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June 6, 2013
Haas Technical Publications

HAAS SERVICE AND OPERATOR MANUAL ARCHIVE

Lathe Service Manual 96-8710 RevL English June 2005

• 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.
Back
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 Changer Forward
ATC REV Automatic Tool Changer Reverse
AWG American Wire Gauge
BHCS Button Head Cap Screw
BT British Tooling (Common usage)
CAD Computer Assisted Design
CAM Computer Assisted Manufacturing (Assisted Machining)
CAT-5 Category 5 Cable
CB Circuit Breaker
CC Cubic Centimeter
CCW Counter Clock Wise
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
CT Caterpillar Tooling
CTS Clear To Send
CW Clock Wise
DB Draw Bar
DC Direct Current
DGNOS Diagnostic
DHCP Dynamic Host Configuration Protocol
DIR Directory
DNC Direct Numerical Control
DOS Disk Operating System
DTE Data Terminal Equipment
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

96-8710 rev L June 2005 Troubleshooting 1

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
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 Printed Circuit Board
PGM Program
POR Power On Reset
POSIT Positions
PROG Program
PSI Pounds per Square Inch
PST Pallet Schedule Table
PWM Pulse Width Modulation
RAM Random Access Memory
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
RTS Request To Send
RXD Receive Data
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 Thru the Spindle Coolant
TXD Transmit Data
VDI Verein Deutscher Ingenieure
VMC Vertical Machining Center
WAN Wide Area Network

96-8710 rev L June 2005 Troubleshooting 2

 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.

96-8710 rev L June 2005 Troubleshooting 3

1.1 G ENERAL M ACHINE O PERATION

MACHINE 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").

96-8710 rev L June 2005 Troubleshooting 4

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.

96-8710 rev L June 2005 Troubleshooting 5

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 ballscrews (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 ballscrew (see “Thermal Growth” section).

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 ballscrew (see “Thermal Growth” section).

96-8710 rev L June 2005 Troubleshooting 6

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 ballscrews (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

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

96-8710 rev L June 2005 Troubleshooting 7

 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

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.

96-8710 rev L June 2005 Troubleshooting 8

THERMAL GROWTH
A possible source of accuracy and positioning errors is thermal growth of the ballscrews. As the machine
warms up, the ballscrews 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 ballscrew 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.

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 ballscrews to warm up to the correct temperature and stabilize.
Once the machine is at temperature, the ballscrews 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.

96-8710 rev L June 2005 Troubleshooting 9

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.

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.

96-8710 rev L June 2005 Troubleshooting 10

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 lathes
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.
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

96-8710 rev L June 2005 Troubleshooting 11

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.

96-8710 rev L June 2005 Troubleshooting 12

1.4 S ERVO M OTORS / B ALLSCREWS

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 ball screw. Replace or repair
the coupling ("Axis Motor Removal/Installation")
• Check for a damaged ball screw, and replace if necessary ("Ball Screw Removal and Installation"
section).

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

NOISE
Ball 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 ball screws or bearing sleeves without due consideration; they
are extremely durable and reliable. Verify that customer complaints are not due
to tooling, programming, or fixturing problems.

Servo motor noise.

•Disconnect the servo motor from the ball 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.

96-8710 rev L June 2005 Troubleshooting 13

Ball screw noise.
• Ensure oil is getting to the ball 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 ball screw. Loosen the clamp nuts at both ends of
the ball screw. If the symptom disappears, replace the bearing sleeve. Be certain to check for
damage to the ball screw shaft where the bearing sleeve is mounted. If the noise persists, the ball
screw is damaged and must be replaced. When replacing the ball screw in an older machine,
always replace the bearing sleeve with the current angular contact design bearing sleeve.
• Misalignment in the ball screw itself will tend to cause the ball 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 ball screw ball nut mounts is indicated by heating up of the ball nut on the ball
screw, and noise and tightness throughout the travel of the ball screw. Misalignment at the yoke
where the ball nut mounts is indicated by noise and tightness at both ends of the travel of the ball
screw. The ball nut may get hot.

NOTE: Customer complaints of Ball 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 ball screw is in
place and the coupling is tight (Brush motors only).
• Check parameters for that axis.
• Check for backlash in the ball screw as outlined below.

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 the following figure.

96-8710 rev L June 2005 Troubleshooting 14

 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 the figure above 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.

96-8710 rev L June 2005 Troubleshooting 15

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.

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 the above figure 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.

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.

96-8710 rev L June 2005 Troubleshooting 16

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 ball screw for binding ("Accuracy/
Backlash" section). If the motor is binding by itself, replace in accordance with "Axis Motor Removal/
Installation".

S ERVO 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 ball screw.

B ALL S CREWS - V ISUAL I NSPECTION

The three main causes of Ball 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 Ball Screw itself.
Loss of Lubrication:
The lubrication system of the machine provides a layer of oil for the Ball 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 move-
ment of the Ball 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.
Ball 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 Ball Screws is material fatigue. Material fatigue typically occurs at
the end of the Ball Screw service life. Signs of material fatigue include black, contaminated
coolant, pitting of the screw surface, loss of preload, and metal flakes on the Ball Screw.
Ball 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 Ball
Screws.
Check the condition of the lube on the Ball Screw threads.

96-8710 rev L June 2005 Troubleshooting 17

 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 Ball Screws for wear.
Contamination of the lube and/or coolant systems can be caused by a wearing Ball 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 Ball 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.

CLEANING
In most cases, a thorough cleaning of the suspect Ball 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 Ball 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.

96-8710 rev L June 2005 Troubleshooting 18

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.
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.

96-8710 rev L June 2005 Troubleshooting 19

 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.

96-8710 rev L June 2005 Troubleshooting 20

1.6 H YDRAULIC S YSTEM

H YDRAULIC PRESSURE
“Low hydraulic pressure” alarm (134).
• 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 T AILSTOCK
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.

96-8710 rev L June 2005 Troubleshooting 21

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.

E LECTRICAL 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.

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.

96-8710 rev L June 2005 Troubleshooting 22

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.
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.

96-8710 rev L June 2005 Troubleshooting 23

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.

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.

96-8710 rev L June 2005 Troubleshooting 24

CRT T EST PATTERN
This is current commands page displays a grid of 6 x 9 blocks which allows technicians to align the display on
the CRT and make sure the display is centered and ‘square’. The page is accessed by entering DEBUG mode
from the alarms screen, pressing CURNT COMDS, and then pressing PAGE UP.

S AVING THE MACHINE INFORMATION

To review a machine’s set-up save the parameters, settings, offsets, variables and G-code programs and alarm
history to a floppy disk. To do this, insert a blank diskette, press LISTPROG, POSIT, enter the machine's serial
number and press F2. The new file suffix will be “.HIS”.

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.

96-8710 rev L June 2005 Troubleshooting 25

 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.

101 COMM. FAILURE WITH MOCON/MOCON MEMORY FAULT During a self-test of communications between the
MOCON and main processor the main processor does not respond, and one of them is possibly bad. Check cable
connections and boards. This alarm could also be caused by a memory fault which was detected on the MOCON.
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 fault, or power failure.
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 Parameter 9. 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 Too much load or speed on Live Tooling motor. The difference between the motor
position and the commanded position has exceeded Parameter 23. 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.
105 Z SERVO ERROR TOO LARGE Too much load or speed on Z-axis motor. The difference between the motor
position and the commanded position has exceeded Parameter 37. 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.
106 A SERVO ERROR TOO LARGE Too much load or speed on A-axis motor. The difference between the motor
position and the commanded position has exceeded Parameter 51. 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.
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 Servo Off alarm. This alarm will also be generated if there is a low pressure condition in the hydraulic
counterbalance system. In this case, the alarm will not reset until the condition has been corrected.
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 Excessive load on Live Tooling 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.

26 Alarms 96-8710 rev L June 2005

110 Z SERVO OVERLOAD Excessive load on Z-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.
111 A SERVO OVERLOAD Excessive load on A-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.
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, relays 1-8, 2-3, and 2-4.
116 SPINDLE ORIENTATION FAULT Spindle did not orient correctly. During a spindle orientation function, the spindle
rotated but never achieved proper orientation. This can be caused by failure of encoder, cables, belts, MOCON or
vector drive.
117 SPINDLE HIGH GEAR FAULT Gearbox did not shift into high gear. During a change to high gear, the spindle is
rotated slowly while air pressure is used to move the gears but the high gear sensor was not detected in time.
Parameters 67, 70 and 75 can adjust the time-out times. Check the air pressure, the solenoids circuit breaker CB4,
and the spindle drive.
118 SPINDLE LOW GEAR FAULT Gearbox did not shift into low gear. During a change to low gear, the spindle is
rotated slowly while air pressure is used to move the gears but the low gear sensor was not detected in time.
Parameters 67, 70 and 75 can adjust the time-out times. Check the air pressure, the solenoid’s circuit breaker CB4,
and the spindle drive.
119 OVERVOLTAGE Incoming line voltage is above maximum. The servos will be turned off and the spindle, 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 defined by Parameter 76. The LOW AIR PR
alarm will appear on the screen as soon as the pressure gets low, and this alarm appears after some time has
elapsed. Check your incoming air pressure for at least 100 PSI and ensure that the regulator is set at 85 PSI.
121 LOW LUBE 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 servos,
spindle drive, coolant pump, and tool changer. One common cause of this overheat condition is an input line voltage
too high. If this condition 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 spindle.
123 SPINDLE DRIVE FAULT Failure of spindle drive, motor or regen load. This can be caused by a shorted motor,
overvoltage, overcurrent, undervoltage, failure of drive or shorted or open regen load. Undervoltage and overvoltage of
DC bus are also reported as alarms 160 and 119, respectively.
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.

96-8710 rev L June 2005 Alarms 27

 126 GEAR FAULT Gearshifter 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 when the door was commanded to
close, or a high signal at the Door Switch when the door was commanded to open after the time allowed by param-
eter 251.
129 M FIN FAULT M-Fin was active at power on. Check the wiring to your M code interfaces. This test is only per-
formed at power-on.
130 CHUCK UNCLAMPED The control detected that the chuck is unclamped. The spindle RPM may be too high to
allow the chuck to unclamp or the spindle was command on while the chuck was unclamped and the door was open.
There may also be a possible fault in the air solenoids, relays on the I/O Assembly, or wiring.
132 POWER DOWN FAILURE Machine did not turn off when an automatic power-down was commanded. Check
wiring to Power Interface (POWIF) card on power supply assembly, relays on the I/O 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 PRESSURE Hydraulic pressure is sensed to be low. Check pump pressure and hydraulic tank
oil level. Verify proper pump and machine phasing. Also, check 3-phase power phasing.
135 X-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150
degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the
stops for several minutes.
136 Y-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150
degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the
stops for several minutes.
137 Z-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150
degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the
stops for several minutes.
138 A-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150
degrees F (65 deg.C). This can be caused by an extended overload of the motor such as leaving the slide at the
stops for several minutes.
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 encoder connectors.
140 Y 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 encoder connectors.
141 Z 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 encoder connectors.
142 A MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been
damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.
143 SPINDLE ORIENTATION LOST Spindle orientation lost during a fine spindle control motion. This can be caused
by failure of encoder, cables, belts, MOCON or vector drive. This can also be caused by failure to orient spindle prior
to G05 Fine Spindle Control Motion. Be sure to run M19 before G05.
144 TIMEOUT - CALL YOUR DEALER Time allocated for use prior to payment exceeded. Call your dealer.
145 X LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides
before they hit the limit switches. Verify the value of parameter 125 Grid Offset and check the wiring to the limit switch
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 Live Tooling hit limit switch or switch disconnected. The stored stroke limits should stop the
slides before they hit the limit switches. Verify the value of parameter 126 Grid Offset and check the wiring to the limit
switch 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.

28 Alarms 96-8710 rev L June 2005

147 Z LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides
before they hit the limit switches. Verify the value of parameter 127 Grid Offset and check the wiring to the limit switch
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.
148 A LIMIT SWITCH Normally disabled for rotary axis.
149 SPINDLE TURNING A signal from spindle drive indicating that the spindle drive is stopped is not present when an
M85 was commanded. Command the spindle to stop or to an RPM less than or equal to parameter 586 before
commanding an M85.
150 I_MODE OUT OF RANGE Cycle power on the machine. If the alarm reoccurs, call your dealer and report the
sequence of events that lead to the alarm.
151 HPC LOW PRESSURE A low coolant pressure condition has been detected. To disable this alarm, set parameter
209 Common Switch 2 DSBL CLNT IN to 1.
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 Z Reference signal from encoder was not received as expected. All servos are turned off.
Can be caused by loose connections, encoder contamination, or parameter error.
154 Y AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. All servos are turned off.
Can be caused by loose connections, encoder contamination, or parameter error.
155 Z AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. All servos are turned off.
Can be caused by loose connections, encoder contamination, or parameter error.
156 A AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. Can be caused by loose
connections, encoder contamination, or parameter error.
157 MOCON WATCHDOG FAULT The self-test of the MOCON has failed. Call your dealer.
158 VIDEO/KEYBOARD PCB FAILURE During power-on tests, the control has detected a problem in either the key-
board or the video memory. 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 the
voltage specified by Parameter 294.
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. Running the axis into a mechanical stop can cause this. A short in the motor or a short of
one motor lead to ground can also cause it.
162 Y AXIS DRIVE FAULT Current in Live Tooling servo motor beyond limit. Possibly caused by a stalled or overloaded
motor. The servos are turned off. Running the axis into a mechanical stop can cause this. A short in the motor or a
short of one motor lead to ground can also cause it.
163 Z AXIS DRIVE FAULT Current in Z servo motor beyond limit. Possibly caused by a stalled or overloaded motor.
The servos are turned off. Running the axis into a mechanical stop can cause this. A short in the motor or a short of
one motor lead to ground can also cause it.
164 A AXIS DRIVE FAULT Current in A servo motor beyond limit. Possibly caused by a stalled or overloaded motor.
The servos are turned off. Running the axis into a mechanical stop can cause this. A short in the motor or a short of
one motor lead to ground can also cause it.
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 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.

96-8710 rev L June 2005 Alarms 29

 167 Z 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.
168 A 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.
169 SPINDLE DIRECTION FAULT Problem with rigid tapping hardware. The spindle started turning in the wrong
direction.
171 RPM TOO HIGH TO UNCLAMP The spindle speed exceeded the max speed allow in parameter 248 to unclamp.
Reduce the speed of the spindle to a value less than or equal to parameter 248.
172 DOOR IS OPEN AND SPINDLE IS TURNING The chuck is not allowed to unclamp while the door is open and the
spindle is on.
173 SPINDLE ENCODER Z CH MISSING The Z channel pulse from the spindle encoder is missing for rigid tapping
synchronization.
174 TOOL LOAD EXCEEDED The tool load limit is set and the load limit for a tool was exceeded in a feed. It is not
recommended to use tool load monitoring while in G96 Constant Surface Speed Mode. It is not possible for the
system to distinguish the load due to spindle acceleration from the load on the tool. Tool overload conditions may be
generated during X-axis feeds due to spindle acceleration while in G96 constant surface speed mode.
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.
177 OVERVOLTAGE SHUTDOWN An overvoltage condition persisted longer than the interval specified by parameter
296 and caused an automatic shutdown.
178 DIVIDE BY ZERO! There are some parameters that are used as a divisor and therefore must never be set to zero.
If the problem cannot be corrected by parameters, cycle power on the machine. If the alarm reoccurs, call your dealer
and report the sequence of events that lead to the alarm.
179 LOW PRESSURE TRANS OIL Transmission oil is low or low pressure condition in oil lines.
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 LIVE TOOLING CABLE FAULT Cable from Live Tooling motor encoder does not have valid differential signals.
184 Z CABLE FAULT Cable from Z-axis encoder does not have valid differential signals.
185 A CABLE FAULT Cable from A-axis encoder does not have valid differential signals.
186 SPINDLE NOT TURNING Status from spindle drive indicates it is not at speed when expected. Commanding a
feed when the spindle is stopped can cause this.
187 B SERVO ERROR TOO LARGE Too much load or speed on B-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.
188 B SERVO OVERLOAD Excessive load on B-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.
189 B-AXIS MOTOR OVERHEAT 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.

30 Alarms 96-8710 rev L June 2005

190 B 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 encoder connectors.
191 B LIMIT SWITCH Normally disabled for rotary axis.
192 B AXIS Z CH MISSING Z reference signal from encoder was not received as expected. Can be caused by loose
connections, encoder contamination, or parameter error.
193 B AXIS DRIVE FAULT Current in B servo motor beyond limit. Possibly caused by a stalled or overloaded motor.
The servos are turned off. Running the axis into a mechanical stop can cause this. A short in the motor or a short of
one motor lead to ground can also cause it.
194 B 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.
195 B CABLE FAULT Cable from B-axis encoder does not have valid differential signals.
197 MISC. SOFTWARE ERROR This alarm indicates an error in the control software. Call your dealer and report this
problem.
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 Cycle power on the machine. If the alarm reoccurs, call your dealer and report the sequence of
events that lead to the alarm.
201 PARAMETER CRC ERRO R 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 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 PROG 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 Cycle power on the machine. If the alarm reoccurs, call your dealer and report the
sequence of events that lead to the alarm.
208 QUEUE ALLOCATION ERROR Cycle power on the machine. If the alarm reoccurs, call your dealer and report the
sequence of events that lead to the alarm.
209 QUEUE CUTTER COMP ERROR Cycle power on the machine. If the alarm reoccurs, call your dealer and report the
sequence of events that lead to the alarm.
210 INSUFFICIENT MEMORY Not enough memory to store users program. Check the space available in the LIST
PROG mode and possibly delete some programs.
211 ODD PROG BLOCK Possible corrupted program. Save all programs to disk, delete all, then reload.
212 PROG 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; possibly with main processor. 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. Possible processor board problem. 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. Possible processor board problem. Call your dealer.
216 PROBE ARM DOWN WHILE RUNNING Indicates that the probe arm was pulled down while a program was
running.
217 X PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad
encoder, or a cabling error.
218 Y 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 L June 2005 Alarms 31

 219 Z PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad
encoder, or a cabling error.
220 A PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad
encoder, or a cabling error.
221 B PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad
encoder, or a cabling error.
222 C PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad
encoder, or a cabling error.
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 encoder 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 or MOTIF printed circuit board.
225 Y TRANSITION FAULT Illegal transition of encoder count pulses in Live Tooling. This alarm usually indicates that
the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose connec-
tors at the MOCON or MOTIF printed circuit board.
226 Z TRANSITION FAULT Illegal transition of encoder count pulses in Z 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 or MOTIF printed circuit board.
227 A TRANSITION FAULT Illegal transition of encoder count pulses in A 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 or MOTIF printed circuit board.
228 B TRANSITION FAULT Illegal transition of count pulses in B 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 or MOTIF printed circuit board.
229 C TRANSITION FAULT Illegal transition of count pulses in C 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 or MOTIF printed circuit board.
230 DOOR OPEN The spindle RPM has exceeded the max value in parameter 586 while the door is open. Stop the
spindle, close the door, or lower your spindle rpm to a value less than or equal to the value of parameter 586.
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 CABLE FAULT Cable from spindle encoder does not have valid differential signals.
235 SPINDLE Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder mounted on
the spindle has been damaged and encoder position data is unreliable. Loose encoder connectors at P1-P4 can
also cause this.
236 SPINDLE MOTOR OVERLOAD The spindle motor becomes overloaded.
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).
239 UNKNOWN MOCON1 ALARM Mocon has reported an alarm to the current software. The current version of
software was unable to identify the alarm. See mocon software release notes for additional diagnostics.
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 NUMBER FORMAT ERROR-OR TOO LONG Check input file for an improperly formatted number. Number may
have too many digits or multiple decimal points. The erroneous data will be placed on the MESSAGES page as a
comment with trailing question mark.

32 Alarms 96-8710 rev L June 2005

243 BAD NUMBER Data entered is not a number.
244 MISSING (...) Comment must end with a ‘)’. This alarm can also occur if a comment is greater than 80 characters
long.
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. See MESSAGE PAGE for input line.
246 STRING TOO LONG Input line is too long. The data entry line must be shortened.
247 CURSOR DATA BASE ERROR Cycle power on the machine. If the alarm reoccurs, call your dealer and report the
sequence of events that lead to the alarm.
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 PROG DATA ERROR Possible corrupted program. Save all programs to disk, delete all, then reload.
251 PROG DATA STRUCT ERROR Possible corrupted program. Save all programs to disk, delete all, then reload.
252 MEMORY OVERFLOW Possible corrupted program. Save all programs to disk, delete all, then reload.
253 ELECTRONICS OVERHEAT The control box temperature has exceeded 140 degrees F (60 deg. C). 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
equipped with a Haas vector drive. The spindle motor temperature sensor sensed a high temperature for greater
than 1.5 seconds.
257 PROG DATA ERROR Possible corrupted program. Save all programs to disk, delete all, then reload. Possible
processor board problem.
258 INVALID DPRNT FORMAT Macro DPRNT statement not structured properly.
259 LANGUAGE VERSION Problem with language files. Please reload foreign language files.
260 LANGUAGE CRC Indicates FLASH memory has been corrupted or damaged. Please reload foreign language
files.
261 ROTARY CRC ERROR Rotary table saved parameters (used by Settings 30, 78) have a CRC error. Indicates a
loss of memory - possible processor board problem.
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 variable file has a CRC error. Indicates a loss of memory. Possible
processor board problem.
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 Too much load or speed on C-axis motor. The difference between the motor
position and the commanded position has exceeded Parameter 506. 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.
271 C SERVO OVERLOAD Excessive load on C-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 alarm can be caused by anything that causes a very high load on the motors.
272 C-AXIS MOTOR OVERHEAT 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.
273 C 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 encoder connectors.
274 C LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides
before they hit the limit switches. Verify the value of parameter Grid Offset and check the wiring to the limit switch 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.

96-8710 rev L June 2005 Alarms 33

 275 C AXIS Z CH MISSING Z reference signal from encoder was not received as expected. Can be caused by loose
connections, encoder contamination, or parameter error.
276 C AXIS DRIVE FAULT Current in C servo motor beyond limit. Possibly caused by a stalled or overloaded motor.
The servos are turned off. This can be caused by running the axis into a mechanical stop. It can also be caused by a
short in the motor or a short of one of the motor leads to ground.
277 C 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.
278 C CABLE FAULT Cable from C-axis encoder does not have valid differential signals.
292 320 VOLT POWER SUPPLY FAULT Power to the servos will be turned off when this alarm occurs. Note that error
code 5 on the mini power supply may occur under this condition.
293 INVALID CHAMFER OR CORNER ROUNDING DISTANCE IN G01 Check your geometry.
294 NO END MOVE FOR G01 CHAMFER CORNER ROUNDING A chamfer or corner rounding move was requested in a
G01 command, but no end move was commanded.
295 MOVE ANGLE TOO SMALL IN G01 CORNER ROUNDING Tangent of half angle is zero. Move Angle must be
greater than 1 degree.
296 INVALID PLANE SELECTION IN G01 CHAMFER OR CORNER ROUNDING Chamfer or corner rounding move and
end move must be in the same plane as the beginning move.
301 NORMAL STOP A program stop was encountered.
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 a valid number.
306 INVALID I,J,K, OR Q IN CANNED CYCL 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 FEEDRATE Use a lower feed rate.
310 INVALID G CODE G code not defined and is not a macro call.
311 UNKNOWN CODE Program contained a line or code that is not understood.
312 PROGRAM END End of subroutine reached before M99. Need an M99 to return from subroutine.
313 NO P CODE IN M96, M97, M98, M143, M144, or G65 In M96,M97,M98 or G65 must put subprogram number in P
code. In M143 or M144 must put subspindle speed in P code.
314 SUBPROGRAM 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 An invalid P Code has been detected in M97, M98, M99, M133, M134 or
canned cycle G71, G72, G73 or G70. 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 all other uses.
316 X OVER TRAVEL RANGE Commanded X-axis move would exceed the allowed machine range. Machine coordi-
nates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets.
317 Y OVER TRAVEL RANGE Commanded Live Tooling move would exceed the allowed machine range. Machine
coordinates are in the negative direction. This condition indicates either an error in the user’s program or improper
offsets.
318 Z OVER TRAVEL RANGE Commanded Z-axis move would exceed the allowed machine range. Machine coordi-
nates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets.
319 A OVER TRAVEL RANGE Commanded A-axis move would exceed the allowed machine range. Machine coordi-
nates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets.

34 Alarms 96-8710 rev L June 2005

320 NO FEED RATE 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).
This alarm can also be generated by entering an invalid M95 time format.
325 QUEUE FULL Cycle power on the machine. If the alarm reoccurs, call your dealer and report the sequence of
events that lead to the alarm.
326 G04 WITHOUT P CODE Put a Pn.n for seconds or a Pn for milliseconds.
327 NO LOOP FOR M CODE EXCEPT M97, 98 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 out of range, or too large.
333 X AXIS DISABLED Parameter has disabled this axis.
334 Y AXIS DISABLED Parameter has disabled Live Tooling.
335 Z AXIS DISABLED Parameter has disabled this axis.
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, only one G codes in the same group. This
alarm can also be caused by specifying more then one I, K or R in the same block with chamfer or corner rounding,
or by specifying both P and R in M19.
340 CUTTER COMP BEGIN WITH G02 OR G03 Select cutter compensation earlier. Cutter compensation 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 Cycle power on the machine. If the alarm reoccurs, call your dealer and report
the sequence of events that lead to the alarm.
344 CUTTER COMP WITH G17 & G19 Cutter comp only allowed in XZ plane (G18).
345 INVALID R VALUE IN M19 OR G105 R value must be positive.
346 M CODE DISABLED There was an M85 or M86 commanded. These commands are not allowed while Setting 51
DOOR HOLD OVERRIDE is OFF, the SAFETY CIRCUIT ENABLED, or the Parameter 251 is set zero. Also check
Setting 131 for AUTODOOR and Parameter 57 for DOOR STOP SP
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 WITHOUT CANCELING CUTTER COMP An X/Y cutter compensation exit move is required before a
program stop. Damage to part may occur.
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 C, U, V, or W axis indicate servo off. Check auxiliary axes. Status from control was
OFF.

96-8710 rev L June 2005 Alarms 35

 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 axis not responding. Check auxiliary axes and RS-232 connections.
355 AUX AXIS POSITION MISMATCH Mismatch between machine and aux axis 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.
360 TOOL CHANGER DISABLED Check Parameter 57. Not a normal condition for Lathes.
361 GEAR CHANGER DISABLED Check Parameter 57. Not a normal condition for Lathes.
362 TOOL USAGE ALARM Tool life limit was reached. To continue, hi-light the Usage count in the Current Com-
mands Tool Life display and press ORIGIN. Then 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.
365 P DEFINITION ERROR P value not defined, or P value out of range. An M59 or M69 must have a P value between
the range of 1100 and 1155. If using G154 command, then P value must be between 1 and 99.
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.
370 TAILSTOCK EXCESSIVE DRIFT The tailstock position has changed even though it has not been commanded to
do so. Check for hydraulic leaks.
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 and G37 functions cannot be used with cutter compensation.
377 NO SKIP IN GRAPH/SIM Graphics mode cannot simulate skip function.
378 SKIP SIGNAL FOUND Skip signal check code was included but skip was found when it was not expected.
379 SKIP SIGNAL NOT FOUND Skip signal check code was included but skip was not found when it was expected.
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.
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 the
G10 outside of Cutter Compensation 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 An attempt was made to program the B-axis while it was disabled (DISABLED bit in Parameter
151 set to 1).

36 Alarms 96-8710 rev L June 2005

393 INVALID MOTION IN G84 OR G184 Rigid Tapping can only be in the Z minus direction. Make sure that the dis-
tance from the initial position to the commanded Z depth is in the minus direction.
394 B OVER TRAVEL RANGE Tailstock (B-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.
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 cannot 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?
400 SKIP SIGNAL DURING RESTART A skip signal G-code (G31, G35, G36, G37, G136) was found during program
restart.
401 INVALID TANGENT IN GROUP 1 CORNER ROUNDING Check your geometry.
402 POSSIBLE CORRUPTED FILE The parameters being loaded do not match the expected number of parameters.
This can be due to the loading of an older or newer parameter file than the system binary, or the file is corrupted.
403 TOO MANY PROGS Cannot have more than 500 programs in memory.
404 RS-232 NO PROG 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 Onnnn and must be at begin-
ning of a block.
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 com-
ment.
408 RS-232 NUMBER RANGE ERROR Check your program. The program will be stored but the bad data is turned into
a comment.
409 RS-232 INVALID N CODE Bad Parameter or Setting data. User was loading settings or parameters and some-
thing was wrong with the data.
410 RS-232 INVALID V CODE Bad Parameter or Setting data. User was loading settings or parameters and some-
thing was wrong with the data.
411 RS-232 EMPTY PROG 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
program was completely received. This is a decimal code 26.
413 RS-232 LOAD INSUFFICIENT MEMORY Program received does not 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. Computer sending data may not respond to X-OFF.
415 RS-232 OVERRUN Data sent too fast to CNC.
416 RS-232 PARITY ERROR Data received by CNC has bad parity. Check parity settings, number of data bits and
speed. Also check your cables.
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

96-8710 rev L June 2005 Alarms 37

 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 the 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
427 INTERRUPT OVERRUN The control detected an interrupt overrun condition. An interrupt occurred before the
previous interrupt was completed. Call your dealer.
428 SERVO BAR SWITCH FAILURE One of the switches controlling the Servobar failed.
429 DISK DIR INSUFFICIENT MEMORY CNC memory was almost full when an attempt was made to read the disk
directory.
430 FILE UNEXPECTED END OF INPUT Ending % sign not found. Check your program. An ASCII EOF code was found
in the input data before program receive was complete. This is a decimal code 26.
431 DISK NO PROG NAME 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 Onnnn and must be at the beginning of
a block.
433 DISK EMPTY PROG Check your program. Between % and % there was no program found.
434 DISK LOAD INSUFFICIENT MEMORY Program received does not fit. Check the space available in the LIST PROG
mode and possibly delete some programs.
435 DISK ABORT Could not read disk. Possible corrupted or unformatted disk. Try a known good disk. Also caused
by dirty drive heads. Use an appropriate cleaning kit.
436 DISK FILE NOT FOUND Could not find file. Possible corrupted or unformatted disk. Try a known good disk. Also
caused by dirty drive heads. Use an appropriate cleaning kit.
437 TAILSTOCK UNDERSHOOT The tailstock did not reach its intended destination point. Check the value of param-
eter 293. It may be set too low.
438 TAILSTOCK 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 TAILSTOCK 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 Servobar current commands
page.
441 SERVO BAR MAX BARS REACHED Job Complete. Reset Current # Bars Run on Servobar current commands
page.
442 SERVO BAR MAX LENGTH REACHED Job Complete. Reset Current Length Run on Servobar current commands
page.
443 SERVO BAR ALREADY NESTED An Illegal G105 Pnnn was found in cutoff subprogram.
445 SERVO BAR FAULT Servobar 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 Servobar 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.
450 BAR FEEDER FAULT This means that discrete input 1030 (BFSPLK) is high. See parameter 278 bit 20 CK BF
STATUS.
451 BAR FEEDER SPINDLE INTERLOCK This means that discrete input 1027 (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.

38 Alarms 96-8710 rev L June 2005

453 C AXIS ENGAGED A spindle command was given with the C axis drive engaged. The C axis motor must 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.
455 G112 BLOCK ENDS W/O CANCEL CUTTER COMP An X/Y cutter compensation exit move is required before a G113
is issued to cancel the G112 block.
456 PARAMETER CONFLICT There is a conflict between two or more of the AXIS MOCON CHANNEL parameters.
457 AUX AXIS IS ENABLED One or more auxiliary axes are enabled. For the macro variables 750 and 751 to work the
auxiliary axes must be disabled. Make sure Setting 38 is set to 0.
459 APL DOOR FAULT Door was not completely open while APL was inside CNC, or parameter 315 bit 5 was set to
zero.
460 APL ILLEGAL CODE Internal software error; call your dealer.
461 APL GRIPPER TIMEOUT The gripper failed to reach its target position within the allowed time.
462 U OVER TRAVEL RANGE Commanded u-axis move would exceed the allowed machine range. Machine coordi-
nates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets.
463 V OVER TRAVEL RANGE Commanded bar feeder move would exceed the allowed machine range. Machine
coordinates are in the negative direction. This condition indicates either an error in the user’s program or improper
offsets.
464 W OVER TRAVEL RANGE Commanded W-axis move would exceed the allowed machine range. Machine coordi-
nates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets.
468 U LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides
before they hit the limit switches. Verify the value of parameter 373 Grid Offset and check the wiring to the limit switch
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.
469 V LIMIT SWITCH Bar feeder hit limit switch or switch disconnected. The stored stroke limits should stop the
slides before they hit the limit switches. Verify the value of parameter 409 Grid Offset and check the wiring to the limit
switch 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.
470 W LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides
before they hit the limit switches. Verify the value of parameter 445 Grid Offset and check the wiring to the limit switch
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.
473 INVALID GEOMETRY The geometry specified by the G-code parameters is invalid. If using G76 or G92, either
reduce Setting 95 (Thread Chamfer Size) or increase the number of threads.
501 TOO MANY ASSIGNMENTS IN ONE BLOCK Only one assignment macro assignment (=) is allowed per block.
Divide block 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 BRACKETS 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. Cycle power on the machine. If the
alarm reoccurs, call your dealer and report the sequence of events that lead to the alarm.
506 OPERAND STACK ERROR The macro expression operand stack pointer is in error. Cycle power on the machine.
If the alarm reoccurs, call your dealer and report the sequence of events that lead to the alarm.
507 TOO FEW OPERANDS ON STACK An expression operand found too few operands on the expression stack. Cycle
power on the machine. If the alarm reoccurs, call your dealer and report the sequence of events that lead to the
alarm.
508 DIVISION BY ZERO A division in a macro expression attempted to divide by zero. Re-configure expression.

96-8710 rev L June 2005 Alarms 39

 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 VARIABLE REFERENCE 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 Alphabetic addresses N and O cannot be combined with macro
variables. Do not declare N#1, etc.
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 used with N or O. Do not declare O[#1],
etc.
518 ILLEGAL MACRO EXPRESSION REFERENCE A macro expression cannot be used with to N or O. Do not declare
O[#1], etc.
519 TERM EXPECTED In the evaluation of a macro expression an operand was expected but not found.
520 OPERATOR EXPECTED In the evaluation of a macro expression an operator was expected but not found.
521 ILLEGAL FUNCTIONAL PARAMETER An illegal value was passed to a function, such as SQRT[ or ASIN[.
522 ILLEGAL ASSIGNMENT VAR OR VALUE A variable was referenced for writing. The variable referenced is read only.
523 CONDITIONAL REQUIRED PRIOR TO THEN A “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 parameters.
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 number 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 an “END” in the same subrou-
tine. 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 communications failed.
538 MATCHING END NOT FOUND A WHILE-DO statement does not contain a matching “END” statement. Add the
proper “END” statement.

40 Alarms 96-8710 rev L June 2005

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.
542 OPERATION NOT AVAILABLE This operation is not compatible with FNC mode.
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. Examine 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 its X or Z direction. Increasing the arc radius will often correct this
problem.
605 INVALID TOOL NOSE ANGLE An invalid angle for the 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?
608 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 63. Use an appropriate value for Q.
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 program-
mer 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 COMPENSATION At least one command in the highlighted block cannot
be executed while cutter compensation is active. Block Delete characters (‘/’) and M codes such as M06, M46, M50
and M96 are not allowed. Your program must have a G40 and a cutter compensation exit move before these can be
commanded.
615 NO INTERSECTION TO OFFSETS IN CC While cutter comp was in effect, a geometry was encountered whose
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 cannot
be executed by another PQ canned cycle.
617 MISSING ADDRESS CODE A canned cycle using P & Q is already executing. A canned cycle cannot be executed by
another PQ canned cycle.

96-8710 rev L June 2005 Alarms 41

 618 INVALID ADDRESS VALUE An address code is being used incorrectly. For Value example, a negative value is
being used for an address code that should be positive. Refer to the documentation of the G code that causes the
alarm.
619 STROKE EXCEEDS START POSITION Stock removal stroke in canned cycle projects past start position. Change
start position.
620 C AXIS DISABLED Parameters have disabled this axis.
621 C OVER TRAVEL RANGE C-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.
622 C AXIS ENGAGEMENT FAILURE The C axis failed to engage or disengage in the time specified in parameter 572.
Either the gears are not meshing or the mechanical stop is not set properly. Check the engage and disengage
switches and the mechanical stop. Also, check the grid offset for the C axis. This alarm can also be caused by an
obstruction or by low air pressure to the actuating piston.
623 INVALID CODE IN G112 Only G0 to G3 and G17 are used in G112. G113 cancels G112. No incremental axes are
used in G112. G18 cancels G17. G41 and G42 tool nose compensations are permitted.
624 COMMAND NOT ALLOWED IN G14 MODE G87 and G88 are not supported in G14 mode.
629 EXCEEDED MAX FEED PER REV For G77, reduce diameter of part or change geometry. For G5, reduce X or Z
travel.
652 U 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.
653 V 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.
654 W 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.
655 MISMATCH AXIS WITH I, K CHAMFERING I, (K) was commanded as X axis (Z axis) in the block with chamfering.
656 INVALID I, K, OR R IN G01 The move distance in the block commanded with chamfering or corner rounding is
less than the chamfering or corner rounding amount.
657 NOT ONE AXIS MOVE WITH CHAMFERING Consecutive blocks commanded with chamfering or corner rounding,
for example: G01 Xb Kk G01 Zb Ii After each chamfering or corner rounding block, there must be a single move
perpendicular to the one with chamfering or corner rounding.
658 INVALID MOVE AFTER CHAMFERING The command after the block commanded with chamfering or corner
rounding is either missing or wrong. There must be a move perpendicular to that of the chamfering or corner round-
ing block.
659 NOT ONE AXIS MOVE WITH CHAMFERING Consecutive blocks commanded with chamfering or corner rounding,
for example: G01 Xb Kk G01 Zb Ii After each chamfering or corner rounding block, there must be a single move
perpendicular to the one with chamfering or corner rounding.
664 U AXIS DISABLED Parameter has disabled this axis.
665 V AXIS DISABLED Parameter has disabled bar feeder.
666 W AXIS DISABLED Parameter has disabled this axis.
701 U SERVO ERROR TOO LARGE MOCON2 Too much load or speed on U-axis motor. The difference between the
motor position and the commanded position has exceeded Parameter 362. The motor may also be stalled, discon-
nected, 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.
702 V SERVO ERROR TOO LARGE Too much load or speed on bar feeder motor. The difference between the motor
position and the commanded position has exceeded Parameter 398. 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.

42 Alarms 96-8710 rev L June 2005

703 W SERVO ERROR TOO LARGE MOCON2 Too much load or speed on W-axis motor. The difference between the
motor position and the commanded position has exceeded Parameter 434. The motor may also be stalled, discon-
nected, 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.
704 Sp SERVO ERROR TOO LARGE Too much load or speed on Sp-axis motor. The difference between the motor
position and the commanded position has exceeded Parameter 184. 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.
705 Tt SERVO ERROR TOO LARGE MOCON2 Too much load or speed on Tt-axis motor. The difference between the
motor position and the commanded position has exceeded Parameter 470. The motor may also be stalled, discon-
nected, 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.
706 Ss SERVO ERROR TOO LARGE MOCON2 Too much load or speed on Ss-axis motor. The difference between the
motor position and the commanded position has exceeded Parameter 542. The motor may also be stalled, discon-
nected, 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.
707 J SERVO ERROR TOO LARGE MOCON2 Too much load or speed on J-channel motor. The difference between the
motor position and the commanded position has exceeded a parameter. The motor may also be stalled, discon-
nected, 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.
708 S SERVO ERROR TOO LARGE MOCON2 Too much load or speed on S-channel motor. The difference between
the motor position and the commanded position has exceeded a parameter. The motor may also be stalled, discon-
nected, 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.
711 U SERVO OVERLOAD MOCON2 Excessive load on U-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.
712 V SERVO OVERLOAD Excessive load on bar feeder 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.
713 W SERVO OVERLOAD MOCON2 Excessive load on W-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.
714 Sp SERVO OVERLOAD Excessive load on Sp-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.
715 Tt SERVO OVERLOAD MOCON2 Excessive load on Tt-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 b!y 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.
716 Ss SERVO OVERLOAD MOCON2 Excessive load on Ss-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.
717 J SERVO OVERLOAD MOCON2 Excessive load on J-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.

96-8710 rev L June 2005 Alarms 43

 718 S SERVO OVERLOAD MOCON2 Excessive load on S-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.
721 U-AXIS MOTOR OVERHEAT MOCON2 Servo motor overheat. The temperature sensor in the motor indicates over
150 degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the
stops for several minutes.
722 V-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150
degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the
stops for several minutes.
723 W-AXIS MOTOR OVERHEAT MOCON2 Servo motor overheat. The temperature sensor in the motor indicates over
150 degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the
stops for several minutes.
724 Sp MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150 degrees F
(65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the stops for
several minutes.
725 Tt MOTOR OVER HEAT MOCON2 Servo motor overheat. The temperature sensor in the motor indicates over 150
degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the
stops for several minutes.
726 Ss MOTOR OVER HEAT MOCON2 Servo motor overheat. The temperature sensor in the motor indicates over 150
degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the
stops for several minutes.
727 J-AXIS MOTOR OVERHEAT MOCON2 Servo motor overheat. The temperature sensor in the motor indicates over
150 degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the
stops for several minutes.
728 S-AXIS MOTOR OVERHEAT MOCON2 Servo motor overheat. The temperature sensor in the motor indicates over
150 degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the
stops for several minutes.
731 U MOTOR Z FAULT MOCON2 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 encoder connectors.
732 V 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 encoder connectors.
733 W MOTOR Z FAULT MOCON2 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 encoder connectors.
734 Sp MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder mounted
on the spindle has been damaged and encoder position data is unreliable. This can also be caused by loose
encoder connectors.
735 Tt MOTOR Z FAULT MOCON2 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 encoder connectors.
736 Ss MOTOR Z FAULT MOCON2 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 encoder connectors.
737 J MOTOR Z FAULT MOCON2 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 encoder connectors.
738 S MOTOR Z FAULT MOCON2 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 encoder connectors.
741 U AXIS Z CH MISSING MOCON2 Z reference signal from encoder was not received as expected. Can be caused
by loose connections, encoder contamination, or parameter error.
742 V AXIS Z CH MISSING Z reference signal from encoder was not received as expected. Can be caused by loose
connections, encoder contamination, or parameter error.
743 W AXIS Z CH MISSING MOCON2 Z reference signal from encoder was not received as expected. Can be caused
by loose connections, encoder contamination, or parameter error.

44 Alarms 96-8710 rev L June 2005

744 Sp AXIS Z CH MISSING Z reference signal from encoder was not received as expected. Can be caused by loose
connections, encoder contamination, or parameter error.
745 Tt AXIS Z CH MISSING MOCON2 Z reference signal from encoder was not received as expected. Can be caused
by loose connections, encoder contamination, or parameter error.
746 Ss AXIS Z CH MISSING MOCON2 Z reference signal from encoder was not received as expected. Can be caused
by loose connections, encoder contamination, or parameter error.
747 J AXIS Z CH MISSING MOCON2 Z reference signal from encoder was not received as expected. Can be caused
by loose connections, encoder contamination, or parameter error.
748 S AXIS Z CH MISSING MOCON2 Z reference signal from encoder was not received as expected. Can be caused
by loose connections, encoder contamination, or parameter error.
751 U AXIS DRIVE FAULT MOCON2 Current in U servo motor beyond limit. Possibly caused by a stalled or overloaded
motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. It can also be
caused by a short in the motor or a short of one motor lead to ground.
752 V AXIS DRIVE FAULT Current in bar feeder motor beyond limit. Possibly caused by a stalled or overloaded motor.
The servos are turned off. This can be caused by running the axis into a mechanical stop. It can also be caused by a
short in the motor or a short of one motor lead to ground.
753 W AXIS DRIVE FAULT MOCON2 Current in W servo motor beyond limit. Possibly caused by a stalled or over-
loaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. It can also
be caused by a short in the motor or a short of one motor lead to ground.
754 Sp AXIS DRIVE FAULT Current in Sp servo motor beyond limit. Possibly caused by a stalled or overloaded motor.
The servos are turned off. This can be caused by running the axis into a mechanical stop. It can also be caused by a
short in the motor or a short of one motor lead to ground.
755 Tt AXIS DRIVE FAULT MOCON2 Current in Tt servo motor beyond limit. Possibly caused by a stalled or over-
loaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. It can also
be caused by a short in the motor or a short of one motor lead to ground.
756 Ss AXIS DRIVE FAULT MOCON2 Current in Ss servo motor beyond limit. Possibly caused by a stalled or over-
loaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. It can also
be caused by a short in the motor or a short of one motor lead to ground.
757 J AXIS DRIVE FAULT MOCON2 Current in J servo motor beyond limit. Possibly caused by a stalled or overloaded
motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. It can also be
caused by a short in the motor or a short of one motor lead to ground.
758 S AXIS DRIVE FAULT MOCON2 Current in S servo motor beyond limit. Possibly caused by a stalled or overloaded
motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. It can also be
caused by a short in the motor or a short of one motor lead to ground.
761 U CABLE FAULT MOCON2 Cable from U-axis encoder does not have valid differential signals.
762 V CABLE FAULT Cable from bar feeder encoder does not have valid differential signals.
763 W CABLE FAULT MOCON2 Cable from W-axis encoder does not have valid differential signals.
764 Sp CABLE FAULT Cable from spindle motor encoder does not have valid differential signals.
765 Tt CABLE FAULT MOCON2 Cable from Tt-axis encoder does not have valid differential signals.
766 Ss CABLE FAULT MOCON2 Cable from Ss-axis encoder does not have valid differential signals.
767 J CABLE FAULT MOCON2 Cable from J-axis encoder does not have valid differential signals.
768 S CABLE FAULT MOCON2 Cable from S-axis encoder does not have valid differential signals.
771 U PHASING ERROR MOCON2 Error occurred in phasing initialization of brushless motor. This can be caused by a
bad encoder, or a cabling error.
772 V PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad
encoder, or a cabling error.
773 W PHASING ERROR MOCON2 Error occurred in phasing initialization of brushless motor. This can be caused by
a bad encoder, or a cabling error.
774 Sp 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 L June 2005 Alarms 45

 775 Tt PHASING ERROR MOCON2 Error occurred in phasing initialization of brushless motor. This can be caused by
a bad encoder, or a cabling error.
776 Ss PHASING ERROR MOCON2 Error occurred in phasing initialization of brushless motor. This can be caused by
a bad encoder, or a cabling error.
777 J PHASING ERROR MOCON2 Error occurred in phasing initialization of brushless motor. This can be caused by a
bad encoder, or a cabling error.
778 S PHASING ERROR MOCON2 Error occurred in phasing initialization of brushless motor. This can be caused by a
bad encoder, or a cabling error.
781 U TRANSITION FAULT MOCON2 Illegal transitions of count pulses in U 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 or MOTIF printed circuit board.
782 V TRANSITION FAULT Illegal transition of count pulses in bar feeder. 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 or MOTIF printed circuit board.
783 W TRANSITION FAULT MOCON2 Illegal transition of count pulses in W 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 or MOTIF printed circuit board.
784 SP MOT ENC TRANSITION FAULT Illegal transition of count pulses in Sp axis. This alarm usually indicates that
the encoder on the spindle motor has been damaged and encoder position data is unreliable. This can also be
caused by loose connectors at the MOCON or MOTIF printed circuit board.
785 Tt TRANSITION FAULT MOCON2 Illegal transition of count pulses in Tt 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 or MOTIF printed circuit board.
786 Ss TRANSITION FAULT MOCON2 Illegal transition of count pulses in Ss axis. This alarm usually indicates that
the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose connec-
tors at the MOCON or MOTIF printed circuit board.
787 J TRANSITION FAULT MOCON2 Illegal transition of count pulses in J channel. This alarm usually indicates that
the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose connec-
tors at the MOCON or MOTIF printed circuit board.
788 S TRANSITION FAULT MOCON2 Illegal transition of count pulses in S channel. This alarm usually indicates that
the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose connec-
tors at the MOCON or MOTIF printed circuit board.
791 COMM. FAILURE WITH MOCON2 During a self-test of communications between the MOCON2 and main proces-
sor the main processor does not respond, and one of them is possibly bad. Check cable connections and boards.
This alarm could also be caused by a memory fault, which was detected on the MOCON2.
792 MOCON2 WATCHDOG FAULT The self-test of the MOCON2 has failed. Call your dealer.
796 SUB SPINDLE NOT TURNING Status from subspindle drive indicates it is not at speed when expected. This can
also be caused by commanding a feed when the spindle is stopped.
797 SUB SPINDLE ORIENTATION FAULT Spindle did not orient correctly. During a spindle orientation function, the
spindle rotated but never achieved proper orientation. This can be caused by failure of encoder, cables, belts,
MOCON or vector drive.
900 A PARAMETER HAS BEEN CHANGED When the operator alters the value of a parameter, alarm 900 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 resetable alarm; it is for
information purposes only.
901 PARAMETERS HAVE BEEN LOADED BY DISK When a file has been loaded from floppy disk, alarm 901 will be
added to the alarm history along with the date and time. Note that this is not a resetable alarm; it is for information
purposes only.
902 PARAMETERS HAVE BEEN LOADED BY RS232 When a file has been loaded from RS-232; alarm 902 will be
added to the alarm history along with the date and time. Note that this is not a resetable alarm; it is for information
purposes only.

46 Alarms 96-8710 rev L June 2005

903 CNC MACHINE POWERED UP When the machine is powered up, alarm 903 will be added to the alarm history
along with the date and time. Note that this is not a resetable alarm; it is for information purposes only.
923 LOW OIL PRESSURE Oil Pump for platter gear has no pressure. Check that pump is pumping oil through lines.
Check to make sure filter next to pump is not plugged. PARAMETER 618 determines delay to check pressure after
start.
924 SS LOW LUBE OR LOW PRESSURE Way lube is low or empty or there is no lube pressure or too high a pres-
sure. 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. PARAMETER 616 determines cycle time.
932 BAR 100- ZERO VALUE A non zero value must be entered for #3100 Part Length + Cutoff, #3102 Min Clamping
Length and #3109 Length of Barstock on the Bar 100 Commands page.
933 BAR 100- MAXIMUM PARTS COMPLETED Job Completed. To Continue, reset #3103 Max # Parts and/or #3106
Current # Parts Run on the Bar 100 Commands page.
934 BAR 100- CURRENT BAR FINISHED Load a new bar. Reset alarm and press Cycle Start to continue.
935 BAR 100 FAULT Bar 100 program error. Cycle power on the machine. If the alarm reoccurs, call your dealer and
report the sequence of events that lead to the alarm.
937 INPUT LINE POWER FAULT Input line power failed. This alarm will be generated whenever incoming power to
machine falls below reference voltage value in parameter 730 and duration of time in parameter 731. Cycle the
power to continue.
938 LANGUAGES LOADED Foreign languages were recently loaded into the control.
939 LANGUAGES FAILED TO LOAD Foreign languages failed to be loaded into the control. Languages either ex-
ceeded total flash memory, or not enough flash memory available. Try deleting a language from disk.
958 TOOL OFS WEAR HAS BEEN CHANGED
961 FLOPPY OFFSET NOT FOUND This alarm is generated because FNC has lost the offset placemark it needs to
correctly advance program. Try to reload program.
962 UNABLE TO RETRIEVE FILE INFORMATION File functions are taking to long to process. Try loading again.
963 UNABLE TO FNC FROM THIS DEVICE This device may not function from FNC. Please change setting 134 connec-
tion type to an appropriate FNC device, from the operators manual.
964 TOOL TURRET ROTATE FAULT The turret did not rotate to the correct location within the time specified in
parameter 60. Check for obstructions that would prevent the turret from rotating. Check the operation of the
position sensors: slow, position_1, and in_position.

965 TURRET CLAMP/UNCLAMP FAULT The turret either did not clamp within the time specified in parameter
62 or unclamp in the time specified in parameter 63. Check the air supply. Check for obstructions that would
prevent the turret from clamping. Check the operation of the position sensors: slow, position_1, and in_position.

968 DOOR HOLD OVERRIDE ENGAGED Whenever setting 51 is changed to ON, alarm 968 will be added to the alarm
history along with the date and time the change was made. Note that this is not a resetable alarm; it is for information
purposes only.

NOTE: Alarms 1000-1999 are user defined.

The following alarms are for the VTC:

1001 SMTC FLT Tool Not Found. Specified tool not found in tool table.
1002 SMTC POCKET UP TIMEOUT Pocket did not reach UP position within time limit.
1003 SMTC FLT MS TOOL ONE SW Carousel not on tool one when expected or when on tool one and not expected.
1004 SMTC FLT TC MARK TIMEOUT Carousel did not come off mark switch or did not reach next mark switch within
time limits.
1007 GEAR FAULT Machine did not reach specified gear within time limit.

96-8710 rev L June 2005 Alarms 47

 1008 DB CLAMP/UNCL FLT Drawbar did not reach open or closed position within time limit.
1009 SMTC FAULT NOT FOUND Errors in macro, call your dealer.
1010 TSC FAULT Through the tool coolant pressure not reached or not stabilized within time limit. Another cause
coulbe that pressure is still present at completion of purge.
1012 SMTC ATC MTR TIMEOUT Arm did not reach destination within time specified.
1013 SMTC MIS ORIGIN SW Arm not at origin at start of tool change, start of carousel motion, or at the completion of
arm motion.
1014 SMTC MIS CLAMP SW Arm not at the clamp/unclamp position at completion of motion.
1015 SMTC-POCKET DWN TIMEOUT Pocket did not reach the down position within time limit.
1017 SMTC TOO HI TOOL# Specified tool exceeds max limit. Maximum number of tools is 26.
1018 SMTC SP NOT IN GEAR Live tooling spindle not in gear at start of tool change.
1021 NO DEPTH OF CUT DEFINED Missing value on command line that is needed for canned cycle.
1022 NO DEPTH OF HOLE DEFINED Missing value on command line that is needed for canned cycle.
1023 NO FEED RATE Missing value on command line that is needed for canned cycle.
1024 NO PECK AMOUNT DEFINED Missing value on command line that is needed for canned cycle.
1025 NO R PLANE DEFINED Missing value on command line that is needed for canned cycle.
1026 NO START DIAMETER DEFINED Missing value on command line that is needed for canned cycle.

48 Alarms 96-8710 rev L June 2005

 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
8-32 30 in. lb.
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 CRASH 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.

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)

96-8710 rev L June 2005 Mechanical Service 49

 TURRET R EMOVAL AND R EPLACEMENT

23 PARTS LIST
21 24 25 28
36 35 19 SHCS 5/16-18 x 1
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 Thrust 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 38
(bronze)
43 42 33 Turret cam
41 39 40
34 15/16 steel ball
35 HHB 5/16-18 x 1
Removal 36 Lever cam
1. Remove the sliding tool changer and turret assembly covers. 37 Belleville spacer
38 Belleville washers
2. Change Parameter 76 from 500 to 50000 (so you will not trip
39 Key
on a low air pressure alarm).
40 Ring switch
3. Remove the air line. 41 Lock nut
42 Spur gear
4. Put a 3/4" wrench on the bolt at the end of the air cycle. 43 Turret shaft
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.

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.

96-8710 rev L June 2005 Mechanical Service 50

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.

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.

96-8710 rev L June 2005 Mechanical Service 51

 T URRET SHAFT 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.

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.

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 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.

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.
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.

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”.

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 3. Loosen the turret motor coupling clamp screw closest to the motor. (Refer to the following figure.
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.

Turret motor adjustment.

T URRET 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 the following figure.
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)

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

Turret alignment verification (X-axis)

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.

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 NOTE: The turret must be in the UNCLAMPED position

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 “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.
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 180°, 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.
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.

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 90deg.

Spindle High

180deg. 0deg.

X-Axis
Spindle Low

270deg.
Tool Pocket

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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 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.

C ENTERING INNER TURRET COUPLING (W ITHOUT BRASS P LUG)

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.

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 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.
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.

B OLT O N T URRET A LIGNMENT

1. Clean the turret thoroughly before beginning alignment.
2. Index tool position #1 into the cutting position.
3. If the machine has a tailstock, move the turret and tailstock head next to each other and use the
tailstock head as a secure mounting point for the indicator. If there is no tailstock, move the turret
as close the fixed spindle bulkhead as possible. Assemble a short and rigid indicator mount as
possible on the spindle retaining cap. A rigid setup is critical for proper turret indication.
4. Select four (4) equally spaced SHCS that secure the turret to the coupler and mark them with a felt
pen. Loosen all the remaining bolts.

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 5. Place the indicator tip at the outside edge of the turret, point A in the following figure. Sweep the
indicator along this edge by jogging the X-axis, direction B. This edge should be parallel to the X-
axis within 0.0002” along its entire length and should as close to zero as possible.

el
rav
ofT
xis
X-

Z-A C
Ax
is
of
Tr

B
a
ve
l

Point A

Hybrid Turret Shown

The previous illustrations shows a turret that is twisted about the coupler along direction “B” as described in
step five. The turret flats should be parallel to the X-axis with in 0.0002”.
6. If the reading is not within specification install a boring bar tool onto the top of the turret. Slightly
loosen the four (4) marked SHCS and tap on the side of tool holder to twist the turret about the
coupler. The clearance between the SHCS that secure the turret to the coupler allows for this
adjustment. This step is to remove the twist between the turret tool positions and the center of
rotation of the coupler. See the previous figure.
7. Place the indicator tip back at point A and set the indicator dial at zero (0). Jog the turret away
from the indicator along the Z-axis (Direction C). Index the turret 180° so that tool position #7, on
SL-10 and SL-30, or tool position #6 on SL-20 and SL-40, is in the cutting position.
8. Jog the turret back into position along the Z-axis relative to the indicator tip. This reading not to
exceed 0.001”. If the reading is out of specification, then the turret is not yet on the same center of
rotation as the coupler. If the indicator is showing the turret is lower at this position, index the
turret 180 degrees to bring tool position #1 back into the cutting position. Ensure that the turret is
above the coupler center of rotation so that when the turret is moved onto center, gravity does not
work against you.
9. Loosen the four (4) marked SHCS and tap on the turret perpendicular to the X-axis. Move the turret
half of the distance indicated. This will place this half of the turret on the center of rotation of the
coupler. See the following figure.

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The above example illustrates a turret that is off center from the coupler center of rotation. The reading taken at
point “A” in step seven, indicates how far off center the turret is. It must be moved half of this value to place it
on to the coupler center of rotation. This must also be performed 90° from the first position.
10. Recheck that the turret did not become twisted by repeating step #5.
11. Index the turret so that tool position #4, on SL-10 and SL-30 or tool position #3 on SL-20 and SL-
40, is in the cutting position.
12. Place the indicator at point A on the flat for this tool position. Repeat steps #7 through #10. This
will move the turret on to the center of rotation of the coupler for the other half of the turret. See the
previous figure.
13. If the turret is moved relative to the coupler again, twist and on-center, in both directions, must be
measured again to ensure they are within specifications.
14. The tool positions of the turret are now on center with the coupler. Torque all of the SHCS and
recheck readings.
15. Index tool position #1 into the cutting position.
16. Install the appropriate alignment bar onto the spindle and remove all runout from the alignment bar.
Install a test indicator in the end of the spindle alignment bar.
17. On SL-10s there is not enough travel in the X-axis to reach the indication hole on the turret, so a
good tool holder must be used. Install the tool holder in tool position #1. Ensure that the tool is
seated completely against the turret and the front edge is pushed back against the turret face.
Check with shim stock that the tool is completely seated against the turret.
18. Jog the X-axis to the centerline position listed in parameter 254. If the 3/16” pin hole is used for
centerline verification, the turret must be moved 3.0000” (SL-20/SL-30; 3.5200 for SL-40) further
away form the home position to place the pin hole in line with the spindle.
19. Place the indicator tip into the 3/16” indication hole in the turret or the tool holder. Sweep the hole
360 degrees. TIR not to exceed 0.002” for tool position #1.
20. Sweep all other tool positions in the same manner. All other positions TIR not to exceed 0.006”
21. After the turret is indicated into position, sweep the flats of the turret that are parallel to the Z-axis.
They are to be parallel to the Z-axis within 0.001” along their length. Direction C. If they are out of
specification, the turret gearbox may have to be re-squared on the X-axis.

C ONVERTING 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 ACTUAL 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.

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

T URRET I N / OUT A DJUSTMENT

Extension
Sleeve

Jam
Nuts

Air Cylinder Rod

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

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.
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.
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".

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 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."

WEDGE ALIGNMENT
This procedure is meant to be followed using the data collected and entered on the “Service Lathe Alignment”
report. It is important that this form be filled out in its entirety before any adjustments of the wedge are at-
tempted.
Run the spindle at its highest RPM to check for noise and vibration. If vibration or noise is detected, repair this
first before making any wedge adjustments.
Verify the spindle alignment and if necessary correct before beginning the wedge alignment (see the “Spindle
Alignment Verification” section)
1. Mount the magnetic base on turret face and take check two positions on the spindle face (see the
following figure).

2. A difference in readings between the two positions proves the wedge is out of alignment. To correct
the alignment, loosen all linear guide truck bolts for the wedge, leaving the outside corner bolt,
closest to the spindle snug. This will create a pivot when the wedge is moved for alignment (see
the following figure).

NOTE: X and Z-axis way covers will need to be disconnected from the wedge in order
to access the linear guide trucks

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 3. Loosen the bolts on the ballscrew nut face on the Z-axis.
4. Pivot the wedge to bring the spindle face reading to zero.
5. Snug the wedge bolts to keep the wedge from moving during the next procedure.
6. Verify the turret alignment by completing the steps in the “Turret Alignment Verification” sections

NOTE: While moving the wedge try not to change the squareness of the wedge to the
Z-axis.

7. When both alignments are correct, gently snug all the Z-axis linear guide truck bolts then torque to
the required values.
8. Jog the Z-axis towards the spindle stopping 1" from the end of travel. Torque nut face bolts to
required values (tighten in star pattern)
9. Check for binding at the start, middle and end of travel.

T OOLROOM L ATHE X AND Z-AXIS ALIGNMENT

Place a granite tri-stone on the cross slide tooling plate. Place a magnetic base on the base casting and put
the tip of the indicator onto the edge parallel to the X-axis and align the stone parallel to the X-axis with in
.0001” over full travel.
Disconnect the Z-axis ball screw nut from the nut housing.
Place the indicator tip on the granite parallel to the Z-axis. Loosen all but one of the SHCS which secure the
saddle to the Z-axis. The one screw left tight will work as a pivot to align the axis. Align the X-axis to the Z-axis
within .0005”/10”. Tighten the saddle SHCS to 30 ft-lb.
Retighten the ballscrew SHCS to 30 ft-lb.

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3.2 S PINDLE

S PINDLE 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.

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
0.0001".

NOTE: If the reading is greater than 0.0001" remove the test bar, clean both mating
surfaces.

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

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 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 procedure.

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.

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.

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 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)

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.

Hydraulic cylinder (Coolant Collector not shown)

6. Unplug 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.

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 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.

TOOLROOM L ATHE S PINDLE

Removal
1. Remove the work holding device (i.e. chuck).
2. Remove the sheet metal panel from the left side of the machine casting. This will gain access to the spindle
motor and belt.
3. Remove the belt from the spindle pulley. To do this loosen the three bolts on the motor mounting plate (see
the spindle motor removal section). Use a bottle jack to lift the motor mounting plate. This will gain slack in the
belt so it can be removed from the pulley.
4. Remove the SHCS that secure the spindle front cap to the spindle housing.
5. Remove the spindle cartridge from the motor end of the spindle housing.
Installation
Tools Required
Blue Loctite
1/2" Torque Wrench (Up to 250 ft-lbs)
1. Inspect the new spindle once it is removed from the packaging. Check the alignment of the spacer between
the two bearings. Use a dial indicator on the spacer and bearings to check the run-out. The run-out is not to
exceed .0004” adjust if necessary.

2. Thoroughly clean out the spindle cavity. Ensure that there are no particulates or other contaminates are
removed. Clean thoroughly with alcohol.
3. Install spindle into housing.
4. Place the retainer ring on the spindle with the O-ring toward the spindle.
5. 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 bolts in a star pattern and in three increments to their final torque value.
Check alignment of the spindle and retaining ring with a .001 shim at each torque value.

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6. Ensure that the spindle can spin freely. If not, remove the retainer ring and spindle and reinstall.
7. Install the drive belt onto the spindle and motor pulley and apply proper tension to the belt.
8. Tighten the three motor mount bolts.
9. Replace the sheet metal motor cover.

M INI L ATHE SPINDLE R EMOVAL AND R EPLACEMENT

1. Remove the door, the coolant collector, and left front and left side enclosure panels.
2. Disconnect the air/oil lube lines that supply the spindle and the air closer.
3. Remove the work holding device, air closer, adapter and drawtube.
4. Remove the belt from the driven pulley.
5. Attach the spindle drive sprocket removal tool as specified by the factory to the driven sprocket.
6. Using a hydraulic ram, pull the sprocket off the end of the spindle.
7. Remove the oil injection cover off the back of the spindle.
8. Remove the SHCS that secure the spindle front cap to the spindle housing. These are accessed
via the through holes in the spindle nose itself.

9. Remove the spindle cartridge from the spindle housing.

10. Thoroughly clean out the spindle cavity. Ensure that there are no particulates or other contami-
nates are removed. Clean thoroughly with alcohol.
11. Ensure that the spindle is also free from any contaminates before installing it into the spindle head
housing.
12. Slide the spindle cartridge into the spindle head housing.
13. Orient the front cap such that the oil drain passage is pointed downwards. Also ensure that the O-
ring is installed on the front cap and that it is cut at the oil passage point.

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 14. Once the spindle front cap is oriented properly, evenly torque the front cap bolts to 10 ft-lb.
15. Reinstall the oil injection cover.
16. Heat the drive sprocket on a hot plate at 450 degrees F for at least 5 minutes and then install onto
the spindle shaft.
17. After the sprocket cools, reinstall the air closer, adapter, drawtube and work holding device.
18. Reconnect the air/oil lube lines.
Mini Lathe Spindle Break-in
1. Load the Mini Lathe spindle break in program, O02222, into the control. Ensure that Parameter 57,
bit 22 is set to 1 so that the Macro feature is enabled. Parameter 266, bit 3 must also be set to 1
to ensure the control is reading the thermal probe.
2. Attach a thermal probe cable P/N 33-9022 to the side of the spindle head casting with a 1/4-20 x
¾” SSS. Ensure that the thermal probe is seated completely against the casting. This will ensure
accurate readings.
3. From the control cabinet, there is a cable that normally plugs into the X-axis ball screw thermal
probe cable (33-9022A). Disconnect them from each other and plug the spidle head thermal probe
cable in place of the X-axis ball screw thermal probe cable.

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 4. Verify that the thermal probe is working by inputting the following code into MDI; #119 = #1092 /
65534 * 500; M99
5. Press ‘Cycle Start’ and then look at the macro page under the ‘Current Commands’ menu. Macro
#119 should read some where around the ambient temperature. This verifies that both the probe
and macros are functioning properly.
6. Double check that the spindle air/oil lines are attached and that the air regulator for the spindle air/
oil is set to 25 psi.
7. Run the program. It should take around 5 hours. If the spindle does not pass, the control will state
this. Do not reset the program. There is important information in the macro page. Call the Factory.
8. Remove the thermal probe from the spindle. Reattach X-axis thermal probe and reinstall the sheet
metal.

M INI L ATHE R EMOVAL AND R EPLACEMENT OF A IR C LOSER

1. Install the air closer adapter onto the spindle drive sprocket.
2. Measure the runout of the O.D. of the adapter. Runout should not exceed .001.
3. Install the air closer onto the adapter.
4. Measure the radial runout of the non-rotating portion the air closer as close the end as possible. If
the readings are high, reclock the air closer to remove the excess runout. Runout NTE .0005”.

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. Inspect the new spindle once it is removed from the packaging. Check the alignment of the spacer
between the two bearings. Use a dial indicator on the spacer and bearings to check the run-out.
The run-out should be between .0005-.0015, adjust if necessary.

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 2. Install spindle into housing. Check location of oil holes for proper alignment.
3. 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.
4. 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.

Spindle retaining bolts.

5. 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.
6. 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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 7. 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.
8. Attach the two 1/4" nylon tubes onto the swivel fittings.

Alignment of oil mist holes.

9. Install the spindle drive pulley.

10. Install the drive belts onto the spindle and motor pulleys.
11. 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.

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 12. 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.

13. Mount the encoder onto the spindle housing below the spindle shaft with four mounting bolts.
14. Place the 3/8" timing belt on the spindle pulley, with the other end on the encoder pulley.
15. Align and attach the hydraulic cylinder adapter onto the spindle shaft with the mounting bolts.
Tolerance on the face of the adapter plate perpendicular to centerline within .001". Check tolerance
of large I.D. bore circular within .002".
16. Slide the hydraulic cylinder into spindle shaft. Insert and snug the mounting bolts.
17. Attach and clamp the oil drain hose and coolant drain hose onto hydraulic cylinder.
18. Attach and screw in clamp and unclamp hoses.
19. Set the magnetic base on top of the spindle housing with the indicator touching the top of the
hydraulic cylinder.
20. Spin the hydraulic cylinder and verify that the runout is under 0.001 inches. If runout is over 0.001
inches, spin the hydraulic cylinder to its high point and tap cylinder with a rubber mallet. Tighten
and torque the bolts.
21. Replace all previously removed sheet metal.

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T OOL R OOM L ATHE S PINDLE M OTOR
Removal

Note: It will take two people to lower the motor mount plate, motor and fan from the
machine.

1. Remove the sheet metal panel from the left side of the machine casting.
2. Before removing the spindle motor make sure to stabilize the motor and fan assemblies.
3. Disconnect all electrical connections from the under side of the motor.
4. Remove the three SHCS from the mounting plate and remove the pulley belt.
5. Leave the mounting plate connected to the spindle motor and carefully remove the mounting plate, spindle
motor and fan.
6. Remove the four SHCS that are connecting the mounting plate to the motor. Then remove the four SHCS that
are connecting the fan to the spindle motor.

Installation

Note: It will take two people to lift and attach the motor mount plate, motor and fan
to the machine.

1. Attach the motor mount plate to the motor using the four SHCS, torque the SHCS to 70 ft-lbs. Attach the fan
to the motor using the four SHCS.
2. Lift the mounting plate, motor and fan into place and fasten the plate to the casting using the three SHCS.
Do not tighten the bolts, they should be snug enough to hold the motor into place. Install the drive belt, check
for correct tension and tightening the three SHCS on the motor mount plate.
3. Reconnect the electrical connections on the motor.
4. Reinstall the sheet metal motor cover.

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S PINDLE 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".

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 on the following page.

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 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.

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 the “Turret Alignment Verification” section
on pg. 57.

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

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 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.
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 a boring bar 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. The tool holder must be seated completely
against the turret.
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. Once the runout is less than 0.002” TIR, verify that the spindle head parallelism to the Z-axis is
within 0.0004”/10”.
15. Evenly torque the spindle head bolts to 300 ft. lbs and ensure that all SSS in the spindle head
casting are bottomed out on the dowel pins.

M INI L ATHE S PINDLE H EAD A LIGNMENT

1. The X and Z-axes must be perpendicular to each other prior to aligning the spindle head.
2. Remove the door, the left side and the end panel.
3. Install a spindle alignment bar (P/N T-2113) on the spindle.
4. Remove the run-out from the base and end of the alignment bar. NTE 0.0001” at each end.
5. Place an indicator on the tool platter and run the indicator along the side alignment bar along the
Z-axis. Alignment bar parallelism to the Z-axis NTE 0.0004” per 10” of travel.
6. Loosen the nuts that secure the spindle head to the base casting.
7. Using the ½”-13 SSS, adjust the position of the spindle head on the base casting until the parallel-
ism of the alignment bar to the Z-axis is with in 0.0004” over 10” of travel. There are socket set
screws (SSS) on both sides of the spindle head casting.

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 8. Once the alignment of the spindle is achieved, torque the nuts that secure the spindle head to the
base casting to 250 ft-lb.
9. After torquing the nuts, ensure that all of the SSS are bottomed out on the dowels within the
spindle head.

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3.3 TL-S ERIES S UB S PINDLE

SPINDLE MOTOR REPLACEMENT

1. Remove the sheet metal covering the sub spindle motor and the union.
2. Cut all plastic ties to the motor wiring. Disconnect the wiring from the motor.
3. Remove the encoder:
Loosen the set screw that holds the encoder to the motor shaft. Remove the screw that holds the
encoder bracket to the motor.
4. Remove the four (4) bolts that mount the motor to the spindle head.

Caution! You may need to use a hoist to lift the sub spindle motor as it weights approx.
90 lbs.

5. Install the replacement motor in reverse steps for removal. Make sure the wiring is fed beneath the
belt.

SUB SPINDLE M OTOR B ELT R EPLACEMENT

1. Remove all sheet metal covering the sub spindle motor.
2. Remove the chuck and unhook the hoses to the union.
3. Disconnect the electrical wiring to the encoder.
4. Loosen the set screw that holds the encoder to the motor shaft.
5. Remove the screw that holds the encoder bracket to the motor.
6. Loosen but do not remove the four (4) sub spindle motor mounting bolts.
7. Remove and replace the motor belt.
8. Reassemble in reverse steps for removal. Make sure the motor wiring is connected and secured
properly.

S UB SPINDLE HEAD ALIGNMENT

1. Insure that the main spindle is aligned. Following standard alignment procedures in the lathe
service manual.
2. Mount the spindle alignment bar (Part # T-2113) to sub spindle face. Before installing the test bar,
insure that both mating surfaces are cleaned thoroughly.
3. Mount a magnetic base and a .0001” indicator on the turret face. Rest the indicator tip on the top
surface nearest the sub-spindle face and manually rotate the sub-spindle. Tap on the alignment bar
flange and indicate it to zero runout. Jog the indicator in the Z-axis direction to the end of the
alignment bar and set the indicator to read zero. Rotate the sub spindle to check runout. runout
should not exceed .0002. If the runout exceeds .0002, then use different tension on the test bar
mount bolts to adjust. (See the following figures.)

NOTE: Test bar should be indicated to .0 runout before checking alignment of

sub-spindle

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 4. Rest indicator tip on the top surface. Using the “Z” axis jog the indicator tip over eight inches of the
test bar to check spindle flatness, max tolerance is .0003”.

Adjust for Flatness

(Back Shim)

Adjust for Parallelism

(Side to Side)

Adjust for Flatness

(Front Shim)

Shim stock location

5. If the sub-spindle is out of tolerance then shimming is necessary. See the following figure for shim
stock information and the figure above for the location of where the shim stock will be
inserted.

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 Shim stock information
Repeat steps 4 and 5 until the flatness is within specifications.
6. With the indicator on the nose of the test bar, place the indicator tip on the top of the beveled lip of
the main spindle and set it to zero.
7. Rotate the bar 360° and check the concentricity of the sub spindle to the main spindle. The
tolerance is .002” TIR. Adjust side to side using set screws.
8. If the height is out of tolerance you need to change the front and back sub-spindles shims by the
amount of correction necessary, and still maintain flatness.
9. Repeat steps 5 –9 until the Flatness and Top to Bottom Centerline tolerance are within
specifications.
10. Rest the indicator tip that is riding on the top of the test bar to run along the side of the test bar.
Use the “Z” axis to jog the indicator tip over eight inches of the test bar to check the sub-spindle
parallelism, max tolerance is .0003”.
11. If the sub-spindle is out of tolerance adjust the parallelism adjusting screws to bring it in.
Repeat steps 10 and 11 until parallelism is within specifications.
12. With the indicator on the nose of the test bar place the indicator tip on the side (90° position) of the
beveled lip of the main spindle and zero.
13. Rotate the bar 360° and check the concentricity of the sub to main spindle. The tolerance is .002”
TIR.

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3.4 T AILSTOCK ALIGNMENT
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 TAILSTOCK A LIGNMENT 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 (00 and
1800), then proceed to the Tailstock Leveling Procedure.
•If this measurement is out of tolerance from side to side (900 and 2700),
then the insert needs to be replaced and realigned as described in the
Tailstock Insert Removal and Installation section.

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 the following figure).
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 .001" by adjusting the jack bolts.
3. Sweep the diameter of the Test Bar and note the vertical runout.

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 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.

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 .001".
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.

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 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.
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 (see following figure). 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.

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.

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 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 indica-
tor 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.
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-lb.
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.
3. Run the screw nut completely down to its farthest travel (far right).

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 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.
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.

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 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.

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.

Extended
Cylinder Rod
BHCS

Encoder

Tailstock
Hydraulic Adapter
Cylinder
BHCS

Encoder
SHCS
Rail Support Rail

Hydraulic cylinder replacement.

2. Move to mid travel before disconnecting

3. Disconnect the hydraulic lines from both ends of the cylinder.

96-8710 rev L June 2005 Mechanical Service 90

 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.

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.

SL10 TAILSTOCK
Seal Replacement
Disassembly
1. Remove the 4 nuts on the back of the tailstock cylinder.
2. Remove the back of the cylinder and then the cylinder housing.
3. Remove the two seals from the end of the cylinder.
4. Remove the two seals from the end of the cylinder. One of the seals is inside the bore of the
cylinder.

96-8710 rev L June 2005 Mechanical Service 91

Assembly
1. Install two seals to the end of the cylinder. Note the differences between the seals there is an
apparent thickness difference.
2. Install the two seals to the end of the cylinder. Note the orientation of the seals. They must be
installed facing the proper direction See the following illustration).
3. Reinstall the cylinder in the housing, replace the back of the tailstock cylinder and secure with 4
nuts.

96-8710 rev L June 2005 Mechanical Service 92

3.5 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

Lathe transmission mounting plate.

Installation
Overview
All Haas gearbox replacements for lathes are supported using only 16DP gearsets. They have oil pumps, with
oil pressure switches, and use motor encoders with an M23 connector.
The 16dp haas gearbox are identified with a “16DP” engraved on the top surface of the gearbox housing.
If the gearbox that is being replaced already has an oil pump and pressure switch then the necessary software,
parameter 57 bit 26 set to 1, power cable, and signal cables are already in place.

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The 16DP gearbox may require value changes for parameter 150 when changing the gearbox, so they need to
be verified.
The gearbox motor encoder connector type has changed. An adaptor cable has been attached that converts to
the previous style molex connector in case it is needed. If the adaptor cable is not needed, remove it and
attach the existing M23 connector to the motor encoder.
In order for the transmission to function correctly the follwing items need to be verified and/or installed:
The control must have software version 5.08 or later
Parameter 150 set correctly (see the following list)
Parameter 57 bit 26 “trans lo oil” set to 1
The encoder cable for the motor encoder is correct
Replace CBL890 (Hi Gear, Lo Gear, Trans Lo Oil) and installing CBL300A (oil pump power cable),
if necessary
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 Installation
section, for proper belt tension procedures and tension chart.
5. Remove the existing CBL890 and replace it with the CBL890 included in the service kit (33-1894).
CBL890 connects to IOPCB P15 inside the control cabinet, exits the control cabinet through the
top or bottom opening, and connects to the gearbox Hi Gear, Lo Gear, and Trans Lo oil connec-
tors.
If the control cabinet cables exit through the bottom of the cabinet, thread the end of CBL890 up
through the gray rubber grommets in the opening in the bottom of the control cabinet as shown. If
the control cabinet cables exit through the junction box at the top of the control, thread CBL890
through the top junction box.

Bottom-Exit Control Cabinet.

Remove the cable guide covers necessary to route CBL890 to IOPCB P15 and place CBL890 in
the cable guide.

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 Route the other end of cable 890 in the most direct, yet safe path to the bracket on the side of the
Haas gearbox. Plug the connectors into their appropriate slots in the bracket, and plug the match-
ing Hi Gear, Lo Gear, and Trans Lo Oil (from the pressure switch) connectors together. If there is
no available slots in the bracket, or no bracket, the connectors may be tied out of the way.
6. Install CBL300A (33-8169). CBL300A connects to IOPCB P41 inside the control cabinet, exits the
control cabinet through the top or bottom opening, and connects to the gearbox oil pump power
leads connector.
Thread CBL300A through the same opening into the control cabinet as CBL890, and connect it to
IOPCB P41.
Outside the control cabinet, route CBL300A in the most direct, yet safe path to the bracket
mounted on the side of the Haas gearbox. Plug the connector into the appropriate slot on the
bracket and plug the matching connector from the gearbox oil pump motor into the opposite side of
the bracket as shown in the following figure. If there is no bracket, the connectors may be tied out
of the way.

Terminal
Connections
on Motor

Buss

Push-in
Connectors

7. Inside the control cabinet, replace the cable guide covers. Close the control cabinet door and turn
the main power to machine on.
Check that the oil pump works properly
Power the machine on. Verify that parameter 150 is correct and that parameter 57 bit 26 trans lo oil is set to 1.
Push power up restart and check that the transmission oil pump is running. You will be able to see the oil
flowing through the clear line and feel the oil pump humming as it runs. The oil pump will run whenever the
spindle is turning.
Parameter 150 values for Haas 16DP gearboxes:
SL-30 / TL-25 with gearbox option 1054
SL-30B / TL-25B 744
SL-30 with OPC12 and gearbox option 943
SL-40 / 40L (incl XP option) 744
SL-40B / 40LB (incl XP option) 434

96-8710 rev L June 2005 Mechanical Service 95

Check that the low transmission oil pressure alarm works
Command a spindle speed and then disconnect the pressure switch. There will be a 60 second pause and then
Alarm 179 should be generated. Reconnect the switch after the test.
8. Replace the left side panel.

NOTE: If you are using a floor jack, replace the bottom left front panel.

55 HP L ATHE T RANSMISSION AND M OTOR

Removal
1. Remove the sheet metal on the left side of the lathe in order to gain access to the motor and
transmission
2. Remove the motor cables from the buss, under the motor.
3. Disconnect all the motor feedback cables at the subplate on the motor/transmission.

Note: The next step requires the use of additional lifting means, for example use a
forklift to pick up the assembly.

4. Use lifting eyes to support the motor/transmission assembly. There is a provision for a lifting eye
close to the center of the motor cover and another at the pulley end. Use a lifting strap between
the two lifting eyes and secure the strap to the lifting equipment.
5. Support the motor/transmission assembly.
6. Remove the bolts that secure the transmission to the spindle casting.
7. Lift the motor/assembly up to clear the belts and then pull the assembly away from the spindle
casting.
Installation
1. Install new belts on the spindle pulley. These need to be a matched set.

Note: The next step requires the use of additional lifting means, for example use a
forklift to pick up the assembly. Use lifting eyes to lift and position the motor/
transmission assembly. There is a provision for a lifting eye close to the center
of the motor cover and another at the pulley end. Use a lifting strap between
the two lifting eyes and secure the strap to the lifting equipment.

96-8710 rev L June 2005 Mechanical Service 96

 Buss

Setscrew (2)

Ratchet Wrench w/Hex Key

2. Lift the assembly and position it over the belts. Lower the assembly into position and loosely
install the four mounting bolts.
3. Tension the belts using the tension adjusting screws. These 2 screws are located under the
transmission. A long 1/4" Allen wrench and a torque wrench are needed to adjust these screws.
Adjust them to 44 in lb. Once both are adjusted recheck the first one, then the second. It may be
necessary to recheck the screws a few times in order to attain the proper torque.
4. Torque the mounting bolts to 80 ft lb.
5. Replace the wires on the motor. Match the cables numbers, from the machine, to the numbers on
the buss.
6. Replace the motor feedback cables. These are located on the sub-panel on the left of the motor
assembly.
7. Ensure all cables are away from moving parts.
8. Reinstall any other spindle related pieces that were removed (e.g. Coolant collector and hose)
9. Command the spindle forward at low RPM (Do not exceed 500 rpm); look for leaks. Start the run-in
program. This program will run for about 2 hours.

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3.6 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 is ½ of a revolution of
the encoder. These values are: X-axis =.236, Z-axis=.118, B-axis (TL-15) = .118. Older HL series machines with
ball screw tailstocks will have the grid offset set to .050.

Note: Machines with non hydraulic tailstock machines have no grid offset to set.
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 B).
3. Calculate the grid offset using the following formula, and write the result in Parameter 125 (X-axis),
127 (Z-axis), or 170 (B-axis), 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.

A-axis (tool changer) grid offset always must be set to zero.

Setting the Offset using the Grid Feature
The control will calculate grid offset parameters (125, 126, 127, and so on) using the ‘GRID’ command. It is
recommended that the GRID command be used on each axis separately as follows:
1) Turn the machine off and back on. This will un-zero all the axes.
2) Select the ALARMS screen and enter DEBUG mode.
3) Perform a ZERO SINGLE AXIS on each of the desired axes individually. Ignore any ZERO RET
MARGIN TOO SMALL alarms. Note: if a SERVO ERROR TOO LARGE alarm was generated, this
indicates that a GRID OFFSET parameter is out of range (make sure it is -138718 to +138718.)
4) Select the Positions screen, enter GRID and press ENTER. The message GRID OFSET DONE
should appear and the GRID OFFSET parameters for the homed axes will have been updated. If
the message “NO ZERO” appears, this indicates that none of the axes had been zeroed.
5) Perform AUTO ALL AXIS and verify that the DIST TO GO value for each of the selected axes is
now close to 0.118". Note that on a lathe with a C axis (such as a TL-15), the C axis does not have
a home switch. Consequently the GRID command will not alter parameter 517 C axis GRID
OFFSET. The grid offset for the C axis must continue to be calculated my hand.

96-8710 rev L June 2005 Mechanical Service 98

3.7 L UBE A IR P ANEL

8 9

7
11
10 AIR

AIR 1

MAX
2

5
MIN

6 4 3

Lube Air Panel (Front View).

LUBE AIR 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 approximately 3cc of oil (at approximately 20 psi).

3. Oil Reservoir - Stores the oil (Vactra #2) that is used for lubrication in the linear guides and ball
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.

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.

96-8710 rev L June 2005 Mechanical Service 99

 8 9

10

77
1

2
5 4
6
3

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 (10-12 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.

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 ball screws, linear guides, and
spindle bearings.

9. Oil Ports - Connect to nylon tubing that carries the oil to the ball 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.

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LUBE PANEL R EMOVAL

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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3.8 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. Drain the hydraulic fluid.

2. Disconnect the hydraulic hoses. Be sure to mark the positions of the hoses so they can be put
back to their original fittings

3. Disconnect the cables.

4. Remove the four bolts from base of unit, then slide hydraulic unit out.

INSTALLATION

CAUTION! POWER OFF THE MACHINE BEFORE PERFORMING THIS PROCEDURE.

1. Position the hydraulic power unit in place and secure with four mounting bolts.

2. Connect pump motor, pressure switch and solenoid valve cables

3. Replace the hydraulic hoses.

4. Fill the hydraulic unit with DTE25 to the top of the sight glass.

5. Replace any panels that were removed to access the hydraulic unit.

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 SL-S ERIES H YDRAULIC SCHEMATICS

Chuck Only 6GPM Chuck and Tailstock 6GPM

0-600 0-600 0-600 0-600 0-600 0-600
PSI PSI PSI PSI PSI PSI

M1 R1 M2 R2 M1 R1 M2 R2

40 PSI 0.070
A2
40 PSI A2 DECR TAILSTOCK
DECR TAILSTOCK (PS)
B2
(PS) B2
0.047

P1
BRAKE A1
P1 CHUCK
BRAKE A1 10 MICRON B1
CHUCK 20 PSI
10 MICRON B1 BYPASS
20 PSI
BYPASS

A B A B

Chuck and Subspindle 6GPM Pressure Gauge Solenoid

0-600 0-600 0-600 0-600 Coupler

Control Valves
PSI PSI PSI PSI Line Junction
Control Valve
(with spring return) Power Take-Off
M1 R1 M2 R2
Control Valve Motor Coupling
(direct operated by
solenoid with
spring return) Non-Return Valve
Pressure
A2 Orifice Compensating
40 PSI Valve
SUB- Electrical Switch
DECR (with spring return)
(PS) SPINDLE Filter

B2
Heat Exchanger

Fan
P1 A B
BRAKE A1 Motor
CHUCK
10 MIC-
RON B1 Tank Fill
20 PSI
BYPASS Line
2 HP
Manifold Block
CASE
FILL
M 1 IN FEMALE
PIPE COUPLER TANK
A B TANK
PORT
FILL
Pilot Line

Variable Pump
LEVEL
TEMP
GAGE
CASE
DRAIN 8 GALLON
RESERVOIR
WITH BAFFLE
100 6 GPM TANK DRAIN
MESH 550 PSI 1/2 NPT

96-8710 rev L June 2005 Mechanical Service 103

 Chuck and Tailstock 3GPM Chuck Only 3GPM
0-600 0-600
0-600 0-600 0-600 0-600 PSI PSI
PSI PSI PSI PSI
M1 R1 M2 R2
M1 R1 M2 R2

40 PSI A2
0.070 DECR TAILSTOCK
40 PSI A2 (PS)
DECR B2
TAILSTOCK
(PS)
B2

0.047
P1
BRAKE A1
P1 CHUCK
10 MICRON B1
BRAKE A1
20 PSI
CHUCK BYPASS
10 MICRON
20 PSI B1
BYPASS

Pressure Gauge

Control Valves
A B A B
Control Valve
(with spring return)
Control Valve
(direct operated by
solenoid with
spring return)

Orifice
Electrical Switch
(with spring return)
Solenoid

Coupler
A B Line Junction
Power Take-Off

Motor Coupling

Non-Return Valve
Pressure
Compensating
Valve

Filter
1.5 HP
CASE
FILL
M 1 IN FEMALE Heat Exchanger
PIPE COUPLER TANK
PORT
FILL Fan
TANK
Motor

LEVEL
TEMP Tank Fill
GAGE
CASE Line
DRAIN 8 GALLON
RESERVOIR Manifold Block
WITH BAFFLE
100 3 GPM TANK DRAIN Pilot Line
MESH 550 PSI 1/2 NPT
Variable Pump

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3.9 TURRET C ROSS -SLIDE SPRING

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

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

Spring tension relief.

7. 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.

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 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.

8. Remove cylinder spring retainer attached to pivot arm and replace with new cylinder spring retainer.

9. Install new cross slide spring. Attach spring to spring retainer in turret housing and cylinder spring
retainer of pivot arm.

10. Place a wrench on pivot arm then pull towards rear of bracket until pivot arm locks to restore spring
tension.

11. Tighten 3/8" SHCS of lower pivot arm and nut of upper pivot arm on spring bracket.

12. Remove the wood safety block.

13. Re-attach the X-axis way cover.

14. 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.

96-8710 rev L June 2005 Mechanical Service 108

 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

Front view of parts catcher/tray

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.

96-8710 rev L June 2005 Mechanical Service 109

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.

LATHE TOOL PRESETTER SETUP

This procedure measures probe faces and sets parameters based on the actual distances. If a diameter
difference greater than the tolerance 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.

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 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).

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.

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 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 B ALL S CREW R EPLACEMENT
Please read this section in its entirety before attempting to remove or replace the ball screws.

TOOLS REQUIRED:
• Spanner Wrench (32mm or 40/50mm) • Shaft Lock (32mm or 40/50mm)

Z-A XIS B ALL 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 ball screw.

3. Remove the cover from the motor housing. Disconnect the oil line from the ball 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

For 32mm Ball 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 ball screw.

b. At the motor end, loosen the motor coupling on the ball screw side of the coupling. Remove
the four motor mount SHCS and the motor. Remove the Woodruff key from the key way on the ball
screw.

c. In the motor housing, loosen the lock nut screw, attach the spanner wrench to the clamp nut
and remove the nut from the ball 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 ball screw nut to the nut housing. Pull the ball screw forward to clear the nut from the
housing and angle the ball screw towards the right of the bearing support. Carefully remove ball
screw.

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 CAUTION! Be careful during removal or installation of ball screw, to protect the
surfaces.

40mm Ball 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 ball screw side of the coupling.
Remove the four motor SHCS and the motor. Remove the Woodruff key from the key way on the
ball 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 ball 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 ball screw
in place and remove the bearing support. Pull forward on the ball screw and carefully remove.

CAUTION! Be careful during removal or installation of ball screw, to protect the

surfaces.

Z-A XIS B ALL S CREW I NSTALLATION

Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing and the ball screw nut are free of
dirt, burrs, grease or other contaminants.

CAUTION! Mating surfaces must be clean or misalignment may occur, seriously

affecting the proper operation of the machine.

For 32mm Ball Screw:

1. Reinsert the ball screw, with the motor housing bumper on it, from the right hand side of the
bearing support into the motor housing. Align the ball screw with the bearing support end and insert
the ball screw. Prevent contact with the screw threads, to avoid any possible damage.

2. Hold the ball screw level on the motor side. Slide the bearing sleeve onto the ball 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 ball 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 ball screw.

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 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 ball screw on the support side.

b. At the motor side of the ball 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.

f. Align the ball 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 ball screw nut SHCS to 15 FT-LBS.

g. Place the Woodruff key back into the key way slot on the ball 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 ball 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 ball
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 ball screw nut.

7. Zero return Z axis and set grid offset.

For 40mm Ball Screw:

1. Reinsert the ball screw with bumpers into the bearing sleeve in the motor housing. (Make sure the
ball screw nut will be able to slide in to the wedge nut housing). Support the ball 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 ball 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 ball 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 ball screw on the support side.

b. Attach the clamp nut onto the motor side of the ball screw.

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 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.

e. At the bearing support end, remove the shaft lock.

f. Align the ball 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 ball screw nut SHCS to 30
FT-LBS.

g. Place the Woodruff key back into the key way slot on the ball screw.

h. Install the motor with the coupling attached to the ball 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 ball 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 ball
screw by hand when the servos are off. Check for backlash or noisy operation.

9. Replace the ball screw hardstops and reconnect oil line to the ball screw nut.

10. Zero return Z axis and set grid offset according to section 3.5.

M INI L ATHE Z- AXIS B ALLSCREW A LIGNMENT

1. Move the Z-axis Ballscrew nut to the middle of the ballscrew. With all the bolts loose, take a
“before” torque reading on the ballscrew.

2. Screw down (do not torque) the SHCS on the face of the nut.

3. Torque down the SHCS that fasten the nut housing to the side.

4. Now loosen the SHCS on the face of the nut. Run the Z-axis fully each way, then return the nut to
the middle of the ballscrew.

5. Torque the SHCS on the face of the nut. Run the ballscrew nut to the motor end of the ballscrew.
screw down the SHCS (do not torque) the bearing support.

6. Run the ballscrew nut to the bearing end of the ballscrew. Run the ballscrew nut back to the motor
end and torque the SHCS.

7. Run the ballscrew nut back to the bearing end and torque the SHCS. Take three ballscrew torque
readings. One approximately 1” from each end, then one reading at the middle. Readings NTE 3 in-
lb of each other.

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T OOLROOM L ATHE Z-AXIS BALLSCREW

Removal
1. Remove the hand wheel.

2. Remove the bearing locknut.

3. Remove the bearing support. Once removed, pull the dowel pins out of the casting.

4. Remove the SHCS from the ballscrew nut.

5. Remove the motor mount cover plate and unclamp the coupler from the ballscrew.

6. Unscrew the bearing locknut in side the motor housing.

7. Unscrew the ballscrew from the machine.

Cover Plate SHCS Motor Grease Fitting Z-Axis Bumper

Housing SHCS
Bearing Sleeve Bumper Bumper Bracket

SHCS Bearing
Locknut
Bearing Bearing
Locknut Support
SHCS

Key Ball Screw Nut

Servo Motor Nut Housing

Ball Screw
Motor Mount Casting

Motor Coupling Assy

SHCS

Z-Axis Ball Screw Installation

1. Install the ball nut into the nut housing and snug the fastening screws.

2. Thread the ballscrew into the clamp nut on the motor support side and then torque to 15 ft-lb. Then torque
the SHCS in the nut to 15 Inch-lb.

3. Lock the ball screw by using the 32mm lock tool (T-1601). Torque the clamp nut on the ballscrew support
end (not the motor end) to 4 inch-lb. and torque the SHCS in the nut to 15 inch-lb. Remove the lock tool.

4. Install the bearing support leaving the bolts loose. Install the dowel pins and then torque the bolts to 30 ft-lb.

5. Check for binding in the beginning, middle and end of travel. Check for backlash or noisy operation.

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X- AXIS B ALL S CREW R EMOVAL
Please read this section in its entirety before attempting to remove or replace the ball screws.

SPECIAL TOOLS REQUIRED:

• Torque Wrench • Straight Nose Snap Ring Tool
• Spanner wrench (32mm) • Coupler Installation Tool (Haas part number T-1451)
• Lock collar Nut Wrench P/N T-1601

1. Turn the machine on. Zero return all axes and put the machine in handle jog mode.

2. Remove all sheet metal necessary to gain access to the X-axis ball screw, servo motor, and
coupler. Remove the way cover.

3. Handle jog the turret down the X-axis until there is access to the motor housing cover.

4. Remove the motor housing cover.

5. Loosen the clamp collar that ties the X-axis motor coupler to the ball screw.

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 6. Jog the X-axis to the home position. Remove the temperature sensor and oil line. Remove all but
one of the SHCS that secure the ball nut to the nut mount. Loosen the remaining SHCS to hand
tight.

Coupler Installation Tool

Oil Line

Temperature
Sensor

7. Carefully handle jog the X-axis until there is just enough room to install the coupler installation tool
(P/N T-1451). Install the coupler installation tool into the coupler to prevent damage to the coupler
when the motor is removed.

8. Brace the gearbox casting to prevent it from movement when disconnected from the nut. Use a
block of wood or other such material that will not cause damage.

Brace Gearbox Casting

Bearing Pack

Lock Nut

9. Disconnect the motor cables. Remove the four (4) SHCS that secure the axis motor to the motor
housing. Pull the motor away from the casting, this will slide the coupler off of the ball screw,
leaving it attached to the motor output shaft.

10. Remove the bearing locknut and the bearing housing from the bearing support end of the ball
screw.

11. Remove the ball screw retaining ring from the motor end of the ball screw.

12. Ball screw removal for the (SL-10):

a. Remove the last SHCS from the ball nut.

b. Slide the ball screw down through the bearing support casting.

c. Thread the ball nut up the ball screw towards the motor end, as you feed the ball screw down
through the bearing support casting.

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 d. Thread the nut up the ball screw until the ball screw can be swung down through the opening in
the wedge casting.

e. Remove the ball screw through the back side of the wedge casting.

f. Take extreme care not to damage the ball screw while pulling it through the castings.

Tool Changer Key Retaining

Gear Box Ring Motor

Coupling

Upper
Bearing
Lower
Bearing
Pack

Wedge
Lower Lock Nut

Ball screw removal for (SL-20, SL-30, and SL-40):

a. Loosen the counterbalance spring nut at the motor end of the ball screw. Using a crescent wrench,
hold swing arm and loosen upper hex bolt to slowly release the spring tension.

b. Remove the last SHCS from the ball nut.

c. Guide the ball screw out of the front of the machine

X- AXIS B ALL S CREW I NSTALLATION (SL-10)

1. Reinstall the bumpers onto the ball screw.

2. Replace the ball screw into the wedge casting in the reverse order by which it was removed:

a. Thread the ball nut up the ball screw towards the motor end until there is clearance to install the
ball screw through the wedge casting.

b. Slide the bearing support end of the ball screw through the bearing support casting.

c. Swing the ball screw up through the hole in the wedge casting.

d. Thread the ball nut down the ball screw, towards the bearing support end, until the ball screw
can be reinserted into the motor end bearing.

3. Ensure that the upper bearing is properly seated and then install the retaining ring.

4. Reinstall the bearing support cartridge into the bearing support casting and over the ball screw.
Secure with the SHCS and torque in a crisscross pattern to 15 ft-lbs.

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 5. Reinstall the lock nut onto the bearing support end of the ball screw. Torque the lock nut to 50 ft-
lbs and then torque the SHCS in the lock nut to 15 in-lbs.

6. Thread the ball nut up the ball screw until the nut is back in alignment with the nut housing.
Torque the SHCS to 15 ft-lbs.

7. Reinstall the oil line and the temperature sensor.

8. Check for binding in the beginning, middle and end of travel. Check for backlash or noisy operation.

X- AXIS B ALL SCREW I NSTALLATION (SL-20,30,40)

1. Reinstall the bumpers onto the ball screw.

2. Replace the ball screw into the wedge casting in the reverse order by which it was removed:

a. Thread the ball nut up the ball screw towards the motor end until there is clearance to install the
ball screw through the wedge casting.

b. Slide the bearing support end of the ball screw through the bearing support casting.

c. Thread the ball nut down the ball screw, towards the bearing support end, until the ball screw
can be reinserted into the motor end bearing.

3. Ensure that the upper bearing is properly seated and then install the retaining ring.

4. Reinstall the bearing support cartridge into the bearing support casting and over the ball screw.
Secure with the SHCS and torque in a crisscross pattern to 15 ft-lbs.

5. Retighten the counterbalance spring: See the Turret Cross Slide Spring Replacement section of
this manual.

6. Reinstall the lock nut onto the bearing support end of the ball screw. Torque the lock nut to 50 ft-
lbs and then torque the SHCS in the lock nut to 15 in-lbs.

7. Thread the ball nut up the ball screw until the nut is back in alignment with the nut housing.
Torque the SHCS to 15 ft-lbs.

8. Reinstall the oil line and the temperature sensor.

9. Check for binding in the beginning, middle and end of travel. Check for backlash or noisy operation.

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TOOLROOM LATHE X- AXIS BALL SCREW

Removal

Cross Slide Lube Fitting

Ballscrew

Nut Housing

Motor
Coupling

Bearing and
Lock Nut

Bearing Handle

1. Remove the hand wheel and the covers from the saddle to gain access to the X-axis ball screw, servo motor,
and coupler.

2. Remove the motor housing cover.

3. Loosen the clamp collar that couples the X-axis motor to the ball screw.

4. Remove the lubrication line from the ball nut. Remove the SHCS that secure the ball nut to the nut mount.

7. Remove the bearing locknut and the bearing housing from the bearing support end of the ball screw (the
opposite end away of the motor).

8. Remove the ball screw retaining ring from the motor end of the ball screw.

9. Slide the ballscrew away from the motor. Once the ball screw nut is clear of the nut housing lift the ballscrew
up, then towards the front of the machine then lift out of the casting assembly. It may be necessary to slide the
saddle towards the motor.

Installation
1. Install the new bearing pack into the motor end of the saddle casting.

2. Place the ballscrew bumper on the support end (not the motor end) of the ballscrew.

3. Install the ballscrew in the nut housing. Note the orientation of the lubrication fitting and the machined flat on
the ball screw. The fitting should be at the 7 O’clock position and the flat should face down.

4. Snug the bolts that secure the ball nut to the nut housing.

5. Move the saddle towards the rear of the machine and torque the clamp nut on the motor support end to 15ft-
lb. Then torque the SHCS in the nut to 12 inch-lbs.

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6. Lock the ballscrew (lock tool T-1601) and torque the SHCS that secure the bearing cartridge to 15 ft-lb.
Remove the lock tool.

7. Torque the SHCS in the nut face to 15 ft-lb.

8. Move the saddle to the front bearing support and install the bearing support over the end of the ballscrew.

9. Torque the clamp nut on the bearing support side to 4 inch-lb and the SHCS in the nut to 15 in-lb.

10. Install the lubrication line from the ball nut to the saddle assembly. Install the hand wheel.

11. Check for binding in the beginning, middle and end of travel. Check for backlash or noisy operation.

12. Reinstall the saddle covers.

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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.

LUBRICATION

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.

1. Disconnect air supply to C-axis actuator block and install an in-line regulator, with a cut off valve.

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 2. Press <SETNG GRAPH> and turn setting #7 off. Press <ALARM MESGS>, Type DEBUG and
press <ENTER>.

3. Press <ZERO RETURN>, type “C” and Press <ZERO SINGLE AXIS>

4. Set parameter 278 (C-axis drive) to zero (0), which will prevent the actuator block from engaging
the C-axis. Set parameter 498 (C-axis Disable) to one (1).

5. Command M19 (spindle orient) in MDI mode.

6. Engage the actuator block by applying pressure to the in-line regulator. Set the pressure to 45 psi.

7. Observe the mesh gar contact, insure full contact and smooth mesh of gears if necessary move
the drive gear by hand to insure full gear mesh.

8. Press <POSIT>, use page up or down to find “Pos-Raw Dat 1 data page. Locate the “C” Axis
actual column and record the value. Replace the value in parameter 517 (C-axis Grid Offset) with
this number. This value should be between 0 and 1260.

9. Release the air from the actuator block and set parameter 498 back to zero (0). Zero return the C-
axis; the value in the raw-data page Actual column should now read zero.

10. Engage and disengage the actuator block several times and insure that the gears are meshing
smoothly, observe the raw data Actual column to insure it remains at zero.

11. Disconnect the regulator from actuator block and reconnect normal air supply, enable parameter
278 bit 27 C-axis drive.

12. Press <MDI/DNC> and enter the following program.

M154;
M155;
M99;

13. Press <RESET><CYCLE START>, the machine should orient the spindle, engage and disengage
the C-axis without fault.

14. If the machine displays an alarm, double check the grid offset and spindle encoder pulley for proper
operation.

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S ETTING G EAR MESH C ONTACT L OAD

1. Install the in-line air regulator to the actuator block, adjust the air pressure on the regulator to 45
psi. Activate the air supply to the C-Axis pivot block. Ensure the regulator is set to 45psi.

2. 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 Loctite to the threads.

Stop Block Adjustment Stop Block Lockdown

Screws

3. Install the set screw, but do not put pressure on the stop block.

4. Place a magnetic base indicator on top of the spindle head and rest the indicator finger on top of
the pivot block.

5. Handle jog the C-axis and observe the indicator. If runout is over .0001” in 360° 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 .0001” in 360°, inspect the driven gear for damaged teeth.

6. Once the proper runout is achieved set the indicator finger to zero at the lowest point of the runout.

7. Screw down the adjustment set screw until the pivot block is .0005” from the gear mesh contact
point.

8. Tighten the two SHCS Stop Block Lockdown Screws, located on the side of the pivot stop block.
Torque to 35 ft/lbs. Reconnect the C-Axis air supply from the C-Axis solenoid.

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3.14 A UTO D OOR REMOVAL AND R EPLACEMENT

The following section describes the removal and replacement of the Auto-Door motor, clutch, and chain, and
how to adjust the action of the door.

MOTOR REPLACEMENT

Motor Removal
1. Shut off power to the machine.

2. Detach the motor cable from the extension cable 33-1312.

3. Loosen the front two FBHCS on the door drive mount. This will loosen the tension on the chain.

4. Detach the clutch and shaft adapter from the motor shaft by loosening the two (2) SSS on the
shaft adapter.

5. Remove the four (4) SHCS and lock washers that mount the motor to the door drive motor mount
and remove the motor.

Door Drive Door Drive Door Drive

Motor Motor Mount Mount

Chain
Clutch
Motor Mounting
SHCS

Motor Replacement
6. Remount the motor to the motor mount by the way in which it was removed.

7. Remount the clutch with the shaft adapter to the new motor. Hook the stabilizing arm of the clutch
to the prong on the door drive chain retainer.

8. Reassemble the chain to the motor assembly see the Chain Replacement and Adjustment section
for instructions.

9. Reattach the motor cable to the extension cable 33-1312.

96-8710 rev L June 2005 Mechanical Service 127

CLUTCH REPLACEMENT

Clutch Removal
1. Turn off power to the machine.

2. Unplug both of the clutch cables from the bridge rectifier on the motor mount.

3. Loosen the front two FBHCS on the door drive mount. This will loosen the tension on the chain.
Remove the chain from the sprocket on the clutch assembly.

4. Cut the cable ties that fasten the clutch cable to the motor mount. Loosen the two (2) set screws
on the shaft adapter and remove the clutch assembly.

5. Loosen the set screw on the front end of the clutch assembly and dismantle the clutch with the
sprocket from the shaft adapter. Be careful not to lose the woodruff key on the shaft.

6. Remove the three (3) SHCS that fasten the sprocket and cog hub to the clutch (the clutch is in two
parts).

2X Setscrew
Door Drive Door Drive Door Drive
Motor Motor Mount Mount Woodruff Key

3X SHCS

Setscrew

Shaft
Adapter

Cog Hub
Chain

Sprocket
Door Drive
Chain Retainer
Clutch

Stabilizing
Arm

Clutch Replacement
1. Replace the clutch as it was removed. When tightening the set screw on the clutch, make sure
that the sprocket turns freely. Hook the stabilizing arm of the clutch to the prong on the door drive
chain retainer.

2. The clutch sprocket should be aligned with the nylon derailers (sprockets) on the chain rail. Fasten
the clutch cable with ties as shown in the following figure.

3. See the Chain Replacement and Adjustment section to reattach the chain.

4. After the clutch has been installed and the chain adjusted properly manually open the door. While
holding the door open command the door to close. This can be done by pushing a button on the
side of the pendant or executing a program. Hold the door open until the machine alarms out.
Repeat this three times.

96-8710 rev L June 2005 Mechanical Service 128

 Cable Ties
Clutch
Stabilizing Arm Bridge
Rectifier

Clutch Cabling

CHAIN REPLACEMENT AND ADJUSTMENT

Chain Removal
1. Shut off power to the machine.
2. Loosen the front two FBHCS on the door drive mount. This will loosen the tension on the chain.
3. Detach the master chain link from the left and right sides of the chain rail and remove the chain.

Door Drive Door Drive Door Drive

Motor Motor Mount Mount

Chain
BHCS
Chain
Tension

Chain Replacement
1. Replace the chain by fastening the left and right master links to the chain rail on the left and right
ends.
2. Run the chain under the two nylon derailers (sprockets) and over the sprocket on the motor
assembly.
3. Adjust the chain tension by pivoting the motor assembly on the back two screws and tighten the
front two FBHCS on the door drive mount. There should be about 1/8” [3.2cm] clearance between
the chain and the chain rail.
4. Actuate the door manually to test the door movement. If the chain can be heard grinding on the
sprockets, it is too tight. Adjust the chain tension as necessary.

96-8710 rev L June 2005 Mechanical Service 129

AUTODOOR PARAMETERS

The movement of the Auto-Door is controlled by parameters 235, 236, and 251. See the parameters chapter in
this manual for their descriptions.

Adjust the parameters to assure that the door opens and closes properly.

1. Verify Setting 131 is set to ON. Set the value in parameters 235 and 236 to 3.

2. Set parameter 251 to a value of 3000 (Autodoor motor-on time is 3 seconds). The time needed to
fully open or close the door depends on the size of the machine.

3. Test the door by running this short program: G04 P3.;

M30;

4. When closing, the door should stop about one inch [2.54cm] before reaching the end. Adjust
parameter 251 as necessary.

5. Adjust parameters 235 and 236 as necessary for proper closure.

3.15 W AY C OVERS

M INI-L ATHE X-AXIS W AYCOVERS

Removal
The front and rear way covers are removed in the same manner; but have to be done independently. The
following describes the steps to remove the front way cover - The rear is done in similarly.

1. Jog the X-axis to the rear of the machine and press E-stop.

2. Remove the 8 screws from the left side of the saddle and the 2 from the right side of the saddle.

Z-Axis
Way Cover
Screws

Saddle Cover Screws (8)

96-8710 rev L June 2005 Mechanical Service 130

 3. Push down on the way cover leaf closest to the saddle and then pull towards the front of the
machine.

4. Loosen the screws on the bottom, underneath the way cover and remove the one closest to the
front of the machine.

5. Loosen the 8 the top rail bolts. These are accessible from the right side of the machine. It will be
necessary to remove the right side exterior panel. Loosen all the bolts, but remove the two end
bolts.

Top Rail Bulkhead

(8X) SHCS

6. Remove the 4 screws holding the front flange to the front of the machine.
7. Remove the way cover from the machine.
Installation
1. Install the new way cover.
2. Loosely install the top rail bolts.
3. Jog the X-axis all the way to the front of the machine. Adjust the top rail bulkhead towards or way
from the spindle to align the way covers.
4. Check for vertical misalignment. Chec!k in two places; the lower area closest to the floor pan and
the upper right side.

Properly aligned

Misaligned

Properly aligned

Misaligned

Lower- floor pan section Upper right side

96-8710 rev L June 2005 Mechanical Service 131

 5. Tighten the top rail screws once the alignment is achieved.
6. Install the screws securing the way cover to the saddle and the screws securing the way cover to
the front of the machine.
7. Install the remaining screws for the saddle cover and Z-axis wiper.
Cycle the X-axis a number of times and check for proper operation and look for any misalignment. Misalign-
ment can also be noticed by movement of the front enclosure (“oil-canning”).

3.16 S TEADY R EST A LIGNMENT AND A DJUSTMENT

If the clamp handle does not properly lock the steady rest in place, the tension bar needs to be adjusted.
1. Remove the 1 1/8" cap nut from the clamp handle and orient the handle in the un-clamped (vertical)
position.

2. Grip the tension bar and adjust in a counter clockwise direction so that the clamp will move closer
to the base creating more tension.

Note: Make sure that the tension bar is not so tight that the steady rest will still move
in the un-clamped position but will properly lock in the clamped position.

3. Re-install the cap nut.

Clamp
Handle

End
Nut
Tension Bar

96-8710 rev L June 2005 Mechanical Service 132

 4. ELECTRICAL SERVICE

40

Install lock-out clasp

and lock with paddlock
to secure Circuit Breaker
in the OFF position

Make sure the circuit breaker is locked in the off position before attempting any electrical work to avoid pos-
sible shock.

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.

96-8710 rev L June 2005 Electrical Service 133

 TURRET CLAMP/UNCLAMP SOLENOID
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.

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

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.

96-8710 rev L June 2005 Electrical Service 134

 5. Unscrew the entire solenoid assembly from the T-fitting.

Pressure Gauge

Main Air Line

Lube Line Pressure Switch

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.

96-8710 rev L June 2005 Electrical Service 135

 4.2. LINE 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

ELECTRICAL CONNECTIONS

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.

L1 L2 L3

Ground Line

40

T5 Transformer

Main Circuit Breaker

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.

96-8710 rev L June 2005 Electrical Service 136

 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.
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.

T5 Transformer

HIGH VOLT LOW VOLT

K1 HIGH VOLT 488-458V

LOW VOLT --------------
457-429V
260-244V
428-403V
243-227V
402-377V
226-211V
376-354V
210-195V LOW VOLT -------------- 260-244V 243-227V 226-211V 210-195V

Contactor

96-8710 rev L June 2005 Electrical Service 137

 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.
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.

PHASE
DETECT
PASS FAIL
NE6

NE5

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.

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.

96-8710 rev L June 2005 Electrical Service 138

 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.
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)

96-8710 rev L June 2005 Electrical Service 139

 4.3 FUSE 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.

(Control cabinets require a key)

3. Using a large flat tip screwdriver, un-latch 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).

96-8710 rev L June 2005 Electrical Service 140

 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
FU14
P15 NE13
P14
P21
P13
NE4 NE11 NE10 NE9 NE8 NE7 FU13
TB2
NE12 FU12
P16 P17 P18 P19 P20

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 volt-
age to the machine does not exceed 200 volts (Max 260 leg to leg or leg
to ground, or 400 volts on high voltage machines-max 520 volts leg to leg
of leg to ground).

96-8710 rev L June 2005 Electrical Service 141

 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.

96-8710 rev L June 2005 Electrical Service 142

 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 needs 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.

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.

96-8710 rev L June 2005 Electrical Service 143

P OWER & L OW V OLTAGE 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.

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 prop-
erly 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.

96-8710 rev L June 2005 Electrical Service 144

 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.

VIDEO &
KEYBOARD J13
SERIAL PCB
KEYBOARD
P1 INTERFACE
PCB
700B
850
J3

RS 232/ 32-4090 J1
P850
MICRO
PROCESSOR PORT 1
PCB Serial User’s Port
P850A

PORT 2
Aux Axis Port

* Serial interface replaces cable 700 with cable 700B.

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.
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.

96-8710 rev L June 2005 Electrical Service 145

 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.
The best way to minimize transmission errors is to have a good common ground between the PC and CNC
control

96-8710 rev L June 2005 Electrical Service 146

 4.5 F RONT P ANEL
Please read this section in its entirety before attempting to replace any component of the
control panel.

LCD ASSEMBLY REPLACEMENT

CAUTION! Use an electro-static discharge (ESD) strap on wrist when working inside
the pendant.

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. Disconnect the data cable from the receiver board on the LCD assembly (J3).
4. Disconnect the power cable and ground wire from the power supply board on the LCD assembly
(TB1).
5. Disconnect the cables to the keyboard from the receiver assembly (P1) and power supply (TB2) on
the LCD assembly.
6. Remove the four (4) hex nuts and washers beginning with the bottom, then remove the LCD
assembly and set aside in a safe place.

CAUTION! Take extreme care to not drop or damage the LCD assembly when
removing from the control panel.

7. Replace by sliding the new assembly onto the four bolts (two each on top and bottom). Place the
washers and hex nuts on the bolts to hold in place. Refer to the following. Once all washers have
been attached and nuts have been hand-tightened, tighten down completely.

Interior of control panel (rear).

96-8710 rev L June 2005 Electrical Service 147

 8. Plug the keyboard cables into the new receiver board (P1) and the power supply (TB2).
9. Plug the power cable into the power supply board (TB1) and attach the green wire to ground.
10. Plug the data cable into the receiver board (J3).
11. Replace the back cover panel and attach with the four screws previously removed.

SL-10 PENDANT COMPONENTS ACCESS

The SL-10 pendant door hinges on the left side. There are two (2) screws on top of the pendant that need to be
removed so that the pendant door may pivot open.
Caution: when closing the door, be sure not to pinch the cable.

JOG 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 the following figure when reconnecting; otherwise damage may
occur to the machine.

96-8710 rev L June 2005 Electrical Service 148

 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

Jog handle encoder.

4. Using the 5/64" allen wrench, loosen the two screws holding the knob to the control panel and
remove.

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.

96-8710 rev L June 2005 Electrical Service 149

 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 “LCD Assembly Replacement” section 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.

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.

96-8710 rev L June 2005 Electrical Service 150

 6. To replace, first put the bezel spacer in place and fasten temporarily with screws in the top cor-
ners.

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.

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.

96-8710 rev L June 2005 Electrical Service 151

 4.6 SPINDLE E NCODER 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. Carefully install the pulley onto the new encoder aligning the setscrew hole with the flat on the
encoder shaft. Use only one setscrew to hold the pulley on the shaft. Remove the setscrew and
apply a small drop of removable grade loctite to the setscrew threads. Some pulleys may have two
setscrew holes and screws, remove the unused setscrew.

2. Place the belt onto the pulley.

3. Mount the new encoder and tighten the bolts. Belt tension is very critical to the proper perfor-
mance of the encoder. Do not create an excessive amount of tension on the belt. The maximum
radial load (side load) for the encoder shaft is 13-1/2 lbs (60 N). Exceeding this maximum radial
load may damage the encoder.

4. Replace the sheetmetal removed in REMOVAL, Step 1.

Mounting bolts (2)

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 A2-6, 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.

LUBRICATION

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.

96-8710 rev L June 2005 Technical Reference 153

 5.3 L IVE T OOLING O PERATION

Live tool motor speed functions are controlled primarily by the Q address code. The Q address specifies RPM
in integer values from 1 to maximum spindle speed (Parameter 131). NOT TO BE CHANGED BY USER! The
maximum spindle speed is 5000 RPM.

Speeds from S1 to the value in Macro variable 730 (usually 1200) will automatically select low gear and speeds
above the value in Macro variable 730 will select high gear. Two M codes, M41 and M42 can be used to override
the gear selection. M41 for low gear and M42 for high gear. Low gear operation above S1250 is not recom-
mended. High gear operation below S100 may lack torque or speed accuracy. Accuracy is best at the higher
speeds and in low gear.

LIVE T OOL W ARM -U P P ROGRAM

Live tooling motors, which have been idle for more than 4 days, must be thermally cycled prior to operation.
This will prevent possible overheating of the motor due to settling of lubrication. A 20-minute warm-up program
has been supplied with the machine, which will bring the motor up to speed slowly and allow the motor to
thermally stabilize. This program may also be used daily for warm-up prior to high-speed use. The program
number is O02020 (Live Tool Warm-Up).
O02020 (Live Tooling Warm-Up)
M133 Q250;
G04 P200.;
M133 Q500;
G04 P200.;
M133 Q1250;
G04 P200.;
M133 Q2500;
G04 P200.;
M133 Q3750;
G04 P200.;
M133 Q5000;
G04 P200.;
M30;

LIVE T OOLING RUN -I N P ROGRAM

Live tooling motors must go through a run-in cycle at the time of machine installation prior to operating at
speeds above 1,000 RPM. A program has been supplied with the machine that will run-in the live tooling motor
during machine installation and should also be used after long periods of machine down-time (two weeks or
more). The program number is O02021 (Live Tool motor Run-In). Cycle Time: 2 hours. See Installation Section
for copy of the program.

LIVE T OOLING ORIENTATION

Orientation of the spindle is automatically performed for tool changes and can be programmed with M119
commands. Orientation is performed by turning the spindle until the encoder reference is reached, the spindle
motor holds the spindle locked in position. If the spindle is orientated and electronically locked, commanding
spindle forward or reverse will release the lock.

154 Technical Reference 96-8710 rev L June 2005

 5.4 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.

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.

96-8710 rev L June 2005 Technical Reference 155

 5.5 INPUT/O UTPUT ASSEMBLY

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.

5.6 C ONTROL P ENDANT

JOG 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.

S PINDLE 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 S TOP 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.

156 Technical Reference 96-8710 rev L June 2005

 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.

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.

SL-S ERIES 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.

96-8710 rev L June 2005 Technical Reference 157

 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 SL-Series control cabinet.

158 Technical Reference 96-8710 rev L June 2005

 5.7 M ICROPROCESSOR ASSEMBLY

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; 1MB or
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:

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.

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.

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.

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.

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.

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.

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.

+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.

96-8710 rev L June 2005 Technical Reference 159

 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)

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.

160 Technical Reference 96-8710 rev L June 2005

 5.8 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.

5.9 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. 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.

96-8710 rev L June 2005 Technical Reference 161

 5.10 P OWER S UPPLY A SSEMBLY

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.

C IRCUIT BREAKERS

The main circuit breaker is used to protect the wiring in the machine 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.
The main circuit breaker furnishes power to the spindle and sub-spindle circuit breakers. These breakers do not
have extended handles and can be set/reset only with the cabinet door open. Normally, the spindle and
Subspindle circuit breakers would be left ON at all times. Since power is removed from the control by turning
the main circuit breaker OFF (turn the handle counterclockwise), there is no danger in leaving the other two
breakers ON at all times. However, when troubleshooting a power fault, it may be necessary to have the main
breaker ON after the door is opened, in which case the operator may decide to turn either the spindle or sub-
spindle breaker to the OFF position. It should be remembered that turning the sub-spindle breaker OFF will
removes power to the spindle contactor as well as the sub-spindle contactor, but the reverse is not true.
Turning the spindle breaker OFF will not remove power from any control electronics except for the spindle
transformer and spindle vector drive.

A trip of any of these breakers indicates a serious overload problem and this should not be reset without
investigating the cause of the trip.

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.

LOW VOLTAGE POWER SUPPLY

There are two low voltage power supplies. One, the stack supply, operates from 118VAC and provides +5V,
+12V and -12V power to all of the logic sections of the control. Mouned on top of this supply is the servo power
supply, which furnishes +12V and -12V power to the servo amplifiers. This supply is powered from the 335VDC
bus from the sub-spindle vector drive.

162 Technical Reference 96-8710 rev L June 2005

 LOW 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.

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.

96-8710 rev L June 2005 Technical Reference 163

 5.11 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.

HIGH VOLT LOW VOLT

HIGH VOLT 488-458V 457-429V 428-403V 402-377V 376-354V

LOW VOLT -------------- 260-244V 243-227V 226-211V 210-195V LOW VOLT -------------- 260-244V 243-227V 226-211V 210-195V

Transformer with 354-488V range Transformer with 195-260V range

O PTIONAL 480V 60H Z T RANSFORMER

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)

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.

164 Technical Reference 96-8710 rev L June 2005

 SECONDARY 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.

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 Input Voltage Range Tap

493-510 1 (504) 445-456 5 (456)
481-492 2 (492) 433-444 6 (444)
469-480 3 (480) 420-432 7 (432)
457-468 4 (468)

O PTIONAL 480V 50H Z T RANSFORMER

Input Voltage Range Tap Input Voltage Range Tap

423-440 1 (504) 381-390 5 (456)
412-422 2 (492) 371-380 6 (444)
401-411 3 (480) 355-370 7 (432)
391-400 4 (468)

5.12 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. A light on the amplifier will tell of a blown fuse. If
necessary replace the fuse (Haas p/n 93-1089). If the fuse blows again the amplifier may be damaged, in which
case the amplifier needs to be replaced.

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).

Size Fuse Name Type Rating Voltage Location

(amps)

5mm FU1-FU3 Slo-Blo ½ 250V PSUP pcb, upper right

1/4 F1 Ultra fast 15 250V Amplifier
5mm FU4,5 Fast blow 5A 250V PSUP, bottom right corner

96-8710 rev L June 2005 Technical Reference 165

 5.13 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:

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.

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.

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 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.

96-8710 rev L June 2005 Technical Reference 167

 5.14 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 squirts approximately 3 cc of oil every 30 minutes with 60 Hz power (36 minutes with 50 Hz power)
throughout the oil lines to the lube points. Each lube point receives approximately 1/16 of oil.

The lube pump and spindle fan are on the same circuit. This circuit is turned on whenever a program is
running, and it remains on after a program is stopped for the time specified by SPIN. FAN OFF
DELAY(Parameter 208).

There is an internal level switch in the reservoir and external pressure switch on the lube panel. These are
wired in series and provide a signal to the control system. An input value of 0 means that oil level and pressure
are high. A value of 1 means low pressure or low oil level. Under normal conditions the pressure will remain
high for a period of several minutes after each pump cycle.

The control system monitors both the amount of time the input is 0 and the amount of time its 1. If the input
value is 0, meaning acceptable, for at least two minutes, the low-time counter is restarted. If the input value is
1, meaning unacceptable, even for an instant, the high-time counter is restarted. If the low-time counter
exceeds the LUBE CYCLE TIME, (Parameter 117), nominally 36 minutes, and the control is not running a
program or in jog lock, Alarm 121 shall be generated. Lube pressure is checked only when the pump is
activated.

168 Technical Reference 96-8710 rev L June 2005

 5.15 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.

The operator's lamp is using 115 VAC taken from P19 on the main power distribution.

DOOR 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.

LIMIT S WITCHES

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.

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.

96-8710 rev L June 2005 Technical Reference 169

 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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 5.16 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:

DISCRETE 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

96-8710 rev L June 2005 Technical Reference 171

 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

172 Technical Reference 96-8710 rev L June 2005

 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 X.XXX Software version number
YY/MM/DD Today's date
MDL SL-__ Model number
DC BUSS Mocon II

96-8710 rev L June 2005 Technical Reference 173

 5.17 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.

5.18 T HE E QUATIONS OF M OTION

An analysis of the physics of motion of a machine tool can give some important insights into the famous
“blocks per second” issue. The following mathematics calculates the block per second requirement in order to
achieve a worst case chordal deviation error while moving around a curve made up of a series of points:
Let:
a = acceleration,
v=speed (or feed rate),
r = radius of curvature,
e = error from chordal deviation
l = block length (or travel length from point to point)
b = blocks per second

The following are known:

For a circular motion:
a = v*v/r (1)
and in motion:
v=b*l (2)
which gives:
b=v/l (3)
and
e = r – sqrt(r*r-l*l/4) (4)
which gives:
r*r – 2*r*e + e*e = r*r – l*l/4 (5)
and:
l= sqrt(8*r*e – 4*e*e) (6)
Since r>>e, e*e is small compare to r*e and we can assume:
l = sqrt(8*r*e) (7)
And combining we get:
b = sqrt(a*r) / sqrt (8*r*e) (8)
Or
b = sqrt(a / (8*e) ) (9)
Thus, block per second is dependent only on the machine acceleration and the maximum chordal error al-
lowed.

174 Technical Reference 96-8710 rev L June 2005

 Note also that an important equation (7) is the relationship between radius of curvature (r), chordal error (e) and
block length (l). If you have a radius or curvature close to 1/4 inch and your maximum chordal error is 0.00005
inch, the recommended block length is 0.01 inch. This shows that it is not always required to use very short
blocks.

5.19 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)

96-8710 rev L June 2005 Technical Reference 175

 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, ball 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

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.
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.

176 Parameters 96-8710 rev L June 2005

 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 Service use only.
25 3 EREV/MREV The 2 EREV/MREV and 3 EREV/MREV bits have two definitions
depending on whether one or two encoders are present. For single
encoder systems, the bits are used to define the ratio between the
electrical rotation of the spindle motor and the mechanical rotation of the
motor. For two encoder systems, the definition is the electrical rotation of
the motor to the mechanical rotation of the spindle motor encoder, which
includes any pulley ratio between the motor and the motor encoder.
26 2 EREV/MREV The 2 EREV/MREV and 3 EREV/MREV bits have two definitions
depending on whether one or two encoders are present. For single
encoder systems, the bits are used to define the ratio between the
electrical rotation of the spindle motor and the mechanical rotation of the
motor. For two encoder systems, the definition is the electrical rotation of
the motor to the mechanical rotation of the spindle motor encoder, which
includes any pulley ratio between the motor and the motor encoder.
27 NON MUX PHAS For HAAS Service use 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

2 X P GAIN
Proportional gain in servo loop.

3 X D GAIN
Derivative gain in servo loop.

4 X I GAIN
Integral gain in servo loop.

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

96-8710 rev L June 2005 Parameters 177

 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

7 X ACCELERATION
Maximum acceleration of axis in steps per second per second.

8 X MAX SPEED
Max speed for this axis in steps per second.

9 X MAX ERROR
Max error allowed in servo loop before alarm is generated. Units are encoder steps.

10 X FUSE LEVEL
Used to limit average power to motor. If not set correctly, this parameter can cause an
“overload” alarm.

11 X BACK EMF
Back EMF of motor in volts per 1000 RPM times 10. Thus a 63 volt/KRPM motor gives 630.

12 X STEPS/REVOLUTION
Encoder steps per revolution of motor. Thus, an 8192 line encoder gives: 8192 x 4 = 32768

13 X BACKLASH
Backlash correction in encoder steps.

14 X DEAD ZONE
Dead zone correction for driver electronics. Units are 0.0000001 seconds.

15 Y SWITCHES
See Parameter 1 for description.

16 Y P GAIN
See Parameter 2 for description.

17 Y D GAIN
See Parameter 3 for description.

18 Y I GAIN
See Parameter 4 for description.

19 Y RATIO (STEPS/UNIT)
See Parameter 5 for description.

20 Y MAX TRAVEL (STEPS)

See Parameter 6 for description.

21 Y ACCELERATION
See Parameter 7 for description.

22 Y MAX SPEED
See Parameter 8 for description.

23 Y MAX ERROR
See Parameter 9 for description.

178 Parameters 96-8710 rev L June 2005

 24 Y FUSE LEVEL
See Parameter 10 for description.

25 Y BACK EMF
See Parameter 11 for description.

26 Y STEPS/REVOLUTION
See Parameter 12 for description.

27 Y BACKLASH
See Parameter 13 for description.

28 Y DEAD ZONE
See Parameter 14 for description.

29 Z SWITCHES
See Parameter 1 for description.

30 Z P GAIN
See Parameter 2 for description.

31 Z D GAIN
See Parameter 3 for description.

32 Z I GAIN
See Parameter 4 for description.

33 Z RATIO (STEPS/UNIT)
See Parameter 5 for description.

34 Z MAX TRAVEL (STEPS)

See Parameter 6 for description.

35 Z ACCELERATION
See Parameter 7 for description.

36 Z MAX SPEED
See Parameter 8 for description.

37 Z MAX ERROR
See Parameter 9 for description.

38 Z FUSE LEVEL
See Parameter 10 for description.

39 Z BACK EMF
See Parameter 11 for description.

40 Z STEPS/REVOLUTION
See Parameter 12 for description.

41 Z BACKLASH
See Parameter 13 for description.

42 Z DEAD ZONE
See Parameter 14 for description.

96-8710 rev L June 2005 Parameters 179

 43 A SWITCHES
See Parameter 1 for description.

44 TURRET P GAIN
See Parameter 2 for description.

45 TURRET D GAIN
See Parameter 3 for description.

46 TURRET I GAIN
See Parameter 4 for description.

47 TURRET RATIO (STEPS/UNIT)

See Parameter 5 for description.

48 TURRET MAX TRAVEL (STEPS)

See Parameter 6 for description.

49 TURRET ACCELERATION
See Parameter 7 for description.

50 TURRET MAX SPEED

See Parameter 8 for description.

51 TURRET MAX ERROR

See Parameter 9 for description.

52 TURRET FUSE LEVEL

See Parameter 10 for description.

53 TURRET BACK EMF

See Parameter 11 for description.

54 TURRET STEPS/REVOLUTION
See Parameter 12 for description

55 TURRET BACKLASH
See Parameter 13 for description.

56 TURRET DEAD ZONE

See Parameter 14 for description.

Parameters 57 through 128 are used to control other machine dependent functions. They are:

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.

180 Parameters 96-8710 rev L June 2005

 6 NETWORK/ZIP This is used to activate the internal Zip/Enet PC104 board at power-on
time. When it is set to 0, the CNC will not access the board. When it is set
to 1, the CNC will access it at power-on time and display the message
“LOADING” on the Zip/Enet settings page just below setting 139. After
some time (2 minutes maximum,) the control will instead display the
message “DISK DONE” indicating that communications have been
established with the internal PC104 board and the user can now use the
control.
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 UNUSED
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 listing of 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.
26 TRANS OIL When this parameter is set to 1, it enables transmission low oil pressure
detection via input 1014.
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 SP MOTOR ENC This parameter bit enables a second encoder that is mounted on the
spindle motor and wired into the “C” axis input of the Mocon. It is required
to control the vector algorithm on a belted machine when the belts slip at
high load.
When two encoders are present, the first is mounted on the spindle or
output of the transmission, and is wired to the “spindle” input on the
MOCON.
Most mills use a single encoder that is mounted on either the spindle
(transmission output) or spindle motor but always connected to the
spindle input on the Mocon.
31 DOOR STOP SP Enables functions to stop spindle and manual operations at door switch.

96-8710 rev L June 2005 Parameters 181

 58 LEAD COMPENS SHIFT
Shift factor when applying ball screw compensation. Ball 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.

59 MAX FEED RATE (INCH)

Maximum feed rate in inches per minute.

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.

61 TURRET LOCK DELAY

Amount of time to delay after the turret is sensed to be locked. This delay allows for
mechanical settling.

62 TURRET UNLOCK ERROR TIME

Maximum delay allowed for tool turret to unlock. Units are milliseconds. After this time, an
alarm is generated.

63 TURRET LOCK ERRTIME

Maximum delay allowed for tool turret to lock. Units are milliseconds. After this time, an alarm
is generated.

64 Z TOOL CHANGE OFFSET

For turret, displacement from home switch to tool 0.

65 NUMBER OF TOOLS
Number of tool positions in tool changer. This number must be set to the lathe's configuration.

66 SPINDLE ORI DELAY

Maximum delay allowed when orienting spindle. Units are in milliseconds. After this time, an
alarm is generated.

67 GEAR CHANGE DELAY

Maximum delay allowed when changing gears. Units are milliseconds. After this time, an
alarm is generated.

68 DRAWBAR MAX DELAY

Maximum delay allowed when clamping and unclamping tool. Units are milliseconds. After this
time, an alarm is generated.

69 A AIR BRAKE DELAY

Delay provided for air to release from brake prior to moving. Units are milliseconds.

70 MIN SPIN DELAY TIME

Minimum delay time in program after commanding new spindle speed and before proceeding.
Units are milliseconds.

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.

182 Parameters 96-8710 rev L June 2005

 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 the velocity 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.

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.

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.

75 GEAR CHANGE SPEED

Command speed used to rotate spindle motor when changing gears. Units are maximum
spindle RPM divided by 4096.

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.

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.

78 GEAR CH REV TIME

Time in milliseconds before motor direction is reversed while in a gear change.

79 SPINDLE STEPS/REV
Sets the number of spindle encoder steps per revolution of the spindle. This number takes into
account the pulley ratio between transmission and spindle, plus transmission and encoder. If
there are 2 encoders employed, this number applies to the encoder on the spindle (connected
to the SP input of the mocon) If only 1 encoder is employed, it will be for that encoder. In
most installations, the single encoder will be mounted on the motor but will still connect to the
SP input of the mocon.

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.

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.

96-8710 rev L June 2005 Parameters 183

 82 M MACRO CALL O9001
Same as 81.

83 M MACRO CALL O9002

Same as 81.

84 M MACRO CALL O9003

Same as 81.

85 M MACRO CALL O9004

Same as 81.

86 M MACRO CALL O9005

Same as 81.

87 M MACRO CALL O9006

Same as 81.

88 M MACRO CALL O9007

Same as 81.

89 M MACRO CALL O9008

Same as 81.

90 M MACRO CALL O9009

Same as 81.

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.

92 G MACRO CALL O9011

Same as 91.

93 G MACRO CALL O9012

Same as 91.

94 G MACRO CALL O9013

Same as 91.

95 G MACRO CALL O9014

Same as 91.

96 G MACRO CALL O9015

Same as 91.

184 Parameters 96-8710 rev L June 2005

 97 G MACRO CALL O9016
Same as 91.

98 G MACRO CALL O9017

Same as 91.

99 G MACRO CALL O9018

Same as 91.

100 G MACRO CALL O9019

Same as 91.

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.

102 IN POSITION LIMIT Y

Same definition as Parameter 101.

103 IN POSITION LIMIT Z

Same definition as Parameter 101.

104 IN POSITION LIMIT A

Same definition as Parameter 101.

105 X MAX CURRENT

Fuse level in % of max power to motor. Applies only when motor is stopped.

106 Y MAX CURRENT

Same definition as Parameter 105.

107 Z MAX CURRENT

Same definition as Parameter 105.

108 A MAX CURRENT

Same definition as Parameter 105.

109 D*D GAIN FOR X

Second derivative gain in servo loop.

110 D*D GAIN FOR Y

Second derivative gain in servo loop.

111 D*D GAIN FOR Z

Second derivative gain in servo loop.

112 D*D GAIN FOR A

Second derivative gain in servo loop.

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.

114 Y ACC/DEC T CONST

Same definition as Parameter 113.

96-8710 rev L June 2005 Parameters 185

 115 Z ACC/DEC T CONST
Same definition as Parameter 113.

116 A ACC/DEC T CONST

Same definition as Parameter 113.

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.

118 SPINDLE REV TIME

Time in milliseconds to reverse spindle motor.

119 SPINDLE DECEL DELAY

Time in milliseconds to decelerate spindle motor.

120 SPINDLE ACC/DECEL

Accel/decel time constant in 200ths of a step/ms/ms for spindle motor.

121 X PHASE OFFSET

The motor phase offset for X motor. This is arbitrary units.

122 Y PHASE OFFSET

See Parameter 121 for description.

123 Z PHASE OFFSET

See Parameter 121 for description.

124 A PHASE OFFSET

See Parameter 121 for description.

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.

126 Y GRID OFFSET

See Parameter 125 for description.

127 Z GRID OFFSET

See Parameter 125 for description.

128 A GRID OFFSET

See Parameter 125 for description.

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.

130 GEAR STROKE DELAY

This parameter controls the delay time to the gear change solenoids when performing a gear
change.

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.

186 Parameters 96-8710 rev L June 2005

 132 Y SCREW COMP. COEF.
This parameter is used to hold the thermal compensation coefficient. This is the coefficient of
heating of the ball screw. This parameter should be set to zero.

133 Z SCREW COMP. COEF.

This parameter is used to hold the thermal compensation coefficient. This is the coefficient of
heating of the ball 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.

134 X EXACT STOP DIST.

135 Y EXACT STOP DIST.

136 Z EXACT STOP DIST.

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.

NOTE: To change the values of parameters 134-137 permanently the machine must
be rebooted.

138 X FRICTION COMPENSATION

139 Y FRICTION COMPENSATION

140 Z FRICTION COMPENSATION

141 A FRICTION COMPENSATION

These parameters compensate for friction on each of the four axes. The units are in 0.004V.

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.

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.

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.

145 X ACCEL FEED FORWARD

This parameter sets the feed forward gain for the X-axis servo. It has no units.

146 Y ACCEL FEED FORWARD

Same as Parameter 145.

147 Z ACCEL FEED FORWARD

Same as Parameter 145.

148 A ACCEL FEED FORWARD

Same as Parameter 145.

96-8710 rev L June 2005 Parameters 187

 150 MAX SP RPM LOW GEAR
Maximum spindle RPM in low gear.

151 B SWITCHES
See Parameter 1 for description.

152 B P GAIN
See Parameter 2 for description.

153 B D GAIN
See Parameter 3 for description.

154 B I GAIN
See Parameter 4 for description.

155 B RATIO (STEPS/UNIT)

See Parameter 5 for description.

156 B MAX TRAVEL (STEPS)

See Parameter 6 for description.

157 B ACCELERATION
See Parameter 7 for description.

158 B MAX SPEED

See Parameter 8 for description.

159 B MAX ERROR

See Parameter 9 for description.

160 B FUSE LEVEL

See Parameter 10 for description.

161 B BACK EMF

See Parameter 11 for description.

162 B STEPS/REVOLUTION
See Parameter 12 for description.

163 B BACKLASH
See Parameter 13 for description.

164 B DEAD ZONE

See Parameter 14 for description.

165 IN POSITION LIMIT B

See Parameter 101 for description.

166 B MAX CURRENT

See Parameter 105 for description.

167 B D*D GAIN

See Parameter 109 for description.

168 B ACC/DEC T CONST

See Parameter 113 for description.

188 Parameters 96-8710 rev L June 2005

 169 B PHASE OFFSET
See Parameter 121 for description.

170 B GRID OFFSET

See Parameter 125 for description.

171 B EXACT STOP DIST.

See Parameter 134 for description.

172 B FRICTION COMPENSATION

See Parameter 138 for description.

173 B ACCEL FEED FORWARD

See Parameter 145 for description.

174 B SCREW COMP. COEF.

This parameter is used to hold the thermal compensation coefficient. This is the coefficient of
heating of the ball screw. This parameter should be set to zero.

175 B AIR BRAKE DELAY

See Parameter 69 for description.

176 Sp SWITCHES
See Parameter 1 for description.

177 C P GAIN
See Parameter 2 for description.

178 C D GAIN
See Parameter 3 for description.

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

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.

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)

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.

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.

96-8710 rev L June 2005 Parameters 189

 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.

184 C MAX ERROR

See Parameter 9 for description.

185 C FUSE LEVEL

See Parameter 10 for description.

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.

187 C sp MOT HI GEAR ST/REV

This name is used when a Vector Drive is installed. This function takes on two meanings
depending on how many spindle encoders are used on the machine. If only one encoder is
present, it is the number of encoder steps per mechanical revolution of the spindle motor when
the transmission is in high gear. (On direct drive machines, the encoder is mounted on the
motor, while on others, it is on the spindle or transmission output.) N = (Encoder steps/enc
rev)/(Enc pulley ratio X High Gear Ratio) For machines with a spindle and spindle motor
encoder, it is the number of spindle motor encoder steps per mechanical revolution of the
encoder. Its purpose is to specify the resolution of the spindle motor encoder. This parameter
is used in conjunction with parameter 176 bits 25 and 26, which control the ratio between the
electrical revolution of the motor to the mechanical revolution of the encoder.
If a vector drive is not installed, this parameter is called: STEPS/REVOLUTION and is not
used.

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.

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.

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.

191 C MAX CURRENT

See Parameter 105 for description.

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.

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.

190 Parameters 96-8710 rev L June 2005

 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.

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.

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.

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.

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.

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.

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.

201 X SCREW COMP. COEF.

This parameter is used to hold the thermal compensation coefficient. This is the coefficient of
heating of the ball 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.

205 A SCREW COMP. COEF.

This parameter is used to hold the thermal compensation coefficient. This is the coefficient of
heating of the ball screw. This parameter should be set to zero.

206 RESERVED

207 RESERVED

96-8710 rev L June 2005 Parameters 191

 208 SPIN. FAN OFF DELAY
Delay for turning the spindle fan off after the spindle has been turned off.

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 RESET STOPS TL CHGR Tool changer can be stopped with RESET button.
2 UNUSED
3 ENABLE CHIP CONVEYR Enables chip conveyor, if machine is so equipped.
4 50% RAPID KEYBOARD 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.
6 UNUSED
7 UNUSED
8 UNUSED
9 SPIGOT KEY INVERT
10 T SUBROUTINE
11 RESERVED
12 REVERSED CONVEYOR Reverses the direction of the chip conveyor.
13 M27-M28 CONVEYOR 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.
14 RESERVED
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 CNVR DOOR HOLD 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 DISABLED COOLANT IN
19 T.C. 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.
20 REMOTE TOOL RELEASE This bit supports the VTC-48. It specifies that the machine has a remote
tool release button. It should be set to 1 on the VTC-48 and zero on all
other lathes.
21 FLOPPY ENABLE Enables an installed floppy disk drive.
23 MCODE RELAY BOARD If set to 1, adds 16 additional relays, for a total of 56.

192 Parameters 96-8710 rev L June 2005

 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.
28 UNUSED
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 SPINDLE 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.

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.

216 CNVYR RELAY DELAY

Delay time in 1/50 seconds required on conveyor relays before another action can be
commanded. Default is 5.

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.

218 CONVYR RETRY REV TIM

Amount of time that the conveyor is reversed in 1/50 seconds after overcurrent is sensed.
Default is 200.

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.

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.

96-8710 rev L June 2005 Parameters 193

 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.

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.

226 EDITOR CLIPBOARD

This parameter assigns a program number (nnnnn) to the contents of the clipboard (for the
advanced editor).

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.

228 QUICKCODE FILE

This parameter set the program numbers to store in the Quick Code definition.

229 X LEAD COMP 10E9

This parameter sets the X-axis lead screw compensation signed parts per billion.

230 Y LEAD COMP 10E9

This parameter sets the Y-axis lead screw compensation signed parts per billion.

231 Z LEAD COMP 10E9

This parameter sets the Z-axis lead screw compensation signed parts per billion.

232 A LEAD COMP 10E9

This parameter sets the A-axis lead screw compensation signed parts per billion.

233 B LEAD COMP 10E9

This parameter sets the B-axis lead screw compensation signed parts per billion.

234 C BELT COMPENSATION

This parameter sets the belt compensation.

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.

194 Parameters 96-8710 rev L June 2005

 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.

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.

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.

239 SPNDL ENC STEPS/REV

This parameter sets the number of encoder steps per revolution of the spindle encoder.

240 1ST AUX MAX TRAVEL

This parameter sets the maximum travel of the first auxiliary axis in the positive direction.

241 2ND AUX MAX TRAVEL

This parameter sets the maximum travel of the second auxiliary axis in the positive direction.

242 3RD AUX MAX TRAVEL

This parameter sets the maximum travel of the third auxiliary axis in the positive direction.

243 4TH AUX MAX TRAVEL

This parameter sets the maximum travel of the fourth auxiliary axis in the positive direction.

244 1ST AUX MIN TRAVEL

This parameter sets the maximum travel of the first auxiliary axis in the negative direction.

245 2ND AUX MIN TRAVEL

This parameter sets the maximum travel of the second auxiliary axis in the negative direction.

246 3RD AUX MIN TRAVEL

This parameter sets the maximum travel of the third auxiliary axis in the negative direction.

247 4TH AUX AXIS MIN TRAVEL

This parameter sets the maximum travel of the fourth auxiliary axis in the negative direction.

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.

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.

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.

96-8710 rev L June 2005 Parameters 195

 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.

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 ballscrew tailstock or
TL-15.

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 ballscrew tailstock or TL-15.

254 SPINDLE CENTER

Reserved for service use only.

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.

256 PALLET LOCK INPUT

It should be set to zero on all machines.

257 SPINDLE ORIENT OFSET

This is used for the Vector Drive and the value is determined at the time of assembly.

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.
3 TH SNSR COMP This parameter is used for Ball 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

196 Parameters 96-8710 rev L June 2005

 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.

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 Ball 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
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.

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 Ball 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

96-8710 rev L June 2005 Parameters 197

 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.

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.
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 Ball 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.

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.

198 Parameters 96-8710 rev L June 2005

 3 TH SNSR COMP This parameter is used for Ball 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
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.

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 Ball 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.

96-8710 rev L June 2005 Parameters 199

 272 X THERM COMP T. CONST
This parameter supports Ball 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.

273 Y THERM COMP T. CONST

This parameter supports Ball 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.

274 Z THERM COMP T. CONST

This parameter supports Ball 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.

275 A THERM COMP T. CONST

This parameter supports Ball 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.

276 B THERM COMP T. CONST

This parameter supports Ball 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.

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 CHECK PALLET IN
3 CHK HIDDN MACRO VAR
4 DISPLAY ACTUAL RPM When set to 1, displays the actual spindle speed on the Current
Commands display page.
TSC PURGE ENABLE
6 HYDRAULIC TAILSTOCK This bit enables the hydraulic tailstock
7 SPINDLE DRIVE LOCK This bit must be set to 0 if machine is equipped with a Haas vector
spindle drive.
8 CHUCK OPEN CSTART 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 CONCURRENT 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 VECTOR DRIVE (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.
12 uP ENCLOSURE TEMP (Microprocessor enclosure temperature) When set to 1, the enclosure
temperature will be displayed on INPUTS2 screen of the diagnostics
display.

200 Parameters 96-8710 rev L June 2005

 13 HAAS REMOTE JOG HDL 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 MOTOR OTEMP NC Spindle Motor Over 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.
16 UNUSED
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 DEL:Y SWITCH ENABLE 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 DEL:Y SWITCH 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 CHK BARFEED 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 CHK BF SPIND I-LOCK 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.
22 UNUSED
23 UNUSED
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.
27 UNUSED
28 VSMTC ENABLE
29 DOOR SAFETY SW INV 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.
30 UNUSED
31 INV SPIND SPD DECEL Inverse spindle speed deceleration. When this parameter is set to 1, the
spindle decelerates faster at lower speeds, resulting in a shorter
deceleration time.

96-8710 rev L June 2005 Parameters 201

 285 X LINEAR SCREW OFFS
Reserved for future use; set to zero.

286 Y LINEAR SCREW OFFS

Reserved for future use; set to zero.

287 Z LINEAR SCREW OFFS

Reserved for future use; set to zero.

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.

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.

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.

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.

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.

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.

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.

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.

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.

202 Parameters 96-8710 rev L June 2005

 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.

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.

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.

315 COMMON SWITCH 4

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.
1 NO SPIND CAN CYCLE
2 UNUSED
3 UNUSED
4 UNUSED
5 DOOR OPEN SWITCH 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.
6 SIMPLE TAILSTOCK 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.
7 BRUSHLESS BARFEEDER This parameter bit supports the brushless bar feeder. When it is set to 1,
it indicates that a brushless bar feeder is present.

96-8710 rev L June 2005 Parameters 203

 8 MINI POWER SUPPLY This parameter bit is intended for the Mini Lathe. When it is set to zero,
the control behaves as before. This parameter bit must be set to 1 on all
Mini Lathes. Note: Parameter 294 MIN BUSS VOLTAGE must be set to
zero on all Mini Lathes.
9 AUTO PARTS LOADER This parameter indicates that a Haas Lathe APL is installed. When this bit
is set to 1, a COMMANDS screen for the HAAS APL is displayed.
10 ZERO RET ON C ENGAGE This parameter bit controls what the C-axis will do upon engagement. If
this bit is set to zero, the C-axis will rapid to zero upon engagement.
When this bit is set to 1, the C-axis will perform a zero return upon
engagement. Note that in either case, the spindle is oriented upon C-axis
engagement. Note also, that in order to avoid spindle oscillation during
movement of the C-axis, the spindle is shifted to high gear (on lathes with
a gear box) before engaging the C-axis.
11 SETING 92 ENABLE This parameter bit is intended to prevent damage to lathes fitted with a
pneumatic double-chuck. If setting 92 CHUCK CLAMPING is switched
from O.D. to I.D. or back while the spindle is turning, the chuck will be
considered clamped in the opposite direction and will move immediately.
A pneumatic double-chuck will be damaged if it is moved while the
spindle is turning. This parameter bit must be set to 1 before setting 92
can be altered, and since parameters can only be altered after ESTOP
has been pressed, this ensures that the spindle will be at rest when the
bit is altered. It is strongly advised that this bit be returned to zero
immediately after use.
16 SS REV SPIND ENCODR Reverses sense direction of subspindle encoder
17 SS VEC DRIVE ENCODR 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 SWITCH ENABL 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 SWITCH ON 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 DISABLE GEARBOX 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 TURING CENTER This bit is used for the VTC-48.
24 SS INVERT GEARBOX 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.
25 POWER DISCONN RELAY This parameter when set to 1, with parameter 57 (SAFETY CIRC) set to 1,
and the door is opened, I GAIN on all the axes is cleared. This feature is
intended to be used in conjunction with customer supplied hardware who
require the servo power to be cut when the door is opened.
26 STATUS RELYS
27 UNUSED

204 Parameters 96-8710 rev L June 2005

 28 UNUSED
29 RND5 TRM/TRL
30 RND5 HANDWHEEL
31 INTUITIVE PROG SYS When it is set to 1, the Intuitive Programming System is activated.

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.

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

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.

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 * 10000.

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

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.

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.

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.

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.

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.

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.

327 X LS PER INCH

This parameter is used on machines equipped with linear scales. It should be set to zero.

328 Y LS PER INCH

Same as parameter 327.

96-8710 rev L June 2005 Parameters 205

 329 Z LS PER INCH
Same as parameter 327.

330 A LS PER INCH

Same as parameter 327.

331 B LS PER INCH

Same as parameter 327.

333 X LS PER REV

This parameter is used on machines equipped with linear scales. It should be set to zero.

334 Y LS PER REV

Same as parameter 333.

335 Z LS PER REV

Same as parameter 333.

336 A LS PER REV

Same as parameter 333.

337 B LS PER REV

Same as parameter 333.

339 X SPINDLE THERM COEF.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
8000.

340 Y SPINDLE THERM COEF.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

341 Z SPINDLE THERM COEF.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
3692.

342 A SPINDLE THERM COEF.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

343 B SPINDLE THERM COEF.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

345 X SPINDLE THERM T.C.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
-12561.

346 Y SPINDLE THERM T.C.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

347 Z SPINDLE THERM T.C.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
-20000.

206 Parameters 96-8710 rev L June 2005

 348 A SPINDLE THERM T.C.
This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

349 B SPINDLE THERM T.C.

This parameter supports the Spindle Head Thermal Compensation feature. It should be set to
0.

351 THRML SENSOR OFFSET

This parameter is used for Ball Screw Thermal Compensation via a temperature sensor
attached to the ball nut.

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.

353 MAX SUBSPINDLE RPM

This is the maximum RPM available to the subspindle. This parameter works in conjunction
with parameters 570 and 571

354 U SWITCH A
See Parameter 1 for description.

390 V SWITCH A
See Parameter 1 for description.

426 W SWITCH A
See Parameter 1 for description.

498 C SWITCH A
See Parameter 1 for description.

570 SUBSPIN ENC ST/REV

This parameter sets the number of encoder steps per revolution of the subspindle encoder.

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.

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.

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.

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.

96-8710 rev L June 2005 Parameters 207

 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.

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.

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.

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.

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.

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.

581 APL FLIPPER SETTLE

This parameter supports the Haas Lathe APL. It specifies the rotational time for the gripper
after the switch is encountered and should be set to 100. Units are milliseconds.

582 APL FLIPPER TIME OT

This parameter supports the Haas Lathe APL. It specifies the allowed rotational time when
searching for the home switch and should be set to 2000. Units are milliseconds.

583 APL MAX POSITIONS

This parameter supports the Haas Lathe APL. It specifies the number of switch positions in
rotation and should be set to 7.

584 APL GRIP OPEN TIME

This parameter supports the Haas Lathe APL. It specifies the maximum allowable time for
opening the gripper and should be set to 500. Units are milliseconds.

208 Parameters 96-8710 rev L June 2005

 585 APL GRIP CLOSE TIME
This parameter supports the Haas Lathe APL. It specifies the maximum allowable time for
closing the gripper and should be set to 500. Units are milliseconds.

586 MAX DOOR OPN SP RPM

This parameter that specifies the maximum allowable spindle RPM while the door is open. If
the door is open when the spindle is commanded to turn faster than this value, or already
turning faster than this value when the door is opened, alarm 230 DOOR OPEN will be
generated. For safety, this parameter should be set to a low value such as 100.

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.

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).

589 Y ENC. SCALE FACTOR

See parameter 588 for description

590 Z ENC. SCALE FACTOR

See parameter 588 for description

591 A ENC. SCALE FACTOR

See parameter 588 for description

592 B ENC. SCALE FACTOR

See parameter 588 for description

593 Sp ENC. SCALE FACTOR

See parameter 588 for description

594 U ENC. SCALE FACTOR

See parameter 588 for description

595 V ENC. SCALE FACTOR

See parameter 588 for description

96-8710 rev L June 2005 Parameters 209

 596 W ENC. SCALE FACTOR
See parameter 588 for description

597 C ENC. SCALE FACTOR

See parameter 588 for description

598 Tt ENC. SCALE FACTOR

See parameter 588 for description

599 Ss ENC. SCALE FACTOR

See parameter 588 for description

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.

602 CHUCK FACE DISTANCE

This parameter supports the brushless bar feeder. When executing G105 Q4, a new bar is
loaded, measured and pushed through the spindle and halted just before the chuck face. This
parameter specifies the distance (in 1/10000 inch) that should be left between the bar and the
chuck face. It should be set as follows:

Mini-Lathe 440000
SL-10 500000
SL-20 540000
SL-30 540000
SL-30BB 650000
SL-40 650000
TL-15 540000

611 BARFEEDER TYPE

This parameter supports the Bar 100 Air-Driven bar feeder. It should be set to 2 on all lathes
fitted with the Bar 100, lathes without the Bar 100 should be set to zero.

616 SS LUBE CYCLE TIME

This parameter supports the VTC-48. It controls the subspindle lubrication in the same manner
as parameter 117. The units are 50ths of a second. If a subspindle low lube condition is found,
alarm 121 LOW LUBE OR LOW PRESSURE is generated and both the main spindle and the
subspindle are shut down. It should be set to 108000.

617 SS SPIN.FAN OFF DEL

This parameter supports the VTC-48. It specifies the time that the subspindle fan should
continue to run after the subspindle has stopped. The units are 1/1000 of a second. It should
be set to 6000.

618 LUBE CHECK DELAY

This parameter supports the VTC-48. It specifies the time between checks on the status of the
oil pressure on a VTC main spindle.

619 PRE GEAR CHANGE DLY

It specifies the delay time (in ms) after the spindle has been commanded to stop and before
the solenoid for the gear change is commanded to start. It should be set to 100 on all
machines.

210 Parameters 96-8710 rev L June 2005

 632 X AXIS MOCON CHANNEL
This parameter enables each axis to be mapped to a particular mocon channel.

633 Y AXIS MOCON CHANNEL

Same as Parameter 632. Set to 7 on machines originally shipped with 5.02 and later software.

634 Z AXIS MOCON CHANNEL

Same as Parameter 632 Set to 2 on 5.02 and later software.

635 A AXIS MOCON CHANNEL

Same as Parameter 632 Set to 3 on 5.02 and later software.

636 B AXIS MOCON CHANNEL

Same as Parameter 632 Set to 4 on 5.02 and later software.

637 C AXIS MOCON CHANNEL

Same as Parameter 632 Set to 5 on 5.02 and later software.

638 X AXIS MOCON CHANNEL

Same as Parameter 632 Set to 6 on 5.02 and later software.

639 Y AXIS MOCON CHANNEL

Same as Parameter 632 Set to 1 on machines originally shipped with 5.02 and later software.

640 Z AXIS MOCON CHANNEL

Same as Parameter 632 Set to 8 on 5.02 and later software.

641 A AXIS MOCON CHANNEL

Same as Parameter 632 Set to 9 on 5.02 and later software.

642 B AXIS MOCON CHANNEL

Same as Parameter 632 Set to 10 on 5.02 and later software.

643 C AXIS MOCON CHANNEL

Same as Parameter 632 Set to 11 on 5.02 and later software.

692 STDY REST OUT RELAY

This parameter supports the steady rest option. If a lathe has the option, this parameter must
be set to the output relay number that activates the clamping mechanism. This number can be
32 through 55 for relays #1132 through #1155, respectively. For lathes without the steady rest
option, it must be zero.

693 STDY REST INP RELAY

This parameter supports the steady rest option. If a lathe has the option and a foot pedal for
the steady rest, this parameter must be set to the input relay number for the foot pedal switch.
This number can be 1 through 49 for relays #1101 through #1049, respectively. For lathes
without a steady rest foot pedal, this parameter should be zero.

710 TOOL CHANGER TYPE

Supports the Tool Room Lathe 4-tool turret. Set this parameter to 2 on lathes fitted with the 4-
tool turret. For all other lathes, it should be set to 1.

96-8710 rev L June 2005 Parameters 211

 715 Color Message
Used to change the color of the text messages displayed at the bottom of an LCD monitor.
Any value from 0 to 255 can be used. The following are some suggestions:
Black: 0 Brown: 3, 4, 11, 12, 19, 20
Red: 5, 6, 13, 143 Orange: 7, 15, 23
Yellow: 30, 31, 39, 55, 63 Pink: 95, 103, 111, 119, 159, 167, 175, 183
Purple: 67, 75, 77, 83, 140, 141, 198, 215 Blue: 64, 88, 210, 248
Green: 24, 40, 56, 104, 120

716 Color CMD Position

Used to change the color of the positions text displayed on the Current Commands page on an
LCD monitor. See color values listed for parameter 715.

717 Color CMD G-Code

Used to change the color of the active G and M code text displayed on the Current Commands
page on an LCD monitor. See color values listed for parameter 715.

718 Color CMD Axes Load

Used to change the color of the axis load text displayed on the Current Commands page on an
LCD monitor. See color values listed for parameter 715.

719 Color CMD Bold Text

Used to change the color of the large feed and speed text displayed on the Current Commands
page on an LCD monitor. See color values listed for parameter 715.

720 Color Override

Used to change the color of the spindle and axis override text displayed on the Current
Commands page on an LCD monitor. See color values listed for parameter 715.

730 PWR FAULT THRESHOLD

731 PWR FAULT MAX TIME
These parameters support the Power Failure Module, which is installed between the AC supply
and the low-voltage power supply for the CNC. These parameters are to be set to 1 if eqiupped
with a Power Failure Module or set to zero for lathes without a Power Failure Module.
734 INPUT MASK (used for the Office lathes)
0 TOOL TURRET UNLOCKD 16 SPINDLE LOCK
1 TOOL TURRET LOCKED 17 SPINDLE FAULT
2 C AXIS DISENGAGED 18 SPINDLE STOPPED
3 SPARE 19 SPINDLE AT SPEED
4 C AXIS ENGAGED 20 LOW HYDRAULIC PRESS
5 SPINDLE HIGH GEAR 21 TAILSTOCK FOOT SW
6 SPINDLE LOW GEAR 22 PROBE NOT HOME
7 EMERGENCY STOP 23 SPARE
8 DOOR SWITCH 24 TOOL UNCLAMP REMOTE
9 M-CODE FINISH 25 SPARE
10 OVERVOLTAGE 26 BRFEED EOB/SB LB SW
11 LOW AIR PRESSURE 27 BRFEED Flt/SB PR SW
12 LOW LUBE PRESSURE 28 GROUND FAULT
13 REGEN OVERHEAT 29 G31 BLOCK SKIP
14 LOW TRANS OIL PRESS 30 BRFEED SP LK/SB EOB
15 SPARE 31 CONVEYR OVERCURRENT

212 Parameters 96-8710 rev L June 2005

 ELECTRONIC THERMAL COMPENSATION

When ballscrews rotate they generate heat. Heat causes the ballscrews to expand. In constant duty cycles,
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 ball 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.

96-8710 rev L June 2005 Parameters 213

 7. MAINTENANCE

GENERAL REQUIREMENTS
Operating Temperature Range 41°F to 104°F (5 to 40°C)
Storage Temperature Range -4°F to 158°F (-20 to 70°C)
Ambient Humidity: 20% – 95% relative humidity, non-condensing
Altitude: 0-7000 ft.

ELECTRICITY REQUIREMENTS
IMPORTANT! REFER TO LOCAL CODE REQUIREMENTS BEFORE WIRING MACHINES.
ALL MACHINES REQUIRE:
Three phase 50 or 60Hz power supply.
Line voltage that does not fluctuate more than +/-10%

15 HP System Voltage Requirements High Voltage Requirements

SL-10 (195-260V) (354-488V)
Power Supply 50 AMP 25 AMP
Haas Circuit Breaker 40 AMP 20 AMP
If service run from elec. panel
is less than 100' use: 8 GA. WIRE 12 GA. WIRE
If service run from elec. panel
is more than 100' use: 6 GA. WIRE 10 GA. WIRE

20 HP System Voltage Requirements High Voltage Requirements

1
SL-20, TL-15 (195-260V) (354-488V)
Power Supply 50 AMP 25 AMP
Haas Circuit Breaker 40 AMP 20 AMP
If service run from elec. panel
is less than 100' use: 8 GA. WIRE 12 GA. WIRE
If service run from elec. panel
is more than 100' use: 6 GA. WIRE 10 GA. WIRE

30-40 HP System Voltage Requirements High Voltage Requirements2

TL-15BB, SL-20BB, SL-30, SL-30BB,
1
SL-40, SL-40BB (195-260V) (354-488V)
Power Supply 100 AMP 50 AMP
Haas Circuit Breaker 80 AMP 40 AMP
If service run from elec. panel
is less than 100' use: 4 GA. WIRE 8 GA. WIRE
If service run from elec. panel
is more than 100' use: 2 GA. WIRE 6 GA. WIRE

55HP System Voltage Requirements High Voltage Requirements

1
SL-40, SL-40BB, SL-40L (195-260V) (354-488V)
Power Supply 150 AMP Must use an external transformer
Haas Circuit Breaker 125 AMP
If service run from elec. panel
is less than 100' use: 1 GA. WIRE
If service run from elec. panel
is more than 100' use: 0 GA. WIRE

214 Maintenance 96-8710 rev L June 2005

 WARNING!
A separate earth ground wire of the same conductor size as the input power is required to be connected to the
chassis of the machine. This ground wire is required for operator safety and for proper operation. This ground
must be supplied from the main plant ground at the service entrance, and should be routed in the same conduit
as the input power to the machine. A local cold water pipe, or ground rod adjacent to the machine cannot be
used for this purpose.

Input power to the machine must be grounded. For wye power, the neutral must be grounded. For delta power,
a central leg ground or one leg ground should be used. The machine will not function properly on ungrounded
power. (This is not a factor with the External 480V Option)

The rated horsepower of the machine may not be achieved if the imbalance of the incoming voltage is beyond
an acceptable limit. The machine may function properly, yet may not deliver the advertised power. This is
noticed more often when using phase converters. A phase converter should only be used if all other methods
cannot be used.

The maximum leg-to-leg or leg-to-ground voltage should not exceed 260 volts, or 504 volts for high-voltage
machines with the Internal High Voltage Option.
1
The current requirements shown in the table reflect the circuit breaker size internal to the machine. This
breaker has an extremely slow trip time. It may be necessary to size the external service breaker up by 20-
25%, as indicated by “power supply”, for proper operation.
2
The high-voltage requirements shown reflect the Internal 400V configuration which is standard on European
machines. Domestic and all other users must use the External 480V option.

AIR REQUIREMENTS
The CNC Lathe requires a minimum of 100 PSI at 4 scfm at the input to the pressure regulator on the back of
the machine. This should be supplied by at least a two horsepower compressor, with a minimum 20-gallon
tank, that turns on when the pressure drops to 100 PSI. At least a 3/8” I.D. hose is recommended. Set the
main air regulator to 85 psi.

The recommended method of attaching the air hose is to the barb fitting at the back of the machine with a hose
clamp. If a quick coupler is desired, use at least a 3/8".

NOTE: Excessive oil and water in the air supply will cause the machine to malfunction.
The air filter/regulator has an automatic bowl dump that should be empty
before starting the machine. This must be checked for proper operation
monthly. Also, excessive contaminants in the air line may clog the dump valve
and cause oil and/or water to pass into the machine.

NOTE: Auxiliary air connections should be made on the unregulated side of the air
filter/regulator.

W INDOWS / G UARDING
Polycarbonate windows and guarding can be weakened by exposure to cutting liquids and chemicals that
contain amines. It is possible to loose up to 10% of the remaining strength annually. If degradation is sus-
pected, window replacement should occur at no more than a two year interval.

Windows and guarding should be replaced if damaged or severely scratched - Replace damaged windows
immediately

96-8710 rev L June 2005 Maintenance 215

 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.

Interval Maintenance Performed

Daily • Check coolant level. Check way lube lubrication tank level.
• Clean chips from way covers and bottom pan.
• Clean chips from turret, housing, rotating union and extension tube. Make sure the
drawtube cover plate is installed either on the rotating union or on the chuck
opening.
• Check hydraulic unit oil level (DTE-25 ONLY). Capacity: 8 gallons.

Weekly • Check for proper operation of auto drain on filter regulator.

• Check air gauge / regulator for 85 psi.
• Clean exterior surfaces with mild cleaner. DO NOT use solvents.
• Clean out small chip catch pan in coolant tank.

Monthly • Inspect way covers for proper operation and lubricate with light oil, if necessary.
• Remove pump from the coolant tank. Clean sediment from inside the tank. Reinstall
pump. Caution! Disconnect the coolant pump from the controller and Power Off the
control before working on the coolant tank.
• Dump the oil drain bucket. Check Gearbox oil level (if applicable). If oil is not visible at
the bottom edge of the sight gauge, remove the end panel and add DTE-25 through the
top filler hole until it is visible in the sight gauge.

Six Months • Replace coolant and thoroughly clean the coolant tank.
• Replace hydraulic unit oil filter.
• Check all hoses and lubrication lines for cracking.

Annually • Replace gearbox oil.

• Clean oil filter and remove residue from the bottom of filter.
• Replace air filter on control box every (2) years.

Caution! Do not use a wash-down hose on the Haas lathe; doing so may cause damage to the spindle.

NOTICE
CLEAN THE GATE
USE SLOT TO
REST PUMP
FILTER REGULARLY
DO NOT USE PLAIN WATER,
PERMANENT CORROSION
DAMAGE WILL RESULT.
BASKET
FILTER
RUST INHIBITING COOLANT
IS REQUIRED.

DO NOT USE TOXIC OR

FLAMMABLE LIQUIDS AS A
COOLANT.

Poor Coolant flow can be caused by a dirty filter. To clean the filter, turn off the coolant pump, lift the coolant
tank lid and remove the filter. Clean and reinstall filter.

216 Maintenance 96-8710 rev L June 2005

 LUBRICATION
System Lubricant Quantity

Way lube and pneumatics Mobile Vactra #2 2-2.5 qts

Transmission Mobil DTE 25 34 oz

PERIODIC M AINTENANCE
A periodic maintenance page is found on the Current Commands screens titled “Scheduled Maintenance” and
accessed by pressing Page Up or Page Down to activate and deactivate a series of checks.

An item on the list can be selected by pressing the up and down arrow keys. The selected item is then
activated or deactivated by pressing Origin. If an item is active, the remaining hours will be displayed, a deacti-
vated item will display, “—” instead.

The maintenance item time is adjusted by using the left and right arrows. Pressing the Origin key will reinstate
the default time.

Items are tracked either by the time accumulated while power is on (ON-TIME) or by cycle-start time (CS-
TIME). When the time reaches zero the message “Maintenance Due” is displayed at the bottom of the screen
(a negative number of hours indicates the hours past due).

This message is not an alarm and does not interfere with machine operation in any way. After the necessary
maintenance has been performed, the operator can select that item on the “Scheduled Maintenance” screen,
press the Origin button to deactivate it, then press Origin again to reactivate it with the default number of hours
remaining.

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.
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.

Caution: Lack of grease significantly reduces clamping force and can result in chatter,
improper clamping, or thrown parts.
Chuck Jaws
Each chuck jaw requires two strokes of grease every 100 clamp/unclamp cycles, or at least once a week. Use
the provided grease gun for chuck lubrication. The Lubrication type is Molybdenum Disulfide Grease (20%-25%
moly content).

96-8710 rev L June 2005 Maintenance 217

 C OOLANT AND COOLANT T ANK
Machine coolant must be water-soluble, synthetic oil based or synthetic based coolant/lubricant. Using
mineral cutting oils will damage rubber components throughout the machine,

Do not use pure water as a coolant; machine components will rust. Do not use flammable liquids as coolant.

The coolant tank must be thoroughly cleaned periodically, especially for mills equipped with High Pressure
Coolant.

Coolant Overview
As the machine runs the water will evaporate which will change the concentration of the coolant. Coolant is
also carried out with the parts.

A proper coolant mixture is between 6% and 7%. To top-off coolant only more coolant or deionized water
should be used. Be sure that the concentration is still within the range. A refractometer can be used to check
the concentration.

Coolant should be replaced at regular intervals. A schedule should be set and held to. This will avoid a build up
of machine oil. It will also ensure that coolant with the proper concentration and lubricity will be replaced.

WARNING!
When machining castings, sand from the casting process and the abrasive properties of cast aluminum and
cast iron will shorten coolant pump life unless a special filter is used in addition to the standard 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.

Shortened pump life, reduction of coolant pressure and increased maintenance are normal and to be expected
in abrasive environments and is not covered by warranty.

LUBRICATION SYSTEM
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.

Air Pressure Oil Pressure Gauge

Regulator

Air in
MAX
Hose Oil Pump
Barb
MIN
Oil Reservoir
Air Nozzle Air Line Oil Filter

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.

218 Maintenance 96-8710 rev L June 2005

 Lube Oil Filter
The way lube oil filter element is a 25-micron porous metal filter (94-3059). It is recommended that the filter
should be replaced annually or every 2000 hours of machine operation. The filter element is housed in the filter
body, which is located in the oil pump reservoir (internal filters).

To change the filter element follow these steps:

1. Remove the screws that hold the oil reservoir to the pump body, carefully lower the reservoir and set aside.

2. Use a strap wrench, pipe wrench or adjustable pliers to unscrew the end cap (see the figure). Caution: Use
a screwdriver or similar tool to stop the filter from turning while the end cap is removed.

3. Remove the oil filter element from the filter body once the end cap is removed.

4. Clean the inside of the filter housing and the filter end cap as required.

5. Install the new oil filter element (p/n 94-3059), O-ring and the end cap. Use the same tools that were used to
remove the filter end cap, to tighten it - Do Not Over Tighten.

6. Replace the oil reservoir; ensure the gasket seats properly between the reservoir and the top flange.

Screwdriver

Oil Filter

Filter Element
O-Ring (P/N 94-3059)

Un-screw end cap

TRANSMISSION OIL
Oil Check
Check the oil level at the sight glass through the opening in the side of the machine as shown in the illustra-
tion. Fill as needed through the fill port on top of the gear box.

Oil Change
1. Remove the sheet metal necessary to gain access to the transmission.

2. Remove the fourteen (14) SHCS from the oil pan and remove it. Inspect the magnetic drain-plug for
signs of metal particles.

3. Wipe down the oil pan and reinstall it with a new gasket.

4. Blow downward with an air hose in the vicinity of the access plate to prevent dirt and metal par-
ticles from entering the gear case. Remove the access plate.

96-8710 rev L June 2005 Maintenance 219

 5. Fill the gear case with 2¼ liters of Mobil DTE-25 gear oil. Check the sight glass. The level should
be 3/4 of the way up when full. Fill as needed.

6. Install access plate with new gasket.

7. Run a spindle warm-up and check for leaks.

Oil Drain Plug

Oil Level Sight
Glass

Bottom View
View Rotated Oil Fill Cup
1808

C HIP A UGER
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.

Machining Remnants
The end of bar remnant must be collected to same way the parts are when using a bar feeder. Remove the
remnant by hand or if using the parts catcher, program it to collect the remnant. Discharge tubes or auger pans
that have remnants pushed through them will not be covered under the warranty.

WORKLIGHT
Before doing any work on the lathe, turn off power to the machine at the main breaker.

Glass

Upper
Channel Retainer
Mounting
Bracket
Retainer
Lens
Lens

220 Maintenance 96-8710 rev L June 2005

 8. PCB's, CABLE LOCATIONS AND BOARD DIAGRAMS

Shown below are three types of commonly used cable connectors. They are shown as seen when plugged
into the pc board. These diagrams are to aid in locating the pins for trouble shooting.

Note:The numbering sequence is the same regardless of the number of pins.

96-8710 rev L June 2005 Cable Locations 221

 96-8710 rev L June 2005
FRONT PANEL SPINDLE HEAD
WIRE NUMBER FUNCTION NAME WIRE NUMBER FUNCTION NAME
90A 115 VAC TO LCD LVPS 190 UNCLAMP FROM SPINDLE HEAD TO I/O PCB
90B 115 VAC TO WORK LIGHT SWITCH 200 COOLANT SPIGOT MOTOR
280 RED/GREEN STATUS LIGHT WIRING "BEACON" 300A 115VAC TO SPINDLE MOTOR FAN/OIL PUMP/OILER
720 ANALOG SPEED COMMAND TO SPINDLE "SPINDLE LOAD METER" 880A HIGH/LOW GEAR UNCLAMP/LOCK SOLENOID POWER
740 POWER ON/OFF CABLE TO FRONT PANEL 890 SPINDLE STATUS SWITCHES
750 JOG-CRANK DATA CABLE "RJH" 950 LOW AIR PRESSURE SENSOR
770 EMERGENCY STOP INPUT CABLE
1050 DOOR SWITCH WIRING THRU SUPPORT ARM
WIRE NUMBER FUNCTION NAME
BARFEEDER AXIS 490B SUPER SPEED TOOL CHANGER
MOTOR POWER CABLE
690B SUPER SPEED TOOL CHANGER
ENCODER CABLE WIRE NUMBER FUNCTION NAME
490X X-AXIS MOTOR POWER CABLE
SUB SPINDLE 660 X-ENCODER CABLE
- HOME LIMIT SWITCH
WIRE NUMBER FUNCTION NAME
-X- AXIS 490X X-AXIS MOTOR POWER CABLE
660 X-ENCODER CABLE FLEXIBLE CABLE CONDUIT
- X-HOME LIMIT SWITCH
WIRE NUMBER FUNCTION NAME
490Y Y-AXIS MOTOR POWER CABLE
TURRET
670 Y-ENCODER CABLE
WIRE NUMBER FUNCTION NAME - Y-HOME LIMIT SWITCH
490Z Z-AXIS MOTOR POWER CABLE
-Z- AXIS 680 Z-ENCODER CABLE FRONT PANEL SUPPORT ARM
- Z-HOME LIMIT SWITCH
350A 24VDC SRVO BRAKE RELEASE WIRE NUMBER FUNCTION NAME
490A A-AXIS MOTOR POWER CABLE
LIVE TOOLING SERIAL PORT 1
690 A-ENCODER CABLE
- A-HOME LIMIT SWITCH SERIAL PORT 2

Cable Locations
WIRE NUMBER FUNCTION NAME 390 4'th AXIS BRAKE ETHERNET
490B B-AXIS MOTOR POWER CABLE BARFEEDER AXIS
-C-AXIS 690B B-ENCODER CABLE
- B-HOME LIMIT SWITCH SUB SPINDLE
230 5'th AXIS BRAKE WIRE NUMBER FUNCTION NAME
TAILSTOCK 810 TOOL CHANGER TURRET MOTOR -X- AXIS
810A TOOL CHANGER SHUTTLE MOTOR
820 TOOL CHANGER STATUS TURRET
WIRE NUMBER FUNCTION NAME
LIMIT SWITCHES 300 115VAC TO OILER -Z- AXIS
960 LOW LUB
990 X/Y/Z HOME SENSORS
WIRE NUMBER FUNCTION NAME LIVE TOOLING
BARFEEDER 940A 230 VAC 3PH TO TSC COOLANT PUMP
130 TSC OVER TEMP -C-AXIS
WIRE NUMBER FUNCTION NAME TAILSTOCK
CHIP CONVEYOR 140 230VAC 3PH POWER TO CHIP
CONVEYOR MOTOR LIMIT SWITCHES
WIRE NUMBER FUNCTION NAME
100 M-FIN BARFEEDER
MFIN/CLG
730B SP. DRIVE LOAD (COOLANT LEVEL CHIP CONVEYOR
GAUGE SENSOR)
MFIN/CLG
WIRE NUMBER FUNCTION NAME
COOLANT 940 230 VAC TO COOLANT PUMP COOLANT
WIRE NUMBER FUNCTION NAME HPC
240 APC PAL HOME/MD PAL UP-APC PAL 1
HOME PAL DOWN SPARE-1
410 APC CE DOOR OPEN
HPC 710 APC #1 PALLET READY 1/APC #1 SPARE-2
PALLET READY 2
770B EMERGANCY STOP INPUT CABLE
WIRE NUMBER FUNCTION NAME 790 APC PIN CLR #1/APC PIN CLR #2 CONTROL CABINET
810A TOOL CHANGER MOTORS
420 APC #2 CLR #1 & #2/APC #2 PAL #2 M28
SPARE-1 & #1 HOME
450 APC #2 CE DOOR OPEN
770B EMERGANCY STOP INPUT CABLE
810 APC MOTOR
880B TRANSMISSION HIGH/LOW GEAR WIRE NUMBER FUNCTION NAME
SOLENOIDS 250 APC DOOR OPEN
310 APC #2 DOOR OPEN
SPARE-2 430 APC PALLET CLAMP LEFT DDOR
460 APC #2 DOOR CLOSED - APC #2
DOOR OPEN
480 APC PALLET CLAMP RIGHT DOOR

222
 MICRO PROCESSOR PCB - P/N 93-1010F
CABLE CONNECTIONS

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
U24

850A 850
U33

U37 U38

U39
U34
93-1010B

U41
U42 U43 U44 U45

RP2 RP3 RP4 RP5

U50 U51 U52 U53 U54

ADDRESS BUS DATA BUS

J3

J1 J2

PROC.
PLUG # CABLE # SIGNAL NAME TO 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 AUX PORT SERIAL PORT #2 ——-

96-8710 rev L June 2005 Cable Locations 223

 BRUSHLESS SERVO AMPLIFIER - P/N 93-5550C

SERVO DRIVE CURRENT COMMAND ( FROM MOCON)

LOW VOLTAGE POWER (INPUT)

POWER TO SERVO MOTOR

335VDC (FROM HAAS VECTOR DRIVE)

BLOWN FUSE INDICATOR

224 Cable Locations 96-8710 rev L June 2005

 BRUSHLESS SERVO AMPLIFIER - P/N 93-5550C

CABLE CONNECTIONS

MOCON
PLUG # CABLE # SIGNAL NAME TO 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 335VDC SPINDLE DRIVE ——-

Y AXIS AMP
P 570 LOW VOLTAGE L. V. POWER SUPPLY ——-
TB A, B, C ——- MOTOR DRIVE Y SERVO MOTOR ——-
P 620 Y DRIVE SIGNAL MOCON PCB P3
TB -HV +HV 490 335VDC SPINDLE DRIVE ——-

Z AXIS AMP
P 570 LOW VOLTAGE L. V. POWER SUPPLY ——-
TB A, B, C ——- MOTOR DRIVE Z SERVO MOTOR ——-
P 630 Z DRIVE SIGNAL MOCON PCB P4
TB -HV +HV 490 335VDC SPINDLE DRIVE ——-

A AXIS AMP
P 570 LOW VOLTAGE L. V. POWER SUPPLY ——-
TB A, B, C ——- MOTOR DRIVE A SERVO MOTOR ——-
P 640 A DRIVE SIGNAL MOCON PCB P5
TB -HV +HV 490 335VDC SPINDLE DRIVE ——-

96-8710 rev L June 2005 Cable Locations 225

 POWER PCB - P/N 93-0227A

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
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
FU14
P14 P15 NE13
P21
P13
NE4 NE11 NE10 NE9 NE8 NE7 FU13
TB2
NE12 FU12

P16 P17 P18 P19 P20

226 Cable Locations 96-8710 rev L June 2005

 POWER PCB - P/N 93-0227A
CABLE CONNECTIONS

PLUG # CABLE # SIGNAL NAME TO 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
P18 90C 115VAC spare
P19 90 3PH 115VAC IO PCB P56
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 L June 2005 Cable Locations 227

 M21 M22 M23 M24 M25 P60 P59 P58
C46 NE1
TB1
P1 K33 K34 K35 K36 K37 TB2 UR2 K38
FU2 UR6 Q40
P2
D10 Q39
U65 FU1
P3 U66
D1 P57
P4 U1
P5 J10
U35 R42
Q1 R3
P6 U57 Q38
U38 R4 R52
P7 U2
U34
Q34 K9
P8
P9 P62 Q26 D21
P10 K10
P11 U3 LE41
K11 D22 D20
P12 U56
Q33 D19 D17
P13 P64 K12
U4 J9 Q25
Q32 T1 Q13
U30 U15
U5 D18
CR5 U51
P14 DISP1 Q14
U16 P54
P15 U50 Q15

34-3080T
U17
U52
P16 U6 U54
U44 U18 Q16
P17 U7
P66 Q30 DISP2
P18 Q10
P67 U10
Q31 U53
P19 U36 Q14
P20 U8 Q28 P65
P21 U59 P68 Q15
C45 U37
Q29
P22 Q16
U46 Q35
P69 Q27 U63
Q10 U62
U60 U23 U22
Q17 U13
P23 D27 U67
U61 U68 D12
P45
P24 D26 U24 K7 Q6
R122 U64
U32 D11 Q18 U14 Q12
U21
P25
R119 P44
U47 U20
P26
U49 U19
U35 P70 P71 Q24
P27 P43
U31 Q9
DISP3
R126 LE31
P28 U U U U U Q37
28 27 26 25 29 U12
RI27 U9 P41
P29 Q22 Q21 Q20 Q19 Q23 U11
K32 P40
P30

P31 P32 P33 P34 P35 P36 P37 P38 Q5 Q3 Q4 P39

I/O PCB T - P/N 32-3080T CABLE CONNECTIONS

I/O PLUG # CABLE # TO LOCATION PLUG #
P1 140B Chip Conveyor
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

228 Cable Locations 96-8710 rev L June 2005

 I/O PCB T - P/N 93-0228A CABLE CONNECTIONS
I/O PLUG # CABLE # TO LOCATION PLUG #
P15 890 Spare / Gearbox
P16 780 Spare
P17 410 TS Foot Sw, Sub Spndl Chuck Foot Switch
P18 790 Probe Home
P19 190 Chuck uncl foot switch / low phase
P20 190A Not Used
P21 240 BF Load Bar/Q / RPL:cvr opn/slider rtrct/grnd flt
P22 1070 Skip
P23 420 Spare (VTC:pocket up/down / tool one /TC mark)
P24 440 Auto Door Open
P25 450 Steady Rest Foot Switch
P26 460 Apl Rotator Mark, Home (VTC:low way/SS lube)
P27 470 Spare (VTC: motor stop/origin/ cl/uncl)
P28 480 Spare (VTC: rem uncl/ss db open/closed)
P29 1040A Not Used
P30 1040 CE Door Lock
P31 230 T/S Fwd
P32 250 T/S Rev
P33 270 T/S Rapid (VTC: purge)
P34 260 Spare (12V output)
P35 200 Spare (VTC spigot CW/CCW)
P36 280 Beacons
P37 140A Not Used
P38 140 Chip Conv En/Rev
P39 160 250V For Chip C
P40 300 SP fan/oil pump/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 Grip 1, Grip 2
P53 880C Wye-Delta Switch
P54 880B High/Low Gear
P55 880A Chuck Unclamp/TT Out / MLB fast push
P56 90 115V Power To IOPCB PSUP P19
P57 External TC Motor Resistor Jumper
P58 810A spare
P59 810 Auto Dr, BF ld bar/Q,APL Rtr(VTC:car CW/CCW)
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 APC Door Open
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 L June 2005 Cable Locations 229

 SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOG
P/N 93-1072C
CABLE CONNECTIONS

J1

J2 J3

DISCRETE INPUTS

J5

U9 Y1

P1

P6 P5 P3 P4

PLUG# CABLE# TO 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.

230 Cable Locations 96-8710 rev L June 2005

 VIDEO & KEYBOARD PCB W/ FLOPPY DRIVE P/N 93-1001A
CABLE CONNECTIONS

C40

U5 U28

J13
JP1
D

J8 D

J3

J12

J1
J14
J2
SPARE FLOPPY

C26 J6
J10

P13
J11

U18 U21
U19
C33 J7
C31
U25 P13A
LINE 1:
LINE 2:
LINE 3:

C34 C35
U23 U24
U26 C32
R18
SUB ASSY

HAAS P/N ID P1
C38 C39
ADDRESS DATA
J4 J5

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 L June 2005 Cable Locations 231

 MOCON PCB - P/N 93-1067F

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
P2
U43

J2 INSTALL JUMPER FOR

P31 MOCON 2
32-4023N
P15

P19 P1

232 Cable Locations 96-8710 rev L June 2005

 MOCON PCB - P/N 93-1067F
CABLE CONNECTIONS

MOCON PLUG # CABLE # SIGNAL NAME TO 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 L June 2005 Cable Locations 233

 GND PIN 1
P1

34-4090
P3 P2

RS-232 PORT #1 PCB - P/N 32-4090

CABLE CONNECTIONS

PLUG # CABLE # TO LOCATION PLUG #

P1 -------- ------------- -------
EXTERNAL

J1 850 VIDEO & J13

EXTERNAL KEYBOARD

234 Cable Locations 96-8710 rev L June 2005

 OPTICAL ENCODER PCB - P/N 32-0400A (SL-20, SL-30)

CABLE CONNECTIONS

PLUG # CABLE # TO LOCATION PLUG #

P1 690B MOCON ——-

96-8710 rev L June 2005 Cable Locations 235

 880B/P1

FU1 115 VAC 115 V Servo Brake

TRANSMISSION P.S. / HYDRAULIC C.B. PCB

P/N 93-4095E
CABLE CONNECTIONS

PLUG # CABLE # TO 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)

236 Cable Locations 96-8710 rev L June 2005

 Y-DELTA SWITCH ASSEMBLY
P/N 32-5851B (40T 10HP)
P/N 32-5864A (SUPER SPEED AND 50T)

TO K5 AUX

K4
Y

TO K5 COIL
TO
SPINDLE TO K5 COIL
MOTOR

TO K4 COIL
650A
TO IO PCB, P12
COM

TO IO PCB, P58

K5

TO K4 COIL

650B
TO HAAS VECTOR DRIVE

96-8710 rev L June 2005 Cable Locations 237

 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

90C 115 VAC TO CB4 - SHIELD +2

91C 115VAC #20
92C RETURN #20
93C SHIELD DRAIN
110 SPARE (115 VAC SERVO POWER)

238 Cable List 96-8710 rev L June 2005

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 LOAD BAR - BARFEEDER LOAD Q

241 END OF BAR #20
242 LOADER OK #20
243 COMMON #20
244 SHIELD DRAIN

250 TAILSTOCK REVERSE OPTION

251 115VAC
252 115VAC RETURN
253 SHIELD DRAIN

96-8710 rev L June 2005 Cable List 239

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
310 AUTO DOOR CLUTCH - PARTS CATCHER

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
430 APL LIGHT/ BF EXTENDED PUSH
440 DOOR OPEN
450 STEADY REST FOOT SWITCH
460 APL ROTOR MARK - APL ROTOR HOME

490 ALL BRUSHLESS AXIS SERVO MOTOR DRIVE POWER CABLE

491 A PHASE

240 Cable List 96-8710 rev L June 2005

492 B PHASE
493 C PHASE
494 GROUND

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

96-8710 rev L June 2005 Cable List 241

640C-2 B PHASE
640C-3 ENABLE
640C-4 FAULT
640C-5 320VDC VOLTAGE MONITOR
640C-6 A PHASE RETURN
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)

242 Cable List 96-8710 rev L June 2005

700 KEYBOARD CABLE - 34 WIRE RIBBON WITH IDC
(FROM VIDEO P4 TO KBIF P1)
710 APL GRIP 1,2

720 ANALOG SIGNAL FROM MOCON TO SPINDLE DRIVE LOAD MONITOR

721 0 TO +10 VOLTS SPINDLE LOAD
722 COMMON
723 SHIELD DRAIN

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

96-8710 rev L June 2005 Cable List 243

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
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) - AUXILIARY PORT TO
ROTARY CONTROLLER

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

244 Cable List 96-8710 rev L June 2005

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

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

96-8710 rev L June 2005 Cable List 245

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

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

246 Cable List 96-8710 rev L June 2005

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

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 L June 2005 Cable List 247

 ELECTRICAL WIRING
DIAGRAMS

248 Electrical Diagrams 96-8710 rev L June 2005

SIDE VIEW CONTROL CABINET
SPINDLE
REGEN RESISTORS REAR OF MACHINE
SERIAL PORT 1

GROUNDING BAR
SERIAL PORT 2
GROUNDING
BAR
ETHERNET PROCESSOR ASSEMBLY

POWER SUPPLY ASSEMBLY

BAR FEEDER AXIS

CNC UNIT
SUB SPINDLE MOCON BOARD
68030 PROCESSOR BOARD P20 P16

VIDEO BOARD DZ3 DZ1

DZ2

32-4075D
230 VAC
POWER CARD

X AXIS FU6 NE6

TB1

TB2
FLOPPY DRIVE

X»-X»AXÂXX¿IX»S Y»-Y»AYÂXY¿IY»S Z»-Z»AZÂXZ¿IZ»S

(OPTIONAL)

TURRET

FAULT FAULT

Z AXIS PWR ON PWR ON

LIVE TOOLING OPERATOR PENDANT A

B
C
A
B
C
-H.V. -H.V.
+H.V. +H.V.

TB3
FUSE OPEN FUSE OPEN

C AXIS GROUND X»-X»AXÂXX¿IX»S Y»-Y»AYÂXY¿IY»S Z»-Z»AZÂXZ¿IZ»S

A»-A»AAÂXA¿IA»S B»-B»ABÂXB¿IB»S

WIRE

TB2 K3

K4

K5

P4
D1
D3
NE1
FU1
TAILSTOCK

R1

T1
P2

D2

D4
NE1

LIMIT SWITCHES

P3
J1 J2 J7

R2
C46

K2
C31
FU1
D1

P3

C2
J3

K1
J4

P1
D10

C1
GROUNDING
R86
D9 SEE NOTES:

32-4095 REV. A TRANS P.S./HYD C.B. ASSY

U33

BARFEEDER BAR Q17

R45

D28
D29
C140

Q18 D30

D31
R3 R4
R270

R194
R195
R196
D27

R44
R46
R43
R48
R47
R50

R49
R6

P4
D14
D15
D16
D13

D32
D22
D21
D20

D33
C45 D34
D5
D4
D3
D2

D35

CHIP CONVEYOR P2
D19
D18
D17
Q13

T1
Q14

U54
Q15
Q16

C32

MFIN\CLG
Q10

LOW VOLT -------------- 260-244V 243-227V 226-211V 210-195V

LINE 2:

LINE 1:

NOTE:

Q11
ABC. 16/97
EXAMPLE: ABC INC. WEEK OF THE YEAR/YEAR
PLACE VEDOR ID AND DATE CODE
REPLACE * WITH REVISION LETTER OF MAX B.O.M.
REV * HS

D26
P1
COOLANT
D24
R122
C9 D12
D25 Q7
R119 D11
D23
K7
LINE 2
LINE 1
32-3080MA

C6
Q6
P51
Q12

DZ3
Q8
IOPCB ASSY.

R130
Q24

DZ2 C29
Q9
R129 D8
DZ1 C28 D7
D6

HPC R128 C27

R126
FU2

Q22 Q21 Q20 Q19 Q23

R127
FU3

D46
K35
Q5 Q3 Q4
FU4

SPARE

SPARE

ITEM DESCRIPTION PAGE # ITEM DESCRIPTION PAGE #

CNC LAYOUT A RELAY COIL DRIVERS, IOPCB 8-11
SYSTEM BLOCK DIAGRAM B,C SPINDLE DRIVE UNIT 12
CABLE INTERCONNECT DIAGRAM D AXIS MOTOR & ENCODER 13,14
SERVO SYSTEM 1 CABINET CONNECTORS 15
MAIN TRANSFORMER 2,3 TOOL CHANGE MOTORS 16
CNC UNIT 4 CHIP CONVEYOR 17
115VAC CIRCUITS 5 OPERATOR PENDANT 18
INPUTS IOPCB 6,7 ELECTRICAL SYMBOLS 19

CONTROL LAYOUT DIAGRAM

HAAS AUTOMATION SL SERIES PAGE A

96-8710 rev L June 2005 Electrical Diagrams 249

 INPUT VOLTAGE
195-260 VAC
353-480 VAC 115 VAC

MAIN 353-480 VAC MAIN OPERATOR

195-260 VAC
POWER INPUT
TRANSFORMER PENDANT
DISTRIBUTION
115 VAC 115 VAC

230 VAC
LOW VOLTAGE

230 VAC
230 VAC

115 VAC

VIDEO, KEYBOARD, AND JOG

BRUSHLESS HAAS VECTOR DRIVE

SERVO
MICRO AMPLIFIERS
PROCESSOR
CMDS 335 VDC
(CNC)

EXCESS
PWR

PWR

SP PWR
SPINDLE COMMANDS
SPINDLE ENCODER
STATUS

CMDS

POSITION
SERVO REGEN SPINDLE MOTOR
DATA
MOTORS ASSY
HOME X & Z AXES
DISCRETE
INPUTS SWITCH TOOL TURRET
AND
OUTPUTS
230 VAC

SENSORS
CMDS GEAR BOX SWITCHES
TOOLCHANGER/OVERHEAT SENSORS/
COOLANT PUMP LOW LUBE/LOW COOLANT/SOLENOIDS
AND
CHIP CONVEYOR

NOTE FOR HIGH VOLTAGE IN, SEE PAGE C.

SYSTEM BLOCK DIAGRAM - LOW VOLTAGE (HIGH VOLTAGE)
HAAS AUTOMATION SL SERIES PAGE B

250 Electrical Diagrams 96-8710 rev L June 2005

96-8710 rev L June 2005 Electrical Diagrams 251
252 Electrical Diagrams 96-8710 rev L June 2005
96-8710 rev L June 2005 Electrical Diagrams 253
 MOCON INPUTS/ 550 640C
IOPCB VOLTAGE MONITOR 0-5V
990
HOME SWITCHES V DRIVE LOAD
510
IOPCB
530 IOPCB
RELAYS 1-8
P24 P10 P17 P22 RELAYS 9-16 P11 P13 520 IOPCB
750 INPUTS RELAYS 25-32 540
JOG INFO P18 1 THRU 32 RELAYS 17-24
IOPCB
P12 P14
1000
SPINDLE ENCODER P20 720
660 P16 LOAD METER
X ENCODER P6
670 640C
Y ENCODER P7 P33 C DRIVE SIGNAL (VECTOR DRIVE)
640B
Z ENCODER 680
P8 MOCON P32
640
NOT USED ON LATHES
P5 A DRIVE SIG
A ENCODER 690 630
P9
BOARD P4 Z DRIVE SIG
B ENCODER 690B 620
P3 Y DRIVE SIG(LIVE TOOLING)
690C 610
C ENCODER P2 X DRIVE SIG
P15
SP ENCODER P20 ADDRESS BUS DATA BUS
860
P19 P1 LOW VOLTAGE POWER

VIDEO BOARD
J13 RS232 USER SERIAL PORT
850
HARD DRIVE
FLOPPY
DRIVE J12 J9 J6 PARALLEL
RS-232 ENET/ PORT
SERIAL ZIP/ J4 (ZIP)
FLOPPY HDD
POWER P10 J8 J2 J2
ENET 760
VIDEO TO OPERATOR PENDANT
P11 FLOPPY
SPARE
P1
ADDRESS BUS DATA BUS
860
LOW VOLTAGE POWER
P4 P5

EXT. BAT.

J6
850
RS-232 SERIAL KEYBOARD
BATTERY 850A
AUX RS-232 (INDEXER)

PROCESSOR S1

BOARD

P3
ADDRESS BUS DATA BUS 860
LOW VOLTAGE POWER

CNC UNIT
HAAS AUTOMATION SL SERIES PAGE 4

254 Electrical Diagrams 96-8710 rev L June 2005

96-8710 rev L June 2005 Electrical Diagrams 255
256 Electrical Diagrams 96-8710 rev L June 2005
96-8710 rev L June 2005 Electrical Diagrams 257
 PIN 1 PIN 1
0VDC K1 SERVO POWER ON

+12VDC PIN 2 PIN 2 LE 1

PIN 3 PIN 3
0VDC K2 APL LIGHT\
BARFEEDER EXTENDED
+12VDC PIN 4 PIN 4 LE 2 PUSHER

PIN 5 PIN 5
0VDC K3 APL GRIPPER 1

+12VDC PIN 6 PIN 6 LE 3

PIN 7 PIN 7
0VDC K4 APL GRIPPER 2

+12VDC PIN 8 PIN 8 LE 4

PIN 9 PIN 9
0VDC K5 SPINDLE BRAKE

+12VDC PIN 10 PIN 10 LE 5

PIN 11 PIN 11
0VDC K6 COOLANT ON

+12VDC PIN 12 PIN 12 LE 6

PIN 13 PIN 13
0VDC K7 AUTO POWER OFF

+12VDC PIN 14 PIN 14 LE 7

PIN 15 PIN 15
0VDC K8 SPINDLE LUBE
SPINDLE FAN
+12VDC PIN 16 PIN 16 LE 8 GEAR BOX OIL PUMP
WAY LUBE PUMP
REGEN BOX FAN
P11 P1
CABLE
0VDC +12VDC MOCON PCB 510 I/O PCB

RELAY COIL DRIVERS, K1 THROUGH K8

HAAS AUTOMATION SL SERIES PAGE 8

258 Electrical Diagrams 96-8710 rev L June 2005

 PIN 1 PIN 1
0VDC K9 SPARE

+12VDC PIN 2 PIN 2 LE 9

PIN 3 PIN 3
0VDC K10 SPARE

+12VDC PIN 4 PIN 4 LE 10

PIN 5 PIN 5
0VDC K11 SPARE

+12VDC PIN 6 PIN 6 LE 11

PIN 7 PIN 7
0VDC K12 SPARE

+12VDC PIN 8 PIN 8 LE 12

PIN 9 PIN 9
0VDC K13 HIGH GEAR SHIFT

+12VDC PIN 10 PIN 10 LE 13

PIN 11 PIN 11
0VDC K14 LOW GEAR SHIFT

+12VDC PIN 12 PIN 12 LE 14

PIN 13 PIN 13
0VDC K15 SPINDLE UNCLAMP

+12VDC PIN 14 PIN 14 LE 15

PIN 15 PIN 15
0VDC K16 SPINDLE LOCK
(USED WITH Y TO
+12VDC PIN 16 PIN 16 LE 16 DELTA OPTION)

P12 P2
CABLE
0VDC +12VDC MOCON PCB 520 I/O PCB

RELAY COIL DRIVERS, K9 THROUGH K16

HAAS AUTOMATION SL SERIES PAGE 9

96-8710 rev L June 2005 Electrical Diagrams 259

 PIN 1 PIN 1
0VDC K17 SPARE

+12VDC PIN 2 PIN 2 LE 17

PIN 3 PIN 3
0VDC K18 SPARE
(OPTION)
+12VDC PIN 4 PIN 4 LE 18

PIN 5 PIN 5
0VDC K19 SPARE A

+12VDC PIN 6 PIN 6 LE 19

PIN 7 PIN 7
0VDC K20 SPARE B

+12VDC PIN 8 PIN 8 LE 20

PIN 9 PIN 9
0VDC K21 TURRET OUT

+12VDC PIN 10 PIN 10 LE 21

PIN 11 PIN 11
0VDC K22 SPARE C

+12VDC PIN 12 PIN 12 LE 22

PIN 13 PIN 13
0VDC K23 SPARE

+12VDC PIN 14 PIN 14 LE 23

PIN 15 PIN 15
0VDC SPARE
K24

+12VDC PIN 16 PIN 16 LE 24

P13 P51
MOCON PCB CABLE
0VDC +12VDC 530 I/O PCB

RELAY COIL DRIVERS, K17 THROUGH K24

HAAS AUTOMATION SL SERIES PAGE 10

260 Electrical Diagrams 96-8710 rev L June 2005

96-8710 rev L June 2005 Electrical Diagrams 261
262 Electrical Diagrams 96-8710 rev L June 2005
96-8710 rev L June 2005 Electrical Diagrams 263
 THREE PHASE
210 VAC IN OMIT THESE WIRES FOR
3 PHASE MOTOR (OPTIONAL)

CHIP CONVEYOR MOTOR

SINGLE PHASE (REVERSIBLE)

4 B

5 F
FU3

FU2
K33
3
2
D
C
M
K33
1 E

6 G
CHIP OVERCURRENT
CONVEYOR DETECTION K35
ON CIRCUIT 140 P8
CHIP IOPCB CHIP CONVEYOR
CONVEYOR
REVERSE

EARTH GND

CHIP CONVEYOR MOTOR

HAAS AUTOMATION SL SERIES PAGE 15

264 Electrical Diagrams 96-8710 rev L June 2005

96-8710 rev L June 2005 Electrical Diagrams 265
266 Electrical Diagrams 96-8710 rev L June 2005
 VTC Vector Drive

96-8710 rev L June 2005 Electrical Diagrams 267

 VTC Servo Amplifier

268 Electrical Diagrams 96-8710 rev L June 2005

 CIRCUIT BREAKER VARISTOR
(SINGLE)

NEON BULB (W/ RESISTOR)

PUSH BUTTON SWITCH

CIRCUIT BREAKER (NORMALLY CLOSED)
(MULTI)

PUSH BUTTON SWITCH

(NORMALLY OPEN)
COIL

RELAY (CLOSED)
DIODE
RELAY (OPEN)

GROUND
RELAY (SINGLE POLE
DOUBLE THROW)

LAMP
(FLOURESCENT) RESISTOR

LED
(LIGHT EMITTING DIODE) SOLENOID

LIMIT SWITCH (CLOSED) TRANSFORMER

LIMIT SWITCH (OPEN) CAPACITOR

M MOTOR OPTO-ISOLATOR

FU2
FUSE

ELECTRICAL SYMBOLS
HAAS AUTOMATION SL SERIES

96-8710 rev L June 2005 Electrical Diagrams 269

 ASSEMBLY DRAWINGS
AND
PARTS LISTS

270 Assembly Drawings 96-8710 rev L June 2005

 1 2 3 4

Datum C

5
6

Start 3
7

9
10

.406 C'Bore Plane Top

11

Plane4
12

14 13

Saddle Assembly
Plane4
Plane5

Datum B

Plane5

Plane9

Start 3

Plane3

Left

1. 20-1226A Base Assembly 8. 20-1230 Motor Bumper

2. 20-1336 Base Machined 9. 30-2923 Oil Line Assembly
3. 62-0014 Motor 10. 24-8765 X-Axis Ballscrew
4. 50-0017 X-Axis Linear Guide (2) 11. 24-8548 Screw Nut
5. 20-7010A Motor Mount 12. 20-0773 Ballscrew Mount
6. 30-1220A Coupling Assembly 13. 20-7416 Bearing Cartridge Housing
7. 25-7042 Motor Mount Cover 14. 20-4394 Support Bumper

Mini Lathe Base Assembly and Parts List

96-8710 rev L June 2005 Assembly Drawings 271

 1 2 3 4 5

Plane4

10

9 8

Slide
Assembly

11

12

15 14 13

1. 20-1337 Saddle Machined 9. 25-7267 Switch Mount

2. 30-2924 Oil Line Assembly 10. 20-7416 Bearing Cartridge Housing
3. 24-8548 Screw Nut 11. 32-2130 Switch
4. 24-8765 Z-Axis Ballscrew 12. 54-0045 Belt
5. 20-1237 Ballscrew Support 13. 20-1231 Motor Face Plate
6. 20-4239 Sprocket (2) 14. 62-0014 Motor
7. 20-0488A Adapter Race 15. 20-3006 Nut Housing Machined
8. 20-1232 Support Bumper (2)

Mini Lathe Saddle Assembly and Parts List

272 Assembly Drawings 96-8710 rev L June 2005

 1 2

3 4

BOTTOM VIEW

1. 20-1229 Tool Platter

2. 20-1338 Slide Machined
3. 50-0018 Z-Axis Linear Guide (2)

Mini Lathe Slide Assembly and Parts List

96-8710 rev L June 2005 Assembly Drawings 273

 1 2 3 4 5

Plane1

9 8 7

Tailstock Wedge
Assembly Assembly

1. 62-0014 Motor 6. 30-0153 Support Bearing Assembly

2. 20-7010A Motor Mount Machined 7. 20-0735 Snap Lock Ring Bumper
3. 50-8766 X-axis Linear Guide Assembly 8. 30-1220A Coupling Assembly
4. 30-2290 Ball Screw Assembly 9. 25-0857B Control Box Bracket
5. 30-2388A Oil Line Assembly

SL-10 Casting Assembly and Parts List

274 Assembly Drawings 96-8710 rev L June 2005

 9 10
8
6 7
5
3 4
1 12 11
13
14
2
33 34

16 17
15

18
32 31

30 19

29

28 20
27

31
26
21

25
22
23

24

1. 57-0142 Seal Kit 18. 20-0858 Handle

2. 20-1070 Gland Retainer 19. 20-0859 Eccentric Clamp
3. 20-1017 Cylinder Head 20. 48-1755 Dowel Pin 1/2 x 2 (2)
4. 57-0140 O-Ring 21. 40-16643 SHCS 5/8-11 x 2-1/4 (4)
5. 20-1012A Shaft 22. 20-1052 TS Base Machined
6. 57-0136 Hydraulic Piston Seal 23. 44-1699 SSS 1/2-13 Flat PT (2)
7. 57-0141 Quad Ring 24. 48-1750 Dowel Pin 1/2 x 1 1/2 (2)
8. 57-0143 Rod Seal 25. 51-2012 Bearing Locknut
9. 20-1020 Knock-Out Tube 26. 20-0861 Clamp Plate
10. 57-0020 O-Ring 27. 20-0860 Clamp Rod
11. 46-1653 Hex Nut 5/16-18 (4) 28. 20-0988F TS Head Machined
12. 45-1600 Split Lock Washer (4) 29. 59-2016 Grease Fitting (6)
13. 20-1014 End Cap 30. 56-2086 Retaining Ring
14. 20-1016 Tie Rod (4) 31. 57-0135 Wiper
15. 20-1013 Cylinder Tube 32. 20-0857 Shaft Cap
16. 57-0140 O-Ring 33. 44-16395 SSS 3/8-16 x 1/2 Full Dog
17. 58-0045 Str Adapter (2) 34. 44-0052 SSS 3/8-16 x 1/2 Flat pt

SL-10 Tailstock Assembly and Parts List

96-8710 rev L June 2005 Assembly Drawings 275

 1 2 3 12 13 4 5 6 7

10

14 11
15 Tool Changer
Assembly

1. 62-0009 Motor 9. 20-0928 Ring Bumper

2. 30-1219 Coupling Assembly 10. 20-0773 Bearing Support Housing Machined
3. 20-7010A Motor Mount Machined 11. 30-2244 Ball Screw Assembly
4. 20-1126 Snap Lock Ring Bumper 12. 32-2051 X-axis Home Limit Switch
5. 30-2387 Lube Line Assembly 13. 25-7266 Switch Mounting Bracket
6. 50-8766 X-axis Linear Guide Assembly 14. 25-7042A Motor Mount Cover
7. 20-0986B Wedge Machined 15. 20-0848 TC Housing Cover
8. 30-0154 Bearing Motor Housing

SL-10 Wedge Assembly and Parts List

276 Assembly Drawings 96-8710 rev L June 2005

 1 2 3

4
33

5
32

31
6
29
30
28 7

26
27 8

9
25

24
10
23
11
22
12

21 20 19 18 17 16 15 14 13

1. 30-3076 Air Cylinder Assembly 17. 24-4010 Belleville Washers (2)

2. 62-0014 Motor 18. 22-8550A TC Belleville Spacer
3. 20-8512A Worm Housing 19. 58-3052 Coolant Elbow
4. 30-1220A Coupling Assembly 20. 30-3660A Coolant Transfer Assembly
5. 30-3655 Coolant Line Assembly 21. 20-8517A TC Turret Cams (2)
6. 20-8509 Worm Shaft 22. 59-2059 15/16 Steel Balls (3)
7. 20-8510A TC Transfer Shaft 23. 20-8532 Turret Retainer
8. 32-2011 Switch 24. 20-8530 TC Turret Sfaft
9. 20-8533 TC Switch Ring 25. 20-8516 TC Cam Lever
10. 25-0981 Turret Switch Bracket 26. 20-8518 Spring Retainer
11. 58-1679 Bulkhead Fitting 27. 59-0035 Spring
12. 58-0203 Coolant Valve 28. 20-8576 Cam Cage
13. 20-0929 Coolant Knob 29. 20-8505A Male Turret Coupling
14. 46-7016 Bearing Nut N-13 30. 20-8506A Female Turret Coupling
15. 58-0202 Coolant Line 31. 20-0675 Turret Mount Coupling
16. 20-8522A TC Spur Gear 32. 20-8511A TC Cluster Gear
22-8544 Spur Gear Key 33. 20-0985A TC Turret Housing

SL-10 Tool Changer Assembly and Parts List

96-8710 rev L June 2005 Assembly Drawings 277

 1 2 3 4 2 5 6

17 16 15 8 13 12 11 10 9 8 7
18 14

23

19 20 21 22

24

1. 50-3400 Linear Guide 13. 20-7010A Motor Mount

2. 25-9746 Cable Clamp Base 14. 30-0156 Motor Housing Bearing Assy
3. 20-9058 Ballscrew Bumper 15. 59-6600 Guide Rail Plug
4. 25-7266 X-Axis Mounting Bracket 16. 22-7458 Linear Guide Cam
5. 58-3030 Banjo Elbow 5/16 x M6 17. 22-2629 Stub Shaft/Worm Key
6. 25-7080 Bumper Bracket 18. 62-0014 Yaskawa Sigma 09 Motor
7. 30-0153 Support Bearing Assembly 19. 25-8653A Roller Bracket
8. 48-0045 Dowel Pin 20. 54-0030 Guide Wheel
9. 24-7325 Str Fit Metric Linear Guide 21. 26-8623 Seal Rail Wiper
10. 20-9007 Nut Housing 22. 22-8624 Seal Rail Backing Bar
11. 30-8717A Oil Line Assembly 23. 93-0209 Slide Spring Service Kit
12. 24-9013 Ballscrew 24. 36-8980B Rail Interface

SL-20 Casting Assembly and Parts List

278 Assembly Drawings 96-8710 rev L June 2005

 4
1 3 5 6 7 8 9 10
2

11

12

13

14

22 21 20 19 18 17 16 15

28

25 26 27 29 30

31
23
24

32
40 39 38 37 36 35 34 33

SL-30 Casting Assembly w/Tailstock

96-8710 rev L June 2005 Assembly Drawings 279

 SL-30 Casting Assembly w/Tailstock Parts List

1. 22-2629 Key stub shaft

2. 62-0014 Motor
3. 20-7010A Motor mount
4. 25-7042A Snap lock motor mount cover plate
5. 26-7233A Gasket, deflector shield
6. 20-0143 Snap lock ring bumper
7. 25-7267 Brack mounting y-axis
8. 32-2040 Z-axis limit switch cable
9. 30-1962 Z-axis Ballscrew Assembly
10. 20-9007 Nut housing machined
11. 58-3031 Banjo Elbow 5/16F X M6 M
12. 25-7080 Bumper bracket
13. 48-0045 Dowel pin 3/8 x 1 1/2
14. 22-7458 Cam linear guide
15. 20-9058 Bumper
16. 50-9010 Linear guide X-axis
17. 59-6600 Guide rail plug
18. 30-8863 Oil line assembly
19. 58-1560 Adpt 1/8 M BSPT - 5/16 F
20. 58-2010 Nylon tubing 5/32
21. 58-3031 Banjo Elbow 5/16F X M6 M
22. 30-1220A Coupling assembly
23. 54-0030 Guide wheel
24. 25-8653A Roller Bracket
25. 25-8841 Seal strip
26. 20-8807 Tailstock head
27. 20-8808 Tailstock body
28. 93-0210 Spring cross slide
29. 20-8720 Swing arm spring
30. 20-8721A Bushing swing arm spring
31. 20-0534 Bracket spring T/C
32. 22-8064 Waycover bottom guide bs strip
33. 59-6655 Rubber plug guide rail
34. 50-3400 Linear guide
35. 20-8988A Tailstock cylinder attach bracket
36. 32-0400A Encoder read head assembly
37. 25-8024A Encoder strip
38. 20-9210A Tailstock arm
39. 25-8028 Guide, waycover TS bottom
40. 59-0013 Hydraulic cylinder

280 Assembly Drawings 96-8710 rev L June 2005

 1 3
2 4 5 6 7 8 9 10 11

12

13

15 14

19
20

16 17 18 21

22 23

24

25

31 30 29 28 27 26

1. 22-2629 Stub Shaft Key 17. 25-8297 Tailstock Waycover Rail/Guide

2. 62-0016 Motor 18. 20-8807A Tailstock Head Machined
3. 25-9203 Motor Mount Cover Plate 19. 20-8617 Strain Relief Conduit
4. 26-7233A Deflector Shield Gasket 20. 20-8618 Strain Relief Conduit
5. 30-0450 Ball Screw Assembly 21. 20-8203A Tailstock Body Machined
6. 20-0841 Rear Support 22. 30-8335 Oil Line Assembly
7. 55-7423 Standoff 23. 25-8296 Z-Axis Waycover Bottom Guide
8. 25-7267 Y-Axis Mounting Bracket 24. 26-8320 Tailstock Guide Strip
9. 32-2040 Z-Axis Limit Switch 25. 59-6655 Guide Rail Rubber Plug
10. 30-8325A Oil Line Assembly 26. 50-8205 Tailstock Linear Guide
11. 20-0150 Nut Housing Machined 27. 25-6651 Drip Rail
12. 58-3031 Banjo Elbow 5/16 F x M6 M 28. 32-0017 Read Head
13. 22-7458 Linear Guide Cam 29. 20-8228 Hydraulic Cylinder Mount
14. 50-9305 Linear Guide 30. 25-8300 Encoder Strip
15. 24-7325 Str Fit Metric Linear Guide 31. 59-0034 Hydraulic Cylinder
16. 54-0030 Support Wheel

SL-40 Casting Assembly w/Tailstock and Parts List

96-8710 rev L June 2005 Assembly Drawings 281

 18 19
9
1 2 3 4 5 6 7 8

10

SL-40 Tool Changer 11 12

Assembly

13
SL-40 Wedge Assembly

Plane2

17 16 15 14

1. 62-0016 Motor 10. 30-1215 Coupling Assembly

2. 20-0151 Motor Mount 11. 20-0150 Ball Screw Nut Housing Machined
3. 20-9212 Bearing Cartridge Housing 12. 20-8807A Tailstock Head Machined
4. 20-0735 Snap Lock Ring Bumper 13. 20-1764 Tailstock Base Machined
5. 24-9970C Z-Axis Ball Screw 14. 25-8001A Read Head
6. 50-9971 Z-Axis Linear Guides (2) 15. 50-0028 B-Axis Linear Guides (2)
7. 20-1769 Z-Axis Bumper (Support End) 16. 52-0042 Hydraulic Cylinder
8. 20-0152 Z-Axis Support Bearing Housing 17. 20-1767 Cylinder Attach Bracket
9. 30-0201 Support Bearing Assembly

SL-40L Casting Assembly and Parts List

282 Assembly Drawings 96-8710 rev L June 2005

 1 2 3 4 5 6 7 8 9 10

11
12

Plane6 Plane6

Start 3

Plane5

13
Sub-spindle Assembly

20
19
18
SL-30 Tool Changer
Assembly

SL-30 Wedge Assembly 14 15

16
17

1. 62-0014 Motor (2) 11. 20-0132 Bearing Housing Machined (2)

2. 20-7010A Motor Mount (2) 12. 51-2025 Bearing (2)
3. 30-1220A Coupling Assembly (2) 13. 20-7185 Ball Screw Support Bumper (2)
4. 30-0154 Motor Housing Bearing (2) 14. 30-3556 B-Axis Ball Screw Assembly
5. 25-7042A Motor Mount Cover (2) 15. 50-3400 Sub-spindle Linear Guide Rail (2)
6. 20-0143 Snap Lock Ring Bumper 16. 32-2040 Limit Switch
7. 30-1962 Z-Axis Ball Screw Assembly 17. 25-7267 Switch Mounting Bracket
8. 50-9010 Linear Guide Rail (2) 18. 20-8771A Tool Changer Housing
9. 30-8863 Oil Line Assembly 19. 20-8507A Turret Coupling Mount
10. 20-9007 Nut Housing Machined 20. 20-0169A Tool Changer Housing Cover

TL-25 Casting Assembly and Parts List

96-8710 rev L June 2005 Assembly Drawings 283

 1 2 3

4 5 6

9
10

11

13

Plane3

Plane1

12

View Rotated 1808

1. 20-0609 Front Cap 8. 60-1815 Encoder

2. 20-0608A Spindle Shaft 9. 20-0611 Sub-spindle Motor Pulley
3. 20-0627 Nut Housing Machined 10. 20-0630A Spindle Head Machined
4. 20-7442 End Cap 11. 30-1616A Oil Line Assembly
5. 20-0610 Spindle Pulley 12. 20-5576 Sub-spindle Base Machined
6. 90-0008 ZKP100 Rotating Union 13. 62-1010D Motor 5HP
7. 54-0095 Belt

TL-25 Sub-spindle Assembly and Parts List

284 Assembly Drawings 96-8710 rev L June 2005

 1 6
2 3 4 5 7 8 9 10 11

12
19

18 17 12 16 15 14 13

20
21

25 24 22
23

1. 62-0009 Motor w/Brake 14. 20-7008F Nut Housing Machined

2. 22-2629 Stub Shaft Key 15. 24-7325 Str Fit Metric Linear Guide
3. 30-1044 Oil Line Carrier 16. 30-8716 Lube Line Assembly
4. 41-1717 Long Stud/Set Screw 17. 22-7458 Linear Guide Cam
5. 58-2110 Sleeve Nuts Lube Assembly 18. 25-7266 X-Axis Mounting Bracket
6. 25-7042A Snap Lock Motor Mount Cover Plate 19. 30-1220A Coupling Assembly
7. 26-7233A Deflector Shield Gasket 20. 20-8535 Tool Changer Access Plate
8. 20-7185 Z-Axis Motor End Bumper 21. 57-8546 TC Access Plate Gasket
9. 58-3031 Banjo Elbow 5/16 F x M6 M 22. 57-8576 TC Cover Gasket
10. 30-0616B X-Axis Ball Screw Assembly 23. 20-8545 TC Housing Cover
11. 20-7185 Z-Axis Support End Bumper 24. 20-8364 Spacer
12. 48-0045 Dowel Pin 23. 25-7459 Trip Table Bracket
13. 50-8549 Linear Guide

SL-20 Wedge Assembly and Parts List

96-8710 rev L June 2005 Assembly Drawings 285

 2
1 3 4 5 6 7 8

19

17 16 15 14 13 12 11 10 9
18

20
21
25 24
22
23

1 30-1044 Oil Line Assembly 14. 48-0045 Dowel Pin 3/8 x 1-1/2
2. 25-7042A Snap Lock Motor Mount Cover Plate 15. 32-2055 X-Axis Home Limit Switch
3. 26-7233A Deflector Shield Gasket 16. 25-7266 Limit Switch Mounting Bracket
4. 30-0618B X-Axis Ball Screw Assembly 17. 22-2629 Stub Shaft Key
5. 30-0593 Wedge Oil Line Kit 18. 62-0009 Motor w/Brake
6. 58-3031 Banjo Elbow 5/16 F x M6 M 19. 30-1220A Coupling Assembly
7. 50-8766 X-Axis Linear Guide 20. 20-8535 Tool Changer Access Plate
8. 59-6600 Guide Rail Plug 21. 57-8546 TC Access Plate Gasket
9. 20-7474 Support End Bumper 22. 57-8576 TC Cover Plate
10. 20-7008F Nut Housing Machined 23. 20-8545 TC Housing Cover
11. 24-7325 Str Fit Metric Linear Guide 24. 20-8364 Spacer
12. 22-7458 Linear Guide Cam 25. 25-7459 Table Trip Bracket
13. 20-7474 Motor End Bumper

SL-30 Wedge Assembly and Parts List

286 Assembly Drawings 96-8710 rev L June 2005

 1 2 3 4 5 6

18

12
17 16 15 14 13 11 10 9 8 7

19 21
20 22

26 25 24 23

1. 58-2760 2-Way Manifold 14. 59-6600 Guide Rail Plug

2. 30-1044 Oil Line Carrier 15. 32-2063 X-Axis Home Limit Switch
3. 20-7474 Motor End Bumper 16. 25-7267 Limit Switch Mounting Bracket
4. 30-1530 Oil Line Assembly 17. 62-0009 Yaskawa Sigma Motor w/Brake
5. 50-9011 Linear Guide 18. 30-1220A Coupling Assembly
6. 20-7474 Support End Bumper 19. 20-8545 Tool Changer Housing Cover
7. 58-3031 Banjo Elbow 5/16 F M6 M 20. 57-8576 TC Cover Gasket
8. 30-1397A X-Axis Ball Screw Assembly 21. 20-8535 TC Access Plate
9. 20-9007 Nut Housing Machined 22. 57-8546 TC Access Plate Gasket
10. 24-7325 Str Fit Metric Linear Guide 23. 20-8204 X-Riser
11. 22-7458 Linear Guide Cam 24. 25-7459 Trip Table Bracket
12. 25-7042A Snap Lock Motor Mount Cover Plate 25. 93-0211 Cross Slide Spring Kit
13. 26-7233A Deflector Shield Gasket 26. 20-8721 Swing Arm Bushing

SL-40 Wedge Assembly and Parts List

96-8710 rev L June 2005 Assembly Drawings 287

 13
1 2 3 4 5 6 7 8 9 10 11 12 1516 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

50
49
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32

SL-20 Tool Changer Assembly

288 Assembly Drawings 96-8710 rev L June 2005

 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 and 57-0029 Seal
4. 56-2090 Retaining Ring RR-300 54. 20-8532 Reatiner turret T/C
5. 22-8538 Rod end spacer 55. 22-8543 Key
6. 32-2153 Unclamp switch 56. 57-2154 O-ring
7. 32-2154 Clamp switch 57. 59-0035 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. 93-0346 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. 56-9057 Retaining Ring 63. 20-8507A Turret mounting coupling
14. Not Used 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. 32-2010 Switch (30" Cable)
29. 30-3655 Coolant line assembly
30. 25-8534 Home bracket
31. 25-8536 Switch bracket
32. 20-8533 Ring switch T/C
33. 20-8530 Shaft Turret T/C
34. 58-8657Copper 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. 30-3660A 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

96-8710 rev L June 2005 Assembly Drawings 289

 7
1 2 3 4 5 6 8 10 13 141516 17 18 19 20 21

65
22
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

290 Assembly Drawings 96-8710 rev L June 2005

 SL-30 Tool Changer Assembly Parts List
1. 51-2984 Thrust washer TRB-3446 51. 20-8557 Bushing and 57-0029 Seal
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. Not Used 59. 57-2975 O-ring 2-172 buna
10. 93-0346 Motor 60. 20-0516 Plate turret cover
11. Not Used 61. 57-8970 Gasket plate coolant T/H
12. Not Used 62. 51-2983 Thrust washer TRD-4860
13. 93-30-1220A 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. Not Used
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. 30-1957 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

96-8710 rev L June 2005 Assembly Drawings 291

 1 2 3 4 7 8 9 10 11 12 13 14 15 16 17
5
55 56 6
54
18
53
52 19
51 20
21
50
22
49
48 23
47
24
46
25
45
26

44
43
42
34 33 32 31 30 29 28 27
41

40 39 38 37 36 35

SL-40 Tool Changer Assembly

292 Assembly Drawings 96-8710 rev L June 2005

 SL-40 Tool Changer Assembly Parts List
1. 30-3650 Air Cylinder Assembly 50. 20-8557 Bushing and 57-0029 Seal
2. 32-2162 Clamp Switch 51. 51-3001 Needle Thrust Bearing
3. 32-2161 Unclamp Switch 52. 51-2983 Thrust Washer TRD-4860
4. 49-4115 1-1/2 Steel Washer 53. 57-0047 O-Ring
5. 56-9057 Retaining Ring 5100-150 54. 20-0397 Turret Block
6. 45-2001 Shim .002 Thick 55. 20-0250 Coupling Mount
7. 62-0014 Motor 56. 22-8538 TC End Rod Spacer
8. 57-0075 O-Ring 2-02 Buna
9. 30-1220A Coupling Assembly
10. 57-2129 Worm Seal
11. 20-8512A Worm Housing
12. 20-8515 Worm Bearing Clamp
13. 51-2042 Bearing Locknut BH-04
14. 51-7001 Ball Bearing 5204-1SB-Kff
15. 57-2022 O-Ring
16. 20-8509 Worm Shaft
17. 59-2057 5/16 Steel Balls
18. 20-0249 TC Housing Machined
19. 57-2831 O-Ring 2-130 Buna
20. 20-8510 TC Transfer Shaft
21. 20-8537 TC Spring Retainer
22. 32-2011 Switch (30" Cable)
23. 30-3655 Coolant Line Assembly
24. 25-8534 Home Bracket
25. 25-8536 Clamp Bracket
26. 20-8533 TC Switch Ring
27. 20-8530 TC Turret Shaft
28. 58-7242 Coolant Tubing
29. 57-1045 Seal CR6372
30. 20-8539 TC Rear Bearing
31. 46-7016 Locknut
32. 20-8511A TC Gear Cluster
33. 20-8522A TC Spur Gear
34. 22-8544 TC Spur Gear Key
35. 24-4010 Belleville Washer (2)
36. 22-8550A Belleville Spacer
37. 20-8516 TC Cam Lever
38. 30-3660A Transfer Coolant Nozzle Haas Turret, (30-1159 BOT Turret, 30-6065 VDI Turret)
39. 93-8138 TC Turret Cam (2)
40. 59-2059 15/16 Steel Balls
41. 20-0247 Female Turret Coupling
42. 20-0248 Male Turret Coupling
43. 57-0029 Seal CR29841
44. 49-1010 Shoulder Bolt 3/8 x 1-1/2
45. 59-0035 Die Springs
46. 20-8532 TC Turret Retainer
47. 22-8543 TC Turret Key
48. 57-2154 O-Ring 2-240 Buna
49. 20-8518 Spring Retainer

96-8710 rev L June 2005 Assembly Drawings 293

 SL-40 Hydraulic Tool Changer

294 Assembly Drawings 96-8710 rev L June 2005

 SL-40 Hydraulic Tool Changer
1. 58-0038 Fitting ORB
2. 58-0723 Check Valve
3. 2266-6-8s
4. 93-0590 Solenoid
5. 52-0156 Hydraulic Accumulator
6. 20-2437 Valve Block
7. 20-2443 Key Shim
8. 62-0014 Servo Motor
9. 20-2428 Rigid Coupling
10. 57-1025 Seal
11. 20-2427 Worm Retainer
12. 51-2041 Bearing Lock Nut
13. 51-0159 Bearing
14. 20-2425 Worm Shaft
15. 51-0161 Bearing
16. 20-2431 Piston Retainer
17. 59-0669 Die Spring
18. 48-0042 Dowel Pin
19. 20-8557 Front Bushing
20. 51-0158 Thrust Washer
21. 51-0157 Thrust Bearing
22. 59-0670 Shims
23. 51-0172 Needle Bearing
24. 20-2432 Hydraulic Piston
25. 20-2430 Turret Shaft
26. 20-2434 Worm Bushing
27. 51-0160 Bearing
28. 20-2433 Worm Gear
29. 59-0671 Belleville Spring
30. 20-2435 Flanged Bearing Retainer
31. 32-2234 Proximity Switch
32. 20-2472 Support Block
33. 32-2130 Home Switch
34. 20-2438 Support Block
35. 32-2235 Proximity Switch
36. 20-2426 Turret Worm Clamp
37. 20-2436 BOT Worm Turret
38. 20-0247 Female Turret Coupling
39. 20-0248 Male Turret Coupling
40. 20-2422 T/C SL-40 Housing
41. 25-5452 T/C Access Plate
42. 20-2424 T/C Housing
43. 58-0728 Coolant Tube
44. 58-3087 Compression Fitting
45. 58-0080 Plug
46. 59-0103 Spring
47 20-0401 Coolant Shaft
48 20-2423 X Riser X
49 57-0346 Gasket

96-8710 rev L June 2005 Assembly Drawings 295

 COUPLING ASSEMBLY MOTOR BEARING HOUSING

SPACER RING
SNAP LOCK SNAP RING
RING BMPR LOCK BMPR BEARING LOCKNUT

BALL SCREW SUPPORT SUPPORT BEARING ASSEMBLY

MOTOR MOUNT BEARING LOCKNUT
BEARING ASSEMBLY

BALL SCREW ROTATED 908

BALL SCREW ASS'Y "A" BALL SCREW SNAP LOCK RING BMPR MOTOR COUPLING APPLICATION
MOUNT ASS'Y

30-2977 BS ASS'Y 32mm 24-8765 BALLSCR 32mm NONE 20-7010A 30-1220A MINI LATHE (Z)

30-2972 BS ASS'Y 32mm 24-8765 BALLSCR 32mm NONE 20-7010A 30-1220A MINI LATHE (X)

30-2290 BS ASS'Y 32mm 24-7146 BALLSCR 32mm 20-0735 SNAP LOCK RING BMPR 1.75 20-7010A 30-1220A SL10 (Z)

30-2244 BS ASS'Y 32mm 24-8548B BALLSCR 32mm 20-1126 SNAP LOCK RING BMPR 1.68 20-7010A 30-1220A SL10 (X)

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

296 Assembly Drawings 96-8710 rev L June 2005

 WHERE USED APPLICATION

30-2972 BS ASS'Y 32mm MINI LATHE (X)

30-2977 BS ASS'Y 32mm MINI LATHE (Z)
30-2290 BS ASS'Y 32mm SL10 (Z)
30-2244 BS ASS'Y 32mm SL10 (X)
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

96-8710 rev L June 2005 Assembly Drawings 297

 Levelling Screw Levelling Screw
(40-164391) (40-0128)
Pendant
Arm
Knuckle
(25-6661)
Knuckle Cover Pendant
(25-6660) Arm
Knuckle Swivel Knuckle
Plate (25-6659) (25-1312)

F1
TOOL
OFFSET
MEASURE
RESET

F2

NEXT
TOOL
POWER
UP
RESTART

F3

TOOL
RELEASE
TOOL
CHANGER
RESTORE

F4

PART
ZERO
SET
PRGRM
CONVRS

ALARM
MESGS
DISPLAY
POSIT

PARAM
DGNOS
OFFSET

SETNG
GRAPH
CURNT
COMDS

HELP
CALC
EDIT

MEM
INSERT

SINGLE
BLOCK
ALTER

DRY
RUN
DELETE

OPTION
STOP
UNDO

BLOCK
Pendant Arm
Mount (20-7109)
CHIP +B MDI DELETE
FWD HOME DNC COOLNT
+A ORIENT
+Z CLNT PAGE SPINDLE ATC
-Y
UP UP FWD ATC
CHIP HAND REV
STOP +X JOG JOG .0001
.001
LOCK -X CLNT CUSOR .1
1. .01
DOWN 10. .1
CHIP ZERO 100.
REV -Z RET ALL
-A
END AXES ORIGIN
AUX PAGE SINGL
-B HOME
CLNT DOWN AXIS
LIST G28
PROG SELECT
OVERRI PROG SEND
DES SHIFT RS232 RECV
10 100% A B
RS232 ERASE
PROG
FEED RATE
FEED RATE +10 HAND C D
FEED RATE CNTRL
FEED F E &
7
-10 100% G H
@
8 :
SPINDLE
+10 I 9
SPINDLE
SPINDLE
HAND
CNTRL J K
SPIN L M
%
4 $
CW
STOP N 5 !
6
CCW O P
5%
SPINDLE
R S
Q *1 ,
2

Wavy Washer
RAPID 25%
50% T U
?
3
RAPID
RAPID 100% V W
RAPID
X Y
+
- =
Z / 0 #
EOB [
( ] *
) CANCEL
SPACE WRITE
ENTER

Pendant Mount (55-0020)

(20-7110) SL-40 Only

Pendant Leveling Assembly

298 Assembly Drawings 96-8710 rev L June 2005

 SHCS
(40-1961)

Washers
(45-1730)
2X Dowel Pin
(48-0020)
Mech Pivot
Tool
(20-8995)
Dowel Pin
(20-8996)

Bearing
(51-7001)

Tool Setter
Shaft
Threaded (20-8993)
Insert
(48-0049)
2X Ball
(59-0019)
2X Springs
(59-0018)

Case
(20-8992)
Mounting
Bolts are
Accessed
Tool Setting Arm
Behind SL-10.................(20-1053)
Sheetmetal SL-20-30............(20-8989)
SL-30 Big Bore..(20-0474)
SL-40.................(20-8291)

Lathe Tool Setting Arm

96-8710 rev L June 2005 Assembly Drawings 299

 1. Steady Rest (Customer Supplied)
2. 20-1750 Steady Rest Mount Machined (SL-40/40L)
3. 20-1649 Steady Rest Mount Machined (SL-30)
4. 25-4598 Waycover LT T/S (SL-40/40L)
25-8756A Waycover LT T/S (SL-30)
5. 48-0009 Dowel Pin 1/2 x 3 1/4
6. 20-0858 Handle
7. 20-1626A Handle Collar
8. 20-1627B Locking Pin (SL-40/40L)
20-1621B Locking Pin (SL-30)
9. 20-1751A Steady Rest Base Machined (SL-40/40L)
10. 20-1648 Steady Rest Base Machined (SL-30)
11. 20-1620 Steady Rest Limit Stop
12. 25-4600A Waycover Steady Rest (SL-40/40L)
25-1316 Waycover Steady Rest (SL-30)
13. 50-0027 Linear Guide
14. 20-1625B Steady Rest Brake (SL-30)
20-2406 Steady Rest Brake (SL-40/40L)
15. 57-0045 Brake Pad
16. 20-1620 Right Travel Stop
17. 20-1628A Steady Rest Push Bar (SL-40/40L)
20-1622 Steady Rest Push Bar (SL-30)
18. 25-1320A Strip Shield (SL-40/40L)
25-1314 Strip Shield (SL-30)

SL-30 and SL-40 Steady Rest

300 Assembly Drawings 96-8710 rev L June 2005

 25-4742
Foot Switch
Cover

(Steady Rest)
30-2203*
Foot Switch Assembly
32-9300A**
Cable (Tailstock)
25-1256
(Chuck) Foot Switch
Cover

25-1255A
Foot Switch
Cover
32-2254
32-2255 Limit Switch
Limit Switch (Tlstk)
(Chuck)
25-1253A
Foot Switch Bulkhead

25-1252
Foot Switch Pedal

59-0069
Foot Switch Spring

25-1254B
Foot Switch
Base Plate

59-1041
Control Legs (4)

* 30-5105 Foot Switch Assembly w/Steady Rest and Tailstock (SL-30/40)

30-5106 Foot Switch Assembly Chuck w/Steady Rest SL-30/40)
** 32-9300B Cable w/30-5105 and 30-5106 Foot Switch Assemblies
32-9311B Cable w/30-2203 Foot Switch Assembly (20/30)
32-9312B Cable w/30-2203 and 30-5105 Foot Switch Assemblies (SL-40)
32-9312B Cable w/30-5106 Foot Switch Assembly (SL-30/40)

Foot Switch Assembly

96-8710 rev L June 2005 Assembly Drawings 301

 30-2202
Foot Switch Assembly
32-9300A* (Chuck)
Cable

25-1255A
Foot Switch Cover

32-2255
Limit Switch

25-1253A
Foot Switch Bulkhead

25-1252
Foot Switch Pedal

59-0069
Foot Switch Spring

25-1254B
Foot Switch Base Plate
59-1041
Control Legs (2)

* 32-9300B Cable w/30-5105 and 30-5106 Foot Switch Assemblies

32-9311B Cable w/30-2202 Foot Switch Assembly (SL-20/30)
32-9312B Cable w/30-2202 Foot Switch Assembly (SL-40)

Foot Switch Assembly

302 Assembly Drawings 96-8710 rev L June 2005

 Parker Hydraulic Power Unit

96-8710 rev L June 2005 Assembly Drawings 303

 Rexroth Hydraulic Power Unit

304 Assembly Drawings 96-8710 rev L June 2005

 Haas Hydraulic Power Unit

4 5
3
6

2 10
11

7
1 12 13

9 8
22
24

19 23
21
20

18

17 14

16 15

1. 58-0741 Gauge 13. 25-6938 Valve Block Bracket

2. 53-3009 Pressure Switch 14. 58-0855 Hydraulic Tube
3. 90-0114 Hydraulic Valve 15. 25-6936 Reservoir
4. 59-0439 Pressure Adjusting Valve 16. 59-0798 Suction Strainer
5. 20-3109 Valve Block (Tailstock) 17. 59-0797 Level Sight Gauge
6. 90-0105 Hydraulic Valve (Tailstock) 18. 58-0858 Hydraulic Tube Return
7. 90-0104 Hydrulic Valve (Chuck) 19. 58-0856 Hydraulic Tube Pressure
8. 20-3108 Valve Block (Chuck) 20. 57-0389 Reservoir Gasket
9. 59-0439 Pressure Adjusting Valve 21. 25-6935 Reservoir Cover Plate
10. 58-0875 In-Line Filter 22. 58-0857 Hydraulic Tube Pressure
11. 58-0879 Hydraulic Tube 23. 59-0799 Filter Breather
12. 62-0999A Pump Motor 24. 25-6937 Subplate Motor Mount

96-8710 rev L June 2005 Assembly Drawings 305

 Mini Lathe External Sheetmetal and Parts List
25 26 1 2 3

5
22 24
6
23 7
8

10
21

11

20
12
19

14

18

15

13
17 16

1 20-1292 Pendant Arm 14. 20-1224 Door V-Track

2 25-6661 Pendant Arm Knuckle 15. 25-4148 Chip Tray Door Bracket
3 40-164391 Leveling SHCS 16. 25-4128 Chip Tray Door
4 25-6660 Knuckle Cover 17. 25-4121 Spindle Cover
5 25-6659 Knuckle Swivel Plate 18. 30-2961 Door Assembly
6 20-7109A Pendant Arm Mount 19. 25-4122 Left End Panel
7 55-0020 Wavy Washer 20. 25-4124 Coolant Collector
8 20-7110A Pendant Mount 21. 25-4125 Coolant Collector Door
9 25-4110 Top Right Cover 22. 25-4112 Back Panel
10. 25-4111 Right End Panel 23. 32-0042 Regen Cover
11. 25-4106A Lube Cover 24. 25-4144 Toolbox
12. 25-6152A Air Hose Bracket 25. 25-4108 Top Hat
13. 25-4109 Front Skirt 26. 25-4145 Toolbox Door

306 Assembly Drawings 96-8710 rev L June 2005

 Mini Lathe Internal Sheetmetal and Parts List

1 2
3
4
5

21
9

10

11
12

20

13

15
14

16
19

18
17

1 32-0106 Work Light Assembly 12 25-4132C Saddle Bra

2 25-4092 Upper Roller Track 13 25-4143 Chip Tray Body
3 25-4105A Splash Liner 14 25-4130 Chip Tray
4 25-4100 CE Hanger 15 26-0054 Door Brass Wiper
5 25-4136 Header 16 25-4104A Fixed Bulkhead
6 20-1240A Guide Bar Assembly 17 25-4107 Bulkhead Bracket
7 Not Used 18 25-4089 Part Tray
8 25-4134A Rear Way Cover 19 25-4138 Part Catcher Drawer
9 25-4135A Front Way Cover 20 25-4147 Part Catcher Drawer Frame
10 25-4133 Z-Axis Sliding Cover 21 25-4102A Stand
11 25-4139A Z-Axis Way Cover Wiper

96-8710 rev L June 2005 Assembly Drawings 307

 SL-10 External Sheetmetal and Parts List
32 33 35
34
36
31 1

3
o
View Rotated 180
30
4

6
7
29
27 8

28

CK
TAIL STO

9
10

11
26 12
25
13

24
22 21
17
18

19
23 14
20
15
16

1 25-0875 Monitor Cover 19 25-0860 Door Inner Liner

2 25-0876 Pendant Back Cover 20 25-0862 Front Skirt
3 25-0879 Z-Axis Right Bottom Wiper Retainer 21 25-0865 Lower Door Rail
4 26-0030 Z-Axis Right Bottom Wiper Felt 22 22-6506 Door V-Track
5 59-0009 R-Type Hinge Half 23 20-6016 Door V-Track Spacer
6 25-0868A Right Side Panel Weldment 24 25-6190 Bottom Left Side Panel
7 25-1002 Tailstock Pan 25 25-0398 Tramp Lube Oil Bottle Panel
8 25-0890 NOTS Tray 26 25-6185 Coolant Collector
9 25-1023 Motor Pump Coolant Tray 27 25-0606 Coolant Collector Door
10 25-0889 Coolant PM Tray 28 25-6150 Coolant Collector Enclosure
11 25-0548 Discharge Chute Weldment 29 25-6189A Top Left End Panel
12 25-0887 Auger Pan Weldment 30 26-0869 Upper Door Rail
13 25-6551 Auger Mount 31 25-0025D Main Electrical Control Box
14 25-0888 Chip Tray Extension 32 25-8709 J-Box
15 25-0878B Chip Tray Right 33 32-0042 Regen Assembly
16 25-0877B Chip Tray Left 34 25-0857 Control Box Bracket
17 25-6574 Chip Tray Bottom 35 25-0867 Rear Panel
18 25-0858 Door Weldment (25-0016 Window) 36 25-0863 Hydraulic Pump Mount Weldment

308 Assembly Drawings 96-8710 rev L June 2005

 SL-10 Internal Sheetmetal and Parts List
19 20 21

14
18

17

15

16
13 1

2
12
3

4
11

6
5

10

1 25-0870 X-Axis Top Cover 12 25-0886 Fan Mount

2 25-0871 X-Axis Front Cover 13 36-3035 Spindle Motor Fan
3 25-0983 X-Axis Wiper Retainer 14 25-0861 Fixed Bulkhead
4 26-0038 X-Axis Way Cover Felt 15 25-0880 Z-Axis Left Bottom Wiper Retainer
5 25-0872 X-Axis Way Cover 16 26-0032 Z-Axis Left Bottom Wiper Felt
6 26-0034 X-Axis Top Wiper Felt 17 25-0881 Z-Axis Left Top Wiper Retainer
7 25-0866 Moving Bulkhead 18 26-0033 Z-Axis Left Top Wiper Felt
8 26-0035 X-Axis Side Wiper Felt 19 25-0859 Door Drain
9 25-0873 Z-Axis Sliding Cover 20 26-0039 Door Wiper
10 25-7195 Lube Rack Bracket 21 25-0947 Top Wiper Retainer
11 25-0885 Belt Cover

96-8710 rev L June 2005 Assembly Drawings 309

 SL-20 External Sheetmetal and Parts List
28

21
27

26
22
25 23 11

24 View Rotated 1808

w/Parts
4 5 6 8 Catcher

10
1 2 3 9
12

13

VECTOR
20HP DUAL DRIVE

TAIL STOCK

19 14

20
18

17 16 15

1. 59-0023 Door Hinges 16. 25-8903C Front Rail

2. 25-1350 Toolbox Door 17. 25-6550A Chip Auger Tray
3. 25-8909F Left Side Panel 18. 25-8971C Chip Auger Pan
4. 25-1349 Toolbox 19. 25-0607 Coolant Collector
5. 25-8935D Top Door Roller Mount 25-0606 Door
6. 25-8916B Top Panel 20. 22-6115A Motor Enclosure
7. Not Used 21. 25-0428 Left Bottom Rear Cover
8. 25-8924G Left Front Panel 22. 25-1459A Rear Cover
9. 59-0023 Door Hinges 23. 25-0398 Tramp Lube Oil Pan
10. 25-8021 Access Door 24. 25-0243B HP Pump Bracket
11. 30-1489 Door Assembly w/Parts Catcher 25. 25-8067B Coolant Pump Mount
12. 30-1486A Door Assembly 26. 25-0548 Discharge Chute
13. 25-8919C Right Front Panel 27. 25-6628 Discharge Chute Filler
14. 25-8784C Door Drip Panel 28. 25-8914F Right End Panel
15. 22-6506 Door V-Track 25-0623C Right End Panel (TL-15)

310 Assembly Drawings 96-8710 rev L June 2005

 SL-20 Internal Sheetmetal and Parts List

22 23 24

25 26 1

21
2

3
18 19 20

17 5
4 6
16

**29
7

** 27

*15 ** 28

14 9
8
12
10
13
* Parts Catcher Only 11
** For Lifting Only

1. 22-8053 Upper Waycover Guide 16. 25-4320 Z-Axis Bottom Wiper

2. 25-8051 Z-Axis Waycovers 17. 25-4321 Z-Axis Back Wiper
3. 22-8052 Lower Waycover Guide 18. 25-8938E Fixed Bulkhead
4. 25-4423 Cable Rail 19. 30-3191 Upper Door Wiper Assembly
5. 25-8933D Moving Bulkhead 20. 25-4322 Z-Axis Top Wiper
6. 25-8908A Right Support 21. 25-8925C Control Box Mounting Bracket
7. 25-4329 Tailstock Right Waycovers 22. 25-8921D Rear Sliding Cover
8. 22-8075A Lower Tailstock Waycover Guide 23. 25-8928A Tool Changer Tunnel Panel
9. 25-6458 Tool Changer Front Plate 24. 25-4324 X-Axis Wiper
10. 25-8665A Tool Changer Waycover 25. 25-8605B Tool Changer Sliding Cover
11. 25-8926C Front Wedge Cover 26. 25-8694A Tool Changer Splash Shield
12. 25-0250A Tailstock Cover 27. 20-1633 Right Rear Lifting Bracket
13. 25-4317 Upper Tailstock Waycover Guide 28. 20-1632 Right Front Lifting Bracket
14. 25-4316 Left Tailstock Waycovers 29. 20-1631 Left End Lifting Bracket
15. 25-6512 Parts Catcher Tray (Optional)

96-8710 rev L June 2005 Assembly Drawings 311

 SL-30 External Sheetmetal and Parts List
30

28 29

23 22

24
27 25
10
26
View Rotated 1808

w/Parts
4 5 6 Catcher

1 2 3
7 8 9 11 12

20HP VECTOR
DUAL DRIVE

TAIL STOCK

19
18 13

21 20
Big Bore
Only 17

16 15 14

1. 59-0023 Door Hinges (2) 16. 25-6557 Chip Tray

2. 25-1350 Toolbox Door 17. 25-8880B Chip Auger Pan
3. 25-8814E Left Side Panel 18. 20-1521 Lower Tailstock Waycover Guide
4. 25-1349 Toolbox 19. 25-0607 Coolant Collector (25-0606 Door)
5. 25-8819C Top Door Roller Mount 20. 25-6115A Motor Enclosure
6. 25-8818D Top Right Panel 21. 25-6510 Motor Enclosure (Big Bore)
7. 59-0023 Door Hinges (2) 22. 25-0517 Left Bottom Rear Panel
8. 25-8021 Access Door 23. 25-0526 Center Rear Panel
9. 25-8820E Left Front Panel 24. 25-0518 Right Rear Panel
10. 30-1490 Door w/Parts Catcher Assy 25. 25-0398 Tramp Lube Oil Pan
11. 30-1487 Door Assy 26. 25-0243B HP Pump Bracket
12. 25-8786C Right Front Panel 27. 25-8067B Coolant Pump Mount
13. 25-6513A Door Drip Tray 28. 25-0548 Auger Discharge Chute
14. 25-8774C Front Rail 29. 25-0283 Chip Tray Filler
15. 22-6023 Door V-Track 30. 25-8813G Right Side Panel

312 Assembly Drawings 96-8710 rev L June 2005

 SL-30 Internal Sheetmetal and Parts List

23 24 25

27 28 1

22
2
26

3
19 20 21

4
18 6
**32 5
17 29 7

16
*15 ** 30
12
** 31

8
9
13
10
14
* Parts Catcher Only 11
** For Lifting Only

1. 22-8049 Z-Axis Top Waycover Guide 17. 30-3647 Z-Axis Lower Wiper Assembly
2. 25-8047 Z-Axis Waycover 18. 30-3646 Z-Axis Middle Wiper Assembly
3. 22-8048 Z-Axis Bottom Waycover Guide 19. 25-8824C Fixed Bulkhead
4. 22-8783 Moving Bulkhead Support 20. 30-3192 Door Wiper Assembly
5. 22-0830 Cable Channel Cover 21. 30-3645 Z-Axis Upper Wiper Assembly
6. 25-8843A Moving Bulkhead 22. 25-8807B Control Box Mounting Bracket
7. 25-6319 Right End Support Bracket 23. 25-8754C Rear Sliding Cover
8. 25-8025B Right Tailstock Waycover 24. 25-8782B Tool Changer Tunnel Panel
9. 25-0251A Tailstock Cover 25. 30-3648 X-Axis Top Wiper Assembly
10. 25-8757 Tool Changer Waycover 26. 30-3649 X-Axis Side Wiper Assembly
11. 25-8755C Front Wedge Cover 27. 25-8823B X-Axis Tool Changer Sliding Cover
12. 25-6458 Tool Changer Waycover Mount 28. 25-8772A Tool Changer Splash Shield
13. 25-8774 Upper Tailstock Waycover Guide 29. 25-8830A X-axis Drip Channel
14. 25-8756B Left Tailstock Waycover 30. 20-1591 Right Rear Lifting Bracket
15. 25-6512 Parts Catcher Tray (Optional) 31. 20-1590 Right Front Lifting Bracket
16. 25-8849A Z-Axis Drip Tray 32. 20-1589 Left End Lifting Bracket

96-8710 rev L June 2005 Assembly Drawings 313

 SL-40 External Sheetmetal and Parts list

30

29

28

31
32
34
27 33
26 View Rotated 1808
25

6 7 8

1 2 3 4 5 9 10 11 12 13 14 15

TAIL STOCK

24

22 21 16

23
17
19
18

20

1. 25-0780 Left End Rear Panel 18. 25-8235 Front Rail

2. 59-0023 Toolbox Door Hinge 19. 25-8269A Chip Auger Pan
3. 25-1350A Toolbox Door 20. 25-6601 Chip Tray
4. 25-8211F Left End Front Panel 21. 22-8301 Lower Tailstock Waycover Guide (2)
5. 25-4729 Toolbox 22. 25-0640C Coolant Collector
6. 25-8285B Door Rail Mount 23. 25-6129 Motor Enclosure
7. 25-8218A Left Top Panel 24. 25-0641 Left End Front Panel Filler
8. 25-8219A Right Top Panel 25. 25-0243B HP Pump Bracket
9. 25-8206A Front Left Panel 26. 25-8067B Coolant Pump Mount
10. 59-0023 Access Door Hinge 27. 25-0548 Auger Discharge Chute
11. 25-8021 Access Door 28. 25-0164 Discharge Chute Filler
12. 25-8207A Front Left Middle Panel 29. 25-8213C Right End Front Panel
13. 30-1488 Door Assembly 30. 25-8214C Right End Rear Panel
14. 25-8208B Front Right Middle Panel 31. 25-0783 Rear Lower Left Cover
15. 25-8209A Front Right Panel 32. 25-0784 Rear Middle Panel
16. 25-6311 X-Axis Drip Tray 33. 25-0781 Rear Right Panel
17. 22-6023 Door V-Track 34. 25-0398 Tramp Lube Oil Pan Bracket

314 Assembly Drawings 96-8710 rev L June 2005

 SL-40 Internal Sheetmetal and Parts List
9 11
1
8
2 4
7
12
6
10

31 13
28 29 30 32 5

14

15

17
**
33

27
16

26
24
** 34
25
** 35
23
18

19

22 21

** For Lifting Only 20

1. 25-0782 Control Box Mounting Bracket 19. 25-8297 Tailstock Waycover Guide
2. 25-0145B Z-Axis Top Rear Sliding Cover 20. 25-8249 Z-Axis Bottom Right Waycover
3. 25-8246B Z-Axis Bottom Rear Sliding Cover 21. 25-8250 X-Axis Waycover
4. 25-8653A Z-Axis Waycover Support Bracket 22. 25-8245A Front Wedge Cover
5. 25-8261A Tool Changer Cover Spacer 23. 25-0252 Tailstock Cover
6. 25-8262C Tool Changer Cover 24. 25-8298 Spindle Housing Vertical Rail Drip
7. 25-8253 X-Axis Vertical Wiper 25. 25-8248 Z-Axis Bottom Left Waycover
8. 25-8254 X-Axis Horizontal Wiper 26. 25-8267A Lower Door Chip Seal
9. 25-8265 X-Axis Tunnel Panel 27. 25-8252A Z-Axis Horizontal Wiper
10. 25-8263 Tool Changer Splash Shield 28. 25-8243C Fixed Bulkhead
11. 25-8247 Z-Axis Top Right Waycover 29. 25-6312 Vertical Door Seal
12. 25-8295 Z-Axis Top Waycover Guide 30. 25-8251A Z-Axis Vertical Wiper
13. 25-8296 Z-Axis Bottom Waycover Guide 31. 30-3193 Door Wiper Assembly
14. 25-8264 Z-Axis Strip 32. 22-8237A Spindle Housing Support
15. 22-8275 Moving Bulkhead Support 33. 20-1634 Left End Lifting Bracket
16. 25-8244C Moving Bulkhead 34. 20-1636 Right Rear Lifting Bracket
17. 19-5793 Cable Channel Cover 35. 20-1635 Right Front Lifting Bracket
18. 25-8241A Right Enclosure Support

96-8710 rev L June 2005 Assembly Drawings 315

 SL-40L External Sheetmetal (Sheet 1 of 2)

5 6 7 8 9
3 4
1 2

10

Plane4

Plane4

Plane5

Plane5

Plane4

LONG BED
TAIL STOCK
TOOL PRESETTER

30 40
20 50

10 60

Bar

30 40
20 50

10 60

Bar

12 11
14 13
23 20 19 15
16 13
18 17
21
22

LONG BED
TAIL STOCK
TOOL PRESETTER

27
26

25

2
28
24 29

30

31

32

316 Assembly Drawings 96-8710 rev L June 2005

 SL-40L External Sheetmetal (Sheet 2 of 2)

33
34

35
36

39

37 50
38 48 49
47
46
45
43 44
42

41
40

51

52 *

52 * Optional for Crane Only.

BACK VIEW

96-8710 rev L June 2005 Assembly Drawings 317

 SL-40L External Sheetmetal Parts List

1. 25-4541 Left Top Front Panel 47. 30-3353 Regen Assembly

2. 25-4542 Right Top Front Panel 48. 25-8709 J-Box
3. 25-4723 Light Fixture Body 49. 25-0025D Main Electrical Control Box Assembly
4. 25-4563 Left Top Door Mount 50. 25-4553 Left Back Panel
5. 20-1775 Pendant Boom Arm 51. 25-0783 Left Back Lower Panel
6. 20-1773 Boom Arm Detent 52. 20-1254 Boom Support (2)
7. 25-4578 Boom Arm Detent Support
8. 25-4562 Right Top Door Mount
9. 25-4633 Pendant Arm End Cover
10. 25-4564 Door Support Bridge
11. 25-4539 Front Right Panel
12. 25-4535 Front Right Middle Panel
13. 25-6316 Drip Channel (2)
14. 25-4560 Right Door
15. 30-1488 Left Door
16. 25-8207A Front Left Middle Panel
17. 25-4543 Front Left Spacer Panel
18. 25-8021 Access Door
59-0023 Hinges (2)
19. 25-1349 Toolbox
20. 25-8206A Front Left Panel
21. 25-5444 Left End Front Panel
22. 25-1350 Toolbox Door
59-0023 Hinges (2)
23. 25-4546 Left End Rear Panel
24. 25-4533 Front Beam
25. 25-4558 Left Door Drip Rail
26. 20-1772 Z-Axis Roller V-Track (2)
27. 25-4557 Right Door Drip Rail
28. 25-4571 Chip Auger Pan
29. 25-4603 Lower Tailstock Waycover Guides (2)
30. 25-4570 Chip Tray
31. 25-4530 Coolant Tank
32. 25-4555 Lower Left Front Apron
33. 25-4540 Right Front Panel
34. 25-8214C Right Rear Panel
35. 25-0548 Auger Discharge Chute
36. 25-0164 Discharge Chute Filler
37. 25-8067B Coolant Pump Mount
38. 25-0243B HP Pump Mounting Bracket
39. 25-0348 Tramp Lube Oil Pan Bracket
40. 25-0781 Right Rear Panel
41. 20-0841 Right Back Panel Support
42. 25-4577 Monitor Cable Tray
43. 20-1768 Left Back Panel Support
44. 25-4554 Center Back Panel
45. 25-0784 Back Left Center Panel
46. 25-4532 Control Box Support

318 Assembly Drawings 96-8710 rev L June 2005

 SL-40L Internal Sheetmetal

16 17
13 14
11 12
10 15
6 8
5

1 2

19

3 4 18

21
20

8 9 22
48 7
24
47

46
45

43
44
42
23
30 40
20 50

10 60

Bar

30 40
20 50

10 60

Bar

26 25
27
37
25 26
41 29
35 28

34

28
40

38
39
30
31
32
33
36 31

96-8710 rev L June 2005 Assembly Drawings 319

 SL-40L Internal Sheetmetal Parts List
1. 25-4572 Rear V-Track Mount
2. 20-1772 Z-Axis V-Track (2)
3. 25-4573 Front V-Track Mount
4. 25-4556 Z-Axis Drip Channel
5. 25-4581 Tool Pocket
6. 25-4588 Z-Axis Top Wiper
25-4590 Felt Clamp
7. 25-4589 Z-Axis Bottom Wiper
25-4591 Felt Clamp
8. 25-4574 V-Track Rollers (2)
9. 25-4596 Z-Axis Bottom Left Waycover
10. 25-4595 Z-Axis Top Left Waycover
11. 22-8293A Z-Axis Waycover Support Bracket
12. 25-8253 X-Axis Vertical Wiper
13. 25-8254 X-Axis Horizontal Wiper
14. 25-4587 X-Axis Tunnel Panel
15. 25-8262C Tool Changer Cover
16. 22-8275 Bulkhead Support
17. 25-4580 Moving Bulkhead
18. 25-8258 Drip Channel
19. 25-8263 Splash Shield Support
20. 25-8261A Tool Changer Splash Shield
21. 25-4592 Z-Axis Top Front Waycover Guide
22. 25-4597 Z-Axis Right Waycovers
23. 25-4593 Z-Axis Bottom Front Waycover Guide
24. 26-8323 X-Axis Seal (Plastic)
25. 25-4566 Upper Door Wiper Back Plate (2)
26. 26-0086 Upper Door Wiper Felt (2)
27. 25-4568 Right Door Splash Shield
28. 25-6312 Vertical Door Seal (2)
26-0087 Felt
29. 25-4585 Top Tailstock Waycover Guide
30. 25-4599 Tailstock Right Waycover
31. 25-8267A Lower Door Chip Seal
32. 25-0252 Tailstock Cover
33. 25-4737 Tailstock Left Waycover
34. 25-4586 Front Wedge Cover
35. 26-8250 X-Axis Waycover
36. 25-8298 Spindle Housing Vertical Rail Drip
37. 25-4567 Left Door Splash Shield
38. 25-4579 Fixed Bulkhead
39. 25-4745 Fixed Bulkhead Support
40. 25-4531 Left End HPU Support
41. 25-0128 Motor Enclosure
42. 25-4071 Shield
43. 25-0640C Coolant Collector
44. 25-4569 Bottom Cable Wedge Tray
45. 25-4583 Skate Board
46. 20-1776 Control Cabinet Truss
47. 25-4582 Box Support
48. 20-1777 Roof Support

320 Assembly Drawings 96-8710 rev L June 2005

 TL-15 Live Tooling and Sub-Spindle Sheetmetal
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 L June 2005 Assembly Drawings 321

 TL-15 Sheetmetal Parts List

Live Tooling
1 25-0138 Hood
2 20-0163 Brace
3 25-0137 Tray
4 25-0135 Channel Cover
4a 25-6552 Channel Cover (Larger Turret)
5 25-0136 Channel
5a 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 25-0620 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 25-0665A Shipping Bracket
20 25-0612 Heat Shield
21 25-0614A Fan Shield

322 Assembly Drawings 96-8710 rev L June 2005

 TL-25 External Sheetmetal and Parts List

24

23

28
27
25 26
22

21 View Rotated 1808

20 7

w/Parts
1 2 Catcher
3 5 6
19
18 4

VECTOR
20HP DUAL DRIVE

SUB SPINDLE
8
17

16

12
15 14
13 11 10

1 25-8819C Top Door Roller Mount 15. 25-6115A Motor Enclosure

2 25-8818D Top Right Panel 16. 25-0607 Coolant Collector (25-0606 Door)
3 25-8820D Left Front Panel 17. 25-1350 Toolbox Door
4 59-0023 Door Hinge (2) 18. 59-0023 Door Hinge (2)
5 25-8021 Access Door 19. 25-1349 Toolbox
6 30-1487A Door Assembly 20. 25-0243B High Pressure Pump Bracket
7 30-1490 Door w/Parts Catcher Assembly 21. 25-8067B Coolant Pump Mount
8 25-8786C Right Front Panel 22. 25-0548 Auger Discharge Chute
9 25-6513A X-Axis Drip Tray 23. 25-0283 Chip Tray Filler
10 22-6023 Door V-Track 24. 25-4345A Right End Panel
11 25-8774C Front Rail 25. 25-0398 Tramp Lub Oil Pan Bracket
12. 25-8880B Chip Auger Pan 26. 25-0518 Right Rear Panel
13. 25-6557A Chip Tray 27. 25-0526 Center Rear Panel
14. 25-8814E Left Side Panel 28. 25-0517 Left Bottom Rear Cover

96-8710 rev L June 2005 Assembly Drawings 323

 TL-25 Internal Sheetmetal

37 38 39

41 42 1

36
2
40

3
33 34 35

32 6
5 4
46 31

43

30 7

* 29 8
44
26 45

10
11
9
12
27 13
28 14
25
24

15

16
17
23

18

22

20
19

21
* Parts Catcher Only SUB-SPINDLE ASSEMBLY

324 Assembly Drawings 96-8710 rev L June 2005

 TL-25 Internal Sheetmetal Parts List

1 22-8049 Z-Axis Top Waycover Guide

2 25-8047 Z-Axis Waycover
3 22-8048 Z-Axis Bottom Waycover Guide
4 22-8783 Moving Bulkhead Support
5 22-0830 Cable Channel Cover
6 25-8843A Moving Bulkhead
7 25-6543A Right End Support Bracket
8 25-4348 Right Sub-spindle Waycover (4)
9 20-1521 Lower Tailstock Waycover Guide
10 25-8841A Sub-spindle Base Plate
11 25-4344 Sub-spindle Base cover
12. 25-0610 Motor Cover
13. 25-0611 Sub-spindle Encoder Cover
14. 25-0619 Front Union Shroud
15. 25-0618 Rear Union Shroud
16. 20-0631A Upper Motor Arm
17. 25-0621 Little Bracket
18. 25-0620 Conduit
19. 25-0615A Encoder Mounting Bracket
20. 20-0632A Lower Motor Arm
21. 25-0613B Lower Heat Shield
22. 25-0612A Heat Shield
23. 25-0614A Fan Shield
24. 25-8755C Front Wedge Cover
25. 25-8757 Tool Changer Waycover
26. 25-6458 Tool Changer Waycover Mount
27. 25-8774 Upper Tailstock Waycover Guide
28. 25-4349 Left Sub-spindle Waycover (4)
29. 25-6512 Parts Catcher Tray (Optional)
30. 25-8849A Z-Axis Drip Tray
31. 30-3647 Z-Axis Lower Wiper Assembly
32. 30-3646 Z-Axis Middle Wiper Assembly
33. 25-8824C Fixed Bulkhead
34. 30-3192A Door Wiper Assembly
35. 30-3645 Z-Axis Upper Wiper Assembly
36. 25-8807B Control Box Mounting Bracket
37. 25-8754C Rear Sliding Cover
38. 25-8782B Tool Changer Tunnel Panel
39. 30-3648 X-Axis Top Wiper Assembly
40. 30-3649 X-Axis Side Wiper Assembly
41. 25-4354 X-Axis Tool Changer Sliding Cover
42. 25-8772A Tool Changer Splash Shield
43. 25-8830A X-Axis Drip Channel
44. 20-1591 Right Rear Lifting Bracket
45. 20-1590 Right Front Lifting Bracket
46. 20-1589 Left End Lifting Bracket

96-8710 rev L June 2005 Assembly Drawings 325

 Barfeeder Sheetmetal and Parts List
1 2

4
3

300
AR
OB
5 RV
SE

7
8

11

9
1 25-6516A Base Position Control
2 25-6537B Barfeeder Door 8 10
3 59-0101 Gas Spring
4 25-6534A Barfeeder Main Enclosure
5 25-0165 Right Rear Support
6 25-6542 Storage Pan
7 25-6526 Control Tray
8 25-6538 Adjusting End Supports
9 25-6539 Bottom Bar Base
10 44-0004 Leveling Screw
11 25-6540 Charging Table Beam

326 Assembly Drawings 96-8710 rev L June 2005

 Barfeeder External Parts

96-8710 rev L June 2005 Assembly Drawings 327

 Barfeeder External Parts List
1 20-6480 Rotation Control Push Rod
2 59-3024 Spring 1.5 X 6
3 20-6481 J-Slot Control Bushing
4 48-1657 Dowel Pin 5/8 X 1-1/2
5 49-1015 Shoulder Bolt 1/4 X 1/2
6 20-6483 Push Rod Connector
7 20-6484 Push Rod
8 20-0357 Flange Bushing 3/4 in.
9 20-6032 Push Control Bushing 3/4 in.
10 20-6485 Control Arm Positioner
11 59-3026 Spring 1-1/8 X 8.5 X .148
12 20-0356 Flange Bushing 1 in.
13 20-6023 Rotational Control Shaft
14 56-0007 Retaining Ring 1-9/16 in.
15 51- 1016 Linear Bearing 1 in.
16 20-6482 Pusher Control Arm
17 62-2501 Servo Motor
18 30-1220P Coupling Assembly
19 25-6520 Bar Pusher Finger
20 22-6501 Base Bar Carriage
21 25-6521 Latch Pusher Bar
22 20-9256 Spacer
23 59-6701 5/16 Ball Joint w/Stud
24 25-6522 Fork Activator Bar
25 25-6502 Latch Linkage Rod Bar
26 54-0054 Flange Bushing 5/16 in.
27 59-3027 Spring 1/2 X 10
28 58-1750 Coupling Nut 5/16-24
29 20-6478 Ballscrew Bearing
30 22-9256 Spacer
31 54-0030 Guide Wheel
32 30-0153 Support Bearing Assembly (2)
33 24-0007 Ballscrew Assembly
34 51-2012 Bearing Locknut TCN-04-F
35 25-6525 Rail Mounting Plate
36 22-6505 Barfeeder V-Rail

328 Assembly Drawings 96-8710 rev L June 2005

 Barfeeder Internal Parts

13
15
7
14
8
7
6 12
5 10
9 31
4 10 11
9 30

o
View Rotated 180

16
66 17
65 18
1
3 29
27
2 28
26 45
25 44
24
43
42
19
20

41
23
21 46
38 40
22 47
33
39
37 57
36 58
35
32 34

54 52
53

52
55 56 62

51 56
50 55
49
48 61
59
63
60
64
View Rotated 180 o

96-8710 rev L June 2005 Assembly Drawings 329

 Barfeeder Internal Parts List
1. 49-1203 1/8 x 1 Cotter pin 48. 46-0010 3/4-10 Cap nut
2. 49-1201 3/4 x 3 Clevis pin 49. 59-0102 Clamp handle 3/4-10
3. 22-6503 Support stand 50. 45-0004 3/4 Flat washer
4. 25-6541 Charging table 51. 20-6026A Height adjusting
5. 49-1202 1 x 6 Clevis pin 52. 59-0110 Spring 6 x 27/32 x .106
6. 49-1203 1/8 x 1 Cotter pin 53. 51-1015 Flange bearing 3/4
7. 46-0011 1/4 Push cap nut 54. 54-0057 Shaft collar 3/4
8. 20-0341 Transfer table 55. 56-0085 Snap ring
9. 22-9256 Bushing extractor 56. 45-0013 Washer
10. 58-1982 Tubing urethane 3/8 OD x 1/4 ID 57. 25-6549A Height adjusting box
11. 32-2036 Limit switch (end of bar) 58. 59-7200 Grommet material .125
12. 49-1019 Shoulder bolt 1/4 x 1 59. 20-6490A Box cross rollers
13. 25-6528 Bar end mounting 60. 25-0338 Home switch bracket
14. 25-6529 Bar end switch paddle 61. 32-2039 Trolley home limit switch
15. 25-6527A Bar transfer table 62. 25-6523B Main frame
16. 25-6546 Height indicator support bracket 63. 32-2038 Load Q limit switch
17. 25-6547 Height indicator flag 64. 32-2037 Load bar limit switch
18. 29-0051 Height gauge decal 65. 22-6025 1" Acme adjusting screw
19. 46-1702 Nut 66. 49-1020 Acme wing nut 1-5
20. 45-1739 Washer
21. 54-0010 Cam follower
22. 43-7000 Bolt
23. 49-0101 Key
24. 20-6487 Lifting arm shaft
25. 45-0013 Washer
26. 51-1017 Bearing
27. 25-6530 Motion control lift arm
28. 25-6532 Motion control torque box
29. 25-6530 Motion control lift arm
30. 51-1017 Bearing
31. 22-7477 Pressure plate
32. 32-0011 Shuttle motor assembly
33. 49-0100 Key
34. 20-0216 Slip clutch nut
36. 55-0010 Spring washer
36. 22-7477 Pressure plate
37. 45-2020 Plastic washer
38. 20-6486 Motor end clutch linkage
39. 44-1624 Set screw
40. 48-0005 Dowel pin
41. 20-0215 Slip clutch hub
42. 20-6533 Cam end slip linkage
43. 51-1015 3/4 Flange bearing
44. 49-0100 Key
45. 20-6488 Cam shaft assembly
46. 43-7000 Bolt
47. 54-0010 Cam follower with 22-7034 spacer

330 Assembly Drawings 96-8710 rev L June 2005

 Detailed Bar 300 Parts

96-8710 rev L June 2005 Assembly Drawings 331

 Barfeeder 100 Parts
10 11 12 15
4 9
5
6 4
6 7
4
5
3 4
1 2
13 14
0
BAR 10
16
8
17
18
19
17
16
20
25

21
22
24 23
27 26

30 35
28 29
33 36

31 37
34
38
27 25
20
15 25

10 30

39
20
15 25

21
10 30

32
Pusher Assembly 41
23 SL-10 Only 40
26 24
100
BAR

41
43 42

44
52

53

46
51
45

47
48
49
50 SL-10 Only

332 Assembly Drawings 96-8710 rev L June 2005

 Barfeeder 100 Parts List
1. 20-1711 Rear End Cap 49. 59-0482 Stock Tray Front Insulation
2. 57-0015 O-Ring 2-224 Buna 50. 59-0483 Stock Tray Rear Insulation
3. 20-1718 Rear End Interface 51. 20-1724 Bar 100 Center Support
4. 57-2835 O-Ring 2-236 Viton 52. 59-0470 Isolation Pad
5. 20-1712 Outside Tube (2) 53. 25-4503 Height Adjust Pivot
6. 57-2145 O-Ring 2-325 Viton
7. 20-1715 Center Interface
8. 20-1720 Center Pivot Rod
9. 20-1716 Latch End Interface
10. 57-4120 O-Ring 2-226 Viton
11. 57-0207 Urethane Compression Spring 3/16" ID
12. 20-1725A Air Tube Interface
13. 57-2106 O-Ring 2-223 Buna
14. 20-1722A Nose Liner Retainer
15. 57-2258 O-Ring 2-216 Viton
16. 59-0480 Tube Insulation (2)
17. 59-0471 Compression Connector 1-1/4" EMT (2)
18. 20-1719 Fixed Liner Tube
19. 57-2834 O-Ring 2-218 Viton
20. 20-1713 Inside Liner Tube
21. 20-1734A Pusher Nose
22. 20-1731A Pusher Rod (Minilathe Only)
23. 51-0095 Radial Ball Bearing
24. 20-1732 Fixed Pusher Rod
25. 57-0019 O-Ring 2-117 Buna (2)
26. 20-1738 Pusher Switch Body
27. 57-0209 Cup Seal 1" X 1/2"
28. 20-0938 Compression Nut Liner 7K
29. 29-0940 Adapter Flange 7K
30. 20-0993 Universal Liner
31. 20-0939 Spacer Pucks (Drill 1.05") (9)
32. 20-1737A Pusher Rod (SL-10 Only)
33. 25-4486 Control Gage Mount
34. 30-4049 Bar 100 Control Assembly
35. 25-4499 Inside Switch Bracket
36. 61-2025 Limit Switch
37. 25-4500 Outside Switch Bracket
38. 25-4505 Collector Door (Minilathe Only)
25-4705 Collector Door (SL-10 Only)
39. 25-4504 Collector Extension (Minilathe Only)
25-4704 Collector Extension (SL-10 Only)
40. 20-1730 Latch Handle
41. 20-1726 Top Wear Strip (2)
42. 20-1727 Bottom Wear Strip
43. 25-4502 Latch Rail Support
44. 25-4485 Base Alignment Plate (Minilathe Only)
45. 25-4704 Base Alignment Plate (SL-10 Only)
46. 20-1723 Front Tube Support
47. 25-4487 Stock Tray
48. 99-0212 Adhesive Backed Rule 1/16" X 6 Ft.

96-8710 rev L June 2005 Assembly Drawings 333

 Toolroom Lathe (TL-1)
1 5 6 7
2 3
4

8 9

10

11
12 14

15

13
107 99
106
100

99 20 21
18 19
100 16 17 22 23

105 101
104
102
27
28 24
103
25

96 98 29 26
95 97
93 94 30 31

32
108
33
89
90 34
91 35
92 109 37 36
110
38
111
66 40
67 45 39

46 41
88 47
83 44 42
81 62 48 43
79 80 84 50
68 65
69 51
64 49 55
85 87 70 63 52
71 61 53
82 86 72 60 56 54
58
73 57

59
75 74
78 77 76

1. 32-0041 Regen Assy 9. 25-5449 TL-2 Control Support

2. 45-4301-25-4307 Control Cabinet 25-6354 LT-1 Control Support Cover
3. 25-4794 Control Box Isolator (4) 10. 25-4932 X Axis Motor Cover
4. 59-0515 Contorl Box Gasket (4) 11. 25-6351 Wiper Retainer
5. 20-2672 Pendent Arm 12. 26-0372 Wiper Felt
6. 25-6661 Arm End Cap (leveling) 13. 25-4931 Rear Ballscrew Left Cover
7. 25-5524 Control Pendant Shell 14. 25-6352 Saddle Chip Guard
8. 20-1936 Control Box Support Frame 15. 25-4930 Rear Ballscrew Right Cover

334 Assembly Drawings 96-8710 rev L June 2005

 Toolroom Lathe (TL-1)
16. 20-1938 TS Quill 64. 20-7416 Bearing Cartridge
17. 20-1957 Quill Drive Nut 65. 20-1948 X-Axis Ballscrew Nut Housing
18. 20-1939 Drive Screw 66. 20-9062 Tool Mat
19. 20-2453 TS Bearing Spacer 67. 20-1942 Spindle Housing Cover
20. 51-2033 Radial Bearing 68. 20-1189 Spindle Nose A5/5C
21. 20-1958 Quill Driver SCR Collar 69. 20-0862 Clamp Ring A2-5
22. 51-2033 Radial Bearing 70. 20-1869 TL-1 Spindle Housing Machined
23. 20-1940 Nut Retainer 20-2459 TL-2 Spindle Housing Machined
24. 20-1932 Tailstock Handwheel 6" 71. 36-3035 Fan Assembly
25. 20-1873 TS Head Housing Machined 72. 25-0127 Fan Motor End Plate
26. 20-1954 Setscrew (2x) 73. 25-5036 Fan Enclosure
27. 26-0374 Quilll Wiper 74. 25-0143 Spindle Enclosure Bracket
28. 49-0065 TS Handle Clamp 75. 20-0147 Balancing Hub Drive Motor
29. 20-1960 PLT Quill Lock 76. 62-1010 5 H.P. Spindle Motor
30. 20-1966 Shim (4) 77. 20-1951 Motor Mounting Plate
31. 49-0064 Handle Clamp 78. 20-1934 Motor Sprocket
32. 20-1872 TL-1 T-Slot Block 79. 25-6353 TL-1 Spindle Belt Guard
20-2455 TL-2 T-Slot Block 25-5448 TL-2 Spindle Belt Guard
33. 20-1941 Lock Plate 80. 20-2471 TL-1 Spindle Extension
34. HHCS (2) 20-2470 TL-2 Spindle Extension
35. 20-2440 TL-1 T-Slot Block 81. 20-2082 Lock Ring, Back
20-2463YL-2 T-Slot Block 82. 54-0126 Spindle Drive Belt
36. 20-2102 X-Axis Cross Slide 83. 20-1933 TL-1 Spindle Pully
37. 25-5037 Cross Slide Cover 20-2461 TL-2 Spindle Pully
38. 25-5038 Cross Slide Front 84. 20-2081 Lock Ring, Front
39. 30-6406 X-Axis Lube Line 85. 54-0084 Encoder Drive Belt
40. 20-1232 Z-Axis Support Bumper 86. 20-0975 Encoder Sprocket
41. 50-0031 Guide Rail (2) 87. 32-1457 Encoder, RTAP
42. 20-2105 X-Axis Manifold 88. Spindle Assembly
43. 20-1870 Saddle Machined 89. 20-7009 Bearing Housing Machined
44. 59-1700 Prox. Switch 90. 24-0039 Z-Axis Lead Ballscrew
45. 25-9203 Cover 91. 20-7010 Motor Mount
46. 30-1220 Coupling Assembly 92. 62-0024 Yaskawa Servo Motor
47. 62-0024 Yaskawa Servo Motor 93. 30-1220 Coupling
48. 25-5390 Z-Axis Switch Trip Bracket 94. 25-7042 Snap Lock Motor Mount Cover
49. 32-2132 Prox. Switch 95. 20-0146 Motor Bumper
50. 25-5391 Prox. Switch Mounting Bracket 96. 20-7008 Ballscrew Nut Housing
51. 20-1931 X-Axis Handwheel 4.5" 97. 20-0637 Support Bumper
20-1955 X-Axis Handwheel Handle 98. 25-7080 Bumper Bracket
52. 20-2549 Saddle SCR Cover 99. 28-0049 Window (2)
53. 20-1871 Z-Axis Saddle Skirt Machined 100. 25-5050 Window Retainer (2)
54. 20-1930 Z-Axis Handwheel 7.5" 101. 25-6355 Chuck Guard
55. 20-1944 Gear 102. 25-5465 TL-1 Front Chuck Guard
56. 20-1943 Z- Axis Gear Mounting Plate 25-5514 TL-2 Front Chuck Guard
20-0466 Pinion 103. 25-5945 Rear Chuck Guard
20-1946 Shaft 104. 59-0007 Gas Spring
57. 30-5370 Z-Axis Lube Line Assembly 105. 25-1942 Chuck Guard Hinge Bracket
58. 50-0030 Z- Axis Guide Rail (2) 106. 20-2480 Chuck Guard Hinge Pin
59. 20-1947 TL-1 Z-Axis Rack Gear 107. 20-0356 Shaft Sleeve (2)
20-2464 TL-2 Z-Axis Rack Gear 108. 25-5504 Air Gun Hanger
60. 51-2025 Bearing 109. 20-1868 TL-1 Base Machined
61. 20-1952 X-Axis Bumper 20-2451 TL-2 Base Machined
62. 58-0608 X-Axis Lube Line, Ballscrew Nut 110. 44-0018 Leveling Screw
63. 24-0038 X-Axis Ballscrew 111. 14-7068 Foot Pad

96-8710 rev L June 2005 Assembly Drawings 335

 2 3
1

9
8
10
11
30
31 12
29

13

23 14
24
22
21 15
28

16
27 17
18
19
20
25
26 16

View Rotated for Clarity

(Looking Up)

TL 1-2CE

336 Assembly Drawings 96-8710 rev L June 2005

 TL 1-2CE Parts List

1. 25-5932 Left Wing Guard

2. 25-5930 (TL-1-CE) Control Support Cover
25-6783 (TL-2-CE) Control Suport Cover
3. 25-5931 Right Wing Guard
4. 25-5943 (TL-1-CE) Top Roller Guide
25-6787 (TL-2-CE) Top Roler Guide
5. 25-5942 Angle Bracket
6. 25-5948 (TL-1-CE) Back Gutter
25-6789 (TL-2-CE) Back Gutter
7. 40-1979 BHCS ¼-20 x 1-¾
8. 20-0260 Top Door Spacer (2x)
9. 51-2020 Bearing Radial FAFNIR 303
10. 22-7034 Spacer Cam Follower
11. 25-6408 (TL-1-CE) Long Door
25-6791 (TL-2-CE) Right Door
12. 25-6428 Tail Stock Fin
13. 59-6210 Door Handle (2x)
14. 22-6505 (TL-1-CE) V- Rail Bar Feeder
20-0963 (TL-2-CE) V- Track Slide Door
15. 25-5939 (TL-1-CE) Front Gutter
25-6788 Tl-2-CE) Front Gutter
16. 25-5949 Push Bar
17. 54-0030 Guide Wheel (4x)
18. 25-6019 Door Guide Retainer (4x)
19. 26-0163 Lathe Doors Felt Wiper (2x)
25-5746 Outer Felt Retainer (4x)
25-5745 Inner Felt Retainer (2x)
20. 25-5944 Lower Rear Mount (2x)
21. 20-6016 Rail Spacer
40-0069 BACS ¼-20 x 1
22. 25-6406 Short Door
23. 25-6418 (TL-1-CE) Bulkhead
25-6790 (TL-2-CE) Bulkhead
24. 25-5941 (TL-1-CE) Read Guard
25-6784 (TL-2-CE) Rear Guard
25. 26-0177 Front Window Gasket (2x)
26. 28-0170 Front Window (2x)
27. 25-6250 Window Retainer (8x)
28. 28-0171 Top Window (2x)
29. 25-4043 Latch Spring
30. 32-5075 (TL-1-CE) Telemecanque Switch (2x)
31. 25-6429 (TL-2-CE) Door Stop

96-8710 rev L June 2005 Assembly Drawings 337

 Lathe APL

ATIC 2
AUTTOS MLOADER
APL PAR

70 65 4
3
69
1 5

67 66
68 6
APL AUTOMATIC
65 PARTS LOADER

64

7
8
63

62
61

33 9
32 31
34 30 4
35 27
36
37 29 26 10 11
25
23 24
28

38
39
40 41
48 42 43
44 45 46
22
59
21
53
52 20
57 58 47
56 12
19
60 49 18 14
13
17
16
55 54 53

50
54 16
48 51
52 15

338 Assembly Drawings 96-8710 rev L June 2005

 Lathe APL
1. 25-0704 Carriage Cover
2. 59-0197 Cable Carrier
3. 25-0705 Cable Carrier Mount
4. 25-0703 B-Axis Ram
5. 59-0196 Cable Carrier
6. 50-0008 Linear Guide
7. 20-0739 Hard Stop
8. 50-0009 Linear Guide
9. 20-0749 B-Axis Rack
10. 25-0768 Rotator Housing
11. 25-0769 Rotator Cover
12. 87-6535(6700,6710) Light
13. 30-6466 Gripper Assy
14. 20-2299 Jaw
15. 20-2297 Gripper Finger
16. 20-0747 Gripper Plate
17. 20-0755 Gripper Flange
18. 20-0757 Gripper Plate
19. 20-0756 Gripper Jaw
20. 62-0014 Servo Motor
21. 1/8X156X90 Fittings
22. 20-0790 Spindle Bearing Housing
23. 51-0000 Cam Follower
24. 20-0792 Geneva Plate Pin
25. 62-0007 Motor
26. 20-0759 Z-Axis Hard Stop, Lower
27. 59-1056 Bumper Support
28. 25-0716 Bracket, Switch
29. 32-2257 Prox Switch
30. 20-0795 Motor Mounting Spacer
31. 20-0789 Motor Mounting Plate
32. 25-0770 Switch Counter Bracket
33. 32-2256 Prox Switch
34. 5/32X10-32 Tube Fittings
35. 20-1008 Taper Clamp
36. 20-0746 Rotator Plate
37. 20-0791 Geneva Plate
38. 20-0793 Spindle
39. 57-2248 O’ Ring
40. 51-0079 Bearing
41. 51-0078 Sealed Bearing
42. 20-1006 Friction Plate
43. 57-0157 Seal
44. 20-0794 Rotator Trip Block

96-8710 rev L June 2005 Assembly Drawings 339