Manual_Archive_Cover_Page Rev A

June 6, 2013
Haas Technical Publications

HAAS SERVICE AND OPERATOR MANUAL ARCHIVE

SL-Series Service Manual 96-8710 RevC English June 2001

• This content is for illustrative purposes.

• Historic machine Service Manuals are posted here to provide information for Haas machine owners.

• Publications are intended for use only with machines built at the time of original publication.

• As machine designs change the content of these publications can become obsolete.

• You should not do mechanical or electrical machine repairs or service procedures unless you are qualified
and knowledgeable about the processes.

• Only authorized personnel with the proper training and certification should do many repair procedures.

WARNING: Some mechanical and electrical service procedures can be

extremely dangerous or life-threatening.
Know your skill level and abilities.

All information herein is provided as a courtesy for Haas machine owners

for reference and illustrative purposes only. Haas Automation cannot be held
responsible for repairs you perform. Only those services and repairs that are
provided by authorized Haas Factory Outlet distributors are guaranteed.

Only an authorized Haas Factory Outlet distributor should service or repair a

Haas machine that is protected by the original factory warranty. Servicing by
any other party automatically voids the factory warranty.
 June 2001 TROUBLESHOOTING

COMMON ABBREVIATIONS USED IN HAAS MACHINES

AC Alternating Current
AMP Ampere
APC Automatic Pallet Changer
APL Automatic Parts Loader
ASCII American Standard Code for Information Interchange
ATC Automatic Tool Changer
ATC FWD Automatic Tool Change Forward
ATC REV Automatic Tool Changer Reverse
AWG American Wire Gauge
BHCS Button Head Cap Screw
CAD Computer Assisted Design
CAM Computer Assisted Machining
CB Circuit Breaker
CC Cubic Centimeter
CCW Counter Clockwise
CFM Cubic Feet per Minute
CNC Computerized Numeric Control
CNCR SPINDLE Concurrent Spindle with axis motion
CRC Cyclic Redundancy Check Digit
CRT Cathode Ray Tube
CW Clockwise
DB Draw Bar
DC Direct Current
DGNOS Diagnostic
DIR Directory
DNC Direct Numerical Control
DOS Disk Operating System
ENA CNVR Enable Conveyor
EOB End Of Block
EOF End Of File
EPROM Erasable Programmable Read Only Memory
E-Stop Emergency Stop
FHCS Flat Head Cap Screw
FT Foot
FU Fuse
FWD Forward
GA Gauge
HHB Hex Head Bolts
HP Horse Power
HS Horizontal Series Of Machining Centers
ID Inside Diameter
IGBT Isolated Gate Bipolar Transistor
IN Inch
IOPCB Input Output Printed Circuit Board
LAN Local Area Network
LB Pound
LED Light Emitting Diode
LO CLNT Low Coolant
LOW AIR PR Low Air Pressure
LVPS Low Voltage Power Supply
MB Megabyte (1 million)
MCD RLY BRD M-Code Relay Board
MDI Manual Data Input

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MEM Memory
M-FIN M-Code Finished
MM Millimeter
MOCON Motor Control
MOTIF Motor Interface
MSG Message
MSHCP Metric Socket Head Cap Screw
NC Numerical Control
NC Normally Closed
NO Normally Open
OD Outside Diameter
OPER Operator
P Pocket
PARAM Parameter
PCB PrintedCircuit Board
PGM Program
POR Power On Reset
POSIT Positions
PROG Program
PSI Pounds Per Square Inch
PWM Pulse Width Modulation
RAM Random Access Memory
REPT RIG TAP Repeat Rigid Tap
RET Return
REV CNVR Reverse Conveyor
RJH Remote Jog Handle
RPDBDN Rotary Pallet Draw Bar Down
RPDBUP Rotary Pallet Draw Bar Up
RPM Revolutions Per Minute
S Spindle Speed
SDIST Servo Distribution PCB
SFM Surface Feet Per Minute
SHCS Socket Head Cap Screw
SIO Serial Input/Output
SKBIF Serial Key Board Inter Face PCB
SMTC Side Mount Tool Changer
SP Spindle
T Tool Number
TC Tool Changer
TIR Total Indicated Runout
TNC Tool Nose Compensation
TRP Tool Release Piston
TS Tail Stock
TSC Through The Spindle Coolant
VF Vertical Mill (very first)
VF-E Vertical Mill- Extended
VMC Vertical Machining Center
WAN Wide Area Network

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1. TROUBLESHOOTING

This section is intended for use in determining the solution to a known problem. Solutions given are intended to
give the individual servicing the CNC a pattern to follow in, first, determining the problem’s source and second,
solving the problem.

The troubleshooting tips are organized in this section according to the area of the CNC that may be giving sign
of a problem. (Ex.: Out-of round circles in drilling will be found under the heading General Machine Operation -
Accuracy).

If the problem you are experiencing cannot be found under the heading you expect, please try several other
possible headings. If the problem is still not found, contact Haas Automation for further details.

BEFORE YOU BEGIN:

USE COMMON SENSE
Many problems are easily overcome by correctly evaluating the situation. All machine operations are composed
of a program, tools, and tooling. You must look at all three before blaming one as the fault area. If a bored hole
is chattering because of an overextended boring bar, don’t expect the machine to correct the fault. Don’t
suspect machine accuracy if the vise bends the part. Don’t claim hole mis-positioning if you don’t first center-
drill the hole.

FIND THE PROBLEM FIRST

Many mechanics tear into things before they understand the problem, hoping that it will appear as they go. We
know this from the fact that more than half of all warranty returned parts are in good working order. If the
spindle doesn’t turn, remember that the spindle is connected to the gear box, which is connected to the
spindle motor, which is driven by the spindle drive, which is connected to the I/O BOARD, which is driven by
the MOCON, which is driven by the processor. The moral here is don’t replace the spindle drive if the belt is
broken. Find the problem first; don’t just replace the easiest part to get to.

DON’T TINKER WITH THE MACHINE

There are hundreds of parameters, wires, switches, etc., that you can change in this machine. Don’t start
randomly changing parts and parameters. Remember, there is a good chance that if you change something,
you will incorrectly install it or break something else in the process. Consider for a moment changing the
processor’s board. First, you have to download all parameters, remove a dozen connectors, replace the board,
reconnect and reload, and if you make one mistake or bend one tiny pin it WON’T WORK. You always need to
consider the risk of accidentally damaging the machine anytime you work on it. It is cheap insurance to
double-check a suspect part before physically changing it. The less work you do on the machine the better.

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1.1 G ENERAL M ACHINE O PERATION

M ACHINE N OT RUNNING

Machine 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 overvoltage fuses (see "Electrical Service").
• Check wiring to POWER OFF button on front control panel.
• Check wiring to AUTO OFF relay to IOPCB.
• Check connection between 24V transformer and K1 contactor
• Check IOPCB (see "Electrical Service").
• Check POWER PCB (see "Electrical Service").

Machine can be powered on, but turns off by itself.

• Check settings #1 and #2 for Auto Off Timer or Off at M30.

• Check alarm history for OVERVOLTAGE or OVERHEAT shutdown.
• Check AC power supply lines for intermittent supply.
• Check wiring to POWER OFF button on front control panel.
• Check connection between 24V transformer and K1 contactor.
• Check IOPCB (see "Electrical Service").
• Check Parameter 57 for Power Off at E-STOP.
• Check MOTIF or MOCON PCB (see "Electrical Service").

Machine turns on, keyboard beeps, but no CRT display.

• Check for power connections to CRT from IOPCB. Check for green POWER LED at front of CRT.
• Close doors and Zero Return machine (possible bad monitor).
• Check video cable (760) from VIDEO PCB to CRT.
• Check for lights on the processor.

Machine turns on, CRT works, but no keyboard keys work.

• Check keyboard cable (700B) from VIDEO to KBIF PCB.

• Check keypad (see "Electrical Service").
• Check KBIF PCB (see "Electrical Service").

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VIBRATION

Vibration is a subjective evaluation with perceptions varying among individuals, making it difficult to determine in
mild cases if there is an actual problem. In obvious cases, it is a matter of determining the source - which is
not easy, since all parts rotate together and sound can be transferred readily. Vibrations also need to be
distinguished from noise such as a bad bearing. We will assume that vibrations would be something that could
be felt by putting your hand on the spindle ring. One crude method of measurement would be to take an
indicator on a magnetic base extended 10 inches between the turret and spindle housing and observe the
reading of the indicator. A reading of more than .001 would indicate excessive vibration. The two common
sources of noise are the spindle and axis drives. Most complaints about vibration, accuracy, and finish can be
attributed to incorrect machining practices such as poor quality or damaged tooling, incorrect speeds or feeds,
or poor fixturing. Before concluding that the machine is not working properly, ensure that good machining
practices are being observed. These symptoms will not occur individually (Ex. A machine with backlash may
vibrate heavily, yielding a bad finish). Put all of the symptoms together to arrive at an accurate picture of the
problem.

Machine vibrates while spindle is on and is not cutting. Sometimes only at specific RPM.

• If the spindle alone causes vibration of the machine this is usually caused by the belt/pulley drive system
or the chuck jaws are not centered correctly.

Machine vibrates while jogging the axis with the jog handle.

• The HAAS control uses very high gain accelerations curves. This vibration as you jog is simply the
servos quickly trying to follow the handle divisions. If this is a problem, try using a smaller division on
the handle. You will notice the vibration more at individual clicks than when you are turning the handle
faster. This is normal.

The machine vibrates excessively in a cut.

• This is a tough one to call because machining practices come into play. Generally speaking, the least
rigid element of a cut is the tool because it is the smallest part. Any cutter will vibrate if pushed beyond
its tensile strength. In order to eliminate the machine as the source of the problem, you need to check
the spindle and the backlash of the axes as described in the following sections. Once machining
practices have been eliminated as the source of vibration, observe the machine in both operation and
“cutting air.” Move the axes (individually) without the spindle turning and then turn the spindle without
moving the axes. Isolate whether the vibration comes from the spindle head or from an axis.

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ACCURACY

Before 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 eliminate
mispositioning errors caused by thermal growth of the leadscrews (see "Thermal Growth" section).
• Don’t ever use a wiggler test indicator for linear dimensions. They measure in an arc and have sine/cosine
errors over larger distances.
• Don’t use magnetic bases as accurate test stops. The high accel/decel of the axis can cause them to
move.
• Don’t attach test points to the sheet metal of the spindle head.
• Don’t check for accuracy/repeatability using an indicator with a long extension.
• Ensure that test indicators and stops are absolutely rigid and mounted to machined casting surfaces
• Check a suspected error with another indicator or method for verification.
• Ensure that the indicator is parallel to the axis being checked to avoid tangential reading errors.
• Center drill holes before using jobber length drills if accuracy is questioned.
• Once machining practices have been eliminated as the source of the problem, determine specifically what
the machine is doing wrong.

Diameters are out of round

• Check that tooling and machining practices are correct. Bores will be out of round due to tool deflection
much more frequently than due to spindle bearing problems.

Drill

Diameters are incorrect in X-axis

• Ensure the tool probe is set up correctly (settings, etc.)

• Ensure tool offsets are coorect. Note that the coordinate system (FANUC, YASNAC, HAAS) must be
selected before setting tools.
• Ensure Parameter 254, Spindle Center, is set correctly.
• Check for thermal growth of the X-axis leadscrew (see “Thermal Growth” section).

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Center holes are malformed

• Ensure tooling is tight.

• Ensure Parameter 254, Spindle Center, is set correctly.
• Check spindle to turret pocket alignment. It may be out of alignment due to a crash or misadjustment.
• Check for thermal growth of the X-axis leadscrew (see “Thermal Growth” section).

Part faces are conical

• Wedge may be out of alignment due to a crash.

• Check tooling setup. Turning long, unsupported parts may cause conical part faces.
• Check for thermal growth of the leadscrews (see Thermal Growth” section).

CL CL CL

Part/Tooling Problem Geometry Problem

Bores are tapered

• Check that tooling and machining practices are correct. Bores will be tapered if the tooling is inappropriate,
the speeds and feeds are incorrect, or coolant is not getting to the cutting tool when required.
• Although it is rare, the spindle may be out of alignment due to a crash
• Check that the turret face is parallel with x-axis.

CL

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Outside diameter (O.D.) is tapered

• Check tooling setup. Turning long, unsupported parts can cause a tapered O.D.
• Check tailstock setup. Excessive hold pressure on the tailstock can distort parts.
• Spindle to Z-axis may be out of alignment (not parallel).
• Program around it. Reduce depth of final rough cut and finish pass to reduce part deflection.

CL CL

Poor Geometry

CL CL

CL

Poor Technique

Material left after facing a part

• Ensure tooling is correct.

• Ensure turret is aligned to X-axis travel.
• Ensure Parameter 254, Spindle Center, is set correctly.

Material Left After Facing Part

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FINISH

Machining yields a poor finish

• Check the condition of the tooling and the spindle.

• Ensure turret is clamped.
• Ensure tooling is tight.
• Check tooling for chatter or lack of rigidity.
• Check the balance of the chuck, part, and fixture.
• Check for backlash.
• Check turret alignment.

THERMAL GROWTH

A possible source of accuracy and positioning errors is thermal growth of the leadscrews. As the machine
warms up, the leadscrews expand in both linear axes (X and Z), causing accuracy and positioning errors. This
is especially critical in jobs that require high accuracy.

NOTE: Thermal growth will be more noticeable in the X-axis, since errors will be
doubled when cutting a diameter.

Verify Thermal Growth

There are a number of ways to verify the problem. The following procedure will verify thermal growth of the X-
axis reversed-anchored leadscrew in a machine that has not been warmed up:

1. Home the machine. In MDI mode, press POSIT and PAGE DOWN to the OPER page.

2. Jog to an offset location. Select the X-axis and press the ORIGIN key to zero it.

3. Press the OFSET key, then scroll down to G110 (or any unused offset). Cursor to X and press the
PART ZERO SET key. This will set X) at this position.

4. Enter a program that will start at the new zero position, rapid a certain distance in the X direction,
feed the final .25 inches slowly, and then repeat the X movement.

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5. In order to set up the indicator, run the program in SINGLE BLOCK mode, and stop it when X is at
the end of its set travel. Set the magnetic base on the spindle retainer ring or other rigid surface,
with the indicator tip touching the turret in the X-axis, and zero it.

6. Exit SINGLE BLOCK mode, and run the program for a few minutes. Enter SINGLE BLOCK mode
again, stop the program when X is at the beginning of its travel, and take a final reading on the
indicator. If the problem is thermal growth, the indicator will show a difference in the X position.

NOTE: Ensure the indicator setup is correct as described in “Accuracy” section. Error
in setup are common, and often incorrectly appear to be thermal growth.

7. A similar program can be written to test for thermal growth in the Z-axis.

Solutions
Since there are many variables that affect thermal growth, such as the ambient temperature of the shop and
program feed rates, it is difficult to give one solution for all problems.

Thermal growth problems can generally be eliminated by running a warm-up program for approximately 20
minutes before machining parts. The most effective warm-up is to run the current program, at an offset Z
position before the part. This will allow the leadscrews to warm up to the correct temperature and stabilize.
Once the machine is at temperature, the leadscrews won't expand any further, unless they are allowed to cool
down. A warm-up program should be run after each time the machine is left idle.

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1.2 S PINDLE

N OT TURNING

Spindle not turning

• If there are any alarms, see “Alarms” section.

• Check that the spindle turns freely when machine is off.
• If spindle is still not turning, replace MOCON PCB.
• Disconnect the drive belt. If the spindle will not turn, it is seized and must be replaced.

For Brush machines only:

• If spindle drive does not light the RUN LED, check forward/reverse commands from IOPCB.
Check that the drawtube piston is not bound against the spindle shaft on the air cylinder style.
• Check the wiring of analog speed command from MOTIF PCB to spindle drive (cable 720).
• Disconnect the drive belt. If the spindle will not turn, it is seized and must be replaced.

NOTE: Before using the replacement spindle, the cause of the previous failure must
be determined.

NOISE

Most noise attributed to the spindle actually lie in the motor or drive belt of the machine. Isolate the sources of
noise as follows:

Excessive noise coming from the spindle head area.

• Remove the left end covers and check the machine’s drive belt tension.
• Run the motor with the drive belt disconnected. If the noise persists, the problem lies with the motor. If it
disappears, go on to the next step.
• Check for the correct amount of lubrication to the spindle bearings (1cc per hour) in an air mist lubricated
spindle.

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V ECTOR D RIVE

To properly troubleshoot the Vector Drive, use the following questions as a guide:

• What alarms are generated?

• When does the alarm occur?
• Is the Vector Drive top fault light on?
• Is there a fault light on any of the servo amplifiers?
• Does the alarm reset?
• Does the spindle motor turn at all?
• Does the spindle turn freely by hand?
• Have the C-axis parameters been confirmed?
• What is the input voltage to the vector drive unit?
• What does the DC Bus voltage measure? (320 VDC to 345 VDC)
• Does the DC Bus voltage displayed on the diagnostic page match the measured DC Bus voltage?

All of the questions above must be answered. The DC Bus voltage should be between 320 VDC to 345 VDC
with the machine powered up but not running. If the voltage is not in this range, adjust the taps on the main
line transformer until this voltage range is achieved. There is a possibility the drive is faulty, but low Bus
voltage can also be caused by a shorted REGEN load or a shorted amplifier.

If the DC Bus voltage is below 50 VDC and never goes any higher, perform Steps 1-6.
1. With the machine powered up, is the green “POWER-ON” L.E.D. lit? If not, replace the Vector
Drive unit.

2. Power down the machine. Disconnect the REGEN load (terminals 1 and 2 on the Vector Drive
unit) and measure the resistance from each wire-to-chassis ground (open) and between the wire
leads. The resistance should be 8.6 ohms for machines with 20/15 Vector drives and HT10K mills
equipped with 40/30 drives. All other machines with 40/30 drives should measure 6 ohms. If not,
replace the REGEN load or cabling.

3. Disconnect cable 490 at terminals 2 and 3 of the Vector Drive and from the servo amplifiers. With
a multimeter in the diode mode, place the red meter lead to the +HV terminal and the black meter
lead to the -HV terminal of each amplifier. The meter should read open.

4. Reverse the leads: Place the red meter lead on the -HV terminal and the black lead on the +HV
terminal. 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 Vector Drive. The meter should read
greater than 100K ohms. If not, the Vector Drive is faulty.

6. If the green “POWER-ON” L.E.D. was lit (from Step 2), leave both 490 cables (2 and 3) discon-
nected from the drive and power up the machine.
a. Does the DC Bus voltage come up? If not, the Vector Drive is faulty.
b. Measure the voltage between terminals 1 and 3. The voltage should be 300
VDC or more. If not, the Vector Drive is faulty.
If both ‘a’ and ‘b’ check out okay, there is a problem with either the amplifiers or the REGEN load.

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If the fault occurs upon acceleration -or- the spindle accelerates slowly -or- the spindle
makes noise, do the following:
7. Disconnect the output cables to the spindle motor. Turn on the machine and press <RESET>. Do
not command the spindle to turn. With a volt meter, measure the DC voltage between each output
phase (terminals 9, 10, and 11) to the 320V RTN (terminal 3). The meter should read 165 VDC in
each case, else one phase is faulty.

8. Measure the resistance across the motor wires from phase to phase and from each phase to
chassis. The meter should read .1 ohms phase-to-phase and open phase-to-chassis.

If the fault occurs upon deceleration or acceleration just as the spindle reaches its speci-
fied speed, or if an overvoltage alarm (119) occurred, do the following:
9. Disconnect the REGEN load resistors (terminals 1 and 2) and measure the resistance from each
wire lead-to-chassis ground and between the wire leads. The meter should read open lead-to-
ground, and 6 ohms between the leads for machines with 40/30 Vector drives and 8.6 ohms
between the leads on machines with 20/15 Vector drives and HT10K mills.

10. Measure the resistance from terminal 1 to terminal 3. If the resistance is less than 100K, the drive
is faulty.

11. With the REGEN load left disconnected, power-up the machine and command a spindle speed of
700 RPM (300 RPM for lathes in high gear). Press <RESET> while monitoring the DC voltage
between terminal 1 and terminal 3. The voltage should read 330 VDC and then drop to less than
50 VDC momentarily. If not, that drive is faulty. If the voltage at RESET was okay and the alarm
was resettable, the REGEN load should be replaced even if the resistance appears to be

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1.3 T RANSMISSION (SL 30 AND 40)

The transmission cannot be serviced in the field and must be replaced as a unit. Never remove the motor from
the transmission, as this will damage the transmission and void the warranty.

NOISE

Excessive or unusual noise coming from transmission.

Operate the machine in both high and low gears. Monitor for noise in both gear positions, and determine if the
noise varies with the motor or output shaft speed.

• If the noise only occurs in one gear throughout the entire RPM range of that gear position, the problem lies
with the transmission, and it must be replaced.
• If the noise occurs in both gear positions, disconnect the drive belts (see “Transmission” section, Mechani-
cal Service) and repeat the previous step. If the noise persists, the transmission is damaged and must be
replaced.
• Disconnect the drive belts (see “Transmission” section, Mechanical Service) and run the machine in high
gear. Command a change of direction and listen for a banging noise in the transmission as the machine
slows down to zero RPM and speeds back up in reverse. If the noise occurs, the motor has failed and the
transmission must be replaced.

G EARS W ILL N OT C HANGE

Machine will not execute a gear change.

• Check the voltage to the gear shifter motor. The voltage between pins 2 and 3 should be approximately
+28V when high gear is commanded and -28V when low gear is commanded. If these voltages are correct,
the gear shifter motor has failed and the transmission must be replaced. If these voltages are incorrect, the
cabling or transmission power supply is at fault.

I NCORRECT G EAR SELECTED OR SENSED

Spindle speed is not consistent with selected gear.

• Monitor the discrete inputs and outputs SP HIG and SP LOW on the diagnostics display while command-
ing high and low gear. The output SP HIG should be 1 when high gear is selected, and SP LOW should be
1 when low gear is selected. The inputs SP HIG and SP LOW should be 0 when that gear is engaged, and
should both be 1 when the transmission is between gears. These inputs should never read 0 at the same
time.

If any of these inputs/outputs are incorrect, either the gear change limit switches or the wiring to the I/O PCB is
at fault. The limit switches are located inside the transmission, and cannot be replaced.

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1.4 S ERVO M OTORS / L EADSCREWS

N OT OPERATING

All problems that are caused by servo motor failures should also register an alarm. Check the alarm history to
determine the cause of the problem before any action is taken.

Servo motor is not functioning.

• Check the power cable from rear electrical cabinet to ensure connection is tight.
• Encoder is faulty or contaminated (Alarms 139-142, 153-156, 165-168, 182-185). Replace motor
assembly on brushless machines
• Open circuit in motor (Alarms 139-142, 153-156, 182-185). Replace motor assembly ("Axis Motor
Removal / Installation").
• Motor has overheated, resulting in damage to the interior components (Alarms 135-138, 176).
Replace motor assembly ("Axis Motor Removal/Installation").
• Wiring is broken, shorted, or missing shield (Alarms 153-156, 175, 182-185).
• Motor has overheated; no damage to the interior components. OVERHEAT alarm has been
triggered. After thorough check of motor (DO NOT DISASSEMBLE!), take necessary steps to
eliminate the problem and alarm to resume operation. If motor is still inoperable, replace motor
assembly ("Axis Motor Removal/Installation").
• Check for broken or loose coupling between the servo motor and the lead screw. Replace or repair
the coupling ("Axis Motor Removal/Installation")
• Check for a damaged lead screw, and replace if necessary ("Lead Screw Removal and Installation"
section).

NOTE: If a lead screw fails, it is most often due to a failed bearing sleeve. When
replacing the lead screw in an older machine, always replace the bearing
sleeve with the current angular contact bearing sleeve ("Bearing Sleeve
Removal and Installation" section).

NOISE

Lead screw noise is usually caused by a lack of lubrication and is usually accompanied by heating. Other
causes are misalignment, bearing sleeve damage, or ball nut damage. Check the alarm history of the machine
and look for axis overcurrent and following error alarms.

NOTE: Do not replace lead screws or bearing sleeves without due consideration; they
are extremely durable and reliable. Verify that customer complaints are not due
to tooling, programming, or fixturing problems.

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Servo motor noise.

•Disconnect the servo motor from the lead screw and rotate by hand. If the noise persists, replace
the motor assembly ("Axis Motor Removal/Installation" section).
•If motor noise is caused by motor bearings, replace motor.

Lead screw noise.

• Ensure oil is getting to the lead screw through the lubrication system. Look for a plugged metering
valve.
• Check for damage to the bearing sleeve.

NOTE: The current angular contact design sleeve has a fixed pre-load; it cannot be
adjusted.

• Run the axis back and forth. The motor will get very hot if the bearing sleeve is damaged. If so, turn
the axis by hand and feel for roughness in the lead screw. Loosen the clamp nuts at both ends of
the lead screw. If the symptom disappears, replace the bearing sleeve. Be certain to check for
damage to the lead screw shaft where the bearing sleeve is mounted. If the noise persists, the lead
screw is damaged and must be replaced. When replacing the lead screw in an older machine,
always replace the bearing sleeve with the current angular contact design bearing sleeve.
• Misalignment in the lead screw itself will tend to cause the lead screw to tighten up and make
excessive noise at both ends of the travel. The ballnut may get hot. Misalignment radially at the
yoke where the lead screw ball nut mounts is indicated by heating up of the ball nut on the lead
screw, and noise and tightness throughout the travel of the lead screw. Misalignment at the yoke
where the ball nut mounts is indicated by noise and tightness at both ends of the travel of the lead
screw. The ball nut may get hot.

NOTE: Customer complaints of Lead Screw noise may not indicate a bad screw.
Screws from different manufacturers produce varying levels of noise. Often
machines are built with two or more different brands of screws in the same
machine. If complaints are generated about one axis screw in comparison to
another, it is possible that the screws are simply sourced from different
manufacturers.

A CCURACY / B ACKLASH

Accuracy complaints are usually related to tooling, programming, or fixturing problems. Eliminate these
possibilities before working on the machine.

Poor Z-axis accuracy.

• Check for a loose encoder on the servo motor. Also, ensure the key in the motor or the lead screw is in
place and the coupling is tight (Brush motors only).
• Check parameters for that axis.
• Check for backlash in the lead screw as outlined below.

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Initial Preparation-
Turn the lathe ON. ZERO RET the machine and move the carriage to the approximate center of its travel in the
Z-axis. Move the turret to the approximate center of the X-axis travel.

X-Axis:
1. Place a dial indicator and base on the spindle retaining ring with the tip of the indicator positioned
on the outside diameter of the turret, as shown in Fig. 1.4-1

Fig. 1.4-1 Dial indicator in position to check X-axis.

2. Set dial indicator and the “Distance to go” display in HANDLE JOG mode to zero as follows:
• Zero the dial indicator.
• Press the MDI button on the control panel.
• Press the HANDLE JOG button on the control panel.

The “Distance to go” display on the lower right hand corner should read: X=0 Z=0

3. Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) X
direction. Jog back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.

4. Repeat step 3 in the negative (-) direction.

TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY
SHOULD NOT EXCEED .0002.
An alternate method for checking backlash is to place the dial indicator as shown in Fig. 4-1 and manually
push on the turret in both directions. The dial indicator should return to zero after releasing the turret.

NOTE: The servos must be on to check backlash by this method.

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Z-Axis:

1. Place a dial indicator and base on the spindle retaining ring with the indicator tip positioned on the
face of the turret as shown in Fig. 1.4-2.

Fig. 1.4-2 Dial indicator in position to check Z-axis

2. Set dial indicator and the “Distance to go” display in the HANDLE JOG mode to zero as follows:
• Zero the dial indicator.
• Press the MDI button on the control panel.
• Press the HANDLE JOG button on the control panel. The “Distance to go: display on the lower
right hand corner should read: X=0, Z=0

3. Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) Z
direction. Jog back to zero (0) on the display. The dial indicator should read (0) ± .001.

4. Repeat Step 3 in the negative (-) direction.

TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY
SHOULD NOT EXCEED .0002.
An alternate method for checking backlash is to place the dial indicator as shown in Fig. 4-2 and manually
push on the turret in both directions. The dial indicator should return to zero after releasing the turret.

NOTE: The servos must be on to check backlash by this method.

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VIBRATION

Excessive servo motor vibration.

• Check all Parameters of the suspected axis against the Parameters as shipped with the machine. If
there are any differences, correct those and determine how the Parameters were changed.
• A bad motor can cause vibration if there is an open or short in the motor. A short would normally
cause a GROUND FAULT or OVERCURRENT alarm; check the ALARMS. An ohmmeter applied to the
motor leads should show between 1 and 3 ohms between leads, and over 1 megohm from leads to
chassis. If the motor is open or shorted, replace.

OVERHEATING

Servo motor overheating.

• If a motor OVERHEAT alarm occurs (ALARMS 135-138), check the Parameters for an incorrect
setting. Axis flags in Parameters 1, 15, or 29 can invert the overheat switch (OVER TEMP NC).
• If the motor is actually getting hot to the touch, there is excessive load on the motor. Check the user’s
application for excessive load or high duty cycle. Check the lead screw for binding ("Accuracy/
Backlash" section). If the motor is binding by itself, replace in accordance with "Axis Motor Removal/
Installation".

SERVO ERROR

“Servo Error Too Large” alarms occur on one or more axes sporadically.

• Check motor wiring for shorts.

• Driver card may need replacement.
• Servo motor may need replacement.
• Check for binding in motion of lead screw.

L EAD S CREWS - V ISUAL I NSPECTION

The three main causes of Lead Screw failure are:

Loss of Lubrication
Contamination
Machine Crash

Wear of the Nut balls and the screw threads is generally not an issue under proper operating conditions.

Each type of suspect cause will leave telltale signs on the Lead Screw itself.

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Loss of Lubrication:
The lubrication system of the machine provides a layer of oil for the Lead Screw components to operate on,
eliminating metal-to-metal contact. Should a problem with the lubrication system develop, that failure will
accelerate all wear issues.

1. Dry metal-to-metal contact following lube breakdown will create intense heat at the contact points.
The Nut balls will weld to the Nut races due to the heat and pressure of the preload. When
movement of the Lead Screw continues, the welds will be broken, ripping off particles of both the
balls and the races. This loss of diameter will reduce the preload, reducing machine accuracy.
Lead Screws with this type of wear, but no screw surface marring, can be repaired by the factory.

2. A second cause of wear of the Lead Screws is material fatigue. Material fatigue typically occurs at
the end of the Lead Screw service life. Signs of material fatigue include black, contaminated
coolant, pitting of the screw surface, loss of preload, and metal flakes on the Lead Screw.
Lead Screws suffering from material fatigue are not repairable and are considered scrap.

Contamination:
Contamination of the lubrication and/or coolant systems of the machine will produce problems with the Lead
Screws.

Check the condition of the lube on the Lead Screw threads.

1. If the lube is wet and clean, this indicates a properly functioning lube system.

2. If the lube is thick and dark, but free of metal chips, the lube itself is old and must be changed out.
The entire system should be cleaned of the old lube.

3. If the lube is wet and black, the lube system has been contaminated by metal particles. Inspect
the Lead Screws for wear.

Contamination of the lube and/or coolant systems can be caused by a wearing Lead Screw, or by metal chips
entering the systems through open or loose way covers. Check all way covers and seals for excessive clear-
ances.

Machine Crash:
A hard machine crash can cause a Lead Screw to lock up. The static overload created during a machine crash
can break apart the Nut balls, denting the thread surfaces. Turning the Nut by hand will result in an obvious
grinding feeling and/or sound.

1. Check the screw for straightness.

2. Look for ball dents at the ends of the screw length. These indents will be a sure sign of a hard
machine crash. The inertia of the table is transferred, due to the sudden stop, directly to the balls
inside the Nut, creating impressions on the screw surface.

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CLEANING

In most cases, a thorough cleaning of the suspect Lead Screw will resolve “bad screw” issues, including noise
complaints.

1. Manually jog the Nut to one end of the screw.

2. Visually inspect the screw threads. Look for metal flakes, dark or thick lube, or contaminated
coolant: See Visual Inspection - Contamination above.

3. Use alcohol, or other approved cleaning agents, to wash the screw.

CAUTION! Do not use detergents, degreasers, or solvents to clean Lead Screws

or their components. Do not use water-based cleaners to avoid rust.

4. Jog the Nut to the other end of its travel. If metal flakes are now present on the screw threads, you
may have wear issues.

5. Re-lubricate screw threads before returning the machine to service.

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1.5 T URRET C LAMP / U NLCAMP

ALARM 113 and 114

1) Check the tool changer solenoid.
A) Does the solenoid appear to be activating.?
I) If no, check power to the solenoid during a tool change. If there is voltage replace the solenoid.
II) If yes, go on.
B) Are the exhaust mufflers dirty?
I) If yes, remove the muffler and do a tool change. If the alarm goes away then replace the muffler
II) If no, proceed to the next step.
C) Is there water in the airlines?
I) If yes, insure that the air is now dry and replace the solenoid.
II) If no, proceed to the next step.

2) Check air pressure.

A) Is the main regulator set to a minimum 85 psi?
B) Does the air pressure drop more than 10 psi during a tool change?
I) If no, go to the next check.
II) If yes, the lathe has an insufficient volume of air. Must have a supply of 100 psi at 4 sfm at the
regulator. A small diameter air supply hose, hose length, and fitting size may restrict the volume
of air going to the machine.

3) Remove the top toolchanger cover. Confirm that the air cylinder is fully clamping (114 alarm) or fully
unclamping (113 alarm).
A) If yes, go to the next check,.
B) If no, try to push the air cylinder into position.
I) If the air cylinder will not fully clamp or unclamp disconnect the air cylinder from the cam lever
and retry. If the air cylinder still does not fully clamp or unclamp, replace the air cylinder.
II) If the air cylinder fully clamps and unclamps then:
1) Cam balls fell out of time with each other. This would be more common on the original
style cams. This design does not have a cage. Fully clamping the air cylinder by hand
should position the 3 balls correctly.
2) If this problem persists then the cams might be damaged. Replace with part numbers
93-8138 “cam upgrade kit”. This is a cam assembly with the cage. It is compatible with
all lathes.

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4) Clamp switch or unclamp switch is failing or is out of adjustment. (Reed style or telemecanique switches).
A) Switch identification and adjustment.

I) Reed style switches- these types of clamp/unclamp switches are mounted on the air cylinder to
detect the clamp and unclamp position of the turret. The air cylinder has a magnetic piston,
which activates the switch when the magnetic piston is under it. This style detects the move-
ment of the piston, not the turret shaft.

1) Adjust the switch by first confirming that the air cylinder is fully clamped. While observ-
ing the diagnostic data for the control, slide the switch in one direction until the bit
changes from a “1” to a “0”. Mark the position with a pen then do the same while sliding
the switch in the other direction. Position the switch between the two markings and
tighten the clamp.

2) If the alarm still persists then the switch might be failing. Change the clamp switch with
the unclamp switch at the air cylinder and at the lube panel. If the problem goes away
or changes to an unclamp alarm then replace the switch.
II) Telemecanique clamp/unclamp switches at the rear of the turret shaft- these
types of switches detect the position of the turret shaft during a tool change,
these switches are installed on the same bracket which supports the turret
home switch, also called the a-axis home switch.
The amount of shaft movement or turret pop out is very important with this style
of switch. The switches are a direct indication of the position of the shaft. If the
turret in/out travel is not adjusted correctly or the switch bracket is holding the
switches too far apart then alarms during a tool change will occur.

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1.6 H YDRAULIC S YSTEM

H YDRAULIC PRESSURE

“Low hydraulic pressure” alarm (143).

• Check for any leaks.

• Check that the oil level is above the black line.
• Check that the oil pressure is within 50-500 psi. If the hydraulic unit needs to be replaced, see “Hydraulic
Unit Removal/Installation” section.
• Check that the temperature is less than 150 degrees. If the hydraulic unit needs to be replaced, see “Hydrau-
lic Unit Removal/Installation” section.
• Phasing changes cause the hydraulic unit to change directions resulting in alarm 134.
• Make sure the filter has been replaced within the last 6 months.
• If pressure drops below 40 PSI during activation of chuck or tailstock, an alarm will occur.

H YDRAULIC CHUCK

Chuck won’t clamp/unclamp.

• Check for alarm condition.

• Check display for “Low Hydraulic Pressure” alarm (134).
• Check that the oil pressure gauge is within 50-500 psi.
• Use a voltage meter to check the solenoid circuit breaker. Replace solenoid valve if faulty.

N OISE IN H YDRAULIC P OWER U NIT

Hydraulic power unit noise

NOTE: Noise in hydraulic unit should decrease a few minutes after start up

• Check for leaks in hose.

• Check that the oil level is above the black line.
• Check for loose pieces/hardware.
• Check for debris in motor/cooling fins.
• Remove, clean, and reinstall adjustment valves.

H YDRAULIC TAILSTOCK

Tailstock pulsates as it moves

Check operating pressure (Minimum operating pressure is 120 psi.).
Check for leaks at hydraulic cylinder.
Check for leaks at hose fittings.

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1.7 ELECTRICAL T ROUBLESHOOTING

CAUTION! Before working on any electrical components, power off the machine
and wait approximately 10 minutes. This will allow the highvoltage
power on the brushless amplifiers to be discharged.

ELECTRICAL A LARMS

Axis Drive Fault Alarm

• Blown amplifier - indicated by a light at bottom of amplifier when power is on. Replace amplifier.
• Amplifier or MOCON is noise sensitive. If this is the case, the alarm can be cleared and the axis
will run normally for a while.
To check an amplifier, switch the motor leads and control cables between the amplifier and the one
next to it. If the same problem occurs with the other axis, the amplifier must be replaced. If the
problem stays on the same axis, It is either the MOCON or control cable. The problem could also
be the axis motor itself, with leads either shorted to each other or to ground, which is very rare.
• Amplifier faulting out for valid reason, such as overtemp, overvoltage, or +/-12 volt undervoltage
condition. This usually results from running a servo intensive program, or unadjusted 12 volt power
supply. Adjust voltage to correct specifications or replace the power supply.
Overvoltage could occur if regen load is not coming on, but this does not usually happen. The
problem could also be the axis motor itself, with leads either shorted to each other or to ground,
which is very rare.

Axis Overload

• The fuse function built into the MOCON has been overloaded, due to a lot of motor accel/decels, or
hitting a hard stop with the axis. This safety function protects the amplifier and motor, so find the
cause and correct it. If the current program is the cause, change the program. If the axis hits a
hard stop, the travel limits may be set wrong.

Phasing Error

• The MOCON did not receive the proper phasing information from the motors. DO NOT RESET the
machine if this alarm occurs. Power the machine down and back up. If the problem persists, it is
probably a broken wire or faulty MOCON connectors. This problem could also be related to the
Low Voltage Power Supply. Check to see if the LVPS is functioning properly.

Servo Error Too Large

• This alarms occurs when the difference between the commanded axis position and the actual
position becomes larger than the maximum that is set in the parameter.
This condition occurs when the amplifier is blown, is not receiving the commands, or the 320 volt
power source is dead. If the MOCON is not sending the correct commands to the amplifier, it is
probably due to a broken wire, or a PHASING ERROR that was generated.

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Axis Z Fault or Z Channel Missing

• During a self-test, the number of encoder counts was found to be incorrect. This is usually caused
by a noisy environment, and not a bad encoder. Check all shields and grounds on the encoder
cables and the motor leads that come into the amplifiers. An alarm for one axis can be caused by
a bad grounding on the motor leads of another axis.

Axis Cable Fault

• During a self-test, the encoder cable signals were found to be invalid. This alarm is usually caused
by a bad cable, or a bad connection on the motor encoder connectors. Check the cable for any
breaks, and the encoder connectors at the motor controller board. Machine noise can also cause
this alarm, although it is less common.

Alarm 101, "MOCON Comm. Failure"

• During a self-test of communications between the MOCON and main processor, the main
processor does not respond, and is suspected to be dead. This alarm is generated and the servos
are stopped. Check all ribbon cable connections, and all grounding. Machine noise can also
cause this alarm, although it is less common.

Alarm 157, "MOCON Watchdog Fault"

• The self-test of the MOCON has failed. Replace the MOCON.

Alarm 354 - Aux Axis Disconnected

When this alarm is generated, do not press RESET. Turn Setting 7 OFF. Enter DEBUG mode, then view the
Alarms/Messages page. On the Messages page, a code will appear similar to WO1. The list of codes and
their descriptions appears below:

WO1 Power was just turned on or failed. Check the ribbon cables from the Aux Axis PCB to the proces-
sor for correct routing. Check for communication problems between the processor and the Aux
Axis PCB.

WO2 Servo following error too large. Check the encoder for contamination or dirt. Check for an intermit-
tent connection at both ends of the motor cable.

WO3 Emergency Stop. The E-STOP button was pressed, or an E-STOP condition occurred.

WO4 High load. Check for binding in the tool changer gearbox and motor. Rotate the carousel by hand
and feel for any binding. Make sure the tool holders are the correct weight.

WO5 Remote RS-232 commanded off. Check the ribbon cable and the voltage to the Aux Axis PCB.
Check for 115VAC (minimum) to the Aux Axis PCB from the main transformer. Check the fuse
holder and the fuse that is protecting this circuit.

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 June 2001 TROUBLESHOOTING

WO6 Air or limit switch or motor overheat. Check that the motor is not hot. Check for any binding in the
motor. Check for overweight tooling.

WO7 Z channel fault. Either the encoder or the cable is bad. Change the encoder first, as it is easier to
change than the cable. If the problem persists, change the cable.

WO8 Over-current limit, stalled or PCB fault. Check for binding in the tool changer gearbox. Make sure
the belt is not too tight. Ohm out the motor cable, checking pins G to F (should be open), G to H
(should be open), and F to H (should read between 2.5 and 5 ohms). Check all the connections on
the Aux Axis PCB and motor cable.

WO9 Encode ES. Z channel is missing. Bad encoder or cable. See WO7.

WOA High voltage. Check the incoming voltage to the Aux Axis PCB. Incoming voltage must be 115
VAC. See WO5.

WOB Cable fault. Check the cable from the motor to the Aux Axis PCB. Check for loose connections at
each end.

PROCESSOR STACK DIAGNOSTIC

(DISCONNECT CABLES FROM A NORMAL OPERATING SYSTEM)

Remove low voltage cable from the Video & Keyboard PCB

• Processors LED's are normal.

• Runs fine and the CRT is Normal.
• No keypad beep.

Remove the Data & or Address buss from the Video & Keyboard PCB

• Processors LED's Normal - then Run goes out.

Remove the Data & or Address buss from the Micro Processor PCB

• Processors LED's - CRT and Run are out.

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K EYBOARD D IAGNOSTIC

NOTE: Refer to the "Cable Locations" section of this manual for a drawing of the
Keyboard Interface PCB.

NOTE: This Keyboard Grid is for machines with a Keyboard Interface only. This
Keyboard Grid is not for machines with a Serial Keyboard Interface.

The following is an example of how to troubleshoot the keypad:

NOTE: Keypad Diodes 1-24 correspond to chart numbers 1-24.

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Example

1. Pressing the RESET button will cause diodes 1 and 17 to conduct.

• With the POWER OFF read across diode 1.
• A typical reading is between .400-.700 ohms, note your reading.

2. Press and hold the RESET button. If the diode is conducting, the reading should drop about .03 ohms.
• (If your reading was .486 and it dropped to .460, for a difference of .026; the diode is
good).
• The same will hold true for diode 17 in this example. If the reading stays the same or there
is no change, the diode is not conducting. Pull P2 and read between pins 1 and 17.
• Press and hold <RESET>. The meter should read a short (0 ohms) if not the keypad is
bad.

ETHERNET

Error 53 The computer name specified in the network path cannot be located

This error usually happens when NET USE C: \\SERVER\HAAS/PERSISTENT: NO /YES is entered during the
setup phase.

To fix this error first verify the following:

1. A 10 Base-T network is present.

2. The network cable is coming from a hub (not the server).
3. The server name that you specified in yo
2. u NET USE command is correct.
4. Your network is running IPX/SPX protocol.

If all of the above is correct and communications between the Haas CNC and the network are not established,
there may be compatibility issues between an older Novell network and an NT 4.0 server. If the NWLink IPX/
SPX Compatible Transport on the NT server is set to auto detect the protocol’s frame, the NT server may be
detecting the Novell server first and setting the NWLink IPX/SPX Compatible Transport frame protocol to 802.3
The NWLink IPX/SPX Compatible Transport required for the mills to connect to an NT server is 802.2. Since
these two frame protocols are different the mill would never connect to the desired NT server. To remedy this
check the following:

1. On the Ethernet boot disk, edit the [Link] file in the NETI directory.
2. Find the line FRAME=ETHERNET_802.2 and change it to FRAME=ETHERNET_802.3
3. Save the file
4. Insert the boot disk back into the CNC and cycle the power.

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 TROUBLESHOOTING June 2001

If an Error 53 is still present, restore the [Link] file to its previous state and do the following to the NT
server:

1. Open the control panel

2. Double click on the Network icon
3. Select the Protocols tab.
4. Highlight NWLINK IPX/SPX Compatible Transport.
5. Select properties.
6. Select Manual Frame Type Detection.
7. Click on Add.
8. Select Ethernet 802.2
9. Click on Add.
10. Click OK.
11. Close all windows and reboot the NT server.

Once the NT server is rebooted the NWLINK IPX/SPX Compatible Transport Frames is set to 802.2 and the mill
will be able to see the desired server.

Mill code will not work

Make sure the command in the server routes back to the mill.

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1.8 B ARFEEDER TROUBLESHOOTING

Push finger works but the pushrod will not load (during initial installation), ensure there are relays installed in
the top two tool changer locations on the IOPCB. (K9 and K10). This can occur when installing a barfeeder on
an older machine.

Problem with accuracy or incorrect pushes: Try doing a new set up as G105 Q2, Q4 or Q5 may have inadvert-
ently been changed. Once the barfeeder is installed and running the set up procedures should not have to be
repeated unless the bar feeder is moved or the the collet or chuck is is changed.

The End of Bar switch at the right of the transfer tray has a switch paddle that can stick in the down position.
This will cause erroneous bar lengths and other problems. The switch paddle can be formed slightly to assure
clearance in the opening in the transfer tray.

There is a small ampount of play in between the ball screw and the ball nut. This can set up a small amount of
vibration when very fast spindle speeds are used. This is normal operation and will not affect finished part.

Any time the transport assembly on the bar feeder is disassembled or changed, parameters 240, 1st Aux Max
Travel, and 244, 1st Aux Min Travel, may be affected. If these parameters are not correctly set, malfunctioning
of the pushrod can occur and in some instances the barfeeder can crash. These parameters can be checked
by the following procedure:

1. Zero the bar feeder.

2. In handle jog mode, jog in the minus direction, until the V position on the screen
matches parameter 244.

3. Push down on the control arm positioner on the right side of the pushrod to ensure the rotation
control arm moves smoothly in and out of the notch on the left end. Loosen the two screws on the
fork activator and adjust if necessary.

4. On the left end of the pushrod control arm is a pin that drops onto a notch when the pushrod is
loaded. This pin shopuld be just far enough to the left to clear the lobe in the notch. If this pin is
not in the correct position, use the jog handle to adjust it and enter the new number from the
screen into parameter 244.

5. To adjust parameter 240 ensure the pushrod is unloaded and jog the push finger all the way to the
right. Paramter 240 should be set such that the carriage comes within about 3/8” of the ball screw
support end without hitting it. If not, adjust it using the jog handle and enter the V position from the
CRT into parameter 240.

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2. ALARMS

Any time an alarm is present, the lower right hand corner of the screen will have a blinking "ALARM". Push the
ALARM display key to view the current alarm. All alarms are displayed with a reference number and a com-
plete description. If the RESET key is pressed, one alarm will be removed from the list of alarms. If there are
more than 18 alarms, only the last 18 are displayed and the RESET must be used to see the rest. The pres-
ence of any alarm will prevent the operator from starting a program.

The ALARMS DISPLAY can be selected at any time by pressing the ALARM MESGS button. When there are
no alarms, the display will show NO ALARM. If there are any alarms, they will be listed with the most recent
alarm at the bottom of the list. The CURSOR and PAGE UP and PAGE DOWN buttons can be used to move
through a large number of alarms. The CURSOR right and left buttons can be used to turn on and off the
ALARM history display.

Note that tool changer alarms can be easily corrected by first correcting any mechanical problem, pressing
RESET until the alarms are clear, selecting ZERO RET mode, and selecting AUTO ALL AXES. Some mes-
sages are displayed while editing to tell the operator what is wrong but these are not alarms. See the editing
topic for those errors.

The following alarm list shows the alarm numbers, the text displayed along with the alarm, and a detailed
description of the alarm, what can cause it, when it can happen, and how to correct it.

Alarm number and text: Possible causes:

101 MOCON Comm. Failure During a self-test of communications between the MOCON and main
processor, the main processor does not respond, and is suspected
to be dead. Check cable connections and grounding.

102 Servos Off Indicates that the servo motors are off, the tool changer is disabled,
the coolant pump is off, and the spindle motor is stopped. Caused by
EMERGENCY STOP, motor faults, tool changer problems, or power
fail.

103 X Servo Error Too Large Too much load or speed on X-axis motor. The difference between the
motor position and the commanded position has exceeded a
parameter. The motor may also be stalled, disconnected, or the
driver failed. The servos will be turned off and a RESET must be
done to restart. This alarm can be caused by problems with the
driver, motor, or the slide being run into the mechanical stops.

104 Y Servo Error Too Large Same as alarm 103.

105 Z Servo Error Too Large Same as alarm 103.

106 A Servo Error Too Large Same as alarm 103.

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107 Emergency Off EMERGENCY STOP button was pressed. Servos are also turned
off. After the E-STOP is released, the RESET button must be
pressed at least twice to correct this; once to clear the E-STOP
alarm and once to clear the Servos Off alarm.

108 X Servo Overload Excessive load on X-axis motor. This can occur if the load on the
motor over a period of several seconds or even minutes is large
enough to exceed the continuous rating of the motor. The servos
will be turned off when this occurs. This can be caused by running
into the mechanical stops but not much past them. It can also be
caused by anything that causes a very high load on the motors.

109 Y Servo Overload Same as alarm 108.

110 Z Servo Overload Same as alarm 108.

111 A Servo Overload Same as alarm 108.

112 No Interrupt Electronics fault. Call your dealer.

113 Turret Unlock Fault The turret took longer to unlock and come to rotation position than
allowed for in Parameter 62. The value in Parameter 62 is in
milliseconds. This may occur if the air pressure is too low, the tool
turret clamp switch is faulty or needs adjustment, or there is a
mechanical problem.

114 Turret Lock Fault The turret took longer to lock and seat than allowed for in Parameter
63. The value in Parameter 63 is in milliseconds. This may occur if
the air pressure is too low, the tool turret clamp switch is faulty or
needs adjustment, or there is a mechanical problem.

115 Turret Rotate Fault Tool motor not in position. During a tool changer operation the tool
turret failed to start moving or failed to stop at the right position.
Parameters 62 and 63 can adjust the time-out times. This alarm can
be caused by anything that jams the rotation of the turret. A loss of
power to the tool changer can also cause this, so check CB5 and
relays 1-8, 2-3, and 2-4.

116 Spindle Orientation Fault Spindle did not orient correctly. During a spindle orientation function,
the spindle is rotated until the lock pin drops in; but the lock pin never
dropped. Parameters 66, 70, 73, and 74 can adjust the time-out
times. This can be caused by a trip of circuit breaker CB4, a lack of
air pressure, or too much friction with the orientation pin.

117 Spindle High Gear Fault Gearbox did not shift into high gear. During a change to high gear, the
high gear sensor was not detected in time. Parameters 67, 70 and
75 can adjust the time-out times. Check circuit breaker CB4, the
circuit breaker for the air pressure solenoids and the spindle drive.

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118 Spindle Low Gear Fault Gearbox did not shift into low gear. During a change to low gear, the
low gear sensor was not detected in time. Parameters 67, 70 and 75
can adjust the time-out times. Check the solenoid’s circuit breaker
CB4, and the spindle drive.

119 Over Voltage Incoming line voltage is above maximum. The tool changer, and
coolant pump will stop. If this condition persists, an automatic
shutdown will begin after the interval specified by parameter 296.

120 Low Air Pressure Air pressure dropped below 80 PSI for a period of time defined by
Parameter 76. Check your incoming air pressure for at least 100 PSI
and ensure that the regulator is set at 85 PSI.

121 Low Lub or Low Pressure Way lube is low or empty or there is no lube pressure or too high a
pressure. Check tank at rear of machine and below control cabinet.
Also check connector on the side of the control cabinet. Check that
the lube lines are not blocked.

122 Regen Overheat The regenerative load temperature is above a safe limit. This alarm
will turn off the spindle drive, coolant pump, and tool changer. One
common cause of this overheat condition is an input line voltage too
high. If this condition persists, an automatic shutdown will begin
after the interval specified by parameter 297. It can also be caused
by a high start/stop duty cycle of the spindle.

123 Spindle Drive Fault Overheat or failure of spindle drive or motor. The exact cause is
indicated in the LED window of the spindle drive inside the control
cabinet. This can be caused by a stalled motor, shorted motor,
overvoltage, undervoltage, overcurrent, overheat of motor, or drive
failure.

124 Low Battery Memory batteries need replacing within 30 days. This alarm is only
generated at power on and indicates that the 3.3 volt Lithium battery
is below 2.5 volts. If this is not corrected within about 30 days, you
may lose your stored programs, parameters, offsets, and settings.

125 Tool Turret Fault Turret has not seated itself properly. There may be something
obstructing the turret between the housing and the turret itself.

126 Gear Fault GGearshifter is out of position when a command is given to start a
program or rotate the spindle. This means that the two speed gear
box is not in either high or low gear but is somewhere in between.
Check the air pressure, the solenoid’s circuit breaker CB4, and the
spindle drive. Use the POWER UP/RESTART button to correct the
problem.

127 Door Fault The control failed to detect a low signal at the Door Switch input after
the door was commanded and the Door Switch input was not
received after the door was commanded to close and the time set in
parameter #251 has elapsed.

34 96-8710 rev C
 June 2001 ALARMS

129 M Fin Fault M-Fin was active at power on. Check the wiring to your M code
interfaces. This test is only performed at power-on.

130 Chuck Unclamped The control detected that the chuck is unclamped. This is a possible
fault in the air solenoids, relays on the I/O Assembly, or wiring.

131 Tool Not Clamped When clamping or powering up the machine, the Tool Release
Piston is not Home. “This is a possible fault in the air solenoids,
relays on the I/O Assembly, the drawbar assembly, or wiring.

132 Power Down Failure Machine did not turn off when an automatic power-down was com-
manded. Check wiring to POWIF card on power supply assembly,
relays on the IO assembly, and the main contactor K1.

133 Spindle Brake Engaged The brake is engaged. It must be released before the spindle can
turn.

134 Low Hydraulic Hydraulic pressure is sensed to be low. Check pump pressure
and Pressure hydraulic tank oil level. Verify proper pump and
machine phasing.

135 X Motor Over Heat Servo motor overheat. The temperature sensor in the motor indicates
over 150 degrees F. This can be caused by an extended overload of
the motor such as leaving the slide at the stops for several minutes.

136 Y Motor Over Heat Same as alarm 135.

137 Z Motor Over Heat Same as alarm 135.

138 A Motor Over Heat Same as alarm 135.

139 X Motor Z Fault Encoder marker pulse count failure. This alarm usually indicates that
the encoder has been damaged and encoder position data is
unreliable. This can also be caused by loose connectors at P1-P4.

140 Y Motor Z Fault Same as alarm 139.

141 Z Motor Z Fault Same as alarm 139.

142 A Motor Z Fault Same as alarm 139.

143 Spindle Not Locked Shot pin not fully engaged when a tool change operation is being per
formed. Check air pressure and solenoid circuit breaker CB4. This
can also be caused by a fault in the sense switch that detects the
position of the lock pin.

144 Time-out-Call Your Dealer Time allocated for use prior to payment exceeded. Call your dealer.

96-8710 rev C 35
 ALARMS June 2001

145 X Limit Switch Axis hit limit switch or switch disconnected. This is not normally
possible as the stored stroke limits will stop the slides before they
hit the limit switches. Check the wiring to the limit switches and
connector P5 at the side of the main cabinet. Can also be caused by
a loose encoder shaft at the back of the motor or coupling of motor to
the screw.

146 Y Limit Switch Same as alarm 145.

147 Z Limit Switch Same as alarm 145.

148 A Limit Switch Normally disabled for rotary axis.

149 Spindle Turning Spindle not at zero speed for tool change. A signal from the spindle
drive indicating that the spindle drive is stopped is not present while
a tool change operation is going on.

150 I Mode Out Of Range Internal software error; call your dealer.

151 Low TSC

152 Self Test Fail Control has detected an electronics fault. All motors and solenoids
are shut down. This is most likely caused by a fault of the processor
board stack at the top left of the control. Call your dealer.

153 X-axis Z Ch Missing Broken wires or encoder contamination. All servos are turned off.
This can also be caused by loose connectors at P1-P4.

154 Y-axis Z Ch Missing Same as alarm 153.

155 Z-axis Z Ch Missing Same as alarm 153.

156 A-axis Z Ch Missing Same as alarm 153.

157 MOCON Watchdog Fault The self-test of the MOCON has failed. Replace the MOCON.

158 Video/Keyboard PCB Failure Internal circuit board problem. The VIDEO PCB in the processor
stack is tested at power-on. This could also be caused by a short
in the front panel membrane keypad. Call your dealer.

159 Keyboard Failure Keyboard shorted or button pressed at power on. A power-on test of
the membrane keypad has found a shorted button. It can also be
caused by a short in the cable from the main cabinet or by holding a
switch down during power-on.

160 Low Voltage The line voltage to control is too low. This alarm occurs when the AC
line voltage drops below 190 when wired for 230 volts or drops below
165 when wired for 208 volts.

36 96-8710 rev C
 June 2001 ALARMS

161 X-Axis Drive Fault Current in X servo motor beyond limit. Possibly caused by a stalled or
overloaded motor. The servos are turned off. This can be caused by
running a short distance into a mechanical stop. It can also be
caused by a short in the motor or a short of one motor leads to
ground.

162 Y-Axis Drive Fault Same as alarm 161.

163 Z-Axis Drive Fault Same as alarm 161.

164 A-Axis Drive Fault Same as alarm 161.

165 X Zero Ret Margin Too Small This alarm will occur if the home/limit switches move or are
misadjusted. This alarm indicates that the zero return position may
not be consistent from one zero return to the next. The encoder Z
channel signal must occur between 1/8 and 7/8 revolution of where
the home switch releases. This will not turn the servos off but will
stop the zero return operation.

166 Y Zero Ret Margin Too Small Same as alarm 165.

167 Z Zero Ret Margin Too Small Same as alarm 165.

168 A Zero Ret Margin Too Small Not normally enabled for A-axis.

169 Spindle Direction Fault Problem with rigid tapping hardware. The spindle started turning in
the wrong direction.

170 Phase Loss Problem with incoming line voltage between legs L1 and L2. This
usually indicates that there was a transient loss of input power to the
machine.

171 Rpm Too High To Unclamp The spindle speed exceeded the max speed allowed in parameter
248 to unclamp.

173 Spindle Ref Signal Missing The Z channel pulse from the spindle encoder is missing for hard
tapping synchronization.

174 Tool Load Exceeded The tool load monitor option is selected and the maximum load for a
tool was exceeded in a feed. This alarm can only occur if the tool load
monitor function is installed in your machine.

175 Ground Fault Detected A ground fault condition was detected in the 115V AC supply. This can
be caused by a short to ground in any of the servo motors, the tool
change motors, the fans, or the oil pump.

176 Overheat Shutdown An overheat condition persisted longer than the interval specified by
parameter 297 and caused an automatic shutdown.

96-8710 rev C 37
 ALARMS June 2001

177 Over Voltage Shutdown An overvoltage condition persisted longer than the interval specified
by parameter 296 and caused an automatic shutdown.

178 Divide by Zero Software error, or parameters are incorrect. Call your dealer.

179 Low Trans Oil Pressure

181 Macro not completed-spindle disabled Macro code operating Haas optional equipment (bar feeder, etc.) was
not completed for some reason (ESTOP, RESET, Power Down, etc.).
Check optional equipment and run recovery procedure.

182 X Cable Fault Cable from X-axis encoder does not have valid differential signals.

183 Y Cable Fault Same as alarm 182.

184 Z Cable Fault Same as alarm 82.

185 A Cable Fault Same as alarm 182.

186 Spindle Not Turning Trying to feed while spindle is in the stopped position.

187 B Servo Error Too Large Same as alarm 103.

188 B Servo Overload Same as alarm 108.

189 B Motor Overheat Same as alarm 135.

190 B Motor Z Fault Same as alarm 139.

191 B Limit Switch Same as alarm 145.

192 B Axis Z Ch Missing Same as alarm 153.

193 B Axis Drive Fault Same as alarm 161.

194 B Zero Ret Margin Too Small Same as alarm 165.

195 B Cable Fault Same as 182.

197 100 Hours Unpaid Bill Call your dealer.

198 Spindle Stalled Control senses that no spindle fault has occurred, the spindle is at
speed, yet the spindle is not turning. Possibly the belt between the
spindle drive motor and spindle has slipped or is broken.

199 Negative RPM Internal software error; call your dealer.

38 96-8710 rev C
 June 2001 ALARMS

201 Parameter CRC Error Parameters lost maybe by low battery. Check for a low battery and
low battery alarm.

202 Setting CRC Error Settings lost maybe by low battery. Check for a low battery and low
battery alarm.

203 Lead Screw CRC Error Lead screw compensation tables lost maybe by low battery. Check
for CRC Error low battery and low battery alarm.

204 Offset CRC Error Offsets lost maybe by low battery. Check for a low battery and low
battery alarm.

205 Programs CRC Error Users program lost maybe by low battery. Check for a low battery and
low battery alarm.

206 Internal Program Error Possible corrupted program. Save all programs to disk, delete all,
then reload. Check for a low battery and low battery alarm.

207 Queue Advance Error Software Error; Call your dealer.

208 Queue Allocation Error Software Error; Call your dealer.

209 Queue Cutter Comp Error Software Error; Call your dealer.

210 Insufficient Memory Not enough memory to store users program. Check the space
available in the LIST PROG mode and possibly delete some pro-
grams.

211 Odd Prog Block Possible corrupted program. Save all programs to disk, delete all,
then reload.

212 Program Integrity Error Possible corrupted program. Save all programs to disk, delete all,
then reload. Check for a low battery and low battery alarm.

213 Program RAM CRC Error Electronics fault; Call your dealer.

214 No. of Programs Changed Indicates that the number of programs disagrees with the internal
variable that keeps count of the loaded programs. Call your dealer.

215 Free Memory PTR Changed Indicates the amount of memory used by the programs counted in
the system disagrees with the variable that points to free memory.
Call your dealer.

216 Probe Arm Down While Running Indicates that the probe arm was pulled down while a program was
running.

217 X Axis Phasing Error Error occurred in phasing initialization of brushless motor. This can
be caused by a bad encoder, or a cabling error.

96-8710 rev C 39
 ALARMS June 2001

218 Y Axis Phasing Error Same as alarm 217.

219 Z Axis Phasing Error Same as alarm 217.

220 A Axis Phasing Error Same as alarm 217.

221 B Axis Phasing Error Same as alarm 217.

222 C Axis Phasing Error Same as alarm 217.

223 Door Lock Failure In machines equipped with safety interlocks, this alarm occurs when
the control senses the door is open but it is locked. Check the door
lock circuit.

224 X Transition Fault Illegal transition of count pulses in X axis. This alarm usually
indicates that the encoder has been damaged and encoder position
data is unreliable. This can also be caused by loose connectors at
the MOCON and MOTIF PCB.

225 Y Transition Fault Same as alarm 224.

226 Z Transition Fault Same as alarm 224.

227 A Transition Fault Same as alarm 224.

228 B Transition Fault Same as alarm 224.

229 C Transition Fault Same as alarm 224.

231 Jog Handle Transition Fault Illegal transition of count pulses in jog handle encoder. This alarm
usually indicates that the encoder has been damaged and encoder
position data is unreliable. This can also be caused by loose
connectors.

232 Spindle Transition Fault Illegal transition of count pulses in spindle encoder. This alarm
usually indicates that the encoder has been damaged and encoder
position data is unreliable. This can also be caused by loose
connectors at the MOCON.

233 Jog Handle Cable Fault Cable from jog handle encoder does not have valid differential
signals.

234 Spindle Enc. Cable Fault Cable from spindle encoder does not have valid differential signals.

235 Spindle Z Fault Same as alarm 139.

236 Spindle Motor Overload This alarm is generated in machines equipped with a Haas vector
drive, if the spindle motor becomes overloaded.

40 96-8710 rev C
 June 2001 ALARMS

237 Spindle Following Error The error between the commanded spindle speed and the actual
speed has exceeded the maximum allowable (as set in Parameter
184).

240 Empty Prog or No EOB DNC program not found, or no end of program found.

241 Invalid Code RS-232 load bad. Data was stored as comment. Check the program
being received.

242 No End Check input file for a number that has too many digits.

243 Bad Number Data entered is not a number.

244 Missing ) Comment must end with a " ) ".

245 Unknown Code Check input line or data from RS-232. This alarm can occur while
editing data into a program or loading from RS-232.

246 String Too Long Input line is too long. The data entry line must be shortened.

247 Cursor Data Base Error Software Error; Call your dealer.

248 Number Range Error Number entry is out of range.

249 Prog Data Begins Odd Possible corrupted program. Save all programs to disk, delete all,
then reload.

250 Program Data Error Same as alarm 249.

251 Prog Data Struct Error Same as alarm 249.

252 Memory Overflow Same as alarm 249.

253 Electronics Overheat This alarm is generated if the control cabinet temperature exceeds
135°F. This can be caused by an electronics problem, high room
temperature, or clogged air filter.

254 Spindle Motor Overheat Motor driving spindle is too hot. This alarm is only generated in
machines with a Haas vector drive. The spindle motor temperature
sensor sensed a high temperature for greater than 1.5 seconds.

257 Program Data Error Same as alarm 249.

258 Invalid DPRNT Format Macro DPRNT statement not structured properly.

259 Bad Language Version Call your dealer.

260 Bad Language CRC Indicates FLASH memory has been corrupted or damaged.

96-8710 rev C 41
 ALARMS June 2001

261 Rotary CRC Error Rotary table saved parameters (used by Settings 30, 78) have a CRC
error.

262 Parameter CRC Missing RS-232 or disk read of parameter had no CRC when loading from
disk or RS-232.

263 Lead Screw CRC Missing Lead screw compensation tables have no CRC when loading from
disk or RS-232.

264 Rotary CRC Missing Rotary table parameters have no CRC when loading from disk or RS-
232.

265 Macro Variable File CRC Error Macro variables lost maybe by low battery. Check for a low battery
and low battery alarm. Reload the macro variable file.

268 DOOR OPEN @ M95 START Generated whenever an M95 (Sleep Mode) is encountered and the
door is open. The door must be closed in order to start sleep mode.

270 C Servo Error Too Large Same as alarm 103.

271 C Servo Overload Same as alarm 108.

272 C Motor Overheat Same as alarm 135.

273 C Motor Z Fault Same as alarm 139.

274 C Limit Switch Same as alarm 145.

275 C Axis Z Ch Missing Same as alarm 153.

276 C Axis Drive Fault Same as alarm 161.

277 C Zero Ret Margin Too Small Same as alarm 165.

278 C Cable Fault Same as alarm 182.

292 Mismatch Axis with I, K Chamfering I, (K) was commanded as X axis (Z axis) in the block with chamfering.

293 Invalid I,K or R in G01 The move distance in the block commanded with chamfering, corner
R is less than the chamfering, corner R amount.

294 Not G01 after The command after the block commanded with chamfering, corner R
is not Chamfering, Corner R G01.

295 Invalid Move After Chamfering The command after the block commanded with chamfering, corner R
is either missing or wrong. There must be a move perpendicular to
that of the chamfering block.

42 96-8710 rev C
 June 2001 ALARMS

296 Not One Axis Move Consecutive blocks commanded with chamfering, corner R (i.e., G01
Xb Kk; with Chamfering G01 Zb Ii). After each chamfering block,
there must be a single move perpendicular to the one with chamfer-
ing, corner R amount.

302 Invalid R in G02 or G03 Check your geometry. R must be greater than or equal to half the
distance from start to end.

303 Invalid X, B, or Z in G02 or G03 Check your geometry.

304 Invalid I, J, or K in G02 or G03 Check your geometry. Radius at start must match radius at end of arc
within 0.001 inches (0.01 mm.)

305 Invalid Q in Canned Cycle Q in a canned cycle must be greater than zero and must be a valid N
number.

306 Invalid I, J, K, or Q in Canned Cycle I, J, K, and Q in a canned cycle must be greater than zero.

307 Subroutine Nesting Too Deep Subprogram nesting is limited to nine levels. Simplify your program.

308 Invalid Tool Offset A tool offset not within the range of the control was used.

309 Exceeded Max Feed Rate Use a lower feed rate.

310 Invalid G Code G code not defined and is not a macro call.

311 Unknown Code Possible corruption of memory by low battery. Call your dealer.

312 Program End End of subroutine reached before M99. Need an M99 to return from
sub-routine.

313 No P Code In M97, M98, or G65 Must put subprogram number in P code.

314 Subprogram or Macro Not In Memory Check that a subroutine is in memory or that a macro is defined.

315 Invalid P Code In M97, M98 or M99 The P code must be the name of a program stored in memory
without a decimal point for M98 and must be a valid N number for
M99, G70, 71, 72, and 73.

316 X Over Travel Range X-axis will exceed stored stroke limits. This is a parameter in
negative direction and is machine zero in the positive direction. This
will only occur during the operation of a user's program.

317 Y Over Travel Range Same as alarm 316.

318 Z Over Travel Range Same as alarm 316.

319 A Over Travel Range Not normally possible with A-axis.

96-8710 rev C 43
 ALARMS June 2001

320 No Feed Rate Specified Must have a valid F code for interpolation functions.

321 Auto Off Alarm Occurs in debug mode only.

322 Sub Prog Without M99 Add an M99 code to the end of program called as a subroutine.

324 Delay Time Range Error P code in G04 is greater than or equal to 1000 seconds (over 999999
milliseconds).

325 Queue Full Control problem; call your dealer.

326 G04 Without P Code Put a Pn.n for seconds or a Pn for milliseconds.

327 No Loop For M Code Except M97, M98 L code not used here. Remove L Code.

328 Invalid Tool Number Tool number must be between 1 and the value in Parameter 65.

329 Undefined M Code That M code is not defined and is not a macro call.

330 Undefined Macro Call Macro name O90nn not in memory. A macro call definition is in
parameters and was accessed by user program but that macro was
not loaded into memory.

331 Range Error Number too large.

332 H and T Not Matched This alarm is generated when Setting 15 is turned ON and an H code
number in a running program does not match the tool number in the
spindle. Correct the Hn codes, select the right tool, or turn off Setting
15.

333 X-Axis Disabled Parameters have disabled this axis. Not normally possible.

334 Y-Axis Disabled Same as alarm 333.

335 Z-Axis Disabled Same as alarm 333.

336 A-Axis Disabled An attempt was made to program the A-axis while it was disabled
(DISABLED bit in Parameter 43 set to 1).

337 GOTO or P line Not Found Subprogram is not in memory, or P code is incorrect. P not found

338 Invalid IJK and XYZ in G02 or G03 There is a problem with circle definition; check your geometry.

339 Multiple Codes Only one M, X, Y, Z, A , Q, etc. allowed in any block or two G codes in
the same group. Two or more I,K, R are commanded in the same
block with chamfering, corner rounding

44 96-8710 rev C
 June 2001 ALARMS

340 Cutter Comp Begin With G02 or G03 Select cutter compensation earlier. Cutter comp. must begin on a
linear move.

341 Cutter Comp End With G02 or G03 Disable cutter comp later.

342 Cutter Comp Path Too Small Geometry not possible. Check your geometry.

343 Display Queue Record Full A block exists that is too long for displaying queue. Shorten title block.

344 Cutter Comp With G18 and G19 Cutter comp only allowed in XY plane (G17).

345 Invalid R Value in M19 or G105 R value must be positive.

346 Illegal M Code There was an M85 or M86 commanded. These commands are not
allowed while Setting 51 DOOR HOLD OVERRIDE is OFF.

348 Illegal Spiral Motion Linear axis path is too long. For helical motions, the linear path must
not be more than the length of the circular component.

349 Prog Stop W/O Cancel Cutter Comp Cutter compensation has been cancelled without an exit move.
Potential damage to part.

350 Cutter Comp Look Ahead Error There are too many non-movement blocks between motions when
cutter comp is being used. Remove some intervening blocks.

351 Invalid P Code In a block with G103 (Block Lookahead Limit), a value between 0 and
15 must be used for the P code.

352 Aux Axis Power Off Aux B, C, U, V, or W axis indicate servo off. Check auxiliary axes.
Status from control was OFF.

353 Aux Axis No Home A ZERO RET has not been done yet on the aux axes. Check auxiliary
axes. Status from control was LOSS.

354 Aux Axis Disconnected Aux axes not responding. Check auxiliary axes and RS-232 connec-
tions.

355 Aux Axis Position Mismatch Mismatch between machine and aux axes position. Check aux axes
and interfaces. Make sure no manual inputs occur to aux axes.

356 Aux Axis Travel Limit Aux axes are attempting to travel past their limits.

357 Aux Axis Disabled Aux axes are disabled.

358 Multiple Aux Axis Can only move one auxiliary axis at a time.

359 Invalid I, J Or K In G12 Or G13 Check your geometry.

96-8710 rev C 45
 ALARMS June 2001

360 Tool Changer Disabled Check Parameter 57. Not a normal condition for the Lathe.

361 Gear Change Disabled Not used.

362 Tool Usage Alarm Tool life limit was reached. To continue, reset the usage count in the
Current Commands display and press RESET.

363 Coolant Locked Off Override is off and program tried to turn on coolant.

364 No Circ Interp Aux Axis Only rapid or feed is allowed with aux axes.

366 Cutter Comp Interference G01 cannot be done with tool size.

367 Cutter Comp Interference G01 cannot be done with tool size.

368 Groove Too Small Tool too big to enter cut.

369 Tool Too Big Use a smaller tool for cut.

372 Tool Change in Canned Cycle Tool change not allowed while canned cycle is active.

373 Invalid Code in DNC A code found in a DNC program could not be interpreted because of
DNC restrictions.

374 Missing XBZA in G31 or G36 G31 skip function requires an X, B, Z, or A move.

376 No Cutter Comp In Skip Skip G31 function cannot be used with cutter compensation.

377 No Skip in Graph/Sim Graphics mode cannot simulate skip function.

378 Skip Signal Found Skip signal check code was included but skip was found when it was
not expected.

379 Skip Signal Not Found Skip signal check code was included but skip was not found when it
was expected.

380 X,B,A Or G49 Not Allowed In G37 G37 may only specify Z-axis and must have tool offset defined.

381 G43,G44 Not Allowed In G36 Or G136 Auto work offset probing must be done without tool offset.

382 D Code Required In G35 A Dnn code is required in G35 in order to store the measured tool
diameter.

383 Inch Is Not Selected G20 was specified but settings have selected metric input.

384 Metric Is Not Selected G21 was specified but settings have selected inches.

46 96-8710 rev C
 June 2001 ALARMS

385 Invalid L, P, or R Code in G10 G10 was used to changes offsets but L, P, or R code is missing or
invalid.

386 Invalid Address Format An address A..Z was used improperly.

387 Cutter Comp Not Allowed With G103 If block buffering has been limited, Cutter comp cannot be used

388 Cutter Comp Not Allowed With G10 Coordinates cannot be altered while cutter comp is active. Move G10
outside of cutter comp enablement.

389 G17, G18, G19 Illegal in G68 Planes of rotation cannot be changed while rotation is enabled.

390 No Spindle Speed S code has not been encountered. Add an S code.

391 Feature Disabled An attempt was made to use a control feature not enabled by a
parameter bit. Set the parameter bit to 1.

392 B Axis Disabled Same as alarm 333.

393 Invalid Motion in G84 or G184 Rigid Tapping can only be in the Z minus G74 or G84 direction.
Make sure that the distance from the initial position to the com-
manded Z depth is in the minus direction.

394 B Over Travel Range The tailstock (B-axis) has exceeded it's maximum range of travel.

395 Invalid Code in Canned Cycle Any canned cycle requiring a PQ path sequence may not have an M
code in the same block. That is G70, G71, G72, and G73.

396 Conflicting Axes An Incremental and Absolute command can not be used in the same
block of code. For example, X and U cannot be used in the same
block.

397 Invalid D Code In the context that the D code was used it had an invalid value. Was it
positive?

398 Aux Axis Servo Off Aux. axis servo shut off due to a fault.

399 Invalid U Code In the context that the U code was used it had an invalid value. Was it
positive?

403 RS-232 Too Many Progs Cannot have more than 200 programs in memory.

404 RS-232 No Program Name Need name in programs when receiving ALL; otherwise has no way
to store them.

405 RS-232 Illegal Prog Name Check files being loaded. Program name must be Onnnnn and must
be at beginning of a block.

96-8710 rev C 47
 ALARMS June 2001

406 RS-232 Missing Code A receive found bad data. Check your program. The program will be
stored but the bad data is turned into a comment.

407 RS-232 Invalid Code Check your program. The program will be stored but the bad data is
turned into a comment.

408 RS-232 Number Range Error Check your program. The program will be stored but the bad data is
turned into a comment.

409 RS-232 Invalid N Code Bad Parameter or Setting data. User was loading settings or param-
eters and something was wrong with the data.

410 RS-232 Invalid V Code Bad parameter or setting data. User was loading settings or param-
eters and something was wrong with the data.

411 RS-232 Empty Program Check your program. Between % and % there was no program found.

412 RS-232 Unexpected End of Input Check Your Program. An ASCII EOF code was found in the input data
before the complete program was completely received. This is a
decimal code 26.

413 RS-232 Load Insufficient Memory Program received doesn’t fit. Check the space available in the LIST
PROG mode and possibly delete some programs.

414 RS-232 Buffer Overflow Data sent too fast to CNC. This alarm is not normally possible as
this control can keep up with even 38400 bits per second.

415 RS-232 Overrun Data sent too fast to CNC. This alarm is not normally possible as
this control can keep up with as much as 38400 bits per second.

416 RS-232 Parity Error Data received by CNC has bad parity. Check parity settings, number
of data bits and speed. Also check your wiring.

417 RS-232 Framing Error Data received was garbled and proper framing bits were not found.
One or more characters of the data will be lost. Check parity settings,
number of data bits and speed.

418 RS-232 Break Break condition while receiving. The sending device set the line to a
break condition. This might also be caused by a simple break in the
cable.

419 Invalid Function For DNC A code found on input of a DNC program could not be interpreted.

420 Program Number Mismatch The O code in the program being loaded did not match the O code
entered at the keyboard. Warning only.

423 Servo Bar Eob Switch Position Unknown Place 12 inch standard bar in charging position and run G105 Q5 to
set End of Bar Switch Position.

48 96-8710 rev C
 June 2001 ALARMS

424 Servo Bar Metric Unsupported Metric mode is currently unsupported. Change setting (9) to inch.

425 Servo Bar Length Unknown Both the bar length and reference position are unknown. Unload bar,
Run G105 Q4 followed by G105 Q2 or Q3.

426 Servo Bar Illegal Code G105 (feed bar) commanded with an illegal code on block. Legal
codes are I,J,K,P,Q,R

428 Servo Bar Switch Failure One of the switches controlling the Servo Bar failed.

429 Disk Dir Insufficient Memory Disk memory was almost full when an attempt was made to read the
disk directory.

430 Disk Unexpected Check your program. An ASCII EOF code was found in the input data
End of Input before the complete program was received. This is a
decimal code 26.

431 Disk No Prog Need name in programs when receiving ALL; otherwise has no way
to store them.

432 Disk Illegal Prog Name Check files being loaded. Program must be Onnnnn and must be at
the beginning of a block.

433 Disk Empty Prog Name Check your program. Between % and % there was no program
found.

434 Disk Load Insufficient Memory Program received doesn't fit. Check the space available in the LIST
PROG mode and possibly delete some programs.

435 Disk Abort Could not read disk.

436 Disk File Not Found Could not find disk file.

437 TS Under Shoot The tailstock did not reach its intended destination point.

438 TS Moved While Holding Part The tailstock moved more than a preset amount while holding a part
(e.g., the part slips in the chuck).

439 TS Found No Part During an M21 or G01, the tailstock reached the hold point without
encountering the part.

440 Servo Bar Max Parts Reached Job Complete. Reset Current # Parts Run on Servo Bar current
commands page.

441 Servo Bar Max Bars Reached Job Complete. Reset Current # Bars Run on Servo Bar current
commands page.

96-8710 rev C 49
 ALARMS June 2001

442 Servo Bar Max Length Reached Job Complete. Reset Current Length Run on Servo Bar current
commands page.

443 Servo Bar Already Nested An Illegal G105 Pnnn was found in cutoff subprogram.

445 Servo Bar Fault SERVO BAR program error.

446 Servo Bar Bar Too Long The Bar that was just loaded is longer than the Length of Longest
Bar as displayed on the Servo Bar current commands page. The
system was unable to accurately measure it.

447 Servo Bar Bar In Way The end of bar switch was depressed and a load or unload bar was
commanded. Remove the bar.

448 Servo Bar Out Of Bars Add more Bars.

449 Servo Bar Cutter Comp Not Allowed G105 cannot be executed while cutter compensation is invoked.

450 Bar Feeder Fault This means that discrete input 1027 (BFSPLK) is too high. See
parameter 278 bit 20 CK BF status.

451 Bar Feeder Spindle Interlock This means that discrete input 1030 (BF FLT) is high. See parameter
278 bit 21 CK BF SP ILK.

452 Servo Bar Gearmotor Timeout The motor which loads bars and the Push rod did not complete its
motion in the allowed time. Check for jammed bars.

453 C Axis Engaged A spindle command (M14, M41, M42, G05 or G77) was given with the
C axis drive engaged. The C axis motormust be disengaged with
M155 before a spindle brake or gear change.

454 C-Axis Not Engaged A command was given to the C-axis without the C-axis engaged. The
C-axis drive must be engaged with M154 before commanding the C-
axis.

501 Too Many Assignments In One Block Only one assignment “=” is allowed per block. Divide block in error
into multiple blocks.

502 [ Or = Not First Term In Expressn An expression element was found where it was not preceded by “[“ or
“=”, that start expressions.

503 Illegal Macro Variable Reference A macro variable number was used that is not supported by this
control, use another variable.

504 Unbalanced Paren. In Expression Unbalanced brackets, “[“ or “]”, were found in an expression. Add or
delete a bracket.

505 Value Stack Error The macro expression value stack pointer is in error. Call your dealer.

50 96-8710 rev C
 June 2001 ALARMS

506 Operand Stack Error The macro expression operand stack pointer is in error. Call your
dealer.

507 Too Few Operands On Stack An expression operand found too few operands on the expression
stack. Call your dealer.

508 Division By Zero A division in a macro expression attempted to divide by zero. Re-
configure expression.

509 Illegal Macro Variable Use See "MACROS" section for valid variables.

510 Illegal Operator or Function Use See "MACROS" section for valid operators.

511 Unbalanced Right Brackets Number of right brackets not equal to the number of left brackets.

512 Illegal Assignment Use Attempted to write to a read-only macro variable.

513 Var. Ref. Not Allowed With N Or O Alphabetic addresses N and O cannot be combined with macro
variables. Do not declare N#1, etc.

514 Illegal Macro Address Reference A macro variable was used incorrectly with an alpha address. Same
as 513.

515 Too Many Conditionals In a Block Only one conditional expression is allowed in any WHILE or IF-THEN
block.

516 Illegal Conditional Or No Then A conditional expression was found outside of an IF-THEN, WHILE,
or M99 block.

517 Exprsn. Not Allowed With N Or O A macro expression cannot be concatenated to N or O. Do not
declare O[#1], etc.

518 Illegal Macro Exprsn Reference An alpha address with expression, such as A[#1+#2], evaluated
incorrectly. Same as 517.

519 Term Expected In the evaluation of a macro expression an operand was expected
and not found.

520 Operator Expected In the evaluation of a macro expression an operator was expected
and not found.

521 Illegal Functional Parameter An illegal value was passed to a function, such as SQRT[ or ASIN[.

96-8710 rev C 51
 ALARMS June 2001

522 Illegal Assignment Var Or Value A variable was referenced for writing. The variable referenced is read
only.

523 Conditional Reqd Prior To THEN THEN was encountered and a conditional statement was not
processed in the same block.

524 END Found With No Matching DO An END was encountered without encountering a previous matching
DO. DO-END numbers must agree.

525 Var. Ref. Illegal During Movement Variable cannot be read during axis movement.

526 Command Found On DO/END Line A G-code command was found on a WHILE-DO or END macro block.
Move the G-code to a separate block.

527 = Not Expected Or THEN Required Only one Assignment is allowed per block, or a THEN statement is
missing.

528 Parameter Precedes G65 On G65 lines all parameters must follow the G65 G-code. Place
parameters after G65.

529 Illegal G65 Parameter The addresses G, L, N, O, and P cannot be used to pass param-
eters.

530 Too Many I, J, or K’s in G65 Only 10 occurrences of I, J, or K can occur in a G65 subroutine call.
Reduce the I, J, or K count.

531 Macro Nesting Too Deep Only four levels of macro nesting can occur. Reduce the amount of
nested G65 calls.

532 Unknown Code In Pocket Pattern Macro syntax is not allowed in a pocket pattern subroutine.

533 Macro Variable Undefined A conditional expression evaluated to an UNDEFINED value, i.e. #0.
Return True or False.

534 DO Or END Already In Use Multiple use of a DO that has not been closed by and END in the
same subroutine. Use another DO number.

535 Illegal DPRNT Statement A DPRNT statement has been formatted improperly, or DPRNT does
not begin block.

536 Command Found On DPRNT Line A G-code was included on a DPRNT block. Make two separate
blocks.

537 RS-232 Abort On DPRNT While a DPRNT statement was executing, the RS-232 communica-
tions failed.

538 Matching END Not A WHILE-DO statement does not contain a matching END statement.
Add the proper END statement.

52 96-8710 rev C
 June 2001 ALARMS

539 Illegal Goto Expression after GOTO not valid.

540 Macro Syntax Not Allowed A section of code was interpreted by the control where macro
statement syntax is not permitted. In lathe controls, PQ sequences
describing part geometry cannot use macro statements in the part
path description.

541 Macro Alarm This alarm was generated by a macro command in a program.

600 Code Not Expected In This Context During program interpretation, the control found code out of context.
This may indicate an invalid address code found in a PQ sequence.
It may also indicate faulty memory hardware or lost memory. Look at
the highlighted line for improper G-code.

601 Maximum PQ Blocks Exceeded The maximum number of blocks making up a PQ sequence was
exceeded. Currently, no more than 65535 blocks can be between P
and Q.

602 Non Monotonous PQ Blocks in X The path defined by PQ was not monotonic in the X axis. A monotonic
path is one which does not change direction starting from the first
motion block.

603 Non Monotonous PQ Blocks in Z The path defined by PQ was not monotonic in the Z axis. A monotonic
path is one which does not change direction starting from the first
motion block.

604 Non Monotonous Arc In PQ Block A non-monotonic arc was found in a PQ block. This will occur in PQ
blocks within a G71 or G72 if the arc changes it's X or Z direction.
Increasing the arc radius will often correct this problem.

605 Invalid Tool Nose Angle An invalid angle for the for the cutting tool tip was specified. This will
occur in a G76 block if the A address has a value that is not from 0 to
120 degrees.

606 Invalid A Code An invalid angle for linear interpolation was specified. This will occur
in a G01 block if the A address was congruent to 0 or 180 degrees.

607 Invalid W Code In the context that the W code was used it had an invalid value. Was
it positive?

96-8710 rev C 53
 ALARMS June 2001

609 Tailstock Restricted Zone This alarm is caused by an axis moving into the tailstock restricted
zone during program execution. To eliminate the problem, change
the program to avoid the restricted zone or change Setting 93 or
Setting 94 to adjust the restricted zone. To recover, go to jog mode,
press RESET twice to clear the alarm, then jog away from the
restricted zone.

610 G71/G72 Domain Nesting Exceeded The number of troughs nested has exceeded the control limit.
Currently, no more than 10 levels of trough can be nested. Refer to
the explanation of G71 for a description of trough nesting.

611 G71/G72 Type I Alarm When G71 or G72 is executing and the control detects a problem in
the defined PQ path. It is used to indicate which method of roughing
has been selected by the control. It is generated to help the pro-
grammer when debugging G71 or G72 commands.

The control often selects Type I roughing when the programmer has
intended to use Type II roughing. To select Type II, add R1 to the G71/
G72 command block (in YASNAC mode), or add a Z axis reference to
the P block (in FANUC mode).

612 G71/G72 Type II Alarm This alarm is similar to Alarm 611, but indicates that the control has
selected Type II roughing.

613 Command Not Allowed In Cutter Comp. A command (M96, for example) in the highlighted block cannot be
executed while cutter comp. is invoked.

614 Invalid Q Code A Q address code used a numeric value that was incorrect in the
context used. Q used to reference tip codes in G10 can be 0...9. In
M96 Q can reference only bits 0 to 31. Use an appropriate value for Q

615 No Intersection to While cutter comp was in effect, a geometry was encountered whose
Offsets in CC compensated paths had no solution given the tool
offset used. This can occur when solving circular geometries.
Correct the geometry or change the tool radius.

616 Canned Cycle Using P & Q is Active A canned cycle using P & Q is already executing. A canned cycle can
not be executed by another PQ canned cycle.

617 Missing Address This alarm is generated if an address code is missing. This alarm
supports G77.

618 INVALID ADDRESS This alarm is generated if an address code is being used incorrectly.
For example, a negative value is being used for an address code that
should be positive.

619 Stroke Exceeds Start Position This alarm is generated by an incorrect G71 or G72 type 2 command.
It refers to a stroke in the PQ path of a G71 or G72 type 2 canned
cycle has passed the starting point. Try adjusting the starting point in
the block before the G71 or G72.

54 96-8710 rev C
 June 2001 ALARMS

620 C Axis Disabled Same as alarm 333.

621 C Over Travel Range Same as alarm 316.

623 Invalid Code In G112 Only G1, G2, G3 and G17 are allowed. G113 cancels G112. Axes X
and Y Cartesian coordinate are used for G1,G2, and G3.

629 Exceeded Max Feed Per Rev This alarm supports G77 and G5. If the alarm is received during a
G77, reduce diameter of part or change geometry. If the alarm is
received during a G5, reduce X or Z travel.

701 U Servo Error Too Large MOCON2 Same as alarm 103.

702 V Servo Error Too Large Mocon2 Same as alarm 103.

703 W Servo Error Too Large Mocon2 Same as alarm 103.

704 C Servo Error Too Large Mocon2 Same as alarm 103.

705 Tt Servo Error Too Large Mocon2 Same as alarm 103.

706 Ss Servo Error Too Large Mocon2 Same as alarm 103.

707 J Servo Error Too Large Mocon2 Same as alarm 103.

708 S Servo Error Too Large Mocon2 Same as alarm 103.

711 U Servo Overload Mocon2 Same as alarm 108.

712 V Servo Overload Mocon2 Same as alarm 108.

713 W Servo Overload Mocon2 Same as alarm 108.

714 A Servo Overload Mocon2 Same as alarm 108.

715 B Servo Overload Mocon2 Same as alarm 108.

716 C Servo Overload Mocon2 Same as alarm 108.

717 J Servo Overload Mocon2 Same as alarm 108.

718 S Servo Overload Mocon2 Same as alarm 108.

721 U Motor Over Heat Mocon2 Same as alarm 135.

722 V Motor Over Heat Mocon2 Same as alarm 135.

96-8710 rev C 55
 ALARMS June 2001

723 W Motor Over Heat Mocon2 Same as alarm 135.

724 A Motor Over Heat Mocon2 Same as alarm 135.

725 B Motor Over Heat Mocon2 Same as alarm 135.

726 C Motor Over Heat Mocon2 Same as alarm 135.

727 J Motor Over Heat Mocon2 Same as alarm 135.

728 S Motor Over Heat Mocon2 Same as alarm 135.

731 U Motor Z Fault Mocon2 Same as alarm 139.

732 V Motor Z Fault Mocon2 Same as alarm 139.

733 W Motor Z Fault Mocon2 Same as alarm 139.

734 A Motor Z Fault Mocon2 Same as alarm 139.

735 B Motor Z Fault Mocon2 Same as alarm 139.

736 C Motor Z Fault Mocon2 Same as alarm 139.

737 J Motor Z Fault Mocon2 Same as alarm 139.

738 S Motor Z Fault Mocon2 Same as alarm 139.

741 U Axis Z Ch Missing Mocon2 Same as alarm 153.

742 V Axis Z Ch Missing Mocon2 Same as alarm 153.

743 W Axis Z Ch Missing Mocon2 Same as alarm 153.

744 A Axis Z Ch Missing Mocon2 Same as alarm 153.

745 B Axis Z Ch Missing Mocon2 Same as alarm 153.

746 C Axis Z Ch Missing Mocon2 Same as alarm 153.

747 J Axis Z Ch Missing Mocon2 Same as alarm 153.

748 S Axis Z Ch Missing Mocon2 Same as alarm 153.

751 U Axis Drive Fault Mocon2 Same as alarm 161.

56 96-8710 rev C
 June 2001 ALARMS

752 V Axis Drive Fault Mocon2 Same as alarm 161.

753 W Axis Drive Fault Mocon2 Same as alarm 161.

754 A Axis Drive Fault Mocon2 Same as alarm 161.

755 B Axis Drive Fault Mocon2 Same as alarm 161.

756 C Axis Drive Fault Mocon2 Same as alarm 161.

757 J Axis Drive Fault Mocon2 Same as alarm 161.

758 S Axis Drive Fault Mocon2 Same as alarm 161.

761 U Cable Fault Mocon2 Same as alarm 182.

762 V Cable Fault Mocon2 Same as alarm 182.

763 W Cable Fault Mocon2 Same as alarm 182.

764 A Cable Fault Mocon2 Same as alarm 182.

765 B Cable Fault Mocon2 Same as alarm 182.

766 C Cable Fault Mocon2 Same as alarm 182.

767 J Cable Fault Mocon2 Same as alarm 182.

768 S Cable Fault Mocon2 Same as alarm 182.

771 U Phasing Error Mocon2 Same as alarm 217.

772 V Phasing Error Mocon2 Same as alarm 217.

773 W Phasing Error Mocon2 Same as alarm 217.

774 A Phasing Error Mocon2 Same as alarm 217.

775 B Phasing Error Mocon2 Same as alarm 217.

776 C Phasing Error Mocon2 Same as alarm 217.

777 J Phasing Error Mocon2 Same as alarm 217.

778 S Phasing Error Mocon2 Same as alarm 217.

96-8710 rev C 57
 ALARMS June 2001

781 U Transition Fault Mocon2 Same as alarm 224.

782 V Transition Fault Mocon2 Same as alarm 224.

783 W Transition Fault Mocon2 Same as alarm 224.

784 A Transition Fault Mocon2 Same as alarm 224.

785 B Transition Fault Mocon2 Same as alarm 224.

786 C Transition Fault Mocon2 Same as alarm 224.

787 J Transition Fault Mocon2 Same as alarm 224.

788 S Transition Fault Mocon2 Same as alarm 224.

791 Comm. Failure With Mocon2 Same as alarm 101.

792 MOCON2 Watchdog Fault Same as alarm 157.

796 Sub Spindle Not Turning Same as alarm 186.

797 Sub Spindle Orientation Fault Spindle did not orient correctly. During a spindle orientation function,
the spindle is rotated until the lock pin drops in; but the lock pin never
dropped. This can be caused by a trip of circuit breaker CB4, a lack
of air pressure, or too much friction with the orientation pin.

900 Manual Parameter Changes When the operator alters the value of a parameter, alarm 900 “PAR
NO xxx HAS CHANGED. OLD VALUE WAS xxx.” will be added to the
alarm history. When the alarm history is displayed, the operator will
be able to see the parameter number and the old value along with
the date and time the change was made. Note that this is not a re-
settable alarm, it is for information purposes only.

901 Parameter Changes Via Disk Load This is a new feature. When a parameter file has been loaded from
disk, alarm 901 PARAMETERS HAVE BEEN LOADED BY DISK will be
added to the alarm history along with the date and time. Note that
this alarm is not a re-settable alarm, it is for information purposes
only.

902 Parameter Changes Via RS-232 Load When a parameter file has been loaded via RS-232, alarm 902
PARAMETERS HAVE BEEN LOADED BY RS-232 will be added to the
alarm history along with the date and time. Note that this alarm is not
a re-settable alarm, it is for information purposes only.

903 Machine Power Up When the machine is powered up, alarm 903 CNC MACHINE
POWERED UP will be added to the alarm history along with the date
and time. Note that this alarm is not a re-settable alarm, it is for
information purposes only.

End Of List

NOTE: Alarms 1000-1999 are user defined.

58 96-8710 rev C
 June 2001 MECHANICAL SERVICE

3. MECHANICAL SERVICE

RECOMMENDED TORQUE VALUES FOR MACHINE FASTENERS

The following chart should be used as a reference guide for torquing machine fasteners where specified.

DIAMETER TORQUE
1/4 - 20 15 ft. lb.
5/16 - 18 30 ft. lb.
3/8 - 16 50 ft. lb.
M10 - 100 50 ft. lb.
M12 - 65 100 ft. lb.
1/2 - 13 80 ft. lb.
3/4 - 10 275 ft. lb.
1-8 450 ft. lb.

3.1 TURRET

TURRET C RASH RECOVERY P ROCEDURE

1. Change Setting 7, "Parameter Lock", to OFF. Move to Parameter 43 on the Parameters Display.
This is the tool turret motor parameters. Change INVIS AXIS from “1” to “0” (zero).

2. Move to the Alarm Display and type “DEBUG” and then press the WRITE key. Verify that the
debug line is displayed.

NOTE: Ensure there is adequate clearance between the turret and chuck before
performing the next step.

3. Press PRGRM/CNVRS, then the MDI key. Type “M43” into MDI and press CYCLE START. This will
unlock the turret by pushing it in the Z-direction.

4. Press the HANDLE JOG key, and then the POSIT key to get into the Position Display and Jog
mode. The A axis should be displayed below the X and Z axes.

5. Press the letter "A", then "HANDLE JOG", and then a jog speed other than ".1". A message
should indicate that the A axis is being jogged.

6. Turn the JOG handle until the obstruction is cleared and the turret rotates freely. If an
OVERCURRENT alarm is received, press RESET and turn the JOG handle in the opposite direc-
tion.

7. Move to Parameter 43 on the Parameter Display and change INVIS AXIS back to “1”. Change
Setting 7 back to ON.

8. Turn the control power off and then back on. The turret can now be positioned by pressing either
POWER UP/RESTART or AUTO ALL AXES.

NOTE: If alarms 111 or 164 occur after the obstruction is cleared, you may need to
adjust the turret motor coupling.

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 MECHANICAL SERVICE June 2001

IMPORTANT!!
After a crash the following procedures should be performed in order to verify proper turret
alignment.
1. Turret alignment verification (X-Axis)
2. Spindle alignment verification
3. Turret alignment verification (Spindle)

TURRET R EMOVAL AND R EPLACEMENT

23 PARTS LIST
21 24 36 19 SHCS 5/16-18 x 1
25 28 35
29 30 31
19 32 33 20 Turret retaining cap
21 SHCS 7/16-14 x 2-1/4
22 Turret male coupling
23 Turret
24 SHCS 7/16-14 x 2-1/4
25 Female turret coupling
20 26 Thrust washer
27 Thust needle bearing
34 26 27 26 28 Shoulder bolt
26 27 26
22 29 Spring retainer
30 Die spring
31 Coupling mount
32 Coupling mount bushing
37 (bronze)
38 43 42 41 39
33 Turret cam
40
34 15/16 steel ball
35 HHB 5/16-18 x 1
36 Lever cam
Removal 37 Belleville spacer
38 Belleville washers
1. Remove the sliding tool changer and turret assembly covers. 39 Key
40 Ring switch
41 Lock nut
2. Change Parameter 76 from 500 to 50000 (so you will not trip 42 Spur gear
on a low air pressure alarm). 43 Turret shaft

3. Remove the air line.

4. Put a 3/4" wrench on the bolt at the end of the air cycle. Pull down (-X) until the turret is fully
unclamped.

5. Place a block snugly between the back of the turret shaft and the casting to keep the turret shaft
from shifting.

CAUTION! If the shaft moves back when the turret is disconnected the ball
bearings in the turret cam may fall and have to be replaced before the
turret can be reassembled.

60 96-8710 rev C
 June 2001 MECHANICAL SERVICE

6. Remove the four bolts from the turret retainer and remove the retainer.

NOTE: If a shaft extension is available install it at this time. Using the extension gives
you greater movement of the turret and allows you to remove and easily install
the key, washers and needle bearings

CAUTION! The turret is heavy and could be slippery.

7. Remove the turret from the shaft.

8. The two washers, needle bearing, and key should be removed from the shaft and put aside at this
time.

Installation
1. Put a small amount of grease on one side of the washers.

2. Place the washer on the surface of the turret and center it using your fingers. Be sure to keep
grease off the surface facing the needle bearing.

3. Put a small amount of grease on both sides of the second washer.

4. Place the washer on the spring retainer on the lip of the turret shaft. Clean any grease that may
have gotten on the shaft.

5. Place the needle bearing on the lip and stick it to the washer. Be sure the other surface of the
bearing is clean and free of grease.

6. Put a small amount of grease on the turret key to hold it in place.

7. Place the turret on the shaft. (align the turret key)

NOTE: Check that the turret key did not fall off.
Check that the washer is centered on the turret.
Check that the washer and needle bearing are still on the shaft lip.

8. Slide the turret fully on the shaft.

9. Replace the turret retainer and snug the four bolts.

NOTE: Check the turret "O" ring. If you can see either the washer or the needle bearing
they have slid off the shaft. Return to step 7 of the turret removal section.

96-8710 rev C 61
 MECHANICAL SERVICE June 2001

10. Tighten the four turret retainer bolts.

11. Remove the brace from between the turret shaft and the casing.

12. Connect the air. The turret should clamp.

13. Change Parameter 76 back to 500.

14. Exercise the tool changer to verify proper operation.

15. Replace the turret assembly and sliding tool change covers.

62 96-8710 rev C
 June 2001 MECHANICAL SERVICE

TURRET S HAFT REMOVAL AND REPLACEMENT

8
PARTS LIST
1 HHB 1/2-20 x 1-1/2
10
7 2 Rod end spacer
12 9 3 1/2 Rod end male
13 11 4 Air cylinder nut
5 14 15 5 SHCS 1/4-20 x 1
16 6 Air cylinder housing
17
7 Air cylinder
4
8 SHCS 1/4-20 x 3/4
2 6 9 1/4 flat washer
18
10 Bearing retainer
11 Locknut
3 12 Bearing
1 13 Worm housing
14 O-ring
15 SHCS 3/8-16 x 2-1/2
16 5/16 Steel ball
45 44
17 O-ring
18 Cluster Gear Shaft
44 Rear turret shaft seal
45 Rear bearing (bronze
bushing)

Turret Shaft Removal

1. Remove turret as described in previous section.

2. Mark the retaining ring and turret casting for alignment purposes.

3. Remove coolant tube bracket and move out of the way.

4. Remove inspection plate which will allow the gearbox oil to drain. Catch oil in a bucket.

5. Remove the bolt that holds the rod end to the lever cam. Do not adjust the rod end

6. Remove the lever cam.

7. Remove the switch bracket.

8. Remove the two set screws on the home switch cam at the back of the shaft, then remove the key.
Turn the motor shaft to gain access to key or set screws. (servos off, E-stop).

9. Remove back half of curvic coupling (10-12 bolts), inspect O-ring.

10. Remove assembly (coupling holder and shaft) being careful to keep tension on the assembly to
hold the cam and bearings in place.

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 MECHANICAL SERVICE June 2001

Turret Shaft Replacement

Tools required: Installation tool for coupling mount

1. Apply grease to the ball bearing areas of the cam.

2. Install coupling mount (cams and bearing) using the installation tool, and line up key way with the
bolt that is equidistant between the springs (or previous marked alignment).

3. Install turret shaft assembly (align mark on retaining ring with the mark on the casting).

4. Align keyway facing up.

5. Install back half of curvic coupling on to gearbox snug two bolts and center the play between the
bolt holes. Install the remainder of the bolts and torque to specifications.

6. Install lever cam

7. Install key for limit switch cam.

8. Install limit switch cam.

9. Install limit switch bracket.

10. Attach actuator to lever cam.

11. Install inspection plate.

12. Install coolant tube bracket.

13. Add oil to the gear box 10 cups (2400 ml).

14. Install turret as described in previous section.

Turret motor coupling adjustment procedure must be completed for proper alignment.

64 96-8710 rev C
 June 2001 MECHANICAL SERVICE

ADJUSTING TURRET B ACKLASH

1. Affix the magnetic base and indicator on a clean surface and check rigidity.

2. Set the indicator pointer on the worm gear. Pointer should be in line with the lead angle on the
center thread of the worm gear. See figure below.

0
1 1

2 2

3 3
4

3. Rotate the worm gear to the end of rotational travel in the counterclockwise direction. Zero your
indicator.

4. Rotate the worm gear to the end of rotational travel in the clockwise direction. Record your reading.

5. Rotate the worm gear to exactly half the value of your recorded reading; this is the position to now
clamp your coupler. Coupler torque value is 16 ft./lbs.

Example: Rotate the coupler and observe the indicated reading. The force used to rotate the coupler should be
great enough so that when the force is removed you will see the indicated reading lesson; i.e. with little force
T.I.R. is noted at .006 with more force T.I.R. is .012 (see note).

NOTE: While holding the coupler at its maximum rotational movement release the
pressure and note that the backlash reading will fall to a lesser value. By
experimenting with this method you will find a “spongy” area. This spongy area
is the end play in the worm and cluster gear.

NOTE: Excessive backlash can come from the coupler or bearing retainer.

Turret motor coupling adjustment procedure must be completed for proper alignment.

96-8710 rev C 65
 MECHANICAL SERVICE June 2001

TURRET MOTOR COUPLING ADJUSTMENT

NOTE: The turret must be at tool #1 and clamped to perform this procedure.

1. Remove the sliding tool changer cover.

2. Go to Setting 7 and turn off the Parameter Lock. Go to Parameter 43, change “Z CH ONLY” to “1”.

3. Loosen the turret motor coupling clamp screw closest to the motor. (Refer to Figure 3.1-1)

4. Press the ZERO RET key, then the A key, and the ZERO SINGL AXIS key. This will cause the
motor to go to the first encoder Z pulse.

5. With the servos on, move the turret motor coupling back and forth to find the center of its back-
lash, and torque the clamp screw as close to the center of the backlash as possible.

NOTE: If it is tight (no backlash) it will be necessary to force it in one direction or the
other until it pops into its backlash area. If it gets tighter when it is turned, STOP;
this is the wrong direction.

6. Change Parameter 43, “Z CH ONLY” back to “0” (zero).

7. Press the ZERO RET key, A key, and ZERO SINGL AXIS key. This will home the turret at tool #1.

8. Press the EMERGENCY STOP button and turn the turret motor coupling back and forth to verify
that the backlash is centered.

9. Go to Setting 7 and turn on the Parameter Lock.

10. Replace the sliding tool changer cover.

Figure 3.1-1. Turret motor adjustment.

66 96-8710 rev C
 June 2001 MECHANICAL SERVICE

TURRET ALIGNMENT VERIFICATION (X-A XIS )

TOOLS REQUIRED:
• MAGNETIC INDICATOR BASE • DIAL INDICATOR (0.0005" OR LESS RESOLUTION)

1. Remove all tool holders and fittings from the turret.

2. Jog the X-axis to the center of its travel.

3. Place the magnetic indicator base on the spindle retainer ring. Position the indicator tip on the
turret face so there is at least 3.5" of travel in each direction from the center of the X axis and 1/4"
below the center cap. Refer to Figure 3.1-2.

4. Jog the X axis so the indicator is at one end of its travel then zero the indicator.

5. Jog the X-axis to the other end of its travel and check your reading (tolerance 0.0003" TIR)

6. If the reading is greater than the tolerance specified the turret needs to be realigned.

Figure 3.1-2. Turret alignment verification (X-axis)

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 MECHANICAL SERVICE June 2001

T URRET ALIGNMENT (X-AXIS)

It is recommended that you read the following sections in their entirety before starting the
alignment procedures.
1. Remove the rear cover.

2. Remove the sliding toolchanger cover.

NOTE: Be sure to remove the 4 SHCS located behind the turret. The X-axis wiper may
also need to be replaced if damaged.

3. Remove top plate cover to the turret housing. Be sure to check the gasket and see if it needs
replacement.

4. Remove the SHCS that mount the coolant adapter block to the turret housing. The turret must be
in the unclamped position (M43) in order to lift the coolant line over the black access plate.

5. Remove the black access plate. The plate may need to be pried off with a screwdriver.

NOTE: Have a bucket ready to catch oil draining from the housing.

6. Loosen all turret housing mounting bolts except for the front left bolt nearest the turret.

7. Clamp the turret (M44) and jog to the center of the X-travel.

8. Tap on the turret casting in order to bring the face of the turret into alignment.

NOTE: In order to help keep the turret housing from slipping down during the
alignment procedure, keep the turret housing bolts as snug as possible.

NOTE: Verify the turret alignment.

9. Apply Loctite and torque all turret housing mounting bolts to 50 FT LBS.

10. Recheck the turret face to ensure the measurement did not change.

11. Install the access cover and gasket.

12. Pour 10 cups of oil (DTE 25) into gear side of turret housing.

13. Install the Coolant Adapter Block.

NOTE: The turret must be in the UNCLAMPED position

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14. Install Turret Housing Top plate.

15. Install Sliding Tool Changer Cover.

16. ZERO RETURN machine.

After the turret face has been realigned it is important to verify that the spindle is still in
alignment.
Proceed to Chapter 2, Spindle Alignment Verification.

NOTE: All alignments done could change spindle centerline. Verify and enter new
spindle centerline position in Parameter 254.

T URRET ALIGNMENT VERIFICATION (SPINDLE )

This procedure should be performed after spindle alignment has been checked.

TOOLS REQUIRED:
• SPINDLE ALIGNMENT TOOL
• DIAL INDICATOR (0.0005" OR LESS RESOLUTION)

1. Remove all tool holders and fittings from the turret.

2. Clean the turret pockets and tool holders.

3. Mount the spindle alignment tool onto the spindle retainer ring with the dial indicator mounted to
the end of the tool. Refer to Figure 3.1-3.

4. Jog the X axis to the spindle center line. This is the value stored in Parameter 254, found on the
"Position Raw Data" page (this page is entered through Debug mode).

5. Position the indicator tip just inside pocket #1 so that it is almost parallel to the X- axis. Zero the
indicator, then rotate the spindle 1800, the indicator should read ZERO.

NOTE: Use the jog handle in tenths mode to zero the pocket.

6. Next, rotate the spindle and take readings at both the top and bottom of the pocket.

7. If the reading exceeds .0010" from the centerline or .0020" TIR, the inner coupling may need
adjustment.

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8. Perform turret motor coupling adjustment.

NOTE: If the reading is within specifications, but the X axis position is different from
parameter 254, enter the new number in parameter 254.

90deg.

Spindle High

180deg. 0deg.

X-Axis
Spindle Low

270deg.
Tool Pocket

Figure 3.1-3. Turret Pocket Alignment

T URRET A LIGNMENT VERIFICATION (P ARALLELISM OF X-A XIS )

TOOLS REQUIRED:

• MAGNETIC INDICATOR BASE

• DIAL INDICATOR (0.0005" OR LESS RESOLUTION)
• A BAR APPROXIMATELY 12"x 4"x 1" (GROUND TO WITHIN 0.0001" ON THE 1" WIDTH SIDE)

1. Remove all tool holders and fittings from the turret.

2. Clean the turret pockets and tool holders then command tool #1 to the cutting position.

3. Place a clean and undamaged tool holder loosely (do not thread nuts) in the nearest pocket
to the spindle and the other in the opposite tool holder.

4. Place the 12" x 4" x 1" bar across the small diameter of the two tool holders (ground side down).

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Figure 3.1-4. Turret Bar Sweep.

5. Jog the X axis to the center of its travel.

6. Mount the indicator to the spindle retainer ring. Position the indicator tip at the bottom edge of the
bar.

7. Jog the X axis so the indicator is at one end of the bar, and zero the indicator.

8. Jog the X axis to the other end of the bar, and check your reading (tolerance is 0.0003" TIR).

9. If the reading is not within tolerance, loosen all (10) turret bolts with the turret in the clamped
position

10. Rotate the turret 180 degrees and check for .0003" TIR or less with the indicator.

11. Tap on the turret until the readings are within tolerance.

12. Retighten all (ten) turret bolts.

- If the reading is within tolerance, proceed to, Spindle Alignment Verification.

- If the reading is greater than the tolerance specified, proceed to the appropriate coupling adjustment
procedure.

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C ENTERING INNER TURRET C OUPLING (W ITHOUT BRASS PLUG)

This procedure should only be performed if there is not enough adjustment to perform an
outer coupling alignment.

NOTE: If the turret has a 1/4" brass plug, proceed to the next section.

1. Before starting, make sure tool pocket #1 is in position.

2. Pull the turret air cylinder all the way forward (unclamp) and place something snugly between the
back of the turret shaft and the casting to keep the turret shaft from shifting.

3. Remove the four bolts from the center turret shaft cover.

4. To gain access to the rear coupling, either remove the turret or install a turret shaft extension and
slide the turret onto it.

5. Loosen the 10 bolts on the inner coupling and center the coupling to the bolt holes. Retighten them
to the required specifications. (Refer to torque chart at beginning of the section)

6. Install the thrust bearing and both thrust bearing washers to the shoulder of the turret shaft.

7. Reinstall the turret and turret shaft cover. Make sure that the turret makes it over the O-ring before
the bolts are tightened completely. If the bolts tighten up and the O-ring is still visible, one of the
thrust washers is not on the shoulder of the turret shaft.

8. Return to Step 1 of the "Turret Alignment Verification" section and verify your readings.

NOTE: All alignments done could change spindle centerline. Verify and enter new
spindle centerline position in Parameter 254.

C ENTERING INNER T URRET C OUPLING (WITH 1/4" B RASS P LUG )

This procedure is only to be performed if there is not enough adjustment to perform an outer coupling
alignment.

NOTE: This procedure is only to be performed if the turret is equipped with a 1/4" brass
plug.

1. Remove the 1/4" brass plug to gain access to the rear coupling.

2. Loosen, then lightly snug all the inner coupling bolts by doing a tool change to each station.

3. Using a toolholder placed in the turret, move the turret in the necessary direction with a rubber or
plastic mallet to align the spindle.

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4. Tighten all 10 inner coupling bolts (jogging the A axis for access) and torque them to the required
specifications. Refer to torque chart at beginning of section.

NOTE: All alignments done could change spindle centerline. Verify and enter new
spindle centerline position in Parameter 254.

CONVERTING S PINDLE CENTERLINE TO E NCODER STEP

1. Jog the X-axis to the spindle center.

2. Press ALARMS, enter "DEBUG", press WRITE.

3. Press POSIT, and PAGE UP until you see the debug screen POS-RAW DAT 1.

4. Observe the X axis COMMAND position. This will be encoder steps. Ignore the negative sign and
the decimal point.

5. Copy this number to parameter 254 as a positive number with no decimal point.

6. Press ALARMS, enter "DEBUG," press WRITE. Or simply turn the power off and back on. This
deactivates debug mode.

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T URRET IN / O UT A DJUSTMENT

Extension
Sleeve

Jam
Nuts

Air Cylinder Rod

Figure 3.1-5. Turret travel adjustment components.

NOTE: Alarms 113 and 114, "Turret Unlock Fault" and "Turret Lock Fault", can indicate
that a turret in/out adjustment is necessary. These alarms occur when the
Turret Clamp and Unclamp switches sense a turret positioning error.

1. If the turret travel is not .150", ensure there is no mechanical problem or obstruction affecting the
travel. If no problem is found, the air cylinder rod travel needs to be adjusted. To make this adjust-
ment, loosen the two jam nuts, and screw the extension sleeve away from the air cylinder to
increase the turret travel, or towards the air cylinder to decrease the turret travel. When adjust-
ment is complete, tighten the jam nuts to the extension sleeve.

2. Once the turret travel is set, the Clamp/Unclamp switches must be adjusted. Enter the diagnostic
data page in order to monitor the TT UNL (Turret Unlocked) and TT LOK (Turret Locked) discrete
inputs.

For the following procedures follow:

Section I - For production units making turret in / out adjustments with trip switches.

Section II - For production units making turret in / out adjustments using air cylinder mounted reed
switches

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Section I

Turret Unclamp
(Out) Switch

Clamp/Unclamp
Switch Bracket

Cam

Turret Clamp
(In) Switch

Figure 3.1-6. Turret Clamp/Unclamp switches.

a. In MDI, enter an M43 (Unlock Turret). The Turret Unclamp switch should be tripped at this point,
and discrete input TT UNL should read "1".

b. Place a 0.160" gage block between the Turret Clamp switch and the side of the cam, ensuring it is
flat against the cam. The Turret Clamp switch should trip and the discrete input TT LOK should
read "1". Remove the gage block.

If either switch does not trip when the gage block is in place, the switches need to be adjusted. Adjust
the switches by loosening the two SHCS and moving the entire switch bracket; DO NOT move the
individual switches unless absolutely necessary.

c. Enter an M44 (Lock Turret). The Turret Clamp switch should be tripped at this point, and discrete
input TT LOK should be "1".

d. Place a 0.160" gage block between the Turret Unclamp switch and the side of the cam, ensuring it
is flat against the cam. The Turret Unclamp switch should trip and discrete input TT UNL should
read "1". Remove the gage block.

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e. If either switch does not trip when the gage block is in place, the switches need to be adjusted.
Adjust the switches by loosening the two SHCS and moving the entire switch bracket; DO NOT
move the individual switches unless absolutely necessary. Refer to Figure 3.1-6.

Section II

a. In MDI, enter an M43 (Unlock Turret). The Turret Unclamp switch should be tripped at this point,
and discrete input TT UNL should read "1".

If this does not occur, the lower air cylinder mounted reed switch needs to be adjusted by loosening
the worm drive clamp retaining the sensor and moving it until the input reads “1”. Mark the location. Move
the sensor slowly in both directions until the input reads “0” and mark the location. Place the sensor in
between the marks and tighten the worm-drive clamp. Retighten sensor. When the turret is in any other
position than Unlock Turret, the discrete input should read "0."

b. In MDI, enter an M44 (Lock Turret). The Turret Clamp switch should be tripped at this point, and
discrete input TT LOK should read "1".

If this does not occur the upper air cylinder mounted reed switch needs to be adjusted by loosening
the worm drive clamp retaining the sensor and moving it until the input reads “1”. Mark the location. Move
the sensor slowly in both directions until the input reads “0” and mark the location. Place the sensor in
between the marks and tighten the worm-drive clamp. Retighten sensor. When the turret is in any other
position than Lock Turret, the discrete input should read "0."

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3.2 S PINDLE

SPINDLE ALIGNMENT VERIFICATION

This procedure should be performed after the turret face has been realigned.

TOOLS REQUIRED:
• SPINDLE ALIGNMENT TEST BAR (P/N# T-1312)
1. Mount a 0.0001" indicator (short setup) to face of turret.

Figure 3.2-1. Checking runout.

2. Install Spindle Alignment Test Bar. Take up any slack between bolts with washers.

3. Place the indicator tip onto the test bar near the spindle. Rotate the spindle to determine the
runout. The tolerance is .0001"

NOTE: If the tolerance is greater than .0001 then loosen the test bar mounting bolts,
rotate the spindle and tap on the mounted end of the fixture until the runout
within tolerance.

4. Tighten the bolts to the test bar being careful not to alter the alignment.

5. Move the indicator tip to the end of the test bar and check for runout. Tolerance should not exceed
0.0005".

NOTE: If the reading is greater than 0.0005" remove the test bar, clean both mating
surfaces.

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6. Next rotate the test bar until the reading is 1/2 of the total runout. Using the Z-axis, jog the
indicator tip over 10 inches of the test bar to determine if the spindle is high or low. Tolerance
should not exceed (0.0004/10")

NOTE: •If the measurement is greater than the allowable tolerance then the
spindlehead casting must be realigned. Before realigning the
spindlehead, perform a Turret Alignment Verification (Parallelism of X-
axis).
•If the measurement is within the allowable tolerance, go to step 7.

7. Position the indicator tip on the backside of the test bar. Jog the indicator tip over 10 inches of the
test bar to determine spindle parallelism. The maximum allowable tolerance is 0.0004/10".

NOTE: •If this tolerance is out, call HAAS Automation Service Department..
•If the spindle is in alignment, proceed to Turret Alignment Verification section.

SPINDLE REMOVAL

NOTE: POWER OFF THE MACHINE BEFORE PERFORMING THE FOLLOWING PRO-
CEDURE.

1. Remove the chuck or collet nose from the Lathe and the necessary covers to gain access to the
spindle assembly.

2. Disconnect oil return hose and coolant drain hose from Hydraulic Cylinder after powering OFF
machine.

3. Loosen the clamp and unclamp hoses, then remove.

4. Loosen the SHCS from the adapter, and detach the hydraulic cylinder.

5. Loosen the eight SHCS on the inside of adapter and detach from spindle shaft.

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Figure 3.2-2. Hydraulic cylinder.

6. Unplug the encoder. Unscrew the encoder bracket, remove the encoder, then remove the belt.

7. Loosen the four SHCS holding the spindle motor. Slide the motor up by squeezing the belts.
Tighten the SHCS and remove the drive belts from the spindle assembly.

8. Loosen the six SHCS and remove the spindle drive pulley.

9. Disconnect the two lubrication hoses and unscrew the fittings from the spindle housing. Note the
direction of the flat sides of the fittings for lubricating the spindle bearings.

10. Unscrew the six SHCS holding the spindle retaining ring and remove. Also remove the O-ring.

11. Remove Spindle Carefully. (For SL-40 spindle removal, contact HAAS Service for removal tool)

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SL-10 S PINDLE R EMOVAL

NOTE: POWER OFF THE MACHINE BEFORE PERFORMING THE FOLLOWING PRO-
CEDURE.

1. Remove the chuck or collet nose from the Lathe and the necessary covers to gain access to the
spindle assembly.

2. Disconnect oil return hose and coolant drain hose from Hydraulic Cylinder after powering OFF
machine.

3. Loosen the clamp and unclamp hoses, then remove.

4. Loosen the SHCS from the adapter, and detach the hydraulic cylinder.

5. Loosen the SHCS on the inside of adapter and detach from spindle shaft.

Figure 3.2-2. Hydraulic cylinder.

6. Unplug the encoder. Unscrew the encoder bracket, remove the encoder.

7. Loosen the four SHCS holding the spindle motor. Slide the motor towards the spindle to remove
tension from the belts. Slide the belts off of the spindle drive pulley.

8. Disconnect the two lubrication hoses and unscrew the fittings from the spindle housing. Note the
direction of the flat sides of the fittings for lubricating the spindle bearings.

9. Unscrew the SHCS holding the spindle retaining ring and remove. Also remove the O-ring.

10. Remove Spindle Carefully.

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SPINDLE INSTALLATION

TOOLS REQUIRED:

• Blue Loctite
• 1/2" Torque Wrench (Up to 250 ft-lbs)
• HAAS Belt Tensioning Tool P/N# T1510 (SL 20), P/N# T1537 (SL 30 and 40)

1. Install spindle into housing. Check location of oil holes for proper alignment.

2. Place the retainer ring on the spindle with the O-ring toward the spindle. Ensure that the drain
holes are at the bottom of the retainer ring and that the O-ring remains in place.

3. Apply blue Loctite to the six retainer ring mounting bolts and install them. Place a .001 shim
between the spindle and retainer ring. Torque the mounting bolts to 50 FT-LBS.

NOTE: The bolts should be torqued in a star pattern and in increments of 10, 20, 30,40
and finally 50 FT-LBS. Check alignment of the spindle and retaining ring with
a .001 shim at each torque value.

Figure 3.2-3. Spindle retaining bolts.

4. Ensure that the spindle can spin freely and the spindle and housing oil mist holes are aligned. If
not, remove the retainer ring and spindle and reinstall.

5. Screw the oil mist nozzles in by hand until they bottom. Then back off the nozzles 1.5- 2 turns
ensuring that the holes on the nozzles and spindle housing are aligned correctly and pointed
towards the bearings. Make sure the nozzles do not come into contact with spindle shaft.

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6. Tighten the hex nut on the nozzles, ensuring the nozzles do not spin. After tightening the nuts,
verify the nozzle oil mist holes are still positioned correctly.

7. Attach the two 1/4" nylon tubes onto the swivel fittings.

Figure 3.2-4. Alignment of oil mist holes.

8. Install the spindle drive pulley.

9. Install the drive belts onto the spindle and motor pulleys.

10. Apply proper tension to belts by wedging the T-shaped belt tensioner tool underneath the spindle
head casting web, between the spindle head pulleys and motor / gearbox pulleys and the motor
/ gearbox mounting plate. Attach the 1/2" drive torque wrench to tensioner tool and apply the
required torque value. The path of the applied torque should be inline with the motor assembly. The
following chart includes values for proper belt tensioning.

Lathe Tool P/N# Torque Value

SL 20 T1510 95ft-lb

SL 20 BB T1510 95ft-lb

SL 30 T1537 150ft-lb

SL 40 T1537 230ft-lb

11. While applying correct torque amount, tighten the four mounting motor / gearbox plate bolts.

CAUTION! This procedure should be performed with two service persons. One
will apply correct torque amount and the other will tighten mounting
bolts.

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12. Place the 3/8" timing belt on the spindle pulley, with the other end on the encoder pulley.

13. Mount the encoder onto the spindle housing below the spindle shaft with four mounting bolts.

14. Align and attach the hydraulic cylinder adapter onto the spindle shaft with the mounting bolts.
Tolerance on the face of the adapter plate .0007". Check tolerance of large I.D. bore .002".

15. Slide the hydraulic cylinder into spindle shaft. Insert and snug the mounting bolts.

16. Attach and clamp the oil drain hose and coolant drain hose onto hydraulic cylinder.

17. Attach and screw in clamp and unclamp hoses.

18. Set the magnetic base on top of the spindle housing with the indicator touching the top of the
hydraulic cylinder.

19. Spin the hydraulic cylinder and verify that the runout is under 0.003 inches. If runout is over 0.003
inches, spin the hydraulic cylinder to its high point and tap cylinder with a rubber mallet. Tighten
and torque the bolts.

20. Replace all previously removed sheet metal.

SPINDLE HEAD A LIGNMENT

TOOLS REQUIRED:
• Dual Indicator Stand

Depending on lathe model, the following sheet metal pieces may need to be removed:
•The front left panel
•The front bottom panel
•The drain rail
•The front door

1. Loosen all spindle head mounting bolts.

2. Loosen the locknuts on the two jack screws (adjustment bolts) underneath the spindle head
casting, then screw them in to lower the spindle casting.

3. Bolt spindle alignment bar tool to spindle and attach a 0.0001" indicator onto the face of the turret.

4. Jog indicator such that the indicator runs tangent to alignment bar along the Z-axis.

5. Level the spindle head assembly by adjusting the jack screws up or down and jogging the indicator
along the alignment bar in the Z-axis. The tolerance reading should be .0001" within 10".

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Figure 3.2-5. Adjustment bolts.

6. Once the spindle head assembly is level, setup dual indicators on the large magnetic base and
place on the base casting to the rear. Indicate them at the machined bosses to maintain the
spindle head level. See Figure 3.2-6.

Figure 3.2-6. Indicator setup.

NOTE: This setup is to ensure the spindle remains parallel in the Z-axis plane while
raising the spindlehead. It is recommended to only turn the jackscrews a
quarter turn each time so that the spindle head does not become positioned
too high above the turret pocket. Should this happen, you will have to start the
procedure again.

NOTE: If the boss on the spindle head casting is not machined, then an alternate
method to set up the indicators is to retract the B-axis waycover from the left
side and mount the mag base to the base casting. Then position two indicators
on the machined surface beneath the spindle head casting.

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7. Place the tenths indicator at the end of the spindle alignment bar and jog tool turret in the Z- axis
towards the spindle until the indicator rest on the inside of the tool pocket.

8. Align the tool pocket holder along the X-axis with the spindle alignment bar by rotating the spindle
and sweeping the indicator 180o along the axis. Refer to Figure 3.1-3.

NOTE: The tool holder alignment pins create a bump in the pocket that should be
ignored.

9. Jog the turret along the X-axis until a measurement reading within .001" is indicated.

NOTE: Use the jog handle in tenths mode to zero pocket

10. Next, zero the spindle alignment at the top and bottom of the turret pocket by sweeping the
indicator at those positions and adjusting the jack screws equally.

11. Rotate the spindle 180o and adjust the jackscrews until the indicator reads within a .001" at the
top and bottom of pocket. Repeat Steps 8 and 9, to ensure the X-axis is zeroed for each adjust-
ment in the vertical direction.

12. Torque the spindle head mounting bolts to 500 ft-lbs so as not to change the spindle’s position.

13. Once the pocket is zero, X-axis value on the screen becomes the new machine spindle centerline.

14. Tighten the jam nuts on the jack screws under the spindle head.

NOTE: The X-axis value in the Positions page is the new machine centerline. This
value should be stored in Parameter 254.

15. Repeat Steps 3-5 to ensure that the shaft has remained horizontal. If the shaft has moved, return
to Step 11 and recheck the pocket position.

16. Test the other pockets in the same way as pocket #1 (Step 11) without moving the x-axis position.
The tolerances for the other pockets are 0.003 inch from the centerline.

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17. Reinstall the following sheet metal pieces if removed:

•The front left panel
•The front bottom panel
•The drain rail
•The front door

NOTE: All alignments done could change spindle centerline. Verify and enter new
spindle centerline position in Parameter 254. (Refer to Section 1.9)

SL-10 S PINDLE H EAD A LIGNMENT

1. Attach the spindle alignment bar to the spindle. Adjust the position of the alignment bar until the
measured runout at both the base and end of the bar is less than 0.0001”. To adjust the position of
the alignment bar, slightly loosen the mounting bolts and tap on the mounting end of the alignment
bar.

2. Loosen the 8 SHCS mounting bolts for the spindle head.

3. Back out the two set-screws on the front side, lower edge of the spindle head.

4. Attach a 0.0001” dial indicator to the turret.

5. Jog the X and Z-axes to position the dial indicator on the side of the alignment bar.

6. Sweep down the length of the alignment bar to measure the spindle head parallelism with the Z-
axis.

7. Push the spindle head towards the back of the machine. Run in the set-screws on the front, lower
edge of the spindle head until they contact the locating dowels underneath the spindle head.
Adjust the spindle head parallelism with the Z-axis using these two set-screw. The spindle head
should be parallel with the Z-axis with in 0.0004”/10”.

8. Mount two travel dial indicators onto the side of the base. Place the tips at the extreme ends of
the spindle head casting. Zero the indicators.

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9. Attach a 0.0001” dial indicator into the end of the alignment bar.

10. Install an OD tool holder into tool position #1. Ensure that the bore of the tool holder is clean and
free of any burrs, chips or other contaminants.

11. Jog the X-axis down to the original spindle centerline.

12. Jog the Z-axis until the tip of the dial indicator can be placed on the inside of the bore in the tool
holder. Sweep the bore to measure the concentricity of the spindle head to the tool position. The
tool holder bore must be concentric with the spindle within 0.001” TIR.

13. Adjust the position of the spindle head by carefully screwing in the set-screws. Ensure that the
spindle head parallelism to the Z-axis remains constant by moving the spindle equal amounts as
indicated on the two travel dial indicators.

14. If by adjusting the spindle head position, the runout out cannot be made less than 0.001”, then the
tool holder position can be adjusted by moving the X-axis. Jog the X-axis in the 0.0001” mode.

15. Once the runout is less than 0.001” TIR, verify that the spindle head parallelism to the Z-axis is
within 0.0004”/10”.

16. Evenly torque the spindle head bolts to 500 ft.-#.

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3.3 T AILSTOCK A LIGNMENT

Tailstock alignment procedures should only be done after the X and Z axes have been checked for
proper alignment.

There are two different tailstocks, a one-piece original design and the newer two-piece design. If the
tailstock needs to be aligned, follow the procedure for that type of tailstock

O NE- P IECE T AILSTOCK ALIGNMENT V ERIFICATION

TOOLS REQUIRED:

•Spindle Alignment Test Bar (P/N# T-1312)

•Tailstock Taper Bar (P/N# T-1416)
•.0001" Indicator and Magnetic Base

1. Mount the spindle alignment test bar to the spindle.

NOTE: Make sure all contact surfaces, including the test bar, are clean.

2. Mount a .0001 indicator to the end of the alignment bar.

3. Insert the tailstock taper alignment test bar.

4. Place the indicator tip at the base of the tailstock test bar (closest to the tailstock). Check the
total runout at base of the test bar by rotating the indicator 3600. Max. tolerance is .001" from
centerline.

5. Jog the tailstock back and measure the runout at the end of the tailstock test bar.

NOTE: •If these measurements are out of tolerance from top to bottom (0 0 and
1800), then proceed to the Tailstock Leveling Procedure.
•If this measurement is out of tolerance from side to side (90 0 and 270 0),
then the insert needs to be replaced and realigned as described in the
Tailstock Insert Removal and Installation section.

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TAILSTOCK L EVELING P ROCEDURE

This procedure should only be performed after the Tailstock Alignment has been checked.

TOOLS REQUIRED:

•Tenths Indicator
•Tailstock Alignment Tool (Test Bar P/N# T-1416)
•Tailstock Leveling Assembly (Leveling Stand P/N# 93-6001)
•Spindle Alignment Test Bar (P/N T-1312)

1. Loosen the mounting bolts that attach the TS to the linear guide trucks, allowing TS to rest on
bolts. Place the Leveling Stand under the bottom edge of TS and manually raise the jack bolts.
(Refer to Figure 3.3-1)

2. Attach a tenths indicator to the face of the turret. Level the TS by jogging the indicator along the
test bar in the Z-axis and level to within .0005" by adjusting the jack bolts.

3. Sweep the diameter of the Test Bar and note the vertical runout. Refer to Figure 3.3-1.

Figure 3.3-1. Tailstock leveling indicator setup.

4. Raise the TS and bring up to center by equally turning the jack bolts ( do not turn one jack bolt
more than 1/4 turn without turning the other). Adjust to within .0003" and lightly snug bolts during
procedure.

NOTE: Check tailstock parallelism each time the tailstock is raised.

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5. Check for TS level change. Adjust by setting the indicator to zero at the right end of the Test Bar
and jog the indicator over to left end of bar. Snug bolts in upper left corner and loosen the others.
Adjust the right-hand jack bolt only and bring the indicator to within .0005".

6. Once the TS is leveled, the mounting bolts should be torqued to 50 ft-lbs in a clockwise fashion
(first, the inner mounting bolts than the outside). If the horizontal runout is unacceptable, the
tapered insert may have to be reset as described in the following section

NOTE: These steps may have to be repeated to achieve proper alignment.

TWO-PIECE TAILSTOCK ALIGNMENT

1. Using a spindle alignment tool and a Morse taper tool, indicate from spindle to tailstock. Measure
flatness and TIR (total indicated run-out). Determine which direction the tailstock is out of align-
ment (Figure 3.3-2).

Figure 3.3-2

2. If the tailstock is out of alignment in both flatness and parallelism, remove the head from the
tailstock base. Mark the shims so they can be installed in the same order, and inspect them. If
the tailstock is only out of parallel alignment go to step 6.

3. Check the top surface of the tailstock base for parallelism to the Z axis. Check for dents and
lightly stone the top mating surface of the tailstock. Indicate from the turret to the top of the
tailstock base. Readings must be no more than +/- .0004" for 10 inches of travel.

4. Install the shims, lightly stone and clean the shims before installing

5. Install the head of the tailstock and snug the four retaining nuts.

6. Rotate the spindle and measure parallelism. Tap the head into place using a mallet. If flatness is
within tolerance, proceed to step 8.

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7. Measure flatness from base to end of tailstock. Add or remove shims if necessary using the
tailstock head alignment tool. To adjust the number of shims, bolt on alignment tool, snug align-
ment bolts against the tailstock head, then remove the tool (Figure 3.3-3). Loosen either the front
or rear pair of tailstock retaining nuts and add or remove shims as necessary. This will keep
parallelism. Re-tighten the nuts. If necessary loosen the other end to add or remove shims as well.
To re-align, install the alignment tool and position the tailstock against the adjustment bolts of the
alignment tool. Snug the tailstock nuts and remove the tool.

Figure 3.3-3

8. Rotate the spindle and measure run-out at the base and the end of the tailstock. Tap into place
using a mallet. Tolerance is less than .001 TIR.

9. Torque the tailstock head retaining nuts.

SL-10 T AILSTOCK ALIGNMENT

1. Insert the Tailstock Alignment Bar into the tailstock quill.

2. Place a 0.0001” indicator onto the turret. Position the X-axis so that the flatness and parallelism of
the alignment bar can be measured.

3. Place the indicator stylus onto the side of the alignment bar and sweep along the Z-axis. The
tailstock should be parallel with the Z-axis within 0.0004” over the length of the tailstock alignment
bar. If the Z-axis parallelism is not within 0.0004”, then the tailstock foot will need to be adjusted.

4. Loosen the four SHCS that attach the tailstock foot to the lathe base and back out the set screws
at the base of the foot. Push the tailstock foot as close to the turret as possible. Place the
indicator stylus onto the machined surface along the backside of the tailstock foot. Jog the Z-axis
to sweep along this surface. Adjust the position of the tailstock foot until the runout along this
machined surface is less than 0.0001” along the entire length.

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5. Install the spindle alignment bar onto the end of the spindle. Install a 0.0001” dial indicator into the
end of the spindle.

6. Set up two travel dial indicators at the extreme ends of the tailstock foot.

7. Measure the side to side runout of the concentricity of the spindle to the tailstock quill. The total
side to side runout cannot exceed 0.0005”.

8. Using the set screws in the tailstock base, move the entire tailstock assembly until the total side
to side runout does not exceed 0.0005”. Maintain the parallelism with the Z-axis by insuring that
the travel indicators move an equal amount.

9. Torque the SHCS that attach the foot to the lathe base in an even and gradual pattern to 200 ft.-#.
Verify that the runout has been maintained after the tailstock foot is torqued.

T AILSTOCK INSERT R EMOVAL AND I NSTALLATION

CAUTION! Contact HAAS before attempting this procedure.

Tools Required:

•Press Fixture and Spacer •Blow torch

•Spindle Alignment Test Bar (P/N# T-1312) •Devcon liquid steel (P/N# 99-4530)
•Tailstock Taper Alignment Bar (P/N# T-1416)

Removal -

1. Remove the six screws that mount the back plate to the tailstock insert.

2. Remove the 3 screws that mount the insert to the casting.

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3. Run the screw nut completely down to its farthest travel (far right).

Figure 3.3-4. Tailstock insert press.

4. Mount the fixture to the tailstock casting as shown.

5. Pump the hydraulic press a few times so that the fixture stabilizes itself against the tailstock.

WARNING!
Keep hydraulic lines away from the blow torch flame or serious injury
could result.

6. Use the blow torch to heat the insert casting. This will take approx. 30 minutes.

7. Pump the hydraulic press to its maximum pressure while continuing to heat the casting.

NOTE: When the pressure on the gauge begins to drop the insert should begin to slip
out. Once the press is fully extended, run the nut down again and repeat step
6.

NOTE: Use a spacer if the adjustment screw on the press is not long enough to
remove the insert.

8. Once the insert is removed, use a small screw driver or chisel to remove any Devcon. Make sure
fill hole is clear.

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Installation -

1. Clean the tailstock bore and all mounting surfaces.

2. Mount the spindle alignment test bar onto the spindle.

3. Then mount a tenths indicator to the nose of the test bar.

4. Make sure the fill hole at the back of the tailstock casting is not clogged

5. Install the tailstock insert and three mounting screws.

6. Insert the tailstock taper alignment bar.

7. Position the indicator tip at the base of the tailstock test bar.

8. Adjust the insert until the runout at the base of the test bar is less than .0003" TIR. Then tighten
all three screws.

9. Install the rear insert plate. Tighten the three 1/4 x 20 bolts but leave the three 10 x 32 bolts loose.

10. Position the indicator at the end (far left) of the tailstock taper alignment bar.

11. Insert a pry bar into the rear of insert and adjust the runout at the end of the shaft until the reading
is .001" or less from centerline. Then tighten the remaining screws.

12. Inject the Devcon and let stand overnight.

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H YDRAULIC TAILSTOCK C YLINDER

WARNING!
Before performing any service on the hydraulic cylinder or pump, the
machine should be powered off.

REMOVAL -

1. Remove front and rear waycovers.

Figure 3.3-5. Hydraulic cylinder replacement.

2. Move to mid travel before disconnecting

3. Disconnect the hydraulic lines from both ends of the cylinder.

CAUTION! Although the hydraulic system is not under pressure oil will spill out
of the hydraulic lines once disconnected from the cylinder. Have a
bucket ready to catch any oil that spills out.

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4. Remove the (2) SHCS that mount the cylinder rod end block to the rear of the hydraulic tailstock
adapter.

5. Remove the 1/4 - 20 SHCS that mounts the encoder rail to the bottom of the cylinder rod end
block

6. Extend the cylinder shaft so that you can place a wrench on the end of the cylinder rod in order to
unscrew it from the end block.

7. Remove the (2) SHCS that mount the hydraulic cylinder body to the base casting.

8. Unscrew the end block from the cylinder.

9. Collapse the hydraulic cylinder then push the tailstock to the rear of travel.

10. Pull the hydraulic cylinder out from the frontside of the tailstock.

INSTALLATION -

11. With the new cylinder in position, push the tailstock to the front of travel.

12. Install the (2) SHCS that mount the cylinder body to the base casting. Before tightening move the
tailstock to the front end of travel.

13. Thread the end block onto the end of the cylinder rod and tighten.

14. Install the (2) SHCS that attach the end block.

15. Install the 1/4 - 20 SHCS that hold the encoder rail to the bottom of the mounting block.

16. Attach the hydraulic lines to both the front and rear of the cylinder. Check for leaks.

17. Reinstall waycovers.

18. Check the fluid level at the hydraulic tank to determine how much fluid needs to be added.

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3.4 T RANSMISSION

REMOVAL

TOOLS REQUIRED:

• Hoist and lifting straps OR floor jack and (4) wood blocks
1. Power off the machine.

2. Remove the left side panel to access the spindle motor and transmission assembly.

NOTE: If you are using a floor jack, the bottom left front panel needs to be removed.

3. Disconnect all electrical lines from the motor and transmission assembly.

4. Position the hoist directly to the rear of the motor and place the lifting straps around the motor and
transmission. Make sure there is enough tension on the straps so that when you loosen the
mounting bolts, the motor assembly does not shift.

NOTE: If you are using a floor jack, slide the jack under the transmission assembly
from the front side of the machine. Being careful not to damage any compo-
nents, place the wood block supports under the transmission and motor .

5. Remove the four transmission mounting plate bolts. Raise the transmission enough to remove the
drive belts, then slide the entire assembly out.

Mounting Bolts (4)

Fluid sight glass

Mounting plate

Figure 3.4-1. Lathe transmission mounting plate.

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TRANSMISSION INSTALLATION

1. Place lifting straps under new transmission assembly and lift just enough to put tension on the
cables.

NOTE: If you are using a floor jack, slide the jack under the front side of the machine.
Being careful not to damage any components, place the wood block supports
on the jack and slide the transmission and motor onto the jack.

2. Ensure the new transmission is seated securely on the straps and lift up slowly. Lift only high
enough to install the drive belts, then gently swing the assembly into place.

3. Insert the four bolts that secure the transmission mounting plate to the spindle head.

4. Adjust the drive belt tension, then tighten down screws completely. Refer to the Spindle Installa-
tion section, for proper belt tension procedures and tension chart.

5. Reattach all electrical lines at this time.

6. Replace the left side panel.

NOTE: If you are using a floor jack, replace the bottom left front panel.

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3.5 G RID O FFSET C ALCULATION

Please 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 is
released. If DISTANCE TO GO is less than 1/8 (.0295) or greater than 7/8 (.2065) of a revolution, it will alarm
to “Zero Return Margin Too Small”.

In ZERO RETURN mode, the DISTANCE TO GO is the amount the encoder rotated from when the switch was
released until it found the Z channel signal. The ideal amount for the DISTANCE TO GO are; X-axis =.236, Z-
axis=.118, B-axis = .050 (This equals ½ of a revolution of the encoder) on non hydraulic tailstock machines.

SETTING THE OFFSET -

1. Set the grid offset to zero. (Parameter 125 or 127 depending on the axis being set.) Setting #7
(PARAMETER LOCK) must be OFF to reset grid offset.

2. Press ZERO RET and ZERO SINGL AXIS the axis you are setting (X, Z, or A).

3. Calculate the grid offset using the following formula, and write the result in Parameter 125 or 127
(depending on the axis being set).

(DISTANCE TO GO - .236) x Ratio = Grid Offset

The Ratio (steps/unit) for the X and Z axes are the values in Parameters 5 and 33 respectively.

4. ZERO RET the axis again to use this offset.

NOTE: If X-axis grid offset is reset, Parameter 254 should be checked and adjusted
accordingly.

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3.6 L UBE A IR P ANEL

8 9

7
11
10 AIR

AIR 1

MAX
2

5
MIN

6 4 3

Figure 3.6-1. Lube Air Panel (Front View).

L UBE A IR P ANEL COMPONENTS

The following is a list of the Lube Air Panel Assembly components, each with a description of its specific
function.

1. Oil Pressure Gauge - Indicates the pressure (in psi) at which the oil is pumped from the reservoir.

2. Oil Pump - Pumps the oil from the reservoir to various parts of the lathe. Every 30 minutes the
pump cycles and pumps 2.8 to 3.8 cc of oil (at approximately 20 psi).

3. Oil Reservoir - Stores the oil (Vactra #2) that is used for lubrication in the linear guides and lead
screws. Oil is also mixed with air and sent to the spindle bearing for lubrication and cooling.

4. Oil Filter - Filters the oil from the reservoir before it is pumped to the necessary areas.

5. Air Pressure Gauge - Indicates the pressure (in psi) at which the air is being regulated.

6. Air Filter - Filters the air and removes moisture before it is sent to the solenoid valves.

7. Air Pressure Regulator - Maintains the air supplied from the outside source (via the main air line)
at a constant, desired pressure (approximately 85-90 psi).

8. Air Solenoid Assembly - 4-way 2-position valve that controls the air to the turret air cylinder.

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9. Air Solenoid Assembly- 3-way 2-position valve that controls the air to the parts catcher air
cylinder. This assembly is only on machines equipped with a part catcher.

10. Power Cable - Supplies power to the Lube Air Panel from the main control box and carries
signals from switches to control box.

11. Foot Pedal Cable - Connects chuck actuator foot pedal to the lube air panel.

8 9

10

77
1

2
5 4
6
3

Figure 3.6-2. Lube Air Panel (Rear View).

The following is a list of the Lube Air Panel Assembly components on the rear of the panel, each with a descrip-
tion of its specific function.

1. Air Pressure Switch - Monitors the air supply pressure, and sends a signal to the control panel to
“alarm out”, or stop, the machine when the air pressure falls below 70 psi.

2. Solenoid Valve - Opens when the spindle is turning to permit air to be sent to the spindle bear-
ings.

3. Air Regulator - Maintains the correct air pressure (15 psi) being sent to the spindle bearings.

4. Oil Mist Ports - Connect to nylon tubing that carries the oil-air mist to the spindle bearings. One
port supplies the front spindle bearing, and one supplies the rear bearing.

5. Air Pressure Gauge - Indicates the pressure of the air being mixed with oil and supplied to the
spindle bearings.

6. Connector Plate - Contains all of the connectors for the Lube Air Panel.

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7. Pressure Switch - Monitors the oil supply pressure, and sends a signal to the control panel to
stop the machine if the pressure drops below the minimum level for a set period of time.

8. Oil Line - Carries oil to the ports, where it is then sent to the lead screws, linear guides, and
spindle bearings.

9. Oil Ports - Connect to nylon tubing that carries the oil to the lead screws and linear guides.

10. Flowmeters - Maintain the correct amount of oil dropping from the upper ports to the lower ports
where they are mixed with air and sent to the spindle bearings.

L UBE P ANEL REMOVAL

CAUTION! Power off the machine before performing the following procedure.

1. Remove the rear panel.

2. Disconnect the main air line.

3. Disconnect limit switches from lube panel.

4. Disconnect spindle air lines.

5. Disconnect oil line at lube panel.

NOTE: All plastic ties must be cut in order to remove the lube air panel.

6. Remove all conduits.

7. Disconnect main oil line.

8. Remove the mounting screws located at the top of the lube panel.

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3.7 H YDRAULIC P OWER U NIT

Removal

CAUTION! Power off the machine before performing this procedure.

1. Remove necessary panels to access the hydraulic unit.

2. Loosen and disconnect the drawtube clamp and unclamp hoses. Drain the hydraulic fluid.

3. If the unit comes with a hydraulic tailstock solenoid, disconnect the 2 hoses that lead to the
tailstock cylinder. Remember to mark the hoses or else the tailstock and chuck will not function
properly.

NOTE: Right clamp/unclamp hose of hydraulic unit is attached to bottom port of

hydraulic cylinder and left hose is attached to top port. The ports are located
on the side of the hydraulic cylinder.

4. Unclamp and remove oil return hose from hydraulic unit and hydraulic cylinder.

NOTE: The oil return hose is shrink-fitted and should be replaced with a new one
whenever removed.

5. Disconnect pressure switch cable and solenoid valve cable.

6. Disconnect pump motor cable.

7. Loosen and remove the four bolts from base of unit, then slide hydraulic unit out.

Hydraulic Cylinder
Hoses (2)

Valve Block

Hydraulic Tailstock
Hoses (2)

Figure 3.7-1. Hydraulic power unit.

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INSTALLATION

CAUTION! POWER OFF THE MACHINE BEFORE PERFORMING THIS PROCEDURE.

1. Slide hydraulic power unit into place and attach with four mounting bolts.

2. Connect pump motor cable.

3. Connect pressure switch cable and solenoid valve cable.

4. Replace oil return hose and clamp to hydraulic unit and hydraulic cylinder.

NOTE: The oil return hose is shrink-fitted and should be replaced with a new one if
damaged during removal.

5. Connect the clamp and unclamp hoses. Connect tailstock hoses.

NOTE: Right clamp/unclamp hose of hydraulic unit is attached to bottom port of

hydraulic cylinder and left hose is attached to top port. The ports are located
on the side of the hydraulic cylinder.

6. Fill the hydaulic unit with DTE25 to the top of the sight glass.

7. Replace any panels that were removed to access the hydraulic unit.

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3.8 I NTERIOR W ORKLIGHT

BULB REPLACEMENT

1. Jog the Z-axis all the way to the right (positive direction).

2. TURN OFF power to the machine at the main breaker.

3. Loosen the 14 BHCS that attach the light lens retainer

4. Remove the retainer and the light lens.

5. Remove the light bulb and replace with a 24", 20 watt (F20T12-CW) bulb.

6. Replace the light lens and retainer then tighten down the 14 BHCS.

7. Restore power to the machine.

Gasket, Light Lens (2)

(Glued to Bulk Head)

24", 20 Watt Bulb

(F20T12-CW)

Window,
Light

24", 20 Watt
(F20T12-CW) Bulb
Light Lens
Retainer
Washer

1/4-20 X 3/4
Bulk Head BHCS (14)

Figure 3.8-1. Interior worklight assembly.

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3.9 T URRET C ROSS -S LIDE S PRING

WARNING!
Power on machine, but DO NOT PRESS EMERGENCY STOP, or turret will
fall during spring removal.

REPLACEMENT

1. Remove sliding tool changer cover, located in the back of the machine, to gain access to spring.

Sliding Tool Cylinder Spring

Changer Cover Retainer

3/4" HHB

3/8" SHCS Cross Slide

Spring
Spring Retainer
(Beveled) Pivot Arm

Spring Bracket

Figure 3.9-1. Cross-slide spring components.

2. Unbolt X-axis waycover from tool changer box.

3. Jog the turret to top of X-axis travel.

4. Insert a wood block between ballscrew support and ballscrew nut to safely block the assembly.

5. Loosen 3/8" SHCS that holds lower pivot arm to spring bracket, then loosen 3/4" nut of upper pivot
arm of spring bracket.

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6. Place a wrench on the pivot arm and push the spring forward slowly to relieve the spring tension.

WARNING!
Be careful not to release tension too fast.

NOTE: Recommend using a wrench with a cheater bar for leverage when relieving
spring tension.

3/4" HHB

Pivot Arm

3/8" SHCS

Figure 3.9-2. Spring tension relief.

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5. Remove cross slide spring and remove spring retainer located inside turret housing. Use access
hole located on the opposite side of turret to remove spring retainer. Replace used spring retainer
with new beveled spring retainer.

NOTE: Old style bracket is not equipped with a cylinder spring retainer. Remove the
two mounting bolts and old style bracket then replace with new bracket
equipped with pivot arm and remount with two mounting bolts. Skip to Step 7.

6. Remove cylinder spring retainer attached to pivot arm and replace with new cylinder spring retainer.

7. Install new cross slide spring. Attach spring to spring retainer in turret housing and cylinder spring
retainer of pivot arm.

8. Place a wrench on pivot arm then pull towards rear of bracket until pivot arm locks to restore spring
tension.

9. Tighten 3/8" SHCS of lower pivot arm and nut of upper pivot arm on spring bracket.

10. Remove the wood safety block.

11. Re-attach the X-axis way cover.

12. Install sliding tool changer cover.

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3.10 P ARTS C ATCHER

REMOVAL

CAUTION! Power off the machine before performing the following procedure.

1. Disconnect the main air line.

2. Remove necessary panels to access the parts catcher unit

3. Loosen 1 1/2" shaft collar that locates the parts catcher tray, and slide out tray and inner
shaft.

4. Unclamp outer retaining ring that retains the shaft collar on the outer shaft, remove shaft collar and
inner retaining ring.

5. Remove rubber seal from outer shaft.

6. Detach 5/32" airlines attached to the barrel end and rod end ports of the air cylinder.

7. Remove 7/16" hex nut that attaches the air cylinder to the parts catcher shaft.

8. Loosen and remove 1/4" SHCS and washer that attaches air cylinder to cylinder mount and remove
air cylinder.

9. Remove 3/8" SHCS holding the parts catcher pivot mount assembly to the spindle head casting
and slide out mount assembly.

5/32“ Airline (2) 1/4“ SHCS

Parts Catcher
Air Cylinder Tray

7/16“ Hex Nut

Parts Catcher

Parts Catcher Shaft

Parts Catcher Pivot

Mount Assembly

Figure 310-1. Front view of parts catcher/tray

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INSTALLATION

1. Slide parts catcher pivot mount assembly through the sheet metal seal and attach to
spindle head casting using 3/8" SHCS.

2. Install air cylinder to cylinder mount using 1/4" SHCS and washer.

3. Attach air cylinder rod in its fully retracted position to parts catcher shaft with the hex nut.

4. Connect air lines to air cylinder ports.

5. Install rubber seal on outer shaft.

6. Place inner retaining ring on outer shaft, slide shaft collar on and attach outer retaining ring.

7. Connect main air line.

NOTE: Machine must be powered up and controlled in MDI mode to check for proper
activation and deactivation of parts catcher. It must be stopped with the rod
fully extended to properly position chute assembly to the collector door.

8. Slide the inner shaft of the tray assembly into outer shaft of pivot assembly. Locate tray assembly
far back enough to catch the part and clear chuck.

9. Rotate the tray position to open the sliding door of the collector. Tighten the shaft collar to the
parts catcher shaft. Step through MDI program and check tray operation

10. Install necessary panels that were removed.

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3.11 L ATHE T OOL P ROBE

PROBE SETTING

1. Power off the machine and unfasten the forward end panel on the left side of the machine.

2. Loosen all fasteners and set screw on the mounting block.

3. Lower tool setter arm to horizontal position. Install a turning tool in the cutting position pocket on
the turret and jog the Z axis in slow motion until the tool tip touches the square tip of the probe.

4. By tightening 1/4-20 set screw on the mounting block, adjust the height of probe so the tip of the
turning tool touches the middle of the side of square tip. After proper alignment, tighten all four 3/8-
16 screws on mounting block and torque them to 50 ft/lb. Also tighten the 1/4-20 nut on the set
screw against the mounting block.

5. Install .0001” indicator on a safe place on the turret, align the tip of probe within .0005” to X and
Z axes by loosening the four 4-40 clamping screws and rotating the probe body. Tighten the
clamping screws.

6. Rotate tool setter arm to vertical position (home position) and check the alignment of probe, ball
stud and home switch actuator groove to home assembly. If there is misalignment, loosen the two
1/4-20 button head screws and let home assembly self center to the ball stud. Tighten screws after
proper alignment.

7. Home position verify by jog functions normal on X and Z axes.

8. Move turret away and pull down tool setter arm. Control should switch to Tool set offset screen. X
and Z will jog only in slow motion. Using your finger, trigger probe, speaker should beep and
diagnostics input should change from 0 __> 1 __> 0. Using slow jog button, move X or Z clear of the
part, tap the probe, the motion in current direction should stop, offset should update.

PROBE TIP R EPLACEMENT

1. Install stylus tip with supplied wrenches. Additional information can be found in the probe
manufacturer's manual.

2. Install .0001" indicator on a safe place on the turret, align the tip of probe within .0005" to X and
Z axes by loosening the four 4-40 clamping screws and rotating the probe body. Finally tighten the
clamping screws.

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SETTING PROBE OFFSETS

Setting X offsets.

1. Clamp a piece of material in the chuck and take a finish cut on the outside diameter. Move away in
the Z, do not move in the X.

2. Measure the diameter of the part using a micrometer and record the measurement on a piece of
paper.

3. With the tool tip positioned to the outside diameter of the part and using the origin key, zero the X
register of the operator position display.

4. Using the operator position display as a guide move the tool in the X direction until the display
reads the same value as the measured diameter and using the origin key, zero the X register of
the display.

5. Move the tool to a safe position and lower the tool setter arm and touch the tool tip using the jog
handle in the .0001 mode.

NOTE: While jogging, when the tool comes in contact with the probe the control will
beep and jogging in the current direction will stop.

6. Record the value shown in the X operator position display into Setting 59 PROBE OFFSET X+.

7. Subtract 2 times the probe width from the X operator position display and store this value into
Setting 60 PROBE OFFSET X-.

Setting Z offsets.

1. The value of Setting 61 PROBE OFFSET Z+ should be Zero. The value of Setting 62 PROBE
OFFSET Z- should be the width of the probe (i.e. if the probe measures .3937 Setting 62 PROBE
OFFSET Z- would be .3937).

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LATHE TOOL P RESETTER SETUP

This procedure measures probe faces and sets parameters based on the actual distances. If a diameter
difference greater than the tolerence of +/- 0.002 is noticed, preforming this procedure will correct the setup
without any mechanical changes.

1. Parameter 254, spindle center distance must be set correctly before setting LTP.

2. Install 1" diameter axial reference tool in position 1.

3. Select YASNAC for SETTING #33 coordinate system.

4. Offset G54 must be set X=0, Z=0.

5. Tool wear #1 must be set to 0.

6. Handle jog to a position for clear X travel

7. In OFFSET page, use F2 to set tool 1 work shift to centerline.

8. Enter this program in MDI: G54

G50 T5100
X0

9. Run MDI program, the Tool will move to spindle center

10. Select handle jog mode, Distance to go will read X=0.0000, Z=0.0000

11. Manually jog in Z to a position clear of the LTP arm, don’t move the X.

12. Lower the LTP arm, the display will switch to OFFSETS,

13. Select POSITION display again in order to view DISTANCE TO GO Display.

14. Manually jog to probe tip and “probe” the 1"dia reference tool in the -X direction (move down) using
0.0001 feed rate.

15. Record the X distance to go. (e.g.; 4.9993)

16. Subtract 1" from the number in step 15 (e.g.; 4.9993 - 1.0000 = 3.9993).

17. Enter the number from step 16 in SETTING #59 (X+ DISTANCE).

18. Manually jog the tool and “probe” the 1" reference tool in the X+ direction (move up) using 0.0001
feed rate.

19. Record the X distance to go for this position. (e.g. 2.2309).

20. Add 1" to the number in step 19. (e.g. 2.2309 + 1.0000 = 3.2309).

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21. Enter the number from step 20 in SETTING #60 (X- DISTANCE).

22. Subtract the number in SETTING #60 from SETTING #59 (e.g. 3.9993 - 3.2309 = 0.7684).

23. Divide the number in step 22 by 2 (e.g. 0.7684 / 2 = 0.3842 ).

(This is the effective width of the probe head, recall the actual width is 10mm or 0.3937)

24. Enter the number from step 23 (effective probe width) in SETTING #62 and SETTING #63.

VERIFICATION

( Method assumes cut geometry is smaller than Tool Probe setting diameters.)

O.D.
25. Using Handle jog and an OD turning tool, OD turn a diameter. Set DISTANCE TO GO to X=0.000.

26. Measure the diameter. (e.g. 2.125)

27. Jog away in Z direction and lower the tool presetter.

28. Jog to probe the OD tool in the X- direction using the 0.0001 feed rate.

29. Record the X DISTANCE TO GO number. (e.g. 1.8743)

30. Add the number from step 29 to the measured diameter in step 26. (e.g. 2.125 + 1.8743 = 3.9993)

31. The SUM from step 30 should equal the number in SETTING #59 (X+ DISTANCE) +/- 0.0020).

I.D.
32. Using Handle jog and an ID boring tool, ID bore a diameter. Set DISTANCE TO GO to X=0.000.

33. Jog away in Z direction and lower the tool presetter.

34. Measure the bore diameter. (e.g. 1.750)

35. Jog to probe the ID tool in the X+ direction using the 0.0001 feed rate.

36. Record the X DISTANCE TO GO number. (e.g. 1.4809)

37. Add the number from step 36 to the measured diameter in step 34. (e.g. 2.125 + 1.4809 = 3.2309)

38. The SUM from step 37 should equal the number in SETTING #60 (X- DISTANCE) +/- 0.0020.

39. If verifying tool setter arm settings with cut diameters larger than tool probe setting diameter,
subtract the X DISTANCE TO GO from the measured diameter and compare result to the appropri-
ate X +/- setting (#59 or #60).

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3.12 L EAD S CREW R EPLACEMENT

Please read this section in its entirety before attempting to remove or replace the lead screws.

TOOLS REQUIRED:

• Spanner Wrench (32mm or 40/50mm) • Shaft Lock (32mm or 40/50mm)

Z-A XIS L EAD S CREW R EMOVAL

1. Turn the machine ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.

2. Remove rear and right side covers. Remove the hard stops from the bearing support and
motor end of the lead screw.

3. Remove the cover from the motor housing. Disconnect the oil line from the lead screw nut.

SHCS Oil Line Fitting X-Axis Bumper

Cover Plate Motor
Housing SHCS
Bumper Bracket
Bearing Sleeve Bumper

SHCS Bearing
Locknut

Bearing Bearing
Locknut Support
SHCS Casting

Ball Screw Nut

Woodruff Key
Nut Housing
Servo Motor
Ball Screw

Motor Mount Casting

Motor Coupling Assy

SHCS

Figure 3.12-1

For 32mm Lead Screw:

a. At the bearing support side, loosen the lock nut screw. Unscrew the clamp nut an 1/8" and
retighten clamp nut screw. Attach shaft lock tool to bearing support side of lead screw.

b. At the motor end, loosen the motor coupling on the lead screw side of the coupling. Remove
the four motor mount SHCS and the motor. Remove the Woodruff key from the key way on the lead
screw.

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c. In the motor housing, loosen the lock nut screw, attach the spanner wrench to the clamp nut
and remove the nut from the lead screw in the motor housing. Unfasten the six ¼-20 x 1” SHCS
from the bearing sleeve and remove the bearing sleeve from the motor housing. On the bearing
support side, remove bearing support clamp nut.

d. Push the wedge all the way towards the motor end. Underneath the wedge, remove the SHCS that
attach the lead screw nut to the nut housing. Pull the lead screw forward to clear the nut from the
housing and angle the lead screw towards the right of the bearing support. Carefully remove lead
screw.

CAUTION! Be careful during removal or installation of lead screw, to protect the

surfaces.

40mm Lead Screws:

a. At the bearing support side, loosen the lock nut screw. Unscrew the clamp nut an 1/8" away from
the bearing support and retighten clamp nut screw. Attach shaft lock tool.

b. At the motor end, loosen the motor coupling on the lead screw side of the coupling.
Remove the four motor SHCS and the motor. Remove the Woodruff key from the key way on the
lead screw. In the motor housing, loosen the lock nut screw and attach the spanner wrench.
Remove the clamp nut.

c. Disconnect the oil line.

d. Underneath the wedge, remove the SHCS from the lead screw nut and push the wedge towards
the motor housing.

e. On the bearing support side, remove the shaft lock tool and clamp nut. Remove the alignment
pins and the SHCS from the bearing support casting. Make note of any shims. Hold the lead screw
in place and remove the bearing support. Pull forward on the lead screw and carefully remove.

CAUTION! Be careful during removal or installation of ball screw, to protect the

surfaces.

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Z-A XIS L EAD S CREW INSTALLATION

Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing and the lead screw nut are free of
dirt, burrs, grease or other contaminants.

CAUTION! Mating surfaces must be clean or misalignment may occur, seri-

ously affecting the proper operation of the machine.

For 32mm Lead Screw:

1. Reinsert the lead screw, with the motor housing bumper on it, from the right hand side of the
bearing support into the motor housing. Align the lead screw with the bearing support end and
insert the lead screw. Prevent contact with the screw threads, to avoid any possible damage.

2. Hold the lead screw level on the motor side. Slide the bearing sleeve onto the lead screw and
insert bearing sleeve into motor housing. Attach bearing sleeve to the housing with six ¼-20 x 1”
SHCS. Place a drop of blue Loctite on each of the SHCS before inserting. Torque the bearing
sleeve SHCS to 15 FT-LBS.

CAUTION! Do not use more than one drop of Loctite. An excessive amount will
cause a film to develop between the sleeve and housing which could
result in backlash.

3. The following sequence is important to ensure proper installation of the lead screw:

a. On the bearing support end, install the lock nut an 1/8" away from the bearing. Tighten
the lock nut screw. Install the shaft lock onto the bearing support end of the lead screw.

CAUTION! Do not attach bearing clamp nut against bearing support until the
motor side clamp nut is torqued to its proper specification. Damage
will occur to the bearing and lead screw on the support side.

b. At the motor side of the lead screw, attach lock nut.

c. Place a spanner wrench on the lock nut in the motor housing and torque it against the
bearing to 15 FT-LBS.

d. Torque the clamp nut screw and mark with yellow paint.

e. At the bearing support end, remove the shaft lock and loosen the clamp nut screw.
Tighten the lock nut against the bearing to 4 IN-LBS. Retighten the clamp nut screw and
mark with yellow paint.

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f. Align the lead screw nut to the nut housing on the wedge, check oil line fitting is in the
correct position. Apply a drop of blue Loctite to the five SHCS and fasten the nut to the
housing. Torque the lead screw nut SHCS to 15 FT-LBS.

g. Place the Woodruff key back into the key way slot on the lead screw.

h. Install the motor with the coupling attached check condition of the coupler and tighten the
four motor mounting SHCS. Torque the motor mounting SHCS to 30 FT-LBS.

4. Tighten the collar on the motor coupling to the lead screw and torque to 15 FT-LBS. Attach
bumper, and replace motor housing cover.

5. Check for binding in the beginning, middle and end of travel. You should be able to rotate the lead
screw by hand when the servos are off. Check for backlash or noisy operation.

6. Replace the bearing support end hardstops and reconnect oil line to the lead screw nut.

7. Zero return Z axis and set grid offset.

For 40mm Lead Screw:

1. Reinsert the lead screw with bumpers into the bearing sleeve in the motor housing. (Make sure the
lead screw nut will be able to slide in to the wedge nut housing). Support the lead screw on the
bearing support end and re-attach the bearing support housing and bearing.

2. Reinsert alignment pins through the housing into the base casting, replace shims if needed.
Fasten to the base casting using the six bearing support housing SHCS, lock washers and
Loctite.

3. The following sequence is important to ensure proper installation of the lead screw:

a. On the bearing support end, install the lock nut an 1/8" away from the bearing and tighten
clamp nut screw. Install the shaft lock into the bearing support end of the lead screw.

CAUTION! Do not attach bearing clamp nut against bearing support until the motor side
clamp nut is torqued to its proper specification. Damage will occur to the
bearing and lead screw on the support side.

b. Attach the clamp nut onto the motor side of the lead screw.

c. Place a spanner wrench on the lock nut at the motor end of the assembly. Torque the
clamp nut against the bearing to 50 FT-LBS.

d. At the motor end, tighten the lock nut screw and mark with yellow paint.

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e. At the bearing support end, remove the shaft lock.

f. Align the lead screw nut with the nut housing on the wedge. Apply a drop of blue Loctite
to the five SHCS and attach the nut to the housing. Torque lead screw nut SHCS to 30
FT-LBS.

g. Place the Woodruff key back into the key way slot on the lead screw.

h. Install the motor with the coupling attached to the lead screw and tighten the four motor
mounting SHCS. Torque the motor mount SHCS to 30 FT-LBS.

4. Tighten the collar on the motor coupling and re-torque the collar SHCS to 15 FT-LBS. Replace
the motor housing cover.

5. Move turret to support housing end, taking care to stop before hitting the support housing.

6. Torque the bearing support housing SHCS to 30 FT-LBS. Prevent contact with the lead screw
threads, to avoid any possible damage.

7. Loosen the lock nut screw. Tighten the lock nut against the bearing to 4 IN-LBS. Retighten the
clamp screw and mark with yellow paint.

8. Check for binding in the beginning, middle and end of travel. You should be able to rotate the lead
screw by hand when the servos are off. Check for backlash or noisy operation.

9. Replace the lead screw hardstops and reconnect oil line to the lead screw nut.

10. Zero return Z axis and set grid offset according to section 3.5.

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3.13 C-A XIS

NOTE: This option requires the use of a second MOCON PCB. Care should be taken
when tracing signals to and from the MOCONs.

L UBRICATION

The C-Axis gears are automatically lubricated by the machine lube system. The gears are lubricated with one
drop of oil every ten engagements. The amount of oil used is adjusted by a slotted screw on the side of the
oiler block. Turn the screw in (clockwise) for less oil.

Oil Adjustment

For a base line adjustment, turn the screw in completely, then back out 1/2 turn. Check lubrication frequency
and adjust for approximately one drop every ten engagements.

S ETTING G RID O FFSET

NOTE: Grid Offset must be checked and reset if the drive gear or the “C” drive servo
motor is replaced.

Enter MDI DNC mode. Enter the following program:

M19 P0 ;
G28 C0 ;
G04 P2.0 ;
M14

1. Press <SETNG GRAPH> and turn setting #7 off.

2. Press <ALARM MESGS>, Type DEBUG and press <ENTER>.

3. Press <POST>, use page up or down to find “Pos-Raw Dat 1 data page. Locate the “C” Axis
actual column and record the value.

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4. Disconnect the air supply to the C-Axis actuator block and install an inline regulator with a cutoff
valve. Set the pressure to 45psi.

5. Press <MDI DNC>. Press <CYCLE START>. Wait for the spindle to orient and the brake to
apply.

6. Record current values for Parameter 356 U D GAIN and Parameter 357 U I GAIN. Reset Param-
eter 356 to 1000; reset Parameter 357 to 10. This will allow for low servo response so deviations in
position can be read.

7. Engage C-Axis by turning on the air supply to the block (set at 45 psi).

8. Press <POST> raw data page and look at the C-Axis (actual) value. It should read less than
0.0050. Set to the lowest possible value by adjusting Parameter 373 U GRID OFFSET. Repeat
steps 5 through 8 until the lowest value for the position raw data is reached.

NOTE: After changing Parameter 373, you must press <RESET> at least twice before
zero-returning the C-Axis for the new value to enter into memory.

9. Exit debug mode. Press <ALARM MESGS> and type DEBUG. Press <ENTER>.

10. Enter the original values for Parameters 356 and 357, recorded in step 6.

11. Record Parameter 373.

S ETTING G EAR MESH C ONTACT L OAD

1. Disable the C-Axis (Parameter 354).

2. Activate the air supply to the C-Axis pivot block. Ensure the regulator is set to 45psi.

3. Loosen the two SHCS Stop Block Lockdown Screws, located on the side of the pivot stop block.
Remove stop block adjustment set screw and apply one drop of Red Loctite to the threads.

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Stop Block Adjustment Stop Block Lockdown

Screws

4. Install the set screw, but do not put pressure on the stop block.

5. Place a magnetic base indicator on top of the spindle head and rest the indicator finger on top of
the pivot block.

6. Rotate the spindle manually and observe the indicator. If runout is over .004” check the grid offset
and/or servo motor installation. If the grid offset and servo motor installation are correct and the
runout is still over .004” increase the air pressure to 50 psi and recheck.

7. Once the proper runout is achieved set the indicator finger to zero at the lowest point of the runout.

8. Screw down the adjustment set screw until the pivot block is .0005” from the gear mesh contact
point.

9. Tighten the two SHCS Stop Block Lockdown Screws, located on the side of the pivot stop block.
Torque to 50 ft/lbs.

10. Reconnect the C-Axis air supply from the C-Axis solenoid.

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4. ELECTRICAL SERVICE

4.1 S OLENOIDS

Please read this section in its entirety before attempting to replace any solenoid assemblies.

PNEUMATIC CHUCK CLAMP /UNCLAMP S OLENOID

REMOVAL -

1. Turn machine power off and remove the air supply from the machine.

2. Disconnect the two air hoses from the pneumatic chuck clamp/unclamp solenoid.

3. Unplug the solenoid electrical lead at the switch bracket (located on the rear of the lube air panel).

4. Remove the two SHCS holding the assembly to the bracket and remove the assembly.

INSTALLATION -

5. Replace the air solenoid assembly and attach it to the bracket with the two SHCS. Tighten
securely.

6. Reconnect the electrical connection to the solenoid at the switch bracket.

7. Reconnect the two air lines, ensuring that all connections are tight and do not leak.

8. Restore the air supply to the machine.

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TURRET CLAMP/UNCLAMP S OLENOID

REMOVAL -

1. Turn machine power off and remove the air supply from the machine.

2. Disconnect the three air hoses from the turret clamp/unclamp solenoid (see section 3.6).

3. Disconnect exhaust lines.

4. Unplug the solenoid electrical lead in the wire channel (located on the rear of the lube air panel).

5. Remove the two SHCS holding the assembly to the bracket and remove the assembly.

INSTALLATION -

6. Replace the air solenoid assembly and attach to the bracket with the two SHCS. Tighten securely.

7. Reconnect the electrical connection to the solenoid at the switch bracket.

8. Reconnect the three air lines, ensuring that all connections are tight and do not leak.

9. Reconnect exhaust lines.

10. Restore the air supply to the machine.

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S PINDLE L UBE A IR S OLENOID

REMOVAL -

1. Turn the machine power off and remove the air supply from the machine.

Spindle
Lube
Solenoid

Figure 4.1-2. Rear view of lube/air panel.

2. Disconnect the lube line from the spindle lube air solenoid assembly.

3. Disconnect the electrical leads from the main air line pressure switch.

4. Unscrew the solenoid assembly pressure gauge from the assembly.

5. Unscrew the entire solenoid assembly from the T-fitting.

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Pressure Gauge

Main Air Line

Lube Line Pressure Switch

Figure 4.1-3. Top view of spindle lube/air solenoid assembly.

INSTALLATION -

6. Reattach the solenoid assembly at the T-fitting.

7. Reattach the pressure gauge onto the solenoid assembly.

8. Reconnect the lube line to the assembly.

9. Reconnect the electrical leads to the main air line pressure switch.

10. Restore the air supply to the machine.

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4.2. L INE V OLTAGE A DJUSTMENTS

Please read this section in its entirety before attempting to adjust the line voltage.

TOOLS REQUIRED:

•LARGE FLAT TIP SCREWDRIVER

•DIGITAL VOLTMETER

E LECTRICAL C ONNECTIONS

NOTE: The machine must have air pressure at the gauge or a “Low Air Pressure”
alarm will be present on power up.

CAUTION! Working with the electrical services required for the SL can be extremely
hazardous. The electrical power must be off and steps must be taken to
ensure that it will not be turned on while you are working with it. In most
cases this means turning off a circuit breaker in a panel and then locking
the panel door. However, if your connection is different or you are not sure
how to do this, check with the appropriate personnel in your organization
or otherwise obtain the necessary help BEFORE you continue.

WARNING!
The electrical panel should be closed and the three latches on the
door should be secured at all times except during installation and
service. At those times, only qualified electricians should have ac-
cess to the panel. When the main circuit breaker is on, there is high
voltage throughout the electrical panel (including the circuit boards
and logic circuits) and some components operate at high tempera-
tures. Therefore, extreme caution is required.

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1. Hook up the three power lines to the terminals on top of the main switch at upper right of electrical
panel and the separate ground line to the ground bus to the left of the terminals.

NOTE: Make sure that the service wires actually go into the terminal-block clamps. (It
is easy to miss the clamp and tighten the screw. The connection looks fine but
the machine runs intermittently or has other problems, such as servo over-
loads.) To check, simply pull on the wires after the screws are tightened.

2. After the line voltage is connected to the machine, make sure that main circuit breaker (at top-
right of rear cabinet) is OFF (rotate the shaft that connects to the breaker counterclockwise until it
snaps OFF). Turn ON the power at the source. Using an accurate digital voltmeter and appropriate
safety procedures, measure the voltage between all three pair phases at the main circuit breaker
and write down the readings. The voltage must be between 195 and 260 volts (360 and 480 volts for
high voltage option).

NOTE: Wide voltage fluctuations are common in many industrial areas; you need to
know the minimum and maximum voltage which will be supplied to the
machine while it is in operation. U.S. National Electrical Code specifies that
machines should operate with a variation of +5% to -5% around an average
supply voltage. If problems with the line voltage occur, or low line voltage is
suspected, an external transformer may be required. If you suspect voltage
problems, the voltage should be checked every hour or two during a typical day
to make sure that it does not fluctuate more than +5% or -5% from an average.

CAUTION! Make sure that the main breaker is set to OFF and the power is off at your
supply panel BEFORE you change the transformer connections. Make
sure that all three black wires are moved to the correct terminal block and
that they are tight.

3. Check the connections on the transformer at the bottom-right corner of the rear cabinet. The three
black wires labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to
the average voltage measured in step 2 above. The labels showing the input voltage range for each
terminal position are as shown in the following illustrations:

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4. Transformer T5 supplies 24VAC used to power the main contactor. There are two versions of this
transformer for use on 240 and 480V machines (32-0964B and 32-0965B, respectively). The 240V
transformer has two input connectors located about two inches from the transformer, which allow it
to be connected to either 240V or 200V. Users that have 220V-240V RMS input power should use
the connector labeled 200V. Users with the External High Voltage Option should use the 240V
connector if they have 420V-510V 60Hz power or the 200V connector if they have 50Hz power.
Failure to use the correct input connector will result in either overheating of the main contactor or
failure to reliably engage the main contactor.

5. Set the main switch to ON (rotate the shaft that engages the handle on the panel door clockwise
until it snaps into the ON position). Check for evidence of problems, such as the smell of overheat-
ing components or smoke. If such problems are indicated, set the main switch to OFF immedi-
ately and call the factory before proceeding.

WARNING!
Through the Spindle Coolant (TSC) pump is a three phase pump and
must be phased correctly! Improper phasing will cause damage to
the TSC pump and void the warranty. Refer to the TSC start up section
IF YOUR MACHINE IS EQUIPPED WITH TSC.

6. After the power is on, measure the voltage across the upper terminals on the contactor K1 (located
below the main circuit breaker). It should be the same as the measurements where the input
power connects to the main breaker. If there are any problems, check the wiring.

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7. Apply power to the control by pressing the Power-On switch on the front panel. Check the high
voltage buss on the Vector Drive (pin 2 with respect to pin 3 on the terminal bus at the bottom of
the drive). It must be between 310 and 360 volts. If the voltage is outside these limits, turn off the
power and recheck steps 2 and 3. If the voltage is still outside these limits, call the factory. Next,
check the DC voltage displayed in the second page of the Diagnostic data on the CRT. It is labeled
DC BUS. Verify that the displayed voltage matches the voltage measured at pins 2 and 3 of the
Vector Drive +/- 7 VDC.

8. Electrical power must be phased properly to avoid damage to your equipment. The Power Supply
Assembly PC board incorporates a "Phase Detect" circuit with neon indicators, shown below.
When the orange neon is lit (NE5), the phasing is incorrect. If the green neon is lit (NE6), the
phasing is correct. If both neon indicators are lit, then you have a loose wire. Adjust phasing by
swapping L1 and L2 of the incoming power lines at the main circuit breaker.

WARNING!
ALL POWER MUST BE TURNED OFF AT THE SOURCE PRIOR TO ADJUSTING
PHASING.

9. Turn off the power (rotate the shaft that engages the handle on the panel door counterclockwise
until it snaps into the OFF position). Also, set the main switch handle on the panel door to OFF.
(Both the handle and the switch must be set to OFF before the door can be closed). Close the
door, lock the latches, and turn the power back on.

10. Remove the key from the control cabinet and give it to the shop manager.

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I NSTALLATION PROCEDURE FOR EXTERNAL 480V TRANSFORMER

Introduction

The external transformer adds to overall machine reliability and performance, however it does require extra
wiring and a place to locate it. The external transformer provides electrostatically shielded isolation. This type
of transformer acts to isolate all common mode line transients and improve EMI conducted emissions.

The external transformer has a 45 KVA rating.

Installation

The transformer should be located as close to the machine as possible. The input and output wiring of the
transformer should conform to the local electrical codes and should be performed by a licensed electrician. The
following is for guidance only, and should not be construed to alter the requirements of local regulations.

The input wire should not be smaller than the 6AWG for the 45KVA transformer. Cable runs longer than 100”
will require at least one size larger wire. The output wire size should be 4 AWG.

The transformer is 480V to 240V isolation transformers with delta wound primary and secondary windings. The
primary windings offer 7 tap positions, 2 above and 4 below the nominal input voltage of 480V.

For domestic installations and all others using 60Hz power, the primary side should be wired as follows:

Input Voltage Range Tap

493-510 1 (504)
481-492 2 (492)
469-480 3 (480)
457-468 4 (468)
445-456 5 (456)
433-444 6 (444)
420-432 7 (432)

This should produce a voltage on the secondary side of 234-243 V RMS L-L. Verify this and readjust the taps
as required. At the machine, connect the cables at the input of the internal 230V transformer to the 227-243V
taps. Apply power to the machine and verify that the DC voltage between pins 2 and 3 of the Vector Drive (2nd
and 3rd pins from the left) is 329-345VDC. If not, return to the 480V isolation transformer and readjust the taps
as required. Do not use the taps on the internal 230V transformer to adjust the voltage.

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50Hz Installations

The external transformers are 60Hz rated, and cannot be used at 50Hz without derating the input voltage. For
these applications, the internal 230V transformer should be tapped on the lowest setting (195-210V RMS). The
external transformer should be tapped according to the table shown below. If these tap setting do not produce
a DC bus voltage between pins 2 and 3 on the Vector Drive between 320 and 345VDC, readjust the taps on the
external transformer as required. DO NOT move the taps on the internal transformer from the lowest position.

Input Voltage Range Tap

423-440 1 (504)
412-422 2 (492)
401-411 3 (480)
391-400 4 (468)
381-390 5 (456)
371-380 6 (444)
355-370 7 (432)

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4.3 F USE R EPLACEMENT

Please read this section in its entirety before attempting to replace any fuses.

TOOLS REQUIRED:

•REPLACEMENT FUSES

OVERVOLTAGE FUSES

WARNING!
The electrical panel will have residual voltage, even after power has
been shut off and/or disconnected . Never work inside this cabinet
until the small green POWER ON light on the servo amplifiers (servo
drive assembly on brush machines) goes out. The servo amplifiers /
servo drive assembly is on the left side of the main control cabinet
and about halfway down. This light(s) is at the top of the circuit card at
the center of the assembly. Until this light goes out, there are danger-
ous voltages in the assembly EVEN WHEN POWER IS SHUT OFF.

1. Turn machine power off.

2. Turn the main switch (upper right of electrical cabinet) to the off position.

Figure 4.3-1. Unscrew the two screws to open the cabinet door. (Control cabinets require a key)

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3. Using a large flat tip screwdriver, loosen the two screws on the cabinet door and then open the door
enough to safely work on the electrical panel. Wait until at least the green POWER ON light on the
servo amplifiers (servo drive assembly on brush machines) goes out before beginning any work
inside the electrical cabinet.

4. On the POWER SUPPLY board there are three fuses located in a row at the upper right of the
board; these are the overvoltage fuses. An orange light will be on to indicate the blown fuse(s).

P9 P8 P32 P31 P29 P27 P26

P24
P1 P25

P35 P34 P33 P30 P28

P2
FU1 FU2 FU3
P3 NE6 NE5
P5
P4 P23
NE1
P6 NE2 NE3
P7
P10
32-4076G Rev.A P22
SPARE FUSESC4 C3 C2 C7 C6 C5 C1
P11

TB1

10A 115V 10A 115V 10A 230V 10A 230V

MAIN RTY/ COOLANT TSC COOLANT
USER POWER TB3
P12 FU7 FU12 FU11 FU10 FU9 FU8

P15 NE13
P14
P21
P13
NE4 NE11 NE10 NE9 NE8 NE7 FU13
TB2
NE12 FU12
P16 P17 P18 P19 P20

Figure 4.3-2. Power supply board; fuse locations.

5. Using a flat tip screwdriver, turn the fuse(s) counterclockwise to remove and replace the blown
fuse(s) with ones having the same type and rating (½ amp, type AGC, 250V).

CAUTION! When the left fuse is blown, it is still possible to operate the machine,
thereby making an overvoltage situation possible. VERIFY absolute
voltage to the machine does not exceed 260 volts.

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4.4 PCB R EPLACEMENT

Please read this section in its entirety before attempting to replace any PCBs.

M ICROPROCESSOR , MOCON (MOTIF), & V IDEO / K EYBOARD

WARNING!
An anti-static strap should be worn when changing any PCB.

NOTE: The arrangement of these boards may differ from the order of replacement that
follows. The steps for replacement will only differ in which board may need to
be removed before getting to the necessary board.

WARNING!
The electrical panel will have residual voltage, even after power has
been shut off and/or disconnected . Never work inside this cabinet
until the small green POWER ON light on the servo amplifiers (servo
drive assembly on brush machines) goes out. The servo amplifiers /
servo drive assembly is on the left side of the main control cabinet
and about halfway down. This light(s) is at the top of the circuit card at
the center of the assembly. Until this light goes out, there are danger-
ous voltages in the assembly EVEN WHEN POWER IS SHUT OFF.

MOCON (or MOTIF) BOARD -

NOTE: Refer to "Cable Locations" for a diagram of this board.

1. Turn machine power off.

2. Turn the main switch (upper right of electrical cabinet) to the off position.

3. Loosen the two screws on the cabinet door and then open the door enough to safely work on the
electrical panel. Wait until at least the green POWER ON light on the servo amplifiers (servo drive
assembly on brush machines) goes out before beginning any work inside the electrical cabinet.

4. Disconnect all leads to the Motor Controller (MOCON), or Motor Interface (MOTIF) board (for brush
machines). Ensure all cables are properly labeled for reconnecting later.

5. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in
place until all standoffs have been removed.

NOTE: If the VIDEO / KEYBOARD or PROCESSOR boards need replacing, please skip
the next step.

6. Replace the MOCON (or MOTIF) board, attaching it to the VIDEO / KEYBOARD (beneath the
MOCON / MOTIF board) with the standoffs.

7. Reconnect all leads (previously removed) to their proper connections.

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VIDEO / KEYBOARD -

NOTE: Refer to "Cable Locations" for a diagram of this board.

8. Remove the MOCON (or MOTIF) board as described in Steps 1-5.

9. Disconnect all leads to the Video / Keyboard. Ensure all cables are properly labeled for reconnect-
ing later.

10. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in
place until all standoffs have been removed.

NOTE: If the PROCESSOR board need replacing, please skip the next step.

11. Replace the Video / Keyboard, attaching it to the PROCESSOR board (beneath the Video /
Keyboard) with the standoffs.

12. Reconnect all leads (previously removed) to their proper connections.

PROCESSOR BOARD -

NOTE: Refer to "Cable Locations" for a diagram of this board.

13. Remove the MOCON (or MOTIF) board as described in Steps 1-5, and the Video / Keyboard as
described in Steps 8-9.

14. Disconnect all leads to the Processor board. Ensure all cables are properly labeled for reconnect-
ing later.

15. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in
place until all standoffs have been removed.

16. Replace the Processor board, attaching it to the electrical cabinet (beneath the Processor board)
with the standoffs.

17. Reconnect all leads (previously removed) to their proper connections.

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I NPUT / O UTPUT (I/O) B OARD

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 position.

3. Using a large flat tip screwdriver, loosen the two screws on the cabinet door and then open the
door enough to safely work on the electrical panel.

4. Disconnect all leads to the Input/Output board and move aside for removal. Ensure all cables are
properly labeled for reconnecting later. Refer to the Cable Locations section for illustrations show-
ing all cable numbers and the locations on the I/O board.

5. Remove the board by first removing the twelve screws that fasten it to the cabinet. Take care to
hold the board in place until all screws have been removed.

6. Replace the I/O board, attaching it to the cabinet with the twelve screws previously removed.

7. Reconnect all leads to the I/O board at this time.

P OWER & L OW VOLTAGE S UPPLY

POWER BOARD -

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 position.

3. Using a large flat tip screwdriver, loosen the two screws on the cabinet door and then open the
door enough to safely work on the electrical panel.

4. Disconnect all leads to the Power Distribution (POWER) board and move aside for removal. Ensure
all cables are properly labeled for reconnecting later.

5. After all cables have been disconnected, remove the seven screws holding the POWER board to
the cabinet and remove the board. Take care to hold the POWER board in place until all screws
have been removed.

NOTE: If you need to replace the LOW VOLTAGE POWER SUPPLY board, please skip
steps 6 and 7.

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6. Replace the POWER board, attaching it with the seven screws previously removed. Don't forget to
use the lower left screw for a ground connection.

7. Reconnect all cables to the POWER board at their proper location.

LOW VOLTAGE POWER SUPPLY - (Brush machines only)

8. Remove the Power Distribution (POWER) board as described in Steps 1-5.

9. Disconnect all leads to the Low Voltage Power Supply (LVPS) board. Ensure all cables are
properly labeled for reconnecting later.

10. After all cables have been disconnected, unscrew the two standoffs at the bottom of the board.
Unscrew the remaining two screws at the top of the LVPS board, taking care to hold the board in
place until all screws have been removed.

11. Replace the LVPS board, attaching it to the cabinet with the two screws and two standoffs previ-
ously removed.

12. Replace the POWER board as described in Steps 6-7.

RS-232 PCB

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 position.

3. Using a large flat tip screwdriver, loosen the two screws on the cabinet door and then open the
door enough to safely work on the electrical panel.

NOTE: It is suggested to make use of a step ladder high enough to allow you to work
from the top of the electrical cabinet. It will be necessary, when replacing the
RS-232 board, to work from the inside and outside of the cabinet at the same
time.

4. On the left side of the cabinet, at the top of the side panel are two serial port connections labeled
"SERIAL PORT #1" and "SERIAL PORT #2", SERIAL PORT #1 being the upper connection.

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VIDEO &
KEYBOARD J13
SERIAL PCB
KEYBOARD
P1 INTERFACE
PCB
700B
850
J3

RS 232/ 32-4090 J1
P850
MICRO
PROCESSOR PORT 1
PCB
P850A PORT 2

AUX AXIS PORT

* Serial interface replaces cable 700 with cable 700B.

Figure 4.4-1. RS-232 wiring pictorial (with serial keyboard).

5. To remove the RS-232 board, unscrew the two hex screws (on the exterior of the cabinet) holding
the connector to the cabinet. From the inside of the cabinet, pull the connector through the panel,
and disconnect the cable.

6. Replace the RS-232 board by first connecting the appropriate cable to the board (850 to SERIAL
PORT #1, 850A to SERIAL PORT #2, then inserting the board (cable side up) through the left side
panel. Attach with the two hex screws previously removed. Ensure the board for Serial Port #1 is
the upper connector and the board for Serial Port #2 is the lower connector.

RS-232 S ERIAL I NTERFACE

There are two connectors used for the RS-232 interface. The RS-232 connector on the back of most PC's is a
male DB-25, so only one type of cable is required for connection to the controller, or between controllers. This
cable must be a DB-25 male on one end and a DB-25 female on the other. Pins 1, 2, 3, 4, 5, 6, 7, 8, and 20
must be wired one-to-one. It cannot be a Null Modem cable, which inverts pins 2 and 3. To check cable type,
use a cable tester to check that communication lines are correct. The controller is DCE (Data Communication
Equipment). This means that it transmits on the RXD line (pin 3) and receives on the TXD line (pin 2). The RS-
232 connector on most PC's is wired for DTE (Data Terminal Equipment), so no special jumpers should be
required.

The Down Line DB-25 connector is only used when more than one controller is to be used. The first controller's
down line connector goes to the second controller's up line connector, etc.

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The RS-232 interface sends and receives seven data bits, even parity, and two stop bits. The interface
must be set correctly. The data rate can be between 110 and 19200 bits per second. When using RS-232, it is
important to make sure that Parameters 26 (RS-232 Speed) and 33 (X-on/X-off Enable) are set to the same
value in the controller and PC.

If Parameter 33 is set to on, the controller uses X-on and X-off codes to control reception, so be sure your
computer is able to process these. It also drops CTS (pin 5) at the same time it sends X-off and restores CTS
when is sends X-on. The RTS line (pin 4) can be used to start/stop transmission by the controller or the X-on/X-
off codes can be used. The DSR line (pin 6) is activated at power-on of the controller and the DTR line (pin 20
from the PC) is not used. If Parameter 33 is 0, the CTS line can still be used to synchronize output.

When more than one HAAS controller is daisy-chained, data sent from the PC goes to all of the controllers at
the same time. That is why an axis selection code (Parameter 21) is required. Data sent back to the PC from
the controllers is OR’ed together so that, if more than one box is transmitting, the data will be garbled. Be-
cause of this, the axis selection code must be unique for each controller.

RS-232 Remote Command Mode

Parameter 21 must be non-zero for the remote command mode to operate as the controller looks for an axis
select code defined by this parameter. The controller must also be in RUN mode to respond to the interface.
Since the controller powers-on in RUN mode, remote unattended operation is thus possible.

RS-232 L INE N OISE

To minimize line noise on the serial port, reroute the cables; route them straight up the left-hand side of the
control to the processor stack. Do not run them above the I/O PCB or up the center wire channel to the
processor.

Also, disconnect both shield connections on the RS-232 ribbon cables. One connection is at the red-box to
the chassis, the second connection is at the processor stack with the shields for the active circuitry.

These two adjustments make a very big difference in the signals and will minimize and possibly eliminate RS-
232 communications problems.

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4.5 F RONT P ANEL

Please read this section in its entirety before attempting to replace any component of the
control panel.

CRT ASSEMBLY REPLACEMENT

1. 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 hold the
cover panel in place until all screws have been removed.

3. At this time, remove the end cap on the support arm and unplug the white cable and the black
cable at the connection in the control panel. It may be necessary to cut straps off the black
cable's connector to unplug.

4. Unscrew the four hex nuts on the bottom row of the CRT bracket and remove, along with the
washers. Set aside in a safe place.

5. While holding up the CRT assembly, remove the four hex nuts on the top row of the CRT bracket,
along with the washers.

CAUTION! Take extreme care to not drop or damage the CRT assembly when
removing from the control panel.

6. CAREFULLY pull the CRT assembly out toward the rear until it is clear of the control panel and all
wiring. Set CRT assembly down in a safe place so as not to damage.

7. Replace by sliding the new assembly onto the eight bolts (four each on top and bottom). Starting
with the bottom right, place the washers and hex nuts on the bolts to hold in place. Refer to Fig.
4.5-1. Once all washers have been attached and nuts have been hand-tightened, tighten down
completely with the socket.

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744
743

742
741
+ -
731 732

Fan
771

772

750

Green
White
Black

Red
Figure 4.5-1. Interior of control panel (rear).

8. Plug the black cable and white cable into the matching cables. Feed the white cable through the
opening in the top of the control panel.

9. Replace the back cover panel and attach with the screws previously removed.

J OG HANDLE R EPLACEMENT

The JOG handle is actually a 100-line-per-revolution encoder. We use 100 steps per revolution to move one of
the servo axes. If no axis is selected for jogging, turning of the crank has no effect. When the axis being
moved reaches its travel limits, the handle inputs will be ignored in the direction that would exceed the travel
limits.

Parameter 57 can be used to reverse the direction of operation of the handle.

1. Turn the machine power off.

2. Remove the screws holding the cover panel on the back of the control panel. Take care to hold the
cover panel in place until all screws have been removed.

3. Unplug the cable leading to the jog handle encoder. IMPORTANT! The blank pin side of the
connector must face as shown in Fig. 4.5-2 when reconnecting; otherwise, damage may occur to
the machine.

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B Blank pin goes to this

BRN side of connector
A
YEL

+5V A +5V A
BLK RED RED WHT/
YEL
GND B GND B
WHT GRN WHT/ WHT/
RED BRN

Figure 4.5-2. Jog handle encoder.

4. Using the 5/64" allen wrench, loosen the two screws holding the knob to the control panel and
remove.

OFF
ON POWER
POWER

D
E LOA
SPINDL

P
NCY STO
EMERGE

HANDLE

HOLD
FEED
ART
E ST
CYCL

Figure 4.5-3. Jog handle removal.

5. Remove the three screws holding the jog handle encoder to the control panel and remove.

6. Replacement is reverse of removal. Keep in mind the important notice in Step 3.

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SWITCH REPLACEMENT

NOTE: This section is applicable for the POWER ON, POWER OFF, EMERGENCY
STOP, CYCLE START, and FEED HOLD switches.

1. Turn the machine power off.

2. Remove the 16 screws holding the cover panel on the back of the control panel. Take care to hold
the cover panel in place until all screws have been removed.

3. Disconnect all leads to the switch's connectors. Ensure all leads are properly marked for recon-
necting later. Refer to Fig. 4.5-1 for proper locations.

4. Unscrew the two small set screws, one on top and one on the bottom, and turn the switch
counterclock-wise to loosen. Separate from the front portion and pull out.

5. For replacement, screw the front and rear portions together (reverse of removal) and tighten down
the two small set screws when the switch is properly positioned.

NOTE: The POWER ON, POWER OFF, and EMERGENCY STOP switches must all
have the connectors on the bottom of the switch.

6. Reconnect all leads to the correct switch.

S PINDLE LOAD METER REPLACEMENT

1. Turn the power off and disconnect power to the machine.

2. Remove the 16 screws holding the cover panel on the back of the control panel. Take care to hold
the cover panel in place until all screws have been removed.

3. Disconnect the two leads at the back of the spindle load meter assembly. Ensure the two leads
are properly marked for reconnecting later.

4. Unscrew the four screws that hold the spindle load meter assembly to the control panel. Take care
to hold the assembly in place until all screws have been removed. Remove the assembly.

5. Installation is reverse of removal. Ensure leads go the correct location.

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KEYPAD REPLACEMENT

1. Turn the power off and disconnect power to the machine.

2. Remove the four screws holding the rear cover panel to the back of the control panel. Take care to
hold the cover panel in place until all screws have been removed.

3. Unplug the keypad's 24-pin ribbon cable from the Keyboard Interface board.

4. Remove the screws from the front of the control panel. Take care to hold the front cover panel in
place until all screws have been removed. Remove the pieces and set aside in a safe place.

5. Using a flat, blunt tool, such as putty knife, pry the keypad away from the control panel. Pull the
ribbon cable through the opening in the control to remove.

6. To replace, first put the bezel spacer in place and fasten temporarily with screws in the top cor-
ners.

Figure 4.5-5. Keypad installation.

7. Insert the ribbon cable through the opening in the control panel. Expose the adhesive strip on the
back 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 cable into the Keyboard Interface board,
taking care to not bend the pins on the board.

8. Replace the front and rear cover panels and fasten with the screws that were previously removed.

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S ERIAL K EYBOARD INTERFACE

NOTE: Refer to "Cable Locations" for a diagram of this board.

1. Follow all precautions noted previously before working in the control cabinet (See warning at
beginning of "Front Panel" section).

2. Turn the main switch (upper right of electrical cabinet) to the off position.

3. Remove the screws on the back of the control panel, then remove the cover panel. Take care to
hold the panel in place until all screws have been removed.

4. Disconnect all leads to the Serial Keyboard Interface (KBIF) board. Ensure all cables are properly
labeled for reconnecting later.

5. After all cables have been disconnected, unscrew the four screws holding the Serial KBIF board to
the control box. Take care to hold the board in place until all screws have been removed. Place the
screws and standoffs aside for later use.

6. Replace the Serial KBIF board, using the four screws previously removed, starting at the top right.
Attach the screw and standoff loosely, then all other screws and standoffs, until all are mounted.
Tighten down completely.

7. Reconnect all cables to the Serial KBIF board at their proper locations.

8. Replace the Control Panel sheetmetal.

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4.6 S PINDLE ENCODER REPLACEMENT

Please read this section in its entirety before attempting to remove or replace encoder.

REMOVAL -

1. Remove the left hand sheetmetal necessary to enable access to the Encoder.

2. Loosen the two encoder mounting bolts and slide the encoder up until there is slack in the belt.

3. Remove the encoder.

4. Inspect the encoder belt for any damage. If replacement is necessary, refer to the "Spindle"
section for removal.

INSTALLATION -

1. Place the belt onto the pulley.

2. Mount the new encoder and tighten the bolts.

NOTE: When tightening the bolts, ensure the belt remains loose around the pulleys.
If the belt is too tight, it could damage the encoder.

3. Replace the sheetmetal removed in REMOVAL, Step 1.

Mounting bolts (2)

Figure 4.6-1. Encoder belt locations.

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5. TECHNICAL REFERENCE

5.1 S PINDLE

Spindle speed functions are controlled primarily by the S address code. The S address specifies RPM in
integer values from 1 to maximum spindle speed (Parameter 131). NOT TO BE CHANGED BY USER!

Two M codes, M41 (Low Gear) and M42 (High Gear), can be used for gear selection. Spindle speed accuracy
is best at the higher speeds and in low gear.

The spindle is hardened and ground with a A2-5, A2-8, A2-11 spindle nose.

5.2 T WO -S PEED G EAR T RANSMISSION (SL-30 AND 40)

The spindle motor is directly coupled to the transmission, which is between the motor and the spindle casting,
The transmission is V belt-coupled to the spindle pulley. An electric motor drives the gearbox shifter into high
or low gear.

L UBRICATION

The gearbox is lubricated and cooled with Mobil DTE 25 oil.

OPERATION

High gear and low gear are selected by programming an M41 (Low Gear) or M42 (High Gear). The spindle
will not change gears automatically. The spindle will come to a complete stop when changing gears.

The machine will remain in its current gear (until changed with an M41 or M42) even after the machine is
powered off. When the machine is powered up, it will be in the same gear (or between gears) as when it was
powered off.

The current gear status is monitored by discrete outputs SP HIG (Spindle High) and SP LOW (Spindle Low). A
"0" (zero) in either of these outputs indicates it is the current gear. If the outputs are the same, neither gear is
selected. If the gearbox remains in this condition (between gears) for a certain amount of time, Alarm 126,
"Gear Fault", is generated. The only way to reset this alarm is to press the POWER UP/RESTART key. The
current gear can also be monitored by pressing the CURNT COMDS key. This display will show whether the
machine is currently in "HIGH GEAR", "LOW GEAR", or "NO GEAR".

There are a number of parameters related to the gearbox. Their values should not be changed by the operator.

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5.3 S ERVOS ( BRUSHLESS )

SERVO E NCODERS (BRUSHLESS )

Haas machines are equipped with brushless motors, which provide for better performance, and no mainte-
nance. In addition to the performance differences, these machines differ from brush type machines in the
following areas:

•The brushless motors have 8192 line encoders built in, which result in a resolution of 32768 parts per revolu-
tion.

•"In Position" parameters 101, 102, 103, 104 and 165 also affect brushless motors.

•The motor controller board has a dedicated processor which does all the servo control algorithm.

•There is no servo distribution board anymore, therefore there is no CHARGE light present. Care should still be
taken however, since there are high voltages present on the amplifiers, even when power is shut off. The high
voltage comes from the vector drive, which does have a CHARGE light.

•The servo drive cards are replaced by Brushless Servo Amplifiers, and are controlled differently.

•A low voltage power supply card is added to the servo drive assembly to supply the low voltage requirement to
the amplifiers.

•The user interface and motion profiling have not changed however, and the user should not see any functional
differences between a brush type machine and a brushless machine.

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SERVO AMPLIFIERS (BRUSHLESS)

The brushless servo amplifier is a PWM based current source. The PWM outputs control the current to a three
phase brushless motor. The PWM frequency is either 12.5 KHz or 16 KHz. The amplifiers are current limited to
30 amps peak (45A peak for a medium amplifier). However there are fuse limits both in hardware and software
to protect the amplifiers and motors from over current. The nominal voltage for these amplifiers is 320 volts.
Therefore the peak power is about 9600 watts or 13 H.P. The amplifiers also have short circuit, over temperature
and over voltage protection.

There is a 15 amp (20A for a medium amplifier) supply fuse for failure protection. This fuse is relatively slow,
therefore it can handle the 30 amp peak. Continuous current limit to the motor is controlled by software.

The user should never attempt to replace these fuses.

Commands to the amplifier are +/-5 volts current in two legs of the motor and a digital enable signal. A signal
from the amplifier indicates drive fault or sustained high current in a stalled motor.

The connectors on the amplifiers are:

+H.V. + 320 volts DC

-H.V. 320 volts return
A motor lead phase A
B motor lead phase B
C motor lead phase C
J1 Three pin Molex connector used for +/-12 and GND.
J2 Eight pin Molex connector used for input signals.

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5.4 I NPUT/O UTPUT A SSEMBLY

The IOPCB contains a circuit for sensing a ground fault condition of the servo power supply. If more than 0.5
amps is detected flowing through the grounding connection of the 160V DC buss, a ground fault alarm is
generated and the control will turn off servos and stop.

Relay K6 is for the coolant pump 230V AC It is a plug-in type and is double-pole. Relays K9 and K10 are
used for the Barfeeder (when equipped).

The Input/Output Assembly consists of a single printed circuit board called the IOPCB.

The connectors on the IOPCB are:

P1 16-pin relay drivers from MOCON 1 to 8 (510)

P2 16-pin relay drivers from MOCON 9 to 16 (520)
P3 16-pin relay drivers from MOCON 17 to 24 (M21-M24) (540)
P4 34-pin inputs to MOCON (550)
P5 Servo power on relay 1-1 (110)
P6 230V AC from CB3 (930)
P7 230V AC to coolant pump (940)
P8 Auto-off relay 1-7 (170)
P9 Spindle drive commands (710)
P10 Spindle fan and oil pump 115V AC (300)
P12 115V AC to spindle head solenoids (880A)
P13 Turret status inputs (820)
P14 Low TSC (900)
P15 Spindle head status inputs (890)
P16 Emergency stop input (770)
P17 Low Lube input (960)
P18 Over Voltage Input (970)
P19 Low Air Input (950)
P20 Overheat input (830)
P21 Spindle drive status inputs (780)
P22 M-FIN input (100)
P23 Footswitch (190)
P24 Spare 2
P25 Spare 3
P26 Spare terminals for M21 to M24
P27 Door lock (1040)
P28 115V AC from CB4 (910)
P29 A-axis brake solenoid output (390)
P30 Tool changer shuttle motor output (810A)
P31 230 VAC for Chip Conveyor (160)
P33 115V AC three-phase input from power supply assembly (90)
P34 115V AC to CRT (90A)
P35 115V AC to heat exchanger (90B)

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P36 115V AC to CB4 (90C)

P37 115V AC spare (870)
P38 Door open (1050)
P39 Tool changer turret motor output (810)
P40 (770A) A/B
P43 Ground fault sense signal input (1060) Axis Brake
P44 5TH axis brake (319)
P45 HTC Shuttle
P46 Chip Conveyor (140)
P47 Skip input signal (1070)
P48 spare 1
P49 spare 2
P50 Spigot Motor (200)
P51 16 PIN Relay drivers 17-24 (530)
P52 spare 1
P53 Spigot Sense (180)
P54 Servo Brake (350)
P55 Red/green lights (280)
P56 Thru spindle coolant pump (940A)
P57 115V spare
P58 115V spare
P59 Gear Box (370B)
P60 TSC 230 IN 930A

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5.5 C ONTROL P ENDANT

J OG HANDLE

The JOG handle is actually a 100-line-per-revolution encoder. We use 100 steps per revolution to move one of
the servo axes. If no axis is selected for jogging, turning of the crank has no effect. When the axis being
moved reaches its travel limits, the handle inputs will be ignored in the direction that would exceed the travel
limits.

Parameter 57 can be used to reverse the direction of operation of the handle.

P OWER O N /O FF S WITCHES

The POWER ON switch engages the main contactor. The on switch applies power to the contactor coil and
the contactor thereafter maintains power to its coil. The POWER OFF switch interrupts power to the contactor
coil and will always turn power off. POWER ON is a normally open switch and POWER OFF is normally
closed. The maximum voltage on the POWER ON and POWER OFF switches is 24V AC and this voltage is
present any time the main circuit breaker is on.

SPINDLE L OAD M ETER

The Load meter measures the load on the spindle motor as a percentage of the rated continuous power of the
motor. There is a slight delay between a load and the actual reflection of the meter. The eighth A-to-D input
also provides a measure of the spindle load for cutter wear detection. The second page of diagnostic data will
display % of spindle load. The meter should agree with this display within 5%. The spindle drive display #7
should also agree with the load meter within 5%.

There are different types of spindle drive that are used in the control. They are all adjusted differently.

EMERGENCY STOP SWITCH

The EMERGENCY STOP switch is normally closed. If the switch opens or is broken, power to the servos will
be removed instantly. This will also shut off the turret, spindle drive, and coolant pump. The EMERGENCY
STOP switch will shut down motion even if the switch opens for as little 0.005 seconds.

Be careful of the fact that Parameter 57 contains a status switch that, if set, will cause the control to be
powered down when EMERGENCY STOP is pressed.

You should not normally stop a tool change with EMERGENCY STOP as this will leave the tool changer in an
abnormal position that takes special action to correct.

NOTE Tool changer alarms can be easily corrected by first correcting any mechanical
problem, pressing RESET until the alarms are clear, selecting ZERO RE-
TURN mode, and selecting AUTO ALL AXES.

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If the turret should become jammed, the control will automatically come to an alarm state. To correct this,
push the EMERGENCY STOP button and remove the cause of the jam. Push the RESET key to clear any
alarms. Push the ZERO RETURN and the AUTO ALL AXES keys to reset the Z-axis and turret. Never put your
hands near the turret when powered unless the EMERGENCY STOP button is pressed.

KEYBOARD BEEPER

There is a beeper under the control panel that is used as an audible response to pressing keyboard buttons
and as a warning beeper. The beeper is a one kHz signal that sounds for about 0.1 seconds when any keypad
key, CYCLE START, or FEED HOLD is pressed. The beeper also sounds for longer periods when an auto-
shutdown is about to occur and when the “BEEP AT M30” setting is selected.

If the beeper is not audible when buttons are pressed, the problem could be in the keypad, keyboard interface
PCB or in the speaker. Check that the problem occurs with more than one button and check that the beeper
volume is not turned down.

CONTROL CABINET

Probe (Option)
Low volt power supply T5 Transformer

3-phase breaker

1. Motor control PCB

2. Video & keyboard PCB

K1Contactor
3. Micro processor PCB
Power PCB

Power amplifiers
X, Y, Z & A
HAAS Vector Drive

Y-Delta Contactors

I/O Board

LOW VOLT -------------- 260-244V 243-227V 226-211V 210-195V

Transformer

Terminal block

Control cabinet general overview.

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The following illustration shows the connectors on the side of the control cabinet.

SERIAL
PORT 1
SERIAL PORT 1
SERIAL
PORT 2
SERIAL PORT 2
ETHERNET
ETHERNET
SPARE
SPARE

SPARE
SPARE

-X-
AXIS
-X- AXIS

LIVE
TOOLING
LIVE TOOLING

-Z-
AXIS
-Z- AXIS

TURRET
TURRET

LTP/PARTS
CATCHER
SPARE

TAILSTOCK
SPARE

LIMIT
SWITCHES
LIMIT SWITCHES

BARFEEDER
BARFEEDER

CHIP
CONVEYOR
CHIP CONVEYOR
-M-
FUNCTION
-M- FUNCTION
COOLANT
COOLANT

HPC
HPC

SPARE
SPARE

Side of control cabinet.

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5.6 M ICROPROCESSOR A SSEMBLY

The microprocessor assembly is in the rear cabinet at the top left position. It contains three large boards.
They are: microprocessor, the video and the MOCON. All three boards of the processor assembly receive
power from the low voltage power supply. The three PCB’s are interconnected by a local buss on dual 50-pin
connectors. At power-on of the control, some diagnostic tests are performed on the processor assembly and
any problems found will generate alarms 157 or 158. In addition, while the control is operating, it continually
tests itself and a self test failure will generate Alarm 152.

M ICROPROCESSOR PCB (68ECO30)

The Microprocessor PCB contains the 68ECO30 processor running at 40 MHz, one 128K EPROM; between
1MB and 16MB of CMOS RAM and between 512K and 1.5MB of FAST STATIC RAM. It also contains a dual
serial port, a five year battery to backup RAM, buffering to the system buss, and eight system status LED’s.

Two ports on this board are used to set the point at which an NMI* is generated during power down and the
point at which RESET* is generated during power down.

The eight LED’s are used to diagnose internal processor problems. As the system completes power up
testing, the lights are turned on sequentially to indicate the completion of a step. The lights and meanings are:

+5V +5V logic power supply is present. (Normally On)

If this light does not come on, check the low voltage power supply and check that all
three phases of 230V input power are present.

HALT Processor halted in catastrophic fault. (Normally Off)

If this light comes on, there is a serious problem with the processor PCB. Check that the EPROM
is plugged in. Test the card with the buss connectors off.

POR Power-on-reset complete. (Normally On)

If this light does not come on, there is a serious problem with the processor PCB. Check that the
EPROM is plugged in. Test the card with the buss connectors off.

SIO Serial I/O initialization complete. (Normally On)

If this light does not come on, there is a problem with the serial ports. Disconnect anything on the
external RS-232 and test again.

MSG Power-on serial I/O message output complete. (Normally On)

If this light does not come on, there is a problem with serial I/O or interrupts. Disconnect anything
on the external RS-232 and test again.

CRT CRT/VIDEO initialization complete. (Normally On)

If this light does not come on, there is a problem communicating with the VIDEO PCB. Check the
buss connectors and ensure the VIDEO PCB is getting power.

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PGM Program signature found in memory. (Normally On)

If this light does not come on, it means that the main CNC program package was not found in
memory or that the auto-start switch was not set. Check that switch S1-1 is on and the EPROM
is plugged in.

RUN Program running without fault exception. (Normally On)

If this light does not come on or goes out after coming on, there is a problem with the microproces
sor or the software running in it. Check all of the buss connectors to the other two PCB’s and
ensure all three cards are getting power.

There is a two-position DIP switch on the processor PCB labeled S1. Switch S1-1 must be
ON to auto-start the CNC operational program. If S1-1 is OFF, the PGM light will remain off.

Switch S2-1 is used to enable FLASH. If it is disabled it will not be possible to write to FLASH.

The processor connectors are:

J1 Address buss
J2 Data buss
J4 Serial port #1 (for upload/download/DNC) (850)
J5 Serial port #2 (for auxiliary 5th axis) (850A)
J3 Power connector
J6 Battery

MEMORY RETENTION BATTERY

The memory retention battery is soldered into the process board. This is a 3.3V Lithium battery that maintains
the contents of CMOS RAM during power off periods. Prior to this battery being unusable, an alarm will be
generated indicating low battery. If the battery is replaced within 30 days, no data will be lost. The battery is
not needed when the machine is powered on. Connector J6 on the processor PCB can be used to connect an
external battery.

V IDEO K EYBOARD F LOPPY D ISK PCB

The VIDEO and KB PCB generates the video data signals for the monitor and the scanning signals for the
keyboard. In addition, the keyboard beeper is generated on this board. There is a single jumper on this board
used to select inverse video. The video PCB connectors are:

P1 Low Voltage Power Supply PCB (860)

P3* Keyboard info. (700)
P4 Address Buss
P5 Data Buss
P10 Disk Dr. Power
P11 Spare
P12 Disk Dr. Signal
P13 Video Signal (760)
J9 RS422 B
J13 Serial Data (850)

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M OTOR CONTROLLER (MOCON) B RUSHLESS

The brushless machining centers are equipped with a microprocessor based brushless motor controller board
(MOCON) that replaces the motor interface in the brush type controls. It runs in parallel with the main proces-
sor, receiving servo commands and closing the servo loop around the servo motors.

In addition to controlling the servos and detecting servo faults, the motor controller board, (MOCON), is also in
charge of processing discrete inputs, driving the I/O board relays, commanding the spindle and processing the
jog handle input. Another significant feature is that it controls 6 axes, so there is no need for an additional
board for a 5 axis machine.

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5.7 H AAS V ECTOR D RIVE

The Haas vector drive is a current amplifier controlled by the MOCON software, using the C axis output. The
vector drive parameters are a part of the machine parameters and are accessible through the Haas front panel.
The spindle encoder is used for the closed loop control and spindle orientation, as well as rigid tapping if the
option is available. Spindle speed is very accurate since this is a closed loop control, and the torque output at
low speeds is superior to non vector drive spindles.

Never work on the spindle drive until the small red CHARGE light goes out. Until this light goes out, there are
dangerous voltages inside the drive, even when power is shut off.

5.8 R ESISTOR A SSEMBLY

The Resistor Assembly is located on top of the control cabinet. It contains the servo and spindle drive regen
load resistors.

SPINDLE D RIVE R EGEN R ESISTOR

A 5.6-ohm (8.6-ohm (6-ohm for SL-30 and 40) for older machines), 300-watt resistor bank is used by the vector
drive to dissipate excess power caused by the regenerative effects of decelerating the spindle motor. If the
spindle motor is accelerated and decelerated again in rapid succession repeatedly, this resistor will get hot. In
addition, if the line voltage into the control is above 255V, this resistor will begin to heat. This resistor is
overtemp protected at 1000 C. At that temperature, an alarm is generated and the control will begin an auto-
matic shutdown. If the resistor is removed from the circuit, an alarm may subsequently occur because of an
overvoltage condition inside the spindle drive.

O VERHEAT S ENSE SWITCH ( OLDER MACHINES)

There is an overtemperature sense switch mounted near the above-mentioned regen resistors. This sensor is a
normally-closed switch that opens at about 1000 C. It will generate an alarm and all motion will stop. After the
time period, specified by parameter 297, of an overheat condition, an automatic shutdown will occur in the
control.

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5.9 P OWER S UPPLY ASSEMBLY

All power to the control passes through the power supply assembly. It is located on the upper right corner of
the control cabinet.

M AIN C IRCUIT B REAKER CB1

Circuit breaker CB1 is rated at 40 amps (20 amps for High Voltage option, 80 amps for SL-30 and 40) and is
used to protect the vector drive and to shut off all power to the control. The locking On/Off handle on the
outside of the control cabinet will shut this breaker off when it is unlocked. A trip of this breaker indicates a
SERIOUS overload problem and should not be reset without investigating the cause of the trip. The full circuit
breaker rating corresponds to as much as 15 horsepower.

M AIN C ONTACTOR K1

Main contactor K1 is used to turn the control on and off. The POWER ON switch applies power to the coil of
K1 and after it is energized, an auxiliary switch on K1 continues to apply power to the coil. The POWER OFF
switch on the front panel will always remove power from this contactor.

When the main contactor is off, the only power used by the control is supplied through two ½ amp fuses to the
circuit that activates the contactor. An overvoltage or lightning strike will blow these fuses and shut off the main
contactor.

The power to operate the main contactor is supplied from a 24V AC control transformer that is primary fused at
½ amp. This ensures that the only circuit powered when the machine is turned off is this transformer and only
low voltage is present at the front panel on/off switches.

L OW VOLTAGE POWER SUPPLY

The low voltage power supply provides +5V DC, +12V DC, and -12V DC to all of the logic sections of the
control. It operates from 115V AC nominal input power. It will continue to operate correctly over a 90V AC to
133V AC range.

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POWER PCB (POWER)

The low voltage power distribution and high voltage fuses and circuit breakers are mounted on a circuit board
called the POWER PCB.

POWER -U P L OW VOLTAGE CONTROL TRANSFORMER (T5)

The low voltage control transformer, T5, supplies power to the coil of the main contactor K1. It guarantees that
the maximum voltage leaving the Power Supply assembly when power is off is 12V AC to earth ground. It is
connected via P5 to the POWER PCB.

SECONDARY CIRCUIT BREAKERS

The following circuit breakers are located on the Power supply assembly.

CB2 controls the 115 volt power from the main transformer to the servo transformers and, if tripped, will turn off
the servo motors and air solenoids. CB2 could be blown by a severe servo overload.

CB3 controls the power to coolant pump only. It can be blown by an overload of the coolant pump motor or a
short in the wiring to the motor.

CB4 controls the 115V AC to the air solenoids and the oiler. It is never expected to trip. If it does trip, it is
likely caused by a short circuit in the wiring on the I/O assembly or the wiring to the solenoids on the spindle
head.

O PERATOR' S LAMP

The operator's lamp is using 115 VAC taken from P19 on the main power distribution.

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5.10 P OWER T RANSFORMER A SSEMBLY (T1)

The power transformer assembly is used to convert three-phase input power (50/60Hz) to three phase 230V
and 115V power. Two different transformers are used depending on the input voltage range. The low voltage
transformer has four different input connections to allow for a range of voltages from 195 V RMS to 260 V RMS.
The high voltage transformer has five different input connections and will accept a range of voltages from 354V
RMS to 488 V RMS.

The 230 V is used to power the spindle drive, which also develops the 325 VDC power for the axis servo
amplifiers. The 115 V is used by the video monitor, solenoids, fans and pumps, in addition to supplying power
to the main LVPS used by the control electronics.

The transformer assembly is located in the lower right hand corner of the main cabinet. Besides the high/low
voltage variations, two different power levels are available depending on the spindle motor used. The small and
large transformers have power ratings of 14 KVA and 28 KVA, respectively. They are protected by the main
circuit breaker to the levels shown in the preceding table.

Transformer with 354-488V range Transformer with 195-260V range

P RIMARY C ONNECTION T O T1

Input power to T1 is supplied through CB1, the 40 amp or 80 amp three-phase main circuit breaker. Three-
phase 230 to T1 is connected to the first three terminals of TB10.

VOLTAGE SELECTION TAPS

There are four labeled plastic terminal blocks for . Each block has three connections for wires labeled 74, 75,
and 76. Follow the instructions printed on the transformer.

S ECONDARY C ONNECTION TO T1

The secondary output from T1 is 115V AC three-phase CB2 protects the secondary of transformer T1 and is
rated at 25 amps.

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O PTIONAL 480V 60H Z T RANSFORMER

The external transformers have either 30 or 45 KVA ratings depending on the size of the machine to which they
will be attached. SL-20 5K, SL-20 BB, SL-30 and SL-40 machines will get the 45KVA transformer while the
smaller machines will get the 30KVA transformers.

For domestic installations and all others using 60Hz power, the primary side should be wired as follows:

Input Voltage Range Tap

493-510 1 (504)
481-492 2 (492)
469-480 3 (480)
457-468 4 (468)
445-456 5 (456)
433-444 6 (444)
420-432 7 (432)

O PTIONAL 480V 50H Z T RANSFORMER

Input Voltage Range Tap

423-440 1 (504)
412-422 2 (492)
401-411 3 (480)
391-400 4 (468)
381-390 5 (456)
371-380 6 (444)
355-370 7 (432)

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5.11 F USES

The brushless amplifier has one fuse, F1 15 amps. This fuse protects the amplifier itself from drastic damage.
If this fuse is ever blown, the associated motor will stop. This will only happen if there is a failure of the ampli-
fier card. The user should never attempt to replace these fuses.

The POWER PCB contains three ½-amp fuses located at the top right (FU1, FU2, FU3). If the machine is
subject to a severe overvoltage or a lightning strike, these fuses will blow and turn off all of the power. Replace
these fuses only with the same type and ratings. FU 4,5 and 5A protect the chip conveyor (FU6 is only used
with 3 phase motors). FU7-12 are ultra fast 20A fuses. They will only blow in the case of a cable short for either
the TSC or coolant pump. Spare fuses for the power card are located above the breakers on the spare fuse
PCB.

SIZE FUSE NAME TYPE RATING VOLTAGE LOCATION

(amps)

5mm FU1 Slo-Blo ½ 250V PSUP pcb, upper right

5mm FU2 AGC ½ 250V " "
5mm FU3 AGC ½ 250V " "
1/4 FU1 Ultra fast 10 250V I/O PCB
1/4 F1 Ultra fast 15 250V Amplifier (X,Y,Z,A,B)
5mm FU4,5 Fast blow 5A 250V PSUP, bottom right corner
1/4 FU7-12 Ultra fast 20A 250V PSUP, bottom

FU2 on the IOPCB is a spare.

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5.12 S PARE U SER M CODE I NTERFACE

The M code interface uses outputs M21-25 and one discrete input circuit. M codes M21 through M25 will
activate relays labeled M21-25. These relay contacts are isolated from all other circuits and may switch up to
120V AC at three amps. The relays are SPDT. WARNING! Power circuits and inductive loads must have
snubber protection.

The M-FIN circuit is a normally open circuit that is made active by bringing it to ground. The one M-FIN applies
to all of the user M codes.

The timing of a user M function must begin with all circuits inactive, that is, all circuits open. The timing is as
follows:

M21

M-FIN
CNC is: Running Waiting Waiting Running
.05 ms delay
for M-fin for end M-fin

The Diagnostic Data display page may be used to observe the state of these signals.

NOTE: See the 8M option section for more details.

M F UNCTION R ELAYS

The M code relay board has five relays (M21-25) that may be available to the user. M21 is already wired out to
P12 at the side of the control cabinet. This is a four-pin DIN connector and includes the M-FIN signal.

NOTE: Refer to the Diagnostic section in the manual for specific machine Inputs and
Outputs.

NOTE: Some or all of the M21-25 on the I/O PCB may be used for factory installed
options. Inspect the relays for existing wires to determine which have been
used. Contact the Haas factory for more details.

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M-FIN D ISCRETE I NPUT

The M-FIN discrete input is a low voltage circuit. When the circuit is open, there is +12V DC at this signal.
When this line is brought to ground, there will be about 10 milliamps of current. M-FIN is discrete input #10
and is wired from input #10 on the I/O PCB. The return line for grounding the circuit should also be picked up
from that PCB. For reliability, these two wires should be routed in a shielded cable where the shield is
grounded at one end only. The diagnostic display will show this signal a “1” when the circuit is open and a “0”
when this circuit is grounded.

T URNING M F UNCTIONS O N A ND O FF

The M code relays can also be separately turned on and off using M codes M51-M55 and M61-M65. M51 to
M55 will turn on one of the eight relays and M61 to M65 will turn the relays off. M51 and M61 correspond to
M21, etc.

NOTE: Refer to the Diagnostic section in the manual for specific machine Inputs and
Outputs.

W IRING THE R ELAYS

The relays are marked on the IOPCB, with their respective terminals forward of them. If the optional 8M relay
board is installed then the connections on the IOPCB are to be left unused as they are replaced by the relays
on the optional board. Refer to the figure, and the Probe Option figure in the Electrical Diagrams section for the
terminal labeling.

WARNING!
Power circuits and inductive loads must have snubber protection.
COM

COM

COM

COM

COM
NO

NO

NO

NO

NO
NC

NC

NC

NC

NC

M21 M22 M23 M24 M25

IOPCB Relays

CAUTION! If a screw terminal is already in use DO NOT connect anything else to it. Call
your dealer.

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5.13 L UBRICATION P UMP

The lubrication system is a resistance type system which forces oil through metering units at each of the 16
lubricating points within the machine. The system uses one metering unit at each of the lubricating points: one
for each linear guide pad, one for each lead screw and one for spindle lubrication. A single oil pump is used to
lubricate the system. The pump is powered only when the spindle and/or an axis moves. Once powered the
pump cycles approximately 3.0 cc of oil every 30 minutes throughout the oil lines to the lube points. Every
lube point receives approximately 1/16 of oil. The control monitors this system through an internal level switch
in the reservoir and external pressure switch on the lube panel.

L OW L UBRICATION AND L OW P RESSURE S ENSE S WITCHES

There is a low lube sense switch in the oil tank. When the oil is low, an alarm will be generated. This alarm
will not occur until the end of a program is reached. There is also a lube pressure switch that senses the lube
pressure. Parameter 117 controls the lube pressure check. If Parameter 117 is not zero, the lube pressure is
checked for cycling high within that period. Parameter 117 has units of, 1/50 seconds; so 30 minutes gives a
value of 90000. Parameter 57, bit "Oiler on/off", indicates the lube pump is only powered when the spindle fan
is powered. The lube pressure is only checked when the pump is on.

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5.14 S WITCHES

L AMP O N /O FF S WITCH

An on/off switch is supplied for the operator's lamp. It is located on the front panel.

D OOR O PEN S ENSE SWITCH

The DOOR OPEN switch is in the open position when the door is open and closed when the door is fully
closed.

When the doors open, the switch will open and the machine will stop with a “Door Hold” function. When the
door is closed again, operation will continue normally.

If the doors are open, you will not be able to start a program. Door Hold will not stop a tool change operation or
a tapping operation, and will not turn off the coolant pump. Also, if the doors are open, the spindle speed will
be limited to 500 RPM.

The Door Hold function can be temporarily disabled by turning Setting 51 on, if Parameter 57 bits DOOR STOP
SP and SAFETY CIRC are set to zero, but this setting will return to OFF when the control is turned off.

L IMIT SWITCHES

TURRET CLAMP/UNCLAMP SWITCHES

There are two switches used to sense the position of the turret. They are both normally closed and one will
activate at the end of travel during unclamping and the other during clamping. When both switches are closed,
it indicates that the turret is between positions.

The diagnostic display can be used to display the status of the relay outputs and the switch inputs.

DOOR HOLD SWITCH

The switch is normally closed. When the door opens, the switch will open and the machine will stop with a
“Door Hold” function. When the door is closed again, operation will continue normally.

If the door is open, you will not be able to start a program. Door hold will not stop a tool change operation, will
not turn off the spindle, and will not turn off the coolant pump.

The door hold function can be temporarily disabled with Setting 51, but this setting will return to OFF when the
control is turned off.

X AND Z LIMIT SWITCHES

Prior to performing a 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 and Z. After a ZERO RETURN has been performed, the
travel limits will operate unless an axis hits the limit switch. When the limit switch is hit, the zero returned
condition is reset and an AUTO ALL AXES must be done again. This is to ensure that if you hit the limit switch,
you can still move the servo back away from it.

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The limit switches are normally closed. When a search for zero operation is being performed, the X and Z axes
will move towards the limit switch unless it is already active (open); then they will move away from the switch
until it closes again; then they will continue to move until the encoder Z channel is found. This position is
machine zero.

TURRET HOME SWITCH

The tool rotation turret has a switch that is activated when tool #1 is in the cutting position. At POWER ON
this switch indicates that tool #1 is in the cutting position. If this switch is not active at power-on, the first tool
change will rotate the turret until the switch engages and then move to the selected tool. The diagnostic display
will show this status of this input switch as “TOOL #1”. A “1” indicates that tool #1 is in position.

What Can Go Wrong With Limit Switches?

If the machine is operated without connector P5, a LOW LUBE and DOOR OPEN alarm will be generated. In
addition, the Home search will not stop at the limit switch and will instead run into the physical stops on each
axis.

If the switch is damaged and permanently open, the zero search for that axis will move in the negative direction
at about 0.5 in/min until it reaches the physical travel stops at the opposite end of travel.

If the switch is damaged and permanently closed, the zero search for that axis will move at about 10 in/min in
the positive direction until it reaches the physical stops.

If the switch opens or a wire breaks after the zero search completes, an alarm is generated, the servos are
turned off, and all motion stops. The control will operate as though the zero search was never performed. The
RESET can be used to turn servos on but you can jog that axis only slowly.

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5.15 D IAGNOSTIC D ATA

The ALARM MSGS display is the most important source of diagnostic data. At any time after the machine
completes its power-up sequence, it will either perform a requested function or stop with an alarm. Refer to the
alarms list for, their possible causes, and some corrective action.

If there is an electronics problem, the controller may not complete the power-up sequence and the CRT will
remain blank. In this case, there are two sources of diagnostic data; these are the audible beeper and the
LED’s on the processor PCB. If the audible beeper is alternating a ½ second beep, there is a problem with the
main control program stored in EPROM’s on the processor PCB. If any of the processor electronics cannot be
accessed correctly, the LED’s on the processor PCB will or will not be lit.

If the machine powers up but has a fault in one of its power supplies, it may not be possible to flag an alarm
condition. If this happens, all motors will be kept off and the top left corner of the CRT will have the message:

POWER FAILURE ALARM

and all other functions of the control will be locked out.

When the machine is operating normally, a second push of the PARAM/DGNOS key will select the diagnostics
display page. The PAGE UP and PAGE DOWN keys are then used to select one of two different displays.
These are for diagnostic purposes only and the user will not normally need them. The diagnostic data consists
of 32 discrete input signals, 32 discrete output relays and several internal control signals. Each can have the
value of 0 or 1. In addition, there are up to three analog data displays and an optional spindle RPM display.
Their number and functions are:

D ISCRETE I NPUTS / O UTPUTS

DISCRETE INPUTS

# Name # Name

1000 Tool Turret Unlock 1016 Spare

1001 Tool Turret Lock 1017 Spare
1002 Spare 1018 Spare
1003 Low Coolant 1019 Spare
1004 Automatic Door 1020 Low hyd pressure
1005 Spindle In Hi Gear 1021 T.S. Foot Switch
1006 Spindle In Low Gear 1022 Probe Not Home
1007 Emergency Stop 1023 Spare 2b
1008 Door Switch 1024 Tool Unclamp Rmt*
1009 M Code Finish 1025 Low Phasing 115V
1010 Over Voltage 1026 B F End of Bar
1011 Low Air Pressure 1027 Bar Feeder Fault
1012 Low Lube Press. 1028 Ground Fault
1013 Regen Overheat 1029 G31 Block Skip
1014 Spare 1030 B F Spindle Intlk
1015 Spare 1031 Conveyr Overcrnts

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DISCRETE OUTPUTS

# Name # Name

1100 Hyd Pump Enable 1116 Move Spigot CW

1101 Spare 1117 Move Spigot CCW
1102 Spare 1118 Pal Ready Light
1103 Spare 1119 T.S. High Pressure
1104 Spindle Brake 1120 Tool Turret Out
1105 Coolant Pump on 1121 T.S. Reverse
1106 Power Off 1122 T.S. Forward
1107 Way Lube Pump 1123 (CE) Door Locked
1108 SB Motor Load PR 1124 M21 (Auto Door Clutch)
1109 SB Motor Load Bar 1125 M22 (Parts Catcher)
1110 Auto Door Open 1126 M23 (C Axis Engage)
1111 Auto Door Close 1127 HPC Coolant
1112 Spindle Hi Gear 1128 Green Beacon On
1113 Spindle Low Gear 1129 Red Beacon On
1114 Unclamp Chuck 1130 Enable Conveyor
1115 Lock Spindle 1131 Reverse Conveyor

The names of discrete outputs 1124, 1125 and 1126 will change if options are installed. The options and
associated Discrete Outputs are:
1124 Auto Door Clutch
1125 Parts Catcher
1126 C axis Engage
If the machine does not have these options the discrete outputs will remain M21, M22 and M23.

The 32 inputs are numbered the same as the 32 connections on the inputs printed circuit board. The last eight
outputs are reserved for expansion by HAAS.

The second page of diagnostic data is displayed using the PAGE UP and PAGE DOWN keys. It contains:

INPUTS 2

Name Name
X-axis Z Channel X Motor Over Heat
Y-Axis Z Channel Y Motor Over Heat
Z-axis Z Channel Z Motor Over Heat
A-axis Z Channel A Motor Over Heat
B-axis Z Channel B Motor Over Heat
C-axis Z Channel C Motor Over Heat

X Home Switch X drive fault

Y Home Switch Y drive fault
Z Home Switch Z drive fault
A Home Switch A drive fault
B Home Switch B drive fault
C Home Switch C drive fault

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X Cable Input S Z CH Spindle Z Channel

Y Cable Input
Z Cable Input
A Cable Input
B Cable Input
C Cable Input

When equipped with the Temp-Track option, the X and Z ball screw temperatures are now displayed on the
INPUTS2 diagnostics screen just above SP LOAD when parameter 266 or 268 (respectively) bit 9 TEMP
SENSOR is set to 1.

The following inputs and outputs pertain to the Haas Vector Drive. If it is not enabled, these will display a value
of *. Otherwise, it will display a 1 or 0.

HAAS VECTOR DRIVE

Name Name

Spindle Forward Spindle Fault

Spindle Reverse Spindle Locked
Spindle Lock Spindle Cable Fault
Spindle At Speed Spindle Overheat
Spindle Stopped

ANALOG DATA

Name Description

SP LOAD Spindle load in %

SP SPEED Spindle RPM CW or CCW
RUN TIME Total machine run time
TOOL CHANGES Number of tool changes
VER [Link] Software version number
YY/MM/DD Today's date
MDL SL-__ Model number
DC BUSS Mocon II

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5.16 L IVE T OOLING

Live Tooling provides the ability to utilize standard 40mm VDI-driven tools, operated by a 5-HP motor. This
auxiliary motor is capable of 0-3,000 RPM, controllable in 1 RPM increments.

BRAKE

13.25” (348mm) diameter disc, 500 psi (34 bar), with 1,000 lbs. (4450 N) clamp force.

A solenoid actuates a hydraulically operated brake. The brake is located on the main spindle and can be
CLAMPED with an M14 command and UNCLAMPED with an M15 command.

A clamped brake will unclamp at any spindle speed command or while the spindle is at rest.

5.17 F ORMULAS

TO FIND: TO FIND:

S.F.M F.P.R.
TO FIND THE FEED PER REVOLUTION (in inches)
TO FIND THE SFM OF A CUTTER OR WORKPIECE OF A CUTTER.

EXAMPLE: To find the SFM of a cutter rotating at 600 EXAMPLE: To find the feed per revolution of a cutter
RPM with a diameter of 10 inches. rotating at 200 RPM with a table travel of 22 inches per
minute.
SFM = 3.1416 x d x RPM = .262 x d x RPM
12 F.P.R. = I.P.M.
R.P.M.

R.P.M.
F.P.T.
TO FIND THE RPM OF A CUTTER OR WORKPIECE
TO FIND THE FEED PER TOOTH OF A CUTTER.
EXAMPLE: To find the RPM of a cutter rotating at 150
SFM with a diameter of 8 inches. EXAMPLE: To find the feed per tooth of a cutter
rotating at 200 RPM with a table travel of 22 inches per
SFM = 12 x SFM = 3.82 x SFM minute.
3.1416 x d d
F.P.T. = I.P.M.
T x R.P.M.
I.P.M.
D = Depth of cut
TO FIND THE FEED (table travel in inches per minute) d = diameter of cutter
I.P.M. = Feed (table travel in inches per minute)
EXAMPLE: To find the feed of a 10 tooth cutter rotating K = Constant (cubic inches per minute per HPc). Power
at 200 RPM with a feed per tooth of 0.012”. required to remove 1 cubic inch per minute.
HPc = Horsepower at the cutter
IPM = F.P.T. x T x RPM F.P.R. = Feed per revolution
R.P.M. = Revolutions per minute
T = Number of teeth in cutter
W = Width of cut (in inches)

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6. PARAMETERS

Parameters are seldom-modified values that change the operation of the machine. These include servo motor
types, gear ratios, speeds, stored stroke limits, lead screw compensations, motor control delays and macro
call selections. These are all rarely changed by the user and should be protected from being changed by the
parameter lock setting. If you need to change parameters, contact HAAS or your dealer. Parameters are
protected from being changed by Setting 7.

The Settings page lists some parameters that the user may need to change during normal operation and these
are simply called "Settings". Under normal conditions, the parameter displays should not be modified. A
complete list of the parameters is provided here.

The PAGE UP, PAGE DOWN, up and down cursor keys , and the jog handle can be used to scroll through the
parameter display screens in the control. The left and right cursor keys are used to scroll through the bits in a
single parameter.

PARAMETER LIST

Parameter 1 X SWITCHES
Parameter 1 is a collection of single-bit flags used to turn servo related functions on and off.
The left and right cursor arrows are used to select the function being changed. All values are 0
or 1 only. The function names are:

0 REV ENCODER Used to reverse the direction of encoder data.

1 REV POWER Used to reverse direction of power to motor.

2 REV PHASING Used to reverse motor phasing.

3 DISABLED Used to disable the X-axis.

4 Z CH ONLY With A only, indicates that no home switch.

5 AIR BRAKE With A only, indicates that air brake is used.

6 DISABLE Z T Disables encoder Z test (for testing only).

7 SERVO HIST Graph of servo error (for diagnostics only).

8 INV HOME SW Inverted home switch (N.C. switch).

9 INV Z CH Inverted Z channel (normally high).

10 CIRC. WRAP. With A only, causes 360 wrap to return to 0. Note for parameter 498
bit 10: When the bit is set to 1, the lathe will automatically unwind the
C-axis no more than half a rotation. When the bit is set to zero, it
behaves as if the C axis had been rotated many times then
disengaged, when it is engaged again, the control will zero it by
unwinding as many times as it had been wound.

11 NO I IN BRAK With A only, removes I feedback when brake is active.

12 LOW PASS +1X Adds 1 term to low pass filter.

13 LOW PASS +2X Adds two terms to low pass filter.

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14 OVER TEMP NC Selects a normally closed overheat sensor in motor.

15 CABLE TEST Enables test of encoder signals and cabling.

16 Z TEST HIST History plot of Z channel test data.

17 SCALE FACT/X If set to 1, the scale ratio is interpreted as divided by X; where X

depends on bits SCALE/X LO and SCALE/X HI.

18 INVIS AXIS Used to create an invisible axis.

19 DIAMETER PRG Used to set diameter programming. When set to 1, it

will interpret inputs as diameters instead of radii.

20 TRAVL LIMITS Travel limits are used.

21 NO LIMSW ALM Alarms are not generated at the limit switches.

22 D FILTER X8 Enables the 8 tap FIR filter. Used to eliminate high frequency
vibrations, depending on the axis motor.

23 D FILTER X4 Enables the 4 tap FIR filter. Used to eliminate high frequency
vibrations, depending on the axis motor.

24 TORQUE ONLY For HAAS only.

25 3 EREV/MREV For HAAS only.

26 2 EREV/MREV For HAAS only.

27 NON MUX PHAS For HAAS only.

28 BRUSH MOTOR Enables the brush motor option.

29 ROTARY AXIS When set to 1, the axis is treated as a rotary axis.

Position will be displayed in degrees, and inputs will be
interpreted as angles.

30 SCALE/X LO With SCALE/X HI bit, determines the scale factor used in bit
SCALE FACT/X,

31 SCALE/X HI With SCALE/X LO bit, determines the scale factor used in bit
SCALE FACT/X. See below
HI LO
0 0 3
0 1 5
1 0 7
1 1 9

Parameter 2 X P GAIN
Proportional gain in servo loop.

Parameter 3 X D GAIN
Derivative gain in servo loop.

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 PARAMETERS June 2001

Parameter 4 X I GAIN
Integral gain in servo loop.

Parameter 5 X RATIO (STEPS/UNIT)

The number of steps of the encoder per unit of travel. Encoder steps supply four (4) times their
line count per revolution. Thus, an 8192 line encoder and 6mm pitch screw give:
8192 x 4 x 25.4 / 6 = 138718

Parameter 6 X MAX TRAVEL (STEPS)

Max negative direction of travel from machine zero in encoder steps. Does not apply to A-axis.
Thus, a 20 inch travel, 8192 line encoder and 6 mm pitch screw give:
20.0 x 138718 = 2774360

Parameter 7 X ACCELERATION
Maximum acceleration of axis in steps per second per second.

Parameter 8 X MAX SPEED

Max speed for this axis in steps per second.

Parameter 9 X MAX ERROR

Max error allowed in servo loop before alarm is generated. Units are encoder steps.

Parameter 10 X FUSE LEVEL

Used to limit average power to motor. If not set correctly, this parameter can cause an
“overload” alarm.

Parameter 11 X BACK EMF

Back EMF of motor in volts per 1000 RPM times 10. Thus a 63 volt/KRPM motor gives 630.

Parameter 12 X STEPS/REVOLUTION
Encoder steps per revolution of motor. Thus, an 8192 line encoder gives: 8192 x 4 = 32768

Parameter 13 X BACKLASH
Backlash correction in encoder steps.

Parameter 14 X DEAD ZONE

Dead zone correction for driver electronics. Units are 0.0000001 seconds.

Parameter 15 Y SWITCHES
See Parameter 1 for description.

Parameter 16 Y P GAIN
See Parameter 2 for description.

Parameter 17 Y D GAIN
See Parameter 3 for description.

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 June 2001 PARAMETERS

Parameter 18 Y I GAIN
See Parameter 4 for description.

Parameter 19 Y RATIO (STEPS/UNIT)

See Parameter 5 for description.

Parameter 20 Y MAX TRAVEL (STEPS)

See Parameter 6 for description.

Parameter 21 Y ACCELERATION
See Parameter 7 for description.

Parameter 22 Y MAX SPEED

See Parameter 8 for description.

Parameter 23 Y MAX ERROR

See Parameter 9 for description.

Parameter 24 Y FUSE LEVEL

See Parameter 10 for description.

Parameter 25 Y BACK EMF

See Parameter 11 for description.

Parameter 26 Y STEPS/REVOLUTION
See Parameter 12 for description.

Parameter 27 Y BACKLASH
See Parameter 13 for description.

Parameter 28 Y DEAD ZONE

See Parameter 14 for description.

Parameter 29 Z SWITCHES
See Parameter 1 for description.

Parameter 30 Z P GAIN
See Parameter 2 for description.

Parameter 31 Z D GAIN
See Parameter 3 for description.

Parameter 32 Z I GAIN
See Parameter 4 for description.

Parameter 33 Z RATIO (STEPS/UNIT)

See Parameter 5 for description.

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 PARAMETERS June 2001

Parameter 34 Z MAX TRAVEL (STEPS)

See Parameter 6 for description.

Parameter 35 Z ACCELERATION
See Parameter 7 for description.

Parameter 36 Z MAX SPEED

See Parameter 8 for description.

Parameter 37 Z MAX ERROR

See Parameter 9 for description.

Parameter 38 Z FUSE LEVEL

See Parameter 10 for description.

Parameter 39 Z BACK EMF

See Parameter 11 for description.

Parameter 40 Z STEPS/REVOLUTION
See Parameter 12 for description.

Parameter 41 Z BACKLASH
See Parameter 13 for description.

Parameter 42 Z DEAD ZONE

See Parameter 14 for description.

Parameter 43 A SWITCHES
See Parameter 1 for description.

Parameter 44 TURRET P GAIN

See Parameter 2 for description.

Parameter 45 TURRET D GAIN

See Parameter 3 for description.

Parameter 46 TURRET I GAIN

See Parameter 4 for description.

Parameter 47 TURRET RATIO (STEPS/UNIT)

See Parameter 5 for description.

Parameter 48 TURRET MAX TRAVEL (STEPS)

See Parameter 6 for description.

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 June 2001 PARAMETERS

Parameter 49 TURRET ACCELERATION

See Parameter 7 for description.

Parameter 50 TURRET MAX SPEED

See Parameter 8 for description.

Parameter 51 TURRET MAX ERROR

See Parameter 9 for description.

Parameter 52 TURRET FUSE LEVEL

See Parameter 10 for description.

Parameter 53 TURRET BACK EMF

See Parameter 11 for description.

Parameter 54 TURRET STEPS/REVOLUTION

See Parameter 12 for description

Parameter 55 TURRET BACKLASH

See Parameter 13 for description.

Parameter 56 TURRET DEAD ZONE

See Parameter 14 for description.

Parameters 57 through 128 are used to control other machine dependent functions. They are:

Parameter 57 COMMON SWITCH 1

Parameter 57 is a collection of general purpose single bit flags used to turn some functions on
and off. The left and right cursor arrows are used to select the function being changed. All
values are 0 or 1 only. The function names are:

0 REV CRANK Reverses direction of jog handle.

1 DISABLE T.C. Disables tool changer operations.

2 DISABLE G.B. Disables gear box functions.

3 POF AT E-STP Stops spindle then turns the power off at EMERGENCY STOP.

4 RIGID TAP Indicates hardware option for rigid tap.

5 REV SPIN ENC Reverses sense direction of spindle encoder.

6 SYNC THREADS Threads will repeat between passes.

7 EX ST MD CHG Selects exact stop in moves when mode changes.

8 SAFETY CIRC This enables safety hardware, if machine is so equipped.

9 SP DR LIN AC Selects linear deceleration for rigid tapping. 0 is quadratic.

10 PH LOSS DET When enabled, will detect a phase loss.

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 PARAMETERS June 2001

12 OVER T IS NC Selects Regen over temp sensor as N.C.

13 SKIP OVERSHT Causes Skip (G31) to act like Fanuc and overshoot sense point.

14 NONINV SP ST Non-inverted spindle stopped status.

15 SP LOAD MONI Spindle load monitor option is enabled.

16 SP TEMP MONI Spindle temperature monitor option is enabled.

18 ENABLE DNC Enables DNC selection from MDI.

19 ENABLE BGEDT Enables BACKGROUND EDIT mode.

20 ENA GRND FLT Enables ground fault detector.

21 M19 SPND ORT This bit makes the P and R codes a protected feature which can only
be enabled with an unlock code. The unlock code will be printed on
the parameter listingof all new machines. If this bit is set to 0, an M19
will orient the spindle to 0 degrees regardless of the value of any P or
R code in the same block. If this is set to 1, a P code in the block will
cause the spindle to be oriented to the specified angle such as P180.
Alternately, a decimal R code can be used, such as R180.53. Note
that the P and R codes only work on a vector drive machine.

22 ENABLE MACRO Enables macro functions.

23 INVERT SKIP Invert sense of skip to active low=closed.

24 HANDLE CURSR Enable use of jog handle to move cursor.

25 NEG WORK OFS Selects use of work offsets in negative direction.

27 ENA QUIKCODE Enables conversational programming.

28 OILER ON/OFF Enables oiler power when servos or spindle is in motion.

29 NC OVER VOLT Inverts sense of over voltage signal.

30 VEC DRV ENC Second spindle encoder

31 DOOR STOP SP Enables functions to stop spindle and manual operations at door
switch.

Parameter 58 LEAD COMPENS SHIFT

Shift factor when applying lead screw compensation. Lead screw compensation is based on a
table of 256 offsets; each +\-127 encoder steps. A single entry in the table applies over a
distance equal to two raised to this parameter power encoder steps.

Parameter 59 MAX FEED RATE (INCH)

Maximum feed rate in inches per minute.

Parameter 60 TURRET IN POS DELAY

Amount of time to delay after the turret rotates to the tool position. This delay allows the turret
to settle.

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 June 2001 PARAMETERS

Parameter 61 TURRET LOCK DELAY

Amount of time to delay after the turret is sensed to be locked. This delay allows for
mechanical settling.

Parameter 62 TURRET UNLOCK ERROR TIME

Maximum delay allowed for tool turret to unlock. Units are milliseconds. After this time, an
alarm is generated.

Parameter 63 TURRET LOCK ERRTIME

Maximum delay allowed for tool turret to lock. Units are milliseconds. After this time, an alarm
is generated.

Parameter 64 Z TOOL CHANGE OFFSET

For turret, displacement from home switch to tool 0.

Parameter 65 NUMBER OF TOOLS

Number of tool positions in tool changer. This number must be set to the lathe's configuration.

Parameter 66 SPINDLE ORI DELAY

Maximum delay allowed when orienting spindle. Units are in milliseconds. After this time, an
alarm is generated.

Parameter 67 GEAR CHANGE DELAY

Maximum delay allowed when changing gears. Units are milliseconds. After this time, an
alarm is generated.

Parameter 68 DRAWBAR MAX DELAY

Maximum delay allowed when clamping and unclamping tool. Units are milliseconds. After this
time, an alarm is generated.

Parameter 69 A AIR BRAKE DELAY

Delay provided for air to release from brake prior to moving. Units are milliseconds.

Parameter 70 MIN SPIN DELAY TIME

Minimum delay time in program after commanding new spindle speed and before proceeding.
Units are milliseconds.

Parameter 71 SPIN STALL DET DLAY

Time to delay after spindle is started before spindle stall checking is started. Each unit
represents 1/50 of a second.

Parameter 72 LIVE TOOL CHNG DLAY

This parameter specifies the amount of time (in milli seconds) to wait after commanding the
Live Tooling Drive motor to turn at thevelocity specified by parameter 143. This process is
required to engage the live tooling motor and tool and is only performed prior to the first M133
or M134 after a tool change.

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 PARAMETERS June 2001

Parameter 73 SP HIGH G/MIN SPEED

Command speed used to rotate spindle motor when orienting spindle in high gear. Units are
maximum spindle RPM divided by 4096.

Parameter 74 SP LOW G/MIN SPEED

Command speed used to rotate spindle motor when orienting spindle in low gear. Units are
maximum spindle RPM divided by 4096.

Parameter 75 GEAR CHANGE SPEED

Command speed used to rotate spindle motor when changing gears. Units are maximum
spindle RPM divided by 4096.

Parameter 76 LOW AIR DELAY

Delay allowed after sensing low air pressure before alarm is generated. Alarm skipped if air
pressure returns before delay. Units are 1/50 seconds.

Parameter 77 SP LOCK SETTLE TIME

Required time in milliseconds that the spindle lock must be in place and stable before spindle
orientation is considered complete.

Parameter 78 GEAR CH REV TIME

Time in milliseconds before motor direction is reversed while in a gear change.

Parameter 79 SPINDLE STEPS/REV

Sets the number of encoder steps per revolution of the spindle. Applies only to hard tapping
option.

Parameter 80 MAX SPIN DELAY TIME

The maximum delay time control will wait for spindle to get to commanded speed or to get to
zero speed. Units are milliseconds.

Parameter 81 M MACRO CALL O9000

M code that will call O9000. This parameter can contain a value from 1 through 98, inclusive,
zero causes no call. However it is best to use a value that is not already in use (see current M
code list). Using M37 the value 37 would be entered in parameter 81 (for example). A program
would be written to include the M37, such as:
G X0...
M37
.
.
M30
The control would run the program until it got to the M37, It would call program O9000, run
that, and then return to the point that it left, and continue the main program.
Be aware that, if program O9000 contains another M37, it will call itself, and keep calling until
it fills the stack (9 times) and then alarm out with 307 SUBROUTINE NESTING TOO DEEP.
Note that if M33 (for example) is used, it would override the normal M33 Conveyor Stop
function.

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 June 2001 PARAMETERS

Parameter 82 M MACRO CALL O9001

Same as 81.

Parameter 83 M MACRO CALL O9002

Same as 81.

Parameter 84 M MACRO CALL O9003

Same as 81.

Parameter 85 M MACRO CALL O9004

Same as 81.

Parameter 86 M MACRO CALL O9005

Same as 81.

Parameter 87 M MACRO CALL O9006

Same as 81.

Parameter 88 M MACRO CALL O9007

Same as 81.

Parameter 89 M MACRO CALL O9008

Same as 81.

Parameter 90 M MACRO CALL O9009

Same as 81.

Parameter 91 G MACRO CALL O9010

G code that will call O9010. This parameter can contain a value from 1 through 98, inclusive,
zero causes 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 entered in parameter 91 (for example). A program
would be written to include the G45, such as:
G X0...
G45
.
.
M30
The control would run the program until it got to the G45, It would call program O9010, run
that, and then return to the point that it left, and continue the main program.
Be aware that, if program O9010 contains another G45, it will call itself, and keep calling until
it fills the stack (4 times) and then alarm out with 531 MACRO NESTING TOO DEEP.
Note that if G84 (for example) is used, it would override the normal G84 Tapping Canned Cycle.

Parameter 92 G MACRO CALL O9011

Same as 91.

Parameter 93 G MACRO CALL O9012

Same as 91.

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 PARAMETERS June 2001

Parameter 94 G MACRO CALL O9013

Same as 91.

Parameter 95 G MACRO CALL O9014

Same as 91.

Parameter 96 G MACRO CALL O9015

Same as 91.

Parameter 97 G MACRO CALL O9016

Same as 91.

Parameter 98 G MACRO CALL O9017

Same as 91.

Parameter 99 G MACRO CALL O9018

Same as 91.

Parameter 100 G MACRO CALL O9019

Same as 91.

Parameter 101 IN POSITION LIMIT X

How close motor must be to endpoint before any move is considered complete when not in
exact stop (G09 or G61). Units are encoder steps.

Parameter 102 IN POSITION LIMIT Y

Same definition as Parameter 101.

Parameter 103 IN POSITION LIMIT Z

Same definition as Parameter 101.

Parameter 104 IN POSITION LIMIT A

Same definition as Parameter 101.

Parameter 105 X MAX CURRENT

Fuse level in % of max power to motor. Applies only when motor is stopped.

Parameter 106 Y MAX CURRENT

Same definition as Parameter 105.

Parameter 107 Z MAX CURRENT

Same definition as Parameter 105.

Parameter 108 A MAX CURRENT

Same definition as Parameter 105.

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 June 2001 PARAMETERS

Parameter 109 D*D GAIN FOR X

Second derivative gain in servo loop.

Parameter 110 D*D GAIN FOR Y

Second derivative gain in servo loop.

Parameter 111 D*D GAIN FOR Z

Second derivative gain in servo loop.

Parameter 112 D*D GAIN FOR A

Second derivative gain in servo loop.

Parameter 113 X ACC/DEC T CONST

Exponential acceleration time constant. Units are 1/10000 seconds. This parameter provides
for a constant ratio between profiling lag and servo velocity. It is also the ratio between velocity
and acceleration.

Parameter 114 Y ACC/DEC T CONST

Same definition as Parameter 113.

Parameter 115 Z ACC/DEC T CONST

Same definition as Parameter 113.

Parameter 116 A ACC/DEC T CONST

Same definition as Parameter 113.

Parameter 117 LUB CYCLE TIME

If this is set nonzero, it is the cycle time for the lube pump and the lube pressure switch option
is checked for cycling in this time. It is in units of 1/50 seconds.

Parameter 118 SPINDLE REV TIME

Time in milliseconds to reverse spindle motor.

Parameter 119 SPINDLE DECEL DELAY

Time in milliseconds to decelerate spindle motor.

Parameter 120 SPINDLE ACC/DECEL

Accel/decel time constant in 200ths of a step/ms/ms for spindle motor.

Parameter 121 X PHASE OFFSET

The motor phase offset for X motor. This is arbitrary units.

Parameter 122 Y PHASE OFFSET

See Parameter 121 for description.

Parameter 123 Z PHASE OFFSET

See Parameter 121 for description.

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 PARAMETERS June 2001

Parameter 124 A PHASE OFFSET

See Parameter 121 for description.

Parameter 125 X GRID OFFSET

This parameter shifts the effective position of the encoder Z pulse. It can correct for a
positioning error of the motor or home switch.

Parameter 126 Y GRID OFFSET

See Parameter 125 for description.

Parameter 127 Z GRID OFFSET

See Parameter 125 for description.

Parameter 128 A GRID OFFSET

See Parameter 125 for description.

Parameter 129 GEAR CH SETTLE TIME

Gear change settle time. This is the number of one millisecond samples that the gear status
must be stable before considered in gear.

Parameter 130 GEAR STROKE DELAY

This parameter controls the delay time to the gear change solenoids when performing a gear
change.

Parameter 131 MAX SPINDLE RPM

This is the maximum RPM available to the spindle. When this speed is programmed, the D-to-
A output will be +10V and the spindle drive must be calibrated to provide this.

Parameter 132 Y SCREW COMP. COEF.

This parameter is used to hold the thermal compensation coefficient. This is the coefficient of
heating of the lead screw. This parameter should be set to zero.

Parameter 133 Z SCREW COMP. COEF.

This parameter is used to hold the thermal compensation coefficient. This is the coefficient of
heating of the lead screw. The value entered for this parameter is always negative as it is used
to shorten the screw length. It should be set to -6000000.

Parameter 134 X EXACT STOP DIST.

Parameter 135 Y EXACT STOP DIST.

Parameter 136 Z EXACT STOP DIST.

Parameter 137 A EXACT STOP DIST.

These parameters control how close each axis must be to its end point when exact stop is
programmed. They apply only in G09 and G64. They are in units of encoder steps. A value of
34 would give 34/138718 = 0.00025 inch.

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 June 2001 PARAMETERS

NOTE: To change the values of parameters 134-137 permanently the machine must
be rebooted.

Parameter 138 X FRICTION COMPENSATION

Parameter 139 Y FRICTION COMPENSATION

Parameter 140 Z FRICTION COMPENSATION

Parameter 141 A FRICTION COMPENSATION

These parameters compensate for friction on each of the four axes. The units are in 0.004V.

Parameter 142 HIGH/LOW GEAR CHANG

This parameter sets the spindle speed at which an automatic gear change is performed. Below
this parameter, low gear is the default; above this, high gear is the default.

Parameter 143 LIVE TOOL CHNG VEL

This parameter specifies the velocity to command the Live Tooling Drive motor for the period
specified by parameter 72. This process is required to engage the live tooling motor and tool,
and is only performed prior to the first M133 or M134 after a tool change.

Parameter 144 RIG TAP FINISH DIST

This parameter sets the finish tolerance for determining the end point of a hard tapping
operation. Units are encoder counts.

Parameter 145 X ACCEL FEED FORWARD

This parameter sets the feed forward gain for the X-axis servo. It has no units.

Parameter 146 Y ACCEL FEED FORWARD

Same as Parameter 145.

Parameter 147 Z ACCEL FEED FORWARD

Same as Parameter 145.

Parameter 148 A ACCEL FEED FORWARD

Same as Parameter 145.

Parameter 150 MAX SP RPM LOW GEAR

Maximum spindle RPM in low gear.

Parameter 151 B SWITCHES

See Parameter 1 for description.

Parameter 152 B P GAIN

See Parameter 2 for description.

Parameter 153 B D GAIN

See Parameter 3 for description.

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 PARAMETERS June 2001

Parameter 154 B I GAIN

See Parameter 4 for description.

Parameter 155 B RATIO (STEPS/UNIT)

See Parameter 5 for description.

Parameter 156 B MAX TRAVEL (STEPS)

See Parameter 6 for description.

Parameter 157 B ACCELERATION

See Parameter 7 for description.

Parameter 158 B MAX SPEED

See Parameter 8 for description.

Parameter 159 B MAX ERROR

See Parameter 9 for description.

Parameter 160 B FUSE LEVEL

See Parameter 10 for description.

Parameter 161 B BACK EMF

See Parameter 11 for description.

Parameter 162 B STEPS/REVOLUTION

See Parameter 12 for description.

Parameter 163 B BACKLASH

See Parameter 13 for description.

Parameter 164 B DEAD ZONE

See Parameter 14 for description.

Parameter 165 IN POSITION LIMIT B

See Parameter 101 for description.

Parameter 166 B MAX CURRENT

See Parameter 105 for description.

Parameter 167 B D*D GAIN

See Parameter 109 for description.

Parameter 168 B ACC/DEC T CONST

See Parameter 113 for description.

Parameter 169 B PHASE OFFSET

See Parameter 121 for description.

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 June 2001 PARAMETERS

Parameter 170 B GRID OFFSET

See Parameter 125 for description.

Parameter 171 B EXACT STOP DIST.

See Parameter 134 for description.

Parameter 172 B FRICTION COMPENSATION

See Parameter 138 for description.

Parameter 173 B ACCEL FEED FORWARD

See Parameter 145 for description.

Parameter 174 B SCREW COMP. COEF.

This parameter is used to hold the thermal compensation coefficient. This is the coefficient of
heating of the lead screw. This parameter should be set to zero.

Parameter 175 B AIR BRAKE DELAY

See Parameter 69 for description.

Parameter 176 Sp SWITCHES

See Parameter 1 for description.

Parameter 177 C P GAIN

See Parameter 2 for description.

Parameter 178 C D GAIN

See Parameter 3 for description.

Parameter 179 C I GAIN

This parameter is used when a Vector Drive is installed, see Parameter 4 for description. If
Vector Drive is not installed this parameter is not used

Parameter 180 SLIP GAIN

This name is used when a Vector Drive is installed. The slip rate calculated depends on two
other variables: speed and current.

Slip rate = slip gain x (speed/max speed) x (current/max current)

The slip gain value is the value that slip rate would assume at maximum speed, and maximum
current (16.384=1 Hz). If a Vector Drive is not installed, this parameter is called: C AXIS
RATIO (STEPS/UNIT) and is not used.

Parameter 181 MIN SLIP

This name is used when a Vector Drive is installed. The minimum value allowed from the slip
rate. From the equation:

Slip rate = slip gain x (speed/max speed) x (current/max current)

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 PARAMETERS June 2001

it can be seen that at a zero speed, the slip rate would become zero. Therefore a minimum
value for slip rate is required. (16.384 =1Hz). If a Vector Drive is not installed, this parameter
is called: C AXIS MAX TRAVEL (STEPS) and is not used.

Parameter 182 C ACCELERATION

This name is used when a Vector Drive is installed. See Parameter 7 for description. If a
Vector Drive is not installed this parameter is not used.

Parameter 183 C MAX SPEED

This name is used when a Vector Drive is installed. See Parameter 8 for description. If a
Vector Drive is not installed this parameter is not used.

Parameter 184 C MAX ERROR

See Parameter 9 for description.

Parameter 185 C FUSE LEVEL

See Parameter 10 for description.

Parameter 186 C BACK EMF

This name is used when a Vector Drive is installed. See Parameter 11 for description. If a
Vector Drive is not installed this parameter is not used.

Parameter 187 C HIGH GEAR STEPS/REV

This name is used when a Vector Drive is installed. The number of encoder steps per revolution
of the motor when the transmission is in high gear. If the machine does not have a
transmission, this is simply the number of encoder steps per revolution of the motor. If a Vector
Drive is not installed this parameter is not used.

Parameter 188 C ORIENT GAIN

This name is used when a Vector Drive is installed. The proportional gain is used in the
position control loop when performing a spindle orientation. If a Vector Drive is not installed
this parameter si called, C axis BACKLASH, and is not used.

Parameter 189 C BASE FREQ

This name is used when a Vector Drive is installed. This is the rated frequency of the motor. If
a Vector Drive is not installed this parameter is called, C axis DEAD ZONE, and is not used.

Parameter 190 C HI SP CURR LIM

This name is used when a Vector Drive is installed. At speeds higher than the base frequency,
the maximum current that is applied to the motor must be reduced. This is done linearly from
base to maximum frequency. The value set in this parameter is the maximum current at the
maximum frequency. If a Vector Drive is not installed this parameter is called, C axis IN
POSITION LIMIT, and is not used.

Parameter 191 C MAX CURRENT

See Parameter 105 for description.

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 June 2001 PARAMETERS

Parameter 192 C MAG CURRENT

This name is used when a Vector Drive is installed. This is the magnetization component of
the current in the motor, also called the flux or the field current. If a Vector Drive is not
installed this parameter is called, C axis D*D GAIN, and is not used.

Parameter 193 C SPIN ORIENT MARGIN

This name is used when a Vector Drive is installed. When a spindle orientation is done, if the
actual position of the spindle is within this value (plus or minus), the spindle will be considered
locked. Otherwise, the spindle will not be locked. If a Vector Drive is not installed this
parameter is called, C axis ACC / DEC T CONST, and is not used.

Parameter 194 C SP STOP SPEED

This name is used when a Vector Drive is installed. The spindle is considered to be stopped
(discrete input SP ST*=0) when the speed drops below this value. Units are encoder steps/
millisecond. If a Vector Drive is not installed this parameter is called, C axis PHASE OFFSET,
and is not used.

Parameter 195 C START / STOP DELAY

This name is used when a Vector Drive is installed. This delay is used at the start of motion to
magnetize the rotor before acceleration starts. Also when the motor comes to a stop, it
remains energized for this amount of time. Units are milliseconds. If a Vector Drive is not
installed this parameter is called, C axis GRID OFFSET, and is not used.

Parameter 196 ACCEL LIMIT LOAD

This name is used when a Vector Drive is installed. This is the percent of load limit during
acceleration. If the load reaches this limit during acceleration, the control slows the
acceleration. If a Vector Drive is not installed this parameter is called, C axis EXACT STOP
DIST, and is not used.

Parameter 197 SWITCH FREQUENCY

This name is used when a Vector Drive is installed. This is the frequency at which the spindle
motor windings are switched. Note that there is a hysteresis band around this point, defined by
parameter 198. If a Vector Drive is not installed this parameter is called, C axis FRICTION
FACTOR, and is not used.

Parameter 198 SWITCH HYSTERESIS

This name is used when a Vector Drive is installed. This defines the + hysteresis band around
parameter 197. For example if par. 197 is 85Hz, and par. 198 is 5Hz, switching will take place
at 90Hz when the spindle is speeding up, and at 80Hz when the spindle is slowing down. If a
Vector Drive is not installed this parameter is called, C axis FEED FORWARD, and is not
used.

Parameter 199 PRE-SWITCH DELAY

This name is used when a Vector Drive is installed. This is the amount of time allowed for the
current in the motor to drop before the winding change contactors are switched. Units are in
microseconds. If a Vector Drive is not installed this parameter is called, C axis THERMAL
COMP. COEF., and is not used.

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 PARAMETERS June 2001

Parameter 200 POST SWITCH DELAY

This name is used when a Vector Drive is installed. This is the amount of time allowed for the
contactors to stabilize after a switch is commanded, before current is applied to the motor.
Units are in microseconds. If a Vector Drive is not installed this parameter is called, C axis AIR
BRAKE DELAY, and is not used.

Parameter 201 X SCREW COMP. COEF.

This parameter is used to hold the thermal compensation coefficient. This is the coefficient of
heating of the lead screw. The value entered for this parameter is always negative as it is used
to shorten the screw length. It should be set to -12000000.

Parameter 205 A SCREW COMP. COEF.

This parameter is used to hold the thermal compensation coefficient. This is the coefficient of
heating of the lead screw. This parameter should be set to zero.

Parameter 206 Reserved

Parameter 207 Reserved

Parameter 208 SPIN. FAN OFF DELAY

Delay for turning the spindle fan off after the spindle has been turned off.

Parameter 209 COMMON SWITCH 2

This is a collection of general purpose single bit flags used to turn some functions on and off.
The left and right cursor arrows are used to select the function being changed. All values are 0
or 1 only. The function names are:

0 LATHE T.C. Designates control as a lathe.

1 RST STOPS T.C. Tool changer can be stopped with RESET button.

2 BRIDGE Not Used

3 ENA CONVEYOR Enables chip conveyor, if machine is so equipped.

4 50% RPD KBD When (1) the control will support the new style keyboards with
the 50% rapid traverse key. For controls without a 50% rapid
keypad set this bit to (0).

5 FRONT DOOR When enabled the control will look for an additional door switch
and will generate an operator message.

10 T SUBROUTINE Not Used

11 RESERVED

12 REV CONVEYOR Reverses the direction of the chip conveyor.

13 M27-M28 CONVYR Usually the chip conveyor motor and direction relays are
attached to the user relays M21 M22. When this bit is set, the
control expects to see the conveyor hooked up to M27 and M28.

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15 GREEN BEACON When (1) user relay M25 is used to flash a beacon. If the control
is in a reset state, the beacon will be off. If the control is running
normally, the beacon will be steadily on. If the control is in a
M00, M01, M02, M30 feedhold, or single block state, then the
beacon will flash.

16 RED BEACON When (1) user relay M26 is used to flash a beacon. The beacon
flashes if the control is experiencing an alarm or emergency stop
condition.

17 CONVY DR OVRD When (1) the conveyor will continue to run with the door open.
When (0) the conveyor will stop when the door is open, but will
resume when the door is closed. For safety it is recommended
that the bit be set to (0).

18 RESERVED

19 TC FWD CW Determines the direction that the turret moves as viewed from the
spindle, when the turret is commanded forward. When (1), the
turret will rotate clockwise for a forward command, and when (0),
it will rotate counterclockwise. The default is 1.

21 DISK ENABL Enables an installed floppy disk drive.

23 MCD RLY BRD If set to 1, adds 16 additional relays, for a total of 56.

24 HPC ENABLE When this parameter bit is set to zero the machine will behave
normally. When it is set to 1, the High Pressure Coolant pump can
be turned on with M88 (this will first turn off the regular coolant if it
was on, just like an M9). High Pressure Coolant can be turned off
with M89. Note also that if a tool change is commanded when the
HPC pump is running, it will be turned off, followed by a pause of the
length specified by parameter 237. HPC must then be turned back on
by the user’s program.

25 AUX JOG NACC Does not allow accumulation on auxiliary axis jog. If the jog
handle is moved rapidly the auxiliary axis will not develop
extremely large lags.

27 RAPID EXSTOP Default is 1. When this bit is set to 1, the control will execute an
exact stop after all rapid motions, regardless of the next motion.
When set to zero, the control will exact stop after a rapid only if
the next motion is not a rapid move.

29 HYDRAULICS This bit must be set to 1 if a lathe has the hydraulic chuck
clamping option.

30 STALL DETECT Enables detection of spindle stall. If spindle stalls, the spindle
motor is stopped and an alarm is generated.

31 SPNDL NOWAIT When (1), the machine will not wait for the spindle to come up to
speed immediately after an M03 or M04 command. Instead, it
will check and/or wait for the spindle to come up to speed
immediately before the next interpolated motion is initiated. This
bit does not affect rigid tapping.

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 PARAMETERS June 2001

Parameter 214 D:Y CURRENT RATIO%

This name is used when a Vector Drive is installed. This defines the ratio between the two
winding configurations. This default winding is Y, and the parameters are set for the Y winding.
This number is used to adjust the parameters for the delta winding when the windings are
switched. If a Vector Drive is not installed, this parameter is called C axis TOOL CHANGE
OFFSET, and is not used.

Parameter 215 CAROUSEL OFFSET

Parameter used to align tool 1 of tool changing carousel precisely. Units are encoder steps.

Parameter 216 CNVYR RELAY DELAY

Delay time in 1/50 seconds required on conveyor relays before another action can be
commanded. Default is 5.

Parameter 217 CNVYR IGNORE OC TIM

Amount of time in 1/50 seconds before overcurrent is checked after conveyor motor is turned
on. Default is 50.

Parameter 218 CONVYR RETRY REV TIM

Amount of time that the conveyor is reversed in 1/50 seconds after overcurrent is sensed.
Default is 200.

Parameter 219 CONVYR RETRY LIMIT

Number of times that the conveyor will cycle through the reverse/forward sequencing when an
overcurrent is sensed before the conveyor will shut down. An overcurrent is sensed when
chips jam the conveyor. By reversing and then forwarding the conveyor, the chip jam may be
broken. Default is 3.

Parameter 220 CONVYR RETRY TIMEOUT

Amount of time in 1/50 seconds between consecutive overcurrents in which the overcurrents is
considered another retry. If this amount of time passes between overcurrents then the retry
count is set to (0). Default is 1500, 30 seconds.

Parameter 221 MAX TIME NO DISPLAY

The maximum time (in 1/50 sec.) between screen updates. When executing short blocks at a
high feed rate, the control will use the resources available for interpreting G-code and
generation of motion blocks. The display may not update until this time is exceeded. For high
speed operation, updating of the display may cause the motion queue to become exhausted.
This will manifest itself as a pause in motion. See M76 and M77 to disable the display
completely.

Parameter 222 LOW HYD. IGNORE

The amount of time that the control ignores the LO HYD input bit after servos have been
engaged. The hydraulic unit requires a short period of time to come up to pressure. The
default value is 50, which is equal to 1 second.

Parameter 226 EDITOR CLIPBOARD

This parameter assigns a program number (nnnnn) to the contents of the clipboard (for the
advanced editor).

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 June 2001 PARAMETERS

Parameter 227 DISK DIR NAME

When the floppy disk drive is enabled and a floppy disk directory is read. The directory listing
is placed into a program as comments. The program is then made the current program so the
user can read the contents of the floppy disk drive. This parameter designates what program
is used to write the directory listing to. Program O8999 is the default value.

Parameter 228 QUICKCODE FILE

This parameter set the program numbers to store in the Quick Code definition.

Parameter 229 X LEAD COMP 10E9

This parameter sets the X-axis lead screw compensation signed parts per billion.

Parameter 230 Y LEAD COMP 10E9

This parameter sets the Y-axis lead screw compensation signed parts per billion.

Parameter 231 Z LEAD COMP 10E9

This parameter sets the Z-axis lead screw compensation signed parts per billion.

Parameter 232 A LEAD COMP 10E9

This parameter sets the A-axis lead screw compensation signed parts per billion.

Parameter 233 B LEAD COMP 10E9

This parameter sets the B-axis lead screw compensation signed parts per billion.

Parameter 234 C BELT COMPENSATION

This parameter sets the belt compensation.

Parameter 235 AUTO DOOR PAUSE

This parameter that supports the Auto-Door feature. It specifies the length of a pause (in 50ths
of a second) that occurs during the door close sequence. As the door closes and the switch
is activated, the motor is turned off for this amount of time and the door coasts. This allows
the door to close smoothly. This parameter should be set to 3 (0.06 seconds) nominally. It
works in conjunction with parameter 236.

Parameter 236 AUTO DOOR BUMP

This parameter that supports the Auto-Door feature. It specifies the length of time (in 50ths of a
second) that the motor should be reactivated after the pause specified by parameter 235. This
causes the motor to close the door fully and smoothly. This parameter should be set to 15 (0.3
seconds) nominally.

Parameter 237 HPC PRESSURE BLEED

This parameter is for the HPC (High Pressure Coolant) feature. It is the amount of time given
for the coolant to purge when the HPC system is shut off. This should be set to 250 on all
lathes.

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 PARAMETERS June 2001

Parameter 238 SPINDLE AT SPEED %

This parameter is used to allow a program to command the spindle to a certain speed and
then continue to the next block before the spindle has actually reached that speed. This is
intended to make G-code programs run faster because the spindle can usually finish
accelerating while approaching the part. It is recommended that this parameter be set to 20.
The result will be that the lathe will act as though the spindle is at speed when it is within +/-
20% of the commanded speed.

Parameter 239 SPNDL ENC STEPS/REV

This parameter sets the number of encoder steps per revolution of the spindle encoder.

Parameter 240 1ST AUX MAX TRAVEL

This parameter sets the maximum travel of the first auxiliary axis in the positive direction.

Parameter 241 2ND AUX MAX TRAVEL

This parameter sets the maximum travel of the second auxiliary axis in the positive direction.

Parameter 242 3RD AUX MAX TRAVEL

This parameter sets the maximum travel of the third auxiliary axis in the positive direction.

Parameter 243 4TH AUX MAX TRAVEL

This parameter sets the maximum travel of the fourth auxiliary axis in the positive direction.

Parameter 244 1ST AUX MIN TRAVEL

This parameter sets the maximum travel of the first auxiliary axis in the negative direction.

Parameter 245 2ND AUX MIN TRAVEL

This parameter sets the maximum travel of the second auxiliary axis in the negative direction.

Parameter 246 3RD AUX MIN TRAVEL

This parameter sets the maximum travel of the third auxiliary axis in the negative direction.

Parameter 247 4TH AUX AXIS MIN TRAVEL

This parameter sets the maximum travel of the fourth auxiliary axis in the negative direction.

Parameter 248 MAX SPINDLE SPEED ALLOWED

The RPM above which the chuck will not operate. If the spindle is spinning faster than this
value the chuck will not open, and if it is spinning slower than this value the chuck will open.
The default is 0, for safety.

Parameter 249 DLY AFTER CHUCK IS CLMPED

The dwell time that is allowed after clamping the chuck (an M10 command). Program
execution will not continue until this time has expired. Units are in milliseconds.

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 June 2001 PARAMETERS

Parameter 250 DLY AFTER CHUCK IS UNCLMP

The dwell time that is allowed after unclamping the chuck (an M11 command). Program
execution will not continue until this time has expired. Units are in milliseconds.

Parameter 251 A DOOR OPEN ERRTIME

This parameter specifies the number of milliseconds allowed for the door to open (move away
from the door-closed switch). If the door is commanded to open, and does not open within the
allowed time, alarm 127 DOOR FAULT is generated. Also, the value of this parameter plus one
second specifies the number of milliseconds allowed for the door to close (activate the door-
closed switch). If the door is commanded to close, and does not close within the allowed
time, alarm 127 DOOR FAULT is generated. If an automatic door is installed, this parameter
should be set to 2400 (2.4 seconds) nominally, otherwise it should be set to zero.

Parameter 252 TAILSTOCK OVERLOAD -DIR

Determines the overload limit when the tailstock is traveling in the minus direction, toward the
spindle. This is an arbitrary value based on the effective voltage being sent to the tailstock
servo motor. If this value is too low, you may not be able to move the tailstock. Increase the
value until you are able to move the tailstock. The value for Parameter 252 should be
approximately 1/2 the value of Parameter 253. This parameter is used for leadscrew tailstock
or TL-15.

Parameter 253 TAIL STOCK OVERLOAD +DIR

Determines the overload limit when the tailstock is traveling in the positive direction, away from
the spindle. The value for Parameter 253 should be approximately twice the value of Parameter
252. This parameter is used for leadscrew tailstock or TL-15.

Parameter 254 SPINDLE CENTER

Reserved for service use only.

Parameter 255 CONVEYOR TIMEOUT

The amount of time the conveyor will operate without any motion or keyboard action. After this
time, the conveyor will automatically shut off. Note that this parameter value will cause the
conveyor to shut off even if the intermittent feature is functioning. Note also that if this
parameter is set to zero, the chip conveyor will shut off immediately, i.e., pressing CHIP FWD
or CHIP REV will not turn it on.

Parameter 257 SPINDLE ORIENT OFSET

This is used for the Vector Drive and the value is determined at the time of assembly.

Parameter 266 X SWITCHES

Parameter 266 is a collection of single-bit flags used to turn servo related functions on and off.
The left and right cursor arrows are used to select the function being changed. All values are 0
or 1 only. The function names are:

0 X LIN SCALE EN Used to enable linear scales for the X

axis.

1 X INVRT LN SCL Used to invert the X axis linear scale.

2 X DSBL LS ZTST Used to disable the linear scale

Z test.

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 PARAMETERS June 2001

3 TH SNSR COMP This parameter is used for Lead Screw Thermal Compensation via a
temperature sensor attached to the ball nut. When this bit is set to
1, the feature is activated for that axis. Note that the feature can only
be used when temperature sensors are installed. The following
parameters must be set appropriately:
201, 133 XZ SCREW COMP. COEF. =-190000000
272, 274 XZ SCREW COMP T. CONST =-27000000
351 TEMP PROBE OFFSET =450000

4 X 2ND HOME BTN Used to move axis to coordinate specified in Work Ofset G129

5 X NEG COMP DIR Used to negate the direction of thermal compensation

7 MAX TRAV INP

8 NO ZERO/NOHOME This feature is intended for lathes that have extra tools mounted on
the outside of the turret. If this bit is set to zero, it will have no effect.
If it is set to 1, the associated axis will not move when POWER UP/
RESTART, HOME G28 or AUTO ALL AXES is pressed. The reason
for this feature is to help prevent collisions between tools mounted on
the outside of the turret and a sub-spindle mounted on the tailstock.
It is important to note that a single axis HOME G28 (e.g., press Z
then HOME G28) and any G28 specified in a program will still cause
the axis to move regardless of the value of this parameter bit. The
operator must exercise care when commanding any axis move.

Parameter 267 Y SWITCHES

Parameter 267 is a collection of single-bit flags used to turn servo related functions on and off.
The left and right cursor arrows are used to select the function being changed. All values are 0
or 1 only. The function names are

0 Y LIN SCALE EN Used to enable linear scales for the Y axis.

1 Y INVRT LN SCL Used to invert the Y axis linear scale.

2 Y DSBL LS ZTST Used to disable the linear scale Z test.

3 TH SNSR COMP This parameter is used for Lead Screw Thermal Compensation via a
temperature sensor attached to the ball nut. When this bit is set to
1, the feature is activated for that axis. Note that the feature can only
be used when temperature sensors are installed. The following
parameters must be set appropriately:
201, 133 XZ SCREW COMP. COEF. =-190000000
272, 274 XZ SCREW COMP T. CONST =-27000000
351 TEMP PROBE OFFSET =450000

4 Y 2ND HOME BTN Used to move axis to coordinate specified in Work Ofset G129

5 Y NEG COMP DIR Used to negate the direction of thermal compensation

7 MAX TRAV INP

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 June 2001 PARAMETERS

8 NO ZERO/NOHOME This feature is intended for lathes that have extra tools mounted on
the outside of the turret. If this bit is set to zero, it will have no effect.
If it is set to 1, the associated axis will not move when POWER UP/
RESTART, HOME G28 or AUTO ALL AXES is pressed. The reason
for this feature is to help prevent collisions between tools mounted on
the outside of the turret and a sub-spindle mounted on the tailstock.
It is important to note that a single axis HOME G28 (e.g., press Z
then HOME G28) and any G28 specified in a program will still cause
the axis to move regardless of the value of this parameter bit. The
operator must exercise care when commanding any axis move.

Parameter 268 Z SWITCHES

Parameter 268 is a collection of single-bit flags used to turn servo related functions on and off.
The left and right cursor arrows are used to select the function being changed. All values are 0
or 1 only. The function names are:

0 Z LIN SCALE EN Used to enable linear scales for the Z axis.

1 Z INVRT LN SCL Used to invert the Z axis linear scale.

2 Z DSBL LS ZTST Used to disable the linear scale Z test.

3 TH SNSR COMP This parameter is used for Lead Screw Thermal Compensation via a
temperature sensor attached to the ball nut. When this bit is set to
1, the feature is activated for that axis. Note that the feature can only
be used when temperature sensors are installed. The following
parameters must be set appropriately:
201, 133 XZ SCREW COMP. COEF. =-190000000
272, 274 XZ SCREW COMP T. CONST =-27000000
351 TEMP PROBE OFFSET =450000

4 Z 2ND HOME BTN Used to move axis to coordinate specified in Work Ofset G129

5 Z NEG COMP DIR Used to negate the direction of thermal compensation

7 MAX TRAV INP

8 NO ZERO/NOHOME This feature is intended for lathes that have extra tools mounted on
the outside of the turret. If this bit is set to zero, it will have no effect.
If it is set to 1, the associated axis will not move when POWER UP/
RESTART, HOME G28 or AUTO ALL AXES is pressed. The reason
for this feature is to help prevent collisions between tools mounted on
the outside of the turret and a sub-spindle mounted on the tailstock.
It is important to note that a single axis HOME G28 (e.g., press Z
then HOME G28) and any G28 specified in a program will still cause
the axis to move regardless of the value of this parameter bit. The
operator must exercise care when commanding any axis move.

Parameter 269 A SWITCHES

Parameter 269 is a collection of single-bit flags used to turn servo related functions on and off.
The left and right cursor arrows are used to select the function being changed. All values are 0
or 1 only. The function names are:

0 A LIN SCALE EN Used to enable linear scales for the A axis.

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 PARAMETERS June 2001

1 A INVRT LN SCL Used to invert the A axis linear scale.

2 A DSBL LS ZTST Used to disable the linear scale Z test.

3 TH SNSR COMP This parameter is used for Lead Screw Thermal Compensation via a
temperature sensor attached to the ball nut. When this bit is set to
1, the feature is activated for that axis. Note that the feature can only
be used when temperature sensors are installed. The following
parameters must be set appropriately:
201, 133 XZ SCREW COMP. COEF. =-190000000
272, 274 XZ SCREW COMP T. CONST =-27000000
351 TEMP PROBE OFFSET =450000

4 A 2ND HOME BTN Used to move axis to coordinate specified in Work Ofset G129

5 A NEG COMP DIR Used to negate the direction of thermal compensation

7 MAX TRAV INP

8 NO ZERO/NOHOME This feature is intended for lathes that have extra tools mounted on
the outside of the turret. If this bit is set to zero, it will have no effect.
If it is set to 1, the associated axis will not move when POWER UP/
RESTART, HOME G28 or AUTO ALL AXES is pressed. The reason
for this feature is to help prevent collisions between tools mounted on
the outside of the turret and a sub-spindle mounted on the tailstock.
It is important to note that a single axis HOME G28 (e.g., press Z
then HOME G28) and any G28 specified in a program will still cause
the axis to move regardless of the value of this parameter bit. The
operator must exercise care when commanding any axis move.

Parameter 270 B SWITCHES

Parameter 270 is a collection of single-bit flags used to turn servo related functions on and off.
The left and right cursor arrows are used to select the function being changed. All values are 0
or 1 only. The function names are:

0 B LIN SCALE EN Used to enable linear scales for the B axis.

1 B INVRT LN SCL Used to invert the B axis linear scale.

2 B DSBL LS ZTST Used to disable the linear scale Z test.

3 TH SNSR COMP This parameter is used for Lead Screw Thermal Compensation via a
temperature sensor attached to the ball nut. When this bit is set to
1, the feature is activated for that axis. Note that the feature can only
be used when temperature sensors are installed. The following
parameters must be set appropriately:
201, 133 XZ SCREW COMP. COEF. =-190000000
272, 274 XZ SCREW COMP T. CONST =-27000000
351 TEMP PROBE OFFSET =450000

4 B 2ND HOME BTN Used to move axis to coordinate specified in Work Ofset G129

5 B NEG COMP DIR Used to negate the direction of thermal compensation

7 MAX TRAV INP

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 June 2001 PARAMETERS

8 NO ZERO/NOHOME This feature is intended for lathes that have extra tools mounted on
the outside of the turret. If this bit is set to zero, it will have no effect.
If it is set to 1, the associated axis will not move when POWER UP/
RESTART, HOME G28 or AUTO ALL AXES is pressed. The reason
for this feature is to help prevent collisions between tools mounted on
the outside of the turret and a sub-spindle mounted on the tailstock.
It is important to note that a single axis HOME G28 (e.g., press Z
then HOME G28) and any G28 specified in a program will still cause
the axis to move regardless of the value of this parameter bit. The
operator must exercise care when commanding any axis move.

Parameter 271 C SWITCHES

Parameter 271 is a collection of single-bit flags used to turn servo related functions on and off.
The left and right cursor arrows are used to select the function being changed. All values are 0
or 1 only. The function names are:

0 C LIN SCALE EN Used to enable linear scales for the C axis.

1 C INVRT LN SCL Used to invert the C axis linear scale.

2 C DSBL LS ZTST Used to disable the linear scale Z test.

3 TH SNSR COMP This parameter is used for Lead Screw Thermal Compensation via a
temperature sensor attached to the ball nut. When this bit is set to
1, the feature is activated for that axis. Note that the feature can only
be used when temperature sensors are installed. The following
parameters must be set appropriately:
201, 133 XZ SCREW COMP. COEF. =-190000000
272, 274 XZ SCREW COMP T. CONST =-27000000
351 TEMP PROBE OFFSET =450000

4 C 2ND HOME BTN Used to move axis to coordinate specified in Work Ofset G129

5 C NEG COMP DIR Used to negate the direction of thermal compensation

7 MAX TRAV INP

8 NO ZERO/NOHOME This feature is intended for lathes that have extra tools mounted on
the outside of the turret. If this bit is set to zero, it will have no effect.
If it is set to 1, the associated axis will not move when POWER UP/
RESTART, HOME G28 or AUTO ALL AXES is pressed. The reason
for this feature is to help prevent collisions between tools mounted on
the outside of the turret and a sub-spindle mounted on the tailstock.
It is important to note that a single axis HOME G28 (e.g., press Z
then HOME G28) and any G28 specified in a program will still cause
the axis to move regardless of the value of this parameter bit. The
operator must exercise care when commanding any axis move.

Parameter 272 X THERM COMP T. CONST

This parameter supports Lead Screw Thermal Compensation. The value is the time constant
that govern the rate of cool down of the screw. This parameter should be set to -5000.

96-8710 rev C 201

 PARAMETERS June 2001

Parameter 273 Y THERM COMP T. CONST

This parameter supports Lead Screw Thermal Compensation. The value is the time constant
that govern the rate of cool down of the screw. This parameter should be set to 0.

Parameter 274 Z THERM COMP T. CONST

This parameter supports Lead Screw Thermal Compensation. The value is the time constant
that govern the rate of cool down of the screw. This parameter should be set to -3000.

Parameter 275 A THERM COMP T. CONST

This parameter supports Lead Screw thermal Compensation. The value is the time constant
that govern the rate of cool down of the screw. This parameter should be set to 0.

Parameter 276 B THERM COMP T. CONST

This parameter supports Lead Screw thermal compensation. The value is the time constant
that govern the rate of cool down of the screw. This parameter should be set to zero.

Parameter 278 COMMON SWITCH 3

Parameter 278 is a collection of general purpose single bit flags used to turn some functions
on and off. The left and right cursor arrows are used to select the function being changed. All
values are 0 or 1 only. The function names are:

0 INVERT G.B. Default is 0. When this bit is set to 1, the sense of the discrete
inputs for SP HIGH and SP LOW (high and low gear) are inverted.

1 DPR SERIAL Causes the main serial inputs/outputs to go through the floppy disk
video board.

2 CK PALLET IN

3 CK HIDDN VAR

4 DISPLAY ACT When set to 1, displays the actual spindle speed on the Current
Commands display page.

6 HYDRAULIC TS This bit enables the hydraulic tailstock

7 SPND DRV LCK This bit must be set to 0 if machine is equipped with a Haas vector
spindle drive.

8 CHUCK OPN CS When set to 1, the user can press CYCLE START and run a program
with the chuck unclamped. If the spindle is commanded with this bit
set to 1, the spindle will not exceed the CHUCK UNCLAMP RPM
(Parameter 248). The default for this bit is 0. This feature is
ineffective when the CE safety circuit is enabled.

9 CNCR SPINDLE When set to 0, spindle start occurs at the end of a block, as in
normal M code operation. When set to 1, spindle start occurs at the
beginning of a block and concurrent with axis motion.

10 TL SET PROBE This bit must be set to 1 in order to enable the Tool Pre-Setter.

11 HAAS VECT DR (Haas Vector Drive) This bit must be set to 1 if machine is equipped
with a HAAS vector spindle drive. When set to 1, voltage to the Haas
vector drive is displayed in the diagnostics display as DC BUSS.

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 June 2001 PARAMETERS

12 uP ENCL TEMP (Microprocessor enclosure temperature) When set to 1, the

enclosure temperature will be displayed on INPUTS2 screen of the
diagnostics display.

13 HAAS RJH Haas remote jog handle. This bit must be set to 1 if the machine is
equipped with a Haas 5-axis Remote jog handle.

14 SPIN TEMP NC Spindle temperature normally closed. This bit specifies the type
(normally open normally closed) of the spindle temperature sensor.
This bit should be set to 1 for machines with a Haas Vector Drive, and
0 for machines without a Vector Drive.

15 SUBSP TMP NC (Subspindle Temperature Sensor Normally Closed) This bit specifies
the type, normally open or normally closed, of the subspindle
temperature sensor.

17 NO MFIN CKPU When it is set, it will prevent checking of MFIN at power-up. It should
be set to 1 for all machines that have the new Haas Automatic Pallet
Changer attached, and 0 for all other machines.

18 D:Y SW ENABL Delta Wye switch enable, this is used for machine with a Vector
Drive. If this switch is set, but bit 19 is not, then winding switching will
only be done when the spindle is at rest, depending on the target
speed of the spindle

19 DY SW ON FLY Delta Wye switch enable, this is used for machine with a Vector
Drive. This parameter enables switching on the fly, as the spindle
motor is accelerating or decelerating through the switch point.

20 CK BF STATUS This bit has been added for the improved Bar Feeder interface. When
this bit is set to 1, the control will constantly check the Bar Feeder
Status on discrete input 1027. If this input goes high, alarm 450 BAR
FEEDER FAULT will be generated and the servos and spindle will be
turned off. Note that the spindle will simply coast to a stop.

21 CK BF SP ILK This bit has been added for the improved Bar Feeder interface. When
this bit is set to 1, the control will constantly check the Bar Feeder
Spindle Interlock on discrete input 1030. If this input goes high, and
the spindle is being commanded to turn, or coasting or being
manually turned at 10rpm or more, alarm 451 BAR FEEDER
SPINDLE INTERLOCK will be generated and the servos and spindle
will be turned off. Note that the spindle will simply coast to a stop.

24 LIVE TOOLING Lathes fitted with the Live Tooling drive this bit must be set to 1. For
all other lathes, this bit is set to 0.

25 SUBSPINDLE This bit enables G14, G15, M143, M144, M145. It must be set to 1 for
all lathes with the subspindle. When this bit is set to 1, the control
will display FUNCTION LOCKED when the AUTO ALL AXES, HOME
G28, or POWER UP/RESTART buttons are pressed.

26 C AXIS DRIVE This bit enables M154 and M155. It must be set to 1 for all lathes with
the C axis.

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 PARAMETERS June 2001

29 SAFETY INVERT This bit supports the CE door interlock that locks when power is
turned off. For machines that have the regular door lock that locks
when power is applied, this bit must be set to 0. For machines that
have the inverted door lock, this bit must be set to 1.

31 INV SPD DCEL Inverse spindle speed deceleration. When this parameter is set to 1,
the spindle decelerates faster at lower speeds, resulting in a shorter
deceleration time.

Parameter 291 HYDRAULIC TAIL STK NO MOTION DETEC TIME

The number in milliseconds that must pass with no B-axis encoder change before the control
decides that the tailstock has stopped. The parameter affects homing and alarm situations on
the tailstock. If the tailstock pressure is set low and the tailstock does not home properly then
increase this parameter.

Parameter 292 HYD TS RTRACT MARGN (Hydraulic Tailstock Retract Margin)

This parameter sets the acceptable range, in encoder steps, for the retract point. When the
tailstock stops anywhere within this range, the control assumes it is at the retract point. The
default is 5 encoder steps. This means that a 10 encoder step range is set around the retract
point.

Parameter 293 HYD TS SLOW DISTNCE (Hydraulic Tailstock Slow Distance)

This parameter sets the distance, prior to a target point, where the tailstock will transition from
a rapid movement to a feed. For example, if this parameter is set to 30 (the default), this
means the tailstock will slow to a feed 30 encoder steps before reaching the target point. Units
are in encoder steps.

Parameter 294 MIN BUSS VOLTAGE

This parameter specifies the minimum Haas Vector Drive buss voltage. If the machine has a
Haas Vector Drive, the parameter should be set to 270 (volts). Machines without a Vector Drive
should be set to 0. Alarm 160 LOW VOLTAGE will be generated if the voltage falls below the
minimum specified.

Parameter 296 MAX OVER VOLT TIME

Specifies the amount of time (in 50ths of a second) that an overvoltage condition (alarm 119
OVER VOLTAGE) will be tolerated before the automatic shut down process is started.

Parameter 297 MAX OVERHEAT TIME

Specifies the amount of time (in 50ths of a second ) that an overheat condition (alarm 122
REGEN OVERHEAT) will be tolerated before the automatic shut down process is started.

Parameter 298 YAX RTAP BACKLASH

This parameter is normally set to zero, but can be adjusted by the user (to a number typically
between 0 and 1000) to compensate for play in the center of the main spindle. It takes effect
during G95 SUBSPIDLE RIGID TAP when the tool has reached the bottom of the hole and
must reverse direction to back out.

Parameter 299 AUTOFEED STEP-UP

This parameter works with the AUTOFEED feature. It specifies the feed rate step-up
percentage per second and should initially be set to 10.

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 June 2001 PARAMETERS

Parameter 300 AUTOFEED-STEP-DOWN

This parameter works with the AUTOFEED feature. It specifies the feed rate step-down
percentage per second and should initially be set to 20.

Parameter 301 AUTOFEED-MIN-LIMIT

This parameter works with the AUTOFEED feature. It specifies the minimum allowable feed
rate override percentage that the AUTOFEED feature can use and should initially be set to 1.
For more information see AUTOFEED under the new features section.

NOTE: When tapping, the feed and spindle overrides will be locked out, so the
AUTOFEED feature will be ineffective (although the display will appear to
respond to the override buttons.)

NOTE: The last commanded feed rate will be restored at the end of the program execution, or
when the operator presses RESET or turns off the AUTOFEED feature.

NOTE: The operator may use the feed rate override buttons while the AUTOFEED feature is
active. As long as tool load limit is not exceeded, these buttons will have the expected
effect and the overridden feed rate will be recognized as the new commanded feed rate
by the AUTOFEED feature. However, if the tool load limit has already been exceeded,
the control will ignore the feed rate override buttons and the commanded feed rate will
remain unchanged.

Parameter 304 SPINDLE BRAKE DELAY

This parameter specifies the amount of time (in milliseconds) to wait for the main spindle brake
to unclamp when spindle speed has been commanded, and also the amount of time to wait
after the main spindle has been commanded to stop before clamping it.

Parameter 305 SERVO PO BRK DLY

Specifies the time (in milliseconds) that the control should wait after turning off the Hyd Pump
Enable relay (which will activate the brake) before turning off power to the servo motors via the
MOCON. This is intended to allow time for the brake to engage. This parameter should be set
to 200.

Parameter 315

0 ALIS M GRPHC All user defined M codes (such as M50) will be ignored when a
program is run in graphics mode if this bit is set to 0. If it is
necessary to have graphics recognize such M codes, this bit should
be set to 1.

5 DOOR OPEN SW This ensures that when the door is opened automatically, it opens all
the way. It is intended to be used in conjunction with an automatic
parts loader. If this bit is set to zero, the control behaves as before. If
this bit is set to 1, the control will look for a second door switch when
the door is opened automatically. If the switch is not found, alarm
127 DOOR FAULT will be generated. This bit should be set to 1 on all
machines fitted with the second door switch.

16 SS REV SPN E Reverses sense direction of subspindle encoder

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 PARAMETERS June 2001

17 SS VEC D ENC Enables a second encoder that is mounted on the subspindle motor
and wired into the “C” axis input of the Mocon. It is required to control
the vector algorithm when the lathe’s belts might slip at high load.

18 SS VEC DRIVE This bit must be set to 1 if the machine is equipped with a HAAS
vector subspindle drive. When set to 1, voltage to the Haas vector
drive is displayed in the diagnostics display as DC BUSS. For the
TL-15 and VTC-48, this bit must be set to 1. For all others, it must
be set to 0.

19 SS D:Y SW EN Delta Wye switch enable. This is used for the Vector Drive. If this
switch is set, but bit 19 is not, then winding switching will only be
done when the subspindle is at rest, depending on the target speed of
the subspindle.

20 SS DY SW FLY Delta Wye switch on the fly. This is used for the Vector Drive.
Enables switching on the fly, as the subspindle motor is accelerating
or decelerating through the switch point. If bit 18 (SS VEC DRIVE) is
not set, this switch will be ignored.

21 SS IN SPD DC Subspindle Inverse Speed Deceleration. When this parameter is set to

1, the subspindle decelerates faster at lower speeds, resulting in a
shorter deceleration time.

22 SS DISBLE GB Disables gear box functions. For the TL-15 and VTC-48, this bit must
be set to 1. For all others, it must be set to 0.

23 VERT TRN CTR This is a new parameter for the VTC-48.

24 SS INVERT GB This bit allows an alternate gearbox configuration. It inverts the sense
of the gearbox inputs. The default is 0. When this bit is set to 1, the
sense of the discrete inputs for SP HIG and SP LOW (high and low
gear) are inverted.

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 June 2001 PARAMETERS

Parameter 315 SIMPLE T.S.

This parameter supports the SL-10 tailstock, which has no encoder. It should be set to 1 only
on an SL-10 with a hydraulic tailstock. It should be set to zero on all other machines. When
this bit is set to 1 the following differences will be observed:
1. First, note that the SL-10 tailstock consists of a fixed head, and a moveable center rod.
Therefore, the only moving part is called the tailstock center.
2. The tailstock center is always considered to be at zero; as there is no encoder, the control
cannot know where the tailstock center is.
3. Pressing POWERUP/RESTART or AUTOALLAXES will not cause the tailstock center to
physically move. It is the operator’s responsibility to move it out of the way to avoid a
collision.
4. Tailstock center movement using the jog handle and remote jog handle is disabled.
5. M21 TAIL STOCK FORWD and M22 TAIL STOCK REVERS. When an M21 is commanded,
the tailstock center will be commanded to move towards the spindle and maintain continuous
pressure. Note that the program will not wait while this is completed. Instead, the next block
will be executed immediately. Because of this, a dwell should be commanded of sufficient
length to allow the tailstock center movement to complete, or the program should be run in
Single Block mode. When an M22 is commanded, the tailstock center will move away from
the spindle for the time specified by parameter 580, and then stop. The running program will
wait during this time.
6. Setting 94 Z/TS DIFF @X CLEARNCE. Normally, this setting (in conjunction with setting
93) specifies a moveable restricted zone, that is, the minimum allowable difference between
the Z and B axes at, or below, the tailstock center X clearance plane specified by Setting 93.
When SIMPLE T.S. is set to 1, however, this setting is instead used to specify the distance
from the Z axis home position. This is because, lacking an encoder, the control cannot know
the exact position of the tailstock center. Thus, instead of providing a dynamic restricted zone
which moves with the tailstock, it provides only a fixed restricted zone based at the home
position. The software will alert the operator if the X or Z axes enter this restricted zone, but
will not alert the operator if the tailstock center leaves the zone. Care should be taken to
ensure that the tailstock center operates only within this zone.
7. Tailstock center Foot Pedal movement. Because there is no encoder, the concepts of
Retract Point, Advance Point and Hold Point do not apply. The tailstock center foot pedal has
the following effects.
a) If the tailstock center was previously commanded to retract, pressing the pedal will
cause it to advance at low pressure and maintain pressure on anything it encounters
until commanded otherwise.
b) If the tailstock center was previously commanded to advance, pressing and holding
the pedal will cause it to retract at high pressure until the pedal is released.

Parameter 316 MEASURE BAR RATE

This parameter supports the Haas Servo Bar 300 barfeeder. It is the rate at which the bars are
measured. Units are inches*1000.

Parameter 317 MEASURE BAR INC

This parameter supports the Haas Servo Bar 300 barfeeder. This is the increment used for bar
measurement. Units are inches*10,000

Parameter 318 GEAR MOTOR TIMEOUT

This parameter supports the Haas Servo Bar 300 barfeeder. This is the timeout value for
gearmotor operations. Units are in milliseconds.

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 PARAMETERS June 2001

Parameter 319 MAX RETRACT POS

This parameter supports the Haas Servo Bar 300 barfeeder. This is the maximum V axis
position when retracted. Units are inches * 10,000.

Parameter 320 MIN RETRACT POS

This parameter supports the Haas Servo Bar 300 barfeeder. This is the minimum space
between bar and push rod when retracted. Units are inches*10,000

Parameter 321 PUSH ROD ZERO POS

This parameter supports the Haas Servo Bar 300 barfeeder. This is the V axis position for
loading and unloading a bar. Units are in inches*10,000.

Parameter 322 GEARMOTOR BUMP TIME

This parameter supports the Haas Servo Bar 300 barfeeder. Gear motor run time for bump and
internal functions. Units are in milliseconds.

Parameter 323 PUSH RATE

This parameter supports the Haas Servo Bar 300 barfeeder. This is the rate at which the last
1/4 inch of feed is done. Units are inches per minute*1000.

Parameter 324 GEAR MOTOR SETTLE

This parameter supports the Haas Servo Bar 300 barfeeder. This is the minimum dwell time for
reversing the gear motor direction. Units are in milliseconds.

Parameter 325 STANDARD BAR LEN

This parameter supports the Haas Servo Bar 300 barfeeder. This is the length of bar for G105
Q5. Units are in inches per minute*1000.

Parameter 326 G5 DECELERATION

This parameter supports the G05 FINE SPINDLE CTRL feature. This is the rate at which to
decelerate the spindle during G5. Units are in encoder steps per second. It should be set to
15000.

Parameter 327 X LS PER INCH

This parameter is used on machines equipped with linear scales. It should be set to zero.

Parameter 328 Y LS PER INCH

Same as parameter 327.

Parameter 329 Z LS PER INCH

Same as parameter 327.

Parameter 330 A LS PER INCH

Same as parameter 327.

Parameter 331 B LS PER INCH

Same as parameter 327.

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 June 2001 PARAMETERS

Parameter 333 X LS PER REV

This parameter is used on machines equipped with linear scales. It should be set to zero.

Parameter 334 Y LS PER REV

Same as parameter 333.

Parameter 335 Z LS PER REV

Same as parameter 333.

Parameter 336 A LS PER REV

Same as parameter 333.

Parameter 337 B LS PER REV

Same as parameter 333.

Parameter 339 X SPINDLE THERM COEF.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
8000.

Parameter 340 Y SPINDLE THERM COEF.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

Parameter 341 Z SPINDLE THERM COEF.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
3692.

Parameter 342 A SPINDLE THERM COEF.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

Parameter 343 B SPINDLE THERM COEF.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

Parameter 345 X SPINDLE THERM T.C.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
-12561.

Parameter 346 Y SPINDLE THERM T.C.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

Parameter 347 Z SPINDLE THERM T.C.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
-20000.

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 PARAMETERS June 2001

Parameter 348 A SPINDLE THERM T.C.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

Parameter 349 B SPINDLE THERM T.C.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

Parameter 351 THRML SENSOR OFFSET

This parameter is used for Lead Screw Thermal Compensation via a temperature sensor
attached to the ball nut.

Parameter 352 RELAY BANK SELECT

In all previous versions, parameter 209 bit 23 MCD RLY BRD assumes that relay bank zero is
to be used. This parameter allows the user to change which bank is to be used. It may be
set to a number from 0 to 3 (inclusive). M codes M21 through M28 will be switched to the
selected bank. Note that this feature requires the I/O-S board. If a previous board is installed
without the additional banks of relays, this parameter should be set to zero.

Parameter 353 MAX SUBSPINDLE RPM

This is the maximum RPM available to the subspindle. This parameter works in conjunction
with parameters 570 and 571
The following 6 parameters are reserved for future use:

354 U Axis Switches

390 V Axis Switches
426 W Axis Switches
462 Tt Axis Switches
498 C Axis Switches
534 Ss Axis Switches

Parameter 354 U SWITCH A

See Parameter 1 for description.

Parameter 390 V SWITCH A

See Parameter 1 for description.

Parameter 426 W SWITCH A

See Parameter 1 for description.

Parameter 498 C SWITCH A

See Parameter 1 for description.

Parameter 570 SUBSPIN ENC ST/REV

This parameter sets the number of encoder steps per revolution of the subspindle encoder.

210 96-8710 rev C

 June 2001 PARAMETERS

Parameter 571 SUBSPINDLE ST/REV

This parameter sets the number of encoder steps per revolution of the subspindle. This
parameter only applies to the subspindle rigid tapping option.

Parameter 572 C AXIS ENG TIMEOUT

Specifies the C axis timeout value for seeing the engaged switch on engagement or the
disengaged switch on disengage. The units are in milliseconds and it should be set to 1000 for
all lathes.

Parameter 573 C AXIS ENG DELAY 1

Specifies the C axis delay after spindle orientation and before engagement. Its purpose is to let
the spindle orientation settle. The units are milliseconds and it should be set to 250 for all
lathes.

Parameter 574 C AXIS ENG DELAY 2

Specifies the C axis delay after engagement before the motion completes. Its purpose is to
allow the C axis engagement to come up to pressure. The units are milliseconds and it should
be set to 250 for all lathes.

Parameter 575 THRD PTCH FACT PPM

This allows the customer to factor the feed rate on G32, G76 and G92 threading as necessary
for particular applications. The units are ppm (parts per million.) This parameter can be
adjusted as necessary, for example, increasing the value by 100 will advance the lead of the
thread by 1 ten-thousandth of an inch per inch. Note that this parameter is internally limited to
1000. All lathes should be shipped with this parameter set to 200.

Parameter 576 MAX SS RPM LOW GEAR

Max subspindle RPM in low gear. This is the maximum RPM available to the subspindle.
When this speed is programmed, the D-to-A output will be +10V and the subspindle drive must
be calibrated to provide this. Gear ratio low to high is 4.1:1.

Parameter 577 SS ORIENT OFFSET

Subspindle Orientation Offset. It is used to orient the subspindle properly anytime it needs to
be locked such as prior to a tool change, or orient subspindle command. This is used for the
vector drive and the value is determined at assembly time. The Subspindle position is
displayed on the POS-RAW DAT screen just to the right of SYSTEM TIME.

Parameter 578 SS HIGH GR MIN SPD

Command speed used to rotate subspindle motor when orienting subspindle in high gear.
Units are maximum subspindle RPM divided by 4096.

Parameter 579 SS LOW GR MIN SPD

Command speed used to rotate subspindle motor when orienting subspindle in low gear. Units
are maximum subspindle RPM divided by 4096.

Parameter 580 TS HYD RETRACT TIME

This parameter has been added for the SL-10 hydraulic no-encoder tailstock. It specifies the
amount of time (in ms) that the tailstock center will be commanded to retract as a result of
commanding an M22 and only takes effect when SIMPLE TS is set to 1.

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 PARAMETERS June 2001

Parameter 587 EXTENDED PUSH TIME

This parameter supports the barfeeder pusher rod which is mounted on the barfeeder trolley
(for barfeeders with the 1-foot extension option.) The units are 50th’s of a second. It causes a
delay of the amount of time specified to enable the pusher rod to full extend before the trolley
begins to travel back to the home position. This parameter should be set to 150 (3 seconds)
on the SL-30 Big Bore and SL-40 only. For all other lathes, it should be set to zero. On older
lathes without the pusher rod, this parameter will have no effect. Note also that with this
change, the I/O board discrete output has been changed from #23 to #1.

Parameter 588 X ENC. SCALE FACTOR

These are new axis parameters that work in place of the axis parameters called SCALE/X LO
and SCALE/X HI. If SCALE FACT/X is set to 1, the scale ratio is determined by SCALE/X LO
and SCALE/X HI as follows:

HI LO
0 0 3
0 1 5
1 0 7
1 1 9

If, however, SCALE FACT/X is set to zero, the value of ENC. SCALE FACTOR will be used for
the scale ratio instead. Note that any value outside the range of 1 to 100 will be ignored and
the scale ratio will remain unaffected. Note also that currently, these parameters are intended
for use only on rotary axes (A and B).

Parameter 589 Y ENC. SCALE FACTOR

See parameter 588 for description

Parameter 590 Z ENC. SCALE FACTOR

See parameter 588 for description

Parameter 591 A ENC. SCALE FACTOR

See parameter 588 for description

Parameter 592 B ENC. SCALE FACTOR

See parameter 588 for description

Parameter 593 Sp ENC. SCALE FACTOR

See parameter 588 for description

Parameter 594 U ENC. SCALE FACTOR

See parameter 588 for description

Parameter 595 V ENC. SCALE FACTOR

See parameter 588 for description

Parameter 596 W ENC. SCALE FACTOR

See parameter 588 for description

212 96-8710 rev C

 June 2001 PARAMETERS

Parameter 597 C ENC. SCALE FACTOR

See parameter 588 for description

Parameter 598 Tt ENC. SCALE FACTOR

See parameter 588 for description

Parameter 599 Ss ENC. SCALE FACTOR

See parameter 588 for description

Parameter 600 PEAK SPIN. PWR - KW

This parameter supports the spindle kilowatt (KW) load display which appears on the current
commands page, next to the spindle load percentage. This parameter should be set to the
peak power output in KW for the spindle motor.

ELECTRONIC THERMAL COMPENSATION

When ballscrews rotate they generate heat. Heat causes the ballscrews to expand. In constant duty cycles as
in mold making the resultant ball screw growth can lead to cutting errors on the next morning start up. Haas'
ETC algorithm can accurately model this heating and cooling effect and electronically expand and contract the
screw to give near glass scale accuracy and consistency.

This compensation is based on a model of the lead screw which calculates heating based on the distance
traveled and the torque applied to the motor. This compensation does not correct for thermal growth due to
changes in ambient temperature or due to part expansion.

Electronic thermal compensation works by estimating the heating of the screw based on the total amount of
travel over its length and including the amount of torque applied to the screw. This heat is then turned into a
thermal coefficient of expansion and the position of the axis is multiplied by the coefficient to get a correction
amount.

If the machine is turned off when there is some compensation applied (due to motion and heating of screw),
when the machine is turned back on, the compensation will be adjusted by the clock indicated elapsed time.

SPINDLE HEAD THERMAL COMPENSATION

This feature integrates spindle speed over time and builds a model of thermal growth. As the model shows the
spindle head warming up, the control adjusts the axes to compensate for thermal growth.

X-AXIS T HERMAL COMPENSATION

During machining, the heating of the ballscrews transfers heat by conduction to the thermal sensor body. This
causes the resistance of the sensor to vary according to the temperature. The resistance value is read by the
software which compensates for the change in temperature by adjusting the accuracy of the program accord-
ingly.

The thermal sensor is connected to the ballscrew and compensates program accuracy for changes in
ballscrew temperature.

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 MAINTENANCE June 2001

7. MAINTENANCE SCHEDULE

The following is a list of required regular maintenance for the HAAS SL-Series Turning Centers. Listed are the
frequency of service, capacities, and type of fluids required. These required specifications must be followed in
order to keep your machine in good working order and protect your warranty.

  

   

     
       
     
        

          

       
         
        

             
             
             
          
    
                
                 
   

         
    
       

   

               
  
          
                 
        

Poor Coolant flow can be caused by a dirty filter.

To clean the filter:
Turn off the coolant pump.
Lift the coolant tank LID.
Remove the filter.
Clean and reinstall filter.
214 96-8710 rev C
 June 2001 MAINTENANCE

7.1 L UBRICATION C HART

         

             

         

    

*Mineral cutting oils will damage rubber based components throughout the machine.

WARNING!
When machining castings, sand from the casting process and the
abrasive properties of cast aluminum and cast iron will shorten pump
life unless a special filter is used in addition to the 100 mesh suction
filter. Contact Haas Automation for recommendations.

Machining of ceramics and the like voids all warranty claims for wear
and is done entirely at the customer's risk. Increased maintenance
schedules are absolutely required with abrasive swarf. The coolant
must be changed more often, and the tank thoroughly cleaned of
sediment on the bottom. A larger coolant tank is recommended.

Shortened pump life, reduction of pressure and increased mainte-

nance are normal and to be expected in abrasive environments and is
not covered by warranty.

L u b ricatio n R eq u iremen ts:

Each jaw requires two strokes of grease:
- Every 1000 clamp / unclamp cycles
- or at least once a week
Use provided grease gun for chuck lubrication

L u b ricatio n typ e: Mo lyb d en u m D isu lfid e Grease (20% to 25% mo ly co n ten t)

96-8710 rev C 215

 MAINTENANCE June 2001

7.2 C HUCK M AINTENANCE

CHUCK MAINTENANCE

Ensure all moving part are thoroughly greased.

Check for excessive wear on jaws.
Check T-nuts for excessive wear.
Check front retaining bolts for damage.
Chucks should be broken in according to the manufactures' specifications.
Caution: Lack of grease significantly reduces clamping force and can result in chatter, improper clamping,
or thrown parts.
Disassemble and inspect chuck once a year
Refer to chuck manual for disassembly procedures
Check for excessive wear
Check for galling or burnishing
Clean guide ways of contamination, chips and coolant
Lubricate chuck before reassembly

7.3 L UBRICATION S YSTEM

All machine lubrication is supplied by the external lubrication system. The reservoir is located on the lower
rear of the machine (see Figure below). Current lube level is visible in the reservoir. If additional lube needs to
be added, remove the cap from the fill port and add lube to proper level.

External Lubrication System

WARNING!
DO NOT ADD LUBE ABOVE THE “HIGH” LINE MARKED ON THE RESERVOIR.
DO NOT ALLOW THE LUBE LEVEL TO GO BELOW THE “LOW” LINE MARKED
ON THE RESERVOIR AS MACHINE DAMAGE COULD RESULT.

To lubricate the system, pull up on the primer pull-tab located next to the fill port. The primer will automatically
send 3cc of lube through the system.

216 96-8710 rev C

 June 2001 MAINTENANCE

7.4 C HIP A UGER

MAINTENANCE
During normal operation, most chips are discharged from the machine at the discharge tube. However, very
small chips may flow through the drain and collect in the coolant tank strainer. To prevent drain blockage,
clean this trap regularly. Should the drain become clogged and cause coolant to collect in the machine’s pan,
stop the machine, loosen the chips blocking the drain, and allow the coolant to drain. Empty the coolant tank
strainer, then resume operation.

96-8710 rev C 217

 CABLE LOCATIONS June 2001

8. PCB'S, CABLE LOCATIONS AND BOARD DIAGRAMS

J6

U7
U8 D1
D2
D3
U1 U2 U3 U4 U5 U6 D4
S2 D5
2 1
D6
D7
D8
U9 U10 U11 U12 U13 U14

U15

J5 J4

U16 U17 U18 U19 U20 U21 U22 U23

U24

850A 850
U33

U37 U38

U39
U34
93-1010B

U41
U42 U43 U44 U45 U46 U47 U48 U49

RP2 RP3 RP4 RP5

U50 U51 U52 U53 U54

ADDRESS BUS DATA BUS

J3

J1 J2

MICRO PROCESSOR PCB - P/N 93-1010B

218 96-8710 rev C
 June 2001 CABLE LOCATIONS

MICRO PROCESSOR PCB - P/N 93-1010B

CABLE CONNECTIONS

PROC.
PLUG # CABLE # SIGNAL NAME ð TO ð LOCATION PLUG #

J1 ADDRESS BUSS VIDEO ——-

J2 DATA BUSS MOTIF PCB ——-
J3 860 LOW VOLTAGE POWER SUPPLY PCB ——-
J6 N/A EXTERNAL BATTERY (EXT. BATTERY) ——-
J4 850 SERIAL PORT #1 SERIAL PORT #1 ——-
J5 850A SERIAL PORT #2 SERIAL PORT #2 ——-

96-8710 rev C 219

 CABLE LOCATIONS June 2001

SERVO DRIVE SIGNAL ( FROM MOCON)

LOW VOLTAGE (INPUT)

TO SERVO MOTOR

325VDC (FROM HAAS VECTOR DRIVE)

BRUSHLESS SERVO AMPLIFIER - P/N 93-5550C

220 96-8710 rev C

 June 2001 CABLE LOCATIONS

BRUSHLESS SERVO AMPLIFIER - P/N 93-5550C

CABLE CONNECTIONS

MOCON
PLUG # CABLE # SIGNAL NAME ð TO ð LOCATION PLUG #

X AXIS AMP
P 570 LOW VOLTAGE L. V. POWER SUPPLY ——-
TB A, B, C ——- MOTOR DRIVE X SERVO MOTOR ——-
P 610 X DRIVE SIGNAL MOCON PCB P2
TB -HV +HV 490 320VDC SPINDLE DRIVE ——-

Y AXIS AMP
P 570 LOW VOLTAGE L. V. POWER SUPPLY ——-
TB A, B, C ——- MOTOR DRIVE X SERVO MOTOR ——-
P 620 X DRIVE SIGNAL MOCON PCB P3
TB -HV +HV 490 320VDC SPINDLE DRIVE ——-

Z AXIS AMP
P 570 LOW VOLTAGE L. V. POWER SUPPLY ——-
TB A, B, C ——- MOTOR DRIVE X SERVO MOTOR ——-
P 630 X DRIVE SIGNAL MOCON PCB P4
TB -HV +HV 490 320VDC SPINDLE DRIVE ——-

A AXIS AMP
P 570 LOW VOLTAGE L. V. POWER SUPPLY ——-
TB A, B, C ——- MOTOR DRIVE X SERVO MOTOR ——-
P 640 X DRIVE SIGNAL MOCON PCB P5
TB -HV +HV 490 320VDC SPINDLE DRIVE ——-

96-8710 rev C 221

 CABLE LOCATIONS June 2001

P9 P8 P32 P31 P29 P27 P26

P24
P1 P25

P35 P34 P33 P30 P28

P2
FU1 FU2 FU3
P3 NE6 NE5
P5
P4 P23
NE1
P6 NE2 NE3
P7
P10
32-5200H P22
SPARE FUSES C4 C3 C2 C7 C6 C5 C1
P11

TB1

10A 115V 10A 115V 10A 230V 10A 230V

MAIN RTY/ COOLANT TSC COOLANT
USER POWER TB3
P12 FU7 FU12 FU11 FU10 FU9 FU8

P14 P15 NE13

P21
P13
NE4 NE11 NE10 NE9 NE8 NE7 FU13
TB2
NE12 FU12

P16 P17 P18 P19 P20

POWER PCB - P/N 93-0227A

222 96-8710 rev C

 June 2001 CABLE LOCATIONS

POWER PCB - P/N 93-0227A

CABLE CONNECTIONS
I/O PLUG # CABLE # SIGNAL NAME ð TO ð LOCATION PLUG#
P1 +12VDC CNC Unit Fan
P2 90B 115VAC Low Voltage Power Supply
P3 90B 115VAC Probe PS
P4 90B 115VAC Work Light
P5 90B 115VAC Switch Door Fan
P6 90B 115VAC Servo Fan
P7 90B 115VAC Delta-Wye
P8 860 +12/-12/+5 VDC In From Low Voltage Power Supply
P9 860 +12/-12/+5 VDC In From Low Voltage Power Supply
P10 90B 115VAC Door Fan
P11 90B 115VAC Monitor
P12 90C 115VAC Regen Fan
P13 90C 115VAC SMTC PCB P4
P14 90C 115VAC spare
P15 90C 115VAC spare
P16 90C 115VAC spare
P17 90C 115VAC Trans PCB P2
P19 90 3PH 115VAC IO PCB P56
P18 90C 115VAC spare
P20 930 230V CLNT/TSC IO PCB P44
P21 160 Chip Conv. 230V 3PH IO PCB P39
P23 170 Auto Off/Contactor Contactor K1/IO PCB P42
P22 740 On/Off Front Panel
P24 Prim/Sec To T5
P25 71, 72, 73 Overvolt Protection From Contactor K1
P26 860 +12VDC SKBIF
P27 860 +12/+5 VDC IO PCB P60
P28 860 +12/+5 VDC Motif PCB P15
P29 860 +12/+5 VDC Processor PCB J3
P30 860 +12/-12/+5 VDC spare
P31 860 +12/+5 VDC Video PCB P1
P32 860 +12/-12/+5 VDC Mocon 1 PCB P15
P33 860 +12/-12/+5 VDC Mocon 2 PCB P15
P34 860 +12 VDC SMTC PCB P2
P35 860 +12 VDC MCD Relay PCB P2
TB1 94, 95, 96 115VAC From Transformer
TB2 90A 115 VAC Out Barfeeder / T/C PCBA P8
TB3 77, 78, 79 3PH 230V In From Transformer

96-8710 rev C 223

 CABLE LOCATIONS June 2001

I/O PCB S - P/N 93-0228

M21 M22 M23 M24 M25 P60 P59 P58

FU2 C46 NE1

TB1 TB2
P1 K38
K33 K34 K35 K36 K37
U66 Q39 Q40
P2 D10
U65 FU1
P3
J10 R87 LE18
P4 R52
LE40 LE35 Q1 R3 P57
P5 D1
P6 LE33 U57 LE34 LE17
U34
P7 U1 Q38 K9
P61 P62 U38 U35 Q34
P8 K10
Q26
P10 P9 U2
K11
P11 U56 LE41 P56 D22 D21 D20
P12 U3 P63 Q33 J9 K12 D19 D18 D17
P13
Q25 U58
Q32 DISP1 U15 P55
U4 T1 Q13
P14 U30 U45 U51
U16 Q14
P15 P54 P53
U5 P64 Q15
P16 U17
DISP2 P52
P17 CR5 U54 U52 Q16
U6 U18
P18 U50 U36 Q13
P66 Q10 P51
LE38
P19 U7 Q30 U10
U44 U37
P20 P67 LE39 Q14 P50 P49
Q31
U53 P65
P21 U6 Q15 P48
LE36 U46 P47
P22 P68 Q28
C45
U8 LE37 U13 Q16
Q29 Q17 U23 LE21 K7
P23 P68 Q35 P46
LE19 Q10
Q27 U62
U7 LE22 Q12 U63
P24 Q18 U14 U22
U68 U24 U67 P45
R122 U55
P25 U8 D12 LE20
Q6
D11 U64 P44
P26 U32 U48 U49Q24 U21
R119
U8 U20
P27 K17 U47 U19 P43
P70 K18 R126
P28 U31 Q9 P42
DISP3 Q37 RI27
U U U U U LE31 U12 U9
LE25 P41
P29 28 27 26 25 29
93-0228S U11
K35 P40
P30
Q22 Q21 Q20 Q19 Q23 LE32

P31 P32 P33 P34 P35 P36 P37 P38 Q5 Q3 Q4 P39

I/O PCB S - P/N 93-0228A CABLE CONNECTIONS

I/O PLUG # CABLE # ð TO ð LOCATION PLUG #
P1 140B Not Used
P2 820B TT Unlock/Lock
P3 820 C-axis Engage/Disengage
P4 900 Spare
P5 770 E-Stop Switch A
P6 770A E-Stop Switch B
P7 770B E-Stop Switch C
P8 1050 Door Open
P9 1050A Door Open
P10 100 (External) M-Fin
P11 970 Over Volt VD J1
P12 950 Low Air/Hyd. Pressure
P13 960 Low Lube
P14 830 Regen Overheat

224 96-8710 rev C

 June 2001 CABLE LOCATIONS

I/O PCB S - P/N 93-0228A CABLE CONNECTIONS

I/O PLUG # CABLE # ð TO ð LOCATION PLUG #
P15 890 Spare Gearbox
P16 780 Spare
P17 410 TS Foot Sw, Sub Spndl Chuck FS
P18 790 Probe Home
P19 190 Chuck Uncl Foot Sw
P20 190A Not Used
P21 240 Bar Feeder (Load Bar/Q)
P22 1070 Skip
P23 420 Spare
P24 440 Auto Door Open
P25 450 Spare
P26 460 Apl (Rotator Mark, Home)
P27 470 Spare
P28 480 Spare
P29 1040A Not Used
P30 1040 CE Door Lock
P31 230 T/S Fwd
P32 250 T/S Rev
P33 270 T/S Rapid
P34 260 Spare (12V output)
P35 200 Spare
P36 280 Beacons
P37 140A Not Used
P38 140 Chip Conv En/Rev
P39 160 250V For Chip C
P40 300 Luber
P41 300A Not Used
P42 170 Auto Off
P43 940 Coolant
P44 930 230V For Coolant
P45 940A HP Cooloant
P46 390 Spin Brake
P47 350 Hyd Pump En
P48 120 Not Used (Jumper)
P49 350A Brake Release
P50 130 Not Used (Jumper)
P51 430 APL Light/BF Extend Push
P52 710 APL Gripper
P53 880C Wye-Delta Switch
P54 880B High/Low Gear
P55 880A Chuck Unclamp/TT Out
P56 90 115V Power To IOPCB PSUP P19
P57 External TC Motor Resistor Jumper
P58 810A spare
P59 810 Auto Door MTR, Bar Feeder, APL Rotator
P60 860A 5V/12V Logic Power IOPCB PSUP P27
P61 540 Outputs Cable 24-55 MOCON P14
P62 540A Outputs Cable MCD Relay MCD Realy P1
P63 550 Inputs Cable MOCON P10
P64 520 Outputs Cable 8-15 MOCON P12
P65 510 Outputs Cable 0-7 MOCON P11
P66 M27 Air Blast
P67 M28 Sub Spin Chuck Sol
P68 310 Parts Catcher/Auto Door Clutch
P69 220 C-Axis Engage
P70 530 Outputs Cable 16-23 MOCON P13
TB1 M21-24 Probe, M-Fin, User Spare
TB2 M25 User Space

96-8710 rev C 225

 CABLE LOCATIONS June 2001

J1

J2 J3
JOG HANDLE

DISCRETE INPUTS 32-4031E

J5

U9 Y1

J12

P1

P6 P5 P3 P4 P2

SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOG

P/N 93-1072B

226 96-8710 rev C

 June 2001 CABLE LOCATIONS

SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOG

P/N 93-1072B

CABLE CONNECTIONS

PLUG# CABLE# ð TO ð LOCATION PLUG#

P1 700 PROCESSOR 850
P2 —- KEYPAD —-
P3 700A CYCLE START/
HOLD SWITCHES —-
P4 720 SP LOAD METER P4
P5 705 P5
P6 —- —-
J1 750A —-
J2 150 REMOTE JOG HANDLE —-
J3 750 MOCON P18
J5 —- (MIKRON ONLY) —-
J7 —- EXTERNAL KEYBOARD —-
J12 860C FT. PANEL FAN —-

* See "Keyboard Diagnostic" section of this manual for Troubleshooting information.

96-8710 rev C 227

 CABLE LOCATIONS June 2001

VIDEO & KEYBOARD PCB W/ FLOPPY DRIVE P/N 93-1001A

228 96-8710 rev C

 June 2001 CABLE LOCATIONS

VIDEO & KEYBOARD PCB W/ FLOPPY DRIVE

P/N 93-1001A
CABLE CONNECTIONS

VIDEO PLUG # CABLE # SIGNAL NAME ð TO ð LOCATION PLUG #

P1 860 LOW VOLTAGE POWER SUPPLY PCB ——-

J3* 700 KEYBOARD INFO. KEYBOARD INT. ——-
J4 ——- ADDRESS BUSS MICRO PROC. PCB ——-
J5 ——- DATA BUSS MOTIF PCB ——-
J10 ——- FLOPPY DR. POWER FLOPPY DRIVE ——-
J11 ——- SPARE N/A N/A
J12 ——- FLOPPY DR. SIGNAL FLOPPY DRIVE ——-
P13 760 VIDEO SIGNAL CRT ——-
J9 ——- RS422 B N/A N/A
J13 850 SERIAL DATA N/A J1

* Not used with Serial Keyboard Interface

96-8710 rev C 229

 CABLE LOCATIONS June 2001

MOCON PCB - P/N 93-1067E

P24 P10 P34 P26 P27 P28 P11 P13

P18 P17 P21 P22

P12 P14

P20
P16

P6 P33

P32
P7

P5
P8

P4

P9

P3

P30
U43
P2

P31
32-4023M
P15

P19 P1

230 96-8710 rev C

 June 2001 CABLE LOCATIONS

MOCON PCB - P/N 93-1067E

CABLE CONNECTIONS

MOCON PLUG # CABLE # SIGNAL NAME ð TO ð LOCATION PLUG #

P1 ——- DATA BUSS VIDEO PCB ——-

MICRO PROC. PCB ——-
P2 610 X DRIVE SIGNAL X SERVO DRIVE AMP. P
P3 620 Y DRIVE SIGNAL Y SERVO DRIVE AMP. P
P4 630 Z DRIVE SIGNAL Z SERVO DRIVE AMP. P
P5 640 A DRIVE SIGNAL A SERVO DRIVE AMP. P
P32 640B B DRIVE SIGNAL B SERVO DRIVE AMP. P
P6 660 X ENCODER INPUT X ENCODER ——-
P7 670 Y ENCODER INPUT Y ENCODER ——-
P8 680 Z ENCODER INPUT Z ENCODER ——-
P9 690 A ENCODER INPUT A ENCODER ——-
P30 690B B ENCODER INPUT B ENCODER ——-
P10 550 MOTIF INPUTS/
I/O OUTPUTS I/O PCB P4
P11 510 I/O RELAYS 1-8I/O PCB P1
P12 520 I/O RELAYS 9-16 I/O PCB P2
P13 530 I/O RELAYS 17-24 I/O PCB P51
P14 540 I/O RELAYS 25-32 I/O PCB P3
P15 860 LOW VOLTAGE POWER SUPPLY PCB ——-
P16 720 SP. LOAD METER LOAD METER ——-
P17 980 VOLTAGE MONITOR N/A N/A
P18 750 JOG ENCODER INPUT JOG HANDLE ——-
P19 ADDRESS BUSS VIDEO PCB ——-
MICRO PROC. PCB ——-
P20 1000 SP. ENCODER INPUT SPINDLE ENCODER ——-
P21 X-AXIS TEMP SENSOR
P22 730B SP. DRIVE LOAD SPINDLE DRIVE ——-
P24 990 HOME SENSORS X, Y & Z LIMIT ——-
P26 Y-AXIS TEMP SENSOR
P27 Z-AXIS TEMP SENSOR
P31 690C C-AXIS ENCODER INPUT SPINDLE MOTOR (lathe)
P33 640C VCTR DR CUR. CMD. VECTOR DRIVE J3

96-8710 rev C 231

 CABLE LOCATIONS June 2001

RS-232 PORT #1 PCB - P/N 32-4090

CABLE CONNECTIONS

PLUG # CABLE # ð TO ð LOCATION PLUG #

P1 -------- ------------- -------
EXTERNAL

J1 850 VIDEO & J13

EXTERNAL KEYBOARD

232 96-8710 rev C

 June 2001 CABLE LOCATIONS

OPTICAL ENCODER PCB - P/N 32-0400A (SL-20, SL-30)

CABLE CONNECTIONS

PLUG # CABLE # ð TO ð LOCATION PLUG #

P1 690B MOCON ——-

96-8710 rev C 233

 CABLE LOCATIONS June 2001

880B/P1

FU1 115 VAC 115 V Servo Brake

TRANSMISSION P.S. / HYDRAULIC C.B. PCB

P/N 93-4095C
CABLE CONNECTIONS

PLUG # CABLE # ð TO ð LOCATION PLUG #

P1 880B IO PCB P12
P2 90 POWER PCB P8
P3 410 GEAR BOX
P4 350 IO PCB P54
TB2 340 HYDRAULIC MTR
TB3 70 MAIN TRANSFORMER
(VECTOR DRIVE UNIT)

234 96-8710 rev C

 June 2001 CABLE LOCATIONS

Y-DELTA SWITCH ASSEMBLY

P/N 32-5850B

TO K5 AUX

K4

TO K5 COIL

TO K5 COIL
TO SPINDLE MOTOR

TO K4 COIL
650A

TO IO PCB, P12

TO IO PCB, P58

K5

TO K4 COIL

650B
TO HAAS VECTOR DRIVE

96-8710 rev C 235

 CABLE LIST June 2001

9. CABLE LIST

THE FOLLOWING IS A SUMMARY OF THE CABLES USED IN THE WIRING OF THIS CONTROL:

WIRE/
TERMINAL FUNCTION NAME:
NUMBER

INCOMING POWER 195-260 VAC (354-488 VAC OPTIONAL)

L1 INCOMING 195-260VAC, PHASE 1, TO CB1-1

L2 INCOMING 195-260VAC, PHASE 2, TO CB1-2
L3 INCOMING 195-260VAC, PHASE 3, TO CB1-3

71 PROTECTED 195-260VAC CB1-4 TO K1-1

72 PROTECTED 195-260VAC CB1-5 TO K1-2
73 PROTECTED 195-260VAC CB1-6 TO K1-3

74 195-260VAC FROM K1-4 TO XFORMER T1

75 195-260VAC FROM K1-5 TO XFORMER T1
76 195-260VAC FROM K1-6 TO XFORMER T1

77 230VAC PHASE 1, FROM XFORMER T1 TO VECTOR DRIVE/CHIP CONV.

78 230VAC PHASE 2, FROM XFORMER T1 TO VECTOR DRIVE/CHIP CONV.
79 230VAC PHASE 3, FROM XFORMER T1 TO VECTOR DRIVE/CHIP CONV.

90 115VAC FROM TB2(CB2 OUTPUT) TO IOPCB P33 - SHIELD + 3

91 115VAC FROM TB2-1TO IOPCB P33 PIN 1
92 115VAC FROM TB2-2 TO IOPCB P33 PIN 2
93 115VAC FROM TB2-3 TO IOPCB P33 PIN 3
94 SHIELD DRAIN

- 115VAC FROM XFORMER T1 TO TB1(CB2 INPUT)

94 STEPPED-DOWN 115 VAC (FROM XFORMER T1)
95 STEPPED-DOWN 115 VAC (FROM XFORMER T1)
96 STEPPED-DOWN 115 VAC (FROM XFORMER T1)

90A 115 VAC TO CRT - SHIELD +2

91A 115VAC #16
92A RETURN #16
93A SHIELD DRAIN

90B 115 VAC TO HEAT EXCHANGER - SHIELD +2

91B 115VAC #16
92B RETURN #16
93B SHIELD DRAIN

236 96-8710 rev C

 June 2001 CABLE LIST

90C 115 VAC TO CB4 - SHIELD +2

91C 115VAC #20
92C RETURN #20
93C SHIELD DRAIN

110 SPARE (115 VAC SERVO POWER)

140 230VAC 3PH POWER TO CHIP CONVEYOR MOTOR

141 PHASE A 230VAC
142 PHASE B 230VAC
143 PHASE C 230VAC
144 STARTING WINDING 230VAC
145 STARTING WINDING 230VAC

140A 230VAC 3PH POWER IN CONDUIT TO CHIP CONVEYOR

141A PHASE A 230VAC
142B PHASE B 230VAC
143B PHASE C 230VAC

160 3PH 230VAC TO CHIP CONVEYOR CONTROLLER

161 PHASE A 230VAC
162 PHASE B 230VAC
163 PHASE C 230VAC
164 SHIELD DRAIN

170 AUTO OFF FUNCTION - SHIELD +2

171 UNSWITCHED LEG 1 #20
172 SWITCHED LEG 2 #20
173 SHIELD DRAIN

180 SPARE
181 SIGNAL
182 COMMON

190 UNCLAMP FROM SPINDLE HEAD TO IOASM

191 INPUT 25
192 DIGITAL RETURN
193 SHIELD DRAIN

200 SPARE
201 +12VDC
202 RETURN

210 DATA CABLE TO 3" FLOPPY DISK DRIVE (34 PINS)

230 TAILSTOCK FORWARD OPTION

231 115VAC
232 115VAC RETURN
233 SHIELD DRAIN

240 BARFEEDER OPTION

241 END OF BAR #20
242 LOADER OK #20
243 COMMON #20
244 SHIELD DRAIN

96-8710 rev C 237

 CABLE LIST June 2001

250 TAILSTOCK REVERSE OPTION

251 115VAC
252 115VAC RETURN
253 SHIELD DRAIN

260 SPARE 12VDC

270 TAILSTOCK RAPID OPTION

271 115VAC
272 115VAC RETURN
273 SHIELD DRAIN

280 115 VAC RED/GREEN BEACON CABLE - SHIELD + 3

281 RED LAMP 115VAC
282 GREEN LAMP 115VAC
283 COMMON 115VAC
284 SHIELD DRAIN

290 CABLE OP LIGHT + SPINDLE MOTOR FAN

291 115VAC
292 115VAC RETURN
293 SHIELD DRAIN

300 115VAC TO OIL PUMP

301 LEG 1 115VAC FUSED AT 3 A #20
302 LEG 2 115VAC FUSED AT 3 A #20
303 SHIELD DRAIN

330 230V 3PH FROM CB6 TO K2 (LATHE HYDRAULICS)

331 PHASE 1 230VAC
332 PHASE 2 230VAC
333 PHASE 3 230VAC

340 230V 3PH FROM K2 TO HYDRAULIC PUMP (LATHE)

341 PHASE 1 230VAC
342 PHASE 2 230VAC
343 PHASE 3 230VAC

350 115VAC HYD PUMP ENABLE - SHIELD +2

351 115VAC
352 115VAC RETURN

390 115VAC TO 4’TH AXIS BRAKE (LATHE PART DOOR) - SHIELD +2

391 115VAC #20
392 115VAC RETURN #20
393 SHIELD DRAIN

410 TAILSTOCK FOOT SWITCH

411 SIGNAL #20
412 RETURN #20
413 SHIELD DRAIN

490 ALL BRUSHLESS AXIS SERVO MOTOR DRIVE POWER CABLE

491 A PHASE
492 B PHASE
493 C PHASE
494 GROUND
238 96-8710 rev C
 June 2001 CABLE LIST

490A 320VDC FROM SPINDLE DRIVE TO THE AMPLIFIERS - SHIELD +2

491A HIGH VOLT P1/+ RED #12
492A HIGH VOLT N/- BLACK #12
493A SHIELD DRAIN

490B 320VDC FROM AMPLIFIER TO SERVO POWER SUPPLY

491B HIGH VOLT + RED #20
492B HIGH VOLT - BLACK #20

500 OVERTEMP SENSOR FROM SPINDLE MOTOR - SHIELD +2

501 OVERTEMP SIGNAL #20 (N.C.)
502 OVERTEMP COMMON #20
503 SHIELD DRAIN

510 RELAY CARD 1 DRIVE CABLE - 16 WIRE RIBBON #24

520 RELAY CARD 2 DRIVE CABLE - 16 WIRE RIBBON #24

530 RELAY CARD 3 DRIVE CABLE - 16 WIRE RIBBON #24

540 RELAY CARD 4 DRIVE CABLE - 16 WIRE RIBBON #24

550 INPUTS CARD CABLE (MOCON - P10) 34 WIRE RIBBON

570 LOW VOLTAGE BRUSHLESS AMPLIFIER POWER CABLE ASSEMBLY

571 +12VDC #22
572 COMMON
573 - 12VDC #22

610 X AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(MOTOR CONTROLLER BOARD SIDE CONNECTION)
610-1 +A CHANNEL
610-2 ANALOG GROUND
610-3 +B CHANNEL
610-4 ANALOG GROUND
610-5 ENABLE
610-6 LOGIC GROUND
610-7 FAULT
610-8 LOGIC GROUND
610-9 NOT USED
610-10 SHIELD/ANALOG GROUND

630 Z AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(SAME AS 610-1 THRU 610-10)

640 A AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(SAME AS 610-1 THRU 610-10)

640C HAAS VECTOR DRIVE CURRENT COMMAND CABLE.(ALL #24)

640C-1 A PHASE
640C-2 B PHASE
640C-3 ENABLE
640C-4 FAULT
640C-5 320VDC VOLTAGE MONITOR
640C-6 A PHASE RETURN

96-8710 rev C 239

 CABLE LIST June 2001

640C-7 B PHASE RETURN

640C-8 DIGITAL GROUND
640C-9 FAULT RETURN
640C-10 ANALOG GROUND

650 230VAC, THREE PHASE POWER TO SPINDLE MOTOR - SHIELD +3

651 PHASE 1
652 PHASE 2
653 PHASE 3
654 SHIELD DRAIN

650A 230VAC, THREE PHASE POWER, CONTACTOR TO SPINDLE MOTOR

(WYE TO DELTA OPTION)
651A PHASE 1
652A PHASE 2
653A PHASE 3
654A SHIELD DRAIN

650B 230VAC, THREE PHASE POWER, CONTACTOR TO VECTOR DRIVE

(WYE TO DELTA OPTION)
651B PHASE 1
652B PHASE 2
653B PHASE 3

660 X-AXIS ENCODER CABLE(ALL #24)

660-1 LOGIC RETURN(D GROUND)
660-2 ENCODER A CHANNEL
660-3 ENCODER B CHANNEL
660-4 +5 VDC
660-5 ENCODER Z CHANNEL (OR C)
660-6 HOME/LIMIT SWITCH
660-7 OVERHEAT SWITCH
660-8 ENCODER A*
660-9 ENCODER B*
660-10 ENCODER Z* (OR C*)
660-11 X HALL A(NOT USED)
660-12 X HALL B(NOT USED)
660-13 X HALL C(NOT USED)
660-14 X HALL D(NOT USED)
660-15 SHIELD DRAIN
660-16 NOT USED

680 Z-AXIS ENCODER CABLE

(SAME AS 660-1 THRU 660-16)

690 A-AXIS ENCODER CABLE

(SAME AS 660-1 THRU 660-16)

700 KEYBOARD CABLE - 34 WIRE RIBBON WITH IDC

(FROM VIDEO P4 TO KBIF P1)

720 ANALOG SIGNAL FROM MOCON TO SPINDLE DRIVE LOAD MONITOR

721 0 TO +10 VOLTS SPINDLE LOAD
722 COMMON
723 SHIELD DRAIN

240 96-8710 rev C

 June 2001 CABLE LIST

740 POWER ON/OFF CABLE TO FRONT PANEL - SHIELD +4

741 POWER ON SWITCH LEG 1 (24 VAC) #20
742 POWER ON SWITCH LEG 2 #20 N.O.
743 POWER OFF SWITCH LEG 1 (24 VAC) #20
744 POWER OFF SWITCH LEG 2 #20 N.C.
745 SHIELD DRAIN

750 JOG-CRANK DATA CABLE(REM JOG SIDE CONNECTION)(ALL #24)

750-1 LOGIC RETURN ( D GROUND) 0 VDC
750-2 ENCODER A CHANNEL
750-3 ENCODER B CHANNEL
750-4 +5 VDC
750-5 JUMPER TO 750-1 (0 VDC)
750-6 X-AXIS
750-7 Y-AXIS
750-8 ENCODER A* CHANNEL
750-9 ENCODER B* CHANNEL
750-10 JUMPER TO 750-4 (+ 5VDC)
750-11 Z-AXIS
750-12 A-AXIS
750-13 X 10
750-14 X1
750-15 SHIELD DRAIN
750-16 NOT USED

750A JOG HANDLE DATA CABLE - SHIELD + 4 (ALL #24)

751A +5 VDC
752A 0 VDC
753A ENCODER A CHANNEL
754A ENCODER B CHANNEL
755A SHIELD DRAIN

760 MONITOR VIDEO DATA CABLE - SHIELD + 7 (ALL #24)

(FROM VIDEO P3 TO CRT)

770 EMERGENCY STOP INPUT CABLE - SHIELD + 2

771 SIGNAL #20
772 RETURN (D GROUND) #20
773 SHIELD DRAIN

770A SECOND E-STOP (BARFEEDER OPTION)

771A SIGNAL #20
772A RETURN (D GROUND) #20
773A SHIELD DRAIN

790 SPARE INPUTS FROM IOPCB P24(PROBE HOME OPTION)

791 SPARE 1
792 SPARE 2
793 COMMON
794 SHIELD DRAIN

820 TOOL CHANGER STATUS - SHIELD +7(ALL #20)

821 TURRET UNCLAMPED
822 TURRET CLAMPED

96-8710 rev C 241

 CABLE LIST June 2001

823 UNUSED
824 PART LOAD
825 DATA GROUND
826 SHIELD DRAIN

830 OVERHEAT THERMOSTAT - SHIELD +2

831 OVERHEAT SIGNAL #20
832 OVERHEAT RETURN (D GROUND) #20
833 SHIELD DRAIN

850 SERIAL PORT #1 INTERFACE CABLE (16 WIRE RIBBON #24)

850A SERIAL PORT #2 INTERFACE CABLE (16 WIRE RIBBON #24)

860 +5V/+12V/-12V/GND FROM MAIN POWER SUPPLY (ALL #18)

861 +5 VOLTS
862 LOGIC POWER RETURN
863 LOGIC POWER RETURN
864 +12 VOLTS
865 -12 VOLTS

860A 12 VOLT POWER TO IOPCB - SHIELD +2 (ALL #20)

861 +12 VOLTS
865 LOGIC POWER RETURN (D GROUND)
863 SHIELD DRAIN

860B +5 POWER TO 3" FLOPPY DRIVE

860C +5,+12,-12 POWER TO 68030

870 115VAC TO OILER - SHIELD +2

871 115VAC LEG 1 #18
872 115VAC LEG 2 #18

880A 115VAC TO SPINDLE HEAD SOLENOIDS - SHIELD +6 (ALL #24)

881 SPINDLE LOCK
882 TOOL UNCLAMP
883 LOW GEAR
884 HIGH GEAR
885 115VAC COMMON
886 SHIELD DRAIN
887 PRECHARGE

880B TRANSMISSION HIGH/LOW GEAR SOLENOIDS FOR LATHE

881 115 VAC SOLENOID COMMON (IO P12-5) #18
882 HIGH GEAR SOLENOID (IO P12-4) #18
883 LOW GEAR SOLENOID (IO P12-3) #18

890 SPINDLE HEAD INPUT STATUS SWITCHES - SHIELD +6 (ALL #24)

891 HIGH GEAR SIGNAL
892 LOW GEAR SIGNAL
893 TOOL UNCLAMPED SIGNAL
894 TOOL CLAMPED SIGNAL
895 SPINDLE LOCKED SIGNAL
896 COMMON (DATA GROUND)
897 SHIELD DRAIN

242 96-8710 rev C

 June 2001 CABLE LIST

900 SPARE - SHIELD +2

901 SIGNAL #20
902 RETURN #20
903 SHIELD DRAIN

910 115 VAC CIRCUIT BREAKER (CB4) TO SOLENOIDS - SHIELD +2

911 115VAC #20
912 RETURN #20
913 SHIELD DRAIN

910A SPARE 115VAC

911A 115VAC #20
912A RETURN #20
913A SHIELD DRAIN

910B 115VAC TO SERVO FAN - SHIELD +2

911B 115VAC #20
912B RETURN #20
913B SHIELD DRAIN

910C 115VAC TO CONTACTOR COILS (WYE TO DELTA OPTION)

911C 115VAC #20
912C RETURN #20
913C SHIELD DRAIN

910D 115VAC TO PART CATCHER

911D 115VAC #20
912D RETURN #20
913D SHIELD DRAIN

930 230 VAC FOR COOLANT PUMP FROM CB3 - SHIELD + 2

931 230VAC #20
932 230VAC RETURN #20
933 SHIELD DRAIN

940 230 VAC SINGLE PHASE POWER TO COOLANT PUMP - SHIELD +2

941 230VAC #20
942 RETURN #20
943 SHIELD DRAIN

950 LOW AIR PRESSURE/OIL LUBE SENSOR - SHIELD + 3

951 LOW AIR SIGNAL #20
952 LOW OIL LUBE SIGNAL #20
953 COMMON (DATA GROUND) #20
954 SHIELD DRAIN

950A LOW HYDRAULIC PRESSURE SWITCH FOR LATHE - SHIELD +2

952 LOW HYDRAULIC RETURN (D GROUND) (65) #20
953 LOW HYD PRESSURE SWITCH FOR VERTICAL TRANSMISSION #20
954 SHIELD DRAIN

960 LOW HYD PRESSURE - SHIELD + 2

961 LOW HYD PRESSURE SIGNAL #20
962 COMMON #20
963 SHIELD DRAIN

96-8710 rev C 243

 CABLE LIST June 2001

970 VECTOR DRIVE OVERVOLTAGE - SHIELD +2

971 OVERVOLTAGE SIGNAL #24
972 OVERVOLTAGE RETURN #24
973 SHIELD DRAIN

990 HOME SENSORS - SHIELD +4 (ALL #20)

991 COMMON (DATA GROUND)
992 X-AXIS HOME SWITCH
993 Y-AXIS HOME SWITCH
994 Z-AXIS HOME SWITCH
995 SHIELD DRAIN

1000 SPINDLE ENCODER CABLE (MOCON SIDE CONNECTION) ALL #24

1000-1 LOGIC RETURN (D GROUND)
1000-2 ENCODER A CHANNEL
1000-3 ENCODER B CHANNEL
1000-4 +5 VDC
1000-5 ENCODER Z CHANNEL
1000-6 NOT USED
1000-7 NOT USED
1000-8 ENCODER A* CHANNEL
1000-9 ENCODER B* CHANNEL
1000-10 ENCODER Z* CHANNEL
1000-11 NOT USED
1000-12 NOT USED
1000-13 NOT USED
1000-14 NOT USED
1000-15 SHIELD DRAIN
1000-16 NOT USED

1020 SPINDLE TEMPERATURE SENSOR CABLE - SHIELD +3

1021 SIGNAL
1022 ANALOG RETURN
1023 +5 VOLTS TO SENSOR
1024 SHIELD GROUND

1030 SPINDLE LOAD RESISTOR - SHIELD +2

1031 REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B1) #14
1032 REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B2) #14
1033 SHIELD DRAIN

1040 115VAC TO MIKRON DOOR INTERLOCK SWITCH - SHIELD +2

1041 115VAC #20
1042 RETURN #20
1043 SHIELD DRAIN

1050 DOOR SWITCH INPUT - SHIELD +2

1051 DOOR OPEN SIGNAL #20
1052 DOOR OPEN RETURN (D GROUND) #20
1053 SHIELD DRAIN

244 96-8710 rev C

 June 2001 CABLE LIST

1060 GROUND FAULT DETECTION SENSE INPUT

1061 + INPUT FROM SENSE RESISTOR
1062 - INPUT FROM SENSE RESISTOR

1070 SKIP INPUT FROM SENSOR - SHIELD +2

1071 LOGIC COMMON
1072 SKIP SIGNAL
1073 SHIELD DRAIN

96-8710 rev C 245

 ELECTRICAL DIAGRAMS June 2001

ELECTRICAL
WIRING DIAGRAMS

246 96-8710 rev C

 June 2001 ELECTRICAL DIAGRAMS

96-8710 rev C 247

 ELECTRICAL DIAGRAMS June 2001

248 96-8710 rev C

 June 2001 ELECTRICAL DIAGRAMS

96-8710 rev C 249

 ELECTRICAL DIAGRAMS June 2001

250 96-8710 rev C

 June 2001 ELECTRICAL DIAGRAMS

96-8710 rev C 251

 ELECTRICAL DIAGRAMS June 2001

252 96-8710 rev C

 June 2001 ELECTRICAL DIAGRAMS

96-8710 rev C 253

 ELECTRICAL DIAGRAMS June 2001

254 96-8710 rev C

 June 2001 ELECTRICAL DIAGRAMS

96-8710 rev C 255

 ELECTRICAL DIAGRAMS June 2001

256 96-8710 rev C

 June 2001 ELECTRICAL DIAGRAMS

96-8710 rev C 257

 ELECTRICAL DIAGRAMS June 2001

258 96-8710 rev C

 June 2001 ELECTRICAL DIAGRAMS

96-8710 rev C 259

 ELECTRICAL DIAGRAMS June 2001

260 96-8710 rev C

 June 2001 ELECTRICAL DIAGRAMS

96-8710 rev C 261

 ELECTRICAL DIAGRAMS June 2001

262 96-8710 rev C

 June 2001 ELECTRICAL DIAGRAMS

96-8710 rev C 263

 ELECTRICAL DIAGRAMS June 2001

264 96-8710 rev C

 June 2001 ELECTRICAL DIAGRAMS

96-8710 rev C 265

 ELECTRICAL DIAGRAMS June 2001

266 96-8710 rev C

 June 2001 ELECTRICAL DIAGRAMS

96-8710 rev C 267

 ASSEMBLY DRAWINGS June 2001

ASSEMBLY DRAWINGS

AND

PARTS LISTS

268 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

1 2 3 4 2 5 6

17 16 15 8 14 13 12 11 10 9 8 7
18 38

30
27 28 29 31 32 33 34

20 22
19 21 23 24 25 26 35 36

37

SL-20 Casting Assembly

96-8710 rev C 269

 ASSEMBLY DRAWINGS June 2001

SL-20 Casting Assembly Parts List

1.50-3400 Linear guide 30. N/A

2. 25-9746 Cable clamp base 31. N/A

3.20-9058 Ballscrew bumper 32. N/A

4.25-7266 X-axis mounting bracket 33. 93-0209 Service kit slide spring

5.58-3030 BAnjo elbow 5/16 F x M6 34. N/A

6.25-7080 Bumber bracket 35.22-8052 Z-axis Waycover BTM

7.30-0153 support bearing assembly 36.36-8980B Rail interface

8.48-0045 Dowel pin 37. N/A

9.24-7325 Str fit metric linear guide 38. 30-0156 motor housing bearing assembly

10. 20-9007 nut housing

11.30-8717 oil line assembly

12. N/A

13.24-9013 ballscrew

14.20-7010A motor mount

15.59-6600 Plug Guide Rail

16.22-7458 Cam Linear Guide

17.22-2629 Key Stub Shaft/worm

18.62-0014 Yaskawa Sigma 09 Motor

19.25-8925B Support back cover

20. 25-8653A Roller bracket

21. N/A

22. 54-0030 Guide wheel

23. N/A

24.26-8623 Seal rail wiper

25.22-8624 Seal rail backing bar

26. N/A

27. N/A

28. N/A

29. N/A

270 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

2 5 10
1 3 4 6 7 8 9 11 12 13

14

15

16

17

30 29 28 27 26 25 24 23 22 21 20 19 18

39

31 32 33 34 35 36 37 38 40 41

42

43
44

45

46

47
57 56 55 54 53 52 51 50 49 48

SL-30 Casting Assembly w/Tailstock

96-8710 rev C 271

 ASSEMBLY DRAWINGS June 2001

SL-30 Casting Assembly w/Tailstock Parts List

1. 22-8793 Support, control box

30. N/A
2. 22-2629 Key stub shaft
31. 54-0030 Guide wheel
3. 62-0014 Yaskawa sigma motor 09
32. 25-8653A Roller Bracket
4. N/A
33. 25-8807A Support control bracket
5. 25-7042A Snap lock motor mount cover plate
34. 25-8841 Seal strip
6. 26-7233A Gasket, deflector shield
35. N/A
7. 20-9058 Ballscrew bumper
36. N/A
8. 25-7267 Brack mounting y-axis
37. 25-8792A Rail interface
9. 32-2040 Z-axis limit switch cable
38. N/A
10. N/A
39. 93-0210 Spring cross slide
11. N/A
40. 20-8720 Swing arm spring
12. 20-9007 Nut housing machined
41. 20-8721A Bushing swing arm spring
13. N/A
42. 20-0534 Bracket spring T/C
14. 58-3031 Banjo Elbow 5/16F X M6 M
43. 22-8048Z-axis way cover bottom guide
15. 25-7080 Bumper bracket
44. N/A
16. 48-0045 Dowel pin 3/8 x 1 1/2
45. 22-8064 Waycover bottom guide
17. 22-7458 Cam linear guide
46. 22-8048 Z-axis Waycover boottom guide
18. 20-9058 Bumper
47. 22-8064 Waycover bottom guide bs strip
19. 50-9010 Linear guide X-axis
48. 59-6655 Rubber plug guide rail
20. 59-6600 Guide rail plug
49. 50-3400 Linear guide
21. 30-8863 Oil line assembly
50. 20-8988A Tailstock cylinder attach bracket
22. 58-1560 Adpt 1/8 M BSPT - 5/16 F
51. N/A
23. N/A
52. 32-0400A Encoder read head assembly
24. N/A
53. 25-8024A Encoder strip
25. 58-2010 Nylon tubing 5/32
54. 20-9210A Tailstock arm
26. N/A
55. 25-8028 Guide, waycover ts bottom
27. 58-3031 Banjo Elbow 5/16F X M6 M
56. N/A
28. N/A
57. 59-0013 Hydraulic cylinder
29. N/A

272 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

2 4
1 3 5 6 7 8 9 10 11 12

13

14

15

27 25 23 21 20 19 18 17 16
26 24 22

31
28 29 30 32 33 34

35

36

37
38

38

49 48 47 46 45 44 43 41 40 39
42

SL-40 Casting Assembly w/Tailstock

96-8710 rev C 273

 ASSEMBLY DRAWINGS June 2001

SL-40 Casting Assembly w/Tailstock Parts List

1. 25-8284 Support control/back 30. N/A

2. 22-2629 Key, stub shaft 31. 20-8617 Conduit strain releif

3. 62-0016 Yaskawa sigma motor 13 32. 20-8618 Conduit strain releif

4. 25-9203 Cover plate motor mount 33. N/A

5. 26-7233A Gasket, deflector shield 34. 30-8335 Oil line

6. N/A 35. 25-8296 Guide Z waycover bottom

7. 20-81041 Support 36. 26-8320 T/S Strip guide

8. 55-7423 Standoff 37. 25-8297 T/S Rail guide

9. 25-7267 Bracket mounting Y-axis 38. 59-6655 Rubber plug, guide rail

10. 32-2040 Z-axis limit switch 39. 50-8205 Linear guide tailstock

11. 30-8325 Oil line SL-40 40. N/A

12. 20-0150 Nut housing machined 41. 25-6651 Drip rail

13. N/A 42. N/A

14. 58-3031 Banjo elbow 5/16 F x M6 M 43. N/A

15. 22-7458 Cam linear guide 44. N/A

16. 40-1660 1/2-13 x 1 1/2 45. 32-0017 Read head

17. 50-9305 Linear guide 46. 20-8228 Hydraulic mount

18. 24-7325 Str fit metric linear guide 47. 25-8300 Encoder strip

19. 20-6565 Tail stock head 48. 59-0034 Hydraulic cylinder

20-8203A Tailstock body
49. N/A
20. N/A

21. N/A

22. N/A

23. N/A

24. N/A

25. N/A

26. N/A

27. N/A

28. 54-0030 Support wheel

29. 25-8297 Rail/guide Waycover T/S

274 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

4
5
3 7
6 8
9 13
10 11 12 14 15 16 17 18
1
2

19
29
28

26 25 24 2 19 23 22 21 20
27

30

31

32
33

37 35
36
34

SL-20 Wedge Assembly

96-8710 rev C 275

 ASSEMBLY DRAWINGS June 2001

SL-20 Wedge Assembly Parts List

1. 62-0009 Kawa sigma motor 09 w/ brake. 31. N/A
2. 22-2629 Key, stub shaft 32. 20-8535 Plate Access T/C
3. N/A 33. 57-8546 Gasket, plate access T/C
4. N/A 34. 57-8576 Gasket, coverT/C
5. N/A 35. 20-8545 Cover housing T/C
6. N/A 36. 20-8364 Spacer
7. 30-1044 Oil line carrier 37. 25-7459 Bracket trip table
8. N/A

9. N/A

10. N/A

11. 41-1717 Long stud / set screw

12. 58-2110 Sleeve nuts lube assembly

13. 25-7042A Snap lock motor mount cover plate

14. 26-7233A Gasket deflector shield

15. 20-7185 Bumper Z-axis motor end

16. 58-3031 Banjo elbow 5/16 F x M6 M

17. 24-8548B Bumper

18. 20-7185 Bumper (2)

19. 48-0045 Dowel pin

20. 50-8549 Linear guide

21. 20-7008F Nut housing machined

22. 24-7325 Str fit metric linear guide

23. 30-8716 Lube line assembly

24. 22-7458 Cam linear guide

25. 25-7266 X-axis mounting bracket

26. N/A

27. N/A

28. 30-1219 Coupler

29. N/A

30. N/A

276 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

1 9
2 5 7 10
3 4 6 8 11 12 13 14 15 16

30
29

25 24 23 22 21 20 19 18 17
26
27
28

31
32

36 35
34
33

SL-30 Wedge Assembly

96-8710 rev C 277

 ASSEMBLY DRAWINGS June 2001

SL-30 Wedge Assembly Parts List

1. N/A 31. 20-8535 Plate access T/C
2. N/A 32. 57-8546 Gasket plate Access T/C
3. N/A 33. 57-8576 Gasket cover T/C
4. 30-1044Oil Line 34. 20-8545 Cover Housing T/C
5. 25-7042A Snap lock motor mount cover plate 35. 20-8364 Spacer
6. 26-7233A Gasket deflector shield 36. 25-7459 Bracket trip table
7. N/A

8. N/A

9. N/A

10. N/A

11. N/A

12. 24-8765B Ballscrew

13. 30-0593 Wedge oil line kit

14. 58-3031 Banjo Elbow 5/16 F x M6 m

15. 50-8766 Linear guide X-axis

16. 59-6600 Plug, guide rail

17. 20-7474 Bumper

18. 20-7008F Nut housing

19. 24-7325 Str fit metric linear guide

20. 22-7458 Cam linear guide

21. 20-7474 Bumper

22. 48-0045 Dowel pin 3/8 x 1 1/2

23. 32-2055 Limit switch X home

24. 25-7266 X-axis mounting bracket

25. 22-2629 Key stub shaft

26. 62-0009 Kawa Sigma Motor 09 w/brake

27. N/A

28. N/A

29. N/A

30. 30-1219 Coupler

278 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

6 12
2 7 13
1 3 4 5 8 9 10 11 14 15

30
31

26 25 24 23 21 20 19 18 17 16
27 22
28
29

35 37 39
32 33 34 36 38 40

45 44 42 41
43

SL-40 Wedge Assembly

96-8710 rev C 279

 ASSEMBLY DRAWINGS June 2001

SL-40 Wedge Assembly Parts List

1.N/A 31. N/A
2. N/A 32. 40-0033 SHCS 1/2-13 x 4
3. 58-2760 2 way manifold 33. 45-1740 1/2 Washer
4. N/A 34. 46-1654 Hex nut
5. N/A 35. 40-1500 SHCS 5/16-18 x 1
6. N/A 36. N/A
7. N/A 37. 20-8545 Cover housing T/C
8. 30-1044 Oil Line Assembly 38. 57-8576 Gasket cover T/C
9. 20-7474 Bumper 39. 20-8535 Plate access T/C
10. N/A 40. 57-8546 Gasket plate access T/C
11. 30-1530 oil line 41. 20-8204 X-riser
12. 50-9011 Linear guide 42. 25-7459 Bracket trip table
13. N/A 43. N/A
14. N/A 44. 93-0211 Cross Slide Spring Kit
15. 20-7474 Bumper, X-axis 45. SwingArm Bushing
16. 58-3031 Banjo Elbow 5/16 F x M6 M

17. 24-0008A Ballscrew

18. 20-9007 Nut housing

19. 24-7325 Str fit metric linear guide

20. 22-7458 Cam linear guide

21. 25-7042A Snap lock motor mount cover plate

22. 26-7233A Gasket deflector shield

23. 59-6600 Plug Guide Rail

24. 32-2063 Limit switch X home

25. 25-7267 Bracket mounting

26. N/A

27. N/A

28. 62-0009 Yaskawa sigma motor with brake

29. N/A

30. 30-1219 Coupling

280 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

13
1 2 3 4 5 6 7 8 9 10 11 12 141516 1718 19 20 21 22 23
24
65
64 25

63 26
62 27
61 60
28

59 29
58
57
56

55
54 30
31
53
52

51
50
49
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32

SL-20 Tool Changer Assembly

96-8710 rev C 281

 ASSEMBLY DRAWINGS June 2001

SL-20 Tool Changer Assembly Parts List

1. 51-2984 Thrust washer TRB-3446 51. 59-2059 15/16 Steel Balls
2. 20-8523 Nut tool holder 52. 49-1010 Shoulder bolt 3/8 x 1 1/2
3. 57-2994 O-ring 53. 20-8557 Bushing front turret
4. 56-2090 Retaining Ring RR-300 54. 20-8532 Reatiner turret T/C
5. 20-8538 Rod end spacer 55. 22-8543 Key
6. 32-2153 Unclamp switch 56. 57-2154 O-ring
7. 32-2154 Clamp switch 57. 59-3011 Spring, Turret Coupling
8. 30-3650 Air Cylinder assembly 58. 20-8518 Reatiner springs T/C
9. 20-8364 Spacer anti-rotate T/C 59. 58-3105 Pipe plug 1/4 NPT
10. 62-0014 Yaskawa Sigma 09 motor 60. 57-8970 Coolant plate gasket
11. 40-1632 1/4-20 x 1/2 61. 20-0516 Plate Cover coolant
12. 49-4115 Washer 62. 57-2150 O-ring
13. Retaining Ring 5100-150 63. N/A
14. N/A 64. 51-3001 Bearing thrust needle
15. 30-1220A Coupling assembly 65. 51-2983 Thrust washer TRD-4860
16. 57-2129 Seal
17. 20-8512A Housing worm
18. 51-2042 Bearing locknut BH-04
19. 20-8515 Clamp bearing worm
20. 51-7001 Bearing
21. 57-2022 O-ring
22. 20-8509 Shaft worm
23. 59-2057 5/16 steel ball
24. 20-8503A Turret housing
25. 57-2831 O-ring
26. 20-8510 Shaft transfer T/C
27. 20-8537 Retainer spring
28. 32-2011 30" telemechanique switch
29. 30-3655 Coolant line assembly
30. 25-8534A Home bracket
31. 25-8536 Switch bracket
32. 20-8533 Ring switch T/C
33. 20-8530 Shaft Turret T/C
34. Copper line
35. 57-1045 Seal
36. 20-8539 Bearing rear
37. 20-8511A Gear cluster T/C
38. 46-7016 Locknut
39. 20-8522A Gear spur T/C
40. 22-8544 Key gear spur T/C
41. 24-4010 Bellville washer
42. 22-8550A Spacer Bellville T/C
43. 20-8516 Lever cam T/C
44. 93-8138 Cam Turret T/C
45. 30-3660 A transfer housing
46. 20-8531B Turret T/C
47. 48-0049 Dowel pin 1/2 x 1
48. 57-0029 Seal CR29841
49. 20-8506A Coupling, turret female
50. 20-8505A Coupling, turret male

282 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

12
7 11
1 2 3 4 5 6 8 9 10 13 141516 17 18 19 20 21

65
22 23
64
63
62 24
61 60 25
59 26
58
27
57
56
55
28
54 29
53 30
52
31
51
50
49
48
47
46 45 44 43 42 41 40 39 38 37 36 35 34 33 32

SL-30 Tool Changer Assembly

96-8710 rev C 283

 ASSEMBLY DRAWINGS June 2001

SL-30 Tool Changer Assembly Parts List

1. 51-2984 Thrust washer TRB-3446 51. 20-8557 Bushing front turret
2. 20-8321 Nut tool holder 52. 20-8532 Reatiner Turret T/C
3. 56-2090 Retaining ring RR-300 53. 22-8543 Key turret T/C
4. 22-8538 Spacer rod end T/C 54. 49-1010 Shoulder bolt 3/8 x 1 1/2
5. 30-3650 Air cylinder assembly 55. 57-2154 O-ring 2-240 buna
6. 56-9057 Retaining ring 5100-150 56. 59-0035 Die springs
7. 49-4115 Washer 1 1/2 steel 57. 20-8518 Spring Retainer T/C
8. 45-2001 .002 Shim 58. 59-2059 15/16 balls
9. N/A 59. 57-2975 O-ring 2-172 buna
10. 62-0014 Yaskawa sigma 09 motor 60. 20-0516 Plate turret cover
11. N/A 61. 57-8970 Gasket plate coolant T/H
12. N/A 62. 51-2983 Thrust washer TRD-4860
13. 30-1220A coupling assembly 63. 20-0676 Mount, coupling turret
14. 57-2129 Seal CR6372 64. 51-3001 Bearing thrust needle
15. 51-2042 Bearing locknut BH-04 65. 48-0049 Dowel pin 1/2 x 1
16. 20-8512A Housing Worm
17. 20-8515 Clamp bearing worm T/C
18. 57-2022 O-ring 2-150 V-1164-75
19. 51-7001 Ball bearing
20. 20-8509 Shaft worm
21. 59-2057 5/16 steel ball
22. 20-0674 Machined housing
23. N/A
24. 57-2831 O-ring 2-130 buna
25. 20-8510 Shaft transfer T/C
26. 20-8537 Reatiner spring T/C
27. 32-2011 30" telemechanique switch
28. 32-2154 Clamp reed switch
29. 32-2153 Unclamp reed switch
30. 25-8536 Clamp bracket
31. 25-8534A "A" Home BracketT/C
32. 20-8533 Ring switch
33. 20-8530 Shaft turret T/C
34. 30-3655 Coolant tubing
35. 57-1045 Seal CR23646
36. 20-8539 Bearing Rear T/C
37. 20-8511A GEar Cluster T/C
38. 46-7016 Lock nut
39. 20-8522A Gear spur T/C
40. 22-8544 Key gear spur T/C
41. 24-4010 Bellville washer
42. 22-8550A Space Belleville T/C
43. 20-8516 Lever Cam T/C
44. 93-8138 Cam turret T/C
45. 30-3660A transfer housing
46. 57-2994 O-ring 2-039 buna
47. 20-0671 Turret
48. 57-0030 O-ring
49. 20-8768A Coupling Turret male
50. 20-8769A Coupling Turret Female

284 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

8
9
10 12
1 2 3 4 5 6 7 11 13 14 15 16 17 18 19 20 21 22

66 23
65

64
24

63 25

62 26

27

28

29
61

60 30

59 31

58 32
57
33
56

55

54

53
52

51
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34

SL-40 Tool Changer Assembly

96-8710 rev C 285

 ASSEMBLY DRAWINGS June 2001

SL-40 Tool Changer Assembly Parts List

1. 51-2984 Thrust washer TRB-3446 51. 20-0248 coupling turret male
2. 20-8321 Nut tool holder 52. 57-8970 Coolant plate and gasket
3. 57-2994 O-ring 2-039 buna 53. 20-0516 Coolant plate
4. 56-2090 Retaining ring RR-300 54. 57-0029 Seal CR29841
5. 22-8538 Spacer rod end T/C 55. 49-1010 Shoulder bolt 3/8 x 1 1/2
6. 30-3650 Air cylinder assembly 56. 59-0035 Die springs
7. 40-1639 SHCS 3/8-16 x 1 57. 20-8557 Bushing front turret
8. N/A 58. 20-8532 Retainer turret T/C
9. 49-4115 1 1/2 steel washer 59. 22-8543 Key turret T/C
10. 56-9057 Retaining ring 5100-150 60. 57-2154 O ring 2-240 buna
11. 45-2001 Shim .002 thick 61. 20-8518 Spring retainer
12. 57-0075 O-ring2-021 buna 62. 57-0047 O-ring 2-172 buna
13. 62-0014 Yaskawa sigma 09 motor 63. 20-0250 Coupling mount
14. 30-1220A coupling 64. 51-3001 Bearing thrust needle
15. 57-2129 Seal, worm 65. 51-2983 Thrust washer TRD-4860
16. 20-8512A Housing worm 66. 48-0049 Dowel pin 1/2 x 1
17. 20-8515 Clamp bearing worm
18. 51-2042 Bearin locknut BH-04
19. 51-7001 Ball bearing 5204-1SB-Kff
20. 57-2022 O-ring
21. 20-8509 Shaft worm
22. 59-2057 5/16 steel balls
23. 20-0249 T/C housing machined
24. 57-2831 O ring 2-130 buna
25. 20-8510 Shaft transfer T/C
26. 20-8537 Spring Retainer T/C
27. 32-2011 30" Telemechanique switch
28. 40-1800 SHCS 8-32 x 3/4
29. 30-3655 Coolant line assembly
30. 32-2162 Clamp switch
31. 32-2161 Unclamp switch
32. 25-8534 Home bracket
33. 25-8536 Clamp bracket
34. 20-8533 Ring switch T/C
35. 20-8530 Shaft turret T/C
36. 58-8657 Coolant tubing
37. 57-1045 seal CR6372
38. 20-8539 Bearing rear T/C
39. 20-8511A Gear cluster T/C
40. 46-7016 Lock nut
41. 20-8522A Gear spur T/C
42. 22-8544 Key gear spur T/C
43. 24-4010 Belville washer
44. 22-8550 Belleville spacer
45. 20-8516 Lever cam T/C
46. 93-8138 Cam turret T/C
47. 59-2059 15/16 steel balls
48. 30-3660A transfer coolant
49. 57-0030 O-ring
50. 20-0247 Coupling turret female

286 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

COUPLING ASSEMBLY MOTOR BEARING HOUSING

SPACER RING SNAP LOCK SNAP RING

RING BMPR LOCK BMPR BEARING LOCKNUT

MOTOR MOUNT BALL SCREW SUPPORT SUPPORT BEARING ASSEMBLY

BEARING LOCKNUT
BEARING ASSEMBLY

BALL SCREW ROTATED 90°

BALL SCREW ASS'Y "A" BALL SCREW SNAP LOCK RING BMPR MOTOR COUPLING APPLICATION
MOUNT ASS'Y

30-0615 BS ASS'Y 32mm (1.26) X 33.268 24-9013 BALLSCR 32mm (1.26) X 33.268 20-0142 SNAP LOCK RING BMPR 6.00 20-7010A 30-1220A SL20 (Z)

30-0617 BS ASS'Y 32mm (1.26) X 48.228 24-9012 BALLSCR 32mm (1.26) X 48.228 20-0143 SNAP LOCK RING BMPR 7.00 20-7010A 30-1220A SL30 (Z)

30-1397A BS ASS'Y 32mm (1.26) X 25.650 24-7146 BALLSCR 32mm (1.26) X 25.650 20-0141 SNAP LOCK RING BMPR 4.00 20-7010A 30-1220A SL40 (X)

30-0618B BS ASS'Y 32mm (1.26) X 16.475 24-8765 BALLSCR 32mm (1.26) X 16.475 NONE 20-7010A 30-1220A SL30 (X)

30-0616B BS ASS'Y 32mm (1.26) X 13.525 24-9548 BALLSCR 32mm (1.26) X 13.525 NONE 20-7010A 30-1220A SL20 (X)

30-0450 BALLSCR 40mm (1.57) x 57.897 24-0003A BS ASS’Y 40mm (1.57) x 57.897 30-1215 SL40 (Z)

Ball Screw Assembly

96-8710 rev C 287

 ASSEMBLY DRAWINGS June 2001

WHERE USED APPLICATION

30-0615 BS ASSY 32mm(1.26) x 33.27 SL20 (Z)
30-1962 BS ASSY 32mm(1.26) x 48.23 SL30 (Z)
30-1397A BS ASSY 32mm(1.26) x 25.65 SL40 (X)
30-0616B BS ASSY 32mm(1.26) x 13.53 SL20 (X)
30-0618B BS ASSY 32mm(1.26) x 16.78 SL30 (X)
30-0157 BS ASSY 32mm(1.26) x 25.65 SL40 (Z)
30-0450 BS ASSY 40mm (1.57) x 57.90 SL40 (Z)

Coupling Assembly

288 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

2
3
4

6
CHUCK

7
TAILSTOCK
8

ITEM PART/NO QTY DESCRIPTION

1 22-7163 2 RIDER TRAP DOOR
2 25-1252 2 PEDAL, FOOT SWITCH
3 25-1253 1 BULKHEAD, FOOT SWITCH
4 25-1254 1 BASE PLATE, FOOT SWITCH
5 25-1255 1 COVER, FOOT SWITCH
6 32-2000 2 LIMIT SWITCH 4 WIRE, 8 INCH
7 32-9300A 1 CABLE, FS COILED
12 59-0069 2 SPRING, C0975-112-100-M
13 59-1041 2 LEGS, CONTROL

Foot Switch Assembly

96-8710 rev C 289

 ASSEMBLY DRAWINGS June 2001

Parker Hydraulic Power Unit

290 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

Rexroth Hydraulic Power Unit

96-8710 rev C 291

 ASSEMBLY DRAWINGS June 2001

SL-20 External Sheetmetal

30

28

29

27
22
26 24 View Rotated 180
25

4 7 8
12
3 13
2
10 11
1
15

20
SL

20
SL

16

20 19
21 17 14
18

Parts
Catcher

292 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

SL-20 Internal Sheetmetal

51
59

53 55
Live Tooling 58
56

54
50
60
69 68 70 57
35 32
31 38

63
61
33
62
36

41

37 66
*71
42 49
40
46

44
48

*Parts Catcher Only 45

96-8710 rev C 293

 ASSEMBLY DRAWINGS June 2001

SL-20 Sheetmetal Parts List

1 Door Hinges 52 (Not Used)
2 Toolbox Door 53 Panel Tunnel T/C
3 Left Side Panel 54 Sliding Cover Support
4 Toolbox 55 Cable Bracket
5 (Not Used) 56 Toollchanger Sliding Cover
6 (Not Used) 57 Chip Guard
7 Door Rail Mount 58 Z-axis Way Covers
8 Top Panel 59 Upper Waycover Guide
10 Hinge 60 Lower Waycover Guide
11 Access Door 61 Support, Right
12 Left Front Panel 62 Channel Stiffener, Bulkhead
13 Door 63 Rod Guide, Toolchanger
14 Door, Parts Catcher Option 64 (Not Used)
15 Front Right Panel 65 (Not Used)
16 Door, Drip Tray 66 Moving Bulkhead
17 V Track Door 67 (Not Used)
18 Panel Front 68 Gasket
19 Chip Removal Tray 69 Window
20 Lower Tailstock Waycover Guide 70 Lens Retainer
21 Chip Tray 71 Door Tray Chip Guard (Parts Catcher)
22 Back Cover
23 (Not Used)
24 Tramp Lube Oil Pan
25 High Pressure Pump Bracket
26 Coolant Pump Mount
27 Auger Chute
28 Belt Conveyor Cover
29 Auger Chute Filler
30 Front Right Side
31 Light Fixture
32 Z-axis upper wiper
33 Z-axis lower wiper
34 (Not Used)
35 Upper Door Wiper
36 Vertical Door Chip Seal
37 Lower Door Chip Seal
38 Fixed Bulkhead
39 (Not Used)
40 Waycover Tailstock, Left
41 Z-axis Drip Channel
42 Spindle Housing Corner Drain
43 (Not Used)
44 X-axis Waycover
45 Front Wedge Cover
46 Tailstock Cover
47 (Not Used)
48 Waycover Tailstock, Right
49 Upper Tailstock Waycover Guide
50 Rear Sliding Cover
51 Rear Sliding Cover (Live Tooling)

294 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

SL-30 External Sheetmetal

23 23a

30

28
23b
29

27

26 24 View Rotated 180

25

4 7 8
12
6 13
2 10 11
1
15

5
Big Bore
Only 30
SL

16

20 19
21 17 14
18

Parts
Catcher

96-8710 rev C 295

 ASSEMBLY DRAWINGS June 2001

SL-30 Internal Sheetmetal

59
52
Live Tooling

53 55
56 58

54
50
60
69 68 70 57
35 32
31 39

34 65

36

64

41

61
* 71 37 67
42 49
40 43

47
44
48

*Parts Catcher Only 45

296 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

SL-30 Sheetmetal Parts List

1 Door Hinges 52 Rear Sliding Cover (Live Tooling)
2 Toolbox Door 53 Panel Tunnel T/C
3 (Not Used) 54 Sliding Cover Support
4 Toolbox 55 Cable Bracket
5 Motor Enclosure (Big Bore) 56 Toollchanger Sliding Cover
6 Left Side Panel 57 Chip Guard
7 Door Rail Mount 58 Z-axis Way Covers
8 Top Panel 59 Upper Waycover Guide
10 Hinge 60 Lower Waycover Guide
11 Access Door 61 Support, Right
12 Left Front Panel 62 (Not Used)
13 Door 63 (Not Used)
14 Door, Parts Catcher Option 64 Rod Guide, Toolchanger
15 Front Right Panel 65 Channel Stiffener
16 Door, Drip Tray 66 (Not Used)
17 V Track Door 67 Moving Bulkhead
18 Panel Front 68 Gasket
19 Chip Removal Tray 69 Window
20 Lower Tailstock Waycover Guide 70 Lens Retainer
21 Chip Tray 71 Door Tray Chip Guard (Parts Catcher)
22 (Not Used)
23 Rear Panel
24 Tramp Lube Oil Pan
25 High Pressure Pump Bracket
26 Coolant Pump Mount
27 Auger Chute
28 Belt Conveyor Cover
29 Auger Chute Filler
30 Front Right Side
31 Light Fixture
32 Z-axis Upper Wiper
33 (Not Used)
34 Z-axis Wiper
35 Upper Door Wiper
36 Vertical Door Chip Seal
37 Lower Door Chip Seal
38 (Not Used)
39 Bulkhead
40 Waycover Tailstock, Left
41 Z-axis Drip Channel
42 Spindle Housing Corner Drain
43 (Not Used)
44 X-axis Waycover
45 Front Wedge Cover
46 (Not Used)
47 Tailstock Cover
48 Waycover Tailstock, Right
49 Upper Tailstock Waycover Guide
50 Rear Sliding Cover
51 (Not Used)

96-8710 rev C 297

 ASSEMBLY DRAWINGS June 2001

SL-40 External Sheetmetal

23 24

22

17
18

21 View Rotated 180

19
20

3 4 60
8 9 10
2 57
1 58 6 7

SL 40

40
SL

11

16
14

12

13
15

298 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

SL-40 Internal Sheetmetal

50
44 49
43
42
41 45

46
48

59

29 26 30 52
47

25 54 51

53

27

31
55
28 33
34
32
36
35
40 56

38 37

39

96-8710 rev C 299

 ASSEMBLY DRAWINGS June 2001

SL-40 Sheetmetal Parts List

1 Left Rear Side Panel
2 Left Front Side Panel 52 Enclosure Support
3 Door Rail Mount 53 Channel Stiffener
4 Top Panel 54 Strip, Z-axis
6 Hinge 55 Moving Bulkhead
7 Access Door 56 Right Enclosure Seal
8 Left Front Panel, Inner 57 Front Right Outer Panel
9 Door 58 Left Front Panel Outer
10 Front Right Panel, Inner 59 Waycover, Bottom Left Z-Axis
11 Door, Drip Tray 60 Top Right Panel
12 V Track Door
13 Panel, Front
14 Lower Tailstock Waycover Guide
15 Chip Tray
16 Support
17 Rear Panel
18 Rear Panel
19 High Pressure Pump Bracket
20 Coolant Pump Mount
21 Auger Chute
22 Belt Conveyor Cover
23 Front Right Side Panel
24 Rear Right Side Panel
25 Light Fixture
26 Z-axis Upper Wiper
27 Z-axis Lower Wiper
28 Lower Door Chip Seal
29 Vertical Door Chip Seal
30 Upper Door Wiper
31 Fixed Bulkhead
32 Tailstock Waycover, Left
33 X-axis Drip Channel
34 Spindle Housing Corner Guide
35 Tailstock Wiper
36 X-axis Guide Shield
37 X-axis Waycover
38 Front Wedge Cover
39 Tailstock Waycover, Right
40 Upper Tailstock Waycover Guide
41 Rear Sliding Cover
42 X-axis Drip Tray
43 Tool Changer Filler
44 Cable Bracket
45 Tool Changer top Seal / Side Seal / Retainer
46 Tool Changer Sliding Cover
47 Tool Changer Cover Filler
48 Tool Changer Front Cover
49 Right, Z-axis Waycover Guide
50 Upper Waycover Guide
51 Lower Waycover Guide

300 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

SL-10 External Sheetmetal

32
29 30
31
33
28 1

3
o
View Rotated 180
27
4

6
7
26
8

9
10

25 11
24 12
13

23

21 20

17 14
15
16
18

22
19

96-8710 rev C 301

 ASSEMBLY DRAWINGS June 2001

SL-10 External Sheetmetal Parts List

1 25-0875 Monitor cover
2 25-0876 Pendant back cover
3 25-0879 Z-axis Right bottom wiper retainer
4 26-0030 Z-axis Right bottom wiper felt
5 59-0009 R-type hinge half
6 25-0868A Panel right side weldment
7 25-1002 Tail stock pan
8 25-0890 Tray No Tailstock
9 25-1023 Motor pump coolant tray
10 25-0889 Coolant PM tray
11 25-0548 Discharge chute weldment
12 25-0887 Auger pan weldment
13 25-6551 Auger mount
14 25-0888 Chip tray extension
15 25-0877 Chip tray
16 N/A
17 25-0858 Door weldment (25-0016 window)
18 25-0860 Door inner liner
19 25-0862 Front skirt
20 25-0865 Lower door rail
21 22-6506 V-track
22 20-6016 V-track spacer
23 25-0864 Left panel
24 25-0398 Tramp lube oil bottle panel
25 25-6185 Coolant collector
26 25-0606 Coolant collector door
27 26-0869 Upper door rail
28 25-0025D Main electrical control box
29 25-8709 J-box
30 32-0042 Regen
31 25-0857 Control box bracket
32 25-0867 Rear panel
33 25-0863 Hydraulic pump mount weldment

302 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

SL-10 Internal Sheetmetal

19 20 21

14
18

17

15

16
13 1

2
12
3

4
11

6
5

10

96-8710 rev C 303

 ASSEMBLY DRAWINGS June 2001

SL-10 Internal Sheetmetal Parts List

1 25-0870 X-axis top cover

2 25-0871 X-axis front cover
3 25-0983 X-axis wiper retainer
4 26-0038 X-axis waycover felt
5 25-0872 X-axis waycover
6 26-0034 X-axis top wiper felt
7 25-0866 Moving bulkhead
8 26-0035 X-axis side wiper felt
9 25-0873 Z-axis sliding cover
10 25-7195 Lube rack bracket
11 25-0885 Belt cover
12 25-0886 Fan mount
13 36-3035 Spindle motor fan
14 25-0861 Fixed bulkhead
15 25-0880 Z-axis left, bottom wiper retainer
16 26-0032 Z-axis Left, bottom wiper felt
17 25-0881 Z-axis left, top wiper retainer
18 26-0033 Z-axis left, top wiper felt
19 25-0859 Door drain
20 26-0039 Door wiper
21 25-0947 Top wiper retainer

304 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

TL-15 Live Tooling and Sub-Spindle Sheet Metal

1 2
3

8
4

5
7 6

Live Tooling

9
10 11

12

14

21 13

20

19 16 15

17
18
Sub-Spindle

96-8710 rev C 305

 ASSEMBLY DRAWINGS June 2001

TL-15 Sheetmetal Parts List

Live Tooling
1 25-0138 Hood
2 20-0163 Brace
3 25-0137 Tray
4 25-0135 Channel Cover
25-6552 Channel Cover (Larger Turret)
5 25-0136 Channel
25-6553 Channel (Larger Turret)
6 20-0161 Belt Arm Cover
7 20-0162 Belt Arm

Sub-Spindle
8 25-0617 Moving Bulkhead
9 25-0610 Motor Cover
10 25-0611 Encoder Cover
11 25-0619 Front Union Shroud
12 25-0618 Rear Union Shroud
13 Bottom Union Shroud
14 25-0621 Little Bracket
15 25-0615 Encoder Bracket
16 20-0631 Upper Motor Arm
17 20-0632 Lower Motor Arm
18 25-0613A Duct Shield
19 Shipping Bracket
20 Heat Shield ?
21 25-0614A Fan Shield

306 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

Barfeeder Sheetmetal and Parts List

00
R3
O BA
RV
SE

4
3

00
R3
BA
VO
5 SE
R

1
7
8

11

1 25-6516A Baseposition control

2 25-6537B Door, bar feeder
3 59-0101 Gas spring 8
4 25-6534A Main enclosure bar feeder
5 25-0165 Right rear support 9
6 25-6542 Storage pan
7 25-6526 Control tray 10
8 25-6538 Adjusting end supports
9 25-6539 Base, bottom bar
10 Leveling screw
11 25-6540 Charging table beam

96-8710 rev C 307

 ASSEMBLY DRAWINGS June 2001

Barfeeder External Parts

13
12

11 14
6 10
5 8
4 7 6
3
2 9
1

17 16
18
19
20
22
21

23

26
25 27
26
28

29
30
24
31

46 32
45

33
39 34
38 33
37 47
35
36
40
41
42
44

43 40

308 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

Barfeeder External Parts List

1 Retaining bolt
2 20-6478 Ballscrew bearing
3 20-6480 Rotation control push rod
4 59-3024 1.5 x 6 spring
5 20-6481 J-slot control bushing
6 48-1657 Dowelpin 5/16 x 1 1/2
7 49-1015 Shoulder bolt 1/4 x 1/2
8 20-6483 Push rod connector
9 Retaining bolt
10 20-6484 Push rod
11 20-0357 Flange bushing 3/4 in
12 Bolt
13 20-6032 Push control bushing 3/4
14 20-6485 Control arm positioner
15 Removed
16 59-3026 Spring 1 1/8 x 8.5 x .148
17 20-0356 Flange bushing 1in.
18 20-6023 Rotational control shaft
19 56-0007 Retaining ring 1 9/16
20 51-1016 1 inch linear bearing
21 20-6482 Pusher control arm
22 32-5236A Servo motor
23 30-1220P coupling assembly
24 25-6520 Bar pusher finger
25 22-6501 Carriage, base bar
26 Washer
27 25-6521 Latch pusher bar
28 Bolt
29 Spacer
30 59-6701 5/16 ball joint w/stud
31 25-6522 Fork activator bar
32 25-6502 Latch linkage rod bar
33 54-0054 5/16 flange bushing
34 59-3027 1/2 x 10 spring
35 Nut
36 58-1750 5/16-24 coupling nut
37 Nut
38 Spacer
39 54-0030 Guide wheel
40 30-0153 Support bearing assembly
41 24-0007 Ballscrew assembly
42 24-0007 Ballscrew assembly
43 Clamp bolt fro 51-2012 (44)
44 51-2012 Bearing locknut TCN-04-F
45 25-6525 Rail mounting plate
46 22-6505 V-rail bar feeder
47 20-6478 Ballscrew bearing

96-8710 rev C 309

 ASSEMBLY DRAWINGS June 2001

Barfeeder Internal Parts

17
19
11
18
10
9
8
7 12
13 29
6 14 16
15 28

o
View Rotated 180

20
1 21
5 22
2
27
4 30
26
3 31
25 39
24 33
23
38
37

36
33
32 40
35
41
33

42 57
43 58
44
34 45

46 48
47

55
56
48
53 54 59

49 60
50 61
51
52 66
64
62
65
63
View Rotated 180 o

310 96-8710 rev C

 June 2001 ASSEMBLY DRAWINGS

Barfeeder Internal Parts List

1 49-1203 1/8 x 1 cotter pin 52 59-0102 Clamp handle 3/4-10
2 49-1201 Clevis pin 3/4 x 3 53 45-0004 Washer 3/4 flat
3 22-66503 Support stand 54 20-6026A Height adjusting
4 25-6541 Charging table 55 59-0110 Spring 6 x 27/32 x .106
5 49-1202 1 x 6 clevis pin 56 51-1015 3/4 flange bearing
6 49-1203 1/8 x coter pin 57 54-0057 3/4 shaft coller
7 46-0011 Nut 1/4 cap push 58 Snap ring
8 20-0341 Transfer table 59 Washer
9 22-9256 Bushing extractor 60 Shoulder bolt
10 58-1982 Tubing urethane 3/8 OD x 1/4 ID 61 Plastic washer
11 32-2036 Limit switch, end of bar 62 25-6549A Height adjusting box
12 49-1019 Shoulder bolt 1/4 x 1 63 59-7200 Grommet material .125
13 Washer 64 20-6490A Box cross rollers
14 25-6528 Bar end mounting 65 25-0338 Bracket home switch
15 25-6529 Bar end switch paddle 66 32-2039 Limit switch trolley home
16 25-6527A bar transfer table 67 25-6523B Main frame
17 25-6546 Height indicator support bracket 68 32-2038 Limit switch load Q
18 25-6547 Height indicator flag 69 Removed
19 29-0051 Decal, height gauge 70 25-6531 Motion control
20 NUt 71 32-2037 Limit switch load bar
21 Washer 72 22-6025 1" acme adjusting screw
22 54-0010 Cam follower 73 49-1020 Nut 1-5 acme wing
23 Bolt
24 Key
25 20-6487 Shaft lifting arm
26 Washer
27 51-1017 Bearing
28 25-6530 Motion control lift arm
29 25-6532 Motion control torque box
30 25-6530 Motion contro lift arm
31 51-1017 Bearing
32 22-7477 Pressure plate
33 32-0011 Motor assembly shuttle
34 Key
35 20-0216 Nut slip clutch
36 55-0010 Spring washer
37 22-7477 Pressure plate
38 Plastic washer
39 Clamp bolt for 20-6486 (40)
40 20-6486 Motor end clutch linkage
41 Set screw
42 Dowel pin
43 20-0215 Hub slip clutch
44 Clamp bolt for 20-6533 (45)
45 20-6533 Cam end lift linkage
46 51-1015 3/4 flange bearing
47 Key
48 20-6488 Cam shaft assembly bar
49 Bolt
50 54-0010 Cam follower with 22-7034 Spacer, cam follower
51 46-0010 Nut 3/4-10 cap

96-8710 rev C 311