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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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    96-81001TROUBLESHOOTINGJune 1998COMMON ABBREVIATIONS USED IN HAAS MACHINESACAlternating CurrentAMPAmpereAPCAutomatic Pallet ChangerAPLAutomatic Parts LoaderASCIIAmerican Standard Code for Information InterchangeATCAutomatic Tool ChangerATC FWDAutomatic Tool Change ForwardATC REVAutomatic Tool Cha...

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    296-8100TROUBLESHOOTINGJune 1998NCNormally ClosedNONormally OpenODOutside DiameterOPEROperatorPARAMParameterPCBPrinted Circuit BoardPGMProgramPORPower On ResetPOSITPositionsPROGProgramPSIPounds Per Square InchPWMPulse Width ModulationRAMRandom Access MemoryREPT RIG TAPRepeat Rigid TapRETReturnREV...

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    96-81003TROUBLESHOOTINGJune 19981. TROUBLESHOOTINGThis section is intended for use in determining the solution to a known problem. Solutions given are intendedto give the individual servicing the CNC a pattern to follow in, first, determining the problem’s source and,second, solving the problem...

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    496-8100TROUBLESHOOTINGJune 19981.1 GENERAL MACHINE OPERATION MACHINE NOT RUNNING´ Machine cannot be powered on.l Check input voltage to machine (see "Electrical Service").l Check main circuit breaker at top right of electrical cabinet; switch must be at the on position.l Check overv...

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    96-81005TROUBLESHOOTINGJune 1998 VIBRATIONVibration is a subjective evaluation with perceptions varying among individuals, making it difficult todetermine in mild cases if there is an actual problem. Because the VF Series uses a gear head, it will benoisier than a direct drive or belt system. I...

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    696-8100TROUBLESHOOTINGJune 1998´ Machine will not interpolate a round hole.lCheck that the machine is level (see "Installation" section).lCheck for backlash ("Servo Motors/Leadscrews" section).´ Bored holes do not go straight through the workpiece.lCheck that the machine is...

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    96-81007TROUBLESHOOTINGJune 1998 THERMAL GROWTHA possible source of accuracy and positioning errors is thermal growth of the leadscrew. As the machinewarms up, the leadscrews expand in all three linear axes, causing accuracy and positioning errors, orinaccurate boring depths. This is especiall...

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    896-8100TROUBLESHOOTINGJune 19981.2 SPINDLE NOT TURNING´ Spindle not turning.lIf there are any alarms, refer to "Alarms" section.lCheck that the spindle turns freely when machine is off.lIf motor turns but spindle does not, see "Belt Assembly" and "Spindle Motor &...

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    96-81009TROUBLESHOOTINGJune 1998 OVERHEATINGWhen 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. Amachine that runs at high RPM continuously wi...

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    1096-8100TROUBLESHOOTINGJune 1998 SPINDLE DRIVELow line voltage may prevent the spindle from accelerating properly. If the spindle takes a long time toaccelerate, slows down or stays at a speed below the commanded speed with the load meter at full load,the spindle drive and motor are overloaded....

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    96-810011TROUBLESHOOTINGJune 1998lDuplicate the cutting conditions under which the deflection occurs, but do not execute an automatictool change. Try instead to release the tool using the tool release button on the front of the spindlehead. If sticking is observed, the deflection is not caused ...

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    1296-8100TROUBLESHOOTINGJune 1998´ Servo motor noise.lDisconnect the servo motor from the lead screw and rotate by hand. If the noise persists, replacethe motor assembly ("Axis Motor Removal/Installation" section).lNoise is caused by motor brushes (VF-E only). No problems will occur ...

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    96-810013TROUBLESHOOTINGJune 1998Figure 1-1. Dial indicator in position to check X-axis.2.Set dial indicator and the “Distance to go” display in the HANDLE JOG mode to zero as follows:Ø Zero the dial indicator.Ø Press the MDI button on the control panel.Ø Press the HANDLE JOG button on the ...

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    1496-8100TROUBLESHOOTINGJune 1998Figure 1-2. Dial indicator in position to check Y-axis.2.Set dial indicator and the “Distance to go” display in the HANDLE JOG mode to zero as follows:Ø Zero the dial indicator.Ø Press the MDI button on the control panel.Ø Press the HANDLE JOG button on the ...

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    96-810015TROUBLESHOOTINGJune 19982.Manually push up and down on the spindle head while listening for a ‘clunk’. Also, watch for any rapidchange in the dial indicator. Either of these indicate possible backlash.Note: Servos must be on to check for backlash in the Z-axis.Note: Do not mistake defl...

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    1696-8100TROUBLESHOOTINGJune 1998 VIBRATION´ Excessive servo motor vibration.lIf no “A” axis is present, swap the suspected bad servo motor with the “A” driver and check to seeif there is a driver problem. If needed, replace the DRIVER PCB ("Electrical Service" section).lCheck al...

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    96-810017TROUBLESHOOTINGJune 19981.4 AUTOMATIC TOOL CHANGER DEFLECTIONDeflection is usually caused by ATC misalignment, and sometimes caused by damaged or poor qualitytooling, a damaged spindle taper, or a damaged drawbar or poor air supply. Before beginning anytroubleshooting, observe the dire...

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    1896-8100TROUBLESHOOTINGJune 1998´ During a tool change, ATC appears to be pulled up; no popping noises.lCheck the adjustment of the “Z” offset ("Setting Parameter 64" section).Note: If the offset is incorrect, a tool changer crash has occurred, and a thoroughinspection of the ATC i...

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    96-810019TROUBLESHOOTINGJune 1998´ During a tool change spindle crashes into top of the tool holder after a turret rotation.When the spindle head moves down over the top of the tool holder during a tool change, the pull studwill bind inside the drawbar bore of the spindle, forcing the ATC down, ...

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    2096-8100TROUBLESHOOTINGJune 1998 NOISY OPERATIONTo isolate noise(s) in the ATC, carefully observe the ATC in operation and look for the following:´ ATC makes noise as the shuttle moves.lCheck the adjustment of the roller bolts on the ATC ("Roller Bolt Replacement" section). Loose roll...

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    96-810021TROUBLESHOOTINGJune 1998 SPINDLE ORIENTATIONA switch is used to sense when the pin drops in to lock the spindle. When the pin drops the switch opens,indicating orientation is complete. The normally-closed side of this switch is wired to the spindle drive andcommands it into the COAST S...

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    2296-8100TROUBLESHOOTINGJune 1998´ ATC turret will not rotate; turret motor is getting power.lCommand a tool change feel for power being applied to the turret motor.lIf power is applied but the output shaft on the motor does not turn, check for binding between theturret motor assembly and the Ge...

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    96-810023TROUBLESHOOTINGJune 19984) Pause until spindle is at speed,5) Command high or low gear solenoid active,6) Pause until in new gear or reversal time,7) Alarm and stop if max gear change time elapsed,8) If not in new gear, reverse spindle direction,9) Turn off high and low gear soleno...

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    2496-8100TROUBLESHOOTINGJune 1998 LOW COOLANT´ Alarm 151, "Low Thru Spindle Coolant"lCheck coolant tank level.lCheck for slow coolant drainage from machine enclosure.lRead the filter gauges and check the intake strainer to ensure there is no clogging. Read gauges withTSC running with ...

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    96-810025TROUBLESHOOTINGJune 19981.7 CHIP CONVEYOR´ Chip conveyor does not turnlCheck that Parameter 209 bit switch ENA CNVR is enabled.lCheck that the front enclosure door is competely closed and door switches function properly.Check that hub is connected to auger with bolt.lCheck that all...

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    2696-8100TROUBLESHOOTINGJune 19981.8 HYDRAULIC COUNTERBALANCE MECHANICAL DIAGNOSISImportant! Hydraulic counterbalance oil contains red dye for easier recognition.´ Noise in the systemlSlight moan or creaking at slow speeds is normal for rubber seals.lWhile Z-axis is in motion a whistle sound ...

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    96-810027TROUBLESHOOTINGJune 1998 1.9 LINEAR SCALESPerform the "Linear Scale Alignment Check" if any of the linear scale alarms (279-290) are received. LINEAR SCALE ALIGNMENT CHECKNote: This procedure is only accurate if the machine is square.1. Remove the right side way cover for th...

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    2896-8100TROUBLESHOOTINGJune 19981.10 AUTOMATIC PALLET CHANGER´ Checking pallet repeatability on to the receiver.lMaximum tolerance is .+/-0005.lPallets are not considered repeatable from one to the other. Pallets should use seperateoffsets.lIf pallet is out of tolerance check the alignm...

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    96-810029TROUBLESHOOTINGJune 1998´ Recovery from an E-Stop initiated during a pallet change

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    3096-8100TROUBLESHOOTINGJune 1998

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    96-810031TROUBLESHOOTINGJune 19981.11 ELECTRICAL TROUBLESHOOTINGCAUTION! Before working on any electrical components, power off the machine and waitapproximately 10 minutes. This will allow the high voltage power on the brushless amplifiersto be discharged. ELECTRICAL ALARMS´ Axis Drive Fault...

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    3296-8100TROUBLESHOOTINGJune 1998´ Axis Cable FaultlDuring 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 motor co...

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    96-810033TROUBLESHOOTINGJune 1998The following is an example of how to troubleshoot the keypad:Note: Keypad Diodes 1-24 correspond to chart numbers 1-24Example1. Pressing the RESET button will cause diodes 1 and 17 to conduct.lWith the POWER OFF read across diode 1.lA typical reading is betwe...

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    3496-8100TROUBLESHOOTINGJune 1998

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    35ALARMS96-8100June 19982. ALARMSAny time an alarm is present, the lower right hand corner of the screen will have a blinking "ALARM". Push the ALARMdisplay key to view the current alarm. All alarms are displayed with a reference number and a complete description.If the RESET key is pre...

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    36ALARMS96-8100June 1998109Y Servo Overloadsame as 108.110Z Servo Overloadsame as 108.111A Servo Overloadsame as 108.112No InterruptElectronics fault. Call your dealer.113Shuttle In FaultTool changer not completely to right. During a tool changer operationthe tool in/out shuttle failed to get to ...

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    37ALARMS96-8100June 1998121Low Lube orWay lube is low or empty or there is no lube pressure or too high a pressure.Low PressureCheck tank at rear of mill and below control cabinet. Also check connectoron the side of the control cabinet. Check that the lube lines are notblocked.122Regen OverheatTh...

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    38ALARMS96-8100June 1998133Spindle LockedShot pin did not release. This is detected when spindle motion is commanded.Check the solenoid that controls the air to the lock, relay 2-8, the wiring to the senseswitch, and the switch.134Tool Clamp FaultWhen UNCLAMPING the tool did not release from sp...

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    39ALARMS96-8100June 1998151Low Thru SpindleFor machines with Through the Spindle Coolant only. This alarm will shut off the Coolantspindle, feed, and pump all at once. It will turn on purge, wait for the amount of timespecified in parameter 237 for the coolant to purge, and then turn off the pu...

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    40ALARMS96-8100June 1998166Y Zero RetSame as 165.Margin Too Small167Z Zero RetSame as 165.Margin Too Small168A Zero RetNot normally enabled for A-axis.Margin Too Small169Spindle DirectionProblem with rigid tapping hardware. The spindle started turning in theFaultwrong direction.170Phase LossProbl...

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    41ALARMS96-8100June 1998188B Servo OverloadSame as 108.189B Motor OverheatSame as 135.190B Motor Z FaultSame as 139.191B Limit SwitchSame as 148.192B Axis Z Ch MissingSame as 153.193B Axis Drive FaultSame as 161.194B Zero Ret MarginSame as 168.Too Small195B Cable FaultSame as 182.196Coolant Spigo...

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    42ALARMS96-8100June 1998213Program RAM CRC ErrorElectronics fault; Call your dealer.214No. of ProgramsIndicates that the number of programs disagrees with the internalChangedvariable that keeps count of the loaded programs. Call your dealer.215Free Memory PTRIndicates the amount of memory used by...

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    43ALARMS96-8100June 1998243Bad NumberData entered is not a number.244Missing )Comment must end with a " ) ".245Unknown CodeCheck input line or data from RS-232. This alarm can occur while editingdata into a program or loading from RS-232.246String Too LongInput line is too long. The dat...

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    44ALARMS96-8100June 1998271C Servo OverloadSame as 108.272C Motor OverheatSame as 135.273C Motor Z FaultSame as 139.274C Limit SwitchSame as 145.275C Axis Z Ch MissingSame as 153.276C Axis Drive FaultSame as 161.277C Zero Ret MarginSame as 165.Too Small278C Cable FaultSame as 182.279X Axis Linear...

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    45ALARMS96-8100June 1998303Invalid X, Y, or Z InCheck your geometry.G02 or G03304Invalid I, J, or K InCheck your geometry. Radius at start must match radius at end of arc withinG02 or G030.0010 inches.305Invalid Q InQ in a canned cycle must be greater than zero.Canned Cycle306Invalid I, J, K, or...

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    46ALARMS96-8100June 1998327No Loop For ML code not used here. Remove L Code.Code Except M97, M98328Invalid 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 me...

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    47ALARMS96-8100June 1998347Diff Step RatioParameters 19 and 33 must be same value.On G19 Plane348Motion Not AllowedThis alarm is generated if the mill is in Inverse Time Feed mode, and aIn G93 ModeG12, G13, G70, G71, G72, G150, or any Group 9 motion command is issued.349Prog Stop W/OCutter compen...

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    48ALARMS96-8100June 1998369Tool Too BigUse a smaller tool for cut.370Pocket DefinitionCheck geometry for G150.Error371Invalid I, J, K, OR QCheck G150.372Tool Change InTool change not allowed while canned cycle is active.Canned Cycle373Invalid Code in DNCA code found in a DNC program could not be ...

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    49ALARMS96-8100June 1998390No Spindle SpeedS code has not been encountered. Add an S code.391Feature DisabledAn attempt was made to use a control feature not enabled by a parameterbit. Set the parameter bit to 1.392B Axis DisabledSame as 336.393Invalid Motion InRigid Tapping can only be in the Z...

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    50ALARMS96-8100June 1998413RS-232 LoadProgram received doesn’t fit. Check the space available in the LIST PROGInsufficient Memorymode and possibly delete some programs.414RS-232 Buffer OverflowData sent too fast to CNC. This alarm is not normally possible as thiscontrol can keep up with even 384...

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    51ALARMS96-8100June 1998503Illegal Macro VariableA macro variable number was used that is not supported by this control,Referenceuse another variable.504Unbalanced Paren. InUnbalanced brackets, “[“ or “]”, were found in an expression. Add orExpressiondelete a bracket.505Value Stack ErrorThe m...

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    52ALARMS96-8100June 1998522Illegal AssignmentA variable was referenced for writing. The variable referenced is readVar Or Valueonly.523Conditional ReqdTHEN was encountered and a conditional statement was not processedPrior To THENin the same block.524END Found With NoAn END was encountered withou...

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    53ALARMS96-8100June 1998540Macro SyntaxA section of code was interpreted by the control where macro statementNot Allowedsyntax is not permitted.613Command Not AllowedA command (M96, for example) in the highlighted block cannot beIn Cutter Comp.executed while cutter comp. is invoked.End Of ListNot...

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    54ALARMS96-8100June 19981010 Missing Pallet @ Receiver Pallet change sequence was halted because receiver switch was notactivated. Pallet is either unclamped or not on the receiver. Ensure thepallet is correctly located on receiver (against hardstop) then run M18to clamp the pallet.1011 Unknown ...

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    MECHANICAL SERVICE96-810055January 1998MECHANICAL 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. lb.M...

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    MECHANICAL SERVICE5696-8100January 1998Figure 1-1. View of VF-3/4 head covers.INSTALLATION -1. Protect table surface with a piece of cardboard.2. Replace each side cover from the top side with seven SHCS. Jog Z-axis as necessary to make access toscrews easier.CAUTION! Be careful not to run t...

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    MECHANICAL SERVICE96-810057January 19982. TOOL RELEASE PISTON (TRP) ASSEMBLYPlease read this section in its entirety before attempting to replace tool release piston assembly. 2.1 TRP REMOVALNote: This procedure applies to machines with 40 taper spindles only. Refer to thefollowing sections f...

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    MECHANICAL SERVICE5896-8100January 1998Figure 2-2. Mounting location for tool release piston assembly 2.2 TRP INSTALLATION1. Ensure drive belt has been properly replaced as described in "Belt Assembly" section.2. Verify spindle sweep adjustment is correct (as shown in "Spindle ...

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    MECHANICAL SERVICE96-810059January 19987. Apply precharge pressure several times to allow the seal to center itself with the drawbar. While holdingdown precharge, tighten the bolts.8. Install the coolant hose. A wrench must be used, tighten snug. Do not overtighten!!9. Adjust the clamp/unclamp...

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    MECHANICAL SERVICE6096-8100January 1998CAUTION! Only increase the pressure to the point where tool changes become obviouslyquiet. Any further pressure increases are not beneficial. Excessive pressure to the pre-chargesystem will cause damage to the tool changer and tooling in the machine. 2.4 T...

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    MECHANICAL SERVICE96-810061January 19981. Install Nominal Shims in Fork and on TRP Spacers.Part No.Description30-0013A (NEW)30-0013 (OLD STYLE)Fork:(45-0014)0.010 Shim Washer1 ea.None(45-0015)0.018 Shim Washer7 ea.5 ea.TRP Spacers: (45-0019)0.093 Nylon Washer1 ea.1 ea.(45-0017)0.010 Shim Washer2 ...

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    MECHANICAL SERVICE6296-8100January 1998Figure 2-6. Fork shim location.4. The Tool Push-out adjustment is 0.060 +/-0.010. Add or remove shims from the tool releasefork to make adjustments. The shims come in 0.010 and 0.018 thicknesses.Jog upward 0.060. Press and hold the tool release button, ...

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    MECHANICAL SERVICE96-810063January 1998Figure 2-7. TRP shim location 2.7 SETTING TRP SWITCHES Figure 2-8. Tool Clamp / Unclamp Switches.1. Setting the upper switch (Tool Clamped). Push the switch in slowly until it trips, then push it alittle farther. Lock down the screws. Double-Check th...

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    MECHANICAL SERVICE6496-8100January 19982. Setting the lower switch (Tool Unclamped). Use the air pressure regulator on the back of themachine or an extra regulator placed in line.a) Jog the Z-Axis to 0.030 above the aluminum block.b) Put a jumper across the air switch to prevent a low pressure...

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    MECHANICAL SERVICE96-810065January 19984. For the VF-0, remove the four SHCS holding the mounting plate to the spindle head casting. Slide theassembly forward enough to allow the drive belt to be pulled up over the spindle pulley.Figure 3-2. Head casting area showing belt location.5. Remove th...

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    MECHANICAL SERVICE6696-8100January 1998within tolerance, continue; if not, sweep must be readjusted.Note: Drive belt tension must be adjusted after every installation. 3.3 TENSION ADJUSTMENTNote: The drive belt's tension should be adjusted after every service on the transmissionor spindle of the...

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    MECHANICAL SERVICE96-810067January 1998Figure 3-3. Belt tension tool.FOR THE VF-0:4. Loosen the four SHCS holding the motor mounting plate to the head casting.Note: Ensure the motor is broken free by moving it slightly by hand.5. Set the belt tension tool in place as shown in Figure 3-3. Mou...

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    MECHANICAL SERVICE6896-8100January 19984. SPINDLE ASSEMBLYPlease read this section in its entirety before attempting to replace spindle.IMPORTANT! The current pulley is shrink-fitted onto the spindle and is not field-serviceable.It is identified by two threaded holes on top of the spindle pulle...

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    MECHANICAL SERVICE96-810069January 1998Figure 4-1. Position wood block under spindle.9. At the panel, go to the JOG mode and choose Z-axis. Slowly jog in the negative (-) direction until thespindle rests on the block, then remove the screws that were previously loosened (step 7).10. Jog Z-axis...

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    MECHANICAL SERVICE7096-8100January 1998to remove burrs or high spots.2. Place spindle on wood block making sure both spindle dogs contact the block. Align the two 10-32 holeslocated on the spindle lock so they are approximately 90 degrees from the front of the spindle on the rightside.Figure 4-...

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    MECHANICAL SERVICE96-810071January 1998 4.3 DRAWBAR REPLACEMENTREMOVAL -1. Place a tool holder with no cutter in the spindle.2. Remove head cover panels as shown in "Head Covers Removal'.3. Remove the tool release piston in accordance with appropriate section.4. Remove the snap ring fro...

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    MECHANICAL SERVICE7296-8100January 199820. Reinstall the head covers.21. Test-run the machine and perform the necessary ATC adjustments in the "Automatic Tool Changer"section. 4.4 SPINDLE SWEEP ADJUSTMENTNote: The machine must be properly leveled for the spindle sweep adjustment to ...

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    MECHANICAL SERVICE96-810073January 19985. TOOL CLAMP/UNCLAMP SWITCH ADJUSTMENTPlease read this section in its entirety before adjusting clamp/unclamp switches or settingdrawbar height.TOOLS REQUIREDüMachined aluminum block (2" x 4" x 4")ü6" flexible ruler or .020" shim...

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    MECHANICAL SERVICE7496-8100January 1998of the hand wheel at a time. Between these moves, push the tool release button and feel for movement byplacing your finger between the tool holder and the spindle. Do this until no movement is felt. You are nowat zero (0).CAUTION! Do not jog too far in the ...

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    MECHANICAL SERVICE96-810075January 19982. Remove tool release bolt. If machine is equipped with TSC, loosen the three set screws and remove theTSC coolant tip.3. Add or subtract required shim washers (See previous section for correct amount to add or remove).4. Before installing tool release ...

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    MECHANICAL SERVICE7696-8100January 19985. Check the adjustment by setting the jog handle at .06 and activating the tool release. The DB OPN signalshould be a "1". If the adjustment is not correct, adjust until it is within specifications. You may have to readjust the switchseveral time...

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    MECHANICAL SERVICE96-810077January 19989. Check the switch several times. This is done by by moving the piston up and down to ensure that the "ToolUnclmp" status appears when the piston makes contact with the shim and drawbar, and does not appear whenit is in the retracted position. ...

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    MECHANICAL SERVICE7896-8100January 19986. SPINDLE ORIENTATIONPlease read this section in its entirety before attempting to orient the spindle.Note: If machine is equipped with a vector drive, skip to the next section. 6.1 ORIENTATION - SPINDLE DRIVE WITH SHOT PIN ORIENTATION1. Remove cover pa...

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    MECHANICAL SERVICE96-810079January 1998Figure 6-2. VF-0 motor with orient ring location.7. There is a 0.015"-0.030" backlash in the spindle system when it is oriented. Be certain to compensate forthis backlash when performing the adjustment.8. Using a 5/8" open end wrench, rota...

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    MECHANICAL SERVICE8096-8100January 19987. SETTING PARAMETER 64 (TOOL CHANGE OFFSET)Please read this section in its entirety before attempting to set Parameter 64.Note: Setting 7 must be "unlocked" before setting Parameter 64.1. WITHOUT a tool in the spindle taper, initiate a tool cha...

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    MECHANICAL SERVICE96-810081January 1998Figure 7-2. Screen showing calculator.7. Take the number in the Z-axis machine display (center left of page) and multiply it by Parameter 33, whichis Z RATIO (STEPS/UNIT).If Z-axis work display is negative (-), add the number to the number that you calcula...

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    MECHANICAL SERVICE8296-8100June 19983.8 SPINDLE MOTOR & TRANSMISSIONPlease read this section in its entirety before attempting to remove or replace transmission.NOTE: The drive belt's tension should be adjusted after every service on the transmissionor spindle. MOTOR REMOVAL (VF-0)1. Ensure...

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    MECHANICAL SERVICE96-810083June 19989. Remove the four SHCS and carefully lift the spindle motor assembly off the spindle head. Take care tonot damage the drive pulley during removal.NOTE: It is recommended that the HAAS Transmission Hoist be used in this operation(Refer to "Hoist Pre-Asse...

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    MECHANICAL SERVICE8496-8100June 1998Figure 3-28. Exploded view of boom modification plate components.3. Assemble the boom assembly as follows:A. Lubricate the components of the assembly:1) Using a grease brush, apply grease to the through-hole and the side surface of the pulleywheel.2) Wipe a t...

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    MECHANICAL SERVICE96-810085June 1998E. Attach the cable to the winch as follows:1) FOR LEFT-HAND OPERATION -Pass the cable under the winch drum and through the hole in the drum flange.Form a loop of cable and securely anchor it in place using the tie-down clasp, carriagebolt, and hex nut. The c...

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    MECHANICAL SERVICE8696-8100June 19985. Remove the six SHCS holding the transmission to the head casting. Slide the transmission forward enoughto release the drive belt from the transmission and spindle pulleys.6. Press the POWER OFF button on the control panel and turn the main breaker off. If ...

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    MECHANICAL SERVICE96-810087June 1998Figure 3-32. Support base/mast support assembly location.10. With the boom modification plate in place, insert the mast into the mast support. Using the two clevispins, attach the boom to the mast.Figure 3-33. Mounting boom assembly to mast.11. Place the ho...

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    MECHANICAL SERVICE8896-8100June 1998Figure 3-34. Fully assembled hoist in position12. Raise the transmission, ensuring the hoist is being lifted in the locking position, clearing the enclosures.Swing the boom toward the front of the machine and lower onto the wood blocks.Figure 3-35. Lifting ...

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    MECHANICAL SERVICE96-810089June 1998 TRANSMISSION INSTALLATION1. If machine is equipped with Through the Spindle Coolant option, reinstall the pressure regulator, checkvalve assembly, and bracket. Install two cable ties on the replacement transmission as follows:Ø Place one cable tie around th...

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    MECHANICAL SERVICE9096-8100June 1998NOTE: The hoist must be disassembled before removing from the mill table. Break downthe hoist by removing the boom assembly, then the mast. It will not be necessary tocompletely break down the hoist after the first assembly.NOTE: Ensure the positioning ring has...

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    MECHANICAL SERVICE96-810091June 1998INSTALLATION -1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.Figure 3-38. Motor coupling components.2. Reinstall and tighten down the four SHCS that hold the motor to the housing.3. Visually inspect the coupler ...

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    MECHANICAL SERVICE9296-8100June 19984. If the bearings are to be serviced, move the table to the rear of its travel and remove the SHCS holdingthe front way covers to the saddle. Slide the way cover to the forward position.Figure 3-39. Y-axis motor and components.REMOVING LUBE / AIR PANEL -5. ...

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    MECHANICAL SERVICE96-810093June 1998Figure 3-40. Lube/Air Panel.INSTALLATION -1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.2. Replace and tighten down the four SHCS that hold the motor to the housing.3. Visually inspect the flex plates to ensure...

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    MECHANICAL SERVICE9496-8100June 199813. Slide the way cover back into place, and attach to the saddle with the SHCS.14. Check for backlash in the Y-axis lead screw (Troubleshooting section) or noisy operation. Z-AXIS MOTOR REMOVALCAUTION! ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH SHAFT STOP BLO...

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    MECHANICAL SERVICE96-810095June 1998Figure 3-42. Z-axis motor and components for machines equipped with hydraulic counterbalance.8. Loosen the SHCS on the motor coupling at the lead screw.9. On the motor housing, loosen the four SHCS and remove the motor from the housing.10. Disconnect the Z-...

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    MECHANICAL SERVICE9696-8100June 199810. Slide the way cover back into place, and attach to the saddle with the 10-32x3/8" SHCS.11. Check for backlash in Z-axis lead screw (Troubleshooting section), or noisy operation. COUPLER REPLACEMENT1. Remove the axis motor in accordance with "Ax...

  • Page 98

    MECHANICAL SERVICE96-810097June 19983.10 LEAD SCREW REMOVAL AND INSTALLATIONPlease read this section in its entirety before attempting to remove or replace the lead screws.TOOLS REQUIREDüSpanner wrench (32 mm or 40/50 mm)ü2" x 4" wood block (21"-231/2" long)üShaft lock (32...

  • Page 99

    MECHANICAL SERVICE9896-8100June 1998Figure 3-45. Lead screw assembly.9. Remove the axis motor in accordance with "X-Axis Motor Removal".NOTE: The motor's electrical connections do not need to be removed for this operation.After removing motor from the housing, set it to one side.10. ...

  • Page 100

    MECHANICAL SERVICE96-810099June 1998THIS PROCEDURE ASSUMES THAT THE NUT AND MOTOR HOUSING WILL NOT BE REMOVED.INSTALLATION -1. Center the mill table on the saddle.2. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt,burrs, grease, or othe...

  • Page 101

    MECHANICAL SERVICE10096-8100June 1998Figure 3-47. Bearing sleeve mounting location.6. Insert the six ¼-20 x 1" SHCS attaching the bearing sleeve to the motor housing. (Place a drop of blueLoctite® on each of the SHCS before inserting.) Tighten to torque specification.CAUTION! Do not use...

  • Page 102

    MECHANICAL SERVICE96-8100101June 1998ØMove the table all the way to the right. Tighten down completely the SHCS that mount thebearing support to the saddle.ØLoosen the clamp nut on the bearing support end. Adjust the nut until it seats on the bearing.Retighten the clamp nut hand-tight, then 1...

  • Page 103

    MECHANICAL SERVICE10296-8100June 1998NOTE: The motor's electrical connections do not need to be removed for this operation.After removing motor from the housing, set it to one side.6. Loosen the 10-32 x 1/2" SHCS and remove the clamp nut on the lead screw in the motor housing.7. For 32 mm...

  • Page 104

    MECHANICAL SERVICE96-8100103June 1998...push back into the machine, then pull out forward.THIS PROCEDURE ASSUMES THAT THE NUT AND MOTOR HOUSING WILL NOT BE REMOVED. INSTALLATION -1. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt,burrs,...

  • Page 105

    MECHANICAL SERVICE10496-8100June 19986. Insert the six ¼-20 x 1" SHCS attaching the bearing sleeve to the motor housing. (Place a drop of blueLoctite® on each of the SHCS before inserting.) Tighten to torque specifications.CAUTION! Do not use more than one drop of Loctite®. An excessiv...

  • Page 106

    MECHANICAL SERVICE96-8100105June 1998 Z-AXIS LEAD SCREW REMOVALWARNING! ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH THE SHAFT STOPBLOCK. DO NOT MOVE THE SPINDLE DURING LEAD SCREW SERVICE.1. Turn the machine ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.2. Loosen the six SHCS t...

  • Page 107

    MECHANICAL SERVICE10696-8100June 1998Figure 3-50. Z-axis lead screw and components.INSTALLATION -WARNING! ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH SHAFT STOP BLOCK.DO NOT MOVE THE SPINDLE DURING LEAD SCREW SERVICE.1. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing,...

  • Page 108

    MECHANICAL SERVICE96-8100107June 1998Figure 3-51. Reinstalling the lead screw.4. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bearings in thesleeve to facilitate mounting on the lead screw.)5. Insert the six ¼-20 x 1" SHCS attaching the bearin...

  • Page 109

    MECHANICAL SERVICE10896-8100June 19989. Reinstall the motor according to "Z-Axis Motor Removal and Installation". Reinstall the hard stop at thesupport bearing end of the lead screw.10. Reconnect electrical power.11. Jog the spindle down and remove the cylinder shaft stop.12. For 4...

  • Page 110

    MECHANICAL SERVICE96-8100109June 19983.11 BEARING SLEEVE REMOVAL AND INSTALLATIONPlease read this section in its entirety before attempting to remove or replace the bearingsleeve.TOOLS REQUIREDüSpanner wrenchüPre-load fixtureüWood block (16" long)üZ-Axis: Cylinder shaft stop (P/N 99-7...

  • Page 111

    MECHANICAL SERVICE11096-8100June 1998CAUTION! DO NOT PRY THE BEARING SLEEVE AWAY FROM THE HOUSING. DAMAGETO THE SLEEVE, BEARING, OR LEAD SCREW WILL RESULT.INSTALLATION -1. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt,burrs, grease,...

  • Page 112

    MECHANICAL SERVICE96-8100111June 1998Note: For the angular contact design bearing, no pre-load is necessary. Do the follow-ing:Ø Tighten the clamp nut on the motor housing to 15 foot-pounds.Ø Tighten the SHCS on the clamp nut.Ø Tighten the clamp nut on the support bearing end of the lead scre...

  • Page 113

    MECHANICAL SERVICE11296-8100June 19986. Reinstall the axis motor.7. Check for backlash in the Y-axis lead screw (Troubleshooting section) or noisy operation. Z-AXIS BEARING SLEEVE REMOVALWARNING! ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH SHAFT STOP BLOCKBEFORE SERVICING ANY Z-AXIS COMPONENTS.1....

  • Page 114

    MECHANICAL SERVICE96-8100113June 1998Note: The motor's electrical connections do not need to be removed for this operation.After removing from motor housing, set it to one side.10. Loosen the 10-32 x ½" SHCS and remove the clamp nut from the motor housing end of the lead screw.11. Loosen...

  • Page 115

    MECHANICAL SERVICE11496-8100June 19983.12 AUTOMATIC TOOL CHANGERTOOLS REQUIREDüTwo-jaw pullerüHydraulic jackü1-2-3 BlocküCardboard CARRIAGE CASTING REPLACEMENTNote: If the carriage casting is damaged in a crash, it must be replaced. Look specifi-cally for broken bosses where the roller bolt...

  • Page 116

    MECHANICAL SERVICE96-8100115June 1998Note: REPLACE ONLY ONE ROLLER BOLT AT A TIME. Carefully inspect the v-grooverollers for roughness or damage, and replace if necessary.5. Tighten the eccentric locks on the bottom rollers until there is no play between the rollers and the V-guideon the ATC hol...

  • Page 117

    MECHANICAL SERVICE11696-8100June 1998 SHUTTLE STROKE ADJUSTMENT6. Move the ATC away from the spindle and loosen the four HHBs in the ATC holding arm in the X-axis plane.7. Push the cam follower to its full upward stroke, then push the entire ATC assembly in by pushing on thetool changer holdin...

  • Page 118

    MECHANICAL SERVICE96-8100117June 1998Figure 3-57. Automatic Tool Changer - Mechanical Assembly (Top View)4. With the extractor fork removed, inspect the alignment key mounted under the extractor. If it isdamaged due to improper spindle orientation, replace it and correct the orientation (Refer ...

  • Page 119

    MECHANICAL SERVICE11896-8100June 1998 SHUTTLE MOTOR REMOVAL1. Turn the VMC off.2. Remove the cover from the tool carriage casting.3. Remove the hex bolt that attaches the cam follower to the slip clutch (see Fig. 3-56).4. Push the tool changer in as far as it will go.5. Loosen the set scre...

  • Page 120

    MECHANICAL SERVICE96-8100119June 1998Figure 3-59. Front view of holding plate showing FHCS location.4. Reattach the slip clutch assembly to the shuttle motor shaft. Before placing on the shaft, put two or threedrops of red Loctite® on the slip clutch hub.5. Insert and tighten down the set scr...

  • Page 121

    MECHANICAL SERVICE12096-8100June 1998Figure 3-60. Carriage casting with cover removed.8. Carefully lift the turret motor assembly off of the tool carriage casting.Note: The gear motor should never be disassembled and is not field-serviceable. Allgear motors should be returned to Haas for evalua...

  • Page 122

    MECHANICAL SERVICE96-8100121June 1998Figure 3-61. Required spacing for Geneva driver.4. Attach the turret motor assembly to the carriage casting with the four SHCS.5. Reconnect the power and limit switch lines to the turret motor.6. Power on the VMC and ZERO RETURN all axes (ZERO RET - AUTO A...

  • Page 123

    MECHANICAL SERVICE12296-8100June 19983. Remove the turret motor assembly (Refer to previous section).4. Place a support for the ATC under the center of the carousel.5. Loosen the nut inside the carriage casting that attaches the ATC carousel assembly to the casting. Thereis a socket head in th...

  • Page 124

    MECHANICAL SERVICE96-8100123June 19983.13 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 less ...

  • Page 125

    MECHANICAL SERVICE12496-8100June 19983.14 ENCLOSURE REPLACEMENTPlease read this section in its entirety before attempting to replace the doors or windows.TOOLS REQUIREDüTrim installation tool (dull-edged knife or caulking spatula) DOOR REPLACEMENTCAUTION! If possible, have two people performi...

  • Page 126

    MECHANICAL SERVICE96-8100125June 1998Figure 3-62. Roller/roller guide assembly.DOOR ADJUSTMENTS -10. Close both doors and check that the vertical gap between them is uniform. If it is not:Ø Determine which door must be adjusted.Ø Loosen the door's outer lower roller attachment and pivot the ...

  • Page 127

    MECHANICAL SERVICE12696-8100June 1998ØLoosen the door's upper roller fasteners and tilt the door forward or back, as necessary, to adjustdoor position.Figure 3-64. View of gap between front of door and front panel flange.SWITCH ADJUSTMENT -12. Move the door to the fully closed position. Go to...

  • Page 128

    MECHANICAL SERVICE96-8100127June 1998Figure 3-65. Cross-section of window seal.INSTALLATION -5. Replace the seal around the enclosure's cutout, with the locking tab facing the inside of the machine.6. Replace the window panel into the seal. The tool can be placed between the window panel and ...

  • Page 129

    MECHANICAL SERVICE12896-8100June 19983.15 HYDRAULIC COUNTERBALANCETOOLS REQUIREDü(1) 4 x 4 x 14" head support blocküHydraulic counterbalance service kit, consists of:lPressure tank with manifold assembly, prefilled with (2) quarts DTE-25 hydraulic oillHydraulic cylinder with hose attached...

  • Page 130

    MECHANICAL SERVICE96-8100129June 19985. Place the CGA 580 end of charge/discharge kit into a bucket to the contain the hydraulic oil whiledischarging the system.6. Slowly turn the T-handle clockwise until the system begins to discharge. Complete discharge may takeup to 10 minutes. Verify tank...

  • Page 131

    MECHANICAL SERVICE13096-8100June 1998 HYDRAULIC CYLINDER REPLACEMENTREMOVAL-1. Remove the hydraulic tank as described in previous section.2. To gain access to the cylinder rod, remove the three SHCS holding the Z-axis way cover to the spindle head.3. Remove the cotter pin and lock nuts from t...

  • Page 132

    MECHANICAL SERVICE96-8100131June 19984. Remove the band clamp that holds the cylinder to the stabilizer bracket. Loosen the two SHCS that attachthe bracket to the column.5. Remove the hydraulic cylinder from the top of the column.Figure 3-69. VF-Series hydraulic counterbalance - right side vi...

  • Page 133

    MECHANICAL SERVICE13296-8100June 19986. Return complete assembly to HAAS Automation.INSTALLATION-7. Install cylinder with cylinder rod extended from top of column.Note: Cylinder rod should pass through column bracket and spindle head bracket.Cylinder body must rest in column bracket counterbor...

  • Page 134

    MECHANICAL SERVICE96-8100133June 19983.16 THROUGH THE SPINDLE COOLANT SYSTEM - ADJUSTMENTSTOOLS REQUIREDüTool holder with small TSC drill or restrictor (with a small orifice #T-1461)üTSC Gauge Kit (P/N 93-9011), includes:l0-15 PSI Precharge pressure gaugel0-160 PSI Purge pressure gauge (Not use...

  • Page 135

    MECHANICAL SERVICE13496-8100June 19982. With no tool in the spindle, prime the TSC system as described above.3. Insert a standard (no through hole in pull stud) tool holder into the spindle.4. Turn on TSC.5. Check for leaks while TSC is still running. Shut off TSC.6. Remove pressure gauge a...

  • Page 136

    MECHANICAL SERVICE96-8100135June 19983.17 AIR / OIL LINE DIAGRAM

  • Page 137

    MECHANICAL SERVICE13696-8100June 1998THROUGH THE SPINDLE COOLANTSYSTEM FLOW DIAGRAM

  • Page 138

    MECHANICAL SERVICE96-8100137June 1998THROUGH THE SPINDLE COOLANTSYSTEM FLOW DIAGRAM50 TAPER SPINDLE

  • Page 139

    MECHANICAL SERVICE13896-8100June 19983.18 AUTOMATIC PALLET CHANGER (APC) PALLET REPLACEMENTTOOLS REQUIRED:üHoistüStraps or ChainsüEyebolts (2)CAUTION! Be careful when changing out pallets, each pallet weighs approx. 300lbs.Note: Pallets that have been replaced must be re-aligned to the...

  • Page 140

    MECHANICAL SERVICE96-8100139June 1998IMPORTANT! New pallets should be machined on the VMC in order for them to beperpendicular to spindle.PALLET CLAMP RAIL REPLACEMENTTOOLS REQUIRED:üHoistüStraps or ChainsüEyebolts (2)Note: This procedure must be performed with the pallets on the APC.1. ...

  • Page 141

    MECHANICAL SERVICE14096-8100June 1998 ALIGNMENT PIN REPLACEMENTTOOLS REQUIRED:üHoistüStraps or ChainsüEyebolts (2)CAUTION! Be careful when changing out pallets, each weighs approx. 300lbs.Note: The receiver must removed in order to access the alignment pins.1. Both pallets must be on the...

  • Page 142

    MECHANICAL SERVICE96-8100141June 19989. Reconnect the air to the machine.10. Postion a pallet onto thte receiver and clamp/unclamp the pallet to the receiver several times. Check forthe pallets sticking during this process. If the pallets are sticking, loosen the clamp rail bolts and clamp/u...

  • Page 143

    MECHANICAL SERVICE14296-8100June 1998Figure 3-74 Loosening Chain Sprocket6. Loosen the 4 bolts that mount the sprocket bracket to the casting.7. Loosen the chain sprocket tensioner screw slightly.8. At this point there should be enough slack in the chain to slide the drive pin out.9. Re-asse...

  • Page 144

    96-8100143ELECTRICAL SERVICEJune 19984. ELECTRICAL SERVICE4.1 SOLENOIDSPlease read this section in its entirety before attempting to replace any solenoid assem-blies. AIR SOLENOID ASSEMBLYREMOVAL -1.Turn machine power on and raise spindle head to uppermost position. Turn power off.2.Remove s...

  • Page 145

    ELECTRICAL SERVICE14496-8100June 1998INSTALLATION:8.Replace the air solenoid assembly and attach to the bracket with the SHCS previously removed.Tighten securely.9.Reconnect all air lines at this time, ensuring that all connections are tight and do not leak.10.Reconnect the two leads to the low a...

  • Page 146

    96-8100145ELECTRICAL SERVICEJune 1998 SPINDLE LUBE AIR SOLENOID1.Turn the machine power off and remove the air supply from the machine.Figure 4-3. Front side of lube/air panel.2.Disconnect the air lines from the spindle lube air solenoid assembly.3.Unplug the electrical leads at the quick-disc...

  • Page 147

    ELECTRICAL SERVICE14696-8100June 19984.Unscrew the assembly from the T-fitting.Figure 4-5. Top view of spindle lube/air solenoid assembly.5.Replace the assembly, ensuring it is approximately horizontal to the floor, and tighten fittingssecurely.6.Reconnect all air lines.7.Reconnect wiring leads...

  • Page 148

    96-8100147ELECTRICAL SERVICEJune 1998WARNING! The electrical panel should be closed and the three screws on the door shouldbe secured at all times except during installation and service. At those times, only qualifiedelectricians should have access to the panel. When the main circuit breaker is o...

  • Page 149

    ELECTRICAL SERVICE14896-8100June 1998227 to 243left c244 to 260left sFigure 4-7. Power lines; hookup location.Note: Make sure that the service wires actually go into the terminal-block clamps. [It iseasy to miss the clamp and tighten the screw. The connection looks fine but themachine runs inter...

  • Page 150

    96-8100149ELECTRICAL SERVICEJune 1998Figure 4-8. Transformer connections.CAUTION! Make sure that the main breaker is set to OFF and the power is off at your supplypanel BEFORE you change the transformer connections. Make sure that all three black wiresare moved to the correct terminal block and ...

  • Page 151

    ELECTRICAL SERVICE15096-8100June 1998Figure 4-9a. Transformer with 354-488V Figure 4-9b Transformer with 195-260V range4.Set the main switch to on (rotate the shaft that engages the handle on the panel door clockwise untilit snaps into the on position). Check for evidence of problems, su...

  • Page 152

    96-8100151ELECTRICAL SERVICEJune 19986.Check the DC voltage displayed in the second page of Diagnostic data on the CRT. It is labeled DC BUS.This voltage must be between 150 and 175 volts. If the voltage is outside these limits, turn off thepower and recheck the incoming power and the transformer...

  • Page 153

    ELECTRICAL SERVICE15296-8100June 19984.On the POWER SUPPLY board there are three fuses located in a row at the upper right of the board;these are the overvoltage fuses. An orange light will be on to indicate the blown fuse(s).5.Using a flat tip screwdriver, turn the fuse(s) counterclockwise to re...

  • Page 154

    96-8100153ELECTRICAL SERVICEJune 1998 SERVO DRIVER & SDIST FUSES1.Turn the main switch (upper right of electrical cabinet) to the off position.2.Using a large flat tip screwdriver, loosen the three screws on the cabinet door and then open the doorenough to safely work on the electrical panel...

  • Page 155

    ELECTRICAL SERVICE15496-8100June 19984.4 PCB REPLACEMENTPlease read this section in its entirety before attempting to replace any PCBs. MICROPROCESSOR, MOCON (MOTIF) & VIDEO / KEYBOARDNote: The arrangement of these boards may differ from the order of replacement thatfollows. The steps for r...

  • Page 156

    96-8100155ELECTRICAL SERVICEJune 199810.After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in placeuntil all standoffs have been removed.Note: If the PROCESSOR board need replacing, please skip the next step.11.Replace the Video / Keyboard, attaching it ...

  • Page 157

    ELECTRICAL SERVICE15696-8100June 1998Note: The connection labeled "860A" on the board should be used for the cable marked"860B". Some boards, the connection for cable 920 has been incorrectly marked as"1030". Please note its location for future reference.Note: On so...

  • Page 158

    96-8100157ELECTRICAL SERVICEJune 19985.Remove the board by first removing the twelve screws that fasten it to the cabinet. Take care to holdthe board in place until all screws have been removed.6.Replace the I/O board, attaching it to the cabinet with the twelve screws previously removed.7.Reconn...

  • Page 159

    ELECTRICAL SERVICE15896-8100June 1998 RS-232Note: 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 switc...

  • Page 160

    96-8100159ELECTRICAL SERVICEJune 19984.5. 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 back ...

  • Page 161

    ELECTRICAL SERVICE16096-8100June 19988.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 handle is...

  • Page 162

    96-8100161ELECTRICAL SERVICEJune 1998 Figure 4-17. Jog Handle removal Figure 4-18. Jog Handle wiring diagram5.Remove the three screws holding the jog handle encoder to the control panel and remove.6.Replacement is rever...

  • Page 163

    ELECTRICAL SERVICE16296-8100June 1998 SPINDLE 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.Disconnec...

  • Page 164

    96-8100163ELECTRICAL SERVICEJune 19988.Insert the ribbon cable through the opening in the control panel and place the keypad in the upperright corner of the lower opening and press to the control panel to mount. Plug the ribbon cable intothe Keyboard Interface board, taking care to not bend the p...

  • Page 165

    ELECTRICAL SERVICE16496-8100June 1998Please note the differences in installation between the VF-0, VF-1, VF-2, and the VF-3,VF-4.5.For the VF-1, VF-2, and VF-3, VF-4, put some blue Loctite on the threads of the four set screws andscrew approximately halfway into the standoffs. Screw the hex end o...

  • Page 166

    96-8100165ELECTRICAL SERVICEJune 1998Figure 4-21. VF-0 encoder installation.13.Place the belt on the 36-tooth pulley, then loop over the 18-tooth pulley. Place the encoder assemblyon the four standoffs (mounting bracket on the VF-0) and attach with the four 10-32 SHCS, placingthe #10 lock washer...

  • Page 167

    ELECTRICAL SERVICE16696-8100June 1998

  • Page 168

    TECHNICAL REFERENCE96-8100167June 19985. TECHNICAL REFERENCE5.1 TOOL CHANGERThe tool changer is an all electric fixed shuttle type. Tools are always loaded through the spindle and shouldnever be installed directly in the carousel in order to avoid crashes. The pocket open to the spindle mustal...

  • Page 169

    168TECHNICAL REFERENCE96-8100June 1998 PULL STUDSThe tool holders used are CT #40 taper, V flange, commonly called “CT 40”. For the 50 taper spindle option,the tool holders used are CT #50 taper, V flange, commonly called “CT 50”. Use A “45 Degree, P40T Type 1(P50T Type 1 for 50 taper) inch...

  • Page 170

    TECHNICAL REFERENCE96-8100169June 1998 5.2 TOOL CLAMP/UNCLAMPThe tool holder drawbar is held clamped by spring pressure. Air pressure is used to release the tool clamp.When the tool is unclamped, air is directed down the center of the spindle to clear the taper of water, oil, orchips. Tool unc...

  • Page 171

    170TECHNICAL REFERENCE96-8100June 1998 5.3 SPINDLE OPERATIONSpindle speed functions are controlled primarily by the S address code. The S address specifies RPM in integervalues from 1 to maximum spindle speed (Parameter 131). NOT TO BE CHANGED BY USER! When using theThrough the Spindle Coolant...

  • Page 172

    TECHNICAL REFERENCE96-8100171June 1998 5.4 CONTROL PANELFigure 5-1. Control cabinet general overview.

  • Page 173

    172TECHNICAL REFERENCE96-8100June 1998Figure 5-2. Connectors on side of control cabinet. 5.5 SERVOS BRUSH / BRUSHLESS SERVO ENCODERSHaas machines are equipped with brushless motors, which provides for better performance, and nomaintenance. In addition to the performance differences, these ma...

  • Page 174

    TECHNICAL REFERENCE96-8100173June 1998 SERVO CHARACTERISTICSServo characterstics are explained in detail in the previous chapter. The following is an example of how toachieve 130 inches/minute.The exponential accel/decel time constant is set by Parameters 113, 114, 115, 116 and 168. It has uni...

  • Page 175

    174TECHNICAL REFERENCE96-8100June 1998 5.6 INPUT/OUTPUT ASSEMBLYThe IOPCB contains a circuit for electronically turning the tool changer power on and off. This prevents anyarcing of the tool changer relays and increases their life tremendously. This includes an adjustable currentlimit to the t...

  • Page 176

    TECHNICAL REFERENCE96-8100175June 1998P39 Tool changer turret motor output (810)P40 (770A) A/BP43 Ground fault sense signal input (1060) Axis BrakeP44 5TH axis brake (319)P45 HTC ShuttleP46 Chip Conveyor (140)P47 Skip input signal (1070)P48 spare 1P49 spare 2P50 Spigot Motor (200)P51 16 PIN Rel...

  • Page 177

    176TECHNICAL REFERENCE96-8100June 1998 GEAR CHANGE SEQUENCEWhen a gear change is performed, the following sequence of events occurs:1)If the spindle is turning, it is commanded to stop,2)Pause until spindle is stopped,3)Gear change spindle speed is commanded forward,4)Pause until spindle is at sp...

  • Page 178

    TECHNICAL REFERENCE96-8100177June 1998You should not normally stop a tool change with EMERGENCY STOP as this will leave the tool changer in anabnormal position that takes special action to correct.Note that tool changer alarms can be easily corrected by first correcting any mechanical problem, pr...

  • Page 179

    178TECHNICAL REFERENCE96-8100June 1998SIOSerial I/O initialization complete. (Normally On)If this light does not come on, there is a problem with the serial ports. Disconnect anything on theexternal RS-232 and test again.MSG Power-on serial I/O message output complete. (Normally On)If this light...

  • Page 180

    TECHNICAL REFERENCE96-8100179June 1998P11SPAREP12FLOPPY DR. SIGNALP13VIDEO SIGNAL (760)J9RS422 BJ13SERIAL DATA (850) MOTOR INTERFACE PCB (MOTIF)The Motor Interface PCB provides all of the interfaces to motors and discrete inputs and outputs. It containsa single pot R54 to adjust the output of ...

  • Page 181

    180TECHNICAL REFERENCE96-8100June 1998P7Y encoder input (670)P8Z encoder input (680)P9A encoder input (690)P30B encoder input (690B)P31C encoder input (690C)P18Jog encoder input (750)P20Spindle encoder input (1000)P10Inputs from I/O board (550)P11I/O relays K1-8 (510)P12I/O relays K9-16 (520)P13I...

  • Page 182

    TECHNICAL REFERENCE96-8100181June 1998 SERVO DRIVE REGEN RESISTORA 25-ohm, 300-watt resistor is used by the brush-type servo drives to dissipate excess power caused by theeffects of decelerating the servo motors. If the servo motors are accelerated and decelerated again in rapidsuccession repeat...

  • Page 183

    182TECHNICAL REFERENCE96-8100June 1998 LOW VOLTAGE POWER SUPPLYThe low voltage power supply provides +5V DC, +12V DC, and -12V DC to all of the logic sections of the control.It operates from 115V AC nominal input power. It will continue to operate correctly over a 90V AC to 133VAC range. POWER...

  • Page 184

    TECHNICAL REFERENCE96-8100183June 1998CB4 controls the 115V AC to the air solenoids, 4th axis brake, and the oiler. It is never expected to trip. Ifit does trip, it is likely caused by a short circuit in the wiring on the I/O assembly or the wiring to the solenoidson the spindle head.CB5 Contro...

  • Page 185

    184TECHNICAL REFERENCE96-8100June 1998 VOLTAGE SELECTION TAPSThere are five labeled plastic terminal blocks for high voltage. Each block has three connections for wireslabeled 74, 75, and 76. Follow the instructions printed on the transformer. SECONDARY CONNECTION TO T1The secondary output from...

  • Page 186

    TECHNICAL REFERENCE96-8100185June 1998The POWER PCB contains three ½-amp fuses located at the top right (FU1, FU2, FU3). If the machine is subjectto a severe overvoltage or a lightning strike, these fuses will blow and turn off all of the power. Replace thesefuses only with the same type and r...

  • Page 187

    186TECHNICAL REFERENCE96-8100June 1998 M-FIN DISCRETE INPUTThe M-FIN discrete input is a low voltage circuit. When the circuit is open, there is +12V DC at this signal.When this line is brought to ground, there will be about 10 milliamps of current. M-FIN is discrete input #10and is wired from...

  • Page 188

    TECHNICAL REFERENCE96-8100187June 1998 5.16 LUBRICATION SYSTEMThe lubrication system is a resistance type system which forces oil through metering units at each ofthe 16 lubricating points within the machine. The system uses one metering unit at each of thelubricating points: one for each linea...

  • Page 189

    188TECHNICAL REFERENCE96-8100June 1998 LIMIT SWITCHESNote: There are a number of limit switches located on the VMC, and some are difficult toreach. Ensure the problem is the switch before beginning removal procedures. Thefollowing is a list of all switches, their general location, and a functio...

  • Page 190

    TECHNICAL REFERENCE96-8100189June 1998If the switch is damaged and permanently open, the zero search for that axis will move in the negativedirection at about 0.5 in/min until it reaches the physical travel stops at the opposite end of travel.If the switch is damaged and permanently closed, the z...

  • Page 191

    190TECHNICAL REFERENCE96-8100June 1998 5.18 HYDRAULIC COUNTERBALANCEThe spindle head weight is balanced by the upward pull of a hydraulic cylinder. The hydraulic oil forces thepiston to retract into the cylinder body. The oil is then pressurized by a nitrogen reservoir. The system isself con...

  • Page 192

    TECHNICAL REFERENCE96-8100191June 1998 5.20 DISCRETE INPUTS / OUTPUTSThe inputs/outputs that are followed by an asterisk (*) are active when equal to zero (0).DISCRETE INPUTS#NameDescription#NameDescription1000TC INTool Changer In1016spare1001TC OUTTool Changer Out1017spare1002T ONEAt Tool One1...

  • Page 193

    192TECHNICAL REFERENCE96-8100June 1998The inputs are numbered the same as the connections on the inputs printed circuit board.Note: If the machine is equipped with an APC the following inputs and outputs willchange:1009 Pallet Clamped SW1121 PAL Clamp1021 Door SW1122 Door1022 Pin #1 CLR1125 APC M...

  • Page 194

    TECHNICAL REFERENCE96-8100193June 1998 ANALOG DATANameDescriptionDC BUSSVoltage from Haas Vector Drive (if equipped)uP TEMPMicroprocessor enclosure temperature (displayedonly when Parameter 278 bit "uP ENCL TEMP" is setto 1).SP LOADS...

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    194TECHNICAL REFERENCE96-8100June 1998

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    96-8100195PARAMETERSJune 1998 6. 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 chang...

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    19696-8100PARAMETERSJune 1998BRUSH MOTOREnables the brushless motor option.LINEAR DISPLThis bit changes the display from degrees to inches (ormillimeters) on the A and B axes.SCALE/X LOWith SCALE/X HI bit, determines the scale factor used in bitSCALE FACT/X,SCALE/X HIWith SCALE/X LO bit, determin...

  • Page 198

    96-8100197PARAMETERSJune 1998Parameter13XBACKLASHBacklash correction in encoder steps.Parameter14XDEAD ZONEDead zone correction for driver electronics. Units are 0.0000001 seconds.Parameter15YSWITCHESSee Parameter 1 for description.Parameter16YP GAINSee Parameter 2 for description.Parameter17YD G...

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    19896-8100PARAMETERSJune 1998Parameter31ZD GAINSee Parameter 3 for description.Parameter32ZI GAINSee Parameter 4 for description.Parameter33ZRATIO (STEPS/UNIT)See Parameter 5 for description.Parameter34ZMAX TRAVEL (STEPS)See Parameter 6 for description.Parameter35ZACCELERATIONSee Parameter 7 for ...

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    96-8100199PARAMETERSJune 1998Parameter49AACCELERATIONSee Parameter 7 for description.Parameter50AMAX SPEEDSee Parameter 8 for description.Parameter51AMAX ERRORSee Parameter 9 for description.Parameter52AFUSE LEVELSee Parameter 10 for description.Parameter53ABACK EMFSee Parameter 11 for descriptio...

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    20096-8100PARAMETERSJune 1998INVERT SKIPInvert sense of skip to active low=closed.HANDLE CURSREnable use of jog handle to move cursor.NEG WORK OFSSelects use of work offsets in negative direction.SPIN COOLANTEnables spindle low oil pressure detection.ENA QUIKCODEEnables conversational programming...

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    96-8100201PARAMETERSJune 1998Parameter68DRAW BAR MAX DELAYMaximum delay allowed when clamping and unclamping tool. Units are milliseconds.After this, time an alarm is generated.Parameter69A AIR BRAKE DELAYDelay provided for air to release from brake on A-axis prior to moving. Unitsare millisecond...

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    20296-8100PARAMETERSJune 1998Parameter81M MACRO CALL O9000M code that will call O9000. Zero causes no call.Parameter82M MACRO CALL O9001 same as 81Parameter83M MACRO CALL O9002 same as 81Parameter84M MACRO CALL O9003 same as 81Parameter85M MACRO CALL O9004 same as 81Parameter86M MACRO CALL O9...

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    96-8100203PARAMETERSJune 1998Parameter110D*D GAIN FOR YSecond derivative gain in servo loop.Parameter111D*D GAIN FOR ZSecond derivative gain in servo loop.Parameter112D*D GAIN FOR ASecond derivative gain in servo loop.Parameter113X ACC/DEC T CONSTExponential acceleration time constant. Units are ...

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    20496-8100PARAMETERSJune 1998Parameter127Z 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 thatthe gear status must be stable before consid...

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    96-8100205PARAMETERSJune 1998Parameter144RIG TAP FINISH DISTThis parameter sets the finish tolerance for determining the end point of a rigidtapping operation. Units are encoder counts.Parameter145X ACCEL FEED FORWARDParameter146Y ACCEL FEED FORWARDParameter147Z ACCEL FEED FORWARDParameter148A AC...

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    20696-8100PARAMETERSJune 1998Parameter163B BACKLASHSee Parameter 13 for description.Parameter164B DEAD ZONESee Parameter 14 for description.Parameter165IN POSITION LIMIT BSame definition as Parameter 101.Parameter166B MAX CURRENTSame definition as Parameter 105.Parameter167D*D GAIN FOR BSecond de...

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    96-8100207PARAMETERSJune 1998Parameter179C I GAINSee Parameter 4 for description.Parameter180C SLIP GAINThe value that the slip rate would assume at maximum speed and maximumcurrent.Parameter181C MIN SLIPThe minimum value allowed for the slip rate.Parameter182C ACCELERATIONSee Parameter 7 for des...

  • Page 209

    20896-8100PARAMETERSJune 1998Parameter194SPINDLE STOP FREQThe spindle is considered to be stopped (discrete input SP ST*=0) when thespeed drops below this value. Units are encoder steps/millisecond.Parameter195C START/STOP DELAYThis delay is used at the start of motion to magnetize the rotor bef...

  • Page 210

    96-8100209PARAMETERSJune 1998Parameter209COMMON SWITCH 2Parameter 209 is a collection of general purpose single bit flags used to turn somefunctions on and off. The left and right cursor arrows are used to select the function beingchanged. All values are 0 or 1 only. The function names are:HORIZO...

  • Page 211

    21096-8100PARAMETERSJune 1998DSBL CLNT INIf set to 1 low coolant input will not be used.DSC INP PRDiscrete pallet rotate/part ready; inputs enabled if set to 1.RMT TOOLS RLSIf set to 1, allows use of remote tool release button on spindle head.FLOPPY ENABLIf set to 1, enables the optional floppy d...

  • Page 212

    96-8100211PARAMETERSJune 1998Parameter217CNVYR IGNORE OC TIMAmount of time in 1/50 seconds before overcurrent is checked after conveyor motor isturned on. Default is 50.Parameter218CONVYR RETRY REV TIMAmount of time that the conveyor is reversed in 1/50 seconds after overcurrentis sensed. Def...

  • Page 213

    21296-8100PARAMETERSJune 1998Parameter230Y LEAD COMP 10E9This parameter sets the Y-axis lead screw compensation signed parts perbillion.Parameter231Z LEAD COMP 10E9This parameter sets the Z-axis lead screw compensation signed parts perbillion.Parameter232A LEAD COMP 10E9This parameter sets the A-...

  • Page 214

    96-8100213PARAMETERSJune 1998Parameter244C AXIS MIN TRAVELThis parameter sets the C-axis minimum travel in the negative direction.Parameter245U AXIS MIN TRAVELThis parameter sets the U-axis minimum travel in the negative direction.Parameter246V AXIS MIN TRAVELThis parameter sets the V-axis minimu...

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    21496-8100PARAMETERSJune 1998Y 2ND HOME BTNUsed to move axis to coordinate specified in Work Ofset G129Y NEG COMP DIRUsed to negate the direction of thermal compensationY DELAY AXIS 0Used with an APL to ensure Y axis is zeroed before A axis of APLParameter268Z SWITCHESParameter 268 is a collectio...

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    96-8100215PARAMETERSJune 1998Parameter272X THERM COMP T. CONSTThis parameter is the thermal compensation time constant, and is the timeconstant governing the rate of cool down of the screw.Parameter273Y THERM COMP T. CONSTThis parameter is the thermal compensation time constant, and is the timeco...

  • Page 217

    21696-8100PARAMETERSJune 1998UP ENCL TEMP(Microprocessor Enclosure Temperature) When set to 1, the enclosuretemperature will be displayed on INPUTS2 screen of the diagnostics display.HAAS RJH(Haas Remote Jog Handle) This bit must be set to 1 if the machine is equippedwith a Haas 5-Axis Remote Jo...

  • Page 218

    96-8100217PARAMETERSJune 1998Parameter279X MAX 3rd DERIVThis parameter supports S-curve. It is initialized to 250000000 and can bealtered as needed. In order to ensure the desired effect, the minimum value thatthe control will use is:11700* ACCELERATION / ACC / DEC T CONSTIf the parameter is set ...

  • Page 219

    21896-8100PARAMETERSJune 1998Parameter299AUTOFEED-STEP-UPThis parameter works with the AUTOFEED feature. It specifies the feed rate step-up percentage per second and should initially be set to 10.Parameter300AUTOFEED STEP-DOWNThis parameter works with the AUTOFEED feature. It specifies the feed r...

  • Page 220

    96-8100219MAINTENANCEJune 19987. MAINTENANCE SCHEDULEThe following is a list of required regular maintenance for the HAAS VF-Series Vertical Machining Centers.Listed are the frequency of service, capacities, and type of fluids required. These required specificationsmust be followed in order to ...

  • Page 221

    MAINTENANCE22096-8100June 1998SYSTEM:WAY LUBE AND PNEUMATICSTRANSMISSIONCOOLANT TANKLOCATIONUnder the control panel at the rear ofAbove the spindle headRear of machinethe machineDESCRIPTIONPiston pump with 30-minute cycle time.Pump is only on when spindle is turningor when axis is moving.LUBRICAT...

  • Page 222

    96-8100221MAINTENANCEJune 1998 TSC MAINTENANCE3 Check dirt indicator on 100 micron filter with TSC system running and no tool in the spindle. Change element when theindicator reaches the red zone.3 Clean pump intake filter when indicator is in red zone. Reset indicator with button. All intake...

  • Page 223

    MAINTENANCE22296-8100June 1998 Figure 3. Placement of aluminum block under spindle. Figure 4. Coolant Tip (TSC machines only).5. The clearance from the tool holder to the block should be zero (0). To accomplish this, set the jogincrements to .001 a...

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    CABLE LOCATIONS96-8100223June 19988. PCB'S, CABLE LOCATIONS AND BOARD DIAGRAMS

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    CABLE LOCATIONS22496-8100June 1998KEYBOARD INTERFACE P/N 32-4030

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    CABLE LOCATIONS96-8100225June 1998MICRO PROCESSOR PCB - P/N 32-3091CABLE CONNECTIONS PROC.PLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG # ADDRESSADDRESS BUSSVIDEO——- & DATADATA BUSSMOTIF PCB——-P3860LOW VOLTAGEPOWER SUPPLY PCB——-P6N/AEXTERNAL BATTERY(EXT. BATTERY)——-P...

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    CABLE LOCATIONS22696-8100June 1998

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    CABLE LOCATIONS96-8100227June 1998BRUSHLESS SERVO AMPLIFIER - P/N 32-5550BCABLE CONNECTIONSMOCON PLUG # CABLE # SIGNAL NAME ð TO ð LOCATION PLUG #P570LOW VOLTAGEL. V. POWER SUPPLY——-TB A, B, C——-MOTOR DRIVEX SERVO MOTOR——-P610X DRIVE SIGNALMO...

  • Page 229

    CABLE LOCATIONS22896-8100June 1998POWER PCB 32-5010

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    CABLE LOCATIONS96-8100229June 1998POWER PCB 32-5010CABLE CONNECTIONSPLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #P1——190-260VAC INPUTCB1—--P3——K1 COILK1 CONTACTOR——P4170AUTO OFFI/O PCBP8P5PRI-SECPRI-SEC/T5T5——P6930230VAC/COOLANT PUMPI/O PCBP6P7910115VAC CB/SOLENOIDI/O PCBP28P890115VAC/...

  • Page 231

    CABLE LOCATIONS23096-8100June 1998I/O PCB 32-3080

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    CABLE LOCATIONS96-8100231June 1998I/O PCB - P/N 32-3080 CABLE CONNECTIONSI/O PLUG #CABLE #ð TO ðLOCATIONPLUG #P1510MOCON PCBP11P2520MOCON PCBP12P3540MOCON PCBP14P4550MOCON PCBP10P5110SERVO POWER ON——-P6930POWER PCBP6P7940COOL PUMP——-P8170POWER PCBP4P9710SPINDLE DRIVE——-P10300SP.FAN/GE...

  • Page 233

    CABLE LOCATIONS23296-8100June 1998

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    CABLE LOCATIONS96-8100233June 1998SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOGP/N 32-4030CABLE CONNECTIONSPLUG#CABLE#ð TO ðLOCATIONPLUG#P1700BPROCESSOR850P2—-KEYPAD—-P3700ACYCLE START/HOLD SWITCHES—-P4730SP LOAD METER—-P5—-SPEAKER—-P6—-AUX FPANEL—-J1—-JOG HANDLE—-J2—-REMOTE JOG HAND...

  • Page 235

    CABLE LOCATIONS23496-8100June 1998VIDEO & KEYBOARD PCB 32-3201

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    CABLE LOCATIONS96-8100235June 1998VIDEO & KEYBOARD PCB W/ FLOPPY DRIVEP/N 32-3201ACABLE CONNECTIONSVIDEO PLUG # CABLE # SIGNAL NAME ð TO ð LOCATION PLUG #P1860LOW VOLTAGEPOWER SUPPLY PCB——-J3*700KEYBOARD INFO.KEYBOARD INT.——-J4——-ADDRESS ...

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    CABLE LOCATIONS23696-8100June 1998VIDEO & KEYBOARD PCB W/O FLOPPY

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    CABLE LOCATIONS96-8100237June 1998VIDEO & KEYBOARD PCB - P/N 32-3200CABLE CONNECTIONSVIDEO PLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #ADDRESS &——-ADDRESS BUSSMICRO PROC. PCB——-DATA——-DATA BUSSMOTIF PCB——-P1860LOW VOLTAGEPOWER SUPPLY PCB——-P13760VIDEO SIGNALCRT——-P4700KEYB...

  • Page 239

    CABLE LOCATIONS23896-8100June 1998MOCON PCB 32-4023

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    CABLE LOCATIONS96-8100239June 1998MOCON PCB - P/N 32-4023CABLE CONNECTIONSMOCON PLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #P1——-DATA BUSSVIDEO PCB——-MICRO PROC. PCB——-P2610X DRIVE SIGNALX SERVO DRIVE AMP.PP3620Y DRIVE SIGNALY SERVO DRIVE AMP.PP4630Z DRIVE SIGNALZ SERVO DRIVE AMP.PP5640A ...

  • Page 241

    CABLE LOCATIONS24096-8100June 1998

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    CABLE LOCATIONS96-8100241June 1998MOTIF PCB - P/N 32-4020CABLE CONNECTIONS MOTIFPLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #ADDRESS——-ADDRESS BUSSVIDEO PCB——-& DATA——-DATA BUSSMICRO PROC. PCB——-P2610X DRIVE SIGNALX SERVO DRIVEP3P3620Y DRIVE SIGNALY SERVO DRIVEP3P4630Z DRIVE SI...

  • Page 243

    CABLE LOCATIONS24296-8100June 1998

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    CABLE LOCATIONS96-8100243June 1998SERVO DISTRIBUTION (SDIST) PCB - P/N 32-5020CABLE CONNECTIONS I/OPLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #P1570X DRIVER LOW VOLTAGEX SERVO DRIVERP1P2580Y DRIVER LOW VOLTAGEY SERVO DRIVERP1P3590Z DRIVER LOW VOLTAGEZ SERVO DRIVERP1P4600A DRIVER LOW VOLTA...

  • Page 245

    CABLE LOCATIONS24496-8100June 1998

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    CABLE LOCATIONS96-8100245June 1998SERVO DRIVER PCBs - P/N 32-4070CABLE CONNECTIONS I/0PLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #X AXISP1570LOW VOLTAGESDIST PCBP1P2——-MOTOR DRIVEX SERVO MOTOR——-P3610X DRIVE SIGNALMOTIF PCBP2P8——-+160VDCSDIST PCBTB2Y AXISP1580LOW VOLTAGESDIST PCBP2P...

  • Page 247

    CABLE LOCATIONS24696-8100June 1998INTERNALPLUGEXTERNALPLUGP1J1RS-232 PORT #1 PCB - P/N 32-4090CABLE CONNECTIONSPLUG #CABLE #ð TO ðLOCATIONPLUG #P1850VIDEO &J13 INTERNALKEYBOARDJ1——-——-——- EXTERNAL

  • Page 248

    CABLE LOCATIONS96-8100247June 1998P3P1P2J1J2SPINDLE LOCK PCB - P/N 32-3095CABLE CONNECTIONSPLUG #CABLE #ð TO ðLOCATIONPLUG #P1890I/O PCB P15P2520I/O PCB P2P3——-VECT DRV——-

  • Page 249

    CABLE LOCATIONS24896-8100June 1998

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    CABLE LOCATIONS96-8100249June 1998TRANSMISSION P.S. / HYDRAULIC C.B. PCB P/N 32-4095 REV.BCABLE CONNECTIONSPLUG #CABLE #ð TO ðLOCATIONPLUG #P1880BIO PCBP12P290POWER PCBP8P3410GEAR BOXP4350IO PCBP54TB2340HYDRAULIC MTRTB370MAIN TRANSFORMER(VECTOR DRIVE UNIT)

  • Page 251

    CABLE LOCATIONS25096-8100June 1998Y-DELTA SWITCH ASSEMBLYP/N 32-5850A

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    CABLE LOCATIONS96-8100251June 1998CABLE LOCATION DIAGRAM

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    CABLE LOCATIONS25296-8100June 1998

  • Page 254

    96-8100253CABLE LISTJune 19989. CABLE LISTJUNE 1998WIRE/TERMINAL FUNCTION NAME:NUMBERINCOMING POWER 195-260 VAC (353-488 VAC OPTIONAL)L1INCOMING 195-260VAC, PHASE 1, TO CB1-1L2INCOMING 195-260VAC, PHASE 2, TO CB1-2L3INCOMING 195-260VAC, PHASE 3, TO CB1-371PROTECTED 195-260 VAC FROM MAIN...

  • Page 255

    25496-8100CABLE LISTJune 1998100 M-FIN (IOASM TO SIDE OF BOX) - (2 + SHIELD)101SIGNAL #20102COMMON #20101SIGNAL #20102COMMON #20103SHIELD DRAIN140 230VAC 3PH POWER TO CHIP CONVEYOR MOTOR (5 + SHIELD)141PHASE A 230VAC142PHASE B 230VAC143PHASE C 230VAC144STARTING WINDING 230VAC145STARTING WINDING 2...

  • Page 256

    96-8100255CABLE LISTJune 1998280 RED/GREEN STATUS LIGHT WIRING (3+ SHIELD)281RED LAMP 115VAC282GREEN LAMP 115VAC283COMMON 115VAC284SHIELD DRAIN300 115VAC TO SPINDLE MOTOR FAN/OIL PUMP/OILER (2 + SHIELD)301LEG 1 115VAC PROTECTED #18302LEG 2 115VAC PROTECTED #18303SHIELD DRAIN350 SERVO BRAKE RELE...

  • Page 257

    25696-8100CABLE LISTJune 1998610-3+B CHANNEL610-4ANALOG GROUND610-5ENABLE610-6LOGIC GROUND610-7FAULT610-8LOGIC GROUND610-9NOT USED610-10SHIELD/ANALOG GROUND620 Y AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD(SAME AS 610-1 THRU 610-10)630 Z AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD...

  • Page 258

    96-8100257CABLE LISTJune 1998660-14X HALL D (NOT USED)660-15SHIELD DRAIN660-16NOT USED670 Y-AXIS ENCODER CABLE(SAME AS 660-1 THRU 660-16)680 Z-AXIS ENCODER CABLE(SAME AS 660-1 THRU 660-16)690 A-AXIS ENCODER CABLE(SAME AS 660-1 THRU 660-16)690BB-AXIS ENCODER CABLE(SAME AS 660-1 THRU 660-16)690CC-A...

  • Page 259

    25896-8100CABLE LISTJune 1998750 JOG-CRANK DATA CABLE (REM JOG SIDE CONNECTION) - (4 + SHIELD) (ALL #28)(CABLE NUMBER 33-5750)750-1LOGIC RETURN (D GROUND) 0VDC750-2ENCODER A CHANNEL750-3ENCODER B CHANNEL750-4+5 VDC750-5N/C750-6X-AXIS750-7Y-AXIS750-8N/C750-9N/C750-10N/C750-11Z-AXIS750-12A-AXIS750-...

  • Page 260

    96-8100259CABLE LISTJune 1998820 TOOL CHANGER STATUS - (7 + SHIELD)7821LOGIC RETURN (D GROUND) (P6-F/H/L/M) #24822GENEVA MARK (INPUT 5 TO P6-G) #24 (LATHE PART DOOR)823TOOL #1 (INPUT 3 TO P6-E) #24824SHUTTLE IN (INPUT 1 TO P6-C) #24 (LATHE TURRET CLAMPED)825SHUTTLE OUT (INPUT 2 TO P6-D) #24 (LATH...

  • Page 261

    26096-8100CABLE LISTJune 1998883LOW GEAR SOLENOID (IO P12-3) #18884SHIELD DRAIN890 SPINDLE STATUS SWITCHES (6 + SHIELD)891SIGNAL RETURN (D GROUND) (65) #24892HIGH GEAR (INPUT 6) #24893LOW GEAR (INPUT 7) #24894TOOL UNCLAMPED (INPUT 15) #24895TOOL CLAMPED (INPUT 16) #24896SPINDLE LOCKED (INPUT 17) ...

  • Page 262

    96-8100261CABLE LISTJune 1998963DOOR OPEN SIGNAL (INPUT 9) #24 (OBSOLETE OPTION)964DOOR OPEN RETURN (D GROUND) (65) #24 (OBSOLETE OPTION)965SHIELD DRAIN970 LOW VOLTAGE SENSOR - (2 + SHIELD)971LOW VOL SIGNAL (INPUT 11 FROM PMON P9-3) #24972LOW VOL RETURN (D GROUND) (PMON P9-4) #24973SHIELD DRAIN98...

  • Page 263

    26296-8100CABLE LISTJune 1998

  • Page 264

    263ELECTRICAL DIAGRAMSJune 199896-8100ELECTRICALWIRING DIAGRAMS

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    264ELECTRICAL DIAGRAMSJune 199896-8100

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    265ELECTRICAL DIAGRAMSJune 199896-8100

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    266ELECTRICAL DIAGRAMSJune 199896-8100

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    267ELECTRICAL DIAGRAMSJune 199896-8100

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    268ELECTRICAL DIAGRAMSJune 199896-8100

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    269ELECTRICAL DIAGRAMSJune 199896-8100

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    270ELECTRICAL DIAGRAMSJune 199896-8100

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    271ELECTRICAL DIAGRAMSJune 199896-8100

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    272ELECTRICAL DIAGRAMSJune 199896-8100

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    273ELECTRICAL DIAGRAMSJune 199896-8100

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    274ELECTRICAL DIAGRAMSJune 199896-8100

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    275ELECTRICAL DIAGRAMSJune 199896-8100

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    276ELECTRICAL DIAGRAMSJune 199896-8100

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    277ELECTRICAL DIAGRAMSJune 199896-8100

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    278ELECTRICAL DIAGRAMSJune 199896-8100

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    279ELECTRICAL DIAGRAMSJune 199896-8100

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    280ELECTRICAL DIAGRAMSJune 199896-8100

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    281ELECTRICAL DIAGRAMSJune 199896-8100

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    282ELECTRICAL DIAGRAMSJune 199896-8100

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    283ELECTRICAL DIAGRAMSJune 199896-8100

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    284ELECTRICAL DIAGRAMSJune 199896-8100

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    285ELECTRICAL DIAGRAMSJune 199896-8100

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    286ELECTRICAL DIAGRAMSJune 199896-8100

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    287ELECTRICAL DIAGRAMSJune 199896-8100

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    288ELECTRICAL DIAGRAMSJune 199896-8100

  • Page 290

    ASSEMBLY DRAWINGSJune 199828996-8100ASSEMBLY DRAWINGS

  • Page 291

    ASSEMBLY DRAWINGSJune 199829096-810050 Taper Tool Release Piston

  • Page 292

    ASSEMBLY DRAWINGSJune 199829196-8100ITQTYPART_NOTITLE1120-9193CAROUSEL SUPPORT PLATE2120-9324CAROUSEL, 32 TOOL33222-7067FKEY, EXTRACTOR46422-9256BUSHING, EXTRACTOR56422-9574ACT-EXTRACTOR63224-2010ACOMPRESSION SPRING73224-9257SPRING, EXTRACTOR83225-7249SLIDING PANEL93225-932832 TOOL SLIDING PANEL ...

  • Page 293

    ASSEMBLY DRAWINGSJune 199829296-8100ITQTYPART_NOTITLE1120-9193CAROUSEL SUPPORT PLATE2120-9324CAROUSEL, 32 TOOL33222-7067FKEY, EXTRACTOR46422-7166AEXTRACTOR, BT-40 TOOL CHN56422-9256BUSHING, EXTRACTOR63224-2010ACOMPRESSION SPRING73224-9257SPRING, EXTRACTOR83225-7249SLIDING PANEL93225-932832 TOOL S...

  • Page 294

    ASSEMBLY DRAWINGSJune 199829396-8100Tool Changer Assembly VF-3/4

  • Page 295

    ASSEMBLY DRAWINGSJune 199829496-810030-0008 TOOL CHANGER ASSEMBLY, 32 TOOL, VF-3,4ITQTYPART NOTITLE1120-7035GVERTICAL AXLE2120-7038ABEARING HOUSING3120-7475ARM, SLIP CLUTCH4120-7476HUB, SLIP CLUTCH5120-9008TOOL HOLDING ARM6120-932532 TOOL GENEVA STAR, 2 PIN7120-9326TOOL CARRIAGE, MACHINING8120-93...

  • Page 296

    ASSEMBLY DRAWINGSJune 199829596-8100ITQTYPART NOTITLE48445-1740WASHER, BLACH HARD 1/2"491045-1800WASHER, SPLIT LOCK 1/4" MED.50245-2020WASHER, NYLON51146-1705LOCK-NUT, ELASTIC, 3/4-1052148-0005PIN, DOWEL 3/16 x 3/8"53148-0019PIN, DOWEL 1/4 x 5/8"54148-0020PIN, DOWEL 1/4 x 1&qu...

  • Page 297

    ASSEMBLY DRAWINGSJune 199829696-8100Tool Changer Assembly VF-6..10

  • Page 298

    ASSEMBLY DRAWINGSJune 199829796-810030-0009 TOOL CHANGER ASSEMBLY, 32 TOOL, VF-6...10ITQTYPART NOTITLE1220-0031ADJ. SWITCH BLOCK2120-7035GVERTICAL AXLE3120-7038ABEARING HOUSING4120-7475ARM, SLIP CLUTCH5120-7476HUB, SLIP CLUTCH6120-932532 TOOL GENEVA STAR, 2 PIN7120-9326TOOL CARRIAGE, MACHINING812...

  • Page 299

    ASSEMBLY DRAWINGSJune 199829896-810030-0009 TOOL CHANGER ASSEMBLY, 32 TOOL, VF-6...10ITEMPARTDESCRIPTIONQTY9658-36571/4 FEMALE 1/8 MALE ADPT19758-7357TOP PLATE TUBE - A19858-7358AOP PLATE TUBE - B19958-7377AIR REG / SOLENOID TUBE110058-7635LOW GEAR TUBE VF-3110158-7636HIGH GEAR TUBE VF-3110258-91...

  • Page 300

    ASSEMBLY DRAWINGSJune 199829996-8100Spindle Assembly VF 50 Taper

  • Page 301

    ASSEMBLY DRAWINGSJune 199830096-810050 Taper Tool Changer Assembly

  • Page 302

    ASSEMBLY DRAWINGSJune 199830196-810030-0015 TOOL CHANGER ASSEMBLY, 50 TAPERITEMQTYPART NOTITLE1120-7035GVERTICAL AXLE2120-7038ABEARING HOUSING3120-7475ARM, SLIP CLUTCH4120-7476HUB, SLIP CLUTCH5120-9008TOOL HOLDING ARM6120-932532 TOOL GENEVA STAR, 2 PIN7120-9326TOOL CARRIAGE, MACHINING8120-933032 ...

  • Page 303

    ASSEMBLY DRAWINGSJune 199830296-8100ITEMQTYPART NOTITLE491045-1800WASHER, SPLIT LOCK 1/4" MED.50245-2020WASHER, NYLON51146-1705LOCK-NUT, ELASTIC, 3/4-1052148-0005PIN, DOWEL 3/16 x 3/8"53148-0019PIN, DOWEL 1/4 x 5/8"54148-0020PIN, DOWEL 1/4 x 1"55248-1750PIN, DOWEL 1/2 x 1 1/2&...

  • Page 304

    ASSEMBLY DRAWINGSJune 199830396-810050T CAROUSEL ASSEMBLY - CTITEMQTYDWG. NO.DESCRIPTION1120-929650 TAPER CAROUSEL - 20 TOOL24020-9297EXTRACTION FINGER 50 TAPER32020-9298ALIGNMENT KEY 50 TAPER44022-9256BUSHING, EXTRACTOR,52024-9257SPRING, EXTRACTOR, VF-ALL6125-934920 TOOL NUMBER RING 50 T7540-160...

  • Page 305

    ASSEMBLY DRAWINGSJune 199830496-8100VF-6/8 (X-Axis) Lead Screw Assembly

  • Page 306

    ASSEMBLY DRAWINGSJune 199830596-8100 VF-10 Leadscrew

  • Page 307

    ASSEMBLY DRAWINGSJune 199830696-8100ITEMQTYPART NO.TITLE1120-0150NUT HOUSING 40/50mm BS MACH2120-9215Y-AXIS BUMPER BRG END3120-9218Y-AXIS BUMPER MTR END4120-9800BASE, MACHINING53422-7458CAM, LINEAR GUIDE6125-7267Y-AXIS MOUNTING BRACKET7125-9203COVER PLATE MOTOR MOUNT8130-1212ALEAD SCREW Y-AXIS913...

  • Page 308

    ASSEMBLY DRAWINGSJune 199830796-8100VF-10 Column

  • Page 309

    ASSEMBLY DRAWINGSJune 199830896-8100ITEM QTY DWG. NO.TITLE1.120-0150NUT HOUSING 40/50 mm BS2.120-9216Z-AXIS BUMPER MTR END 40MM3.120-9217Z-AXIS BUMPER SPRT END 40MM4.120-9801COLUMN, MACHINED5.120-9802SPINDLE HEAD, MACHINED6.3422-7458CAM, LINEAR GUIDE7.222-9826ACOUNTER WEIGHT HEAD BRAC...

  • Page 310

    ASSEMBLY DRAWINGSJune 199830996-8100ITEMQTYDWG. NO.TITLE1.120-0150NUT HOUSING 40/50 mm BS2.120-0153SADDLE, VF-10 MACHINED3.120-0154TABLE, VF-10 MACHINED4.220-0156BUMPER, 1" 40 & 50 mm LD SCREW5.8622-7458CAM, LINEAR GUIDE6.125-7459TRIP BRACKET, TABLE7.125-9219LIMIT SWITCH BRACKET X- AXIS8...

  • Page 311

    ASSEMBLY DRAWINGSJune 199831096-8100APC Assembly

  • Page 312

    ASSEMBLY DRAWINGSJune 199831196-8100ITEMQTY.PART NO.TITLE1.314-7068CASTING, LEVEL PAD2.120-0046SUPPORT, IDLER SPROCKET3.220-0048DRIVE LEG, APC4.220-0049DETENT, APC5.120-0050SUPPORT, MOTOR, APC6.220-0051GUIDE, CHAIN, APC7.120-0052TENSIONER BLOCK8.220-0053PALLET9.420-0054CLAMPING RAIL10.120-0057IDL...

  • Page 313

    ASSEMBLY DRAWINGSJune 199831296-8100VF-1 Base

  • Page 314

    ASSEMBLY DRAWINGSJune 199831396-8100VF-1 Column

  • Page 315

    ASSEMBLY DRAWINGSJune 199831496-8100VF-1 Saddle

  • Page 316

    ASSEMBLY DRAWINGSJune 199831596-8100VF-1 Leadscrew

  • Page 317

    ASSEMBLY DRAWINGSJune 199831696-8100

  • Page 318

    ASSEMBLY DRAWINGSJune 199831796-8100

  • Page 319

    ASSEMBLY DRAWINGSJune 199831896-8100

  • Page 320

    ASSEMBLY DRAWINGSJune 199831996-8100

  • Page 321

    ASSEMBLY DRAWINGSJune 199832096-8100

  • Page 322

    ASSEMBLY DRAWINGSJune 199832196-8100VF-8 Base

  • Page 323

    ASSEMBLY DRAWINGSJune 199832296-8100VF-8 Column

  • Page 324

    ASSEMBLY DRAWINGSJune 199832396-8100VF-8 Saddle

  • Page 325

    ASSEMBLY DRAWINGSJune 199832496-8100VF-6 Base

  • Page 326

    ASSEMBLY DRAWINGSJune 199832596-8100VF-6 Column

  • Page 327

    ASSEMBLY DRAWINGSJune 199832696-8100VF-6 Saddle

  • Page 328

    ASSEMBLY DRAWINGSJune 199832796-8100

  • Page 329

    ASSEMBLY DRAWINGSJune 199832896-8100

  • Page 330

    ASSEMBLY DRAWINGSJune 199832996-8100

  • Page 331

    ASSEMBLY DRAWINGSJune 199833096-8100VF Series Spindle 7.5 K

  • Page 332

    ASSEMBLY DRAWINGSJune 199833196-810020 Pocket Tool Changer

  • Page 333

    ASSEMBLY DRAWINGSJune 199833296-8100VF-3 Base

  • Page 334

    ASSEMBLY DRAWINGSJune 199833396-8100VF-3 Column

  • Page 335

    ASSEMBLY DRAWINGSJune 199833496-8100VF-3 Saddle

  • Page 336

    ASSEMBLY DRAWINGSJune 199833596-8100

  • Page 337

    ASSEMBLY DRAWINGSJune 199833696-8100

  • Page 338

    ASSEMBLY DRAWINGSJune 199833796-8100

  • Page 339

    ASSEMBLY DRAWINGSJune 199833896-8100

  • Page 340

    ASSEMBLY DRAWINGSJune 199833996-8100

  • Page 341

    ASSEMBLY DRAWINGSJune 199834096-8100VF-3/4 Gearbox Assembly 15 HP

  • Page 342

    ASSEMBLY DRAWINGSJune 199834196-8100

  • Page 343

    ASSEMBLY DRAWINGSJune 199834296-8100VF-3/4 Gearbox Assembly HT10K

  • Page 344

    ASSEMBLY DRAWINGSJune 199834396-8100

  • Page 345

    ASSEMBLY DRAWINGSJune 199834496-8100VF-3/4 Gearbox Assembly HT10K TSC

  • Page 346

    ASSEMBLY DRAWINGSJune 199834596-8100

  • Page 347

    ASSEMBLY DRAWINGSJune 199834696-8100VF-Series Hydraulic Couterbalance System

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