lubelines are not blocked.122Regen OverheatThe con...

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    52ALARMSJune 200396-9010 rev G134Tool Clamp FaultWhen UNCLAMPING, the tool did not release from spindle whencommanded. Check air pressure and solenoid circuit breakerCB4. Can also be caused by misadjustment of drawbarassembly.135X Motor Over HeatServo motor overheat. The temperature sensor in th...

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    53ALARMSJune 200396-9010 rev G151Low Thru Spindle CoolantFor machines with Through the Spindle Coolant only. This alarmwill shut off the coolant spigot, spindle and pump, and purge thesystem. Check for low coolant tank level, any filter or intakestrainer clogging, or for any kinked or clogged co...

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    54ALARMSJune 200396-9010 rev G173Spindle Ref Signal MissingThe Z channel pulse from the spindle encoder is missing forhard tapping synchronization.174Tool Load ExceededThe tool load monitor option is selected and the maximum loadfor a tool was exceeded in a feed. This alarm can only occur if thet...

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    55ALARMSJune 200396-9010 rev G193B Axis Drive FaultSame as alarm 161.194B Zero Ret Margin Too SmallSame as alarm 165195B Cable FaultSame as alarm 182.196Coolant Spigot FailureVertical mills only. Spigot failed to achieve commanded locationafter two (2) attempts.197100 Hours Unpaid BillCall your d...

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    56ALARMSJune 200396-9010 rev G217X Axis Phasing ErrorError occurred in phasing initialization of motor. This can becaused by a bad encoder, or a cabling error.218Y Axis Phasing ErrorSame as alarm 217.219Z Axis Phasing ErrorSame as alarm 217.220A Axis Phasing ErrorSame as alarm 217.221B Axis Phasi...

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    57ALARMSJune 200396-9010 rev G239Unknown Mocon AlarmMocon has reported an alarm to the current software. The currentversion of software was unable to identify the alarm. See moconsoftware release notes for additional diagnostics.240Empty Prog or No EOBDNC program not found, or no end of program f...

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    58ALARMSJune 200396-9010 rev G260Language CRCIndicates FLASH memory has been corrupted or damaged.Please reload foreign language files.261Rotary CRC ErrorRotary table saved parameters (used by Settings 30, 78) had acyclic redundancy check (CRC) error. Indicates a loss of memory,possible processor...

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    59ALARMSJune 200396-9010 rev G281Z Axis Linear Scale Z FaultSame as alarm 279.282A Axis Linear Scale Z FaultSame as alarm 279.283X Axis Linear Scale Z CH MissingBroken wires or encoder contamination. All servos are turned off.This Z Channel Missing can also be caused by loose scaleconnectors.284Y...

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    60ALARMSJune 200396-9010 rev G302Invalid R In G02 or G03Check your geometry. R must be greater than or equal to half thedistance from start to end within an accuracy of 0.0010 inches.303Invalid X, Y, or Z In G02 or G03Check your geometry.304Invalid I, J, Or K In G02 Or G03Check your geometry. Ra...

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    61ALARMSJune 200396-9010 rev G328Invalid Tool NumberTool number must be between 1 and the value in Parameter 65.329Undefined M CodeThat M code is not defined and is not a macro call.330Undefined Macro CallMacro name O90nn not in memory. A macro call definition is inparameters and was accessed by ...

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    62ALARMSJune 200396-9010 rev G351Invalid P CodeIn a block with G103 (Block Lookahead Limit), a value between 0and 15 must be used for the P code.352Aux Axis Power OffAux C, U, V, or W axis indicate servo off. Check auxiliary axes.Status from control was OFF.353Aux Axis No HomeA ZERO RET has not b...

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    63ALARMSJune 200396-9010 rev G378Skip Signal FoundSkip signal check code was included but skip was found when itwas not expected.379Skip Signal Not FoundSkip signal check code was included but skip was not foundwhen it was expected.380X, Y, A, or G49 Not Allowed in G37G37 may only specify Z-axis ...

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    64ALARMSJune 200396-9010 rev G405RS-232 Illegal Prog NameCheck files being loaded. Program name must be Onnnnn andmust be at beginning of a block.406RS-232 Missing CodeA receive found bad data. Check your program. The program willbe stored but the bad data is turned into a comment.407RS-232 Inval...

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    65ALARMSJune 200396-9010 rev G432Disk Illegal Prog NameCheck files being loaded. Program must be Onnnnn and mustbe at the beginning of a block.433Disk Empty Prog NameCheck your program. Between % and % there was no programfound.434Disk Load Insufficient MemoryProgram received does not fit. Check ...

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    66ALARMSJune 200396-9010 rev G518Illegal Macro Exprsn ReferenceAn alpha address with expression, such as A[#1+#2], evaluatedincorrectly. Same as 517.519Term ExpectedIn the evaluation of a macro expression, an operand wasexpected and not found.520Operator ExpectedIn the evaluation of a macro expre...

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    67ALARMSJune 200396-9010 rev G541Macro AlarmThis alarm was generated by a macro command in a program.600U Over Travel RangeSame as alarm 316.601V Over Travel RangeSame as alarm 316.602W Over Travel RangeSame as alarm 316.603U Limit SwitchSame as alarm 145.604V Limit SwitchSame as alarm 145.605W L...

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    68ALARMSJune 200396-9010 rev G626Tool Pocket Slide ErrorThis alarm is generated by a side mount tool changer. It isgenerated if the tool pocket has not moved to its commandedposition (and settled) within the total time allowed by parameters306 and 62.627ATC Arm Position TimeoutThis alarm supports...

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    69ALARMSJune 200396-9010 rev G633APC-Clamp ErrorThe pallet did not clamp in the amount of time allowed byparameter 316. This alarm is most likely caused by the VMCtable not being in the correct position. This can be adjustedusing the setting for the X position (#121, #125) as described inthe ‘I...

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    70ALARMSJune 200396-9010 rev G642APC-Incorrect Chain LocationChain not in position to load or unload pallets when necessary.To correct this, the mislocated pallet must be moved back intothe proper position by hand. After correcting the condition, run anM50 to continue machining.643RP-Index Statio...

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    71ALARMSJune 200396-9010 rev G650RP-Pallet Not Engaging RP Main DrawbarThis alarm occurs when the Pull Stud cannot properly engagethe Ball Pull Collet. If this happens, the Ball Pull Collet has beenpushed down into the Collet Housing and pallet clamping is notpossible. Check alignment of the pall...

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    72ALARMSJune 200396-9010 rev G675TT MOTOR OVER HEATSame as alarm 135.676TT MOTOR Z FAULTSame as alarm 273.677TT AXIS Z CH MISSINGSame as alarm 275.678TT AXIS DRIVE FAULTSame as alarm 161.679TT ZERO RET MARGIN TOO SMALLSame as alarm 168.680TT CABLE FAULTSame as alarm 182.681TT PHASING ERRORSame as...

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    73ALARMSJune 200396-9010 rev G698ATC PARAMETER ERRORThe ATC type cannot be determined. Check Parameter 278, bit10, HS3 HYD TC, or Parameter 209, bit 2, CHAIN TC, asappropriate for the installed tool changer.900Par No xxx Has Changed. Old Value Was xxx.When the operator alters the value of a para...

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    74ALARMSJune 200396-9010 rev G911APC PAL Load/Unload At ZeroOne or more of the pallets on the Automatic Pallet Changer has aload or unload position set to zero. This indicates that the APCset up procedure was incomplete. Establish the correct load andunload positions for all pallets and enter the...

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    75ALARMSJune 200396-9010 rev G924 B Indexer Is Not At The Proper Incremental PositionThe indexer has moved to a position that cannot be seated.925 A Indexer Is Not Fully In The Up PositionThe indexer is still seated. It is not completely in the up positionand cannot be rotated. Reset then rezero ...

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    MECHANICAL SERVICE7696-9010 rev GJune 20033. MECHANICAL SERVICERECOMMENDED TORQUE VALUES FOR MACHINE FASTENERSThe following chart should be used as a reference guide for torquing machine fasteners where specified.DIAMETERTORQUE1/4 - 2015 ft. lb.5/16 - 1830 ft. lb.3/8 - 1650 ft. lb.M10 - 10050 ft...

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    MECHANICAL SERVICE77June 200396-9010 rev GLOWER Y-AXIS WAY COVERREMOVAL-1.Zero return all axes.2.POWER OFF the machine.3.Remove the seven SHCS that attach the top of the lower Y-axis way cover to the spindle headcasting. Collapse the way cover down fully.4.Remove the X-axis chip guard (seven SHCS...

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    MECHANICAL SERVICE7896-9010 rev GJune 2003Set ScrewFlatLeft WhenFacing MachineShade RotationSet ScrewFlatRight WhenFacing Machine1Clamp the shaft at the flat with clamping pliers or other such clamping device to hold the shaftwhen adjusting of the spring tension.2.Loosen the set screw so that th...

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    MECHANICAL SERVICE79June 200396-9010 rev G3.2 TOOL RELEASE PISTON (TRP)TOOL RELEASE PISTON REPLACEMENTTOOLS REQUIRED• 2.5" diameter, 2.5' long steel tube• TRP alignment tool, TSC (T-1519)• Magnetic base indicators (2)REMOVAL-NOTE:Newer machines will have a hex-carbide coolant tip that ...

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    MECHANICAL SERVICE8096-9010 rev GJune 200311. Remove the entire tool release piston assembly.NOTE: Step 11 applies only to machines with TSC.12. Remove the seal housing from the tool release piston.Figure 3.2-2. TSC tool release piston.INSTALLATION-NOTE:Newer machines will have a hex-carbide coo...

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    MECHANICAL SERVICE81June 200396-9010 rev GNOTE:The drain line must run straight through the cable tie loop on the transmission,and must not interfere with the pulley or belts.3.Loosely reinstall the tool release piston with two SHCS at the bottom and two HHB (with spacer)at the top.4.Reconnect cl...

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    MECHANICAL SERVICE8296-9010 rev GJune 200312. Jog the spindle head upward. Place two magnetic bases on the column below the TRP. Set theirindicators on opposite ends of the bottom face of the TRP housing. Set both indicator dials to zero.13. Carefully move the TRP upward a distance of 0.005 on e...

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    MECHANICAL SERVICE83June 200396-9010 rev G4.Go to "Parameters" page of CRT and ensure PRE-CHARGE DELAY is set to 300. If not, set it atthis time.5.Press the TOOL RELEASE button on control panel. A banging noise will be heard as the toolrelease piston contacts the drawbar.6.Turn the air ...

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    MECHANICAL SERVICE8496-9010 rev GJune 20033.3 SPINDLE DRIVE BELTSPlease read this section in its entirety before attempting to replace the drive belts.TOOLS REQUIRED• 2.5" diameter, 2.5' long steel tube• Lift fixture (T-1491)• Belt tensioning fixture (T-1511)BELT REMOVALNOTE:For easie...

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    MECHANICAL SERVICE85June 200396-9010 rev GFigure 3.3-1. Spindle drive belt replacement.2.Install the tool release piston assembly in accordance with appropriate section, and reconnect allswitches and air lines.3.Loosen the top two transmission mounting SHCS about 1-1/2 turns.4.Refer to the "...

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    MECHANICAL SERVICE8696-9010 rev GJune 2003BELT TENSION ADJUSTMENT1.Orient spindle pulley such that the alignment mark is oriented to 12 O’clock position. It may behelpful to make a mark near spindle dogs in the same orientation, as it is hard to see mark onpulley after transmission/spindle mot...

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    MECHANICAL SERVICE87June 200396-9010 rev GOrientationMark(12 O'clockposition)T1491T1511ReferenceMarkSpindle MotorTransmission Assy6X 3/8-16 SHCSBeltsFigure 3.3-2

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    MECHANICAL SERVICE8896-9010 rev GJune 20033.4 SPINDLETOOLS REQUIRED•2.5" diameter, 2.5' long steel tubeSPINDLE CARTRIDGEREMOVAL-1.Remove the rear enclosure panel (seven SHCS).2.IMPORTANT! Jog the X-axis all the way to the operator side of the machine. Place the steel tubethrough the 3&quo...

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    MECHANICAL SERVICE89June 200396-9010 rev GSpindle must be installed with oil drainnotch in spindle lock at the bottomCAUTION! When replacing an oil spindle on all HS (horizontal spindle) machines, theoil drain hole must point down. Failure to do so will cause the spindle tooverheat, fail, and wil...

  • Page 91

    MECHANICAL SERVICE9096-9010 rev GJune 200310. IMPORTANT! Remove the steel tube from the column.CAUTION! This step must be followed or the machine will be seriously damaged.11. Replace the rear enclosure panel with seven SHCS.SPINDLE ORIENTATION1.Remove the rear enclosure panel (seven SHCS).2.In ...

  • Page 92

    MECHANICAL SERVICE91June 200396-9010 rev G7Using an open end wrench, rotate the spindle until the appropriate alignment is attained. If thespindle is very difficult to rotate, STOP and return to Step 3.8.Tighten the orientation screws evenly to 15 ft-lbs. Verify that spindle alignment has not cha...

  • Page 93

    MECHANICAL SERVICE9296-9010 rev GJune 20033.5 DRAWBAR REPLACEMENTTOOLS REQUIRED•2-1/2-13 x 2 SHCS•1 inch thick, 6 inch long piece of aluminumNOTE:The aluminum bar will need to have two holes that align with the threadedholes in the spindle pulley.REMOVAL-1.Remove the spindle.2.Place the alu...

  • Page 94

    MECHANICAL SERVICE93June 200396-9010 rev GINSTALLATION-1.Thoroughly coat the replacement drawbar with grease, including the end of the shaft where the fourholding balls are located.CAUTION! Insert the drawbar gently so the O-rings are not damaged. DO NOT use ahammer to force it.NOTE: Carefully in...

  • Page 95

    MECHANICAL SERVICE9496-9010 rev GJune 20033.6 TOOL CLAMP/UNCLAMP SWITCH ADJUSTMENTTOOLS REQUIRED• Right angle plate• Flexible ruler• Machined aluminum block (2"x4"x4")• 1" diameter pipe or pry barTOOL CLAMP/UNCLAMP SWITCH ADJUSTMENT - INITIAL PREPARATION1.Remove the r...

  • Page 96

    MECHANICAL SERVICE95June 200396-9010 rev GIf the block is tight at .110", move the Z-axis in the positive (+) direction one increment at a time. Press theTOOL RELEASE button and check movement between increments until the block is loose.NOTE: The increments jogged in the Z positive (+) direc...

  • Page 97

    MECHANICAL SERVICE9696-9010 rev GJune 20036.Press the MDI key and turn the jog handle to zero (0). Press HANDLE JOG. Jog the Z-axis in thepositive (+) direction .100".7.Press and hold the TOOL RELEASE button, and try to move the block by hand. The block shouldbe tight at .100" and loos...

  • Page 98

    MECHANICAL SERVICE97June 200396-9010 rev G Figure 3.6-3a Shim location (without TSC). Figure 3.6-3b. Shim location (with TSC).4.Put a drop of serviceable (blue) Loctite® on the threads of the tool release bolt and install. Ifreplacing tool release coolant tip, put a dro...

  • Page 99

    MECHANICAL SERVICE9896-9010 rev GJune 2003Figure 3.6-4. Tool release piston assembly.4.While activating tool release, tap unclamp switch assembly towards spring retainer until it justtrips. Switch must trip at .060 +/- .010.THIS ADJUSTMENT IS VERY IMPORTANT FOR PROPER TOOL CHANGER OPERATION,AND ...

  • Page 100

    MECHANICAL SERVICE99June 200396-9010 rev G7.Move the tool release piston in so the shim is pressed against the drawbar. This can be done inone of the following two ways:•Using the pipe or pry bar as a lever, carefully push on the piston until it contacts thedrawbar and the shim is held in place...

  • Page 101

    MECHANICAL SERVICE10096-9010 rev GJune 20033.7 TRANSMISSIONPlease read this section in its entirety before attempting to remove or replace thetransmission.TOOLS REQUIRED• Transmission removal kit, includes:• Transmission removal fixture (T-1482)• Transmission lift fixture (T-1491)• Chain...

  • Page 102

    MECHANICAL SERVICE101June 200396-9010 rev GDisconnect the electrical and oil lines from the oil pump. Plug the oil lines to prevent contamination. Most ofthe lines should be marked and identified. If not marked, do so as it is removed.If machine is equipped with the Through the Spindle Coolant op...

  • Page 103

    MECHANICAL SERVICE10296-9010 rev GJune 2003Figure 3.7-2 Transmission removal fixture and chain hoist.INSTALLATION-1.If machine is equipped with Through the Spindle Coolant option, reinstall the pressure regulator,check valve assembly, and bracket onto the new transmission.2.Remove the lift fixtu...

  • Page 104

    MECHANICAL SERVICE103June 200396-9010 rev G10. IMPORTANT! Remove the two shipping lockbolts from the column and spindle head.CAUTION! Serious machine damage will occur if the axes are moved with the lockbolts inplace.11. Zero return the machine. Jog the Y-axis all the way up.12. IMPORTANT! Insert...

  • Page 105

    MECHANICAL SERVICE10496-9010 rev GJune 20033.8 TOOL CHANGER ASSEMBLYCT-EXTRACTOR RRRRREPLACEMENTREMOVAL -1.Zero return all axes and remove any tooling.2.Rotate the carousel into position by pressing M39 T_ _ (Enter the tool position number that needsreplacement.)3.Jog the Y-axis down, away from ...

  • Page 106

    MECHANICAL SERVICE105June 200396-9010 rev G1.Insert sleeve into pivot hole of each extractor and assemble each extractor with a SHCS and hardwasher (round edge facing head of screw). Before mounting the assembly to the carousel, apply asmall amount of semi-permanent Loctite® to each screw, then ...

  • Page 107

    MECHANICAL SERVICE10696-9010 rev GJune 2003TOOL CHANGER DOORREMOVAL-1.Disconnect the air supply to the machine.2.Disconnect the door spring.3.Remove the rubber bumper and door return spring from the back side of the carousel cover.4.Remove the air door cylinder swivel mount from the cylinder fro...

  • Page 108

    MECHANICAL SERVICE107June 200396-9010 rev GCAUTION! Make sure that fingers are clear of carousel while performing the following:4.Press the carousel "IN" solenoid and hold it while someone places a 4 x 4 to hold the carousel inthe "IN" position.5.With the 4x4 in place and all ...

  • Page 109

    MECHANICAL SERVICE10896-9010 rev GJune 2003Figure 3.8-3. Carousel replacement.INSTALLATION-1.Grease the tool changer shaft.2.Ensure the drive belt is in place before installing the carousel. Slide the carousel assembly on theshaft.3.Place the belt on the drive pulley.4.Install the locking cap (F...

  • Page 110

    MECHANICAL SERVICE109June 200396-9010 rev G7.Install the six SHCS that attach the cylinder cap to the carousel (Fig. 3.8-3, #3). Tighten evenly.CAUTION! Make sure that fingers are clear of turret while performing the following:8.Carefully press the turret "IN" solenoid and hold while so...

  • Page 111

    MECHANICAL SERVICE11096-9010 rev GJune 2003Figure 3.8-4. Tool Changer IN/OUT adjustment nutNOTE:Do not loosen the 1/4" nut located at center. Tighten the 1/2" locknut withoutturning the adjustment screw.Adjustments are made by loosening the 1/2" locknut located at the nose of the ...

  • Page 112

    MECHANICAL SERVICE111June 200396-9010 rev GSETTING PARAMETER 215If your machine is operating with 9.20 to 10.xx software skip to step 15, for machinesequipped with a brushless tool changer, see the brushless tool changer alignment for HS-series machines section.10. Loosen the two 1/4" SHCS o...

  • Page 113

    MECHANICAL SERVICE11296-9010 rev GJune 200321. Rotate the carousel to tool ZERO (on the HS-1 this is pocket #24, HS-2 is #40) This number isthen entered in Parameter 215.22. Press "POWER UP RESTART" and the tool changer will align to tool #1.For machines equipped with a brushless tool ...

  • Page 114

    MECHANICAL SERVICE113June 200396-9010 rev GSIDE MOUNT TOOL CHANGER ALIGNMENT HS-2RP (BRUSH MOTOR)NOTE: For brushless tool changer alignment instructions, see the Brushless ToolChanger Alignment for HS-Series Machines section.1.Remove the tool changer’s shipping retainer bolt. Refer to Figure 3....

  • Page 115

    MECHANICAL SERVICE11496-9010 rev GJune 20033.POWER-UP the machine.4.Press the RESET button to clear the alarm message.5.Press the ZERO RET and then the AUTO ALL AXES button. The machine will move the spindle toits home position (Zero X, Y, Z, and A).6.Go to the SETTINGS screen. Cursor to Setting...

  • Page 116

    MECHANICAL SERVICE115June 200396-9010 rev G1011121314151617181920212223242526272829 30 31 323334353637383940123456789ShoulderBolt(s) X 2Figure 3.8-6.15. Continue to handle jog the tool changer’s carousel to achieve a level condition. Record the Carou-sel Offset number given on the POS-RAW DAT s...

  • Page 117

    MECHANICAL SERVICE11696-9010 rev GJune 2003Figure 3.8-7.Figure 3.8-8.24. Next, move to PARAMETERS screen. Record the values for the Parameters #210 (X-axis), #211(Y-axis) and #64 (Z-axis). After recording the values for these Parameters, enter "0" for their values.25. Go to ALARMS page...

  • Page 118

    MECHANICAL SERVICE117June 200396-9010 rev G27. Record the values in the ACTUAL column for the position of the X and Y-axes given on the POS-RAW DAT screen.Enter the position value for the X-axis in Parameter 210 (This can only be a negative number).NOTE: This number is entered without the decimal...

  • Page 119

    MECHANICAL SERVICE11896-9010 rev GJune 2003Figure 3.8-10.39. Press the MDI/DNC button, then ATC FORWARD button. Repeat steps 22 and 23, to manuallymove the carousel into the machine enclosure.NOTE: The spindle will move to its tool change position and the machine will fault-out and display a SHU...

  • Page 120

    MECHANICAL SERVICE119June 200396-9010 rev GBRUSHLESS TOOL CHANGER ALIGNMENT FOR HS-SERIES MACHINESHorizontal machine models HS-1 and HS-2 use a brushless servo motor for carousel rotation. The alignmentprocedure for the new tool changers differs from the previous tool changers in that it uses a g...

  • Page 121

    MECHANICAL SERVICE12096-9010 rev GJune 2003DETERMINING THE CAROUSEL OFFSETHS-1 Series Machines At this point the tool changer motor has rotated itself to a correct and reliable grid offset position. The nextstep moves the carousel from its grid offset position to a position that lines up the too...

  • Page 122

    MECHANICAL SERVICE121June 200396-9010 rev GCable 1 ( Carousel Drive Motor Cable). The cable is encased in flexible conduit andsupplied with an amphenol connector. This cable must be routed around the back of themachine under the apron and connected to the “Tool Changer” connector on the side ...

  • Page 123

    MECHANICAL SERVICE12296-9010 rev GJune 200313. Enter the letter for the tool turret axis (B or T) and then press the HANDLE/JOG button. Slowlyturn the HANDLE/JOG control in ½ turn increments and observe the rotation of the carousel. Thecarousel will alternate betweencounterclockwise and clockwi...

  • Page 124

    MECHANICAL SERVICE123June 200396-9010 rev GFigure 3.8-13Figure 3.8-1422. Next, move to PARAMETERS screen. Record the values for the Parameters #210 (X-axis), #211(Y-axis) and #64 (Z-axis). After recording the values for these Parameters, enter "0" for their values.23. Go to ALARMS page,...

  • Page 125

    MECHANICAL SERVICE12496-9010 rev GJune 2003Enter the position value for the Y-Axis in Parameter 211.26. Align the Z-axis. Line up the finger groove in the tool holder with the extractor fingers on thecarousel. Handle jog the spindle in +Z direction (towards the rear of the machine). Then handle ...

  • Page 126

    MECHANICAL SERVICE125June 200396-9010 rev G34. Press the ZERO RET and then AUTO ALL AXES button.35. Install a tool holder into the spindle.36. Press the MDI/DNC button, then ATC FORWARD button. Repeat steps 22 and 23, to manuallymove the carousel into the machine enclosure.NOTE: The spindle will ...

  • Page 127

    MECHANICAL SERVICE12696-9010 rev GJune 2003LINEAR TOOL CHANGER ALIGNMENT (HS-1/R)1.Install by hand a 40 taper tool holder into tool positions #1 and #6 on the linear tool changer.Whether the tool holders have a tool installed or not is not important, only that the tool holders bein good conditio...

  • Page 128

    MECHANICAL SERVICE127June 200396-9010 rev GT2T3T4T5T6T1Figure 3.8-185.Tighten one of the Top Beam hold down screws on the side nearest tool position #1 and zero theindicator on the back of the pull stud. Now jog the indicator over to the pull stud on tool #6 andnote the reading. Adjust the fore /...

  • Page 129

    MECHANICAL SERVICE12896-9010 rev GJune 20033.9 CHAIN STYLE SIDE MOUNT TOOL CHANGERAUTOMATIC OPERATION WARNINGExercise caution when working on or around the SMTC. There are many pinch points, and it may move unex-pectedly. Press emergency stop before working in any areas where you could get hurt ...

  • Page 130

    MECHANICAL SERVICE129June 200396-9010 rev GThe tool change recovery procedure will be complete when the following state is reached:The INPUTS portion of the TCR display (upper right corner) indicates:SH AT STANDBY1SHUTTLE MARK1SHUTTLE OUT1ARM MARK1ARM CW or CCW1ARM IN or OUT1TCR KeysThe tool chan...

  • Page 131

    MECHANICAL SERVICE13096-9010 rev GJune 2003Arm at Home4.The double arm is at the home position when the following is displayed on the TCR screen:ARM MARK1ARM CW or CCW1The ARM CW or ARM CCW must be 1 (indicating the Double Arm is completely rotated CW or CCW).TCR With NO Tools in ArmA TCR is nec...

  • Page 132

    MECHANICAL SERVICE131June 200396-9010 rev G5.Use the PAGE DOWN and/or END cursor keys to bump the arm so that either the ARM CW orARM CCW input reads 1, Arm Mark reads 1, and the tool that belongs in the spindle is closest toyou.6.Use the RIGHT ARROW cursor key to bump the shuttle until the SH AT...

  • Page 133

    MECHANICAL SERVICE13296-9010 rev GJune 2003TOOL REMOVAL FROM CHAIN WITH INCORRECT PULL STUDWear gloves, cutting tools are sharp, and the tool pockets are spring loaded.If a tool becomes stuck in the chain due to an incorrect pull stud do not attempt to pry the tool loose from thechain. Damage to...

  • Page 134

    MECHANICAL SERVICE133June 200396-9010 rev GThe TCR screen above shows the shuttle At StandbyNOTE:When moving the shuttle to position via Tool Change Recovery, move theshuttle to position, then press the button one additional time. This will ensurethe shuttle cam is not on the edge of the Shuttle ...

  • Page 135

    MECHANICAL SERVICE13496-9010 rev GJune 20037.Slide the dowel through the alignment tool, (this will act as a handle) and snap the alignment toolinto the arm. The flat side of the tool should be toward the spindle. Remove the dowel pin. Note:the release pin on the double arm must be depressed to ...

  • Page 136

    MECHANICAL SERVICE135June 200396-9010 rev G13. Remove alignment tool from spindle and double arm. While in tool change recovery, use the leftarrow to move the shuttle away from the spindle until the “Shuttle at Standby” and “Shuttle Mark”inputs are both 1.14. Repeat steps - to check the X...

  • Page 137

    MECHANICAL SERVICE13696-9010 rev GJune 2003At SpindleAt StandbyShuttle MarkAt Chain21. Measure the distance between the front surface of the double arm gripper and the front face of thetool holder, using a dial caliper.Measure the distance from thesurface of the double arm tothe surface of the s...

  • Page 138

    MECHANICAL SERVICE137June 200396-9010 rev GLUBRICATIONRe-grease the shuttle mechanism every 6 months.Regrease the tool chain every year.The gearboxes are permanently lubricated.To apply grease a small brush may be used. Common Molybdenum grease is used. To grease the chain, coatthe sliding surfac...

  • Page 139

    MECHANICAL SERVICE13896-9010 rev GJune 2003CHAIN TENSIONING 120 TOOL CHANGERThe chain tension should be sufficient to prevent hand pressure from moving the tool chain sideways more than3/8" in one of the unsupported areas of the chain (see illustration).To adjust chain tension press emergen...

  • Page 140

    MECHANICAL SERVICE139June 200396-9010 rev GCHAIN TENSIONING FOR 60 TOOL CHANGERThe chain tension should be sufficient to prevent hand pressure from moving the tool chain sideways more than3/8" in one of the unsupported areas of the chain (see illustration).JAM NUTSET SCREWCHAINTENSIONADJUSTE...

  • Page 141

    MECHANICAL SERVICE14096-9010 rev GJune 2003CHAIN GUIDE ADJUSTMENTThe chain guides near the double arm need to be snug against the chain to prevent the tool pocket from shiftingduring toolchanges. To adjust, loosen the indicated SHCS, as shown, and retighten, with blue Loctite, whilepressing the ...

  • Page 142

    MECHANICAL SERVICE141June 200396-9010 rev GDOUBLE ARM ROTATIONAL ALIGNMENTThe object is to get the double arm horizontal, with both ends of the double arm lining up equally well.1.Using tool change recovery, make sure the double arm is either cw, or ccw. And arm mark is 1.2.Place a level on the h...

  • Page 143

    MECHANICAL SERVICE14296-9010 rev GJune 20031.To check alignment, place split tool in the double arm. Be sure the split tool is not touching thechain or spindle.09080706050403020102.Use a dial caliper to measure the distance from the face of the split tool to the front surface of thedouble arm gr...

  • Page 144

    MECHANICAL SERVICE143June 200396-9010 rev GDOUBLE ARM X DIRECTION ALIGNMENTThe sideways alignment of the double arm is adjusted by shifting the shuttle cam left or right.1.Zero return auto all axis.2.Use a split alignment tool to align the atc(see illustration)3.Insert the tapered half of the too...

  • Page 145

    MECHANICAL SERVICE14496-9010 rev GJune 2003SMTC Output Cable8.Gently push the 2 halves together, observing the alignment.9.The shuttle may be moved either left or right by shifting the shuttle cam in the desired direction.SpindleSwitchStandbySwitchChainSwitchShuttleCamShuttle CamBearing NutsBear...

  • Page 146

    MECHANICAL SERVICE145June 200396-9010 rev G11. Loosen the bearing nut on the end you want the cam to move away from.12. Tighten the bearing nut on the end you want the cam to move toward until the bearings are againlightly preloaded.13. Tighten the locknut shcs.14. Recheck alignment.15. To remove...

  • Page 147

    MECHANICAL SERVICE14696-9010 rev GJune 2003SMTC Output Cable6.Install the tapered half of the split alignment tool into pocket #17.Install the flange half of the split alignment tool into the double arm.8.Gently push the 2 halves together, observing the alignment.

  • Page 148

    MECHANICAL SERVICE147June 200396-9010 rev G9.Pull the double arm away from the chain (extend the double arm).10. Set the TT invisible axis parameter number to 0. Note this disables the interlocks between thedouble arm and the tool chain axis. Be careful not to bend the double arm or crash tools i...

  • Page 149

    MECHANICAL SERVICE14896-9010 rev GJune 2003GRIPPER ASSEMBLY REPLACEMENTThe gripper assemblies are serviced as a unit. One assembly is used for each end of the double arm. If it isdesired to field retrofit a CT mill to BT operation or vice-versa, this can be accomplished by replacing the grippera...

  • Page 150

    MECHANICAL SERVICE149June 200396-9010 rev GDOUBLE ARM AIR CYLINDER1234215677889101112141313156The air cylinder, and 4 of the 5 O-rings can be inspected without complete double arm removal. If the doublearm clamp bolts are not disturbed, the cylinder may be inspected or 4 O-rings replaced without ...

  • Page 151

    MECHANICAL SERVICE15096-9010 rev GJune 20033.Remove the 6 3/8" shcs holding the cylinder to the double arm.4.Gently pull the air cylinder off of the double arm shaft.5.The piston o-ring and 1 seal housing outer o-ring are now visible.6.Inspect or replace as appropriate.7.Very lightly grease...

  • Page 152

    MECHANICAL SERVICE151June 200396-9010 rev G2.Press the E-STOP button. Disconnect machine air to prevent the tool changer door from closing.3.Rotate the shuttle cam to allow access to the double arm clamp bolts. It is easiest to move thedouble arm to the At Spindle position.4.Disconnect the air li...

  • Page 153

    MECHANICAL SERVICE15296-9010 rev GJune 20038.Slide a small piece of sheetmetal into the slot in the shuttle for the jack bolt to press against.9.Gently tighten the jackbolt until the double arm can be removed.10. Remove the switch cluster bracket and switches. The swich cluster bracket is held b...

  • Page 154

    MECHANICAL SERVICE153June 200396-9010 rev GSHUTTLE CAM REPLACEMENTRemovalCAUTION: When rotating the tool changer cams by hand, wear protective gloves.The cams’ machined edges are very sharp.SpindleSwitchStandbySwitchChainSwitchShuttleCamShuttle CamBearing NutsBearingMountsShuttle OutSwitch (hid...

  • Page 155

    MECHANICAL SERVICE15496-9010 rev GJune 2003Installation1.Loosely reinstall the hardware on the shuttle cam.2.Raise the cam into position. Insert the cam follower into the cam at the At Chain position.3.Press the bearing mounts over the dowel pins. Secure the cam assembly by threading the SHCSint...

  • Page 156

    MECHANICAL SERVICE155June 200396-9010 rev G1.Press E-stop.2.Remove the front and rear sheet metal access panels.3.Disconnect the arm motor connection at the motor. It is normally tucked into the cable carrierbracket.4.Remove the rear SHCS that secures the motor bracket to the shuttle.5.Remove the...

  • Page 157

    MECHANICAL SERVICE15696-9010 rev GJune 200312. Leave the bearing locknuts loose for now.13. Carefully supporting the cam and motor, reinstall the assembly on the dowels, using the 2 motormount shcs loosely installed to support the weight of the assembly.14. Reinstall the arm clamp shcs with blue...

  • Page 158

    MECHANICAL SERVICE157June 200396-9010 rev GCAM ARM REPLACEMENTIf the cam arm has been damaged in a crash, the following procedure can be used to replace it.1.Loosen the double arm clamp bolts and move the arm forward just enough to disconnect the armlink from the cam follower on the cam arm. This...

  • Page 159

    MECHANICAL SERVICE15896-9010 rev GJune 20034.Support the cluster so the wires are not damaged.5.Loosen the bearing locknut shcs in the side of the bearing locknut.6.Remove the bearing locknut.7.Slide the cam arm assembly out the front of the shuttle.8.Inspect the bearings, replace as needed.9.In...

  • Page 160

    MECHANICAL SERVICE159June 200396-9010 rev GHS SMTC PC BOARDP6P4P3P1P2FU1FU2NE1LIMITSWITCHESTOOLCHANGERTSCCHIPCONVEYOR-M-FUNCTIONCOOLANTPALLETCHANGERSMTCOUTPUTArm CW RelayArm CCW RelayShuttle toSpindle RelayShuttle to ChainRelayDC MotorOutput115VInputSolenoid Output(115V)To MCD(8M Option)From I/O ...

  • Page 161

    MECHANICAL SERVICE16096-9010 rev GJune 20033.10 AXIS MOTORPlease read this section in its entirety before attempting to remove or replace the axismotors.X-AXIS MOTORREMOVAL-1.Power ON the machine. Zero return all axes and put machine in HANDLE JOG mode.2.Jog the Y-axis to the bottom of its trave...

  • Page 162

    MECHANICAL SERVICE161June 200396-9010 rev GINSTALLATION-1.Inspect the motor coupling and replace it if required. Visually inspect the flex plates to ensure theyare parallel to the coupling halves. Slide the new coupling onto the motor shaft until the couplinghalf is flush to the end of the shaft....

  • Page 163

    MECHANICAL SERVICE16296-9010 rev GJune 2003HS-1 lock-boltsb. HS-2 - Remove the lower plugs in the column side cover. Slide a bar through the holes. lowerthe spindle down until it rests on the bar. CAUTION! This step must be followed to keep thespindle head from falling during service. If this is...

  • Page 164

    MECHANICAL SERVICE163June 200396-9010 rev GY-axis motorHydrauliccounterbalanceMotor mountMotor couplingcomponentsFigure 3.10-2. Y-axis motor and coupling.8.Loosen the four SHCS and remove the motor from the motor mount.9.Disconnect all wiring from the motor.10. Remove the motor.INSTALLATION-Impor...

  • Page 165

    MECHANICAL SERVICE16496-9010 rev GJune 20036.Replace the rear enclosure panel with seven SHCS.7.Check for backlash in the Y-axis ball screw (Troubleshooting section) or noisy operation.8.Check that Parameter 211, "Y-Axis Tool Change Offset", is set correctly, and adjust if necessary.9....

  • Page 166

    MECHANICAL SERVICE165June 200396-9010 rev G Y-Axis Alignment Tool Insertion4.Once the alignment tool is fully inserted, rotate until the four holes near the O.D. of the tool line upwith the holes near the corners of the motor mount. Attach the alignment tool to the motor mountusing four 5/16-18 x...

  • Page 167

    MECHANICAL SERVICE16696-9010 rev GJune 2003Figure 3.10-3. Z-axis motor and ball screw assembly.5.On the motor mount, loosen the four BHCS and remove the cover plate.6.Loosen the SHCS on the motor coupling at the ball screw.7.Loosen the four SHCS and remove the motor from the mount.8.Disconnect a...

  • Page 168

    MECHANICAL SERVICE167June 200396-9010 rev G6.Replace the cover plate and fasten with four BHCS.7.Replace the Z-axis way cover with thirteen SHCS.8.Check for backlash in the Z-axis ball screw ("Troubleshooting" section) or noisy operation.9.Set the grid offset after the new motor has bee...

  • Page 169

    MECHANICAL SERVICE16896-9010 rev GJune 20033.11 BEARING SLEEVEPlease read this section in its entirety before attempting to remove or replace the bearingsleeve.X-AXIS BEARING SLEEVEREMOVAL-1.POWER ON the machine. Zero return all axes and put the machine in HANDLE JOG mode.2.Remove the rear enclo...

  • Page 170

    MECHANICAL SERVICE169June 200396-9010 rev GFigure 3.11-1. Bearing sleeve mounting location.INSTALLATION-1.Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are freeof dirt, burrs, grease, or other contaminants.CAUTION! Mating surfaces must be clean or misa...

  • Page 171

    MECHANICAL SERVICE17096-9010 rev GJune 20038.Reinstall and tighten the hard stop on the bearing support.9.Reinstall the X-axis motor as described in "X-Axis Motor - Installation".10. Check for backlash in the X-axis ball screw ("Troubleshooting" section), or noisy operation.1...

  • Page 172

    MECHANICAL SERVICE171June 200396-9010 rev GFigure 3.11-2. Y-axis ball screw bearing support end clamp nut.9.Loosen the SHCS and remove the clamp nut on the motor end of the ball screw.10. Loosen the six SHCS and remove the bearing sleeve from the top of the column.CAUTION! Do not pry the bearing ...

  • Page 173

    MECHANICAL SERVICE17296-9010 rev GJune 2003INSTALLATION-1.Ensure all mating surfaces on the bearing sleeve, motor housing, top of column, and ball nut arefree of dirt, burrs, grease, or other contaminants.CAUTION! Mating surfaces must be clean or misalignment may occur, seriouslyaffecting the pr...

  • Page 174

    MECHANICAL SERVICE173June 200396-9010 rev GZ-AXIS BEARING SLEEVEREMOVAL-1.POWER ON the machine. Zero return all axes and put the machine in HANDLE JOG mode.2.Jog the Y-axis to the bottom of its travel. Jog the Z-axis all the way towards the back of themachine.3.Remove the thirteen SHCS that attac...

  • Page 175

    MECHANICAL SERVICE17496-9010 rev GJune 20035.Loosen all of the SHCS on the bearing sleeve approximately 1/4 turn, then torque to 15 ft-lb. DONOT SKIP THIS STEP. It ensures the ball screw is installed and runs parallel and flat to the linearguides and the saddle.6.The following sequence is import...

  • Page 176

    MECHANICAL SERVICE175June 200396-9010 rev G3.12 BALL SCREWPlease read this section in its entirety before attempting to remove or replace the ballscrews.TOOLS REQUIRED:• Torque wrench• Spanner nutX-AXIS BALL SCREWREMOVAL-1.Turn the machine ON. Zero return all axes and put the machine in HANDL...

  • Page 177

    MECHANICAL SERVICE17696-9010 rev GJune 20033.Hold the ball screw at the left side of the machine near the front of the saddle and lower into place,rotating the ballscrew into position.CAUTION! Be careful not to bump or scratch ball screw against column, saddle orbellows support.4.Once in positio...

  • Page 178

    MECHANICAL SERVICE177June 200396-9010 rev GY-AXIS BALL SCREW HS-1REMOVAL-1.POWER ON the machine. Zero return all axes and put machine in HANDLE JOG mode.2.Remove the seven SHCS attaching the upper Y-axis way cover to the head casting, collapse itupward, and tie-wrap it in place.3.Jog the X-axis t...

  • Page 179

    MECHANICAL SERVICE17896-9010 rev GJune 20038.Remove the seven SHCS attaching the lower Y-axis way cover to the head casting, and collapse itdownward.9.Loosen the SHCS and remove the clamp nut on the ball screw bearing plate end.10. Loosen the SHCS and remove the clamp nut on the motor end of the...

  • Page 180

    MECHANICAL SERVICE179June 200396-9010 rev G14. Remove the ball screw from the column by lifting it out of the bearing support, pulling the lower endof the ball screw out the front of the column (over the top of the spindle head), and lowering themotor end out of the top of the column.15. Remove t...

  • Page 181

    MECHANICAL SERVICE18096-9010 rev GJune 20039.Hand-turn the ball screw to move the spindle motor up and down, to assure free movement of theball screw.10. Torque the five SHCS that hold the ball nut to the nut housing to 15 ft-lb.11. The following sequence is important to ensure proper installati...

  • Page 182

    MECHANICAL SERVICE181June 200396-9010 rev G Figure 3.12-5 Y-axis ball screw and motor assembly (from rear).6.Support the spindle head in place, at least 10” from the bottom, before disconnecting the ballscrew.7.Disconnect the cable from the motor encoder.8.Disconnect the oil line from the ball ...

  • Page 183

    MECHANICAL SERVICE18296-9010 rev GJune 20031234Bearing PackWasherLock NutBearing SupportLock Nut10"Min.SpindleHeadFigure 3.12-6INSTALLATION-1.Manually turn the ball nut up the ball screw until it will be possible to install the nut into the nuthousing (about halfway).2Insert the motor end o...

  • Page 184

    MECHANICAL SERVICE183June 200396-9010 rev GY-axis motorMotor mountMotor couplingcomponentsFigure 3.12-7. Y-axis ball screw motor.8.Hand-turn the ball screw to move the spindle motor up and down, to assure free movement of theball screw.9.Torque the five SHCS that hold the ball nut to the nut hous...

  • Page 185

    MECHANICAL SERVICE18496-9010 rev GJune 200315. Replace both Y-axis way covers and attach them to the head casting with seven SHCS each.16. Replace the hood and plug in the service light.17. Replace the rear enclosure panel with seven SHCS.Z-AXIS BALL SCREWREMOVAL-1.Turn the machine ON. ZERO RETU...

  • Page 186

    MECHANICAL SERVICE185June 200396-9010 rev GINSTALLATION-1.Ensure all mating on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt,burrs, grease, or other contaminants.CAUTION! Mating surfaces must be clean or misalignment may occur, seriouslyaffecting the proper operati...

  • Page 187

    MECHANICAL SERVICE18696-9010 rev GJune 200315. Tighten the ball screw against the clamp nuts as follows. The sequence is important to ensureproper installation of the ball screw:•Tighten the clamp nut, hand tight, on the motor end.• Install and tighten clamp nut on bearing support. Ensure th...

  • Page 188

    MECHANICAL SERVICE187June 200396-9010 rev G3.13 PALLET CHANGERSTABILIZER REPLACEMENTREMOVAL-1.Loosen the six BHCS and one SHCS that attach the left front splash shield (on side oppositeoperator) and remove.2.Loosen the hex bolts (2) that mount the stabilizers to the mounting bracket at each end a...

  • Page 189

    MECHANICAL SERVICE18896-9010 rev GJune 20033.Remove the two SHCS that mount the affected limit switch.4.Disconnect the switch from the solenoid mounting bracket. This bracket is located at the rear ofthe machine on the control box side, behind an access panel.INSTALLATION-5.Replace the switch an...

  • Page 190

    MECHANICAL SERVICE189June 200396-9010 rev GINSTALLATION-1.Replace the switch and mount it with two SHCS.2.Reconnect the switch at the solenoid mounting bracket.3.Go to the “Diagnostics” page on the control, in order to monitor the limit switch’s performance.4.Execute an M50 cycle start, and...

  • Page 191

    MECHANICAL SERVICE19096-9010 rev GJune 20035.Complete 10 continuous pallet change cycles to check for any faults.6.Apply sealant and install a gasket, then replace the access panel.7.Apply sealant and install a gasket where the Z-axis way cover meets the rotary table bottom cover.8.Extend the Z-...

  • Page 192

    MECHANICAL SERVICE191June 200396-9010 rev GMOTOR PULLEY REMOVAL / INSTALLATIONREMOVAL1.Remove both set screws2.Reinstall one set screw into the center hole. Tighten until the pulley comes free of the shaft3.Remove pulley assemblyINSTALLATION1.Loosely install both set screws2.Slide the assembly on...

  • Page 193

    MECHANICAL SERVICE19296-9010 rev GJune 20034.Replace the drawbar and air blast manifold.5.Active the pallet lift cylinder solenoid to lift the pallets, then rotate the pallets into position over therotary table. Allow the pallets to settle down into place.6.Execute an M50 CYCLE START (pallet cha...

  • Page 194

    MECHANICAL SERVICE193June 200396-9010 rev GFigure 3.13-3. Rotary table motor and belt assemblyINSTALLATION-1.Replace the drive belt on the motor pulley, then replace the four SHCS into the mounting plate andtighten.2.Mount the motor assembly onto the side of the rotary table with the two mounting...

  • Page 195

    MECHANICAL SERVICE19496-9010 rev GJune 2003ROTARY TABLE DRAWBARREMOVAL-1.Remove the pallet, in accordance with the "Pallet Replacement" section.2.Loosen the four mounting SHCS and remove the air blast manifold from the rotary table top.3.Loosen the eight mounting SHCS and remove a pall...

  • Page 196

    MECHANICAL SERVICE195June 200396-9010 rev GINSTALLATION -1.Lubricate (using Red-i grease) the splines of the new drawbar.2.Apply grease to the contact surfaces to ease the installation of the assembly.3.Carefully place drawbar assembly into mounting location. Apply a drop of blue Loctite to assem...

  • Page 197

    MECHANICAL SERVICE19696-9010 rev GJune 2003INSTALLATION-1.Install a new O-ring on to the drawbar insert and V-seal in the drawbar assembly.2.Place the new insert into drawbar assembly and gently press into place. Be careful not damageinsert.3.Apply a drop of blue Loctite to the insert 3 BHCS and...

  • Page 198

    MECHANICAL SERVICE197June 200396-9010 rev GLOAD STATION DRAWBARNOTE:This only applies to machines up to serial number 50477.REMOVAL-1.Remove the pallet according to the appropriate section.2.Loosen the hex nut that tightens the indexing handle onto the load station and remove the handle.3.Loosen ...

  • Page 199

    MECHANICAL SERVICE19896-9010 rev GJune 2003Figure 3.13-5 Pallet changer load station.PALLET REPLACEMENTREMOVAL-The normal sequence of the pallet changer is:1.Unclamp the pallets,2.Raise the pallets,3.Rotate the pallets,4.Lower the pallets,5.Clamp the pallets.1.Execute a single M50 command from M...

  • Page 200

    MECHANICAL SERVICE199June 200396-9010 rev GINSTALLATION-1.Execute a single M50 command from MDI, then interrupt the sequence by pressing RESET as thelift mechanism starts to rotate. Do not wait until the lifting mechanism is fully down on the sta-tions.2.Check that the pads under the pallet are c...

  • Page 201

    MECHANICAL SERVICE20096-9010 rev GJune 2003AIR BLAST ADAPTERREMOVAL-1.Remove one pallet in accordance with the previous section.2.Execute one more M50 in MDI, to put the empty pallet position inside the machine.3.Remove the thirteen SHCS that attach the Z-axis way cover to the rotary table botto...

  • Page 202

    MECHANICAL SERVICE201June 200396-9010 rev GPALLET ROTATION HARDSTOP ADJUSTMENT1. Loosen the six BHCS and one SHCS that attach each of the front splash shields and remove theshields.2. Slightly loosen the two SHCS that hold each of the hardstops (2) in place.3. In MDI, execute an M50 (pallet chang...

  • Page 203

    MECHANICAL SERVICE20296-9010 rev GJune 2003(3) SHCS(9) BHCSFigure 3.13-6.A-AXIS ALIGNMENT TO H-FRAMETOOLS REQUIREDH-frame alignment tool (T-1516)NOTE:This adjustment must also be done if machine parameters are lost, or the A-axis rotary table is replaced.1.Remove the pallet (from the load statio...

  • Page 204

    MECHANICAL SERVICE203June 200396-9010 rev GFigure 3.13-7. Use of the H-frame alignment tool.8.Set the H-frame alignment tool in place on the pins. Using the jog handle, rotate the table until thealignment tool seats flat on the rotary table.9.Press the POSIT key, then PAGE UP once. Take the actua...

  • Page 205

    MECHANICAL SERVICE20496-9010 rev GJune 20033.14 310FGRP (HS-1RP) OPTIONWarningThe 310FGRP will crash if the following procedures are not followed.Read all material before proceeding.When the 310FGRP is replaced in the HS-1RP, it must have the lift switch adjusted and parameter 224set before any...

  • Page 206

    MECHANICAL SERVICE205June 200396-9010 rev GFigure 3.14-1Figure 3.14-2

  • Page 207

    MECHANICAL SERVICE20696-9010 rev GJune 2003SETTING PARAMETERS 224 AND 1281.Drill and insert a screw into the facegear bolt plug in platter to jack it out and remove it. Loosen the 8mmfacegear bolts one turn.2.In debug mode, go to parameter 224 and enter “0” then press the “write” key.3.T...

  • Page 208

    MECHANICAL SERVICE207June 200396-9010 rev G13. In DEBUG mode, press the POSIT key then page up once. Take the actual number of encoder counts forthe A-axis, disregard the decimal point and negative sign, and enter that number in parameter 224. (Forexample, if the number is -107.9500, then the ent...

  • Page 209

    MECHANICAL SERVICE20896-9010 rev GJune 2003Figure 3.14-4- Rotary Cover, Top View5.Squeeze a bead of Sikaflex on the flange of the Flange Ring Cover, P/N 93-1099. Install the FlangeRing Cover from below so that the part protrudes up into the center pivot hole. Press firmly tocreate a watertight s...

  • Page 210

    MECHANICAL SERVICE209June 200396-9010 rev G10. Repeat Step 9 on the opposite side of the Rotary Top Cover door guide shroud. See Figure 3.12-9.11. Install the Gasket, Top Cover, P/N 57-0064 using one gasket for each end of the H-Frame. SeeFigure 3.12-10.Figure 3.14-6 - Gasket Placement12. Squeeze...

  • Page 211

    MECHANICAL SERVICE21096-9010 rev GJune 20033.15 HYDRAULIC COUNTERBALANCETOOLS REQUIRED• Hydraulic Counter Balance Service Kit consists of :Pressure tank with manifold assembly, prefilled with (2) Quarts DTE-25 Hydraulic OilHydraulic cylinder with hose not attached (if necessary)HYDRAULIC TANK ...

  • Page 212

    MECHANICAL SERVICE211June 200396-9010 rev G5. IMPORTANT! Remove the two shipping lockbolts from the column and spindle head.CAUTION! Serious machine damage will occur if the axes are moved with the lockboltsin place.6.POWER ON the machine and zero return (ZERO RET) the Y-axis only. Check for any ...

  • Page 213

    MECHANICAL SERVICE21296-9010 rev GJune 20035.Remove the cotter pin and lock nuts from the threaded end of the cylinder rod. These are locatedon the back of the spindle head, towards the control panel side of the machine.6.Loosen the two SHCS holding the cylinder clamp to the top of the column.7....

  • Page 214

    MECHANICAL SERVICE213June 200396-9010 rev G7.POWER ON the machine and zero return (ZERO RET) Y-axis only. Observe the cylinder body formotion or abnormal noises. Check for fluid at manifold, cylinder hose connection and cylinder rod.Verify tank pressure at top of travel (600 psi). Remove charging...

  • Page 215

    MECHANICAL SERVICE21496-9010 rev GJune 20033.16 THROUGH THE SPINDLE COOLANT SYSTEM - ADJUSTMENTSTOOLS REQUIREDTool holder with small through coolant drill or small orifice tool (#T-1461).TSCHP Gauge Kit (P/N 93-9011), includes:0-15 PSI gaugeBall valve0-600 PSI coolant gaugeThe old TSC system mus...

  • Page 216

    MECHANICAL SERVICE215June 200396-9010 rev GCHECKING PUMP PRESSURENOTE:If the coolant pressure with no tool in the spindle is 60 psi or less, replace thepump assembly (30-3281A). Old TSC system uses pump head (93-3280B).1.Insert the 0-600 psi coolant pressure gauge into the coolant line between th...

  • Page 217

    MECHANICAL SERVICE21696-9010 rev GJune 20033.17 GRID OFFSET CALCULATIONPlease read this section in its entirety before attempting to set the grid offset.Guidelines -The encoder Z channel signal must occur between 1/8 and 7/8 revolution from where the home switch isreleased. If DISTANCE TO GO is ...

  • Page 218

    MECHANICAL SERVICE217June 200396-9010 rev G3.18 AIR / OIL LINE DIAGRAM

  • Page 219

    MECHANICAL SERVICE21896-9010 rev GJune 2003THROUGH THE SPINDLE COOLANTTHROUGH THE SPINDLE COOLANTTHROUGH THE SPINDLE COOLANTTHROUGH THE SPINDLE COOLANTTHROUGH THE SPINDLE COOLANTSYSTEM FLOW DIAGRAMSYSTEM FLOW DIAGRAMSYSTEM FLOW DIAGRAMSYSTEM FLOW DIAGRAMSYSTEM FLOW DIAGRAMAT BOTTOM REAR OF SPIND...

  • Page 220

    MECHANICAL SERVICE219June 200396-9010 rev G3.19 HS-3R HARMONIC DRIVE COMPONENTSThe Harmonic Drive unit is used to drive the HS-3R Rotary Table.The Harmonic Drive Assembly is made up of the following components:Housed Harmonic DriveO-Ring Pack (included in package)Wave Generator (included in packa...

  • Page 221

    MECHANICAL SERVICE22096-9010 rev GJune 2003ASSEMBLY - MOTOR / WAVE GENERATOR1.Sweat the Pinion Gear (positioned so the groove is away from the flange) over the shaft of theSigma Adapter and set aside.2.Examine the spindle of your Yaskawa Sigma Motor. If your Motor has the Motor Shaft Spaceralrea...

  • Page 222

    MECHANICAL SERVICE221June 200396-9010 rev GASSEMBLY - HARMONIC DRIVE1.Cover your work area with a clean shop rag and place the Harmonic Drive with the smaller-diameterend down on the work surface. You should see the grease cavity of the Harmonic Drive.2.Remove the large O-Ring from the included p...

  • Page 223

    MECHANICAL SERVICE22296-9010 rev GJune 20035.Bolt the Gearbox Adapter to the Harmonic Drive by inserting four SHCS into the countersunk holesin the Gearbox Adapter.NOTE:To test for a dedoidal (out of phase) condition, perform the following operation:Turn the Harmonic Drive/Motor assembly over an...

  • Page 224

    MECHANICAL SERVICE223June 200396-9010 rev GINSTALLATION - BACKLASH TUBE AND PLATE1.Apply grease to the outer side of the Tube and top side (as installed) of the Plate. Also applygrease to the counterbore for the Tube and the machined surface underneath the Table the Platewill move against.2.Assem...

  • Page 225

    MECHANICAL SERVICE22496-9010 rev GJune 2003INSTALLATION - CARRIER MOUNT BRACKET1.Orient the Carrier Mount bracket so the edge side faces forward and the flush side is toward thecenter of the Table. Turn the Carrier bracket so that the mounting holes face the bottom surface ofthe Table. See the F...

  • Page 226

    MECHANICAL SERVICE225June 200396-9010 rev G3.20 HS-3R BRAKE ASSEMBLYThe Brake Assembly has five main components:Brake RingBrake ArmPivot BlockPivot PinBearingASSEMBLY1.Orient the Pivot Block so that you will be inserting the Bearings (Step 2) from the 20-degreechamfered side.2.Insert one Bearing ...

  • Page 227

    MECHANICAL SERVICE22696-9010 rev GJune 2003Brake RingPivot PinBrake ArmPivot BlockINSTALLATION - BRAKE ASSEMBLY1.Clean the threaded holes in the table to remove all oil. Apply Red Loctite onto the (6) Studs (49-0024) and thread into the Stud holes indicated below. Install to a height of 2.175”...

  • Page 228

    MECHANICAL SERVICE227June 200396-9010 rev G5.With an assistant, lift and lower the Brake Ring Assembly onto the Table. Fit the Brake Ring overthe Pivot Pins and Studs. The Brake Ring should rest against the Table. If there is interference,make sure the Pivot Block is in the fully retracted positi...

  • Page 229

    MECHANICAL SERVICE22896-9010 rev GJune 2003INSTALLATION - RING GEAR1.Lubricate and stone the mating surfaces of the Platter and Ring Gear. Wipe clean to removegrease and contaminents.2.Clean the mating surfaces of the Platter and Ring Gear with alcohol.CAUTION! The Ring Gear is a precision-machi...

  • Page 230

    MECHANICAL SERVICE229June 200396-9010 rev G3.21 HS3-7R AIR VALVE ASSEMBLYThis section applies to machines with serial number 51004 and later. See the end of this section for informationspecific to machines built before 51004.The Air Valve Assembly has three main components:3-Way Air ValveHigh-Pre...

  • Page 231

    MECHANICAL SERVICE23096-9010 rev GJune 20033.22 HS3-7R BRAKE CYLINDER PRESSURE BOOSTERTHEORY OF OPERATIONThe Pressure Booster gives the ability to develop and use high hydraulic pressure without incurring the cost ofan on-board HPU. The Pressure Booster has a high-pressure side, a low-pressure s...

  • Page 232

    MECHANICAL SERVICE231June 200396-9010 rev GStreet Elbow (2)7.Thread the Hose Barb into the remaining 90-Degree Elbow and attach to the Pressure Boosterassembly. Orient as shown in the following figure:Hose Barb8.Attach the Braided Hose to the Hose Barb using the supplied hose clamp. Use caution w...

  • Page 233

    MECHANICAL SERVICE23296-9010 rev GJune 2003FINAL ASSEMBLYOrient the Plate as shown and attach to the bottom of the Pressure Booster.Pressure BoosterAssemblyLow Side PortTubingElbowPlatePressure Booster Final Assembly (bottom view)PRESSURE BOOSTER ASSEMBLYPrior to installation of the Pressure Boo...

  • Page 234

    MECHANICAL SERVICE233June 200396-9010 rev G1.Identify the low-pressure Tubing line coming from the low-pressure side of the Pressure Booster.Connect this Tubing line to the Low-Pressure Regulator of the Air Valve Assembly.2.Identify the high-pressure Tubing line coming from the high-pressure side...

  • Page 235

    MECHANICAL SERVICE23496-9010 rev GJune 20036.Tighten the SHCS in a star pattern until the screws are snug. Evenly tighten the screws to seat theBearing, then back off each SHCS 1/16 turn.NOTE:If you are installing the Bearing by yourself, it will be useful to have a mirrorpositioned to see the i...

  • Page 236

    MECHANICAL SERVICE235June 200396-9010 rev GNOTE:Adjusting the Bearing in this manner will move the top part of the outer bearingin the direction pressed, placing leverage against the bottom part of the outerbearing.NOTE:During this procedure, it will be necessary to tighten selected bolts in the ...

  • Page 237

    MECHANICAL SERVICE23696-9010 rev GJune 2003Installation1.Generously apply red grease to the outer ring of the Brake, completely filling the two grooves.Apply Moly grease around the Stud Flex Nuts filling the counterbores on the Brake Ring, horseshoe brake only. Apply moly grease to the Pinion Ge...

  • Page 238

    MECHANICAL SERVICE237June 200396-9010 rev G11. Tighten the SHCS incrementally in a star pattern to avoid misaligning the Bearing. Torque theSHCS in stages up to a final torque of 45 ft./lbs.12. Before replacing the encoder shaft plate, make sure the set screws are backed off.13. Tighten the screw...

  • Page 239

    MECHANICAL SERVICE23896-9010 rev GJune 20033.700"Shaft Length4.175"Encoder ShaftEncoder MountingPlate(O.D. is precision groundfor measuring concentricity)Encoder Cover PlateEncoder Shaft PlateEncoder Coupler TubeFlex CouplingEncoder MountingCupEncoderMeasure fromthis surfaceSet ScrewsE...

  • Page 240

    MECHANICAL SERVICE239June 200396-9010 rev G6.Install the rotary table platter and indicate its bore concentric with the cross-roller bearing,concentricity NTE 0.0005”.NOTE: Be careful not to deflect the encoder shaft - damage to the flex coupling mayresult.7.When installing the encoder shaft pl...

  • Page 241

    MECHANICAL SERVICE24096-9010 rev GJune 20032.Disable the A-axis encoder by setting the parameter 43 bit 3 to 1. Note: This will disable the rotarytable position encoder and enable the drive motor encoder. The drive motor gear will now holdposition allowing backlash to be measured between the rin...

  • Page 242

    MECHANICAL SERVICE241June 200396-9010 rev G8.Begin tightening the left adjusting bolt and check the backlash. Using the cheater bar between thelifting plates or fixtures, nudge the table CW and CCW. Take readings from the indicator. Once thereadings come close to .003”, rotate the table and tak...

  • Page 243

    MECHANICAL SERVICE24296-9010 rev GJune 20033.23HS3-7R HARMONIC DRIVE ASSEMBLY - EXPLODED PARTS LIST1Tube Backlash Adjuster2Cam Backlash Adjuster3Push Block4SCHS5SHCS6Pinion Gear7Sigma Adapter8Harmonic Drive9O-Ring10 MSHCS11 Shoulder Washer12 Gearbox Adapter13 SHCS14 SHCS15 Flat Washer16 HHB17 Sp...

  • Page 244

    MECHANICAL SERVICE243June 200396-9010 rev G3.24 HS3-7R TABLE ASSEMBLY - EXPLODED PARTS LIST1SHCS2Machined Platter3Ring Gear4SHCS5Brake6SHCS7Bearing Crossroller8Bearing Retainer Ring12345678

  • Page 245

    MECHANICAL SERVICE24496-9010 rev GJune 20033.25 HS3-7R ENCODER ASSEMBLY - EXPLODED PARTS LIST

  • Page 246

    MECHANICAL SERVICE245June 200396-9010 rev G3.26 HS3-7R AIR VALVE ASSEMBLY (S/N 51003 AND BEFORE)The Air Valve Assembly has three main components:3-Way Air ValveHigh-Pressure RegulatorLow-Pressure RegulatorTHEORY OF OPERATIONThe Air Valve Assembly actuates the Rotary Table brake. Supplied air fl...

  • Page 247

    MECHANICAL SERVICE24696-9010 rev GJune 20033.Thread a Reducer into the hydraulic port. Thread the Swivel Elbow into the Reducer. Thread theHydraulic Hose from the Pressure Booster into the Swivel Elbow. Orient the Swivel Elbow asshown below and tighten.4.Thread Elbow into the air port. Orient th...

  • Page 248

    MECHANICAL SERVICE247June 200396-9010 rev GPRESSURE BOOSTER ASSEMBLY BENCH TESTPrior to installation of the Pressure Booster Assembly, a test of the entire system should be performed. Thiswill identify leaks and allow for the system to be bled while it is still easily accessible. Set the Air Valv...

  • Page 249

    MECHANICAL SERVICE24896-9010 rev GJune 2003INSTALLATION - HYDRAULIC CYLINDER1.Lift the Hydraulic Cylinder into its area beneath the Table. See the Figure below for the approxi-mate location. The hose connections should face the left of the table (away from the PressureBooster) to prevent kinks i...

  • Page 250

    ELECTRICAL SERVICE249June 200396-9010 rev G4. ELECTRICAL SERVICE40Install lock-out claspand lock with paddlockto secure Circuit Breakerin the OFF positionMake sure the circuit breaker is locked in the off position before attemting any electrical work to avoid possibleshock.4.1 SOLENOIDSPlease rea...

  • Page 251

    ELECTRICAL SERVICE25096-9010 rev GJune 2003Figure 4.1-1. Air solenoid assembly.7.Remove the SHCS holding the assembly to the bracket and remove the assembly.INSTALLATION -1.Replace the air solenoid assembly and attach to the bracket with the SHCS previously removed.Tighten securely.2.Reconnect a...

  • Page 252

    ELECTRICAL SERVICE251June 200396-9010 rev GFigure 4.1-2. Tool release piston assembly with air solenoid assembly.6.Install the new air solenoid on the air solenoid assembly. Reinstall the air solenoid assembly ontothe tool release piston assembly. Take care to not disturb the position of the clam...

  • Page 253

    ELECTRICAL SERVICE25296-9010 rev GJune 20032.Disconnect the air lines from the spindle lube air solenoid assembly.3.Unplug the electrical leads at the quick-disconnect. You will have to slide the wiring channel coverback to disconnect the leads.Figure 4.1-4. Top view of spindle lube/air solenoid...

  • Page 254

    ELECTRICAL SERVICE253June 200396-9010 rev G4.2 LINE VOLTAGE ADJUSTMENTSPlease read this section in its entirety before attempting to adjust the line voltage.TOOLS REQUIRED•Large flat tip screwdriver•Digital voltmeterADJUSTING VOLTAGENOTE:The machine must have air pressure at the air gauge, or...

  • Page 255

    ELECTRICAL SERVICE25496-9010 rev GJune 2003Figure 4.2-1. Control panel general overview.

  • Page 256

    ELECTRICAL SERVICE255June 200396-9010 rev GELECTRICAL CONNECTIONSNOTE:The machine must have air pressure at the air gauge, or a "Low Air Pressure"alarm will be present on power up.CAUTION! Working with the electrical services required for the Horizontal mill can beextremely hazardous. T...

  • Page 257

    ELECTRICAL SERVICE25696-9010 rev GJune 20032. After the line voltage is connected to the machine, make sure that main circuit breaker (at top-right of rear cabinet) is OFF (rotate the shaft that connects to the breaker counterclockwise until itsnaps OFF). Turn ON the power at the source. Using a...

  • Page 258

    ELECTRICAL SERVICE257June 200396-9010 rev GWARNING!Through the Spindle Coolant (TSC) pump is a three phase pump andmust be phased correctly! Improper phasing will cause damage to theTSC pump and void the warranty. Refer to the TSC start up section IFYOUR MACHINE IS EQUIPPED WITH tsc.6.After the p...

  • Page 259

    ELECTRICAL SERVICE25896-9010 rev GJune 20039.Turn off the power (rotate the shaft that engages the handle on the panel door counterclockwiseuntil it snaps into the OFF position). Also, set the main switch handle on the panel door to OFF.(Both the handle and the switch must be set to OFF before t...

  • Page 260

    ELECTRICAL SERVICE259June 200396-9010 rev G50Hz InstallationsThe external transformers are 60Hz rated, and cannot be used at 50Hz without derating the input voltage. Forthese applications, the internal 230V transformer should be tapped on the lowest setting (195-210V RMS). Theexternal transformer...

  • Page 261

    ELECTRICAL SERVICE26096-9010 rev GJune 20034.3 FUSE REPLACEMENTPlease read this section in its entirety before attempting to replace any fuses.OVERVOLTAGE FUSESWARNING!WARNING!WARNING!WARNING!WARNING!The electrical panel will have residual voltage, even after power hasbeen shut off and/or discon...

  • Page 262

    ELECTRICAL SERVICE261June 200396-9010 rev G32-4076G Rev.AFU7C4C3C2C7C6C5C1NE210A 115VMAIN10A 230VCOOLANT10A 115VRTY/USER POWER10A 230VTSC COOLANTSPARE FUSESP1P2P3P4P5P6P7P8P9P10P11P12P13P14P15P16P17P18P19P20P21P22P23P24P25P26P27P28P30P31P32P33P34P35P29TB1TB3TB2NE1NE4FU8FU12 FU11 FU10FU9NE6NE5NE3F...

  • Page 263

    ELECTRICAL SERVICE26296-9010 rev GJune 20034.4 PCB REPLACEMENTPlease read this section in its entirety before attempting to replace any PCBs.MICROPROCESSOR, MOCON & VIDEO / KEYBOARDWARNING!WARNING!WARNING!WARNING!WARNING!The electrical panel will have residual voltage, even after power hasbe...

  • Page 264

    ELECTRICAL SERVICE263June 200396-9010 rev G9.Disconnect all leads to the Video / Keyboard. Ensure all cables are properly labeled for reconnect-ing later. The following illustration shows all cable numbers and the locations on the Video /Keyboard.10. After all cables have been disconnected, unscr...

  • Page 265

    ELECTRICAL SERVICE26496-9010 rev GJune 2003POWER & LOW VOLTAGE SUPPLYPOWER BOARD -NOTE:Refer to "Cable Locations" for a diagram of this board.1.Follow all precautions noted previously before working in the electrical cabinet2.Turn the main switch (upper right of electrical cabinet)...

  • Page 266

    ELECTRICAL SERVICE265June 200396-9010 rev GRS-232 PCBNOTE:Refer to "Cable Locations" for a diagram of this board.1.Follow all precautions noted previously before working in the electrical cabinet (See warning atbeginning of "Servo Driver & SDIST" section).2.Turn the main s...

  • Page 267

    ELECTRICAL SERVICE26696-9010 rev GJune 20037.Replace the Serial Keyboard Interface (KBIF) board, using the four screws previously removed,starting at the top right. Attach the screw and standoff loosely, then all other screws and standoffs,until all are mounted. Tighten down completely.8.Reconne...

  • Page 268

    ELECTRICAL SERVICE267June 200396-9010 rev GRS-232 LINE NOISETo minimize line noise on the serial port, reroute the cables; route them straight up the left-hand side of thecontrol to the processor stack. Do not run them above the I/O PCB or up the center wire channel to theprocessor.Also, disconne...

  • Page 269

    ELECTRICAL SERVICE26896-9010 rev GJune 20034.5 FRONT PANELPlease read this section in its entirety before attempting to replace any component of thecontrol panel.CRT ASSEMBLY REPLACEMENT1.Turn the power off and disconnect power to the machine.2.Remove the screws holding the cover panel on the ba...

  • Page 270

    ELECTRICAL SERVICE269June 200396-9010 rev G8.Plug the black cable and white cable into the matching cables. Feed the white cable through theopening in the top of the control panel.9.Replace the back cover panel and attach with the four screws previously removed.JOG HANDLE REPLACEMENTThe JOG handl...

  • Page 271

    ELECTRICAL SERVICE27096-9010 rev GJune 2003+5VBLK+5VREDGNDWHTAREDBGRNGNDWHT/REDAWHT/YELBWHT/BRNAYELBBRNFigure 4.5-3. Jog Handle removal. Figure 4.5-4. Jog Handle wiring diagram5.Remove the three screws holding the jog handle encoder to the control panel and remove.6.Replacement is reverse of r...

  • Page 272

    ELECTRICAL SERVICE271June 200396-9010 rev GSPINDLE LOAD METER REPLACEMENT1.Turn the power off and disconnect power to the machine.2.Remove the four screws holding the cover panel on the back of the control panel. Take care to holdthe cover panel in place until all screws have been removed.3.Disco...

  • Page 273

    ELECTRICAL SERVICE27296-9010 rev GJune 20037.Insert the ribbon cable through the opening in the control panel. Expose the adhesive strip on theback of the keypad and press the keypad in place in the upper right corner of the keypad recess.Press to the control panel to mount. Plug the ribbon cabl...

  • Page 274

    ELECTRICAL SERVICE273June 200396-9010 rev G4.6 SPINDLE ENCODER REPLACEMENTPlease read this section in its entirety before attempting to remove or replace encoder.REMOVAL -1.Turn machine power on. Lower the spindle head to a position that will allow you to easily work onthe encoder. Turn machine o...

  • Page 275

    ELECTRICAL SERVICE27496-9010 rev GJune 20039.Unscrew the four screws and remove the cover panel on the box at the base of the flexible tube.10. Feed the encoder cable through the flexible tube and connect at the plug in the box on top of theelectrical cabinet.11. Place the 18 tooth belt on the p...

  • Page 276

    275TECHNICAL REFERENCEJune 200396-9010 rev G5. TECHNICAL REFERENCE5.1 TOOL CHANGERTOOL WEIGHT AND SIZECAUTION! Do not exceed the Maximum Specifications given below!HS-1, HS-1R, HS-1RP HS 60/120 SMTCHS-2RP HS-3(R)MAXIMUM TOOL DIAMETERWITH ALL POCKETS FULL 3.5” 3....

  • Page 277

    276TECHNICAL REFERENCEJune 200396-9010 rev GABCABECDEDCTBTTool Holders/Pull StudsABCDE40T40T45T50T40T40T50T50TKit #Kit #Kit #Kit #Kit #Kit #Kit #Kit #45o0.172Thru.1.10420-7595(TSC)22-7171(TSC)20-7594(TSC)22-0075(TSC)20-7165(non-TSC)22-7170(non-TSC)20-7164(non-TSC)22-0039(non-TSC)1.10445oTPS24CTPS...

  • Page 278

    277TECHNICAL REFERENCEJune 200396-9010 rev GTool holders and pull studs must be in good condition and tightened together with wrenches or they may stickin the spindle taper. Clean the tool tapers with a lightly-oiled rag to leave a film to prevent rusting. Tools thatmake a loud bang when being re...

  • Page 279

    278TECHNICAL REFERENCEJune 200396-9010 rev GCAROUSEL ROTATION MOTORA DC brush motor is used to rotate the carousel between tool changes. The motor has an encoder and is drivenby the single axis control mounted inside the control.NOTE:This motor should never be disassembled.TOOL CHANGER POSITION S...

  • Page 280

    279TECHNICAL REFERENCEJune 200396-9010 rev G5.3 SPINDLE OPERATIONSpindle speed functions are controlled primarily by the S address code. The S address specifies RPM ininteger values from 1 to maximum spindle speed (Parameter 131). NOT TO BE CHANGED BY USER! Whenusing the Through the Spindle Cool...

  • Page 281

    280TECHNICAL REFERENCEJune 200396-9010 rev GSPINDLE ORIENTATIONOrientation is performed electrically and no shot pin or solenoid is required for locking the motor in place.Orientation of the spindle is automatically performed for tool changes and can be programmed with M19commands. Orientation is...

  • Page 282

    281TECHNICAL REFERENCEJune 200396-9010 rev G5.4 CONTROL CABINETControl cabinet general overview.5TH5THAXISAXISAXISAXIS-A--A--Z--Z-AXISAXISAXISAXIS-Y--Y-ETHERNETETHERNETAXISAXIS-X--X-SPARESMTC INPUTSPARESPARESERIALSERIALPORT 2PORT 2PORT 1PORT 1SERIALSERIALSPARESMTC OUTPUTSPAREPALLET CHANGERCOOLAN...

  • Page 283

    282TECHNICAL REFERENCEJune 200396-9010 rev G5.5 SERVOS (BRUSHLESS)SERVO ENCODERS (BRUSHLESS)Haas machines are equipped with brushless motors, which provide for better performance, and no mainte-nance. In addition to the performance differences, these machines differ from brush type machines, in ...

  • Page 284

    283TECHNICAL REFERENCEJune 200396-9010 rev G5.6 INPUT/OUTPUT ASSEMBLYThe IOPCB contains a circuit for electronically turning the drawbar motors* power on and off. This prevents anyarcing of the drawbar motor* relays and increases their life tremendously. This includes an adjustable currentlimit t...

  • Page 285

    284TECHNICAL REFERENCEJune 200396-9010 rev G5.7 TWO-SPEED GEAR TRANSMISSIONThe spindle head contains a two-speed gear transmission. The spindle motor is directly coupled to the trans-mission and the transmission is cog belt-coupled to the spindle.GEAR BOX LUBRICATIONThe transmission requires 5 qu...

  • Page 286

    285TECHNICAL REFERENCEJune 200396-9010 rev G5.8 CONTROL PENDANTJOG HANDLEThe JOG handle is actually a 100-line-per-revolution encoder. We use 100 steps per revolution to move one ofthe servo axes. If no axis is selected for jogging, turning of the crank has no effect. When the axis being movedrea...

  • Page 287

    286TECHNICAL REFERENCEJune 200396-9010 rev GKEYBOARD BEEPERThere is a beeper inside the control panel that is used as an audible response to pressing keyboard buttonsand as a warning beeper. The beeper is a 2.3 kHz signal that sounds for about 0.1 seconds when any keypadkey, CYCLE START, or FEED ...

  • Page 288

    287TECHNICAL REFERENCEJune 200396-9010 rev G5.9 MICROPROCESSOR ASSEMBLYThe microprocessor assembly is in the rear cabinet at the top left position. It contains three large boards. Theyare: microprocessor, the keyboard and the MOCON. All three boards of the processor assembly receive powerfrom the...

  • Page 289

    288TECHNICAL REFERENCEJune 200396-9010 rev GThere 1 two-position DIP switch on the processor PCB labled S1. Switch S1-1 must be ON toauto-start the CNC operational program. If S1-1 is OFF, the PGM light will remain off.Switch S2-1 is used to enable FLASH. If it is disabled it will not be possible...

  • Page 290

    289TECHNICAL REFERENCEJune 200396-9010 rev G5.10 SPINDLE DRIVE ASSEMBLYThe spindle drive is located in the main cabinet on the right side and halfway down. It operates from three-phase 200 to 240V AC. It has a 7.5 (or 10) H.P. continuous rating, and a 11.25 (or 15) H.P. one-minute rating.The sp...

  • Page 291

    290TECHNICAL REFERENCEJune 200396-9010 rev G5.12 POWER SUPPLY ASSEMBLYAll power to the control passes through the power supply assembly. It is located on the upper right corner ofthe control cabinet.MAIN CIRCUIT BREAKER CB1Circuit breaker CB1 is rated at 40 amps (20 for High Voltage option) and ...

  • Page 292

    291TECHNICAL REFERENCEJune 200396-9010 rev G POWER-UP LOW VOLTAGE CONTROL TRANSFORMER (T5)The low voltage control transformer, T5, supplies power to the coil of the main contactor K1. It guarantees thatthe maximum voltage leaving the Power Supply assembly when power is off is 12V AC to earth grou...

  • Page 293

    292TECHNICAL REFERENCEJune 200396-9010 rev G5.13 POWER TRANSFORMER ASSEMBLY (T1)The power transformer assembly is used to convert three-phase input power (50/60Hz) to three phase 230Vand 115V power. Two different transformers are used depending on the input voltage range. The low voltagetransform...

  • Page 294

    293TECHNICAL REFERENCEJune 200396-9010 rev GOPTIONAL 480V 60HZ TRANSFORMERAll machines will get the 45KVA transformer.For domestic installations and all others using 60Hz power, the primary side should be wired as follows:Input Voltage RangeTap493-5101 (504)481-4922 (492)469-4803 (480)457-4684 (4...

  • Page 295

    294TECHNICAL REFERENCEJune 200396-9010 rev G5.14 FUSESThe brushless amplifier has one fuse, F1 15 amps. This fuse protects the amplifier itself from drastic damage. Ifthis fuse is ever blown, the associated motor will stop. This will only happen if there is a failure of the amplifiercard. The use...

  • Page 296

    295TECHNICAL REFERENCEJune 200396-9010 rev G5.15 SPARE USER M CODE INTERFACEThe M code interface uses outputs M21-25 and one discrete input circuit. M codes M21 through M25 willactivate relays labeled M21-25. These relay contacts are isolated from all other circuits and may switch up to120V AC at...

  • Page 297

    296TECHNICAL REFERENCEJune 200396-9010 rev GTURNING M FUNCTIONS ON AND OFFThe M code relays can also be separately turned on and off using M codes M51-M55 and M61-M65. M51 toM55 will turn on one of the eight relays and M61 to M65 will turn the relays off. M51 and M61 correspond toM21, etc.NOTE:Re...

  • Page 298

    297TECHNICAL REFERENCEJune 200396-9010 rev G5.17 SWITCHESDOOR OPEN SENSE SWITCHThe DOOR OPEN sense switch is a magnetic reed switch type and consists of two switches; one on each halfof the enclosure front doors. These switches are normally closed and wired in series. When the doors open,one or b...

  • Page 299

    298TECHNICAL REFERENCEJune 200396-9010 rev GWhat Can Go Wrong With Limit Switches?If the machine is operated without connector P5, a LOW LUBE and DOOR OPEN alarm will be generated. Inaddition, the Home search will not stop at the limit switch and will instead run into the physical stops on eachax...

  • Page 300

    299TECHNICAL REFERENCEJune 200396-9010 rev G5.20 PALLET CHANGER FOR THE HS-1ROTARY TABLE (HRT310HRPA)The rotary table is a standard HAAS 310 equipped with a special platter compatible with the pallet operation.The table is mounted on the pallet changer casting, and a drive shaft bearing assembly ...

  • Page 301

    300TECHNICAL REFERENCEJune 200396-9010 rev GLIFTING ASSEMBLYThe pallet lifting assembly consists of a large guided pneumatic cylinder and an H-frame. Pins are mounted inthe H-frame to engage the pallets from below and to give aid in stabilizing the load during rotation of the pallets.The H-frame ...

  • Page 302

    301TECHNICAL REFERENCEJune 200396-9010 rev GLOAD STATIONNOTE:This only applies to machines with serial numbers up to 50477.The load station is a 90 degree manual indexing station that holds a pallet securely into place while maintain-ing the ability to index freely. The load station holds the pal...

  • Page 303

    302TECHNICAL REFERENCEJune 200396-9010 rev GPOWER SUPPLY CABLESThe load station drawbar gearmotor and the main drawbar gearmotor each have a power supply cable. The loadstation motor is equipped with an extension cable to aid in motor replacement. The connector is about 12inches from the gearmoto...

  • Page 304

    303TECHNICAL REFERENCEJune 200396-9010 rev G5.21 DIAGNOSTIC DATAThe ALARM MSGS display is the most important source of diagnostic data. At any time after the machinecompletes its power-up sequence, it will either perform a requested function or stop with an alarm. Refer to theAlarms section for ...

  • Page 305

    304TECHNICAL REFERENCEJune 200396-9010 rev GDISCRETE OUTPUTS # Name #Name1100Power Servos1120Unclamp Pre-Chrg1101Spare1121HTC Shuttle Out1102Spare1122Brake 5th axis1103Spare1123CE Door Lock1104Brake 4th Axis1124R.P. Pallet CW1105Coolant Pump On1125R.P. Pallet CCW1106Auto Power Off1126Air Door110...

  • Page 306

    305TECHNICAL REFERENCEJune 200396-9010 rev GThe following inputs and outputs pertain to the Haas Vector Drive. If it is not enabled, these will display a valueof *. Otherwise, it will display a 1 or 0.Spindle ForwardSpindle FaultSpindle ReverseSpindle LockedSpindle LockSpindle Over heatSpindle at...

  • Page 307

    306TECHNICAL REFERENCEJune 200396-9010 rev G5.22 THE EQUATIONS OF MOTIONAn analysis of the physics of motion of a machine tool can give some important insights into the “blocks persecond” issue. The following mathematics calculates the block per second requirement in order to achieve aworst c...

  • Page 308

    307TECHNICAL REFERENCEJune 200396-9010 rev G5.23 FORMULASTO FIND:TO FIND:S.F.MTO FIND THE SFM OF A CUTTER OR WORKPIECEEXAMPLE: To find the SFM of a cutter rotating at 600RPM with a diameter of 10 inches.SFM==.262xdxRPM123.1416xdxRPMR.P.M.TO FIND THE RPM OF A CUTTER OR WORKPIECEEXAMPLE: To find th...

  • Page 309

    308PARAMETERSJune 200396-9010 rev G6. PARAMETERSParameters are seldom-modified values that change the operation of the machine. These include servo motortypes, gear ratios, speeds, stored stroke limits, lead screw compensations, motor control delays and macrocall selections. These are all rarely ...

  • Page 310

    309PARAMETERSJune 200396-9010 rev G24 TORQUE ONLYFor HAAS diagnostic use only.25 3 EREV/MREVThe 2 EREV/MREV and 3 EREV/MREV bits have two definitionsdepending on whether one or two encoders are present. For singleencoder systems, the bits are used to define the ratio between theelectrical rotatio...

  • Page 311

    310PARAMETERSJune 200396-9010 rev GParameter9X MAX ERRORMax error allowed in servo loop before alarm is generated. Units are encoder steps. This is themaximum allowable error in Hz between the commanded speed and the actual speed. Thepurpose of this parameter is to prevent "motor runaway&qu...

  • Page 312

    311PARAMETERSJune 200396-9010 rev GParameter23Y MAX ERRORSee Parameter 9 for description.Parameter24Y FUSE LEVELSee Parameter 10 for description.Parameter25Y TORQUE PRELOADSee Parameter 11 for description.Parameter26Y STEPS/REVOLUTIONSee Parameter 12 for description.Parameter27Y BACKLASHSee ...

  • Page 313

    312PARAMETERSJune 200396-9010 rev GParameter43A SWITCHESSee Parameter 1 for description AND make sure that this parameter is set to enable the fourth axisbefore you try to enable the fourth axis from settings.Parameter44A P GAINSee Parameter 2 for description.Parameter45A D GAINSee Parameter 3...

  • Page 314

    313PARAMETERSJune 200396-9010 rev GParameter54A STEPS/REVOLUTIONSee Parameter 12 for descriptionParameter55A BACKLASHSee Parameter 13 for description.Parameter56A DEAD ZONESee Parameter 14 for description.Parameters 57 through 128 are used to control other machine dependent functions. They are...

  • Page 315

    314PARAMETERSJune 200396-9010 rev G21 M19 SPND ORTThis bit makes the P and R codes a protected feature which can only beenabled with an unlock code. The unlock code will be printed on theparameter listing of all new machines. If this bit is set to 0, an M19 willorient the spindle to 0 degrees reg...

  • Page 316

    315PARAMETERSJune 200396-9010 rev GParameter63SHUTTLE STOP DELAYThis parameter is also used for vertical mills with a Side Mount Tool Changer. It is used to specifythe time allowed (in milliseconds) for the tool arm motor to stop. If the arm has not stopped afterthe allowed time alarm 627 ATC A...

  • Page 317

    316PARAMETERSJune 200396-9010 rev GParameter77SP LOCK SETTLE TIMERequired time in milliseconds that the spindle lock must be in place and stable before spindleorientation is considered complete.Parameter78GEAR CH REV TIMETime in milliseconds before motor direction is reversed while in a gear chan...

  • Page 318

    317PARAMETERSJune 200396-9010 rev GParameter91G MACRO CALL O9010G code that will call O9010. This parameter can contain a value from 1 through 98, inclusive, zerocauses no call. However it is best to use a value that is not already in use (see current G code list).Using G45 the value 45 would be ...

  • Page 319

    318PARAMETERSJune 200396-9010 rev GParameter107Z MAX CURRENTSee Parameter 105 for descriptionParameter108A MAX CURRENTSee Parameter 105 for descriptionParameter109D*D GAIN FOR XSecond derivative gain in servo loop.Parameter110D*D GAIN FOR YSecond derivative gain in servo loop.Parameter111D*D GAIN...

  • Page 320

    319PARAMETERSJune 200396-9010 rev GParameter127Z GRID OFFSETSee Parameter 125 for description.Parameter128A GRID OFFSETSee Parameter 125 for description.Parameter129GEAR CH SETTLE TIMEGear change settle time. This is the number of one millisecond samples that the gear status mustbe stable before ...

  • Page 321

    320PARAMETERSJune 200396-9010 rev GParameter145X ACCEL FEED FORWARDParameter146Y ACCEL FEED FORWARDParameter147Z ACCEL FEED FORWARDParameter148A ACCEL FEED FORWARDThese parameters set the feed forward gain for the axis servo. They have no units.Parameter149Precharge DELAYThis parameter sets the ...

  • Page 322

    321PARAMETERSJune 200396-9010 rev GParameter165IN POSITION LIMIT BSame definition as Parameter 101.Parameter166B MAX CURRENTSame definition as Parameter 105.Parameter167D*D GAIN FOR BSecond derivative gain in servo loop.Parameter168B ACC/DEC T CONSTSame definition as Parameter 113.Parameter169B P...

  • Page 323

    322PARAMETERSJune 200396-9010 rev GParameter181C MIN SLIPThe minimum value allowed from the slip rate. From the equation:Slip rate = slip gain x (speed/max speed) x (current/max current)It can be seen that at a zero speed, the slip rate would become zero. Therefore a minimum value forslip rate is...

  • Page 324

    323PARAMETERSJune 200396-9010 rev GParameter194SPINDLE STOP FREQThe spindle is considered to be stopped (discrete input SP ST*=0) when the speed drops belowthis value. Units are encoder steps/millisecond.Parameter195C START/STOP DELAYThis delay is used at the start of motion to magnetize the roto...

  • Page 325

    324PARAMETERSJune 200396-9010 rev G5FRONT DOORWhen enabled the control will look for an additional door switch and willgenerate an operator message.6TC Z NO HOMEIn Horizontal mills only. This bit prevents Z-axis motion to machine zeroprior to a tool change.7M36 AUTO MOTIn Horizontal only. When s...

  • Page 326

    325PARAMETERSJune 200396-9010 rev G31 SPNDL NOWAITWhen (1), the machine will not wait for the spindle to come up to speedimmediately after an M03 or M04 command. Instead, it will check and/orwait for the spindle to come up to speed immediately before the nextinterpolated motion is initiated. Th...

  • Page 327

    326PARAMETERSJune 200396-9010 rev GParameter221MAX TIME NO DISPLAYThe maximum time (in 1/50 sec.) between screen updates.Parameter222ROTARY AXIS INCRMNTFor Horizontal mills only. This parameter sets the degrees of rotation of the A-axis at an M36 orPallet Rotate.Parameter223AIR TC DOOR DELAYFor ...

  • Page 328

    327PARAMETERSJune 200396-9010 rev GParameter238MAX TSC SPINDLE RPMWhen TSC is enabled and in use, this parameter limits the maximum spindle speed. Default valueis 10000 RPM. On 50 taper machines, the maximum spindle speed is 5000 RPMParameter239SPNDL ENC STEPS/REVThis parameter sets the number of...

  • Page 329

    328PARAMETERSJune 200396-9010 rev GParameter253 SPIGOT FWD POS DLYThis parameter is used to specify the length of a delay (units are ms) when moving the coolantspigot forward. This parameter should be set to zero on all machines.Parameter254VB AIR DOOR CLEARANCEThis is a new parameter to support ...

  • Page 330

    329PARAMETERSJune 200396-9010 rev GParameter259COLD SPINDLE DAYSThe first time Cycle Start is pressed after the machine has been turned on, the control will comparethe number of days that have passed since the machine was turned off against the value of thisparameter. If the machine has been off...

  • Page 331

    330PARAMETERSJune 200396-9010 rev G5Y NEG COMP DIRUsed to negate the direction of thermal compensation.6Y DELAY AXIS 0Used with an APL to ensure Y axis is zeroed before A axis of APL.7Y MAX TRAVEL INPThis bit is set to 1 on five axes machines. This bit indicates that there is aswitch (visible thr...

  • Page 332

    331PARAMETERSJune 200396-9010 rev G5A NEG COMP DIRUsed to negate the direction of thermal compensation.6A DELAY AXIS 0Used with an APL to ensure A axis is zeroed before B axis of APL.7A MAX TRAVEL INPThis bit is set to 1 on five axes machines. This bit indicates that there is aswitch (visible thr...

  • Page 333

    332PARAMETERSJune 200396-9010 rev G2DSBL SCALE ZUsed to disable the linear scale Z test.3C ZERO AXIS TCUsed to return axis to zero prior to tool change (5-axes mills).4C 2ND HOME BTNUsed to move axis to coordinate specified in Work Offset G129.5C NEG COMP DIRUsed to negate the direction of therma...

  • Page 334

    333PARAMETERSJune 200396-9010 rev G10 HS3 HYD TCThis parameter bit is used with the 38 tool SMTC on the HS-3. When thisis set to zero, the mill will behave normally. When it is set to 1, the controlwill recognize that the toolchanger is a 38-Tool SMTC.11 HAAS VECT DR(Haas Vector Drive) This bit...

  • Page 335

    334PARAMETERSJune 200396-9010 rev G24 HS2 SDMTCRSLThis parameter bit is for the HS-2 sidemount tool changer. It must be setto 1 on all HS-2 mills, and 0 on all other mills.25 HS3 SDMTCRSLThis parameter bit is for the HS-3 sidemount tool changer. It must be setto 1 on all HS-3 mills, and 0 on all ...

  • Page 336

    335PARAMETERSJune 200396-9010 rev GParameter286Y LINEAR SCREW OFFSSee parameter 285 for description.Parameter287Z LINEAR SCREW OFFSSee parameter 285 for description.Parameter288A LINEAR SCREW OFFSSee parameter 285 for description.Parameter289B LINEAR SCREW OFFSSee parameter 285 for description.Pa...

  • Page 337

    336PARAMETERSJune 200396-9010 rev GParameter302FEED ACCELERATIONThis parameter supports the motion control feature. This is the acceleration that applies to feedmotion in encoder steps per second squared. For Vertical mill, 1/2 of the value of parameter 7 is agood starting point. For horizontal M...

  • Page 338

    337PARAMETERSJune 200396-9010 rev GParameter311ARM BUMP TIME/DEGThis parameter supports the side mount tool changers. During tool change recovery, the arm maybe moved a small amount by pressing the ATC FWD or ATC REV key. Each press of the key willcause the arm motors to run for the amount of tim...

  • Page 339

    338PARAMETERSJune 200396-9010 rev GParameter315COMMON SWITCH 40ALIS M GRPHCWhen this bit is set to 0, all user defined M codes (such as M50 normallyused to do a pallet change on a horizontal mill) will be ignored when aprogram is run in graphics mode. If it is necessary to have graphicsrecognize ...

  • Page 340

    339PARAMETERSJune 200396-9010 rev G8MINI MILLWhen parameter 315 bit 8 MINI MILL is set to 1, the Over Voltage discreteinput will be displayed as P.S. Fault.When it is set to 1:(a) The DC BUSS voltage that is normally displayed on the diagnosticsscreen for a Vector Drive machine will not be displa...

  • Page 341

    340PARAMETERSJune 200396-9010 rev G18 HIGH Z TCThis parameter bit supports the Gantry mill. It should be set to 1 on theGR510 and zero on all other mills. On a Gantry mill, the spindle (Z axis) ismounted on the gantry (Y axis) and can be positioned to either a positiveor negative Z position. When...

  • Page 342

    341PARAMETERSJune 200396-9010 rev GParameter333X SCALES PER REVThis parameter is used on machines equipped with linear scales. This parameter should be set to50,000 on mills fitted with linear scales. On all other mills, they should be set to zero.Parameter334Y SCALES PER REVThis parameter is use...

  • Page 343

    342PARAMETERSJune 200396-9010 rev GParameter352RELAY BANK SELECTThis parameter allows the user to change which bank of relays is to be used (Parameter 209 bit 23MCD RLY BRD assumes that relay bank one is to be used). It may be set to a number from 0 to 3(inclusive). M codes M21 through M28 will...

  • Page 344

    343PARAMETERSJune 200396-9010 rev GParameter605 Pallet Changer TypeThis parameter is for use with the Horizontal Mill pallet changer feature (hard coded). On an HS-1RP or HS-2RP which has the hard coded pallet changer feature, this parameter must be set to 1.On all other mills including VF series...

  • Page 345

    344PARAMETERSJune 200396-9010 rev GParameter625Sp-Axis Plus Travel LimitSee Parameter 620Parameter626U-Axis Plus Travel LimitSee Parameter 620Parameter627V-Axis Plus Travel LimitSee Parameter 620Parameter628W-Axis Plus Travel LimitSee Parameter 620Parameter629Tt-Axis Plus Travel LimitSee Paramete...

  • Page 346

    345PARAMETERSJune 200396-9010 rev GParameter705 SMTC2 CLAMP POSThis parameter supports the high speed tool changer. It specifies the absolute position in degrees*1000 which the TT axis will stop at in order to clamp the tool.LEAD SCREW COMPENSATIONSeparate lead screw compensation is provided for ...

  • Page 347

    MAINTENANCE346June 200396-9010 rev G7. MAINTENANCE7.1 GENERAL REQUIREMENTSOperating Temperature Range41°F to 104°F (5 to 40°C)Storage Temperature Range-4°F to 158°F (-20 to 70°C)Ambient Humidity: less than 90% relative humidity, non-condensingAltitude: 0-7000 ft.ELECTRICITY REQUIREMENTSI...

  • Page 348

    MAINTENANCE347June 200396-9010 rev GAIR REQUIREMENTSThe HMC requires a minimum of 100 PSI at 9 scfm at the input to the pressure regulator on the back of themachine. This should be supplied by at least a two horsepower compressor, with a minimum 20-gallon tank,that turns on when the pressure drop...

  • Page 349

    MAINTENANCE348June 200396-9010 rev G7.2 MAINTENANCE SCHEDULEThe following is a list of required regular maintenance for the HAAS HS Series Horizontal Machining Centers.Listed are the frequency of service, capacities, and type of fluids required. These required specifications mustbe followed in ...

  • Page 350

    MAINTENANCE349June 200396-9010 rev G7.3 LUBRICATION CHARTmetsySdnaebuLyaWscitamuenPnoissimsnarTknaTtnalooCelbaTyratoRnoitacoLlenaplortnocehtrednUehtfoedisthgirehtnoenihcamdaeheldnipsforaeRenihcamfoediSretrauqtnorfthgiRelcricnoitpircseD03htiwpmupnotsiP.emitelcycetunimnehwnoylnosipmuProgninrutsiel...

  • Page 351

    MAINTENANCE350June 200396-9010 rev GTSC MAINTENANCE•Top off the coolant tank every eight hour shift during heavy TSC usage.•Refer to the next section, and check gauge (G2) on 100 micron filter with TSC system running and notool in the spindle. Change element when the indicator reaches the re...

  • Page 352

    MAINTENANCE351June 200396-9010 rev GTSC coolant pump assembly.Cleaning the intake filter." Check dirt indicator on 100 micron filter (see the figure below) with TSC system running and no tool in thespindle. Change element when the indicator reaches the red zone.100 Micron 1TSC filter.WARNING...

  • Page 353

    MAINTENANCE352June 200396-9010 rev GTo clean the filter:Turn off the coolant pump.Remove the filter.Clean and reinstall filter.HS-1/2 - TRANSMISSION OILCAUTION!Power down the machine before performing any maintenance tasks.To access the Transmission Oil Fill Cup, remove the SHCS that secure the ...

  • Page 354

    MAINTENANCE353June 200396-9010 rev G7.4 LUBRICATION SYSTEMAll machine lubrication is supplied by the external lubrication system. The reservoir is located on the lower rearof the machine (see Figure below). Current lube level is visible in the reservoir. If additional lube needs to beadded, remo...

  • Page 355

    MAINTENANCE354June 200396-9010 rev G7.5 PALLET CHANGER ROTARY TABLEPerform Every Six Months1.To check and/or add lube to the Pallet Changer rotary table, remove the right-front Access Cover(nearest the control pendant). On HS-1R and HS-1RP models, remove the 9 BHCS. On HS-2RPmodels, remove the ...

  • Page 356

    MAINTENANCE355June 200396-9010 rev G7.7 PERIODIC MAINTENANCEA periodic maintenance page has been added to the control, it is found on the Current Commands screenstitled SCHEDULED MAINTENANCE and accessed by pressing PAGE UP or PAGE DOWN which allows theoperator to activate and deactivate a serie...

  • Page 357

    MAINTENANCE356June 200396-9010 rev G7.9 INTERIOR WORKLIGHTBULB REPLACEMENT1.TURN OFF power to the machine at the mainbreaker.2.Remove the four (4) screws that hold on the plexyglass cover retaining plate.3.Remove the retaining plate and the plexyglass cover.4.Change the flourecent tubes and rea...

  • Page 358

    357CABLE LOCATIONSJune 200396-9010 rev G8. PCB'S, CABLE LOCATIONS AND BOARD DIAGRAMSShown below are three types of commonly used cable connectors. They are shown as seen when pluggedinto the pc board. These diagrams are to aid in locating the pins for trouble shooting. Note:The numbering sequence...

  • Page 359

    CABLE LOCATIONS35896-9010 rev GJune 2003PROC.PLUG #CABLE #SIGNAL NAME# TO #LOCATIONPLUG #J1 ADDRESSADDRESS BUSSVIDEO——-J2 DATADATA BUSSMOTIF PCB——-J3860LOW VOLTAGEPOWER SUPPLY PCB ——-J6N/AREPLACEMENT BAT. CONNECTION——-PORT 1850SERIAL PORT #1KEY. INTERFACE——-PORT 2850ASERIAL P...

  • Page 360

    359CABLE LOCATIONSJune 200396-9010 rev GBRUSHLESS SERVO AMPLIFIER P/N 93-5550CTO SERVO MOTOR325VDC (FROM HAAS VECTOR DRIVE)LOW VOLTAGE (INPUT)SERVO DRIVE SIGNAL ( FROM MOCON)

  • Page 361

    CABLE LOCATIONS36096-9010 rev GJune 2003BRUSHLESS SERVO AMPLIFIER - P/N 93-5550CCABLE CONNECTIONSMOCONPLUG #CABLE #SIGNAL NAME# TO #LOCATIONPLUG #X AXIS AMPP570LOW VOLTAGEL. V. POWER SUPPLY——-TB A, B, C——-MOTOR DRIVEX SERVO MOTOR——-P610X DRIVE SIGNALMOCON PCBP2TB -HV +HV——-320V...

  • Page 362

    361CABLE LOCATIONSJune 200396-9010 rev GPOWER PCB 93-0227A32-5200HFU7C4C3C2C7C6C5C1NE210A 115VMAIN10A 230VCOOLANT10A 115VRTY/USER POWER10A 230VTSC COOLANTSPARE FUSESP1P2P3P4P5P6P7P8P9P10P11P12P13P14P15P16P17P18P19P20P21P22P23P24P25P26P27P28P30P31P32P33P34P35P29TB1TB3TB2NE1NE4FU8FU12 FU11 FU10FU9...

  • Page 363

    CABLE LOCATIONS36296-9010 rev GJune 2003POWER PCB - P/N 93-0227ACABLE CONNECTIONSI/O PLUG #CABLE #SIGNAL NAME# TO #LOCATIONPLUG#P1+12VDCCNC Unit FanP290B115VACLow Voltage Power SupplyP390B115VACProbe PSP490B115VACWork LightP590B115VACSwitch Door FanP690B115VACServo FanP790B115VACDelta-WyeP8860+1...

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    363CABLE LOCATIONSJune 200396-9010 rev GI/O PCB T - P/N 34-3080TI/O PLUG #CABLE ## TO #LOCATIONPLUG #P1140BChip ConveyorP2820BT/C In/smtc arm mark TP3820DB Up/Down / TC out SMTC / shuttle outP4900TSC Pump (Low TSC pressure)P5770E-Stop Switch A Front PanelP6770AE-Stop Switch BP7770BE-Stop Switch ...

  • Page 365

    CABLE LOCATIONS36496-9010 rev GJune 2003I/O PCB T - P/N 93-0228A CABLE CONNECTIONSI/O PLUG #CABLE ## TO #LOCATIONPLUG #P15890Spin Head Status / SP DB openP16780Spare/ 2nd VD OV/contactor on/ cntr balanceP17410T/C Air Door SWP18790Pallet CW/CCWP19190Frnt Door sw / Lo phaseP20190AOp Station Loc...

  • Page 366

    365CABLE LOCATIONSJune 200396-9010 rev GPLUG#CABLE## TO #LOCATIONPLUG#P1700BPROCESSOR850P2—-KEYPAD—-P3700ACYCLE START/HOLD SWITCHES—-P4730SP LOAD METER—-P5—-—-P6—-AUX FPANEL—-J1—-—-J2—-REMOTE JOG HANDLE—-J3750MOCONP18J5—-(MIKRON ONLY)—-J7—-EXTERNAL KEYBOARD—-J12860...

  • Page 367

    CABLE LOCATIONS36696-9010 rev GJune 2003VIDEOPLUG #CABLE #SIGNAL NAME# TO #LOCATIONPLUG #P1860LOW VOLTAGEPOWER SUPPLY PCB——-J3*700KEYBOARD INFO.KEYBOARD INT.——-J4——-ADDRESS BUSSMICRO PROC. PCB——-J5——-DATA BUSSMOTIF PCB——-J10——-FLOPPY DR. POWERFLOPPY DRIVE——-J11—...

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    367CABLE LOCATIONSJune 200396-9010 rev GMOCON PCB - P/N 32-4023LP30P31P16P33P32P5P4P3P2P18P20P6P7P8P9P24P10P17P21P22P11P13P15P1P19P26P27P28P3432-4023MP12P14U43

  • Page 369

    CABLE LOCATIONS36896-9010 rev GJune 2003MOCON PCB - P/N 32-4023LCABLE CONNECTIONSMOCONPLUG #CABLE #SIGNAL NAME# TO #LOCATIONPLUG #P1——-DATA BUSSVIDEO PCB——-MICRO PROC. PCB——-P2610X DRIVE SIGNALX SERVO DRIVE AMP. PP3620Y DRIVE SIGNALY SERVO DRIVE AMP. PP4630Z DRIVE SIGNALZ SERVO DRIVE...

  • Page 370

    369CABLE LOCATIONSJune 200396-9010 rev GRS-232 PORT #1 PCB - P/N 32-4090CABLE CONNECTIONSPLUG #CABLE ## TO #LOCATIONPLUG #P1850VIDEO &J13 INTERNALKEYBOARDJ1——-——-——- EXTERNAL

  • Page 371

    CABLE LOCATIONS37096-9010 rev GJune 2003K4K5TO IO PCB, P58TO IO PCB, P12TO HAAS VECTOR DRIVETO SPINDLE MOTOR650ATO K5 AUXTO K5 COILTO K5 COILTO K4 COILTO K4 COIL650BY-DELTA SWITCH ASSEMBLYP/N 32-5850B

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    371CABLE LOCATIONSJune 200396-9010 rev GM CODE RELAY BOARDP/N 93-1057B CABLE CONNECTIONSPLUG #CABLE #SIGNAL NAME# TO #LOCATIONPLUG #P1540MOCON INPUTIO PCB`P62P2860A12VD TO M-CODE PCBAPSUPP31P3540AIOPCB OUTPUTP4M21M-FUNCTIONM22PROBE OPTIONM24spareP5M25spareM26spareM27spareP6540BM CODE OUTPUT2nd MCDP1

  • Page 373

    CABLE LOCATIONS37296-9010 rev GJune 200350T TRANSMISSION P.S. / HYDRAULIC C.B. PCBP/N 32-4095D CABLE CONNECTIONSPLUG #CABLE ## TO #LOCATIONPLUG #P1880BIO PCBP12P290POWER PCBP8P3410GEAR BOXP4350IO PCBP54TB2340HYDRAULIC MTRTB370MAIN TRANSFORMER(VECTOR DRIVE UNIT)FU1115 VAC115 V Servo Brake880B/P1

  • Page 374

    CABLE LIST373June 200396-9010 rev G9. CABLE LISTWIRE/TERMINAL FUNCTION NAME:NUMBERINCOMING POWER 195-260 VAC (353-480 VAC OPTIONAL)L1INCOMING 195-260VAC PHASE 1, TO CB1-1L2INCOMING 195-260VAC PHASE 2, TO CB1-2L3INCOMING 195-260VAC PHASE 3, TO CB1-371PROTECTED 195-260VAC CB1-4 TO K1-172PRO...

  • Page 375

    CABLE LIST37496-9010 rev GJune 2003100AM-FUNCTION OUTPUT M21 (MCD RELAY BOARD M21) -SHIELD +2101AUNSWITCHED LEG 1 #20102ASWITCHED LEG 2 #20103ASHIELD DRAIN110SPARE (115 VAC SERVO POWER)140230VAC 3PH POWER TO CHIP CONVEYOR MOTOR141PHASE A 230VAC142PHASE B 230VAC143PHASE C 230VAC144STARTING WINDIN...

  • Page 376

    CABLE LIST375June 200396-9010 rev G270115 VAC RELAY OUTPUT TO PURGE SOLENOID - SHIELD +2271UNSWITCHED LEG 1 #20272SWITCHED LEG 2 #20273SHIELD DRAIN280115 VAC RED/GREEN BEACON CABLE -SHIELD +3281RED LAMP 115VAC282GREEN LAMP 115VAC283COMMON 115VAC284SHIELD DRAIN290115VAC TO XFORMER T2 10VAC OUTPUT2...

  • Page 377

    CABLE LIST37696-9010 rev GJune 2003490B325VDC FROM AMPLIFIER TO SERVO POWER SUPPLY491BHIGH VOLT + RED #20492BHIGH VOLT - BLACK #20510RELAY CARD 1 DRIVE CABLE - 16 WIRE RIBBON #24520RELAY CARD 2 DRIVE CABLE - 16 WIRE RIBBON #24530RELAY CARD 3 DRIVE CABLE - 16 WIRE RIBBON #24540RELAY CARD 4 DRIVE ...

  • Page 378

    CABLE LIST377June 200396-9010 rev G650230VAC, THREE PHASE POWER TO SPINDLE MOTOR-SHIELD+3651PHASE 1652PHASE 2653PHASE 3654SHIELD DRAIN650A230VAC, THREE PHASE POWER, CONTACTOR TO SPINDLE MOTOR(WYE-DELTA OPTION)651APHASE 1652APHASE 2653APHASE 3654ASHIELD DRAIN650B230VAC, THREE PHASE POWER, CONTACTO...

  • Page 379

    CABLE LIST37896-9010 rev GJune 2003700KEYBOARD CABLE - 34 WIRE RIBBON WITH IDC(FROM VIDEO P4 TO KBIF P1)710P-COOL / BF COLLET OPEN - BF COLLET CLOSE711SPARE712SPARE713SPARE714SPARE715SPARE720ANALOG SIGNAL FROM MOCON TO SPINDLE DRIVE TO LOAD MONITOR7210 TO +10 VOLTS SPEED COMMAND722COMMON723SHIEL...

  • Page 380

    CABLE LIST379June 200396-9010 rev G750BJOG HANDLE DATA CABLE SHIELD +6 (ALL#24)750B-1+5 VDC JOG HANDLE750B-20VDC750B-3JOG HANDLE A CHANNEL750B-4JOG HANDLE A* CHANNEL750B-5JOG HANDLE B CHANNEL750B-6JOG HANDLE B* CHANNEL760MONITOR VIDEO DATA CABLE - SHIELD +7 (ALL #24)(FROM VIDEO P13 TO CRT)770EMER...

  • Page 381

    CABLE LIST38096-9010 rev GJune 2003820TOOL CHANGER AND MAIN DRAWBAR INPUT STATUS (ALL #20)821TOOL CHANGER IN SIGNAL822TOOL CHANGER OUT SIGNAL823MAIN DRAWBAR UP SIGNAL824MAIN DRAWBAR DOWN SIGNAL825COMMON (RETURN DATA GROUND)826SHIELD DRAIN830VECTOR DRIVE OVERHEAT THERMOSTAT - SHIELD +2831OVERHEAT...

  • Page 382

    CABLE LIST381June 200396-9010 rev G910115 VAC CIRCUIT BREAKER (CB4) TO SOLENOIDS - SHIELD +2911LEG 1 #20912LEG 2 #20913SHIELD DRAIN910A115 VAC TO PALLET CHANGER CW/CCW/AIR SOLENOIDS - SHIELD +2911AUNSWITCHED LEG 1 #20912ASWITCHED LEG 2 (FROM MCD RELAY BOARD M25, M26, M27) #20913ASHIELD DRAIN910B1...

  • Page 383

    CABLE LIST38296-9010 rev GJune 20031000SPINDLE ENCODER CABLE (MoCon SIDE CONNECTION) ALL #241000-1LOGIC RETURN (D GROUND)1000-2ENCODER A CHANNEL1000-3ENCODER B CHANNEL1000-4+5 VDC1000-5ENCODER Z CHANNEL1000-6NOT USED1000-7SPINDLE MOTOR OVERHEAT SENSOR1000-8ENCODER A* CHANNEL1000-9ENCODER B* CHAN...

  • Page 384

    383ELECTRICAL DIAGRAMSJune 200396-9010 rev GELECTRICALWIRING DIAGRAMS

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    384ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    385ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    386ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    387ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    388ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    389ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    390ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    391ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    392ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    393ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    394ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    395ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    396ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    397ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    398ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    399ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    400ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    401ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    402ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    403ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    404ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    405ELECTRICAL DIAGRAMSJune 200396-9010 rev G

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    406ELECTRICAL DIAGRAMSJune 200396-9010 rev G

  • Page 408

    407ELECTRICAL DIAGRAMSJune 200396-9010 rev GHS 60 and 120 Tool Side Mount Tool Changer

  • Page 409

    408ASSEMBLY DRAWINGSJune 200396-9010 rev GASSEMBLY DRAWINGS AND PARTS LISTS

  • Page 410

    409ASSEMBLY DRAWINGSJune 200396-9010 rev G2318171922202125 24261161415234512111310967827HS-1 Base

  • Page 411

    410ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1 Base1.25-9645A Control box support2. 24-7358 STR fit metric linear guide3. 58-2000 Nylon tubing 1/4"4. 58-2010 Nylon tubing 5/325. 20-7186 Bumper Y-axis (motor end)6. 48-0045 Dowel pin 3/8 x 1 1/27. 25-7042 Cover plate motor mount8. 40-1750 BHC...

  • Page 412

    411ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1RPA Column155111022211220194897321813171625232433342632353627282937381614313039

  • Page 413

    412ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1RPA Column1. 30-3971 Hydraulic cylinder assembly2. 49-1004 Shoulder bolt 5/16 x 1 1/4 1/4 x 20 thread3. 25-9665A Bracket, cable carrier4. 25-9614A Bracket, trip SP HD5. 30-3972 Fl tank assembly6. 62-0014 Yaskawa Sigma 09 motor7. 58-3031 Banjo elbow ...

  • Page 414

    413ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1RPA HS Saddle Assembly102526122423222120476598171918161513121114327

  • Page 415

    414ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1RPA HS Saddle Assembly1.20-9557B Extender bar2. 25-7042 Cover plate motor mount3. 20-7186 Bumper Y-axis bearing /motor4. 63-1031 Cable clamp5. 58-2000 Nylon tubing 1/46. 58-2010 Nylon tubing 5/327. 24-7325 STR fit metric linear guide8. 58-2760 Fittin...

  • Page 416

    415ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1 24 Tool, Tool Changer AssemblyBT CONFIGURATIONCT CONFIGURATION24 PLACES24 PLACESVIEW B-BVIEW B-B7634721213141521CONT711110987574732X696872X567016174X18482XSOME ITEMS REMOVED FOR CLARITYSOME ITEMS REMOVED FOR CLARITY24 PLACES24 PLACESVIEW A-A78777997...

  • Page 417

    416ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1 24 Tool, Tool Changer Assembly1. 58-2000 nylon tubing 1/4"2. 58-2010 nylon tubing 5/32"3. 58-2020 3/8 OD natural tubing4. 58-3070 Fitting 1/8 NPT 1/45. 58-16700 Street elbow 1/8"6. 58-16732 1/8 x 1/8 male hex joint7. 58-36851/4 NPT M ...

  • Page 418

    417ASSEMBLY DRAWINGSJune 200396-9010 rev G12345678910111213141516171819202122232425262727A2829303132333435363738394041424344454647484950515253545556HS Transmission Assembly 15 HP VD

  • Page 419

    418ASSEMBLY DRAWINGSJune 200396-9010 rev GHS Transmission Assembly 15 HP VD30-5600B Transmission Assembly1. 58-2020 3/8 OD natural tubing2. 59-0027 Hose clamp 1/2 hose3. 25-7336A Mounting bracket solenoid4. 33-3200 CBL890 SP status SW5. 30-3146 Air solenoid assembly6. 58-2100 Sleeve lube assemb...

  • Page 420

    419ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1, R, RP, Tool Release Piston Assembly123451. 32-2010 Limit Switch Shuttle In/out 24"2. 32-5620 TRP solenoid valve assembly3. 30-3205 TSC TRP base4. 58-3729 Nipple BR 1/4 NPT x 4 1/25. 25-7050B Switch mount tool release

  • Page 421

    420ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1RP Tool Release Piston Assembly, TSCHP720191814151234171656A89111213A10B21221. 58-3056 90 deg 1/4 NPT elbow2. 58-2162 Fitting close nipple 1/4 112 A-B3. 59-2832B Quick exhaust 1/44. 58-3670 1/4 NPT M-18F reducer5. 58-3685 1/4 NPT M-3/8 tube swivel el...

  • Page 422

    421ASSEMBLY DRAWINGSJune 200396-9010 rev GBall Screw AssembliesSNAP LOCK RING BMPRMOTOR MOUNTCOUPLING ASS'YBALL SCREW ROTATED 90°LOCK BEARINGCARTRIDGEMOTOR HOUSINGBEARING ASSEMBLYRADIAL BEARINGBEARING LOCKNUTBall ScrewHS-1, R, RP Base24-9013HS-1, R, RP Saddle24-9013HS-1, R, RP Column24-9514CHS-...

  • Page 423

    422ASSEMBLY DRAWINGSJune 200396-9010 rev GCoupler Assembly30-1517Coupler assembly HS-2 Y axis30-1219Coupler assembly HS-2 X, Z axes30-1220ACoupler assembly HS-1 X, Y, Z axes

  • Page 424

    423ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1RP Pallet Changer (Threaded Drawbar Style)493151110651281142131371. 30-9411B Load station assembly2. Motor assembly HS-1RP3. 30-9414B Air blast manifold4. 30-9415B Lube tube adaptor5. 30-9416A Bearing sleeve assembly6. 30-9417 Nut housing assembly7. ...

  • Page 425

    424ASSEMBLY DRAWINGSJune 200396-9010 rev G21376485HS-2RP Pallet Assembly30-0112 Pallet assembly1. 20-6303 Bushing pallet index2. 20-6301 Pallet 3 1/8 thick3. 25-6302 Shroud pallet 500MM4. 20-6303 Bushing, pallet index5. 20-6455 Insert pallet pullstud6. 20-6440 Pull stud drawbar7. 57-0060 O-ring ...

  • Page 426

    425ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-2RP Load Station Assembly10243029282725263133323420191823219121311816761552143172214

  • Page 427

    426ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-2RP Load Station Assembly1. 59-0045 Mount damper2. 59-0055 2in stroke absorber3. 20-6256 Adjustable stop right4. 33-8076 Pallet clockwise limit switch5. 59-0056 Lock ring6. 20-6476 Shock mounting block, right7. 20-6477 Shock mounting block, left8. 33-...

  • Page 428

    427ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1RP Clutchless Motor AssemblyClutchless motor assembly part number 30-0301A

  • Page 429

    428ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-2RP Main Drawbar Assembly5110294836711Main drawbar assembly 30-01041. 59-2057 5/16 steel balls2. 20-6251 Ball pull collet3. 57-0041 O-ring 2-135 Viton4. 57-2834 O-ring 2-218 Viton5. 20-6445 Drawbar rotary table6. 51-0040 Thrust bearing7. 55-0027 Thrus...

  • Page 430

    429ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-2RP Lift Cylinder Assembly161719182015141312232224811252627228297651094312120-9793

  • Page 431

    430ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-2RP Lift Cylinder Assembly1. 20-6316 H-frame2. 20-6415A Strike mounting plate right3. 20-6414A Strike mounting plate left4. 20-6416A Strike plate shock5. 57-0023 O-ring 2-232 Viton6. 57-0044 O-ring 2-230 Buna7. 20-6320 Cylinder piston8. 51-0014 Sleeve...

  • Page 432

    431ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-2RP Rotating Cylinder Assembly161514136REF 161110789AA451REF1523121. 59-9560 Stabilizer2. 22-9428A Sleeve stabilizer3. 20-6299 V guide mounting rail4. 59-2750 Rotate cylinder5. 22-6334 Cylinder mounting brackets6. 25-9594 Shock mount fixed end7. 25-95...

  • Page 433

    432ASSEMBLY DRAWINGSJune 200396-9010 rev G356421HS-2RP Air Blast Manifold Assembly1. 20-6449 Airblast manifold assembly2. 57-2250 O-ring 2-156 Viton3. 57-6452 Gasket, manifold4. 58-2100 Sleeve lube assembly5. 58-2110 Sleeve nuts lube assesmbly6. 58-6422 Tubing, air blast30-0099 Complete assembly

  • Page 434

    433ASSEMBLY DRAWINGSJune 200396-9010 rev GSECTION A-AAAROTATED 90 FOR CLARITY312456HS-2RP Lube Tube Adaptor Assembly30-0098 Lube tube adaptor assembly1. 49-1004Shoulder bolt 5/16 x 1 1/4 1/4-20 thread2. 20-6456 Lube tube adaptor3. 33-8069 Limit switch main drawbar down4. 25-6339 Switch mounting ...

  • Page 435

    434ASSEMBLY DRAWINGSJune 200396-9010 rev GBACKFRONT252423222126272816192018 1715141234576813109124039414244434550383752515329 30323133343536View BView B274847 4649HS-2RP Air Regulator / Lube Assembly

  • Page 436

    435ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-2RP Air Regulator / Lube Assembly1.32-8030A Lube home DB mold2. 58-0004 1/4 NPTx2 brass nipple3. 58-3685 1/4 NPT M-3/8 tube swivel elbow4. 58-3740 1/4 NPT female cross5.58-1691 Elbow 3/8 Npt x 1/2 OD tube6. 58-2100 Sleeve lube assembly7. 58-2110 Sleev...

  • Page 437

    436ASSEMBLY DRAWINGSJune 200396-9010 rev GPendant Levelling Assembly

  • Page 438

    437ASSEMBLY DRAWINGSJune 200396-9010 rev G1.Top Cover2.Upper Bellow Guide3.Header Panel, Side4.Door5.Right Side Pan6.Left Apron7.Header Panel, Front8.Right Front Panel9.Left Front Panel10.Right Front Door11.Left Front Door12.Front Pan13.Front Coolant Trough14.Aprons Access Cover15.Right Apron16....

  • Page 439

    438ASSEMBLY DRAWINGSJune 200396-9010 rev G2a2b3a4a4b7a7b8910111213143b1561.Left X-Way Bellows Support2a.X-Waycover Bellows2b.X-Waycover Bellows3a.Left Y-axis Waycover Guide3b.Right Y-axis Waycover Guide4a.Y-axis Chip Guard4b.Y-axis Chip Guard5.Upper Y-Axis Bellows6.Right X-Way Bellows Support7a....

  • Page 440

    439ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1RP External Sheetmetal12345678929303132101213141516171819212022232425261127281.Top Cover2.Front Header3.Header Panel Side4.Operator Door5.Right Front Panel6.Right Apron7.Right Side Pan8.Front Pan9.Front Coolant Trough10.Motor Cover11.Left Front Door1...

  • Page 441

    440ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1RP Internal Sheetmetal141613121512a2b17678910113a3b4a4b5a5b1.X-Way Bellows Support2a.X-Waycover Bellows (left)2b.X-Waycover Bellows (right)3a.Left Y-axis Waycover Guide3b.Right Y-axis Waycover Guide4a.Left Y-axis Waycover Guide4b.Right Y-axis Waycove...

  • Page 442

    441ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-1RP SMTC External Sheetmetal1.SMTC Front Apron2.SMTC Rear Apron3.SMTC Window Frame Sides (2)4.SMTC Window FrameTop-Bottom5.SMTC Window Frame Gasket6.SMTC Window7.SMTC Bottom Panel8.SMTC Side Shield9.SMTC Door w/Window10.SMTC Door Shipping Bracket11.SM...

  • Page 443

    442ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-2RP External Sheetmetal1234145678910151617181920222324252627282921111213303233343536373840414243444546473931

  • Page 444

    443ASSEMBLY DRAWINGSJune 200396-9010 rev G1. Rear Top Cover2.Front Top Cover3.Front Header4.Right Bottom Door Track5.Right Top Door Track6.Right Rear Panel7.Right Intermediate Panel8.Right Side Header9.Right Front Panel10.Operator Door11.Operator Door Window12.Operator Door Window Gasket1...

  • Page 445

    444ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-2RP Internal Sheetmetal4568791011121314151617181920222324252627282923121

  • Page 446

    445ASSEMBLY DRAWINGSJune 200396-9010 rev GHS-2RP Internal Sheetmetal Parts List1. Z-Axis Front Waycover2.Front Window3.Window Weather Strip4.Rotating Door5.Rotating Door Guide6.Pallet Shroud7.Pallet Changer Access Cover (4)8.Pallet Changer Top Cover9.PC Section Front Bottom Cover10.PC S...

  • Page 447

    446ASSEMBLY DRAWINGSJune 200396-9010 rev G1Back panel sheet metal21Brace2Y Axis Upper Bellows22z Axis chip conveyor tray gasket3Y Axis bellows top edge cover23X Axis splash guard4Y Axis splash cover24X Axis chip conveyor tray, left5Door enclosure25Chip conveyor chute6Y axis chip guard26X Axis ch...

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