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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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    1TROUBLESHOOTING96-8100 rev EJune 2002COMMON 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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    2TROUBLESHOOTING96-8100 rev EJune 2002LOW 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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    3TROUBLESHOOTING96-8100 rev EJune 20021. 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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    4TROUBLESHOOTING96-8100 rev EJune 20021.1 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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    5TROUBLESHOOTING96-8100 rev EJune 2002VIBRATIONVibration is a subjective evaluation with perceptions varying among individuals, making it difficult to determine inmild cases if there is an actual problem. Because the VF Series uses a gear head, it will be noisier than adirect drive or belt syste...

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    6TROUBLESHOOTING96-8100 rev EJune 2002ACCURACYBefore you complain of an accuracy problem, please make sure you follow these simple do’s and don’ts:• Ensure that the machine has been sufficiently warmed up before cutting parts. This will eliminatemispositioning errors caused by thermal growth...

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    7TROUBLESHOOTING96-8100 rev EJune 2002Machine mis-positions holes.• Check for thermal growth of the leadscrew (see "Thermal Growth" section).• Check that the machine is level (see "Installation" section).• Check for backlash (see "Servo Motors/Leadscrews" section)...

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    8TROUBLESHOOTING96-8100 rev EJune 2002VERIFY THERMAL GROWTHThere are a number of ways to verify the problem. The following procedure will verify thermal growth of the X-axis leadscrew in a machine that has not been warmed up:1. Home the machine. In MDI mode, press POSIT and PAGE DOWN to the OP...

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    9TROUBLESHOOTING96-8100 rev EJune 20021.2 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 "Belt Assembly" and "Spindle Motor...

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    10TROUBLESHOOTING96-8100 rev EJune 2002• Check the pulleys for excessive runout (more than 0.003" axial or radial).• Run the motor or the gearbox with the drive belt disconnected. If the noise persists, the problem lies withthe gearbox/motor. If it disappears, go on to the next step.• Ch...

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    11TROUBLESHOOTING96-8100 rev EJune 2002ALTERNATE SPINDLE RUN-IN PROGRAMRun program #O02021 with the air pressure to the spindle set to 30 psi. (for all spindles). Program time isapproximately 2 hours. If possible run the program overnight by changing M30 to M99 so it can repeat. Adjustspindle sp...

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    12TROUBLESHOOTING96-8100 rev EJune 2002STALLING / LOW TORQUEGenerally, complaints of stalling or low torque relate to incorrect tooling or machining practices. A spindle thatis tending to seize will yield a poor finish machining, run very hot and very loud. Investigate machining prob-lems befo...

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    13TROUBLESHOOTING96-8100 rev EJune 20024. Reverse the leads: Place the red meter lead on the -HV terminal and the black lead on the +HVterminal. The meter should read .7 ohms in both instances. If not, replace the faulty amplifier.5. Measure the resistance between terminals 1 and 3 of the Vect...

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    14TROUBLESHOOTING96-8100 rev EJune 2002ORIENTATIONSpindle loses correct orientation.Non Vector Drive•Check the orientation ring for tightness. Ensure the shaft on which the ring mounts is clean and isfree of grease and oil.•Check the orientation ring for cracks near the bolt holes or near the ...

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    15TROUBLESHOOTING96-8100 rev EJune 2002•Check air supply. Max air pressure drop of 10psi. during a tool change is allowed.•Check drawbar height adjustment.•Does the tool tip to the spindle gauge line exceed 3.5”?•Are the correct pull studs being used?Tool Holder / Spindle FrettingIs frettin...

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    16TROUBLESHOOTING96-8100 rev EJune 20021.3 SERVO MOTORS / LEADSCREWSNOT OPERATINGAll problems that are caused by servo motor failures should also register an alarm. Check the alarm history todetermine the problem’s cause before any action is taken.Servo motor is not functioning.•Check the po...

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    17TROUBLESHOOTING96-8100 rev EJune 2002Lead screw noise.•Ensure oil is getting to the lead screw through the lubrication system (See Air and Oil Diagrams).Look for a plugged metering valve.•Check for damage to the bearing sleeve.NOTE: The current angular contact design sleeve has a fixed pre-lo...

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    18TROUBLESHOOTING96-8100 rev EJune 2002INITIAL PREPARATION -Turn the VMC ON. ZERO RET the machine and move the mill table to the approximate center of its travel in theX and Y directions. Move the spindle head to approximate center of the Z-axis travel, also.CHECKING X-AXIS:1. Set up a dial indi...

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    19TROUBLESHOOTING96-8100 rev EJune 2002CHECKING Y-AXIS:1. Set up a dial indicator and base on the mill table as shown in Fig. 1-2.Figure 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:•Zero the d...

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    20TROUBLESHOOTING96-8100 rev EJune 2002Figure 1-3 Dial indicator in position to check Z-axis.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 inMechanical Service.•Loose SHCS attach...

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    21TROUBLESHOOTING96-8100 rev EJune 2002VIBRATIONExcessive servo motor vibration.• Swap the suspected bad servo motor with a known good driver and check to see if there is a driverproblem. If needed, replace the DRIVER PCB ("Electrical Service" section).• Check all Parameters of the su...

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    22TROUBLESHOOTING96-8100 rev EJune 2002VF-6 with Z axis brake only•Brake power fuse blown•Brake power transformer blown•Brake power rectifier blown•Cabling pinched•Brake failedLEAD SCREWS - VISUAL INSPECTIONThe three main causes of Lead Screw failure are:Loss of LubricationContaminationMach...

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    23TROUBLESHOOTING96-8100 rev EJune 2002Machine Crash:A hard machine crash can cause a Lead Screw to lock up. The static overload created during a machine crashcan break apart the Nut balls, denting the thread surfaces. Turning the Nut by hand will result in an obviousgrinding feeling and/or sound...

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    24TROUBLESHOOTING96-8100 rev EJune 20021.4 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 or poor air supply. Before beginning any troubleshooting,observe the...

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    25TROUBLESHOOTING96-8100 rev EJune 2002•Duplicate the cutting conditions under which the deflection occurs, but do not execute an auto-matic tool change. Try instead to release the tool using the tool release button on the front of thespindle head. If sticking is observed, the deflection is not ...

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    26TROUBLESHOOTING96-8100 rev EJune 2002CRASHINGThe most common ATC crashes are outlined as follows:Shuttle crashes into spindle when a tool change is commanded (tool holder is in the pocketfacing the spindle head).•Rotate the carousel to an empty pocket. Refer to the Programming and Operation m...

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    27TROUBLESHOOTING96-8100 rev EJune 2002SIDE MOUNT TOOL CHANGER RECOVERY FLOW CHART

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    28TROUBLESHOOTING96-8100 rev EJune 2002BREAKAGEBreakage of the ATC is caused by either very hard and repeated crashes or excessive TSC coolant tip wear.ATC shuttle is broken off of the holding plate.•Carefully inspect the bosses on the shuttle casting (where the roller bolts mount) for damage t...

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    29TROUBLESHOOTING96-8100 rev EJune 2002•Ensure the screws holding the turret motor to the mounting plate are tight ("Turret Motor Removal"section).•Ensure the screws attaching the motor mounting plate to the shuttle casting are tight.•Check for excessive noise in the gear train of th...

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    30TROUBLESHOOTING96-8100 rev EJune 2002•Command a tool change with the shuttle disconnected.• If the shuttle cycles, check the slip clutch on the ATC. See "Shuttle Installation" section for slipclutch replacement.NOTE: The slip clutch should move the shuttle with a fair amount of for...

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    31TROUBLESHOOTING96-8100 rev EJune 20021.5 GEARBOX AND SPINDLE MOTORThe gearbox cannot be serviced in the field and must be replaced as a unit. NEVER remove a motor from aVF-Series mill that has a gearbox, as this will damage the gearbox and void the warranty.NOISEWhen investigating complaints ...

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    32TROUBLESHOOTING96-8100 rev EJune 2002LOW PRESSURE ALARMAlarm 179 (Low Pressure Transmission Oil) has been triggered.•Check for low oil supply in reservoir.•Check to see that pump motor is running.•Check for an air leak in the suction side of the pump.•Check for a bad pressure sensor.•Chec...

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    33TROUBLESHOOTING96-8100 rev EJune 20021.6 THROUGH THE SPINDLE COOLANTCOOLANT OVERFLOWTo begin troubleshooting, check the alarm history to determine the problem’s cause before any action is taken.Coolant pouring out of spindle head covers.•Check the customer's tooling for through holes in the ...

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    34TROUBLESHOOTING96-8100 rev EJune 2002LOW COOLANTAlarm 151, "Low Thru Spindle Coolant"•Check coolant tank level.•Check for slow coolant drainage from machine enclosure.•Read the filter gauges and check the intake strainer to ensure there is no clogging. Read gaugeswith TSC running...

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    35TROUBLESHOOTING96-8100 rev EJune 2002PRE-CHARGE FAILUREAlarm 198, "Precharge Failure"NOTE: This alarm only applies to the TSC system. This alarm does not apply to 50taper spindle machines. If this alarm is received on a 50 taper TSC machine,check that parameter 235 is set to zero. A n...

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    36TROUBLESHOOTING96-8100 rev EJune 20021.7 CHIP CONVEYORChip conveyor does not turn•Check that Parameter 209 bit switch ENA CNVR is enabled.•Check that the front enclosure door is completely closed and door switches function properly.•Check that hub is connected to auger with bolt.•Check...

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    37TROUBLESHOOTING96-8100 rev EJune 20021.8 HYDRAULIC COUNTERBALANCE020406080100120140160psiHydraulicTankPressureGaugePressureSwitchCablePressureManifoldOutletPressureSwitchFill ValveHydraulic Tank AssemblyTOP OF TRAVEL PRESSUREA reference table is listed below indicating top of travel pressure ...

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    38TROUBLESHOOTING96-8100 rev EJune 2002TROUBLESHOOTINGThe table below lists observable machine conditions and their probable cause. Find the appropriate correctiveaction step to fix the observed faults....

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    39TROUBLESHOOTING96-8100 rev EJune 20022. Block spindle head at bottom of travel (if the cylinder is to be replaced block the head in the lowestposition that will permit access to the rod attachment).a)Carefully drain remaining gas and oil.b)Replace faulty component(s). (SAE straight thread o-rin...

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    40TROUBLESHOOTING96-8100 rev EJune 2002LEAK FAILURESLeaks can occur at any fitting connection, at the hydraulic cylinder’s rod seal (where the rod entersthe cylinder), at the cylinder’s piston seal, or through hose failures. Inspections for leaks are visualalthough rod seal leaks may be incon...

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    41TROUBLESHOOTING96-8100 rev EJune 20021.9 LINEAR SCALESIf any linear scale faults (alarms 279-290) are detected, contact the Haas service Department.The following information is needed in order to properly diagnose the machine:List of the faults and the datesAny pertinent information on the co...

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    42TROUBLESHOOTING96-8100 rev EJune 2002Recovery from an E-Stop initiated during a pallet changeIs Power ON?Troubleshooting a Power Outage or E-Stop condition witha Pallet in transition between the Receiver and the APC.CAUTION!With the pallet stopped between the APC and receiver thedrive pin on t...

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    43TROUBLESHOOTING96-8100 rev EJune 2002Alignment pinReceiverPalletPallet Clamp SwitchAlignment Pin Receiver BushingFigure 1Pallet known locations. Pallet 1 is on the receiver and engagingthe Pallet Clamped switch. Pallet 2 is on the APC and engagingthe Pallet Home Switch under the control panel...

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    44TROUBLESHOOTING96-8100 rev EJune 2002Figure 3With pallet 2 clamped on the receiver, the tripblock must be engaging the switch as shown.Figure 4Press and hold the solenoid actuation buttons tokeep air pressure flowing to unclamp the receiverand hold the door open. If the buttons are releasedth...

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    45TROUBLESHOOTING96-8100 rev EJune 20021.11 ELECTRICAL TROUBLESHOOTINGCAUTION! Before working on any electrical components, power off the machine andwait approximately 10 minutes. This will allow the high voltage power on thebrushless amplifiers to be discharged.ELECTRICAL ALARMSAxis Drive Faul...

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    46TROUBLESHOOTING96-8100 rev EJune 2002Axis 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 motor...

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    47TROUBLESHOOTING96-8100 rev EJune 2002WO7Z channel fault. Either the encoder or the cable is bad. Change the encoder first, as it is easier tochange than the cable. If the problem persists, change the cable.WO8Over-current limit, stalled or PCB fault. Check for binding in the tool changer ge...

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    48TROUBLESHOOTING96-8100 rev EJune 2002KEYBOARD DIAGNOSTICNOTE: Refer to the "Cable Locations" section of this manual for a drawing of theKeyboard Interface PCB.NOTE: This Keyboard Grid is for machines with a Keyboard Interface only. ThisKeyboard Grid is not for machines with a Serial...

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    49TROUBLESHOOTING96-8100 rev EJune 2002Example1. 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 readin...

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    50TROUBLESHOOTING96-8100 rev EJune 2002If an Error 53 is still present, restore the protocol.ini file to its previous state and do the following to the NTserver:1. Open the control panel2. Double click on the Network icon3. Select the Protocols tab.4. Highlight NWLINK IPX/SPX Compatible Transpor...

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    51ALARMSJune 200296-8100 rev E2. 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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    52ALARMSJune 200296-8100 rev E109 Y 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/o...

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    53ALARMSJune 200296-8100 rev E121 Low 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.122 Regen OverheatThe c...

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    54ALARMSJune 200296-8100 rev E134 Tool 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.135 X Motor Over HeatServo motor overheat. The temperature sensor in ...

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    55ALARMSJune 200296-8100 rev E151 Low 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 c...

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    56ALARMSJune 200296-8100 rev E173 Spindle Ref Signal MissingThe Z channel pulse from the spindle encoder is missing forhard tapping synchronization.174 Tool 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 th...

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    57ALARMSJune 200296-8100 rev E199 Negative RPMA negative spindle RPM was sensed.201 Parameter CRC ErrorParameters lost. Check for a low battery and low battery alarm.202 Setting CRC ErrorSettings lost. Check for a low battery and low battery alarm.203 Lead Screw CRC ErrorLead screw compensation t...

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    58ALARMSJune 200296-8100 rev E224 X Transition FaultIllegal transition of encoder count pulses in X axis. This alarmusually indicates that the encoder has been damaged andencoder position data is unreliable. This can also be caused byloose connectors at the MOCON or MOTIF PCB.225 Y Transition Fau...

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    59ALARMSJune 200296-8100 rev E248 Number Range ErrorNumber entry is out of range.249 Prog Data Begins OddPossible corrupted program. Save all programs to floppy disk,delete all, then reload.250 Program Data ErrorSame as alarm 249.251 Prog Data Struct ErrorSame as alarm 249.252 Memory OverflowSam...

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    60ALARMSJune 200296-8100 rev E267 Tool Door Out of PositionHorizontal mills only. Alarm will be generated during a toolchange when parameter 278 TC DR SWITCH is set to 1, and thetool carousel air door and the tool carousel air door switchindicates that the door is open after commanded to be close...

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    61ALARMSJune 200296-8100 rev E292 320V Power Supply FaultIncomming line voltage is above maximum. The servo will beturned off and the spindle, tool changer, and coolant pump willstop. If this persists, an automatic shutdown will begin after theinterval specified by parameter 296.293 Invalid Chamf...

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    62ALARMSJune 200296-8100 rev E313 No P Code In M97, M98, or G65In M97, M98 or G65 a subprogram number must be put in the Pcode. G47 must have P0 for text engraving or P1 for sequentialserial numbers.314 Subprogram or Macro Not In MemoryCheck that a subroutine is in memory or that a macro is defin...

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    63ALARMSJune 200296-8100 rev E337 GOTO or P line Not FoundSubprogram is not in memory, or P code is incorrect, or a P valueis not found338 Invalid IJK and XYZ in G02 or G03There is a problem with circle definition; check your geometry.339 Multiple CodesOnly one M, X, Y, Z, A, Q etc. allowed in an...

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    64ALARMSJune 200296-8100 rev E362 Tool Usage Alarm RESET.Tool life limit was reached. To continue, reset the usage count inthe Current Commands display and press363 Coolant Locked OffOverride is off and program tried to turn on coolant.364 No Circ Interp Aux AxisOnly rapid or feed is allowed with...

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    65ALARMSJune 200296-8100 rev E390 No Spindle SpeedS code has not been encountered. Add an S code.391 Feature DisabledAn attempt was made to use a control feature not enabled by aparameter bit. Set the parameter bit to 1.392 B Axis DisabledAn attempt was made to program the B-axis while it wasdisa...

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    66ALARMSJune 200296-8100 rev E414 RS-232 Buffer OverflowData sent too fast to CNC. This alarm is not normally possibleas this control can keep up with 115200 bits per second.Computer sending data may not respond to X-OFF415 RS-232 OverrunData sent too fast to CNC. This alarm is not normally possi...

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    67ALARMSJune 200296-8100 rev E505 Value Stack ErrorThe macro expression value stack pointer is in error. Call yourdealer.506 Operand Stack ErrorThe macro expression operand stack pointer is in error. Call yourdealer.507 Too Few Operands On StackAn expression operand found too few operands on thee...

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    68ALARMSJune 200296-8100 rev E528 Parameter Precedes G65On G65 lines all parameters must follow the G65 G-code. Placeparameters after G65.529 Illegal G65 ParameterThe addresses G, L, N, O, and P cannot be used to passparameters.530 Too Many I, J, or K’s In G65Only 10 occurrences of I, J, or K ca...

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    69ALARMSJune 200296-8100 rev E616 U Motor Over HeatSame as alarm 135.617 V Motor Over HeatSame as alarm 135.618 W Motor Over HeatSame as alarm 135.619 U Motor Z FaultSame as alarm 139.620 C Axis DisabledParameters have disabled this axis621 C Over Travel RangeC-axis will exceed stored limits. Thi...

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    70ALARMSJune 200296-8100 rev E629 Carousel Position TimeoutThis alarm supports the side mount tool changers. It isgenerated if the tool carousel has not moved after the allowedtime or has not stopped after the allowed time specified byparameter 60 TURRET START DELAY and parameter 61TURRET STOP DE...

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    71ALARMSJune 200296-8100 rev E638 APC-Door Not OpenThe automatic door did not open (in the allowable time), or mayhave fallen during an APC function. This can be caused by a badair solenoid, a blocked or kinked air line, or a mechanicalproblem. After correcting the condition, run an M50 to contin...

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    72ALARMSJune 200296-8100 rev E647 RP-UP/DOWN Switch Illegal Condition, Lift CylinderThe switches that sense the lifted and lowered position of thepallet changer are indicating the impossible condition that thepallet changer is both lifted and lowered at the same time. Checkthe function of the lif...

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    73ALARMSJune 200296-8100 rev E659 V PHASING ERRORSame as alarm 217.660 W PHASING ERRORSame as alarm 217.661 U TRANSITION FAULTSame as alarm 224.662 V TRANSITION FAULTSame as alarm 224.663 W TRANSITION FAULTSame as alarm 224.664 U AXIS DISABLEDSame as alarm 336.665 V AXIS DISABLEDSame as alarm 336...

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    74ALARMSJune 200296-8100 rev E693 W AXIS DRIVE FAULTSame as alarm 161.694 ATC SWITCH FAULTConflicting switch states detected, such as shuttle at spindle andshuttle at chain simultaneously. Check for damaged or stickingswitches, damaged wiring, or debris build up.695 ATC AIR CYLINDER TIME OUTThe A...

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    75ALARMSJune 200296-8100 rev E907 APC-SWITCH MISSED PAL 3Pallet #3 did not return from the receiver to the APC in theallowable amount of time. This can be caused by the chainswitch block missing the limit switch, or from anothermechanical problem, such as clutch slippage.908 APC-SWITCH MISSED PAL...

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    76ALARMSJune 200296-8100 rev E1003 Pallets JammedThe lift cylinder has not moved from the clockwise position withinthree seconds, or has not reached the counter clockwiseposition within twelve seconds.1004 CW/CCW Switch Illegal ConditionOne or both of the switches that sense the rotational positi...

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    MECHANICAL SERVICE7796-8100 rev EJune 20023. 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 SERVICE7896-8100 rev EJune 20023. Pull front cover from the bottom until you can disconnect the tool release cable (quick disconnect),then remove cover .4. Remove the side covers. Jog Z-axis as necessary to make screw removal easier.INSTALLATION -1. Protect table surface with a piece ...

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    MECHANICAL SERVICE7996-8100 rev EJune 20023.2 TOOL RELEASE PISTON (TRP) ASSEMBLYPlease read this section in its entirety before attempting to replace tool release pistonassembly.OverviewThe Tool Release Piston is actuated by air. It forces the Tool Draw Bar down against the spring stack, releasin...

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    MECHANICAL SERVICE8096-8100 rev EJune 2002CAUTION3/8" - 16 X 1 3/4" SHCSTSC Fitting(Optional)3/8" Air HoseFitting1/4" Air HoseFittingUnclampswitchClampswitchFigure 3.2-1 Tool Release Piston with Optional TSC fitting.Figure 3.3-2 Mounting location for tool release piston assembly

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    MECHANICAL SERVICE8196-8100 rev EJune 200240 TAPER SPINDLE TRP INSTALLATIONThe following sections must be completed after installation:• Set Pre-Charge• Adjust the Tool Clamp/Unclamp Switches• Set the Drawbar Height1. Ensure drive belt has been properly replaced as described in "Belt Asse...

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    MECHANICAL SERVICE8296-8100 rev EJune 2002SPINDLELOCKEDSTATUSSWITCHWITHOUTGEARBOXHIGHGEARSTATUSSWITCHLOWGEARSTATUS SWITCHJUMPERWITHOUTGEARBOXTOOLCLAMPEDSTATUSSWITCHFigure 3.2-3. Air pressure regulator adjustment knob.11. Ensure Parameter 149, Precharge DELAY, is set to 300. If not, set it at thi...

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    MECHANICAL SERVICE8396-8100 rev EJune 2002Aluminum BlockTool HolderSheet ofpaperFigure 3.2-4 Placement of aluminum block under spindle.3. Power on the VMC.4. Insert a tool holder WITHOUT ANY TYPE OF CUTTER into the spindle taper.5. Go to the HANDLE JOG mode. Choose Z-axis and set jog increments t...

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    MECHANICAL SERVICE8496-8100 rev EJune 2002SETTING DRAWBAR HEIGHT1. Press MDI and turn hand wheel to zero (0).2. Press HANDLE JOG button and set increments to .01. Jog the Z-axis in the positive (+) direction0.100".3. Press and hold the TOOL RELEASE button, grasp the block and try to move it...

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    MECHANICAL SERVICE8596-8100 rev EJune 20023. Remove tool release bolt. If machine is equipped with TSC, loosen the three set screws andremove the TSC coolant tip.4. Add or subtract required shim washers (See previous section for correct amount to add or remove).5. Before installing tool release b...

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    MECHANICAL SERVICE8696-8100 rev EJune 20026. Check the adjustment. The switch must trip (DB OPN =1) at 0.06" above the block and not trip(DB OPN =0) at 0.05" above the block.7. Re-adjust and repeat steps 1-6 if necessary.8. Set the pressure regulator back to 85PSI.UPPER (CLAMP) SWITCH ...

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    MECHANICAL SERVICE8796-8100 rev EJune 200250 TAPER SPINDLE TRP REMOVAL1. For TSC equipped machines, place a tool holder in the spindle.2. Remove cover panels from the headstock area in accordance with "Head Covers Removal andInstallation".3. For TSC equipped machines the rotary union an...

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    MECHANICAL SERVICE8896-8100 rev EJune 2002O' Ring Replacement1. Remove and replace the 4 O'rings (57-0027) on the TRP 50T shaft2. Remove and replace the 2 O'rings (57-0092) on the TRP 50T piston, 1 O'ring per piston.3. Remove and replace the 3 O'rings (57-0095). 2 in the center of the TRP 50T ho...

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    MECHANICAL SERVICE8996-8100 rev EJune 2002Figure 3-10.. Shim and spacer location diagram.1. Place the TRP on the machine. The TRP will rest on the spindle lift fork. Caution: Be careful of thespindle lift fork. Place the assembly toward the front of the machine before lowering it. The assem-bly i...

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    MECHANICAL SERVICE9096-8100 rev EJune 2002Purge AirHoseCheckValveAssyDrain hoseHigh PressureCoolant HoseRotatingUnionExtensionTubeTRP a)Put a tool holder in the Spindle (this is absolutely required!). b)Prevent Spindle from rotating to allow for tightening of Extension Tube (inserting a bolt int...

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    MECHANICAL SERVICE9196-8100 rev EJune 2002TOOL PUSH OUT ADJUSTMENT1. Put tool holder in spindle.2. Place machined aluminum block onto machine table. Place a clean sheet of paper under the blockto protect the table.Aluminum BlockTool HolderSheet ofpaperFigure 3.2-9 Pushout Adjustment.3. Jog Z-Axis...

  • Page 93

    MECHANICAL SERVICE9296-8100 rev EJune 20024. 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, and feel for movement in the alu...

  • Page 94

    MECHANICAL SERVICE9396-8100 rev EJune 2002SETTING TRP SWITCHES Figure 3.2-12 Tool Clamp / Unclamp Switches.1. Setting the upper switch (Tool Clamped). Push the switch in slowly until it trips, then push it a littlefarther. Lock down the screws. Double-Check the switch by turning on the TRP a few ...

  • Page 95

    MECHANICAL SERVICE9496-8100 rev EJune 2002COOLANT UNIONCAUTION:Do not remove pipe connectors from the coolant union!! Removingany pipe connector from the union will void your warranty on the union.Use wrenches only on the SAE hose connector and the bottom nutof the Coolant Union. See arrows belo...

  • Page 96

    MECHANICAL SERVICE9596-8100 rev EJune 2002EXTENSION TUBESpecial Tools Required:• 5/8 Allen Wrench• Molybdenum Grease• Wrench or Pliers large enough to tighten a 2” nut.1) Place a Tool Holder in the Spindle.2) Remove the Rotating Union.3) Remove the old Extension Tube (It has left hand threads...

  • Page 97

    MECHANICAL SERVICE9696-8100 rev EJune 200210) Lightly grease the O-Ring on the end of the Extension Tube Assy (30-1242). Apply blue Loctite tothe thread on the end. Insert the Extension Tube down into the Drawbar. Tighten by hand as far aspossible (It has left hand threads).11) Block Spindle rot...

  • Page 98

    MECHANICAL SERVICE9796-8100 rev EJune 20023.3 BELT ASSEMBLYPlease read this section in its entirety before attempting to replace the drive belt.BELT REMOVALNOTE: For easier removal, place transmission in high gear before beginning.1. Remove cover panels from headstock area in accordance with &quo...

  • Page 99

    MECHANICAL SERVICE9896-8100 rev EJune 2002ShifterDriveBeltSpindlePulleyHeadCastingTransmission(Except VF-0)Figure 3.3-2 Head casting area showing belt location.4. Remove the inspection cover from the bottom of the spindle head casting and carefully slide thedrive belt between the sump tank and t...

  • Page 100

    MECHANICAL SERVICE9996-8100 rev EJune 20025. Double-check the spindle sweep to assure that nothing has moved during the previous steps. Ifsweep is within tolerance, continue; if not, sweep must be readjusted.NOTE: Drive belt tension must be adjusted after every installation.TENSION ADJUSTMENTNOTE...

  • Page 101

    MECHANICAL SERVICE10096-8100 rev EJune 2002Outer TubePlungerBelt Tension ToolFigure 3.3-3 Belt tension tool.FOR DIRECT DRIVE MACHINES:1. 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.2. Set the belt t...

  • Page 102

    MECHANICAL SERVICE10196-8100 rev EJune 20023.4 SPINDLE ASSEMBLYPlease read this section in its entirety before attempting to replace spindle.WARNING!The current pulley is shrink-fitted onto the spindle and is not field-serviceable. It is identified by many holes on top of the spindle pulley.Shoul...

  • Page 103

    MECHANICAL SERVICE10296-8100 rev EJune 2002Wood BlockCoveredTable6" min.Z-AxisFigure 3.4-1. Position wood block under spindle.12. At the panel, go to the JOG mode and choose Z-axis. Slowly jog in the negative (-) direction untilthe spindle rests on the block, then remove the screws that wer...

  • Page 104

    MECHANICAL SERVICE10396-8100 rev EJune 2002SPINDLE CARTRIDGE INSTALLATIONTool DrawbarSpindlePulleySpindleHousingFigure 3.4-2. Spindle cartridge.1. Thoroughly clean all mating surfaces of both the cartridge and the head casting, lightly stone ifnecessary to remove burrs or high spots.2. Place spin...

  • Page 105

    MECHANICAL SERVICE10496-8100 rev EJune 20024. If the spindle moves to one side, use a rubber mallet and/or jog in the X or Y directions tostraighten it. The spindle must go in easy. If it does not, check your alignment. Do not force it!5. Install and torque the six SHCS.6. Reattach the brass fit...

  • Page 106

    MECHANICAL SERVICE10596-8100 rev EJune 20028. Angle the transmission back and remove the drawbar from the spindle.NOTE: Direct drive machines do not require movement of the drive assembly toaccess/remove the drawbar.INSTALLATION -9. Thoroughly coat the replacement drawbar with grease, including t...

  • Page 107

    MECHANICAL SERVICE10696-8100 rev EJune 2002DRAWBAR REPLACEMENT - 50 TAPER1. Remove the head covers. Refer to the “Head Covers Removal / Installation” section.2. Remove the tool release piston. Refer to the “50 Taper Spindle TRP Removal” section.3. Remove the TSC extension tube if the machine...

  • Page 108

    MECHANICAL SERVICE10796-8100 rev EJune 2002Figure 3.4-4 Spindle sweep area3. Shim the spindle if necessary to correct the spindle sweep to specifications.4. Recheck sweep. It must be within .0005 in both X/Z and Y/Z planes, as stated in the inspectionreport supplied with the VMC.5. Replace the To...

  • Page 109

    MECHANICAL SERVICE10896-8100 rev EJune 20023.5 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.Orientation of the spindle is automatically performed for tool changes and...

  • Page 110

    MECHANICAL SERVICE10996-8100 rev EJune 2002Figure 3.5-2 Direct drive 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 compen-sate for this backlash when performing the adjustment.8. Using a 5/8" open end w...

  • Page 111

    MECHANICAL SERVICE11096-8100 rev EJune 20023.6 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 ...

  • Page 112

    MECHANICAL SERVICE11196-8100 rev EJune 2002Figure 3.6-2 Screen showing calculator.7. Take the number in the Z-axis machine display (center left of page) and multiply it by Parameter33, which is Z RATIO (STEPS/UNIT).If Z-axis work display is negative (-), add the number to the number that you calc...

  • Page 113

    MECHANICAL SERVICE11296-8100 rev EJune 20023.7 SPINDLE MOTOR & TRANSMISSIONPlease read this section in its entirety before attempting to remove or replace transmission.NOTE: The drive belt tension should be adjusted after every service on the transmis-sion or spindle.MOTOR REMOVAL (DIRECT DR...

  • Page 114

    MECHANICAL SERVICE11396-8100 rev EJune 20029. Remove the four SHCS and carefully lift the spindle motor assembly off the spindle head. Takecare to not damage the drive pulley during removal.NOTE: It is recommended that the HAAS Transmission Hoist be used in this operation(Refer to the "Hoist...

  • Page 115

    MECHANICAL SERVICE11496-8100 rev EJune 2002HOIST PRE-ASSEMBLY1. Attach the mast support to the support base, using the four 3/8-16 x 1¼" SHCS, four 3/8" flatwashers, four split washers, and the four 3/8-16 hex nuts. Ensure the bolts are securely tightened.2. Attach the boom modificati...

  • Page 116

    MECHANICAL SERVICE11596-8100 rev EJune 20023. 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 thepulley wheel.2) Wipe a thin coat of oil on the entire cable.3) Lubricate all clevis ...

  • Page 117

    MECHANICAL SERVICE11696-8100 rev EJune 2002Figure 3.7-5 View of transmission lift fixture.TRANSMISSION REMOVALNOTE: This procedure is not for direct drive machines.1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the transmis-sion. At this time, raise the Z-axis...

  • Page 118

    MECHANICAL SERVICE11796-8100 rev EJune 2002Figure 3.7-6 Solenoid bracket with all lines connected.8. Remove the two SHCS holding the cable carrier to the solenoid bracket and position the cablecarrier so as to not interfere with the transmission removal. It may be necessary to tie the cablecarrie...

  • Page 119

    MECHANICAL SERVICE11896-8100 rev EJune 200210. With the boom modification plate in place, insert the mast into the mast support. Using the twoclevis pins, attach the boom to the mast.Figure 3.7-8 Mounting boom assembly to mast.11. Place the hoist directly over the transmission and attach the hoo...

  • Page 120

    MECHANICAL SERVICE11996-8100 rev EJune 2002Figure 3.7-10 Lifting position for VF-1 through 4.13. For VF-1-4: Place the hoist hook in the bar's lifting eye and place the two hooks on either end ofthe bar into diagonally opposite lifting holes in the motor shroud. Lift just enough to ensure thehook...

  • Page 121

    MECHANICAL SERVICE12096-8100 rev EJune 20027. Insert and tighten down the six SHCS attaching the transmission to the spindle head. If thesescrews include gearbox isolators, ensure the 3/8" fender washer is NOT touching the gearboxhousing.Figure 3.7-11 Gearbox isolators.8. Adjust the drive b...

  • Page 122

    MECHANICAL SERVICE12196-8100 rev EJune 2002TRANSMISSION AND MOTOR REPLACEMENT - 50 TAPERRemoval1. Lower the Z-axis travel to its full negative value (full down). Position the mill table so that it iscentered on the X-axis and as close to the doors as possible (full -Y). This will allow the bestwo...

  • Page 123

    MECHANICAL SERVICE12296-8100 rev EJune 200213. Remove the Encoder belt and the drive belts.CAUTION! Measure the distance between the bottom of the Z-axis motor and theballscrew anchor mount. Cut a wood block to the proper length and put inplace. This is necessary to counteract the Hydraulic Coun...

  • Page 124

    MECHANICAL SERVICE12396-8100 rev EJune 200212. Lubricate any new or removed parts if necessary. Remove the wood spacer (if used). Check tomake sure all connections are secure.13. Reconnect air and power services. If equipped with TSC, check drawbar for runout. See the“Adjusting Extension Tube Ru...

  • Page 125

    MECHANICAL SERVICE12496-8100 rev EJune 20023.8 AXIS MOTOR REMOVAL / INSTALLATIONPlease read this section in its entirety before attempting to remove or replace the motors.Tool Required•Z-Axis: Cylinder shaft stop (P/N 99-7562 - VF-1 through 4, P/N 93-9962 - VF-6 through 11)X-AXIS MOTOR REMOVAL1...

  • Page 126

    MECHANICAL SERVICE12596-8100 rev EJune 2002INSTALLATION -1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.Figure 3.8-2 Motor coupling components.2. Reinstall and tighten down the four SHCS that hold the motor to the housing.3. Reconnect the motor wiring...

  • Page 127

    MECHANICAL SERVICE12696-8100 rev EJune 2002Y-AXIS MOTOR REMOVAL1. Turn the machine power ON. ZERO RETURN all axes and put the machine in HANDLE JOGmode.2. Move the table to the farthest forward position. Using a 5/32" hex wrench, remove the SHCS on theway cover at the rear of the saddle.3. ...

  • Page 128

    MECHANICAL SERVICE12796-8100 rev EJune 200211. While holding the lube/air panel assembly at the bottom edge, loosen the two SHCS and removethe panel assembly.CAUTION! On machines with only two SHCS, remove one screw at a time. Replace thescrew to hold the cabinet in place before removing the othe...

  • Page 129

    MECHANICAL SERVICE12896-8100 rev EJune 20024. Replace the cover plate and fasten with the four BHCS.5. Replace the lube system panel with the two SHCS that mount it.6. Plug in the limit switch connection and Y-axis connection at the side of the control panel.7. Reconnect the three connections la...

  • Page 130

    MECHANICAL SERVICE12996-8100 rev EJune 20025. a. If the machine is equipped with a hydraulic counterbalance, install cylinder shaft stop (See Fig.3.8-6). HANDLE JOG Z-axis up until shaft stop blocks axis.b. Machine with Brake motors: Position table under the spindle head and insert a 4” x 4” x ...

  • Page 131

    MECHANICAL SERVICE13096-8100 rev EJune 20028. Disconnect electrical power. Caution: If the machine is equipped with a Z-axis brake motor thespindle head may drop slightly.9. On the motor housing, loosen the four SHCS and remove the motor from the housing.10. Disconnect the Z-axis connection from...

  • Page 132

    MECHANICAL SERVICE13196-8100 rev EJune 2002COUPLER REPLACEMENTWARNING! MACHINES WITHOUT A COUNTER BALANCEIf debug is on and the Z -axis is disabled the spindle head will fall. Thisis extremely dangerous and should be avoided at all costs.1. Remove the axis motor in accordance with "Axis Moto...

  • Page 133

    MECHANICAL SERVICE13296-8100 rev EJune 20023.9 LEAD SCREW REMOVAL AND INSTALLATIONPlease read this section in its entirety before attempting to remove or replace the lead screws.TOOLS REQUIRED•Spanner wrench (32 mm or 40/50 mm)•2" x 4" wood block (21"-231/2" long)•Shaft lo...

  • Page 134

    MECHANICAL SERVICE13396-8100 rev EJune 20028. Loosen the 10-32 x ½" SHCS and remove the clamp nut on the lead screw support bearing end.Figure 3.9-2 Lead screw assembly.9. Remove the axis motor in accordance with "X-Axis Motor Removal".NOTE: The motor's electrical connections do n...

  • Page 135

    MECHANICAL SERVICE13496-8100 rev EJune 2002THIS 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 freeof dirt, burrs, grease, ...

  • Page 136

    MECHANICAL SERVICE13596-8100 rev EJune 2002Figure 3.9-4 Bearing sleeve mounting location.6. Insert the six ¼-20 x 1" SHCS attaching the bearing sleeve to the motor housing. (Place a drop ofblue Loctite® on each of the SHCS before inserting.) Tighten to torque specification.CAUTION! Do not ...

  • Page 137

    MECHANICAL SERVICE13696-8100 rev EJune 20029. For 40 and 50 mm lead screws only:•Move the table all the way to the right. Tighten down completely the SHCS that mount the bearing support to the saddle.•Loosen the clamp nut on the bearing support end. Adjust the nut until it seats on the bearing...

  • Page 138

    MECHANICAL SERVICE13796-8100 rev EJune 20025. Remove the motor in accordance with "Y-Axis Motor Removal".NOTE: The motor's electrical connections do not need to be removed for thisoperation. After removing motor from the housing, set it to one side.6. Loosen the 10-32 x 1/2" SHCS a...

  • Page 139

    MECHANICAL SERVICE13896-8100 rev EJune 2002...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 freeof dirt, ...

  • Page 140

    MECHANICAL SERVICE13996-8100 rev EJune 20025. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bear-ings in the sleeve to facilitate mounting on the lead screw.)6. Insert the six ¼-20 x 1" SHCS attaching the bearing sleeve to the motor housing. (Plac...

  • Page 141

    MECHANICAL SERVICE14096-8100 rev EJune 200214. Check for backlash in the lead screw ("Accuracy/Backlash" section) or noisy operation.15. Zero return Y axis and set grid offset.Z-AXIS LEAD SCREW REMOVALMachines are currently equipped with either a hydraulic counterbalance system or an e...

  • Page 142

    MECHANICAL SERVICE14196-8100 rev EJune 2002•Hand-turn the lead screw to move the screw up until the bottom end clears the support bearingby approximately six inches (6").•Remove the SHCS from the ball nut and lower the lead screw down and to the right of the supportbearing, past the Z-axis...

  • Page 143

    MECHANICAL SERVICE14296-8100 rev EJune 20022. If 40 or 50 mm lead screw:• Insert the lead screw into the bearing support. Screw the clamp nut on a few turns.• Insert the lead screw, with the bearing support attached, into place on the column. Ensure the lead screw goes through the ball nut hou...

  • Page 144

    MECHANICAL SERVICE14396-8100 rev EJune 20027. The following sequence is important to ensure proper installation of the lead screw:•Tighten the clamp nut, hand tight, on the motor end.•Install and tighten clamp nut on bearing support. Ensure the nut does not touch the support bearing. It will be...

  • Page 145

    MECHANICAL SERVICE14496-8100 rev EJune 2002MINI MILL LEAD SCREWSReplacement of the mini-mill leadscrews follow the same procedures as the other mills. The leadscrews areonly supported at the motor end, thereby simplifing the alignment procedure.1. Use a standard ballscrew support bearing assembl...

  • Page 146

    MECHANICAL SERVICE14596-8100 rev EJune 20023.10 BEARING SLEEVE REMOVAL AND INSTALLATIONPlease read this section in its entirety before attempting to remove or replace the bearing sleeve.TOOLS REQUIRED• Spanner wrench• Pre-load fixture• Wood block (16" long)• Z-Axis: Cylinder shaft stop (...

  • Page 147

    MECHANICAL SERVICE14696-8100 rev EJune 20026. Loosen the six ¼-20 x 1" SHCS and remove the bearing sleeve from the motor housing. Push onthe mill table or the opposite end of the lead screw to loosen.CAUTION! Do not pry the bearing sleeve away from the housing. Damage to the sleeve,bearing...

  • Page 148

    MECHANICAL SERVICE14796-8100 rev EJune 20027. Loosen the six ¼-20 x 1" SHCS attaching the bearing sleeve to the motor housing and retightencompletely. DO NOT SKIP THIS STEP. It ensures the lead screw is installed and runs parallel andflat to the linear guides and the saddle.NOTE: For the an...

  • Page 149

    MECHANICAL SERVICE14896-8100 rev EJune 20023. Move the table to the rear of its travel.4. Tighten the six ¼-20 x 1" SHCS that attach the bearing sleeve to the motor housing.5. Loosely install the clamp nut on the lead screw at the motor housing endNOTE: For the angular contact design beari...

  • Page 150

    MECHANICAL SERVICE14996-8100 rev EJune 2002Figure 3.10-3 Z-axis bearing sleeve.9. Perform Steps 6-10 of "Z-Axis Motor Removal".NOTE: The motor's electrical connections do not need to be removed for thisoperation. After removing from motor housing, set it to one side.10. Loosen the 10-32...

  • Page 151

    MECHANICAL SERVICE15096-8100 rev EJune 20023. Tighten the six ¼-20 x 1" SHCS that attach the bearing sleeve to the motor housing.4. Loosely install the clamp nut on the lead screw at the motor housing end.5. Reinstall the hard stop on the bearing housing end of the lead screw.NOTE: For the...

  • Page 152

    MECHANICAL SERVICE15196-8100 rev EJune 20023.11 AUTOMATIC TOOL CHANGER1. Toolchanger Trap Door2. Loc Nut Elastic3. Washer4. Nylon Washer5. Vertical Axle6. 2 Pin Geneva Star7. Bearing Housing8. Extractor Key9. Extractor Spring10. Extractor Finger11. 20 Pocket Carousel12. Toolchanger Door Spring13...

  • Page 153

    MECHANICAL SERVICE15296-8100 rev EJune 2002CARRIAGE CASTING REPLACEMENTTOOLS REQUIRED• Two-jaw puller• Hydraulic jack• 1-2-3 Block• CardboardNOTE: If the carriage casting is damaged in a crash, it must be replaced. Lookspecifically for broken bosses where the roller bolts mount to the castin...

  • Page 154

    MECHANICAL SERVICE15396-8100 rev EJune 20024. Carefully remove the damaged roller bolt from the ATC shuttle and replace with a new bolt.NOTE: REPLACE ONLY ONE ROLLER BOLT AT A TIME. Carefully inspect the V-grooverollers for roughness or damage, and replace if necessary.5. Tighten the eccentric lo...

  • Page 155

    MECHANICAL SERVICE15496-8100 rev EJune 20024. Move the entire tool changer until the tool alignment key lines up with the spindle dog. Tighten thefour HHB.NOTE: Parameter 64 must be checked, and adjusted if necessary, when the ATC isaligned.5. Make at least 50 tool changes after the alignment is...

  • Page 156

    MECHANICAL SERVICE15596-8100 rev EJune 2002EXTRACTOR FORK REPLACEMENTNOTE: Extractor forks that do not hold the tool holders firmly, or forks that are bent,must be replaced. Damage to the ATC will result if not replaced.1. With no tool holders in the spindle or in the ATC, command "ATC FWD&q...

  • Page 157

    MECHANICAL SERVICE15696-8100 rev EJune 2002SLIDING COVER REPLACEMENTNOTE: If any of the sliding covers on the ATC do not slide freely or are bent in a crash,they must be replaced.1. Loosen the four screws that attach the sliding panel cover to the carousel. Be careful to not losethe spring that ...

  • Page 158

    MECHANICAL SERVICE15796-8100 rev EJune 2002Figure 3.11-4 Wiring harness for shuttle motor.9. Remove the four FHCS attaching the shuttle motor to the holding plate on the tool changer. TheFHCS are visible from the front of the VMC. Do not remove the HHBs holding the shuttle motorgear box together....

  • Page 159

    MECHANICAL SERVICE15896-8100 rev EJune 20024. Reattach the slip clutch assembly to the shuttle motor shaft. Before placing on the shaft, put twoor three drops of red Loctite® on the slip clutch hub.5. Insert and tighten down the set screw holding the slip clutch assembly to the shuttle motor sh...

  • Page 160

    MECHANICAL SERVICE15996-8100 rev EJune 20028. 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.All gear motors should be returned to Haas for evaluation and rebuilding.INSTALLATION -1. Grease t...

  • Page 161

    MECHANICAL SERVICE16096-8100 rev EJune 2002Figure 3.11-7 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 - AU...

  • Page 162

    MECHANICAL SERVICE16196-8100 rev EJune 2002GENEVA STAR REPLACEMENTNOTE: If the ATC Geneva star is damaged or worn in its driven slots, it must bereplaced.1. Turn the machine power off.2. Remove the cover from the front of the ATC shuttle.3. Remove the turret motor assembly (Refer to previous sect...

  • Page 163

    MECHANICAL SERVICE16296-8100 rev EJune 2002GRID 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 164

    MECHANICAL SERVICE16396-8100 rev EJune 20023.12 40 TAPER CAROUSEL SIDE MOUNT TOOL CHANGERSpecial Tools Required: • Lifting Device (1000lb capacity for ATC removal)• Spanner Wrench

  • Page 165

    MECHANICAL SERVICE16496-8100 rev EJune 200240 TAPER CAROUSEL REMOVAL AND INSTALLATIONRemoval:Figure 3.12-1 ATC Assembly, Carousel Removal1. Power Off machine.2. Unscrew the BHCS from the carousel number disc and remove. Refer to Figure 3.12-1.3. Using a spanner wrench, remove nut on the center s...

  • Page 166

    MECHANICAL SERVICE16596-8100 rev EJune 2002Installation:1. Carefully lift and place carousel on to the center shaft.2. Install new carousel retaining nut on to the ATC center shaft and torque to 85 ft-lbs (place thelocking portion of the nut towards the end of the shaft). Remove the pocket stop a...

  • Page 167

    MECHANICAL SERVICE16696-8100 rev EJune 200250 TAPER CAROUSEL REMOVAL AND INSTALLATIONRemovalCAUTION! Do not attempt to remove the carousel with the pockets installed.1. Remove sheetmetal disc covering the carousel. Press <TOOL CHANGER RESTORE>. Press <Y>three times to enter Tool Chan...

  • Page 168

    MECHANICAL SERVICE16796-8100 rev EJune 20026. Lower the ATC assembly with the back side of the cam box towards the ground. See Figure 3.12-5. Figure 3.12-5 ATC Assembly Lifting Position Figure 3.12-6 ATC Mounting BracketInstallation:1. Power Off machine.2. Clean mounting surfaces of the ATC m...

  • Page 169

    MECHANICAL SERVICE16896-8100 rev EJune 2002ATC ALIGNMENTThis procedure is for a newly mounted ATC assembly without the double-arm installed.Cam Box to Tool Pocket Alignment:1. Remove all cam box sheet metal fasteners and covers. Place protective covers on the machinetable.2. Power Up machine. Ra...

  • Page 170

    MECHANICAL SERVICE16996-8100 rev EJune 2002Figure 3.12-8 Airline connection location6. At the top of the ATC assembly, manually rotate the cam box pulley clockwise until the outputshaft is lowered and just before it begins to rotate 1800.7. Align the double-arm underneath the tool pocket and the ...

  • Page 171

    MECHANICAL SERVICE17096-8100 rev EJune 2002Figure 3.12-9 Cam Box / Double Arm Alignment, top view.Checking Parallelism of Double-arm to Table:13. Rotate the cam box pulley clockwise to lower the double arm. Remove the tool holder from thedouble arm.14. Rotate the cam box pulley counter-clockwise...

  • Page 172

    MECHANICAL SERVICE17196-8100 rev EJune 200223. Return the double-arm to the home position.Double-Arm to Spindle Alignment:1. ZERO RETURN the Z-axis.2. In TCR mode, lower the double arm and re-insert the short tool holder without pull stud into thedouble arm. Orient the spindle dogs for a tool cha...

  • Page 173

    MECHANICAL SERVICE17296-8100 rev EJune 20026. Insert a pry-bar between the locating pins and the ATC mounting bracket. Adjust the bracket toalign the tool holder in the double arm to the center of the spindle in the X-axis. Refer to Figure3.12-11.7. Torque the SHCS to 80 ft-lbs.8. Check the Y-ax...

  • Page 174

    MECHANICAL SERVICE17396-8100 rev EJune 2002Figure 3.12-13 Spindle Orientation SettingDOUBLE ARM REMOVAL AND INSTALLATIONRemoval1. In TCR mode, lower the double arm. POWER OFF machine.2. Underneath the double-arm, loosen the six SHCS from the lock ring. Insert four new jack screwsinto the lock ri...

  • Page 175

    MECHANICAL SERVICE17496-8100 rev EJune 2002Installation1. Place the double-arm onto output shaft. Align the double-arm to the home position, then slide thelock ring onto the shaft.2. Reattach the lock ring to the double-arm with six (6) SHCS. Verify the slides are correctly adjustedon the double...

  • Page 176

    MECHANICAL SERVICE17596-8100 rev EJune 200240 TAPER SMTC POCKET REMOVAL AND INSTALLATIONRemoval1. Turn the machine on and rotate the carousel to the pocket you want to change. Remove thesheetmetal in order to gain access to pocket limit switches. Remove the sheetmetal disc coveringthe carousel.2....

  • Page 177

    MECHANICAL SERVICE17696-8100 rev EJune 2002Installation7. Replace the damaged pocket with a new one. Apply grease to the shaft. Install the pocket slideand pocket into the carousel. Apply a drop of Red Loctite to the pocket retaining screw and install.Torque to 14 ft./lbs.8. Clear all alarms. Re...

  • Page 178

    MECHANICAL SERVICE17796-8100 rev EJune 2002Installation1. Replace the damaged pocket with a new one. Apply grease to the shaft. Install the pocket into thepocket slide fingers. Apply a drop of Blue Loctite to the pocket retaining screw and install. Torqueto 23 ft./lbs. Reconnect air to the machin...

  • Page 179

    MECHANICAL SERVICE17896-8100 rev EJune 20024. Tighten set-screw lock nut.Figure 3.12-15 Tool Pocket Orientation / Set-Screw AdjustmentPROXIMITY SWITCH REMOVAL / INSTALLATIONRemoval1. Power Off machine. Remove the carousel number disc and the top cover plate.2. Remove the 1/4”NPT plug near the ...

  • Page 180

    MECHANICAL SERVICE17996-8100 rev EJune 2002InstallationThe proximity trigger disk inside the cam box determines the sensor operation. The sensor must be approxi-mately .030” away from a flat surface on the disk to function properly. An L.E.D. light will come on at the backof the sensor when it i...

  • Page 181

    MECHANICAL SERVICE18096-8100 rev EJune 2002SETTING PARAMETER 64On a Vertical mill: For Z-axis; displacement from home switch to tool change position and machine zero. Onmachines eqipped with 40 taper or 50 taper side mount tool changers this distance is:(Distance from Home in Inches) X (Line Enc...

  • Page 182

    MECHANICAL SERVICE18196-8100 rev EJune 2002Example: 40 Taper SMTC(Difference in Z-axis encoder counts) + (Old Z-axis Tool Change Setting) = New Z-axis Tool Setting20681 + 861699 = 8823808. Enter PARAMETERS page. UNLOCK settings and write new setting value for Parameter 64. LOCKparameter settings....

  • Page 183

    MECHANICAL SERVICE18296-8100 rev EJune 20023.13 ENCLOSURE REPLACEMENTPlease read this section in its entirety before attempting to replace the doors or windows.TOOLS REQUIRED•Trim installation tool (dull-edged knife or caulking spatula)DOOR REPLACEMENTCAUTION! If possible, have two people perfo...

  • Page 184

    MECHANICAL SERVICE18396-8100 rev EJune 2002Figure 3.13-1 Roller/roller guide assembly.DOOR ADJUSTMENTS -10. Close both doors and check that the vertical gap between them is uniform. If it is not:•Determine which door must be adjusted.•Loosen the door's outer lower roller attachment and pivot th...

  • Page 185

    MECHANICAL SERVICE18496-8100 rev EJune 200211. Check the gap between the door and the front panel flange, and verify it is 5/8" throughout thetravel of the door. If it is not:•Loosen the door's upper roller fasteners and tilt the door forward or back, as necessary, toadjust door position.F...

  • Page 186

    MECHANICAL SERVICE18596-8100 rev EJune 2002Figure 3.13-4 Cross-section of window seal.INSTALLATION -1. Replace the seal around the enclosure's cutout, with the locking tab facing the inside of themachine.2. Replace the window panel into the seal. The tool can be placed between the window panel an...

  • Page 187

    MECHANICAL SERVICE18696-8100 rev EJune 20023.14 HYDRAULIC COUNTERBALANCETOOLS REQUIRED•(1) 4 x 4 x 14" head support block•Hydraulic counterbalance service kit, consists of:•Pressure tank with manifold assembly, prefilled with (2) quarts DTE-25 hydraulic oil•Hydraulic cylinder with hose ...

  • Page 188

    MECHANICAL SERVICE18796-8100 rev EJune 20025. 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 maytake up to 10 minutes. Verify ta...

  • Page 189

    MECHANICAL SERVICE18896-8100 rev EJune 2002HYDRAULIC 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 thespindle head.3. Remove the cotter pin and lock nuts from ...

  • Page 190

    MECHANICAL SERVICE18996-8100 rev EJune 20024. Remove the band clamp that holds the cylinder to the stabilizer bracket. Loosen the two SHCSthat attach the bracket to the column.5. Remove the hydraulic cylinder from the top of the column.Figure 3.14-4 VF-Series hydraulic counterbalance - right side...

  • Page 191

    MECHANICAL SERVICE19096-8100 rev EJune 2002NOTE: Do not disassemble unit. Keep the hose attached to the cylinder.6. Return complete assembly to HAAS Automation.INSTALLATION-1. Install cylinder with cylinder rod extended from top of column.NOTE: Cylinder rod should pass through column bracket and...

  • Page 192

    MECHANICAL SERVICE19196-8100 rev EJune 20023.15 THROUGH THE SPINDLE COOLANT SYSTEM - ADJUSTMENTSTOOLS REQUIRED•Tool holder with small TSC drill or restrictor (with a small orifice #T-1461)•TSC Gauge Kit (P/N 93-9011), includes:0-15 PSI Precharge pressure gauge0-160 PSI Purge pressure gauge (Not...

  • Page 193

    MECHANICAL SERVICE19296-8100 rev EJune 2002CHECKING 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...

  • Page 194

    MECHANICAL SERVICE19396-8100 rev EJune 20023.16 AIR / OIL LINE DIAGRAM

  • Page 195

    MECHANICAL SERVICE19496-8100 rev EJune 2002THROUGH THE SPINDLE COOLANTSYSTEM FLOW DIAGRAM - 40 TAPER SPINDLEAT BOTTOM REAR OF SPINDLE HEADPARAMETER 237 (TSC CLNT LINE PURGE)THE TSC PUMP IS A PRECISION GEAR PUMP AND WILL WEAR OUT FASTER AND LOSEREAR OF GEAR BOX/SPINDLE MOTOR ASSEMBLYON TOOL RELEA...

  • Page 196

    MECHANICAL SERVICE19596-8100 rev EJune 2002THROUGH THE SPINDLE COOLANTSYSTEM FLOW DIAGRAM - 50 TAPER SPINDLETHE TSC PUMP IS A PRECISION GEAR PUMP AND WILL WEAR OUT FASTER AND LOSEWHEN MACHINING CASTINGS, SAND FROM THE CASTING PROCESS AND THE ABRASIVE PROPERTIES OFCAST ALUMINUM AND CAST IRON WILL ...

  • Page 197

    MECHANICAL SERVICE19696-8100 rev EJune 20023.17 AUTOMATIC PALLET CHANGER (APC)PALLET REPLACEMENTTOOLS REQUIRED:•Hoist•Straps or Chains•Eyebolts (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 r...

  • Page 198

    MECHANICAL SERVICE19796-8100 rev EJune 2002PALLET CLAMP RAIL REPLACEMENTTOOLS REQUIRED:•Hoist•Straps or Chains•Eyebolts (2)NOTE: This procedure must be performed with the pallets on the APC.1. Loosen the clamp rail bolts.2. Screw the eyebolts into place and lift the pallet carefully.3. Remove ...

  • Page 199

    MECHANICAL SERVICE19896-8100 rev EJune 2002ALIGNMENT PIN REPLACEMENTTOOLS REQUIRED:•Hoist•Straps or Chains•Eyebolts (2)CAUTION! Be careful when changing out pallets, each weighs approx. 300lbs.NOTE: The receiver must be removed in order to access the alignment pins.1. Both pallets must be on ...

  • Page 200

    MECHANICAL SERVICE19996-8100 rev EJune 20029. Reconnect the air to the machine.10. Position a pallet onto the receiver and clamp/unclamp the pallet to the receiver several times.Check for the pallets sticking during this process. If the pallets are sticking, loosen the clamp railbolts and clamp/u...

  • Page 201

    MECHANICAL SERVICE20096-8100 rev EJune 2002LOOSENING THE CHAIN5. Remove the two screws that mount the coverplate over the sprocket located at the far end of theAPC as shown.Figure 3.17-5 Loosening Chain Sprocket6. Loosen the 4 bolts that mount the sprocket bracket to the casting.7. Loosen the ch...

  • Page 202

    MECHANICAL SERVICE20196-8100 rev EJune 2002APC PALLETSThere are two different designs of pallets for use with the APC. This difference in design is for locating the palleton to the receiver. The earlier method uses two friction blocks to slow the pallet and locate it correctly as itenters the mac...

  • Page 203

    MECHANICAL SERVICE20296-8100 rev EJune 2002AIR LUBRICATION PANELLube Air PanelAIR REGULATOR SERVICINGCAUTION: Disconnect or shut off air supply and exhaust the primary and secondarypressure before servicing unit. Turning the adjustment knob counterclock-wise Does Not vent downstream pressure. Do...

  • Page 204

    MECHANICAL SERVICE20396-8100 rev EJune 2002b. Soak the Dump Valve in a mild soap and water mix to clean. Rinse in water and allow to air dry.c. After cleaning the Bowl Assembly reassemble the Dump Valve in the Bowl Assembly. Care should betaken so as not to pinch the O-ring (b). Do not over tight...

  • Page 205

    ELECTRICAL SERVICE20496-8100 rev EJune 20024. 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 r...

  • Page 206

    205ELECTRICAL SERVICE96-8100 rev EJune 2002Figure 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 207

    ELECTRICAL SERVICE20696-8100 rev EJune 2002CAUTION3/8" - 16 X 1 3/4" SHCSTSC Fitting(Optional)3/8" Air HoseFitting1/4" Air HoseFittingUnclampswitchClampswitchFigure 4.2-2 Tool release piston assembly with air solenoid assembly.7. Install the new air solenoid on the air soleno...

  • Page 208

    207ELECTRICAL SERVICE96-8100 rev EJune 2002SPINDLE LUBE AIR SOLENOID1. Turn the machine power off and remove the air supply from the machine.Figure 4.1-3 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 quic...

  • Page 209

    ELECTRICAL SERVICE20896-8100 rev EJune 2002Figure 4.1-5 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 at the quick-disconnect in the w...

  • Page 210

    209ELECTRICAL SERVICE96-8100 rev EJune 20024.2 LINE VOLTAGE ADJUSTMENTSPlease read this section in its entirety before attempting to adjust the line voltage.TOOLS REQUIRED•Large flat tip screwdriver•Digital voltmeterADJUSTING VOLTAGE -NOTE: The machine must have air pressure at the air gauge, o...

  • Page 211

    ELECTRICAL SERVICE21096-8100 rev EJune 2002Figure 4.2-1 Control cabinet general overview.ELECTRICAL 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 ...

  • Page 212

    211ELECTRICAL SERVICE96-8100 rev EJune 2002WARNING!The electrical panel should be closed and the three latches on thedoor should be secured at all times except during installation andservice. At those times, only qualified electricians should have ac-cess to the panel. When the main circuit break...

  • Page 213

    ELECTRICAL SERVICE21296-8100 rev EJune 20023. Check the connections on the transformer at the bottom-right corner of the rear cabinet. The threeblack wires labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds tothe average voltage measured in step 2 above. There ar...

  • Page 214

    213ELECTRICAL SERVICE96-8100 rev EJune 20026. After the power is on, measure the voltage across the upper terminals on the contactor K1 (locatedbelow the main circuit breaker). It should be the same as the measurements where the input powerconnects to the main breaker. If there are any problems, ...

  • Page 215

    ELECTRICAL SERVICE21496-8100 rev EJune 2002The transformer is 480V to 240V isolation transformers with delta wound primary and secondary windings. Theprimary windings offer 7 tap positions, 2 above and 4 below the nominal input voltage of 480V.For domestic installations and all others using 60Hz...

  • Page 216

    215ELECTRICAL SERVICE96-8100 rev EJune 20024.3 FUSE REPLACEMENTPlease read this section in its entirety before attempting to replace any fuses.OVERVOLTAGE FUSEWARNING!The electrical panel will have residual voltage, even after power hasbeen shut off and/or disconnected . Never work inside this ca...

  • Page 217

    ELECTRICAL SERVICE21696-8100 rev EJune 200232-4076G Rev.AFU7C4C3C2C7C6C5C1NE210A 115VMAIN10A 230VCOOLANT10A 115VRTY/USER POWER10A 230VTSC COOLANTSPARE FUSESP1P2P3P4P5P6P7P8P9P10P11P12P13P14P15P16P17P18P19P20P21P22P23P24P25P26P27P28P30P31P32P33P34P35P29TB1TB3TB2NE1NE4FU8FU12 FU11 FU10 FU9NE6NE5NE...

  • Page 218

    217ELECTRICAL SERVICE96-8100 rev EJune 20024. On each of the SERVO DRIVER boards, the fuses (F1, F2, F3) may be replaced by simply pullingout the fuses by hand and replacing with fuses of the same type and rating (F1, F2: 20 amp, typeABC, 250V; F3: 10 amp, type ABC, 250V).Figure 4.3-3 Servo Drive...

  • Page 219

    ELECTRICAL SERVICE21896-8100 rev EJune 20024.4 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 f...

  • Page 220

    219ELECTRICAL SERVICE96-8100 rev EJune 20029. 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, unsc...

  • Page 221

    ELECTRICAL SERVICE22096-8100 rev EJune 2002SERVO DRIVER BOARDS -NOTE: Refer to "Cable Locations" for a diagram of this board.1. Follow all precautions noted previously before working in the electrical cabinet.2. Turn the main switch (upper right of electrical cabinet) to the off positi...

  • Page 222

    221ELECTRICAL SERVICE96-8100 rev EJune 2002POWER & 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 cabinet (See warning atbeginning of "Servo Driver” section...

  • Page 223

    ELECTRICAL SERVICE22296-8100 rev EJune 2002RS-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" section).2. Turn the main switch (u...

  • Page 224

    223ELECTRICAL SERVICE96-8100 rev EJune 2002RS-232 SERIAL INTERFACEThere are two connectors used for the RS-232 interface. The RS-232 connector on the back of most PC's is amale DB-25, so only one type of cable is required for connection to the controller, or between controllers. Thiscable must be...

  • Page 225

    ELECTRICAL SERVICE22496-8100 rev EJune 20024.5. 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...

  • Page 226

    225ELECTRICAL SERVICE96-8100 rev EJune 20028. 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 han...

  • Page 227

    ELECTRICAL SERVICE22696-8100 rev EJune 2002POWER ONCYCLESTART FEED HOLDSPINDLELOADPOWER OFFEMERGENCYSTOPHANDLE +5VBLK+5VREDGNDWHTAREDBGRNGNDWHT/REDAWHT/YELBWHT/BRNAYELBBRNFigure 4.5-3 Jog Handle removalFigure 4.5-4. Jog Handle wiring diagram5. Remove the three screws holding the jog handle enc...

  • Page 228

    227ELECTRICAL SERVICE96-8100 rev EJune 2002SPINDLE LOAD METER REPLACEMENT1. Turn the power off and disconnect power to the machine.2. Remove the 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. Disconn...

  • Page 229

    ELECTRICAL SERVICE22896-8100 rev EJune 20027. 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 cab...

  • Page 230

    229ELECTRICAL SERVICE96-8100 rev EJune 20024.6 SPINDLE ENCODER REPLACEMENTPlease read this section in its entirety before attempting to remove or replace encoder.Removal1. Turn machine power on. Raise or lower spindle head to a position that will allow you to easily workon the encoder (must be ab...

  • Page 231

    ELECTRICAL SERVICE23096-8100 rev EJune 20025. Place the 36-tooth pulley onto the encoder, making the top of the pulley flush with the end of theshaft. Tighten down with the 5/64" hex wrench.6. Unscrew the four screws and remove the cover panel on the box at the base of the flexible tube.7. ...

  • Page 232

    TECHNICAL REFERENCE231June 200296-8100 rev C5. TECHNICAL REFERENCE5.1 TOOL CHANGERTools are always loaded through the spindle and should never be installed directly in the carousel in order toavoid crashes. The pocket open to the spindle must always be empty in the retracted position.Low air pr...

  • Page 233

    232TECHNICAL REFERENCEJune 200296-8100 rev CCAUTION!Do not exceed the Maximum Specifications given below!SIDE-MOUNT TOOL CHANGER SPECIFICATIONS40-Taper VF 0-440-Taper VF 5-1150-Taper VF 550-Taper VF 6-11,VS-3Maximum Tool Diameter3"3"4" 4" with all pockets fullMaximum To...

  • Page 234

    TECHNICAL REFERENCE233June 200296-8100 rev CTURRET ROTATION MOTORA DC brush motor is used to rotate the tool turret between tool changes. This motor is geared down to a lowRPM and connected to a Geneva mechanism. Each 1/2 revolution of the Geneva mechanism moves the toolturret one tool position ...

  • Page 235

    234TECHNICAL REFERENCEJune 200296-8100 rev C5.2 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...

  • Page 236

    TECHNICAL REFERENCE235June 200296-8100 rev C5.3 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 Coo...

  • Page 237

    236TECHNICAL REFERENCEJune 200296-8100 rev CSPINDLE 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 238

    TECHNICAL REFERENCE237June 200296-8100 rev CSPINDLE AIR PRESSUREVerify Spindle air pressure using the gauge located behind the Air Regulator panel. VF machines should show17 psi. Adjust if necessary (see Air Connection in the Installation section). VF machines equipped with a 15Kspindle, must ha...

  • Page 239

    238TECHNICAL REFERENCEJune 200296-8100 rev C5.4 CONTROL CABINET Control cabinet general overview.Connectors on side of control cabinet.

  • Page 240

    TECHNICAL REFERENCE239June 200296-8100 rev C5.5 SERVOS BRUSH / BRUSHLESSSERVO ENCODERSHaas machines are equipped with brushless motors, which provides for better performance, and no mainte-nance. In addition to the performance differences, these machines differ from brush type machines, which ha...

  • Page 241

    240TECHNICAL REFERENCEJune 200296-8100 rev C5.6 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 current limitto th...

  • Page 242

    TECHNICAL REFERENCE241June 200296-8100 rev C5.7 TWO-SPEED GEAR TRANSMISSIONThe spindle head contains a two-speed gear transmission. The spindle motor is directly coupled to thetransmission and the transmission is cog belt-coupled to the spindle.GEAR BOX LUBRICATIONGear Box: Mobil DTE 25 oil.The...

  • Page 243

    242TECHNICAL REFERENCEJune 200296-8100 rev C5.8 CONTROL PENDANTJOG HANDLEThe JOG handle is actually a 100-line-per-revolution encoder. 100 steps per revolution is used to move one ofthe servo axes. If no axis is selected for jogging, turning of the crank has no effect. When the axis being movedr...

  • Page 244

    TECHNICAL REFERENCE243June 200296-8100 rev CKEYBOARD 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 245

    244TECHNICAL REFERENCEJune 200296-8100 rev CPGMProgram signature found in memory.(Normally On)If this light does not come on, it means that the main CNC program package was not found inmemory or that the auto-start switch was not set. Check that switch S1-1 is on and the EPROMis plugged in.RUNP...

  • Page 246

    TECHNICAL REFERENCE245June 200296-8100 rev C5.10 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 10 (or 20) H.P. continuous rating, and a 15 (or 30) H.P. one-minute rating. Thespindle...

  • Page 247

    246TECHNICAL REFERENCEJune 200296-8100 rev C5.12 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 (see chart for ratings) is primarily used to protec...

  • Page 248

    TECHNICAL REFERENCE247June 200296-8100 rev CSECONDARY CIRCUIT BREAKERSThe following circuit breakers are located on the Power supply assembly.CB2 controls the 3-phase 115volt distribution. It can be tripped only if there is a short in the control cables oron the IOPCB.CB3 controls the power to c...

  • Page 249

    248TECHNICAL REFERENCEJune 200296-8100 rev C5.13 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 voltagetransfor...

  • Page 250

    TECHNICAL REFERENCE249June 200296-8100 rev COPTIONAL 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 Range Tap493-5101 (504)481-4922 (492)469-4803 (480)457-4684 ...

  • Page 251

    250TECHNICAL REFERENCEJune 200296-8100 rev C5.15 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 a...

  • Page 252

    TECHNICAL REFERENCE251June 200296-8100 rev CTURNING 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: R...

  • Page 253

    252TECHNICAL REFERENCEJune 200296-8100 rev C5.16 LUBRICATION SYSTEMThe lubrication system is a resistance type system which forces oil through metering units at each of the 16lubricating points within the machine. The system uses one metering unit at each of the lubricating points: onefor each l...

  • Page 254

    TECHNICAL REFERENCE253June 200296-8100 rev C5.17 SWITCHESLAMP ON/OFF SWITCHAn on/off switch is supplied for the operator's lamp. It is located on the side of the operator’s pendant.DOOR OPEN SENSE SWITCHThe DOOR OPEN sense switch is a magnetic reed switch type and consists of two switches; one ...

  • Page 255

    254TECHNICAL REFERENCEJune 200296-8100 rev CX, Y, AND Z LIMIT SWITCHESPrior to performing an POWER UP/RESTART or an AUTO ALL AXES operation, there are no travel limits.Thus, you can jog into the hard stops in either direction for X, Y, or Z. After a ZERO RETURN has been per-formed, the travel lim...

  • Page 256

    TECHNICAL REFERENCE255June 200296-8100 rev CSHUTTLE IN/OUT SWITCHES[Tool Changer Holding Plate (2)]Two switches are used to sense the position of the tool changer shuttle and the arm that moves it. One switchis activated when the shuttle is moved full travel inward and one is activated when it is...

  • Page 257

    256TECHNICAL REFERENCEJune 200296-8100 rev C5.20 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 fo...

  • Page 258

    TECHNICAL REFERENCE257June 200296-8100 rev C5.21 DISCRETE INPUTS / OUTPUTSThe inputs/outputs that are followed by an asterisk (*) are active when equal to zero (0).DISCRETE INPUT#Name#Name1000TC Changer In1023Spare 3 SMTC Pocket Down APC Pin Clr #21001TC Changer Out1024Tool Unclmp Rmt* SMT...

  • Page 259

    258TECHNICAL REFERENCEJune 200296-8100 rev CDISCRETE OUTPUTS#Name #Name1100Powered Servos1119TSC Purge1101Spare1120Unclamp Pre-Chrg1102Spare1121HTC Shuttle Out (Air Drive Shuttle: Move shuttle in)1103Spare APC: APC Door1104Brake 4th Axis1122Brake 5TH Axis1105Coolant Pump On1123CE Door Lock1106A...

  • Page 260

    TECHNICAL REFERENCE259June 200296-8100 rev CINPUTS 2 Name Name NameX Axis Z ChannelX OverheatX Cable InputY Axis Z ChannelY OverheatY Cable InputZ Axis Z ChannelZ OverheatZ Cable InputA Axis Z ChannelA OverheatA Cable InputB Axis Z ChannelB OverheatB Cable InputX Home SwitchX Drive Fau...

  • Page 261

    260TECHNICAL REFERENCEJune 200296-8100 rev CDISCRETE OUTPUTS 2NameNameSpare Output 32Spare Output 44Spare Output 33Spare Output 45Spare Output 34Spare Output 46Spare Output 35Spare Output 47Spare Output 36Spare Output 48 (SMTC: Serp. ATC Enable)TC MTR SWSpare Output 49 (SMTC: Serp. ATC Rev.)Spare...

  • Page 262

    TECHNICAL REFERENCE261June 200296-8100 rev C5.22 THE EQUATIONS OF MOTIONAn analysis of the physics of motion of a machine tool can give some important insights into the famous“blocks per second” issue. The following mathematics calculates the block per second requirement in order toachieve a w...

  • Page 263

    262TECHNICAL REFERENCEJune 200296-8100 rev C5.23 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 == .262 x d x RPM123.1416xdxRPMR.P.M.TO FIND THE RPM OF A CUTTER OR WORKPIECEEXAMPLE: To ...

  • Page 264

    263PARAMETERSJune 200296-8100 rev E6. 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 265

    264PARAMETERSJune 200296-8100 rev E24 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 266

    265PARAMETERSJune 200296-8100 rev EParameter9X 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 267

    266PARAMETERSJune 200296-8100 rev EParameter23Y 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 268

    267PARAMETERSJune 200296-8100 rev EParameter43A 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 269

    268PARAMETERSJune 200296-8100 rev EParameter54A 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 270

    269PARAMETERSJune 200296-8100 rev E21 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 271

    270PARAMETERSJune 200296-8100 rev EParameter63SHUTTLE 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 272

    271PARAMETERSJune 200296-8100 rev EParameter77SP 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 273

    272PARAMETERSJune 200296-8100 rev EParameter91G 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 274

    273PARAMETERSJune 200296-8100 rev EParameter107 Z MAX CURRENTSee Parameter 105 for descriptionParameter108 A MAX CURRENTSee Parameter 105 for descriptionParameter109 D*D GAIN FOR XSecond derivative gain in servo loop.Parameter110D*D GAIN FOR YSecond derivative gain in servo loop.Parameter111D*D G...

  • Page 275

    274PARAMETERSJune 200296-8100 rev EParameter127 Z GRID OFFSETSee Parameter 125 for description.Parameter128 A GRID OFFSETSee Parameter 125 for description.Parameter129 GEAR CH SETTLE TIMEGear change settle time. This is the number of one millisecond samples that the gear status mustbe stable befo...

  • Page 276

    275PARAMETERSJune 200296-8100 rev EParameter146 Y ACCEL FEED FORWARDParameter147 Z ACCEL FEED FORWARDParameter148 A ACCEL FEED FORWARDThese parameters set the feed forward gain for the axis servo. They have no units.Parameter149 Precharge DELAYThis parameter sets the delay time from precharge to...

  • Page 277

    276PARAMETERSJune 200296-8100 rev EParameter166 B MAX CURRENTSame definition as Parameter 105.Parameter167 D*D GAIN FOR BSecond derivative gain in servo loop.Parameter168 B ACC/DEC T CONSTSame definition as Parameter 113.Parameter169 B PHASE OFFSETSee Parameter 121 for description.Parameter170 B ...

  • Page 278

    277PARAMETERSJune 200296-8100 rev EParameter182 C ACCELERATIONMaximum acceleration of axis. The value is the units of encoder steps / second / second at themotor.Parameter183 C MAX FREQThe frequency at which the motor will be run when maximum spindle RPM is commanded. Units:0.01 Hz (two implied d...

  • Page 279

    278PARAMETERSJune 200296-8100 rev EParameter196 C ACCEL LIMIT LOADThis parameter is used when a Vector Drive is installed. This is the % load limit during acceleration.If the load reaches this limit during acceleration the control slows down the acceleration. If a VectorDrive is not installed, th...

  • Page 280

    279PARAMETERSJune 200296-8100 rev E8AUX AXIS TCIn Horizontal mills only. When enabled, means the tool changer carouselis driven by an aux. axis.9SPIGOT KEY INVThis bit controls the direction the spigot moves when the Coolant Up andCoolant Down buttons are pressed. Changing this bit reverses thedi...

  • Page 281

    280PARAMETERSJune 200296-8100 rev EParameter210 X AXIS TOOL CHANGE OFFSETUsed on the HS-2RP mill for X axis displacement from the home position to tool change position.If this parameter contains an incorrect value, a horizontal mill will crash when it does a toolchange.Parameter211 Y AXIS TOOL CH...

  • Page 282

    281PARAMETERSJune 200296-8100 rev EParameter223 AIR TC DOOR DELAYFor Horizontal mills only. This parameter sets the delay to open the tool changer door (inmilliseconds). If the tool changer does not have a pneumatic door, this parameter is set to zero.Parameter224 ROT AXIS ZERO OFSETThis paramet...

  • Page 283

    282PARAMETERSJune 200296-8100 rev EParameter240 1ST AUX MAX TRAVELThis parameter sets the maximum travel of the first auxiliary (C) axis in the positive direction.Parameter241 2ND AUX MAX TRAVELThis parameter sets the maximum travel of the second auxiliary (U) axis in the positive direction.Param...

  • Page 284

    283PARAMETERSJune 200296-8100 rev EParameter254 VB AIR DOOR CLEARANCEThis is a new parameter to support the VB-1 Bridge Mill tool carousel air door. The air door is aclamshell shaped door covering the tool carousel, which raises up at one side by air power to allowthe spindle to access the tools....

  • Page 285

    284PARAMETERSJune 200296-8100 rev EThe user must press CANCEL before continuing. It is recommended that a spindle warm-upprogram be run immediately. This message will only appear once each time the machine hasbeen turned on. The initial value for this parameter is 3 (days). To disable this fe...

  • Page 286

    285PARAMETERSJune 200296-8100 rev E9Y TEMP SENSORThis performs Lead Screw Thermal Compensation via a temperaturesensor attached to the ball nut. When this bit is set to 1, the feature isactivated for that axis. Note that this feature can only be used whentemperature sensors are installed. The ...

  • Page 287

    286PARAMETERSJune 200296-8100 rev E9A TEMP SENSORThis performs Lead Screw Thermal Compensation via a temperaturesensor attached to the ball nut. When this bit is set to 1, the feature isactivated for that axis. Note that this feature can only be used whentemperature sensors are installed. The ...

  • Page 288

    287PARAMETERSJune 200296-8100 rev E16 SCALE Z HISTFor HAAS diagnostic use only.Parameter272 X SCREW COMP T. CONST.This parameter is the thermal compensation time constant, and is the time constant governing therate of cool down of the screw.Parameter273 Y SCREW COMP T. CONST.This parameter is the...

  • Page 289

    288PARAMETERSJune 200296-8100 rev E10 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 290

    289PARAMETERSJune 200296-8100 rev E24 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 291

    290PARAMETERSJune 200296-8100 rev EParameter286 Y LINEAR SCREW OFFSSee parameter 285 for description.Parameter287 Z LINEAR SCREW OFFSSee parameter 285 for description.Parameter288 A LINEAR SCREW OFFSSee parameter 285 for description.Parameter289 B LINEAR SCREW OFFSSee parameter 285 for descriptio...

  • Page 292

    291PARAMETERSJune 200296-8100 rev EParameter302 FEED 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 ...

  • Page 293

    292PARAMETERSJune 200296-8100 rev EParameter311ARM BUMP TIMEThis 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 time (i...

  • Page 294

    293PARAMETERSJune 200296-8100 rev E2NO X MV NXTLThis parameter only affects horizontal mills, and is intended for useprimarily on the HS-3. If this bit is set to zero, it will have no effect. If it isset to one, the X-axis will not move following a NEXT TOOL button press.The reason for this is b...

  • Page 295

    294PARAMETERSJune 200296-8100 rev E10 PAL HARDCODEThis bit supports the hard-coded APC pallet changer function. It must beset to 1 when an APC is present that is wired for two APC door switches.On all other machines, it must be set to 0.11 ADVANCED JOGThis parameter bit enables the Index Jog and ...

  • Page 296

    295PARAMETERSJune 200296-8100 rev EParameter327 X SCALES PER INCHThis parameter is used on machines equipped with linear scales. This parameter should be set to25,400 on mills fitted with linear scales. On all other mills, they should be set to zero.Parameter328 Y SCALES PER INCHThis parameter is...

  • Page 297

    296PARAMETERSJune 200296-8100 rev EParameter347 Z SPINDLE THERM TIME.CONST.See parameter 345 for description.Parameter348 A SPINDLE THERM TIME.CONST.See parameter 345 for description.Parameter349 B SPINDLE THERM TIME.CONST.See parameter 345 for description.Parameter351 THRML SENSOR OFFSETThis is ...

  • Page 298

    297PARAMETERSJune 200296-8100 rev EParameter595 V ENC. SCALE FACTORSee parameter 588 for descriptionParameter596 W ENC. SCALE FACTORSee parameter 588 for descriptionParameter600 PEAK SPIN. PWR - KWThis is a new parameter that has been added to support the spindle kilowatt (KW) load displaywhich a...

  • Page 299

    MAINTENANCE298June 200296-8100 rev D7. MAINTENANCE7.1 GENERAL REQUIREMENTSGENERAL 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.ELECTRIC...

  • Page 300

    299MAINTENANCEJune 200296-8100 rev DThe rated horsepower of the machine may not be achieved if the imbalance of the incoming voltage isbeyond an acceptable limit. The machine may function properly, yet may not deliver the advertised power.This is noticed more often when using phase converters. A ...

  • Page 301

    MAINTENANCE300June 200296-8100 rev D7.2 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 ord...

  • Page 302

    301MAINTENANCEJune 200296-8100 rev D7.3 TSC MAINTENANCE•Check the dirt indicator on the 100-micron mesh filter with the TSC system running and no tool in thespindle. Change the element when the indicator reaches the red zone.•On newer machines, clean the pump intake filter when indicator is in...

  • Page 303

    MAINTENANCE302June 200296-8100 rev D7.4 LUBRICATION CHARTMETSYSSCITAMUENPDNAEBULYAWNOISSIMSNARTKNATTNALOOCNOITACOLehtforaerehttalenaplortnocehtrednUenihcameldnipsehtevobAdaehenihcamfoediSNOITPIRCSED.emitelcycetunim03htiwpmupnotsiPgninrutsieldnipsnehwnoylnosipmuP.gnivomsisixanehwroSETACIRBULeldni...

  • Page 304

    303MAINTENANCEJune 200296-8100 rev D7.5 LUBRICATION SYSTEMAll machine lubrication is supplied by the external lubrication system. The reservoir is located on the lowerrear of the machine (see figure below). Current lube level is visible in the reservoir. If additional lube needsto be added, remo...

  • Page 305

    MAINTENANCE304June 200296-8100 rev D7.6 VF-1 THROUGH 6 / 40T - TRANSMISSION OILThere is no visible indicator for the level of transmission oil in the VF 1-6/40T models.To add transmission oil, remove the access panel located directly behind the spindle head. This willexpose the Transmission Oil ...

  • Page 306

    305MAINTENANCEJune 200296-8100 rev D7.7 VF-6 THROUGH 11 50T - TRANSMISSION OILCAUTION!Power down the machine before performing any maintenance tasks.The VF 6 through 11 50T machines provide a means to check the transmission oil level. The transmissionoil level eye is located behind an access pan...

  • Page 307

    MAINTENANCE306June 200296-8100 rev D7.9 SIDE MOUNT TOOL CHANGER OIL LEVEL CHECK11312 11 10 987654322322212019181716151424CarouselNumber DiscDisc MountingBHCS (6)Oil Fill LevelThe SMTC is factory filled with the appropriate level of oil and does not need to be changed under normalconditions. As a...

  • Page 308

    307MAINTENANCEJune 200296-8100 rev D7.11 WINDOWS / GUARDINGPolycarbonate windows and guarding can be weakened by exposure to cutting liquids and chemicals thatcontain amines. It is possible to loose up to 10% of the remaining strength annually. If degradation issuspected, window replacement shou...

  • Page 309

    CABLE LOCATIONS30896-8100 rev EJune 20028. PCB'S, CABLE LOCATIONS AND BOARD DIAGRAMS

  • Page 310

    CABLE LOCATIONS30996-8100 rev EJune 2002PROC.PLUG #CABLE # SIGNAL NAMEð TO ðLOCATIONPLUG #J1 ADDRESSADDRESS BUSSVIDEO——-J2 DATADATA BUSSMOTIF PCB——-J3860LOW VOLTAGEPOWER SUPPLY PCB ——-J6N/AREPLACEMENT BAT. CONNECTION——-PORT 1850SERIAL PORT #1KEY. INTERFACE——-PORT 2850ASERIAL PORT #2SE...

  • Page 311

    CABLE LOCATIONS31096-8100 rev EJune 2002BRUSHLESS SERVO AMPLIFIER - P/N 93-5550CTO SERVO MOTOR325VDC (FROM HAAS VECTOR DRIVE)LOW VOLTAGE (INPUT)SERVO DRIVE SIGNAL ( FROM MOCON)

  • Page 312

    CABLE LOCATIONS31196-8100 rev EJune 2002BRUSHLESS SERVO AMPLIFIER - P/N 93-5550CCABLE CONNECTIONSMOCON PLUG #CABLE #SIGNAL NAME ð TO ð LOCATIONPLUG #X AXIS AMPP570LOW VOLTAGEL. V. POWER SUPPLY——-TB A, B, C——-MOTOR DRIVEX SERVO MOTOR——-P610X DRIVE SIGNALMOCON PCBP2TB -HV +HV——-3...

  • Page 313

    CABLE LOCATIONS31296-8100 rev EJune 2002POWER PCB 93-0227A32-5200HFU7C4C3C2C7C6C5C1NE210A 115VMAIN10A 230VCOOLANT10A 115VRTY/USER POWER10A 230VTSC COOLANTSPARE FUSESP1P2P3P4P5P6P7P8P9P10P11P12P13P14P15P16P17P18P19P20P21P22P23P24P25P26P27P28P30P31P32P33P34P35P29TB1TB3TB2NE1NE4FU8FU12 FU11 FU10 F...

  • Page 314

    CABLE LOCATIONS31396-8100 rev EJune 2002POWER PCB - P/N 93-0227ACABLE CONNECTIONSI/O PLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG#P1+12VDCCNC Unit FanP290B115VACLow Voltage Power SupplyP390B115VACProbe PSP490B115VACWork LightP590B115VACSwitch Door FanP690B115VACServo FanP790B115VACDelta-WyeP8860+...

  • Page 315

    CABLE LOCATIONS31496-8100 rev EJune 20027("!!'TR V"Q%U7 Q%"Q%#Q$#Q$&Q$'Q$(F F !F F(F&R &R"R "R" R #R!'R $R!(R %R!&R R '4 4 4 4 4Q" Q""Q"!Q"# Q"$ Q"%Q"&R$R#R"G@" AV ÃÃF"!ÃH! H!! H!"H!...

  • Page 316

    CABLE LOCATIONS31596-8100 rev EJune 2002I/O PCB T - P/N 93-0228A CABLE CONNECTIONSI/O PLUG #CABLE #ð TO ðLOCATIONPLUG #P15890SPDB Open/ClosedP167802nd VD OV/contactor On / counterbalanceP17410APC Door Open , VB ClamshellP18790APC Pin ClearP19190Remote Unclamp SW / Low phaseP20190ANot UsedP21...

  • Page 317

    CABLE LOCATIONS31696-8100 rev EJune 200232-4031EJOG HANDLEJ1J2J3J5Y1U9J12P1P6P5P4P2P3DISCRETE INPUTSSERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOGP/N 93-1072B

  • Page 318

    CABLE LOCATIONS31796-8100 rev EJune 2002SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOGP/N 93-1072B CABLE CONNECTIONSPLUG#CABLE#ðTO ðLOCATIONPLUG#P1700BPROCESSOR850P2——-KEYPAD——-P3700ACYCLE START/HOLD SWITCHES——-P4730SP LOAD METER——-P5——-——-P6——-AUX FPANEL——-J1——-——-J2——-RE...

  • Page 319

    CABLE LOCATIONS31896-8100 rev EJune 2002VIDEO PLUG #CABLE #SIGNAL NAME ð TO ðLOCATIONPLUG #P1860LOW VOLTAGEPOWER SUPPLY PCB ——-J3*700KEYBOARD INFO.KEYBOARD INT.——-J4——-ADDRESS BUSSMICRO PROC. PCB——-J5——-DATA BUSSMOTIF PCB——-J10——-FLOPPY DR. POWERFLOPPY DRIVE——-J11——-SPAREN/AN...

  • Page 320

    CABLE LOCATIONS31996-8100 rev EJune 2002MOCON PCB - P/N 93-1067F

  • Page 321

    CABLE LOCATIONS32096-8100 rev EJune 2002MOCON PCB - P/N 93-1067FCABLE 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 AM...

  • Page 322

    CABLE LOCATIONS32196-8100 rev EJune 2002MOTIF PCB - P/N 93-1066

  • Page 323

    CABLE LOCATIONS32296-8100 rev EJune 2002MOTIF PCB - P/N 93-1066CABLE CONNECTIONSMOTIFPLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #ADDRESS ——-ADDRESS BUSSVIDEO PCB——-& DATA——-DATA BUSSMICRO PROC. PCB——-P2610X DRIVE SIGNALX SERVO DRIVEP3P3620Y DRIVE SIGNALY SERVO DRIVEP3P4630Z DRIVE...

  • Page 324

    CABLE LOCATIONS32396-8100 rev EJune 2002RS-232 PORT #1 PCB - P/N 32-4090CABLE CONNECTIONSPLUG #CABLE #ð TO ðLOCATIONPLUG #P1850VIDEO &J13INTERNALKEYBOARDJ1——-——-——-EXTERNAL

  • Page 325

    CABLE LOCATIONS32496-8100 rev EJune 200250T TRANSMISSION P.S. / HYDRAULIC C.B. PCBP/N 93-4095DCABLE CONNECTIONSPLUG #CABLE #ð TO ðLOCATIONPLUG #P1880BIO PCBP12P290POWER PCBP8P3410GEAR BOXP4350IO PCBP54TB2340HYDRAULIC MTRTB370MAIN TRANSFORMER(VECTOR DRIVE UNIT)FU1115 VAC115 V Servo Brake880B/P1

  • Page 326

    CABLE LOCATIONS32596-8100 rev EJune 2002M CODE RELAY BOARDP/N 93-1057B CABLE CONNECTIONSPLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #P1540MOCON INPUTIO PCB`P62P2860A12VD TO M-CODE PCBAPSUPP31P3540AIOPCB OUTPUTP4M21M-FUNCTIONM22PROBE OPTIONM24spareP5M25spareM26spareM27spareP6540BM CODE OUTPUT2nd ...

  • Page 327

    CABLE LOCATIONS32696-8100 rev EJune 2002K4K5TO 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 32-5850A

  • Page 328

    CABLE LOCATIONS32796-8100 rev EJune 2002CABLE LOCATION DIAGRAM

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    CABLE LOCATIONS32896-8100 rev EJune 2002SERVO DISTRIBUTION JCABLE CONNECTIONSP/N 34-4025J

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    CABLE LOCATIONS32996-8100 rev EJune 2002SERVO DISTRIBUTION JCABLE CONNECTIONSP/N 34-4025JPLUG #CABLE #ð TO ðLOCATIONPLUG #P1XP2YP3ZP4AP5BP7P880P9980P10920P11110P12970P131060

  • Page 331

    330CABLE LIST96-8100 rev EJune 20029. CABLE LISTWIRE/TERMINALFUNCTION 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 CB1-4 TO K1-...

  • Page 332

    331CABLE LIST96-8100 rev EJune 200290C115 VAC TO CB4 - (2 + SHIELD)91CLEG 1 #1692CLEG 2 #1693CSHIELD DRAIN100 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 230VAC142P...

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    332CABLE LIST96-8100 rev EJune 2002230 5’th AXIS BRAKE240 SPARE INPUTS FROM IOPCB P25250 SPARE OUTPUTS FROM IOPCB P45260 K210 CABLING FOR EC270 K111 CABLING FOR EC280RED/GREEN STATUS LIGHT WIRING (3+ SHIELD)281RED LAMP 115VAC282GREEN LAMP 115VAC283COMMON 115VAC284SHIELD DRAIN300115VAC TO SPINDL...

  • Page 334

    333CABLE LIST96-8100 rev EJune 2002500OVERTEMP SENSOR FROM SPINDLE MOTOR - (2 + SHIELD)501OVERTEMP WIRE 1 #20 (N.C.)502OVERTEMP WIRE 2 #20503SHIELD DRAIN510RELAY CARD 1 DRIVE CABLE - 16 WIRE RIBBON #24520RELAY CARD 2 DRIVE CABLE - 16 WIRE RIBBON #24530RELAY CARD 3 DRIVE CABLE - 16 WIRE RIBBON #24...

  • Page 335

    334CABLE LIST96-8100 rev EJune 2002650ATHREE PHASE POWER TO SPINDLE MOTOR - (3 + SHIELD)651ALEG 1 OF 230VAC652ALEG 2653ALEG 3654ASHIELD DRAIN650BTHREE PHASE POWER TO SPINDLE MOTOR - (3 + SHIELD)651BLEG 1 OF 230VAC652BLEG 2653BLEG 3654BSHIELD DRAIN660X-ENCODER CABLE (ALL #24)660-1LOGIC RETURN (D ...

  • Page 336

    335CABLE LIST96-8100 rev EJune 2002710FORWARD/REVERSE/RESET TO SPINDLE - (4 + SHIELD)(BRUSH SYSTEMS)711FORWARD COMMAND (CN1-19 TO IO P9-3)712REVERSE COMMAND (CN1-19 TO IO P9-3)713RESET COMMAND (CN1-21 TO IO P9-2)714COMMON (CN1-14 TO IO P9-1)715SHIELD DRAIN720ANALOG SPEED COMMAND TO SPINDLE - (2 +...

  • Page 337

    336CABLE LIST96-8100 rev EJune 2002750-2CYCLE START750-4D GROUND750-6FEED HOLD760MONITOR VIDEO DATA CABLE - (9 + SHIELD) (ALL #24)(FROM VIDEO P3 TO CRT)770EMERGENCY STOP INPUT CABLE - SHIELD +2771SIGNAL (INPUT 8) #20772RETURN (D GROUND) (65) #20772RETURN (D GROUND) (65) #20770ASECOND E-STOP INPU...

  • Page 338

    337CABLE LIST96-8100 rev EJune 2002830OVERHEAT THERMOSTAT - (2 + SHIELD)831OVERHEAT SIGNAL (INPUT 14) #20832OVERHEAT RETURN (D GROUND) (65) #20833SHIELD DRAIN840CIRCUIT BREAKER FOR 160 VDC - SHIELD +2841LEG 1 (TO 81) #14842LEG 2 #14843SHIELD DRAIN850SERIAL PORT #1 TO SERIAL KEYBOARD INTERFACE CAB...

  • Page 339

    338CABLE LIST96-8100 rev EJune 2002890SPINDLE 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) #24897SHIELD DRAIN900LOW COOLANT STATUS - (2...

  • Page 340

    339CABLE LIST96-8100 rev EJune 2002960LOW LUB/DOOR OPEN SENSORS - (4 + SHIELD)961LOW LUB SIGNAL (INPUT 13) #24962LOW LUB RETURN (D GROUND) (65) #24963DOOR OPEN SIGNAL (INPUT 9) #24 (OBSOLETE OPTION)964DOOR OPEN RETURN (D GROUND) (65) #24 (OBSOLETE OPTION)965SHIELD DRAIN970LOW VOLTAGE SENSOR - (2 ...

  • Page 341

    340CABLE LIST96-8100 rev EJune 20021060GROUND FAULT DETECTION SENSE INPUT1061+ INPUT FROM SENSE RESISTOR1062- INPUT FROM SENSE RESISTOR1070SKIP INPUT FROM SENSOR - (2 + SHIELD)1071LOGIC COMMON1072SKIP SIGNAL1073SHIELD DRAIN

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    341ELECTRICAL DIAGRAMSJune 200296-8100 rev EELECTRICALWIRING DIAGRAMS

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    342ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    343ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    344ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    345ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    346ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    347ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    348ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    349ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    350ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    351ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    352ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    353ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    354ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    355ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    356ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    357ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    358ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    359ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    360ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    361ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    362ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    363ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    364ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    365ELECTRICAL DIAGRAMSJune 200296-8100 rev ESENSORSENSORSENSORSWITCHSWITCHSWITCHSWITCHSOLENOIDARM STOWARM MOTOR STOPARM CL/UNCLTC MARKPOCKET UPPOCKET DOWNPOCKET U/DTOOL ONETO I/O P66TO I/O P13TO I/O P13TO I/O P13TO I/O P13TO I/O P74TO I/O P73TO I/O P73CABLEMOUNTINGBRACKETARM (ATC) MOTOR UNITARM (...

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    366ELECTRICAL DIAGRAMSJune 200296-8100 rev E

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    ASSEMBLY DRAWINGS36796-8100 rev EJune 2002ASSEMBLY DRAWINGS

  • Page 369

    ASSEMBLY DRAWINGS36896-8100 rev EJune 2002VF-1 Base42311.50-3300 Linear guide2. 30-0171 Oil line assembly3. 32-2030 Telemechanique switch assembly4. 62-0014 Yaskawa sigma 09 motor**Except XRT

  • Page 370

    ASSEMBLY DRAWINGS36996-8100 rev EJune 2002VF-1 Column1. 30-0170 Oil line assembly2. 62-0009 Yaskawa Sigma 09 motor*3. 32-2040 telemechanique switch assembly4. 50-3300 Linear guide*Except XRT

  • Page 371

    ASSEMBLY DRAWINGS37096-8100 rev EJune 2002VF-1 Saddle42131. 30-0173 Oil line assembly2. 32-2050 Telemechanique switch3. 50-3300 Linear guide4. 62-0014 Yaskawa sigma 09 motor**Except XRT

  • Page 372

    ASSEMBLY DRAWINGS37196-8100 rev EJune 2002VF-3 Base1. 30-0221 Oil line assembly2. 32-2031 Telemechanique switch assembly3. 50-9011 Linear guide4. 62-0014 Motor assembly**Except XRT

  • Page 373

    ASSEMBLY DRAWINGS37296-8100 rev EJune 20022134VF-3 Column1.30-0687 Oil line assembly2. 32-2041 Telemechanique switch assembly3. 50-9011 Linear guide4. 62-0014 Yaskawa Sigma 09 motor**Except XRT

  • Page 374

    ASSEMBLY DRAWINGS37396-8100 rev EJune 20023421VF-3 Saddle1. 30-0223 Oil line assembly2. 32-2050 Telemechanique switch assembly3. 50-9010 Linear guide4. 62-0014 Yaskawa sigma 09 motor**Except XRT

  • Page 375

    ASSEMBLY DRAWINGS37496-8100 rev EJune 2002VF-6 Base34121. 32-5056 Telemechanique limit switch assembly2. 30-0221 OIl line assembly3. 50-9010 Linear guide4. 62-0014 Yaskawa sigma 09 motor**Except XRT

  • Page 376

    ASSEMBLY DRAWINGS37596-8100 rev EJune 20023421VF-6 Column1. 32-2050 Telemechanique limit switch assembly2. 62-0014 Yaskawa sigma 09 motor*3. 30-0464 Oil line assembly4. 50-9010 Linear guide*Except XRT

  • Page 377

    ASSEMBLY DRAWINGS37696-8100 rev EJune 2002VF-6 Saddle24311. 62-0014 Yaskawa sigma 09 motor*2. 50-9806 Linear guide3. 30-0463 Oil line assembly4. 32-2051 Telemechanique limit switch assembly*Except XRT

  • Page 378

    ASSEMBLY DRAWINGS37796-8100 rev EJune 2002VF-8 Base43121. 62-0014 Yaskawa sigma 09 motor*2. 50-9010 Linear guide3. 30-0461 Oil line assembly4. 32-5056 Telemechanique limit switch assembly*Except XRT

  • Page 379

    ASSEMBLY DRAWINGS37896-8100 rev EJune 2002VF-8 Column43211. 32-2050 Telemechanique limit switch assembly2. 62-0014 Yaskawa sigma 09 motor*3. 30-0464 Oil line assembly4. 50-9010 Linear guide*Except XRT

  • Page 380

    ASSEMBLY DRAWINGS37996-8100 rev EJune 20022431VF-8 Saddle1. 62-0014 Yaskawa sigma 09 motor*2. 50-9806 Linear guide3. 30-0463 Oil line assembly4. 32-2051 Telemechanique limit switch assembly*Except XRT

  • Page 381

    ASSEMBLY DRAWINGS38096-8100 rev EJune 200287411413511106931221615VF-10 Base1. 59-6655 Rubber plug guide rail2. 22-7458 Cam, linear guide3. 20-9218 Y-axis bumper, motor end4. 20-0150 Nut housing5. 58-3031 Banjo elbow 5/16 female x M6 male6. 58-1560 Adaptor 1/8m (NSK and THK Linear guides) 59-000...

  • Page 382

    ASSEMBLY DRAWINGS38196-8100 rev EJune 2002VF-10 Column252223 242829313027261996202132141516187541812101711131. 25-7267 Bracket mounting Y-axis2. 25-9929 Stabilizer bracket hyd. cyl.3. 32-2050 Limit switch Z-axis4. N/A5. 59-4002 Hose clamp 13/16 x 1 3/46. 50-9010 Linear guide7. 22-9826A Counterwei...

  • Page 383

    ASSEMBLY DRAWINGS38296-8100 rev EJune 2002BOTTOM1920TOP181715161413123865471210119VF-10 Saddle1. 20-0152 Bearing housing 40mm and 50mm ballscrew2. 20-0156 Bumper3. 59-6655 rubber plug4. 22-7458 Cam, linear guide5. 30-0534 Oil line assembly6. 58-1560 Linear guide adaptor 1/8m (NSK and THK) 59-00...

  • Page 384

    ASSEMBLY DRAWINGS38396-8100 rev EJune 200232 Tool Changer Assembly VF-3/449454446484752515053434241403931 30353334323736381234522292827262524237689101112132120 1918141516171. 30-0005 Turret motor assembly2. 25-7162 Connector bracket3. 57-9335 Shuttle cover gasket4. 25-9334 Shuttle cover plate5. 3...

  • Page 385

    ASSEMBLY DRAWINGS38496-8100 rev EJune 200232 Tool Changer Assembly VF-6..106165151417109212742434026222053474552503812811333128243435192548234130 2932513421364449463937718131. 30-1967 Turret motor assembly2. 25-7162 Connector bracket3. 25-9334 Shuttle cover plate4. 57-9335 Shuttle cover gasket5....

  • Page 386

    ASSEMBLY DRAWINGS38596-8100 rev EJune 200250 Taper Tool Changer Assembly1. 30-0016 Geneva driver assembly2. N/A3. 54-0010 Cam follower T/C4. 20-9289 Shuttle stop block5. 78-1996 Split flex tuning 1/2 I.D.6. 20-9291 Shuttle vertical plate7. 25-9342 Shuttle cover8. 30-0017A carousel assembly9. 20-9...

  • Page 387

    ASSEMBLY DRAWINGS38696-8100 rev EJune 200220 Pocket Tool Changer59575856556160626352545351504948464742 43454441401165646628293031171516121314343233353937363810987262224182119 20232527564312

  • Page 388

    ASSEMBLY DRAWINGS38796-8100 rev EJune 200220 Pocket Tool Changer1. 20-7029B Holding arm2. 57-7379 Tool holding arm gasket3. 79-1000 Wire channel 1in. x 2in.4. 79-1001 Cover wire channel 1"5. 54-0030 Guide wheel6. 22-7263 Block switch mounting7. 54-0020 Bushing guide wheel8. 48-0019 Dowel pin...

  • Page 389

    ASSEMBLY DRAWINGS38896-8100 rev EJune 2002MINI-MILL AND TRM TOOL CHANGERS

  • Page 390

    ASSEMBLY DRAWINGS38996-8100 rev EJune 2002

  • Page 391

    ASSEMBLY DRAWINGS39096-8100 rev EJune 2002431256111098732 Tool Carousel Assembly (BT) VF 3-101. 25-9333 Number ring2. 20-9324 Carousel 32 tool3. 20-9193 Carousel support plate4. 24-2010A Compression spring5. 25-9328 Sliding panel cover6. 24-9257 Spring extractor7. 25-7249 Sliding panel8. 22-925...

  • Page 392

    ASSEMBLY DRAWINGS39196-8100 rev EJune 2002421356111098732 Tool Carousel Assembly Assembly (CT) VF 3-101. 25-9333 Number ring2. 20-9193 Carousel support plate3. 20-9324 Carousel 32 tool4. 24-2010A Compression spring5. 25-9328 Tool sliding panel cover6. 24-9257 Spring extractor7. 25-7249 Slider pa...

  • Page 393

    ASSEMBLY DRAWINGS39296-8100 rev EJune 200243125650 Taper Carousel Assembly (CT) VF 6-101. 20-9296 50 Taper carousel2. 22-9256 Bushing extractor3. 25-9349 Number ring4. 24-9257 Spring extractor5. 22-9297 Extraction finger6. 20-9298 Alignment key

  • Page 394

    ASSEMBLY DRAWINGS39396-8100 rev EJune 2002VF 1-11 Gearbox Assembly 15 HP2926252428273023VIEW A161713181514192011122122781210935VIEW A643132335857545556593734353638394052534951504748414246444543

  • Page 395

    ASSEMBLY DRAWINGS39496-8100 rev EJune 2002VF 1-11 Gearbox Assembly 15 HP1. 25-0108 Fan bracket motor shroud2. 36-3035 Spindle fan assembly3. 59-7130 Protective strip4. 32-2011Telmech. 30" cable assembly5. 32-2010 24" limit switch6. 25-7264 Switch mounting bracket7. 29-0022 Shroud cauti...

  • Page 396

    ASSEMBLY DRAWINGS39596-8100 rev EJune 2002VF 1-11 Gearbox Assembly HT10K363029333435312832VIEW A9108151411161213272524232619181722761221204VIEW A535336484752495150444645434241545558595657403938376462606163

  • Page 397

    ASSEMBLY DRAWINGS39696-8100 rev EJune 2002VF 1-11 Gearbox Assembly HT10K1. 25-0108 Fan bracket motor shroud2. 36-3035 Spindle fan assembly3. 32-2011 Telmech 30" cable assembly4. 32-2010 24" limit switch5. 25-7264 Switch mounting bracket6. 59-1482 Nylon finish plug, 13/167. 29-0022 Shro...

  • Page 398

    ASSEMBLY DRAWINGS39796-8100 rev EJune 2002VF 1-11 Gearbox Assembly HT10K TSC443738414243393640VIEW A11121091716131814153522201921333231342625232430298712282735VIEW A645655546159626058505352514947466364676865664573716970724857

  • Page 399

    ASSEMBLY DRAWINGS39896-8100 rev EJune 2002VF 1-11 Gearbox Assembly HT10K TSC1. 25-0108 Fan bracket motor shroud2. 36-3035 Spindle fan assembly3. 59-7130 Protective strip4. 32-2011 Telmech 30" cable assembly5. 32-2010 24" limit switch6. 25-7264 Switch mounting bracket7. 59-1482 Nylon fi...

  • Page 400

    ASSEMBLY DRAWINGS39996-8100 rev EJune 2002Spindle AssembliesSPINDLES30-0319A 7.5 Spindle Assembly30-2132 10K Spindle Assembly30-1360 15K Spindle Assembly30-1468 15K spindle assembly VF5-1130-0449 50 Taper Spindle AssemblyDRAWBAR30-3410E 7.5k spindle with or without TSC30-0067 50 Taper

  • Page 401

    ASSEMBLY DRAWINGS40096-8100 rev EJune 2002Tool Release Piston AssemblyVIEW BOUT OF POSITION23457689ABA1SECTION A-AOUT OF POSITION18171615101112131440 Taper Complete Assembly Non -TSC 30-3201AMini Mill TRP Assembly 30-1668TRP base XHC 30-3207TRP base 30-32051. 58-3613 1/4 Street elbow2. 58-3050 ...

  • Page 402

    ASSEMBLY DRAWINGS40196-8100 rev EJune 200250 Taper Tool Release Piston131819202117161514222324251234561211109871. 59-0049 Spring compression2. 52-0003 Shaft clamp3. 58-3050 Elbow 1/4 nylon tubing4. 58-3631 Reducer bushing 1/2M-1.8F5. 20-0016B Switch plate6. 20-0021 Spacer upper TRP 50T7. 32-2013 ...

  • Page 403

    ASSEMBLY DRAWINGS40296-8100 rev EJune 2002TSCHP Tool Release Piston AssemblyOUT OF POSITIONVIEW B234A56789BA1272625OUT OF POSITIONSECTION A-A2324222120181910111213141516171. 58-3618 1/4 Street elbow 90 deg.2. 58-3727A 1/4NPT x 4 nipple brass3. 58-3050 Elbow 1/4 nylon tubing4. 58-3670 1/4NPT M 1/...

  • Page 404

    ASSEMBLY DRAWINGS40396-8100 rev EJune 2002Ball Screw AssemblyBALL SCREW ROTATED 90°COUPLING ASS'YBALL SCREWMOTOR MOUNTSNAP LOCK RING BMPRMini-millVF 0-1VF 2VF 3VF 4-5VF-5XTBase24-300630-015730-015730-019630-019630-0196Saddle24-300630-015730-019430-019530-019730-2152Column24-300630-015730-015730-...

  • Page 405

    ASSEMBLY DRAWINGS40496-8100 rev EJune 2002Coupling AssemblyVF 0-5 & Mini-MillVF-5XTVF 6/8VF 7/9VF10/11Base30-021130-121530-121930-121930-1219(30-1220A)Saddle30-021130-121930-1225A30-0516(30-1220A)Column30-021130-121930-121930-1219(30-1220A)50 TaperVF5VF-5XTVF-6/8VF-7/9VF-10/11Base30-121530-1...

  • Page 406

    ASSEMBLY DRAWINGS40596-8100 rev EJune 2002ITEMNO.ITEMNO.QTY.QTY.PARTNO.PARTNO.DESCRIPTIONDESCRIPTION1125-4424BELTENCLOSER310SPVB2125-4426MOTORENCLOSER310SPVB3125-4428MOTORENCLOSERCOVER4225-4429RADIUSCOVERVBMILLS5125-4430SIDECOVER6125-4431CABLECOVER3107125-4432CABLECOVERC-AXISVB8640-1669BHCS,8-32X...

  • Page 407

    ASSEMBLY DRAWINGS40696-8100 rev EJune 2002VR-Series Head Assembly

  • Page 408

    ASSEMBLY DRAWINGS40796-8100 rev EJune 2002VR-Series Head Assembly

  • Page 409

    ASSEMBLY DRAWINGS40896-8100 rev EJune 2002APC Assemblysheet 1 of 2

  • Page 410

    ASSEMBLY DRAWINGS40996-8100 rev EJune 2002APC Assemblysheet 2 of 2

  • Page 411

    ASSEMBLY DRAWINGS41096-8100 rev EJune 2002ITEM QTY.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...

  • Page 412

    ASSEMBLY DRAWINGS41196-8100 rev EJune 20021.Y-axisGutter2.Y-axis Waycover3.Y-axis Guide Rails4.Way Cover Bracket5.Saddle Cover6.X-axis Gutter7.X-axis Gutter8.Saddle Cover9.X-axis Waycover10.X-axis Guide Rails11.X-axis Guide Rails12.Way Cover Bracket13.Y-axis Wiper14.Y-axis Rear Waycover15.Z-axis ...

  • Page 413

    ASSEMBLY DRAWINGS41296-8100 rev EJune 2002VF Exterior Sheet Metal

  • Page 414

    ASSEMBLY DRAWINGS41396-8100 rev EJune 20021.Back Panel, Left2.Side Window (handle not included)3.Roof4.Bridge5.Roof6.Back Panel, Right7.Spindle Head Cover8.Bottom Head Cover9.Bottom Head Cover Inspection Panel10.Left Door11.Right Door12.Right Side Panel13.Front Right Panel14.Apron Extension15.Mid...

  • Page 415

    ASSEMBLY DRAWINGS41496-8100 rev EJune 2002VF Exterior Sheet Metal

  • Page 416

    ASSEMBLY DRAWINGS41596-8100 rev EJune 2002VF Exterior Sheet Metal1.Front Left Panel2.Front Right Panel3.Floor Pan Left4.Floor Pan Right5.Pan Right, Outrigger6.Pan Support7.Pan Support8.Pan Left, Outrigger9.Back Right Panel Extension10.Inner Back Panel, Right11.Inner Back Panel, Left12.Back Left P...

  • Page 417

    ASSEMBLY DRAWINGS41696-8100 rev EJune 20021. Enclosure Side25-07542. Door Assembly25-0386 (Window 28-0011)3. Guide Block20-07124. Panel Front Enclosure25-07535. Keybracket25-09586. Switch Mounting Bracket25-7050C7. Door Keeper25-07578. Lower Door Rail22-76169. Lube Panel Mounting25-7195K10. Encl...

  • Page 418

    ASSEMBLY DRAWINGS41796-8100 rev EJune 20021. Fan guard59-01442. Fan bracket top25-03893. Head Cover25-03824. Back Head Cover25-03885. Z lower cover25-03816. Z upper cover25-03807. Y-axis way cover, rear25-03738. Support Cover25-03779. Saddle cover (2)25-037510. Tab side cover (2)25-037811. Front ...

  • Page 419

    ASSEMBLY DRAWINGS41896-8100 rev EJune 20021.32-1875 Motor Assembly2. 32-2010 Limit Switch3. 32-2000 Limit Switch4. 30-7200A Actuating Arm5. 20-0682 Tool Holding plate6. 25-0466 Door Opener Bracket7. 54-0030 Guide Wheel8. 25-7162 Connector Bracket9. 20-1354A T/C Carriage10. 46-1705 Lock nut11. 45...

  • Page 420

    ASSEMBLY DRAWINGS41996-8100 rev EJune 2002VS-3 Sheet Metal Assembly

  • Page 421

    ASSEMBLY DRAWINGS42096-8100 rev EJune 20021Fan guard2Head cover, top plate3Head cover, left rear cover4Head cover, left front cover5Head cover, right rear cover6Head cover, right front cover7Head cover, rear bottom8Bottom head access plate9Head cover, front bottom cover10Head cover, front11Tool ...

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