Haas Automation Inc.

Mill and Lathe

Service Manual
Mechanical
Components
June 2007
96-0283 rev C

Haas Automation Inc.

2800 Sturgis Road, Oxnard CA 93030
Tel. 888-817-4227 Fax 805-278-8561
www.HaasCNC.com
 Table of Contents
General Machine Troubleshooting ................................................................................................................ 1
VIBRATION ................................................................................................................................................. 1
ACCURACY ................................................................................................................................................. 2
FINISH ...................................................................................................................................................... 5
THERMAL GROWTH ...................................................................................................................................... 5
Way Covers/Head Covers ............................................................................................................................... 7
X-AXIS WAY COVER REMOVAL (HORIZ) ........................................................................................................... 7
Y-AXIS WAY COVER REMOVAL (HORIZ) ............................................................................................................ 7
Z-AXIS WAY COVER (HORIZ) ......................................................................................................................... 8
MDC/EC-300 SHADE-STYLE WAY COVER ADJUSTMENT .................................................................................... 8
EC-300 Y-AXIS WAY COVER ADJUSTMENT ...................................................................................................... 8
HEAD COVERS REMOVAL/INSTALLATION (VERT) .................................................................................................. 9
Tool Release Piston (TRP) Assembly ........................................................................................................... 10
SPINDLE TRP REMOVAL ............................................................................................................................ 11
SPINDLE TRP INSTALLATION ....................................................................................................................... 13
SETTING PRE-CHARGE .............................................................................................................................. 15
TRP SWITCH ADJUSTMENT ........................................................................................................................ 16
TRP INSTALLATION AND ADJUSTMENT - OM-1A/OM-2A .................................................................................. 19
SETTING TRP HEIGHT ............................................................................................................................... 20
TRP DISASSEMBLY .................................................................................................................................... 23
TRP ASSEMBLY ........................................................................................................................................ 23
Belt Replacement & Tensioning .................................................................................................................. 24
DRIVE BELT REPLACEMENT (VERT & EC-SERIES) ........................................................................................... 24
DRIVE BELT TENSIONING (VERT & EC-SERIES) ............................................................................................. 25
SPINDLE BELT TENSIONING (OM-1A/OM-2A) .............................................................................................. 26
APL MOTOR BELT REPLACEMENT ................................................................................................................ 27
VERIFYING BELT TENSION (LATHE) ............................................................................................................... 28
SUB SPINDLE MOTOR BELT REPLACEMENT .................................................................................................... 29
Spindles ......................................................................................................................................................... 30
15K & 50 TAPER SPINDLES ....................................................................................................................... 30
STALLING/LOW TORQUE ............................................................................................................................. 30
SPINDLE DRIVE ........................................................................................................................................ 30
Spindle Troubleshooting .............................................................................................................................. 31
NOT TURNING .......................................................................................................................................... 31
NOISE ..................................................................................................................................................... 31
OVERHEATING (MILLS) ............................................................................................................................... 32
TOOLS STICKING IN SPINDLE TAPER (MILLS) ................................................................................................ 32
SPINDLE LUBRICATION SYSTEM .................................................................................................................... 33
Spindle Assembly ......................................................................................................................................... 35
SPINDLE REPLACEMENT (HORIZ & VERT) ...................................................................................................... 35
EC-630 GEARED HEAD REPLACEMENT .......................................................................................................... 38
SETTING THE DRAW BAR HEIGHT ................................................................................................................. 40
RUN-IN PROGRAMS .................................................................................................................................... 41
DRAW BAR REPLACEMENT ........................................................................................................................... 42
MILL SPINDLE SWEEP ADJUSTMENT ............................................................................................................. 43
Spindle Orientation ...................................................................................................................................... 45
A, B AXIS RE-ALIGNMENT (VERT) ............................................................................................................... 45

96-0283 rev C June 2007 Table of Contents I

 Lathe Spindle Assembly ............................................................................................................................... 46
LATHE SPINDLE REMOVAL ........................................................................................................................... 46
SPINDLE INSTALLATION ............................................................................................................................... 47
TOOL ROOM LATHE SPINDLE MOTOR ............................................................................................................ 48
Spindle Head Alignment .............................................................................................................................. 50
SL-10 AND GT-SERIES SPINDLE HEAD ALIGNMENT ........................................................................................ 51
Gearbox, Transmission, and Spindle Motor ............................................................................................... 53
TROUBLESHOOTING ................................................................................................................................... 53
SPINDLE MOTOR & TRANSMISSION (MILLS) .................................................................................................. 55
Coolant System Operation ........................................................................................................................... 68
TSC TROUBLESHOOTING ........................................................................................................................... 69
TSC-1000 TROUBLESHOOTING ................................................................................................................... 72
Automatic Tool Changer (ATC) ..................................................................................................................... 74
TROUBLESHOOTING ................................................................................................................................... 75
CRASHING ................................................................................................................................................ 78
CARRIAGE CASTING REPLACEMENT ................................................................................................................ 79
ROLLER BOLT REPLACEMENT ....................................................................................................................... 79
ATC ALIGNMENT ...................................................................................................................................... 80
SHUTTLE STROKE ADJUSTMENT ................................................................................................................... 80
EXTRACTOR FORK REPLACEMENT ................................................................................................................. 81
SLIDING COVER REPLACEMENT .................................................................................................................... 81
SHUTTLE IN/OUT MOTOR ........................................................................................................................... 82
CAROUSEL ROTATION MOTOR ....................................................................................................................... 83
GENEVA STAR REPLACEMENT ....................................................................................................................... 84
ATC TRAP DOOR REPLACEMENT .................................................................................................................. 85
Side Mount Tool Changer (SMTC) ............................................................................................................... 86
TROUBLE SHOOTING .................................................................................................................................. 86
40 TAPER CAROUSEL REMOVAL AND INSTALLATION ........................................................................................... 87
50 TAPER CAROUSEL REMOVAL AND INSTALLATION ........................................................................................... 88
ATC ASSEMBLY REMOVAL/INSTALLATION ......................................................................................................... 89
ATC ALIGNMENT (HORIZ) ........................................................................................................................... 90
ATC ALIGNMENT (VERT) ............................................................................................................................ 95
DOUBLE ARM REPLACEMENT ....................................................................................................................... 97
SETTING SPINDLE ORIENTATION ................................................................................................................... 98
EC-300 TOOL CHANGER DOOR OPEN SWITCH ADJUSTMENT ............................................................................ 99
EC-400 TOOL CHANGER DOOR REPLACEMENT .............................................................................................. 100
SMTC POCKET REMOVAL AND INSTALLATION ................................................................................................. 101
TOOL POCKET SLIDER ADJUSTMENT ........................................................................................................... 103
PROXIMITY SWITCH REMOVAL/INSTALLATION ................................................................................................... 103
SETTING PARAMETER 64 ............................................................................................................................ 105
SERVO TOOL CHANGER OFFSETS ............................................................................................................... 106
Turrets ........................................................................................................................................................... 107
TURRET CRASH RECOVERY PROCEDURE ...................................................................................................... 107
TURRET CLAMP/UNCLAMP .......................................................................................................................... 108
TURRET REMOVAL AND REPLACEMENT ........................................................................................................... 110
TURRET CLAMP ADJUSTMENT (HYDRAULIC TURRET) ........................................................................................ 112
TURRET SHAFT REMOVAL AND REPLACEMENT ................................................................................................. 113
TURRET CROSS-SLIDE SPRING REPLACEMENT ............................................................................................... 114
ADJUSTING TURRET BACKLASH ................................................................................................................... 115
TURRET IN / OUT ADJUSTMENT .................................................................................................................. 116
CENTERING INNER TURRET COUPLING (WITHOUT BRASS PLUG) ...................................................................... 117
CENTERING INNER TURRET COUPLING (WITH 1/4" BRASS PLUG) .................................................................... 118
TURRET ALIGNMENT (X-AXIS) .................................................................................................................... 118
TURRET ALIGNMENT VERIFICATION (X-AXIS) ................................................................................................. 119

II Table of Contents 96-0283 rev C June 2007

 SPINDLE ALIGNMENT VERIFICATION ............................................................................................................. 119
TURRET ALIGNMENT VERIFICATION (SPINDLE) ............................................................................................... 120
CONVERTING SPINDLE CENTERLINE TO ENCODER STEP ................................................................................. 121
TURRET ALIGNMENT VERIFICATION (PARALLELISM OF X-AXIS) .......................................................................... 121
BOLT ON TURRET ALIGNMENT .................................................................................................................... 122
WEDGE ALIGNMENT .................................................................................................................................. 124
TOOLROOM LATHE X AND Z-AXIS ALIGNMENT ................................................................................................. 125
Axis Motors ................................................................................................................................................... 126
AXIS MOTOR ENCODERS ........................................................................................................................... 126
AXIS MOTOR AMPLIFIERS .......................................................................................................................... 126
AXIS MOTOR REMOVAL/INSTALLATION ............................................................................................................ 126
PRECAUTIONS .......................................................................................................................................... 127
AXIS MOTOR REPLACEMENT ....................................................................................................................... 127
COUPLING REPLACEMENT ........................................................................................................................... 128
AXIS BRAKE MOTOR (MILLS ONLY) ............................................................................................................. 128
Bearing Sleeve Removal/Installation ......................................................................................................... 129
BEARING SLEEVE REPLACEMENT ................................................................................................................. 129
Ball Screw Removal and Installation ......................................................................................................... 131
BALL SCREW TROUBLE SHOOTING ............................................................................................................. 131
NOT OPERATING ....................................................................................................................................... 131
NOISE .................................................................................................................................................... 131
ACCURACY/BACKLASH ............................................................................................................................... 132
BACKLASH - POSSIBLE CAUSES .................................................................................................................. 134
BALL SCREWS - VISUAL INSPECTION ........................................................................................................... 134
BALL SCREW CLEANING ............................................................................................................................ 135
HORIZONTAL AXIS BALL SCREW REPLACEMENT ............................................................................................. 135
VERTICAL AXIS BALL SCREW REPLACEMENT ................................................................................................. 138
LATHE BALL SCREW REPLACEMENT - X-AXIS ................................................................................................ 143
LATHE BALL SCREW REPLACEMENT - Z-AXIS ................................................................................................. 145
TOOLROOM LATHE BALL SCREW REPLACEMENT ............................................................................................. 147
MINI MILL BALL SCREW REPLACEMENT ....................................................................................................... 148
GR-SERIES X-AXIS BALL SCREW ALIGNMENT .............................................................................................. 149
BALL SCREW COMPENSATION ..................................................................................................................... 150
Tailstock Alignment ..................................................................................................................................... 151
ONE-PIECE TAILSTOCK ALIGNMENT VERIFICATION .......................................................................................... 151
TAILSTOCK LEVELING PROCEDURE .............................................................................................................. 151
TWO-PIECE TAILSTOCK ALIGNMENT ............................................................................................................. 152
SL-10 TAILSTOCK ALIGNMENT ................................................................................................................... 153
SL10 TAILSTOCK SEAL REPLACEMENT ......................................................................................................... 154
TAILSTOCK INSERT REMOVAL AND INSTALLATION .............................................................................................. 154
HYDRAULIC TAILSTOCK CYLINDER ............................................................................................................... 156
EC-300/MDC Pallet Changer ........................................................................................................................ 157
COMPONENTS .......................................................................................................................................... 157
TABLE CLAMPING ..................................................................................................................................... 157
TROUBLESHOOTING .................................................................................................................................. 159
EC-300/MILL DRILL PALLET CHANGER DISASSEMBLY .................................................................................... 160
EC-400 Pallet Changer ................................................................................................................................. 166
PALLET POOL MOTOR REPLACEMENT ........................................................................................................... 170
PALLET CHANGER DISASSEMBLY AND REPLACEMENT ........................................................................................ 171
H-FRAME REPLACEMENT ............................................................................................................................ 172
H-FRAME SWITCH ADJUSTMENT .................................................................................................................. 172
AIR CYLINDER ......................................................................................................................................... 173
PALLET CHANGER H-FRAME TO PALLET ALIGNMENT ........................................................................................ 173

96-0283 rev C June 2007 Table of Contents III

 EC-400 Rotary Replacement ........................................................................................................................ 175
A-AXIS INDEXER LIFT SWITCH SETUP .......................................................................................................... 175
SETTING PARAMETERS 212 AND 128 (INDEXER A AXIS OFFSET) ...................................................................... 175
EC-400 ROTARY INDEXER AIR DIAGRAM ....................................................................................................... 176
RECEIVER REPLACEMENT ........................................................................................................................... 176
Automatic Pallet Changer (APC) (Vertical Machines) ............................................................................... 180
APC PALLET TROUBLESHOOTING ............................................................................................................... 180
PALLET REPLACEMENT ............................................................................................................................... 182
PALLET CLAMP RAIL REPLACEMENT .............................................................................................................. 182
ALIGNMENT PIN REPLACEMENT ................................................................................................................... 183
DRIVE PIN REPLACEMENT .......................................................................................................................... 184
Setting the Grid Offset ................................................................................................................................. 185
Hydraulic Counterbalance ........................................................................................................................... 186
TROUBLESHOOTING .................................................................................................................................. 186
LEAK FAILURES ........................................................................................................................................ 188
MECHANICAL DIAGNOSIS ............................................................................................................................ 188
HYDRAULIC TANK REPLACEMENT ................................................................................................................. 188
HYDRAULIC CYLINDER REPLACEMENT ........................................................................................................... 190
Hydraulic Power Unit (HPU) (Lathe) ............................................................................................................ 193
TROUBLESHOOTING .................................................................................................................................. 193
HPU REMOVAL/INSTALLATION ..................................................................................................................... 193
SL-SERIES HYDRAULIC SCHEMATICS ........................................................................................................... 194
4th Axis Repair (Horiz.) ................................................................................................................................ 196
RING GEAR INSTALLATION ........................................................................................................................... 196
PALLET RECEIVER DISASSEMBLY (EC-630) ................................................................................................... 196
REMOVING THE ROTARY UNION (EC-630) ..................................................................................................... 196
1° INDEXER PLATTER ASSEMBLY (EC-630) ................................................................................................... 197
REPLACING THE 4TH AXIS BRAKE ASSEMBLY ................................................................................................. 197
BLEEDING THE HYDRAULIC BRAKE ............................................................................................................... 198
4th Axis Air Valve Assembly ........................................................................................................................ 198
4th Axis Brake Cylinder Pressure Booster ................................................................................................. 199
BEARING INSTALLATION .............................................................................................................................. 201
ROTARY TABLE PLATTER REMOVAL AND INSTALLATION ....................................................................................... 202
ENCODER INSTALLATION ............................................................................................................................. 203
A-AXIS ALIGNMENT AND PARAMETER SETTINGS .............................................................................................. 205
A-AXIS ALIGNMENT AND PARAMETER SETTINGS (EC-630) ............................................................................... 206
A-AXIS BACKLASH ..................................................................................................................................... 208
EC-400 A-AXIS BACKLASH ADJUSTMENT (FULL 4TH) .................................................................................... 209
EC-630 A-AXIS SERVICE ......................................................................................................................... 210
Harmonic Drive (Horiz) ................................................................................................................................ 211
MOTOR/WAVE GENERATOR ASSEMBLY .......................................................................................................... 212
HARMONIC DRIVE ASSEMBLY ...................................................................................................................... 212
CARRIER MOUNT BRACKET INSTALLATION ...................................................................................................... 214
CABLE BOX ENCODER INSTALLATION ............................................................................................................ 214
Lubrication System ...................................................................................................................................... 215
COMPONENTS .......................................................................................................................................... 216
LUBE PANEL REMOVAL .............................................................................................................................. 217
AIR REGULATOR SERVICING ....................................................................................................................... 218
Parts Catcher (Lathe) ................................................................................................................................... 219
Lathe Tool Probe .......................................................................................................................................... 220
PROBE SETTING ...................................................................................................................................... 220
PROBE TIP REPLACEMENT ......................................................................................................................... 220
LATHE TOOL PRESETTER SETUP (LTP) ........................................................................................................ 220
VERIFICATION .......................................................................................................................................... 221

IV Table of Contents 96-0283 rev C June 2007

 C-Axis (Lathe) ............................................................................................................................................... 221
LUBRICATION ........................................................................................................................................... 221
SETTING GRID OFFSET ............................................................................................................................. 222
SETTING GEAR MESH CONTACT LOAD .......................................................................................................... 223
Auto Door Removal and Replacement (Lathe & Vert.) .............................................................................. 223
MOTOR REPLACEMENT ............................................................................................................................... 223
CLUTCH REPLACEMENT .............................................................................................................................. 224
CHAIN REPLACEMENT AND ADJUSTMENT ........................................................................................................ 225
AUTO DOOR PARAMETERS .......................................................................................................................... 226
Enclosure Replacement (Vert.) .................................................................................................................... 226
DOOR REPLACEMENT ................................................................................................................................. 226
DOOR OPEN SENSE SWITCH ...................................................................................................................... 228
Steady Rest Alignment and Adjustment ..................................................................................................... 228
HORIZONTAL MILL ASSEMBLY DRAWINGS AND PARTS LISTS ............................................................... 229
VERTICAL MILL ASSEMBLY DRAWINGS AND PARTS LISTS .................................................................... 272
LATHE ASSEMBLY DRAWINGS AND PARTS LISTS .................................................................................... 345
COMMON ABBREVIATIONS ......................................................................................................................... 413

This manual and all of its contents are copyright protected 2007, and may not be reproduced without written
permission from Haas Automation, Inc.

96-0283 rev C June 2007 Table of Contents V

VI Table of Contents 96-0283 rev C June 2007
 GENERAL MACHINE TROUBLESHOOTING
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 must be looked at before determining the fault. If a
bored hole is chattering because of an overextended tool, do not expect the machine to correct the fault. Do
not suspect machine accuracy if the vise bends the part. Do not claim hole mis-positioning if a center-drill is
not used.
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 as 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.
This manual presents information for Horizontal machines, Lathes, and Vertical machines:
Horiz is used to indicate Horizontal machines.
Lathe is used to indicate Lathes.
Vert is used to indicate Vertical machines.

VIBRATION
Vibration is a subjective evaluation, which makes it difficult to determine, in mild cases, if there is an actual
problem. In obvious cases, it is a matter of determining the source. Vibrations need to be distinguished from
noise such as a bad bearing. Assuming that vibrations would be something that could be felt by putting your
hand on the spindle covers or spindle ring, a dial indicator may help prove this. This crude method is to take a
dial indicator on a magnetic base extended 10 inches between the table 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 used. 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, it is usually caused by the belt/pulley drive system or on
a lathe, the chuck jaws may not be centered correctly.
Machine vibrates while jogging the axis with the hand wheel/jog handle.
• The Haas control uses very high gain acceleration curves. This vibration as you jog is simply the axis motors
quickly trying to follow the jog 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.

96-0283 rev C June 2007 Mechanical Service 1

 Machine vibrates excessively in a cut
• This can be caused by a number of factors. Generally, the least rigid element of a cut is the tool as 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, 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 as it
cuts and in dry run. Move the axes (individually) without the spindle turning and then run the spindle without
moving the axes. Isolate whether the vibration comes from the spindle head or from an axis.

ACCURACY
Poor accuracy must be verified before performing any maintenance. Check the following:
• 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).
• Do not use a wiggler test indicator for linear dimensions. They measure in an arc and have sine/cosine errors
over larger distances.
• Do not use magnetic bases as accurate test stops. High accel/decel of the axis can cause movement.
• Do not attach magnetic base/test points to the sheet metal of the machine.
• Do not mount the magnetic base on the spindle dogs (mills).
• Do not 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 (e.g.
spindle head casting, spindle nose, or the table).
• Do not rapid to position when checking accuracy. The indicator may get bumped and give an inaccurate
reading. For best results, feed to position at 5-10 inches per minute.
• 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 longer 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.
Mills
Machine will not interpolate a round hole.
• Check that the machine is level (see Installation instruction).
• Check for backlash ("Ball Screw Removal section and Installation instructions).
Bored holes do not go straight through the workpiece.
• Check that the machine is level (see Installation instruction).
• Check for squareness in the Z axis.
Machine bores holes out-of-round.
• Check that the machine is level (see Installation instruction).
• Check the sweep of the machine (see "Draw Bar Replacement" section).
Bored holes are out of round or out of position.
• Check for thermal growth of the ball screw (see "Thermal Growth" section).
• The spindle is not parallel to the Z-axis. Check sweep of the machine ("Draw Bar Replacement").

2 Mechanical Service 96-0283 rev C June 2007

 Machine mis-positions holes.
• Check for thermal growth of the ball screw (see "Thermal Growth" section).
• Check that the machine is level (see Installation instruction).
• Check for backlash (see Installation instructions).
• Check the squareness of the X-axis to the Y-axis.
Machine leaves large steps when using a shell mill.
• Check that the machine is level (see "Installation" section of the Reference manual).
• Check the sweep of the machine (see "Draw Bar Replacement" section).
• Cutter diameter too large for depth of cut.
Boring depth inaccurate.
• Check for thermal growth of the ballscrew (see "Thermal Growth" section).
• Check the hydraulic counterbalance system. Check for:
Abnormal noises from counterbalance system.
Oil leaks (esp. at fittings and at filter at top of cylinder).
Bound cylinder.
Lathes
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 correct. 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).
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).

96-0283 rev C June 2007 Mechanical Service 3

 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.
• 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

CL CL
CL

Poor Technique

Material left after facing a part

• Ensure tooling is correct.
• Ensure turret is aligned to X-axis travel.

4 Mechanical Service 96-0283 rev C June 2007

 • Ensure Parameter 254, Spindle Center, is set correctly.

Material Left After Facing Part

FINISH
Machining yields a poor finish
• Check for backlash ("Ball Screw Removal and Installation" section).
• Check the condition of the tooling and the spindle.
Vertical & Horizontal Machines
• Check for gearbox vibration.
• Check for spindle failure.
• Check the condition of the axis/servo motors.
• Check that the machine is level (see Installation instruction).
Lathes
• Check turret alignment.
• 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.

Chuck

Part

THERMAL GROWTH
A possible source of accuracy and positioning errors is thermal growth of ballscrews. As the machine warms
up, ballscrews expand in all linear axes, causing accuracy and positioning errors (or inaccurate boring depths
for vertical and horizontal machines). This is especially critical in jobs that require high accuracy, machining
multiple parts in one setup, or machining one part with multiple setups.

NOTE: On machines with linear scales, thermal growth will not affect machine
positioning or accuracy. However, it is recommended that the machine be
warmed up before cutting parts. The ballscrew always expands away from the
motor end. Thermal growth in a lathe ballscrew will be more noticeable in the
X-axis, since errors will be doubled when cutting a diameter.

96-0283 rev C June 2007 Mechanical Service 5

 Verify Thermal Growth
There are a number of ways to verify the problem. The following procedure will verify thermal growth of the X-
axis (reverse-anchored for lathes) 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 on the table (example: X-15.0" Y-8.0" for vert & horiz). Select the X-axis and press
the Origin key to zero it. Select the Y-axis for mills and zero it.
3. Press the Offset button, then scroll down to G110 (or any unused offset). Cursor to X and press Part Zero
Set once to set X0, then press again to set Y0. Press Z Face Meas once for a lathe.
4. Enter the following program. It will start at the new zero position, rapid 10 inches in the X direction, feed the
final .25 inches at 10 inches/min., and then repeat the X movement.
G00 G110 X0 Y0;
X10.0;
G01 X10.25 F10. ;
M99;
5. In order to set up the indicator, run the program in Single Block mode, and stop it when X is at 10.25" (or
end of its set travel for Lathes). Mills: Set the magnetic base on the table, with the indicator tip touching
the spindle housing in the X-axis for vert & horiz. Lathes: Set it 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 10.25" for vert & horiz or at the beginning of its travel for lathes, and take a final
reading on the indicator. A difference in the X position indicates a thermal growth problem.

NOTE: Ensure indicator setup is correct as described in "Accuracy" section. Setup

errors are commonly mistaken for thermal growth.

7. A similar program can be written to test for thermal growth in the Y- and Z-axes, if necessary.
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 for lathes, or above the part or table, with the spindle "cutting air" for vert & horiz. This
allows ball screws to warm up to the correct temperature and stabilize. Once at temperature, ball screws won't
expand any further, unless allowed to cool down. A warm-up program should be run after each time the ma-
chine is left idle.
Compensation for Thermal Growth
During normal operation, small inaccuracies in the work pieces may develop due to thermal expansion of the
ball screws. Ball screws are made of steel which expands at the rate of 11 millionths of an inch per degree C.
The Haas control contains built-in features to electronically correct for ball screw growth. This compensation
works by estimating the heating of the screw based on the amount of travel over the length of the screw and is
measured from the motor. Adjustments can be made to the settings as needed. The user can fine-tune this
compensation up to plus or minus 30% with the use of settings 158, 159 and 160. If the part size is too big,
decrease the amount of compensation for the appropriate axis. For example, increasing the value in Setting
158, “X Screw Thermal Comp%”, can increase the amount of thermal compensation.

6 Mechanical Service 96-0283 rev C June 2007

 Recommended Torque Values for Machine Fasteners - The following chart should be used as a reference
guide when replacing way covers/head covers 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

W AY C OVERS/HEAD C OVERS

X-A XIS W AY C OVER R EMOVAL (H ORIZ )

Left/Right Way Cover Removal
1. Jog the X-axis to the center of travel and Power Off the machine.
2. Remove the SHCS that fasten the way covers to the table and remove the SHCS that fasten the way
covers to the outside casting.

Y-A XIS W AY C OVER R EMOVAL (H ORIZ )

Removal - Upper
1. Jog the X-axis to the center of travel and the Y-axis all the way down.
2. Power Off the machine.
3. Remove the BHCS that fasten the way cover to the spindle head and the vertical guides to the column.
4. Remove the top way cover.
Install the way cover in the reverse order above; however, make sure that all necessary gaskets and sealants
are replaced and repaired as necessary.
Removal - Lower
1. Jog the X-axis to the center of travel and the Y-axis all the way up.
2. Power Off the machine.
3. Remove the three (3) BHCS that fasten the way cover to the spindle head.
4. Remove the seven (7) BHCS on each side that fasten the vertical guides to the column.
5. Remove the lower way cover.
Install way covers in the reverse order above; however, make sure that all necessary gaskets and sealants are
replaced and repaired as necessary.

96-0283 rev C June 2007 Mechanical Service 7

 Z-A XIS W AY C OVER (H ORIZ )
There are two parts to the Z-axis way cover; the side closest to the spindle and the part on the other side of the
receiver (i.e. EC-400); farthest from the spindle
Jog the Z-axis to a position that gains the most access to the way cover to be removed. Horizontal mills with
pallet changers: If the way cover closest to the load station, or farthest from the spindle needs to be replaced,
rotate the H-frame 45°.
Power off the machine and remove the way cover bolts from each side of the cover.
The replacement cover is installed like the old one was removed. Ensure that a new gasket and sealant are
used with the screws to properly fasten the way cover.

MDC/EC-300 S HADE-S TYLE WAY C OVER ADJUSTMENT

The front of the column on either side of the spindle is covered by heavy shades, kept taut by spring loaded
canisters. If the shades should need adjusting, refer to the following procedure.

Shade Rotation

Set Screw
Flat
Left When Right When
Facing Machine Facing Machine

1. Clamp the shaft at the flat with clamping pliers or other such clamping device to hold the shaft when
adjusting of the spring tension.
2. Loosen the set screw so that the spring tension may be adjusted.
3. Rotate the shaft one complete revolution against the force of the spring (counterclockwise for the left
canister and clockwise for the right canister). Retighten the set screw.
4. Check the tension of the shade. Repeat this process as needed for proper tension one revolution at a time.
Do not overtighten the spring.

EC-300 Y-A XIS W AY COVER A DJUSTMENT

Upper Way Cover - Removal
1. Handle jog the X-axis to center of travel. Handle jog the Y-axis to its lowest position.
2. Power Off the machine.
3. Remove the twenty six (26) FHCS that attach the vertical guides to the way cover.
4. Remove the six BHCS that the attach the upper way cover to the spindle head and the lower way cover.

8 Mechanical Service 96-0283 rev C June 2007

 20X 1/4-20 UNC 2X Holding Bar
x 1-1/4 SS FHCS
6X 1/4-20 UNC
x 2-1/2 SS FHCS
Upper Y-Axis Holding Bar
Waycovers 2X Guide Rail
P-Cool
6X Spacer
(Optional)
5X Guide
4X Lockwasher Bar
4X BHCS Front Bar
Y-Axis
6X BHCS Waycovers
Lower Y-Axis
Waycovers
Waycover Guide
Rails

Upper Way Cover - Installation

1. Install the four SHCS at the top of the way cover. Slide it up and down to ensure it moves freely.
2. Slide the way cover down until the bottom flange goes under the spindle head cover and fasten it with four
BHCS.
3. Fasten the left and right vertical guides using FHCS.

Lower Y-Axis Way Cover - Removal

1. Handle jog the X-axis to center of travel. Handle jog the Y-axis up fully.
2. Power Off the machine.
3. Remove the SHCS that attach the left and right vertical guides and remove.
4. Remove the four FHCS that attach the top of the lower Y-axis way cover to the spindle head casting.
Collapse the way cover down fully.
5. Remove the way cover from the bottom.

Lower Y-Axis Way Cover - Installation

1. Install the four SHCS at the bottom of the way cover, and tighten evenly.
2. Slide the bottom of the way cover up and down to ensure it moves freely.
3. Slide the top flange of the waycover under the spindle head cover plate and fasten it to the spindle head
cover and upper waycover using four BHCS.
4. Replace the left and right vertical guides using BHCS.

H EAD COVERS REMOVAL /I NSTALLATION (V ERT)

Removal
NOTE: This procedure is for the VF-3/4. However, the procedure varies only slightly
for other models.

50 Taper machines: Before removing the head cover, remove the fan assembly and disconnect the tool
release and fan electrical connectors.

96-0283 rev C June 2007 Mechanical Service 9

 10-32 x 3/8" SHCS Remove side
covers from
top side

VF-3/4 Head Covers

1. Zero return (Zero Ret) all axes, then Handle Jog to center X- and Y-axes under spindle. Protect table
surface with a piece of cardboard.
2. Remove the top and rear covers.
3. Pull front cover from the bottom until you can disconnect the tool release cable (quick disconnect), then
remove cover. Remove the side covers. Jog Z-axis as necessary to make screw removal easier.

Installation
1. Protect table surface with a piece of cardboard. Replace each side cover from the top. Jog Z-axis as
necessary to make access to screws easier.
2. Reconnect tool release cable, if equipped, then replace front cover from the bottom. Replace rear cover and
top cover.

T OOL RELEASE PISTON (TRP) A SSEMBLY

Please read this section in its entirety before attempting to replace the tool release piston
assembly.
Overview
The tool release piston is actuated by air during a tool change. It forces the tool draw bar down against the
spring stack, releasing the tool and allowing another tool to be inserted. Normally the piston is in the upper,
retracted position.
As the piston finishes its downward stroke a hole in the side of the tool release shaft comes clear of the
cylinder housing and is exposed to the compressed air within the cylinder. The air flows down through the shaft
to the tool release nut at the lower end of the shaft. This nut presses on the end of the tool draw bar and the air
flows through a central hole to blow any chips out of the tapered area of the spindle shaft.
The spring retainer captures the compression spring that returns the tool change piston and shaft to the normal
position when the air is released from the cylinder. The upper and lower limit switches are actuated by the
spring retainer. The position of these switches is monitored by the computer control system during a tool
change cycle.
There are different tool release pistons for 40 and 50 taper spindles. In addition, the tool change pistons have
different subassemblies that will need to be adjusted, or may need replacing. The section(s) that follow the
installation instructions must be completed as well or serious damage to the machine could result.

10 Mechanical Service 96-0283 rev C June 2007

 Tool Clamp/Unclamp
The tool release drawbar is clamped by spring pressure. Air pressure is used to release the tool clamp. When
the tool is unclamped, air is directed down the center of the spindle to clear the taper of water, oil, or chips.
Tool unclamp can be commanded from the keyboard, and the button on the side of the spindle head. However,
these buttons only operate in MDI or Jog modes.
Tool Clamp/Unclamp Air Solenoids
A single solenoid controls the air pressure to release the tool clamp (relay K15). When the relay is activated,
115V AC is applied to the solenoid, which applies air pressure to release the tool. Relay K15 is on the I/O
PCB, and circuit breaker CB4 will interrupt power to this solenoid.
Tool Clamp/Unclamp Sense Switches
There are two switches located on the tool release piston assembly that are used to sense the position of the
tool clamping mechanism. They are both normally closed. One will open at the clamped position and the other
will open at the unclamped position. When both switches are closed, it indicates that the draw bar is between
positions.
A tool change operation will wait until the unclamped switch is sensed before the Z-axis or tool changer arm
moves, releasing the tool. This prevents any possibility of damaging the machine. The diagnostic display can
be used to display the status of the relay outputs and the switch inputs. The Precharge and TSC system
applies low air pressure and releases the clamped switch.
Remote Tool Unclamp Switch
The Remote Tool Unclamp switch is mounted on the side of the cover to the spindle head. It operates the same
as the button on the keyboard. It must be held for ½ second before the tool will be released and the tool will
remain released for ½ second after the button is released.

SPINDLE TRP R EMOVAL

1. For TSC equipped machines, place a tool holder in the spindle.
2. Remove cover panels from headstock area in accordance with "Head Covers Removal and Installation".
3. For 50 Taper TSC equipped machines the coolant union and extension tube must be removed before
proceeding. They both have left handed threads.

CAUTION: Do not remove pipe connectors from the coolant union! Remov-
ing any pipe connector from the union will void your warranty on
the union. Use wrenches only on the SAE hose connector and
the bottom nut of the Coolant Union. See arrows below:

SAE Hose Connector

Left Hand Threads

96-0283 rev C June 2007 Mechanical Service 11

 a. Loosen the SAE hose connector at the check valve assembly with a wrench (right arrow in
diagram). Do not use a wrench on the pipe connector attached to the coolant union; the union will
be damaged and the warranty voided.
b. Carefully cut off the clear plastic drain hose at the side of the coolant union. It is safest to use
scissors or snips. Cut it close to the connector, since the hose will be re-used on the replacement
union. Do not cut the black coolant hose. (Note that if you are not replacing the union, leave the
drain hose attached to the union.)
c. Remove the coolant union from the extension tube (bottom arrow in diagram) using two
wrenches (7/8 and 15/16). This is a left-hand thread.
d. Return the coolant union with all pipe thread connectors and black coolant hose intact to Haas
Automation for warranty. Removal of any of the pipe connectors from the union will void any
claims for warranty.
4. Disconnect the air line at the lube/air panel.
5. Disconnect the clamp/unclamp cables (quick disconnect) and the assembly's solenoid wiring located on
the solenoid bracket.
6. a. 40 Taper - Remove the tool release air hose and precharge hose at the fitting shown in the following
figure. If machine is equipped with TSC, also remove the coolant hose.
b. 50 Taper - Remove the three tool release air hoses.
7. Use a strap and overhead lifting device to hold the TRP in position. Remove the four shoulder screws
holding the tool release piston assembly to the head casting. Keep all washers and shims.

Motor and
Transmission

Lifting
Strap

TRP
TRP in Position
Rear View
TRP Shown in Position and as it is Lowered

8. Remove entire tool release piston assembly, by sliding it forward then lifting it upward. The assembly is
heavy so use great care when removing it.

NOTE: Steps 9 and 10 apply only to machines with TSC.

12 Mechanical Service 96-0283 rev C June 2007

 9. Remove the drain and purge lines from the seal housing.
10. Remove the seal housing from the TRP.

1/4" Air Hose 3/8" - 16 X Transmission

Fitting 1 3/4" SHCS (Optional) Tool Release
Piston Assembly
3/8" Air Hose
Fitting
ION
CAUT

TSC Fitting
(Optional) Drive Belt
Clamp
switch Spindle
CAUTI
ON
Unclamp Pulley Head Casting
switch
Tool Release Piston with Optional TSC Fitting Mounting Location for Tool Release Piston Assembly

SPINDLE TRP INSTALLATION

The following sections must be completed after installation:
40 Taper
• Set pre-charge
• Adjust the tool clamp/unclamp switches
• Set the draw bar height
50 Taper
• Tool push out adjustment
• Setting TRP switches
• Extension tube Installation (TSC)
1. Ensure drive belt has been properly replaced as described in "Belt Replacement and Tensioning" section.
2. Verify spindle sweep adjustment is correct (as shown in "Draw Bar Replacement" section) before proceed-
ing. If not correct, re-shim as necessary.

Tool Clamped Switch Tool Unclamped Switch

TRP Shims Fork Shims

(1 ea.) 0.093 Nylon Washer
(2 ea.) 0.010 Shim Washer (1ea.) 0.010 Shim Washer
(7ea.) 0.018 Shim Washer
(3 ea.) 0.015 Shim Washer

TRP Fork Spindle Endcap

Fork Gap Drawbar Gap

50 Taper Shim and Spacer Location Diagram

3. Place the TRP on the machine. The TRP will rest on the spindle lift fork.

96-0283 rev C June 2007 Mechanical Service 13

 CAUTION! Be careful of the spindle lift fork. Place the assembly toward the
front of the machine before lowering it. The assembly is heavy so
use great care when replacing it.

4. Install the 4 bolts, with the shim stock and spacers under the TRP.
Part No. Description 30-0013A (New) 30-0013 (Old Style)
Fork: (45-0014) 0.010 Shim Washer 1 ea. None
(45-0015) 0.018 Shim Washer 7 ea. 5 ea.
TRP: (45-0019) 0.093 Nylon Washer 1 ea. 1 ea.
Spacers: (45-0017) 0.010 Shim Washer 2 ea. 2 ea.
(45-0018) 0.015 Shim Washer 3 ea. 2 ea.

NOTE: TRP Spacers: the nylon washer goes on top of the shims.

5. Reinstall tool release piston assembly loosely if the machine is equipped with TSC. Otherwise tighten the
four mounting bolts securely.
6. 50 Taper - If the machine is equipped with TSC, re-install the extension tube and rotating union in the
following manner. Otherwise, skip this step.

NOTE: If the spindle, draw bar or extension tube has been replaced, the extension
tube runout must be adjusted.

Measure Runout Of
Rotating Union Here Rotating Union
Bearing Holder
Extension Tube
Wave Spring Assembly

50 Taper
TRP Fork TRP
Draw Bar

Spindle
Pulley

a) Place a tool holder in the spindle.

b) Insert a 5/8 Allen wrench into the lower end of the piston shaft. Loosen the 1/4-20 screw in the
clamp collar on top of the piston shaft. Insert a large flat blade screwdriver into the slot in the
clamp collar, and twist the collar off.
c) Screw the bearing holder (20-7655) onto the piston shaft. Tighten using a large wrench or pliers.
d) Wipe clean the hole in the end of the draw bar.
e) Replace the tool release piston.
f) Apply a light layer of molybdenum grease to the inside of the bearing holder. Insert the wave
spring (59-0176) into the bearing holder.

14 Mechanical Service 96-0283 rev C June 2007

 g) Lightly grease the o-ring on the end of the extension tube assy (30-1242). Apply blue Loctite to
the thread on the end. Insert the extension tube down into the draw bar. Tighten by hand as far as
possible (it has left hand threads).
h) Block spindle rotation with a bolt, bar or socket inserted into one of the pulley holes. It will stop
against the TRP fork.
i) Tighten the extension tube to 15-20 ft-lb. Remove the bolt from the spindle pulley.
j) Install the rotating union. Lightly grease the o-ring. Do not put Loctite on the threads.
1) Thread the coolant union onto the end of the extension tube (it has left hand threads).
Do not use Loctite. Tighten the threads snugly using two wrenches.
2) Attach the clear plastic drain hose to the barb connector on the side of the union. Use a
hose clamp if one is available. The hose must travel downward (below the union) to drain
off collected coolant. The union will be damaged if coolant collects inside the union.
3) Thread the black coolant hose onto the connector on the check valve assembly. Tighten
with a wrench. Do not over-tighten!
k) Measure the runout at the top of the rotating union with a dial indicator. Runout should not
exceed .006"
l) Check the tool clamp and unclamp switches. They should not have moved.
m) Test run the TSC system to check for leaks before putting the head covers back on.
7. Reconnect the air hoses at the applicable fittings on the tool release piston assembly.
8. Reconnect the clamp/unclamp cables and solenoid wire to the sides of the solenoid bracket.
9. 50 Taper - Set the main air regulator to 85 psi. Tool push out and TRP switch adjustments must be
completed.
Steps 10-13 only apply to 40 Taper machines with TSC
10. Connect the 5/32" drain line and 5/32" purge line to the seal housing and install the seal housing on the
TRP (use Loctite on the screws). The drain line connector should point toward the rear of the machine.

NOTE: The drain line must run straight through the cable clamp guide on the
transmission, and must not interfere with the pulley or belts.

11. Apply precharge pressure several times to allow the seal to center itself with the draw bar. While holding
down precharge, tighten the bolts.
12. Install the coolant hose. A wrench must be used, tighten snug. Do not overtighten!!
13. Adjust the clamp/unclamp switches in accordance with the appropriate section.

SETTING P RE-C HARGE

Do not perform on machines equipped with Through the Spindle Coolant (TSC). It will
damage the machine. Refer to the "Precharge Regulator Adjustment" section and perform
those adjustments.

NOTE: Set the air pressure regulator to 30 psi on Super Speed machines with an in-
line drive and do not set a precharge on 50 Taper machines. For a standard
40 Taper machine (without TSC), use the procedures in step 4.

96-0283 rev C June 2007 Mechanical Service 15

 1. Turn the air pressure regulator to zero (0). The knob must be pulled out to unlock before adjusting. In-Line
drive machines - Disconnect the air hose from the precharge regulator. Install a test gauge between the
regulator and the solenoid. Command the precharge (Macro #1120-1), the pressure should be 30 psi.

NOTE: At "0" pressure on the precharge regulator, the adjustment knob is out as far
as it will turn.

SP
IN
ST DL
WITH AT E LO
US
OU SWCKED
T GE ITC
AR H
BO
X

TO
ST OL
AT CL
US AM
SW PE
ITCHD

LO
JUSTATW
M U GEA
PE S
GEAR SWR
W IT
IT C
RBO HO H
X UT

H
STAIG
TUH
G
S EA
SW R
IT
C
H

Air Pressure Regulator Adjustment Knob

2. Verify Parameter 149, Precharge DELAY, is set to 300.

3. Execute a tool change. A banging noise will be heard as the tool release piston contacts the drawbar.
4. Turn the air pressure regulator ½ turn in. Execute a tool change and listen for the noise described in step
3. If it is heard, repeat this step until no noise is heard. There should be no noise with or without a tool in
the spindle.

CAUTION! Only increase the pressure to the point where tool changes become
obviously quiet. Any further pressure increases are not beneficial. Exces-
sive pressure to the precharge system will cause damage to the tool
changer and tooling in the machine.

5. Replace the head covers.

TRP SWITCH ADJUSTMENT

TRP Precharge must be adjusted for Inline Spindles before adjusting the Clamp-Unclamp
switches. To adjust the TRP Precharge:
1. Install an inline pressure gauge between the regulator and the check valve.
2. Remove the tool holder from the spindle.
3. Rotate the regulator adjusting knob to the fully out position (turn counter-clockwise).

16 Mechanical Service 96-0283 rev C June 2007

 SP
IN
S D
WITTAT LE LO
HOUS S CK
UT WIT ED
GE CH
AR
BO
X

TO
ST OL
AT CL
US AM
SW PE
ITCD
H

LO
JUSTA W
M TU GE
PE S A
GER SWR
ARWIT IT
BOHOCH
X UT

STHIG
AT H
U GE
S A
SW R
IT
C
H

4. Press MDI.
5. Enter #1120=1, and press Cycle Start.
6. Adjust the pressure regulator to 30 psi. and press Reset.
7. Press Cycle Start again to verify that the regulator is set to 30 psi.
8. Lock the regulator adjusting knob, by pressing it in and remove the inline gauge.

Adjustment Procedure
Upon completion of the Tool Release Piston switch adjustment procedure, the switches should indicate that
the tool is released from the spindle taper with the tool 0.060” out of the taper and that the tool is not released
with the tool 0.050” out of the taper.

1/4" Air Hose 3/8" - 16 X Tool Clamped

Fitting 1 3/4" SHCS Clamp Switch Unclamp Switch Switch Tool Unclamped
3/8" Air Hose Switch
Fitting

TSC Fitting
(Optional)

Clamp
switch CAUTI
ON
Unclamp
switch
Conventional Spindle Switches Inline Spindle Drawbar Switches 50 Taper Tool Clamp/Unclamp
Switches

Lower (Unclamp) Switch

1. TRP height must be set properly before adjusting switches. See the “Setting TRP height” section.
2. Press Param/Dgnos until the diagnostic page is displayed. Confirm that DB OPN=0 and DB CLS=1.
3. Place a tool in the spindle and place a machined aluminum block on the table under the tool holder (Vert),
or set up a fixture to support an aluminum block for horizontal mills. Be sure to place a clean piece of
paper under the block to protect the table, or fixture surface.

96-0283 rev C June 2007 Mechanical Service 17

 Tool Holder

Sheet of
paper
Aluminum Block

4. Jog Z-axis until the tool holder is about 0.030” above the aluminum block. Switch to .001” increments. Jog
one increment at a time until the tool holder just makes contact with the block (should still be able to move
the block). This is the Zero Point. Do not press the Tool Release button; it will cause a Z-axis overload.
5. Change Parameter 76, Low Air Pressure, to 99,999. This eliminates a low air pressure alarm.
6. In order to limit the spindle head deflection during this next part of the procedure, the air pressure needs to
be reduced to lower the output force of the TRP. Turn the regulator down past 50 psi, then adjust back up
to 60 psi.
7. Place a 0.0005” test indicator between the table, or fixture and the face of the spindle head to measure
axial deflection when the TRP is energized. Press and hold the Tool Release button and check that the
block is tight and the head deflection is between 0.002” and 0.004”. If the head deflection is too high,
reduce the air pressure. If the head deflection is too low, or there is no deflection, increase the air pressure.

Tool Holder
Sheet of
Paper
Z-Axis

Aluminum Block

8. Remove the indicator.

9. Press Posit, then Page Up until the Pos-Oper page is displayed. With the Z-axis selected, press Origin to
zero the display.
10. Press .01 and jog the Z-axis to 0.060” (away from the block).
11. Press the Tool Release button and hold it in. Adjust the switch in or out toward the spring retainer until the
switch changes status (DBOPN=1). The switch should now be indicating that the tool is unclamped and
out of the spindle taper.
12. Cycle the tool release several times and confirm that the switch is tripping. Press Param/Dgnos until the
Diagnostics page is displayed. Confirm that (DB OPN=1) and (DB CLS=0).
13. Check the adjustment. Jog the Z-axis to 0.050” (from the block) and confirm that (DB OPN=0 whenthe Tool
Release button is pressed.

NOTE: The switch must trip (DB OPN=1) at 0.060” and not trip (DB OPN=0) at 0.050”.

18 Mechanical Service 96-0283 rev C June 2007

 14. Adjust and repeat steps 11-13 if necessary.
15. Set the pressure regulator back to 85 psi and set Parameter 76 to 1500.
Upper (Clamp) Switch
1. Remove the tool holder from the spindle.
2. Enter MDI mode, erase any code and enter #1120=1.
3 Start with the upper switch all the way in. Place a 0.020” feeler gauge between the TRP and the drawbar.

Tool Release
Piston

TRP
Feeler Gauge

Drawbar Drawbar
Insert
Feeler Gauge
Here
Spindle Cartridge
Assembly

Conventional Spindle Switch Adjustment Inline Spindle Switch Adjustment

4. Press Param/Dgnos until the Diagnostics page is displayed, then press Cycle Start.
5. If DB CLS=0 (Tool Unclamp), the adjustment is complete. If not, adjust the upper switch out until the
switch is just un-tripped (DB CLS=0) and continue with the next step.
6. Press Reset. Replace the 0.020” feeler gauge with a 0.040” feeler gauge. (Checking with the 0.040” feeler
gauge assures that the switch is not too far out of position. If the switch is all the way in, this check is not
necessary.) Press Cycle Start. See that DB CLS=1.
8. Repeat steps 4-7 if necessary. If repetition is not necessary, remove any feeler gauges. The adjustment
procedure is complete.00

TRP I NSTALLATION AND ADJUSTMENT - OM-1A/OM-2A

Upon installation of the TRP, the top of the spindle gear must sit flush with the bottom of the subplate of the
TRP casting. If the TRP subplate casting sits above the spindle, add .01” shims as necessary. Connect an air
pressure gauge to the TRP Pre-Charge, and adjust the pressure until it reads 6 psi upon tool release. Insert
shoulder bolts and torque to 18 ft-lb.

NOTE: Upon tightening of the fasteners, the TRP must fully return to its original
position.

Draw Bar Height Adjustment

1. Place a machined aluminum block on the table under the tool holder (with no tool in the spindle). Be sure
to place a clean piece of paper under the block to protect the table surface.

96-0283 rev C June 2007 Mechanical Service 19

 2. Jog the Z-axis down until the tool holder is about 0.030” above the aluminum block. Set the clearance from
the tool holder to the block to zero by pressing Tool Release, switching to .001” increments, and jogging
down one increment at a time. Move the Z-axis, then press Tool Release while feeling for movement of the
tool holder (place finger between tool holder and spindle). Repeat process until no movement is felt. This is
the zero point.
3. In .01” increments, handle jog the Z-axis to .100” above the block.
4. Press and hold the Tool Release button. Try to move the block. The block should be tight at .100”, and
loose at .110”. If the block moves at .100”, repeat the process, jogging the Z-axis down one increment at a
time until the block is tight. If the block is tight at .110”, repeat the process, jogging the Z-axis up one
increment at a time until the block is loose.

NOTE: The number of increments jogged up or down is equal to the number of shims
to add or remove. If the block was tight at .110”, remove shim washers. If the
block was loose at .100”, add shim washers.

Shim Washer Addition/Removal

To add or subtract shim washers, remove the TRP assembly.
1. Check the condition of the tool release tip and draw bar and replace damaged parts before setting draw bar
height.
2. Remove the tool release bolt.
3. Add or remove the required number of shim washers.
4. Reinstall the tool release bolt.
5. Install the TRP assembly and recheck settings. Adjust as required.

Upper (Clamp) Switch

1. Delete everything in MDI mode and write #1120 = 1.
2. Start with the upper switch all the way in.
3. Place a 0.020” shim between the tool release piston adjustment bolt and draw bar and press Cycle Start.
4. If DB CLS = 0 (tool unclamp), the process is complete. If not, adjust the upper switch out until the switch
untrips (DB CLS = 0), and test the adjustment.
5. Press Reset.
6. Replace the 0.020” shim with a 0.040” shim and press Cycle Start.
7. Verify that DB CLS = 1. Readjust if necessary.

SETTING TRP HEIGHT

This procedure must be done before adjusting the Clamp-Unclamp switches.
Place a tool in the spindle and place a machined aluminum block on the table under the tool holder (Vert), or
set up a fixture to support an aluminum block for horizontal mills. Be sure to place a clean piece of paper under
the block to protect the table, or fixture surface.
1. Jog the Z-axis until the tool holder is about 0.030” from the aluminum block. Switch to .001” increments. Jog
one increment at a time until the tool holder just makes contact with the block firmly against the table, or
fixture surface (should be able to move the block). This is the Zero Point. Do not press the Tool Release
button; it will cause a Z-axis overload.

20 Mechanical Service 96-0283 rev C June 2007

 Tool Holder

Sheet of
paper
Aluminum Block

2. Press the Handle Jog button, then press .01 increments and jog the Z-axis in the positive (+) direction
0.100”.
40 Taper
3. Press and hold the Tool Release button, grasp the aluminum block and try to move it. The block should be
tight.
4. Jog the Z-axis in the positive (+) direction 0.110”.
5. Press and hold the Tool Release button, grasp the aluminum block and try to move it. The block should be
loose.

NOTE: If this is true, no adjustment is necessary. If it is not, proceed to the next step.

6. If the block moves at 0.100”, jog the Z-axis in the negative (-) direction one increment at a time. Check for
movement of the block between increments until the block is tight. Each increment is equal to one piece of
shim stock.
7. The increments jogged in the Z negative (-) direction are the amount of shim washers that must be added to
the tool release bolt (or coolant tip for TSC) for the conventional spindle. Or the amount of shims added to the
tool release piston for the Inline spindle. Refer to Shim section.
8. If the block is tight at 0.110”, move the Z-axis in the positive (+) direction one increment at a time. Press the
Tool Release button and check for movement between increments until the aluminum block is loose.
9. The increments jogged in the Z positive (+) direction are the amount of shims that must be removed. Refer to
Shim section.

50 Taper
Tool Unclamped Tool Clamped
Switch Switch
Fork Shims (1 ea.) 0.093
(1ea.) 0.010 Nylon Washer TRP Shims
Shim Washer (2 ea.) 0.010
(7ea.) 0.018 Shim Washer
Shim Washer (3 ea.) 0.015
Shim Washer
Spindle Endcap

Fork Shim Location TRP Shim Location

96-0283 rev C June 2007 Mechanical Service 21

 10. The tool push out adjustment is 0.060” +/-0.010”. Add or remove shims from the tool release fork to make
adjustments. The shims come in 0.010” and 0.018” thicknesses. Jog away from the plate (upward for Vert)
0.060. Press and hold the Tool Release button, and feel for movement in the aluminum block.
• If the block is tight when the button is pressed, shims may have to be added to the TRP fork.
• If the block is loose when the button is pressed, shims may have to be removed from the TRP fork.
• If the aluminum block is tight at 0.060”, release the button and jog the Z-Axis away from the block 0.001”
and press the Tool Release button again. Feel for movement in the aluminum block. Repeat this until
movement is felt. Note the last position where the block was tight. If the position is 0.070” or more, add
shims to the TRP fork.
• If the aluminum block is loose at 0.060”, jog the Z-Axis toward the block 0.001 at a time and check for
movement in the aluminum block. If the position where the block becomes tight is 0.050” or less, remove
shims from the TRP fork.
11. If shims were added to the TRP fork, add half that amount to the spacers supporting the TRP. This will
keep the two clearance gaps between the TRP and the rotating spindle equal (approximately 0.095” each).
If shims were removed from the TRP fork, remove half that number of shims from the spacers.
12. Apply red grease to the shoulder bolts used to mount the TRP when shim adjustments are complete. Use
blue Loctite on the threads.
Shims
Mounting Bolt Locations
Shims Shim
Tool Release
Bolt

TRP

2 Bolts
Shim Washers On Each
Side

Conventional Spindle Inline Spindle

NOTE: Shims may need to be added or removed if the spindle cartridge, tool release
piston assembly or drawbar have been replaced.

Conventional Spindle
1. To add or subtract shim washers, remove the tool release piston assembly from the head casting.
2. Check the condition of the tool release bolt and the draw bar. Repair or replace these items (if necessary)
before setting the drawbar height.
3. Remove the tool release bolt. Note that it has a left-hand thread. If the machine is equipped with TSC,
loosen the three set screws and remove the TSC coolant tip.
4. Add or subtract the required number of shim washers as previously described.
5. Before installing the tool release bolt, put a drop of serviceable (blue) Loctite on the bolt threads. If replac-
ing the TSC coolant tip, put a drop of Loctite on the three set screws before installing them.
6. Install the tool release piston assembly and recheck the settings. If the settings are not within specifica-
tions, repeat the procedure for setting the TRP height.

22 Mechanical Service 96-0283 rev C June 2007

 Inline Spindle
NOTE: Shims may need to be added or removed if the spindle cartridge, tool release
piston assembly have been replaced.

1. To add or subtract shims, loosen the four hex head bolts that attach the shims to the tool release piston.
2. Add or remove the necessary number of shims, as previously described, then reassemble

In-Line Drive Spindle Draw Bar Height

The draw bar height is set as for the belt driven spindle; however, the shim washers are set up differently. The
draw bar uses a one-piece shim which can be added or removed without having to remove the TRP assembly.
Once the shims have been adjusted, the TRP is re-installed, and the final torque on the bolts is 35 ft-lb.

TRP DISASSEMBLY
1. Loosen and remove the shaft clamp. A punch and mallet may be required to break the clamp loose.
2. Remove the switch trip and compression spring.
3. Remove the 50T upper spacer.
4. Push the TRP shaft down.
5. Remove the 8 bolts holding the TRP assembly together, separate and remove upper half of the housing.
6. Remove the upper TRP piston and remove the lower half of the TRP housing.
7. Remove the TRP lower spacer, the lower TRP 50T piston and the TRP sub plate.

O-ring Replacement
1. Remove and replace the 4 o-rings (57-0027) on the TRP 50T shaft
2. Remove and replace the 2 o-rings (57-0092) on the TRP 50T piston, 1 o-ring per piston.
3. Remove and replace the 3 o-rings (57-0095); 2 in the center of the TRP 50T housing and 1 in the center of the
TRP 50T sub plate.

TRP ASSEMBLY
1. Place the TRP sub plate over the TRP shaft, the lower TRP piston, grooved side up, and the TRP lower
spacer over the TRP shaft.
2. Install the lower TRP housing, the upper TRP piston, grooved side up, and the upper TRP housing over the
TRP shaft.
3. Replace the 8 bolts holding the TRP assembly together. Pattern torque to 50 ft-lb.
4. Place the TRP upper spacer over the TRP shaft.
5. Push the TRP shaft up from the bottom, using the mallet handle. The shaft will bottom out with approxi-
mately 1/4" of the shaft still showing.
6. Place the switch trip and compression spring over the TRP shaft.
7. Tighten the shaft clamp on the TRP shaft, then the shaft clamp locking bolt.

96-0283 rev C June 2007 Mechanical Service 23

 BELT REPLACEMENT & TENSIONING
Please read this section in its entirety before attempting to replace the Vertical or EC-
Series drive belt.

D RIVE B ELT R EPLACEMENT (V ERT & EC-S ERIES)

Removal
NOTE: For easier removal, place transmission in high gear before beginning.

1. Remove cover panels from headstock area in accordance with "Head Covers Removal/Installation".

Transmission
(Optional)
Motor

CAUTION
ADJUSTED - TOOL CLAMP/UN
WILL RESULT.BY TRAINED PERSONN
CLAMP SWITCHES
PLEASE CONSULT EL OR SEVERE MUST BE
SERVICE DAMAGE PROPERLY
Shifter
MANUAL BEFORETO TOOL CHANGER
ADJUSTM
ENT.

Spindle
3/8 - 16 x 1" Drive Pulley
SHCS Belt

Head
Inspection Cover Casting

Spindle Head Casting Disconnect Points Head Casting Area Showing Belt Location

2. Remove tool release piston assembly in accordance with "Spindle TRP Removal".
3. a. Vert: Remove the six SHCS holding the transmission to the head casting and pull the transmission
forward enough (½" to ¾" max.) to allow the drive belt to be pulled upward over the spindle pulley.
b. Horiz: Remove the four large SHCS that attach the transmission mount plate to the spindle head and pull
the transmission/motor assembly toward the front of the machine slightly to remove the tension on the drive
belts, and remove the drive belts.

NOTE: On direct drive machines, remove the four SHCS holding the mounting plate
to the spindle head casting. Slide the assembly forward enough to allow the
drive belt to be pulled up over the spindle pulley.

4. Remove the inspection cover from the bottom of the spindle head casting and carefully slide the drive belt
between the sump tank and the web in the casting.
5. Pull the belt up over the spindle pulley, push the other end down to clear the shifter, and pull out.

NOTE: Do not bend or kink the belt in any way; damage to the fibers in the belt may
result, and the belt will fail soon after installation.

Installation
NOTE: Belt clocking must be correct before placing replacement belt(s) onto the
pulley(s). Rotate the pulleys until the alignment dots are in line, but not facing
each other, as shown in the following illustration.

Belt Clocking

24 Mechanical Service 96-0283 rev C June 2007

 1. a. Vert: Slide the replacement belt(s) under the sump tank and onto the pulley.

NOTE: Do not wrap the belts over the pulley. The pulley can be rather sharp, and may
cut the belts. Do not bend or kink the belt in any way; damage to the fibers in
the belt may result, causing belt failure.

b. Horiz: Slide on the drive belts.

2. a. Vert: Ensuring the belt is properly seated, push the transmission back, tightening the belt. Pull belt
forward from rear of head casting. Pull belt over spindle pulley.
b. Horiz: Replace the TRP solenoid assembly and TSC valve bracket. Orient the transmission/motor
assembly and replace the transmission mount plate to the spindle head.
3. a. Vert: Tighten the drive belt in accordance with the following section.
b. Horiz: Use a belt tensioning tool to tighten the drive belts. Do not over tighten.
4. Set the spindle orientation (“Spindle Orientation” section).

NOTE: The following step is necessary only if the spindle or transmission was
exchanged prior to belt replacement.

5. Double-check the spindle sweep to assure that nothing has moved during the previous steps. If sweep is
within tolerance, continue; if not, sweep must be readjusted.

NOTE: Drive belt tension must be adjusted after every installation.

D RIVE B ELT T ENSIONING (V ERT & EC-S ERIES )

NOTE: The drive belt tension should be adjusted after every service on the transmis-
sion or spindle of the machine. Information placed in parentheses applies to
Direct Drive machines.

1. Turn the machine On. Jog the spindle head down to a level that will allow easy access to the drive belt.
2. Remove the cover panels from the head stock area as shown in "Head Covers Removal/Installation".
3. Remove the tool release piston assembly in accordance with “Spindle TRP Removal”.
4. Loosen the six (four) SHCS holding the transmission (motor mounting plate) to the spindle head casting.
Ensure the transmission (motor) is broken free by moving it slightly by hand.
5. Set the belt tension tool in place. Mount it to the head casting by inserting the two SHCS into the two front
TRP mounting holes. Tighten the SHCS finger tight. Turn the handle until the tool is flat against the trans-
mission casting (motor mounting plate). Ensure the transmission (motor) is straight, and not cocked,
before tensioning belt.

Outer Tube
Plunger

Belt Tension Tool

Belt Tension Tool

96-0283 rev C June 2007 Mechanical Service 25

 6. Turn the handle until the edge of the tool's plunger and the outer tube are flush, and then 1/2 turn more.
This will set the belt at the proper tension.

NOTE: A belt that is correctly tensioned will whine slightly, and requires approximately
12 hours of break-in time.

7. Check if the belt is too loose or too tight. If the belt is set too tight, the belt will whine excessively when the
assembly is at speed; and if it is set too loose, it will vibrate during accelerations and decelerations.
8. With the tool still in place, tighten the six (four) SHCS holding the transmission (motor mounting plate) to
the spindle head casting.
9. Loosen the two SHCS and remove the belt tension tool.

30K Spindle
There are two types of belts (3 rib and 4 rib) used on the 30K Spindle Drive. To ensure maximum performance,
the spindle drive belt should be checked for proper tension every 6 months or 1000 hours of operation. The
tension is measured using a Gates Sonic Tension Meter, model number 505C or 507C (used for all belt tension
measurements).
The following table displays the proper lbf (pounds force)/Hz tension readings.
Belt New Belt Used Belt
Number of Ribs Minimum Maximum Minimum Maximum
3 Rib 53.7 lbf 57.6 lbf 46.2 lbf 50.1 lbf
174 Hz 180 Hz 161 Hz 167 Hz
4 Rib 60.8 lbf 64.8 lbf 52.0 lbf 56.4 lbf
159 Hz 165 Hz 148 Hz 154 Hz

NOTE: Specific settings must be entered into the tension meter to obtain a correct
tension reading, and are listed below. The Gates Sonic Tension Meter is
capable of retaining 10 to 20 separate combinations of settings depending
upon model. Be sure that you are on the correct belt drive storage register
before taking a reading.

Setting for 3 rib belt: Weight 13.1, Width 3, Span 225

Setting for 4 rib belt: Weight 13.1, Width 4, Span 225

S PINDLE BELT T ENSIONING (OM-1A/OM-2A)

The spindle belt tension is measured using a Gates Sonic Tension Meter, model number 505C or 507C.
1. Place the Gates Sonic Tension Meter in Setting #1.
2. Place the meter’s sensor within 3/8” of the belt, and pluck the belt like a guitar string, taking care that the
sensor does not touch the belt.
3. Set belt tension for the Office Mill 30,000 RPM spindle at 43# to 47#.
4. Torque spindle motor fasteners to 30 ft-lb.

26 Mechanical Service 96-0283 rev C June 2007

 APL MOTOR BELT REPLACEMENT
W-Axis Motor Belt Replacement
A lathe’s W-axis motor belts control the raising and lowering of the APL arm. The following instructions are to
service the belts in case a belt is in need of replacement. It is recommended to replace both belts at a time.

Home Switch
Trip Bracket Beam

Carriage Cover
Cable
Junction

Carriage
Assembly
ATIC
AUTOS MLOADER
Hard Stop APL PART

W-Axis Ram

Rotator Assembly Bearing Support

Replacing the Belt(s)

1. Jog the APL U-axis as far to the left of the machine as possible and disable the axis by selecting Param-
eter 354 and changing the bit value from 0 to 1.
2. Remove the hard stop and home switch trip bracket, remove the APL carriage cover, and press E-Stop.
3. Manually push the carriage away from the machine until the two metal linear rail guide pads (held by 2
bolts each) are exposed. The entire arm assembly has to clear the table.

NOTE: Only push as far as needed to be able to access the four bolts on the two guide
rail blocks.

4. Using a sufficient block (which will have to be taller than the parts table) jog the APL down and support the
bottom of the rotating head.

Remove Upper
Guide Rail Block Carriage
with two SHCS Assembly

Pinion
Gear Rotator
B-Axis Assembly
Ram

Remove Support
Support
Upper Belt Blocks
Table
Remove One SHCS
(Right Side Only

96-0283 rev C June 2007 Mechanical Service 27

 5. Remove the top linear rail guide block (2 bolts) which will drop down to the bottom block. Only remove
the inside bolt on the bottom linear guide block. The remaining bolt (outside) on the bottom guide
block should only be loose.
6. Remove the bearing support bracket and position the ram outwards so that there is sufficient clearance to
remove the pinon gear which will yield access to the rear motor belt.
7. Loosen the W-axis motor support housing so that there is enough slack to position the belt. After the belts
have been installed, replace the pinion gear and bearing support. Torque the W-axis motor bolts to 30 ft-lb,
swing the arm back into place, and re-install the linear guide pads. Leave the bolts loose to jog the ram up,
use a level to make sure the arm is straight, then torque the bolts.
8 Manually push the APL back past the home switch plate to the center of the parts table, Zero Return the
W-axis, re-fasten the rubber stop and home plate on the beam.
9. Re-enable the U-axis by changing the bit in Parameter 354 and Zero Return the axis.
10. Finally, re-check the offsets for the U- and W-axis.

V ERIFYING BELT T ENSION (L ATHE )

1. 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 required torque value. The path of the
applied torque should be inline with the motor assembly. A belt tensioning chart follows.

T-1537 T-1537

T-1961 HL-3/-4 & HL-3/-4GB

HL-1/2 & SL 20/20B Through 10/98
95 ft-lb (129 Nm) 95 ft-lb (129 Nm)
T-1537
SL 30/30GB
(New Spindle Center Line)
From 11/98
95 ft-lb (129 Nm)
T-1961

T-1537 T-1650

SL 30B
230 ft-lb (312 Nm) SL 40/40B
(Encoder Pulley 230 ft-lb (312 Nm)
Must be Removed)

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

CAUTION! This procedure should be performed with two service persons;

one to apply torque, the other to tighten bolts.

3. Use a Gates Sonic Tension Meter to measure the belt tension.

4. Mount the encoder onto the spindle housing below the spindle shaft with four mounting bolts.
5. Place the 3/8" timing belt on the spindle pulley, with the other end on the encoder pulley.

28 Mechanical Service 96-0283 rev C June 2007

 6. 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 should be within .001". Check tolerance of large
I.D. bore circular to within .001".
7. Slide the hydraulic cylinder into spindle shaft. Insert and snug the mounting bolts.
8. Attach and clamp the oil drain hose and coolant drain hose onto hydraulic cylinder. Attach and screw in
clamp and unclamp hoses.
9. Set magnetic base on top of the spindle housing with indicator touching the top of the hydraulic cylinder.
10. Replace all previously removed sheet metal.

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 sub spindle motor mounting bolts.
7. Remove and replace the motor belt.
8. Reassemble in reverse steps to remove. Make sure the motor wiring is connected and secured properly.

96-0283 rev C June 2007 Mechanical Service 29

 SPINDLES
Operation
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).
Mills: Speeds from S1 to the Parameter 142 value will automatically select low gear, and speeds above Param-
eter 142 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.
Lathes: The gear box position (low or High gear) must be commanded.
If there is no gear box in the machine, the gear box commands are disabled by parameters and is always in
high gear.

15K & 50 T APER S PINDLES

Non-Serviceable, Anti-Rotation Draw Bar
The draw bar and the spindle are not serviceable as separate items on the 15K spindle. The 15K spindle uses
an extra high clamp draw bar and may be used in both TSC and non-TSC applications. If there is a need to
replace the spindle or the draw bar, the entire spindle must be replaced.

NOTE: The spindle and the draw bar are balanced at the factory as a matched
assembly.

The anti-rotation draw bar does not allow the draw bar to turn in the spindle shaft. By not changing the position
of the draw bar, changes in vibration output of the spindle are minimized. The balance is also retained when the
draw bar does not turn.
Oil Flow
The specification for oil flow is 0.15 - 0.18 cc per 0.5 hour when measured from the spindle restrictor with no
airflow. This oil flow is measured on each machine. The flow rate is adjusted by changing the restrictor used
and by changing the total output of the pump. The pump nominally puts out 3 cc per 0.5 hour. The pump has a
0.5 hour cycle time. The pump runs only when the spindle is running or one of the axes is moving. Different
sized restrictors are used to control flow. They are numbered according to their size, for example, a 3/0
restrictor has twice the flow of a 4/0, which has twice the flow of a 5/0 restrictor.

STALLING/L OW TORQUE
Generally, complaints of stalling or low torque relate to incorrect tooling or machining practices. A spindle that
is seizing will yield a poor finish machining, run very hot and very loud. Investigate machining problems before
concluding the problem exists with the spindle or spindle drive.

S PINDLE D RIVE
Low line voltage may prevent the spindle from accelerating properly. If the spindle takes a long time to acceler-
ate, slows down, or stays at a speed below the commanded speed with the load meter at full load, the spindle
drive and motor are overloaded. High load, low voltage, or too fast accel/decel can cause this problem.
A resistor bank (regen resistors) located on the top of the control cabinet is used by the spindle drive to
dissipate excess power caused by the regenerative effects of decelerating the spindle motor. If the spindle
motor is repeatedly accelerated and decelerated in rapid succession, 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 regen load resistors are not connected or open, it may result in an overvoltage alarm. A functional resistor
will have a reading of 8 ohms.The overvoltage occurs because the regenerative energy being absorbed from the
motor while decelerating is turned into voltage by the spindle drive. If this problem occurs, the possible fixes are
to slow the decel rate or reduce the frequency of spindle speed changes.

30 Mechanical Service 96-0283 rev C June 2007

 SPINDLE TROUBLESHOOTING
Haas Automation does not honor warranty requests for gearbox or spindles without vibra-
tion analyzer signatures.

N OT TURNING
Spindle not turning
• Check machine parameters.
• If there are any alarms, refer to "Alarms" section.
• Check that the spindle turns freely when machine is off.
• If motor turns but spindle does not, see the "Belt Replacement and Tensioning" and "Spindle Motor and
Transmission".
• Command spindle to turn at 1800 RPM (mills) and check spindle drive display. If display blinks “bb”, check
spindle orientation switch.
• If spindle drive does not light the Run LED, check forward/reverse commands from I/O PCB.
• If spindle is still not turning, replace MOCON PCB.
• If spindle is still not turning, replace spindle drive.
• Check for gearbox or motor rotation (if applicable). If the motor or gearbox operates, check the drive belt.
• Disconnect the drive belt (mills). If the spindle will not turn, it is seized and must be replaced.
• Check wye/delta switch, if equipped, for proper operation.

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

NOISE
Check the tooling (mills); balanced tooling will run smoother; possibly reducing the noise.
In-Line : Check for misalignment between the motor and the spindle. If misalignment is noted, loosen the motor
mounting bolts, run the spindle at 1000 RPM, and then tighten the mounting bolts.
Remove the coolant union and run the spindle, if the spindle is quieter, the coolant union may need replacing.
Excessive noise coming from the spindle head area
Most noises attributed to the spindle actually lie in the motor/gearbox or drive belt of a machine. Isolate the
sources of noise as follows:
Determine if the noise is related to the RPM of the motor or the RPM of the spindle. For example: if the noise
appears at 2000 RPM in high gear (40T and 50T), listen for similar noise at 500 RPM (40T) or 620 RPM (50T) in
low gear. If the same noise is heard, the problem lies with the gearbox. If the noise disappears, the problem
could be either the gearbox or spindle, and further testing is necessary.

NOTE: 40 Taper gear ratio is 1:1.25 in high gear, and 3.2:1 in low gear.
50 Taper gear ratio is 1:1.02 in high gear, and 3.16:1 in low gear.

• Remove the vertical head covers or lathe left end covers and check the machine’s drive belt tension;
adjust if necessary. If the belt is worn, replace the belt ("Belt Replacement and Tensioning" section).
• If the noise does not change, remove the belt and go on to the next step.
• Check the vertical machine pulleys for excessive runout (more than 0.003" axial or radial).

96-0283 rev C June 2007 Mechanical Service 31

 • Run the motor or the gearbox with the drive belt disconnected. If the noise persists, the problem lies with
the gearbox/motor. If it disappears, go on to the next step.
• Check for the correct amount of lubrication to the spindle bearings in an air mist-lubricated spindle.
• If the spindle is not getting lubrication, correct the problem per the lube and air diagram at the back of
this manual and replace the spindle ("Spindle Assembly" section).
• If the spindle is getting lubrication, replace the spindle ("Spindle Assembly" section).

O VERHEATING (M ILLS)
When investigating complaints of overheating, a temperature probe must be used to accurately check the
temperature at the top of the spindle taper. The temperature displayed on the Diagnostics page is not relevant.
A machine that runs at high continuous RPM will have a much warmer spindle than a machine that runs at a
lower RPM. New spindles tend to run much warmer than spindles that have already been run-in. In order to run
a valid test on a new spindle, ensure that it is properly run-in. To run-in a new spindle, run program #O02020 (it
will take approximately 6 hours).

NOTE: This program steps the spindle speed from 300 RPM up to 7500 RPM (or max
RPM) at regular intervals of time, stop the spindle and allow it to cool to room
temperature, then restart it so the temperature can be monitored.

Or use an alternate 2-hour spindle run-in program (#O02021) with the air pressure to the spindle at 30 psi. If
possible run the program overnight by changing M30 to M99 so it can repeat. Adjust spindle speed override
depending on maximum spindle speed of machine: set at 50% for 5K RPM machines, 100% for 7.5K, 8K, and
10K, RPM machines; set at 120% for 12K RPM machines; set at 150% for 15K RPM machines.
If spindle temperature rises above 150°, check for correct amount of lubrication. Over lubrication is a common
source of overheating. Check the oil flow carefully. In addition, ensure that the correct oil is being used, see the
"Maintenance” section of the Operator manual.
Start the procedure over from the beginning. If the temperature rises above 150°F (65°C) a second time, call the
Haas factory.

NOTE: Once the run-in program is complete, reset the air pressure, see the chart
under “Checking Spindle Oil Flow” in the next section to checking spindle
temperature.

T OOLS S TICKING IN S PINDLE T APER (M ILLS )

This problem may occur after loading a cold tool into a hot spindle (a result of thermal expansion of the tool
holder inside the spindle taper). It may also occur due to heavy milling, milling with long tooling, or cuts with
heavy vibration. This also is the result of thermal expansion.
If sticking only occurs during these situations, check the application to ensure proper machining techniques
are used; check the feeds and speeds for the tools and material being used. If a tool is pulled out of the
extractors due to a tool stuck in the taper, the unclamp switch is not adjusted correctly or is bad.

NOTE: In a proper working system the spindle will pop slightly during a tool change.
This popping is normal provided it does not create flex in the double arm or
the need to remove the tool with a flat-head screwdriver or mallet.

• Check the tool condition, verifying the tool taper is ground and not turned. Look for damage to the taper
caused by chips in the taper or rough handling. If the tooling is suspected, try to duplicate the symptoms with
new, or proven good tooling.
• Check the condition of the spindle taper. Look for damage such as deep gouges, caused by chips, damaged
tooling, or tool crashing.

32 Mechanical Service 96-0283 rev C June 2007

 • Duplicate the cutting conditions under which the deflection occurs, then try to release the tool using the tool
release button. If sticking is observed, the deflection is not caused by improper ATC adjustment, but is a
problem in the spindle head on the machine.
• Ensure the spindle is not running too hot (150°F [65°C] or above).
• Check air supply. Max air pressure drop of 10 psi [69 kilopascals] during a tool change is allowed.
• Check draw bar height adjustment (mills).
• Does the tool tip to the spindle gauge line exceed 3.5”? If so, check machining practices.
• Are the correct pull studs being used? Are they pull studs overtorqued?
Tool Holder/Spindle Fretting
Fretting is the result of movement of a tool holder in the spindle. Fretting can leave a wave pattern on the
mating surfaces and will affect the fit and finish of both the tool holder and the spindle.
• If light fretting is present, check the application to ensure proper machining techniques are used; check the
feeds and speeds for the tools and material being used.
• Check pullstuds for dimpling.
• Light fretting and rust may be cleaned from the tool holder with a fine scotchbrite hand pad and solvent. If
scotchbrite is used, clean the tool holder and spindle taper thoroughly after use with an alcohol pad. Apply
a thin coat of light oil to the taper of the tool holder. Grease the pull stud.

SPINDLE L UBRICATION SYSTEM

Lubrication of the spindle bearings is supplied by and air-oil mist. Air is supplied to the machine at all times. An
air valve to supply the lubrication is turned on and off automatically by the control. Oil is supplied from a
lubrication oil tank at the back of the machine. This tank also supplied lubrication oil to the linear guides and
ball-screws of the machine. The oil pump is turned on automatically by the control when the spindle is turning.
Absence of the air supply is detected by the control and if lost, the control will automatically stop the spindle,
stop axes motion, and show an alarm condition. Absence of the oil supply or absence of oil pressure is also
automatically detected by the control and will stop the spindle, stop axes motion, and show an alarm condi-
tion.
It is important to note that lubrication to the spindle is a mist of oil sent very slowly to the spindle. In addition,
the mist is turned off when the spindle is not turning. Thus oil does not build up in the spindle bearings.
Checking Spindle Oil Flow
Disconnect the air/oil line to the spindle at the lube-air panel (30K 30 Taper and 15K GR-Series are discon-
nected at the check valve). Install a short piece of hose into the port on the regulator and place the other end
into a graduated cylinder. Lower spindle air pressure regulator to 0 psi. Program a repetitive machine axis
movement, do not run the spindle and note the amount of oil collected. The program should be allowed to run
for four hours. Reset the spindle air pressure regulator to proper pressure, once completed.

NOTE: Use 5% or 25% rapid for axis movement. Moving axes faster will not change
results.

The following gives the range for each type of spindle:

40 Taper (7.5K and 10K) 1.5 to 2.5 cc every four hours
Set spindle air pressure regulator to 17 psi
15K 40 Taper / 12K 1.1 to 1.4 cc every four hours* For GR-Series machines see below.
Set spindle air pressure regulator to 20 psi
50 Taper 1.7 to 2.1 cc every 4 hours
Set spindle air pressure regulator to 17 psi

96-0283 rev C June 2007 Mechanical Service 33

 30K 30 Taper* *Airmatic Pumps (These pumps are identified by the addition of a solenoid on
top of the pump) The 30K 30 taper and the GR series 15K or higher spindle
use this type of pump.
Set spindle air pressure regulator to 25 psi for 30K spindles and 20 psi for 15K.
Lathes 1.0 cc every two hours for the lathe.
*Airmatic Pumps
Disconnect the air/oil line at the check valve. Manually energize the solenoid 30 times, holding it for 2 seconds
each time.
Each pulse from the pump will deliver .01 cc for the 30K 30-taper, or .2cc for the GR 15K. After 30 pulses, .3 cc
30K or 6cc 15K, should have been collected per injector (the 30K spindle has two injectors).

34 Mechanical Service 96-0283 rev C June 2007

 SPINDLE ASSEMBLY
Please read this section in its entirety before attempting to replace spindle.
WARNING!
The pulley is shrink-fitted to the spindle and is not field-ser-
viceable. Any attempt to remove the pulley can damage the
spindle or its components, the service warranty will be voided.

NOTE: Adjust drive belt tension after transmission or spindle service.

S PINDLE R EPLACEMENT (H ORIZ & V ERT )

NOTE: Vertical mills equipped with a 15K Spindle must remove the spindle and draw
bar as a unit. Do not remove the draw bar separately.
Removal
1. Ensure the machine is OFF, and remove the spindle head cover/panels.
2. Put the tool into the spindle and remove any covers necessary to access the spindle.
3. Remove the tool release piston assembly in accordance with appropriate section and remove the spindle
drive belt from the spindle pulley. It is not possible to completely remove the belt at this time.
4. Draw bars are held in the spindle shaft by a spiral ring (newer assemblies). 30K spindles: The draw bar is
not serviceable. Remove the spiral ring with a small screwdriver. Wedge the tip of the screwdriver to take
out one end of the ring from the shaft groove. Force the ring end to stay open and simultaneously rotate the
screwdriver all the way around so the entire ring comes out of the groove.
5. Put the tool release piston on and remove the tool. First disconnect the oil line from the fitting at the oil
injection cover, then remove the brass fitting.

NOTE: When replacing a new design spindle in any vertical machine, it is important
to note that the cavity between the housing and the spindle cartridge will be
filled with either oil or grease. An oil filled spindle is identified by the oil fill hole
to the left side of the spindle head near the spindle bore as viewed from above.

6. Ensure oil plug is inserted into oil injection port of spindle before removing spindle, or oil may spill into the
spindle cartridge. The plug should fit flush with the spindle sides, if not use tape to cover the hole.
7. In-line drive and 30K spindles: Remove the hose & oil fitting on the spindle and plug the oil-fitting hole(s)
with the set screws from the new spindle.
8. Remove the spindle drive belt from the spindle pulley.
9. With 5/16" hex wrench, loosen the six SHCS that hold the spindle to the underside of the head casting
approximately 2 turns.

Z-Axis

Wood Block

Covered
6" Table
mi
n.

Position Wood Block Under Spindle

96-0283 rev C June 2007 Mechanical Service 35

 10. Vert: Put a wood block (minimum 6" thick) on the table directly under the spindle to help support the
spindle. Slowly jog the spindle head down until the spindle rests on the block.
12. Remove the 6 bolts from the spindle.
13. Vert: Jog the Z-axis up slowlyuntil it is completely free of the casting.
Horiz: Slide the spindle out of the casting.
In-line drive: Remove spider coupling and transfer tube from the spindle or motor. Check these two
components for any irregularities, and replace if needed.
Installation
Tool Drawbar Tool Drawbar
Front
Spindle
Pulley Spindle
Spindle Pulley Spindle
Housing Housing

10 - 32
Holes

30K Spindle Cartridge Vertical Spindle Cartridge Underside View of Vertical Spindle Cartridge

In-line drive: Loosen the motor mounting plate bolts (4 bolts), and loosen the motor mounting bolts under
the plate (4 bolts).
1. Thoroughly clean all mating surfaces of both the cartridge and the head casting, and lightly stone (if
necessary) to remove burrs or high spots.
2. Mount the new spindle to the block. HORIZ only: Carefully install the new spindle into the bored sleeve of
the head casting. Apply grease to the inside of the through bore in the spindle head. The oil drain hole
must point down. Failure to do so causes the spindle to overheat, fail, and voids the warranty.

6X SHCS
6X Lockwasher EC-300
Spindle Head
Assembly

Spindle
Assembly

EC-400
Spindle Head 1/4” Tube X Spindle must be installed
Assembly 1/8” NPT with oil drain notch in
spindle lock at the bottom
1/4” Tube X 1/8” NPT

HORIZ only: Evenly tighten the six mounting SHCS on the front side of the spindle in a cross pattern
until all bolts are completely tight.
HORIZ only: Reset spindle orientation and check the tool changer adjustment.
HORIZ only: Refer to "Spindle Troubleshooting - Overheating" and use the spindle run-in program. Verify
that the spindle temperatures are acceptable.
3. Align the two 10-32 holes located on the spindle lock so they are approximately 90° from the front of the
spindle on the right side.
In-line drive: Install set screw plug into the oil fitting. This will prevent contamination to the bearings. Put
grease on the O-ring of the transfer tube and install the transfer tube on the new spindle. Install the spider
coupling on spindle. Orient the motor and spindle couplers.

36 Mechanical Service 96-0283 rev C June 2007

 4. Slowly jog the Z-axis down until the top portion of the spindle is inside the head casting. At this point, align
spindle to the spindle bore. While performing this operation, you must make sure the spindle cartridge is
straight to the spindle bore. If the spindle moves to one side, use a rubber mallet and/or the axes to align
it. The spindle should slide into the casting easily. If not, check your alignment. Do not force it!
5. Install the spindle bolts and torque to 50 ft-lb.
6. Vert: Re-attach the brass fitting to the oil injection cover and connect the oil line to the fitting. Fill the cavity
between the housing and the spindle cartridge with Mobil Vactra 2 oil. The oil fill hole is to the left side of
the spindle head near the spindle bore, as viewed from the top.

30K Spindle Quick Disconnect Fittings to Oil Injection Cover

CAUTION! Do not overtighten the fittings on the oil injection cover.

Overtightening may damage the spindle cartridge.

NOTE: If replacing copper tubing to spindle, clean out with filtered air.
7. In-line drive: Take the spindle sweep on the table and shim if needed. Loosen the spindle bolts again just
for spindle and motor alignment. Remove set screw plug, install oil fitting, and connect the hose. Do not
overtighten fittings.
8. In-line drive: Command the spindle to 300 RPM. Carefully tighten the motor bolts, and the motor mount-
ing bolt under the motor plate (80 ft-lb). Tighten the spindle bolts evenly to 50 ft-lb. Stop spindle and check
by hand for binding. If there is no binding, refill spindle orifice with Vactra Oil #2.
WARNING:
Never pour oil into the spindle housing. If binding is felt, loosen
the motor mount bolts and go back to step 7.
9. Vert: Reinstall the drive belt and adjust the tension. Reinstall the tool release piston assembly.
10. Vert: Remove the tool release piston. Carefully install the spiral ring on the spindle shaft. Feed one end of
the spiral ring into the shaft groove. Rotate the ring until the entire ring is in the groove. Check the spindle
sweep and clamp/unclamp switch adjustment.
11. In-line drive: Verify the spindle air/oil regulator is set to 20 psi.
12. In MDI, write a program to move the machine axis at 5 inches per minute.
13. a. In-line drive: Disconnect the oil fitting from the air/oil mixer that feeds directly to the spindle. Use a
graduated cylinder to verify the correct amount of oil is getting to the spindle (1.1 cc to 1.4 cc per 4 hours). If
necessary, change restrictors to change oil flow. Do not adjust oil pump volume. If any changes are made,
run the test again.

96-0283 rev C June 2007 Mechanical Service 37

 b. Vert: Check for correct amount of lubrication to the spindle bearings (0.5-1.0 cc every two hours) in an air
mist-lubricated spindle.
• If the spindle is not getting lubrication, correct the problem and replace the spindle.
• If the spindle is getting lubrication, replace the spindle.

NOTE: Refer to the appropriate sections and check the spindle orientation and ATC
alignment.

14. In-line drive: Check draw bar and adjust the tool clamp/unclamp limit switches.

EC-630 G EARED H EAD R EPLACEMENT

1. Remove pallet from the load station. Workholding can remain on this pallet. Install the geared head service
fixture and pallet to the load station.
2. Use a crane or forklift to lift the pallet and fixture assembly into the pallet load station and lower into posi-
tion. Orient the slide assembly so that it is parallel to the pallet changer door (Perpendicular to the spindle
centerline).
3. Command a pallet change to bring the service fixture into the machine.
4. Remove the screws holding the lower waycover to the spindle head. Disconnect the coolant lines and
fittings. Remove the coolant ring from the spindle. Disconnect the P-Cool control and coolant lines, but leave
the unit attached to the sheetmetal.
5. The upper waycover is held to the spindle head cover with clips behind the waycover. Remove these clips, lift
the waycover and support with a 2" X 4" piece of wood to allow removal of the spindle cover screws. Remove
the spindle cover.
6. Jog the Y-axis to the top of its travel and secure with a 4" X 4" wooden beam of suitable length. If necessary,
lower the Y-axis enough to allow the spindle head to rest on the block. This is to prevent the spindle from falling
if the brake fails while power is off.
7. Power off the machine and lock out the circuit breaker.

8. At the rear of the spindle assembly, remove the tail bracket and disconnect all lines (electrical, air, lubricant,
coolant) that run from the tail bracket to the spindle assembly. Label cables and lines if necessary for
reconnection to the new spindle. Plug the 3/4" air line. Put an insulating cover on each motor head.
9. On the I/O board inside the control cabinet, remove the connector on P3 and replace with a tool changer
jumper (33-8521). Remove the connector on P15 and replace with a spindle status jumper (33-8668A). install
an encoder jumper, TRP unclamp jumper, motor overheat jumper, and disable GB in parameter 209. This will
allow axis motion while the spindle is disconnected.

38 Mechanical Service 96-0283 rev C June 2007

 10. Power the machine back on and clear any alarms. Remove the wood blocking the Y-axis and jog down until
even with the spindle removal bracket.
11. Jog the Z-axis toward the spindle to give the slide fixture sufficient clearance to rotate and jog the A-axis to
-90 degrees.

12. Jog the Z-axis to bring the slide fixture up to the geared head. Slide the spindle removal bracket against the
geared head casting and lock in place with the T-pin. Jog the Z- and Y- axes to align the bolt holes on the
geared head module and the bracket. Use the four 1/2-13 x 2” bolts supplied to secure the bracket to the
spindle. Remove the six bolts through the notches in the bracket. Remove the T-pin and slide the spindle back.
Remove any shims and note their locations. Note: Wires have very little clearance. Move the geared head out
slowly and push wires into a safe position.

13. Slide the geared head back to the extent of the slide fixture's travel and lock with the T-pin. Jog the Z-axis
back far enough to zero the A-axis, then zero the Z-axis.
14. Command a pallet change to bring the geared head to the pallet load station. Remove the T-pin and slide
the geared head to the left for easier access to install the lifting bracket. Attach the lifting bracket to the geared
head bracket with the lift arm pointed toward the rear of the spindle. Secure the bracket with slide pins and
cotter pins. Slide the geared head back and lock with the T-pin.
15. Remove the four bolts holding the geared head bracket to the fixture slide. Using a crane or forklift, carefully
lift the geared head out of the pallet load station. Set the geared head down on the pallet that the service fixture
was shipped in, and secure the geared head to the pallet using four 1/2-13 x 1” bolts. Remove the lifting
bracket.

96-0283 rev C June 2007 Mechanical Service 39

 16. While the new geared head is out of the machine, install the TSC union. Remove the screws holding the
geared head connector bracket. This will simplify installation of the tail bracket when the geared head is
installed. Leave the bracket at the rear of the assembly. Do not disconnect any cables at the bracket.
17. Attach the lifting bracket to the new geared head. Lift the assembly into the pallet load station, orienting the
geared head to the right. Secure the bracket to the slide with four bolts and make sure the T-pin is locked.
Remove the lifting bracket.
18. Command a pallet change. Jog the Z-axis forward for sufficient clearance and jog the A-axis to -90 degrees.
Jog the Z-axis toward the machine column. Remove the T-pin and slide the geared head into the column,
jogging the axes as necessary to align the geared head bolt holes and square the geared head to the column.

NOTE: Take care to ensure the spindle is square with the column, especially if the
machine was involved in a crash. Do not attempt to use the bolts to square the
spindle; this will lead to stripped bolts and holes. Use only the axes to square
the spindle.

19. Once the geared head is square against the column, install bolts through the notches in the geared head
bracket. Clean the shims and place where noted previously, then tighten the mounting bolts. Remove the bolts
holding the bracket to the geared head.
20. Jog the Y-axis to the top of its travel, block the axis with the 4" X 4" beam and power off the machine.
Reinstall the tail bracket. Reconnect geared head electrical cables, control cables and coolant lines. Remove
the jumpers from the I/O control board and replace the appropriate cable connectors. Power on the machine.

21. Perform a spindle sweep using a precision test bar and a .0005" indicator. Shim geared head if necessary.
22. Reinstall sheetmetal spindle cover, waycovers, coolant fittings and coolant lines at the front of the spindle.
23. Command a pallet change and remove the pallet and service fixture slide assembly through the pallet load
station door. Place the fixture on the pallet that the new geared head shipped in, and secure with four bolts.

S ETTING THE D RAW B AR HEIGHT

Draw bar height must be set properly before adjusting switches. Add or subtract shim washers to the tool
release piston until proper height is achieved (see “Setting TRP Height”).
Vertical Machines
1. Power on the mill and set the TRP air pressure regulator to 40 psi.
2. Vert: Place a sheet of paper on the mill table under the spindle for protection, then place an aluminum
block (approx. 4” x 4” x 4”) on the paper. Horiz: Set up a fixture with a loosey clanped block on the pallet.
3. Insert an empty tool holder in to the spindle.

40 Mechanical Service 96-0283 rev C June 2007

 4. Jog the spindle so that the tool holder is approximately .03” from the block.
5. Set the clearance from the block to the tool holder to zero. Do this by pressing “Tool Release” and jogging
the Z-axis with the jog speed set to .001". Move the axis, then press the Tool Release button while feeling
for movement on the tool holder. Feel between the tool holder and the spindle. Repeat this process until no
movement is felt.
6. Change the jog speed to .01 and jog the Z-axis to .060" from the block.
7. Press and hold the Tool Release button. Try to move the block. The block should be tight at .050" and
loose at .060". If it can be moved at .050", jog the Z-axis towards the block one increment at a time until it
is tight. If it is tight at .060", jog the Z-axis away one increment at a time until it is loose.
8. The number of increments jogged are the number of shims to add or remove. If the block was tight at .060",
remove shim washers. If the block was loose at .050", add shim washers. See the “TRP Switch Adjust-
ment” section.
TRP Unclamp Switch
Use the same set-up as the previous instructions.
1. Using an empty tool holder in the spindle, and the jog speed set to .001”, jog the Z-axis until it has pinched
the aluminum block against the table or fixture, then jog away up .030”.
2. Bolts holding the lower switch must be loose so the switch can move for proper adjustment.
3. Go to the Discrete Inputs page on the control and find the input, “Draw Bar Open”.
4. Press and hold the Tool Release button. Slide the switch towards the piston until the switch trips. The
input “Draw Bar Open” should read “1”. Tighten the screws that secure the switch.
5. Release the Tool Release button and verify that the switch trips (Draw Bar Open = 1) at .030" from the
block and not tripped (Draw Bar Open = 0) at .020" from the block.
TRP Clamp Switch
Loosen the mounting screws and push the switch in slowly until it trips (Draw Bar Closed = 1). Tighten the
bolts to secure the switch.
Set TRP air pressure regulator to 50 psi after the TRP drawbar height and switches have been set. Perform a
spindle run-in before machining.

RUN-IN PROGRAMS
Perform the Spindle Run-in Program: Run program O02023. As the spindle is running, check for proper oil flow.
Periodically check the temperature of the spindle. Stop the program if the spindle begins to overheat.

CAUTION! 30K only: Never run the spindle without a tool holder in the spindle. Running
the spindle without a tool holder will damage the spindle.

Belt Driven Spindles: The belt may whip during acceleration and deceleration but should not when a constant
speed has been reached. Check the behavior of the belt at different speeds, throughout the RPM range. If the
belt whips while at a constant RPM, adjust the belt tension.

Office Mill Spindle Run-in

NSK Spindle: The spindle run-in program must be run prior to machine use and especially at the time of
installation. Failure to run this program can result in spindle over heating and spindle failure. The run-in will
distribute grease which may have settled in the bearings during shipping. The program is #O02027 (SPINDLE
RUN-IN) and will take approximately fifty (50) minutes to run. During this time, verify spindle rotation. The
spindle should be checked periodically for spindle temperature rise. If the temperature rises above 140°F,
restart the program from the beginning. If the temperature again rises above 140°F, contact your dealer.

96-0283 rev C June 2007 Mechanical Service 41

 NOTE: Do not tighten the collet without mounting a tool or “dummy bar” as this will
damage the collet, spindle, and collet nut.

40K, ISO20 Spindle: The spindle run-in program must be run prior to any machining use (especially upon
installation or after any transportation). Failure to run this program can result in spindle over heating and
spindle failure. The run-in will distribute grease which may have settled in the bearings during shipping. The
program is #O02025 (SPINDLE RUN-IN) and will take approximately six (6) hours to run. During this time, verify
spindle rotation.

IMPORTANT: A balanced ISO20 toolholder must be in the spindle during run-in and/
or warm-up.

DRAW B AR R EPLACEMENT
Removal
In-Line spindles: Should a spindle fail, both the spindle and draw bar are to be replaced as a unit. If the draw
bar fails, it is not necessary to replace the spindle. However, the draw bar is replaceable on the 8K spindle, not
on the 12K spindle.

NOTE: 15K Spindles: The spindle and draw bar must be removed as a unit. Do not
remove the draw bar separately.

1. Place an empty tool holder in the spindle.

In-line: Remove motor.
2. Remove the necessary covers to access the spindle.
3. Remove the TRP. In-line: Remove the key from the draw bar and remove from spindle.
4. Remove the snap ring from the top of the spindle shaft.
50 taper: Remove the TSC extension tube if the machine is equipped with the TSC option. Refer to the
“Spindle TRP Removal” section.
5. Reinstall the TRP. Remove the tool holder from the spindle, then remove the TRP again.
50 taper: Remove six bolts holding the spindle cap to the machine and remove the draw bar.
40 taper: Remove bolts from the transmission and use 2” x 4” blocks of wood, placed underneath the front
of the transmission housing, to keep it from falling forward. Angle the transmission back and remove the
draw bar from the spindle.
NOTE: Direct drive machines do not require movement of the drive assembly to
access/remove the draw bar.

Installation
6. Thoroughly coat the replacement draw bar with grease, including the end of the shaft where the four holding
balls are located.

CAUTION! Excess grease may cause the draw bar to hydraulic lock preventing the full
stroke of the draw bar.

7. Install the two keys, flat side up. Use a “C” clamp to press the keys together to seat them against the draw
bar. Torque the 5/16-18 retaining bolts to 30 ft-lb.

42 Mechanical Service 96-0283 rev C June 2007

 Transfer Tube
Coupler Spider
Coupler Hub

Draw
Bar

Shaft

Shaft Adapter
Horizontal Draw Bar

8. If machine is equipped with Through the Spindle Coolant option, grease the O-rings.
9. Insert four new balls (six new balls for 50 taper) in the replacement draw bar and insert into the spindle
shaft. Be sure that as the shaft is installed, the balls do not fall out of the bores in the draw bar.

CAUTION! Insert draw bar so the O-rings are not damaged. Do not force it.

NOTE: Carefully inspect the spindle shaft for galling or burrs inside the spindle shaft
where the end of the draw bar rides. If it is damaged, replace the spindle.

10. 40 Taper: The tool release piston will have to be reinstalled at this time; therefore, install a tool holder with
no cutter into the spindle taper. Remove the tool release piston and install the spiral ring on the spindle
shaft. Reinstall the tool release piston.
11. Set the draw bar height, and clamp/unclamp switches as described in the following section. Install the
draw bar and re-install the tool release piston.
12. Reinstall the sheetmetal.
13. Test-run the machine and perform necessary tool changer adjustments. Verify the operation of the spindle
by running it. Run through the spindle speed range, pausing at each 1000 rpm increment. If there is
excessive vibration, loosen the bolts to the spindle cartridge and spindle head. Run the spindle at 1000
RPM and snug the bolts. Stop spindle and tighten bolts.

MILL SPINDLE S WEEP ADJUSTMENT

Vertical Mills
NOTE: The machine must be properly leveled for the spindle sweep adjustment to be
accurate; no more than .0002” twist on the Y-axis (vert mill).

1. To check spindle sweep, place a .0005” indicator on a suitable holder, place on spindle nose and jog the Z-
axis in the negative (-) direction enough so that you can adjust the indicator to sweep a 5" radius from the
center of X- and Y-axis travel. Slowly jog Z-axis in the negative (-) direction to zero out indicator.
2. Establish a reference point (indicator zero), sweep the three remaining points and record the reading.

96-0283 rev C June 2007 Mechanical Service 43

 10" dia.
circle

Spindle Sweep Area

3. Shim the spindle, if necessary, to correct the spindle sweep to specifications.

4. Recheck sweep. It must be within .0005” in both X/Z and Y/Z planes, as stated in the inspection report
supplied with the mill.
Horizontal Mills
NOTE: The machine must be properly leveled for the spindle sweep adjustment to be
accurate.

1. Place an indicator on the table and insert a 6" precision test bar into the spindle.
2. Jog the Z-axis while indicating the bottom, then the side, of the test bar. The readings must be within
0.0005”/10" in both the Y/Z and X/Z planes, as stated in the inspection report supplied with the machine.
3. Shim the spindle, if necessary, to correct the spindle sweep to specifications. Recheck spindle sweep.

44 Mechanical Service 96-0283 rev C June 2007

 SPINDLE ORIENTATION
Please read this section in its entirety before attempting to orient the spindle.
Orientation of the spindle is automatically performed for tool changes and can be programmed with M19.
1. Place the machine in low gear.
2. Adjust Parameter 257, "Spindl Orient Ofset", until the spindle dogs are parallel to the X-axis. Ensure that the
dogs are within 0.030" using a dial indicator.
For 50 taper mills with an offset tool changer: Add a 5° offset (111 encoder steps) to Parameter 257 to
match the tool changer arm offset.

A, B A XIS RE -ALIGNMENT (V ERT )

Gimbaled head mills only - If tramming the A or B axis is necessary, sweep a 10” diameter circle on the
table with a dial indicator mounted to the spindle. To select A or B axis when in the jog mode, use the shift key
on the keyboard, then select A or B axis. The display will indicate which axis is enabled. It is recommended
that when jogging the A and B axes, the operator use only the .0001, .0010, or .0100 increments.
The rule of thumb is that for every .001” out of position, add or subtract 100 from the appropriate parameter.
This will re-calibrate the distance from the A/B axes home switch. Parameters 212 and 213 are the tool change
offset parameters for the A and B-axis. These parameters also control the tram of the A and B-axis. Record the
factory set values before changing parameters 212 and 213 in the event that an invalid number is entered.
When adjusting the tram, it is recommended that the same feedrate to home the A or B axis between checking
the sweeps, this will allow the machine to repeat accurately. The A and B-axis should be trammed individually
to reduce the possibility of error.

96-0283 rev C June 2007 Mechanical Service 45

 LATHE SPINDLE ASSEMBLY

LATHE S PINDLE R EMOVAL

NOTE: Power off the machine before performing the following procedure.

Mini Lathe (ML): Remove the door, the coolant collector from the spindle, and the left front and left side
enclosure panels. Disconnect the air/oil lube lines that supply the spindle and the air closer.

Note: Ensure the turret and tailstock, if equipped, are in the home position.

1. Remove the chuck or collet nose from the lathe and the necessary covers to gain access to the spindle
assembly. ML: Remove the work holding device, air closer, adapter, and drawtube (by screwing it out).
Toolroom Lathe (TL): Remove sheetmetal panel from the left side of the machine casting. This will gain
access to the spindle motor and belt.
TL: 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.
ML: Remove the belt from the drive pulley. Attach a hydraulic puller to the drive sprocket.
TL and ML: Remove the SHCS that secure the spindle front cap to the spindle housing and remove the
spindle cartridge from the motor end of the spindle housing.
2. Disconnect oil return hose and coolant drain hose from the hydraulic cylinder.
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.

Adapter
Hydraulic cylinder

Clamp/Unclamp
hoses

Coolant
collector

Coolant
drain hose

Oil return hose

Hydraulic Cylinder
6. 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.
7. Unplug the encoder. Unscrew the encoder bracket, remove the encoder, then remove the belt.
8. Loosen the six SHCS and remove the spindle drive pulley.

46 Mechanical Service 96-0283 rev C June 2007

 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 SHCS holding the spindle retaining ring (located at spindle nose) and remove. Also remove O-ring.
11. Remove the spindle carefully through the machine front.

Adapter

Clamp/Unclamp
Hoses

SL-10 Hydraulic Cylinder (Coolant Collector not Shown)

SPINDLE INSTALLATION
Tools Required: Blue Loctite, 1/2" Torque Wrench (Up to 250 ft-lb), Haas Belt Tensioning Tool P/N 93-8143
(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. Also verify the axial
run-out on the face of the bearing, which should not exceed .0004".

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.

96-0283 rev C June 2007 Mechanical Service 47

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

Housing Align Oil Holes (2)

Spindle retainer
bolts (6) Spindle

Drawtube

Oil Nozzles (2) to 10 psi

Spindle Retaining Bolts Alignment of Oil Mist Holes

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 stop. Then un-screw the nozzles 1.5 - 2 turns, ensuring
that the holes on the nozzles and spindle housing are aligned correctly and pointed toward the bearings.
Make sure the nozzles do not come into contact with the spindle shaft.
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, and set the oil pressure to 10 psi..
8. Attach the two 1/4" nylon tubes onto the swivel fittings.
9. Install the spindle drive pulley, and drive belts onto the spindle and motor pulleys.
See “Verifying Belt Tension (lathe)” to complete this procedure.

T OOL R OOM LATHE 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.

48 Mechanical Service 96-0283 rev C June 2007

 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 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, and torque the SHCS to 70 ft-lb. 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 in place. Install the drive belt, and
check for correct tension. Tighten the three SHCS on the motor mount plate.
3. Reconnect the electrical connections on the motor, and install the sheet metal motor cover.

96-0283 rev C June 2007 Mechanical Service 49

 S PINDLE H EAD ALIGNMENT
TOOLS REQUIRED: Dual Indicator Stand
Depending on lathe model, the following sheet metal pieces may need to be removed: Front left panel, front
bottom panel, drain rail, front door
1. Loosen all spindle head mounting bolts. Loosen the locknuts on the two jack screws (adjustment bolts)
underneath the spindle head casting, then screw them in to lower the spindle casting.
2. Bolt spindle alignment bar tool to spindle and attach a 0.0001" indicator onto the face of the turret. Jog
indicator such that the indicator runs tangent to alignment bar along the Z-axis.
3. 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".

Spindle housing

Adjustment
bolts (2)

Adjustment Bolts Indicator Setup

4. 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 face to maintain the spindle head level (see
figure). This setup is to ensure the spindle remains parallel in the Z-axis plane while raising the spindle
head. 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.

NOTE: If the face of the spindle head casting is not machined, 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. Two indicators are then positioned
on the machined surface beneath the spindle head casting.

5. Place the tenths indicator at the end of the spindle alignment bar and jog the tool turret in the Z- axis
towards the spindle until the indicator rest on the inside of the tool pocket.
6. 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 “Turrets - Turret Alignment Verification” section).
Note that the tool holder alignment pins create a bump in the pocket that should be ignored.
7. 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

8. 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.
9. Rotate the spindle 180o and adjust the jackscrews until the indicator reads within a .001" at the top and
bottom of pocket. Repeat Steps 6 and 7, to ensure the X-axis is zeroed for each adjustment in the vertical
direction.

50 Mechanical Service 96-0283 rev C June 2007

 10. Torque the spindle head mounting bolts to 500 ft-lb so as not to change the spindle’s position.
11. Once the pocket is zero, X-axis value on the screen becomes the new machine spindle centerline. 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.

12. Repeat Step 2 to ensure that the shaft has remained horizontal. If the shaft has moved, return to Step 9
and recheck the pocket position.
13. Test the other pockets in the same way as pocket #1 (Step 9) without moving the X-axis position. The
tolerances for the other pockets are 0.003 inch from the centerline.
14. Reinstall the sheet metal pieces that were removed for this process.

SL-10 AND GT-S ERIES 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 eight SHCS mounting bolts for the spindle head. Back out the two set-screws on the front side,
lower edge of the spindle head.
3. Attach a 0.0001” dial indicator to the turret. Jog the X- and Z-axes to position the dial indicator on the side
of the alignment bar.
4. Sweep down the length of the alignment bar to measure the spindle head parallelism with the Z-axis.
5. 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”.
6. 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.

7. Attach a 0.0001” dial indicator into the end of the alignment bar.
8. Install a boring bar tool holder into tool position #1. Ensure 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.
9. Jog the X-axis down to the original spindle centerline.
10. 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.

96-0283 rev C June 2007 Mechanical Service 51

 11. Adjust the position of the spindle head by carefully screwing in the set-screws, if the tool pocket is low. Or
loosen the set screws and push the head stock towards the back of the machine if the pocket is high.
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.
12. Once the runout is less than 0.002” TIR, verify that the spindle head parallelism to the Z-axis is within
0.0004”/10”. Evenly torque the spindle head bolts to 300 ft-lb and ensure that all SSS in the spindle head
casting are bottomed out on the dowel pins.

52 Mechanical Service 96-0283 rev C June 2007

 G EARBOX , TRANSMISSION, AND SPINDLE MOTOR
Transmission Oil Lubrication System
All of the Haas mills with a transmission use a pumped oil system to lubricate the gears of the transmission.
There is a sump below the transmission and a motor and pump above the transmission.
Power to the motor is turned on and off automatically by the control when spindle rotation is commanded.
There is a pressure sense switch in the oil lines that detects the pressure of the pump. If pressure is not
detected, the control will automatically turn off the spindle, stop axes motion, and show an alarm condition.

Spindle Motor Cooling System

There is a fan supplying forced-air cooling of the spindle motor. It is mounted directly above the motor and
ducting directs the airflow over the cooling fins of the motor.
Power to the spindle motor fan is turned on automatically when the spindle is turning. There is an over-tempera-
ture detecting switch mounted in the motor. The control monitors the over-temperature switch and will respond
to an over-temperature condition by stopping the spindle, stop axes motion, and showing an alarm.

Gearbox (Mill)
There is a double solenoid valve controlling air to the gear box. This solenoid sends air to select either the high
gear or the low gear. When power is removed from the solenoids, the valve remains in its last state. Air is
always required to ensure the gears are held in either high or low gear. Circuit breaker CB4 will interrupt power
to these solenoids. Power is left on the solenoid which is commanded last.
Two gear box switches are used to sense the position of the gears. One switch indicates High by opening and
the other indicates Low by opening. Between gears, both switches are closed indicating a between-gear
condition. The diagnostic display shows the switch status and the Curnt Comds display shows which gear is
selected. If the switches indicate the gear box is between gears, the display will indicate “No Gear”.

NOTE: The transmission high/low gear position switches are located at the bottom
of the gearbox assembly, facing the spindle and are difficult to reach. Removal
of this assembly is necessary to replace these switches.

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.
The gearbox cannot be serviced in the field and must be replaced as a unit.

Transmission (Lathe)
The Lathe 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 air solenoid drives the gearbox shifter into
high or low gear. 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.
High gear and low gear are selected by programming an M41 (Low Gear) or M42 (High Gear). The transmis-
sion will not change automatically. The spindle will come to a complete stop when changing gears.

TROUBLESHOOTING
Noise
Gearboxes can be damaged by gearshift cylinders, or bearings, resulting in noisy operation. While gearbox
vibration can cause a poor finish on a workpiece, noisy gearbox operation may not.

96-0283 rev C June 2007 Mechanical Service 53

 Excessive or unusual noise coming from the gearbox, transmission, and/or spindle motor.
Operate the machine in both high and low gears. Monitor for noise in both gear positions, and if the pitch of the
noise varies with the motor or the 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 gearbox or transmission, and it must be replaced.
• If the noise occurs in both gear positions, disconnect the drive belt(s) and repeat the previous step. If the
noise persists, the gearbox or transmission is damaged and must be replaced.
• With the drive belt(s) disconnected, run the machine in high gear. Command a change of direction and listen
for a banging noise in the gearbox or transmission as the machine slows to zero RPM and speeds back up in
reverse. If noise occurs, the motor has failed and the gearbox or transmission must be replaced.

Gears Will Not Change

Machine will not execute a gear change.
NOTE: An alarm will display when a gear change problem occurs, an alarm will also
occur. Refer to ALARMS section of te Electrical Components manual to
diagnose each problem before working on the machine.

When a gear change is performed, the following sequence of events occurs:

If the spindle is turning, it is commanded to stop, pauses until spindle is stopped, gear change spindle speed
is commanded forward, pauses until spindle is at speed, commanded high or low gear solenoid active, pauses
until in new gear or reversal time, alarms and stops if max. gear change time elapsed, if not in new gear,
reverses spindle direction, and turns off high and low gear solenoids
• If pressure is too low, the gears will not change - Check air supply pressure. In addition, disconnect the air
lines from the solenoid and blow compressed air through the air lines to ensure the lines are not clogged.
• Check the air solenoid assembly on the solenoid bracket (rear of gearbox). If the solenoid and limit switches
operate properly, the problem lies with the gear change piston; replace the gearbox.
• Check contactor CB4.
• Lathe/50T Vert: 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.
Low Pressure Alarm (Mill)
Alarm 179 (Low Pressure Transmission Oil) has been triggered.
• Check for low oil supply in reservoir. The gearbox is lubricated and cooled with oil. It uses an oil sump and is
cooled by gear oil.
• Check to see that pump motor is running.
• Check for an air leak in the suction side of the pump.
• Check for a bad pressure sensor.
• Check for a broken or damaged cable.
• Check for a worn pump head.

54 Mechanical Service 96-0283 rev C June 2007

 Incorrect Gear Selected or Sensed (Lathe)
Spindle speed is not consistent with selected gear
Monitor discrete inputs and outputs SP Hig and SP Low on the diagnostics display while commanding 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.

S PINDLE M OTOR & T RANSMISSION (M ILLS)

Please read this section in its entirety before attempting to remove/replace a transmission.
NOTE: The drive belt tension should be adjusted after every service on the transmis-
sion or spindle.

Motor Removal
1. Vert: Ensure the mill is on. You will need to move the head stock to remove the transmission. Raise the Z-
axis to the full up position.
2. a. Vert: Remove the cover panels from head stock area ("Head Covers Removal and Installation" section).
b. Horiz: Remove the rear enclosure panel.
3. a. Vert: Remove the tool release piston assembly ("Tool Release Piston Assembly" section).
b. Horiz: Disconnect the electrical cable to the fan.
4. Press the Power Off button on the control panel and turn the main breaker off. If there is an external
breaker box, turn it off and lock it out.
5. a. Vert: Disconnect the air supply and remove the electrical and pneumatic lines from the solenoid bracket
on top of the spindle motor assembly. Mark any connections that have not been previously labeled for
reassembly.
b. Horiz: At the rear of the spindle and motor shroud, remove the four (4) SHCS that hold the fan mounting
bracket in place. Disconnect the air supply and remove the electrical and pneumatic connections from the
solenoid valve assembly.

4X SHCS
Spindle Motor
Assembly

4X SHCS Encoder
Mounting
Bracket

Spindle
Encoder

4X SHCS

EC-400: Remove the motor shroud, which is held on with four (4) BHCS. Disconnect the encoder cable,
spindle air blast, and TSC coolant union, if equipped.

96-0283 rev C June 2007 Mechanical Service 55

 4X BHCS Cable Carrier Assembly
6X Hex Nut
6X Lockwasher

Fan Mounting
Bracket
8X BHCS 4X
SHCS
EC-300
Motor Shroud
Fan
EC-400 Motor 2X Two Washers
Shroud as Spacer Fan Guard 4X Lockwashers

EC-300: Remove the Y-axis cable carrier and bracket. Loosen the X-axis cable carrier and position it away
from the back of the spindle casting.
6. Vert: Remove the two SHCS holding the cable carrier to the solenoid bracket and position the cable carrier
so as to not interfere with removal of the motor. It may be necessary to tie the cable carrier back to the Z-
axis motor to keep it in place.
7. Vert: If machine is equipped with Through the Spindle Coolant option, remove the pressure regulator and
bracket from the old transmission and install them on the new transmission.

Lifting Points

SP
IND
STA
WIT TULE LO
HO S SWCK
UT ED
GE ITCH
AR
BO
X

TO
ST OL
AT CL
US AM
SW PE
ITCD
H

LO
JUSTATW
MP USGE
ER SWAR
GE
ARWITHITC
BO OUH
X T

STHIGH
AT
USGE
SWAR
IT
CH

Direct Drive with Lifting Eyeholes

8. a. Vert: Remove the four SHCS and carefully lift the spindle motor assembly off the spindle head. Take
care to not damage the drive pulley during removal.

NOTE: For this operation, the Haas Transmission Hoist is recommended.

b. Horiz: Remove the four (4) bolts that mount the spindle motor assembly to the column and remove the
spindle motor assembly.
Direct Drive Installation
1. Carefully lower the motor assembly down to just above the spindle head casting, taking care not to dam-
age the drive pulley or pinch the drive belt.
2. Place the drive belt on the motor's drive pulley and lower the motor down onto the spindle head casting.
3. Insert and tighten down the four SHCS attaching the motor to the spindle head casting. Adjust the drive
belt as noted in "Belt Replacement and Tensioning" before tightening down completely.
4. Refer to the appropriate section and set the spindle orientation. Check for proper orientation of the machine
and be aware of any unusual noises or vibration that may occur because of incorrect belt tension.

56 Mechanical Service 96-0283 rev C June 2007

 5. Reattach the cable carrier to the solenoid bracket and reconnect all electrical and fluid lines. Replace any
leaking or damaged lines at this time, if necessary.

NOTE: Ensure the orient ring has an adequate layer of grease around the circumfer-
ence before starting operation.

In-Line Drive Installation (Horiz & Vert)

1. Sweep the spindle before the motor installation is started.
2. Check the condition of the coupler hub on top of the spindle, and the condition of the coupler spider. Lift the
motor up and position it just above the TRP using a forklift or hoist. Check the condition of the coupler hub
on the motor, and align it with the coupler on the spindle. Inspect the transfer tube for damage and the O-
rings for deterioration. Replace, if necessary.

NOTE: Ensure that the transfer tube has been installed prior to motor installation.

3. Lower/bring the motor toward the TRP. The couplers should engage with very little interference. It may be
necessary to rotate/move the spindle back and forth slightly to line up the coupler hubs or rock the motor
housing to square the assemblies. Do this by hand on the spindle dogs, at the spindle nose.
4. Once the coupler hubs are mated, put the bolts in that hold the motor to the spacer blocks; leave them
loose. Join all the motor cables to the harness of the machine. Command a spindle speed of 1000 RPM,
the motor mounting bolts are to be left loose. Let the spindle run for about 5 minutes, to allow the spindle
assembly to seat and help the final alignment. Snug bolts while spindle is rotating, then stop the spindle
and torque the bolts.
5. Install the airblast (purge) bracket (or TSC, if applicable) and solenoid on top of the motor. Ensure the
cylinder is centered over the motor shaft, and adjust as necessary. Connect the air line to the solenoid.

Coupler Spider

Coupler Hub

O-Ring

Air Blast
Transfer Cylinder
Tube Assy. Align
Shaft
Motor
Shaft Adapter Shaft
End

Transfer Tube and Motor Shaft Motor and Air Blast Purge Bracket

EC1600-3000 Transmission and Motor Replacement

NOTE: The motor and transmission are removed as a unit.

Removal
1. Power Off the machine. Remove all air and power service from the machine.
2. Remove the rear enclosure panel and the upper Y-axis way cover (refer to “Y-axis Way Cover Removal”).
3. Remove the TRP Blast air line.

96-0283 rev C June 2007 Mechanical Service 57

 4. Remove the TRP assembly. Refer to “Tool Release Piston Replacement”.

NOTE: An Extension Tube is threaded through the center of the TRP and into the
spindle. You must pull the Extension Tube out before you can remove the TRP
on machines that have Through the Spindle Coolant (TSC) (see Coolant Union
procedure).

CAUTION! The TRP assembly is very heavy. When moving, ensure you have a place
to set the assembly when removed.

NOTE: Make sure you collect all washers and spacers from beneath the TRP
assembly. Keep these separated in sets.

5. If your machine is equipped with TSC, remove the TSC Assembly.

6. Remove the Low Air/Low Oil, Fan, Spindle Head Solenoid, Spindle Status, and P-Cool cables from the
manifold attached to the transmission.

NOTE: It will probably be necessary to position the head before removing cables, or
alarms may occur.

7. Remove the three cables from the Encoder Assembly.

8. Remove the Encoder Assembly (take the belt off first by loosening the encoder screws).

CAUTION! Before proceeding, make sure you have appropriate lifting equipment to
safely lift 250 lbs., room to maneuver it, and a stable place to set the
transmission/motor assembly once it is removed. A transmission hoist,
T-2155, is available.

T-2155
Transmission Hoist

9. Lift the transmission by using handle jog to lift the spindle. The spindle and transmission assembly will
slide up the Y-axis linear guides. Place a block of wood under the front of the spindle (inside the enclosure)
and use handle jog to lower the spindle/transmission onto the block.
10. The power terminal block is under the rear of the transmission. Remove it (2 screws). Note wiring configura-
tion, then remove the six power cables (1-6).
11. Attach a heavy chain or strap to the lifting eyes of the top motor plate using hooks or C-clips of appropriate
weight rating (approximately 250 lbs.).

58 Mechanical Service 96-0283 rev C June 2007

 NOTE: A lifting eye must be screwed into a receptacle in the front end of the
transmission assembly. A rear lifting eye is there as part of the assembly, but
the fan must be removed and set it on top of the transmission to access it.

12. Remove the four large SHCS that attach the transmission mount plate to the spindle head and lift the
transmission/motor assembly slightly. This will remove the tension on the drive belt. Remove the drive belt.
13. Lift the transmission/motor assembly and slide it out of the enclosure.
Installation
CAUTION! Before proceeding, make sure you have appropriate lifting equipment to
safely lift 250 lbs. A transmission hoist, T-2155, is available.

1. Hang the transmission belt on the rear of the spindle.

2. Attach a heavy chain or strap to the lifting eyes of the top motor plate of the transmission using hooks or
C-clips of appropriate weight rating (approximately 250 lbs.).

NOTE: A lifting eye must be screwed into a receptacle in the front end of the
transmission assembly. A rear lifting eye is there as part of the assembly, but
the fan must be removed and set it on top of the transmission to access it.

3. Check all the wiring on the transmission before lifting it into the enclosure, to ensure that nothing has come
loose during removal.
4. Lift the transmission/motor assembly into place, lining the face up with the bolt holes on the casting.
5. Slide the transmission belt onto the transmission pulley.
6. Insert the four bolts required to attach the transmission to the casting.
7. Rotate the spindle to seat the belt into the notches on the transmission gear, and ensure the spindle
rotates freely.
8. Place a block of wood under the transmission and lift and lower it until the proper belt tension is achieved.
9. Tighten the top two bolts to 80 ft/lbs.
10. Loosen and remove the straps from the transmission, and remove the lifting eye.
11. Tighten the lower two bolts to 80 ft/lbs.
12. Lift the transmission by using handle jog to lift the spindle. The spindle and transmission assembly will
slide up the Y-axis linear guides. Place a block of wood under the front of the spindle (inside the enclosure)
and use handle jog to lower the spindle/transmission onto the block.
13. The power terminal block is under the rear of the transmission. Remove it (2 screws). A plate covering the
terminal block contains the numbers 1 thru 6 to indicate where wires should be attached. Check that the
wires not previously removed are still properly connected.
14. The two large power cables contain wires numbered from 1 to 6. Make sure they are attached in the proper
place per the terminal block plate. They should be attached opposite wires 1 thru 6 on the other side of the
terminal block (wires are labeled). Reattach the terminal block to the bottom of the transmission.
15. Attach the encoder assembly to the face of the transmission, and pull the encoder belt onto the pulley on
the end of the transmission.
16. Attach the three cables to the encoder assembly and the Low Air/Low Oil, Fan, Spindle Head Solenoid,
Spindle Status, and P-Cool cables to the manifold attached to the transmission.
17. If your machine is equipped with TSC, replace the TSC assembly.

96-0283 rev C June 2007 Mechanical Service 59

 18. Replace the TRP assembly (“Tool Release Piston Replacement” section) and the TRP Blast air line.
19. Replace sheet metal and reconnect air and power services.
20. Set spindle orientation (“Spindle Orientation” section), and check tool changer function.

Vertical Machine Transmission Replacement

NOTE: This procedure is not for direct drive machines.

Removal
1. Ensure the mill is on. You will need to raise and lower the head stock to remove the transmission. At this
time, raise the Z-axis to the full up position. 50 taper: Lower the Z-axis to its full negative value (full down).
Position the mill table so that it is centered on the X-axis and as close to the doors as possible (full Y-
axis). This will allow the best working surface.
2. Clean the mill table of any grease, coolant, or chips. You will be standing on the mill table during this
procedure and need firm footing.
3. Press the Power Off button on the control panel and turn the main breaker off. If there is an external
breaker box, turn it off and lock it up.
Remove the cover panels from head stock area ("Head Covers Removal and Installation" section).
50 taper: Remove the TRP assembly. Refer to the “Tool Release Piston Assembly” section.

CAUTION! The TRP assembly is very heavy. When moving, ensure you have a place
to set the assembly when removed.

NOTE: Make sure you collect all washers and spacers from beneath the TRP
assembly. Keep these separated in sets.

4. Remove the TSC extension tube if the machine is equipped with Through the Spindle Coolant option. Refer
to the “Through The Spindle Coolant System” section.

NOTE: The TSC union and extension shaft are reverse thread.

5. If your machine is equipped with TSC, remove the 3/16” SHCS that attach the TSC valve bracket to the
right side of the motor. Let the TSC valve bracket hang off the right side of the spindle head, ensuring that
the hoses do not get kinked.
6. If machine is equipped with the Through the Spindle Coolant option, remove the pressure regulator, check
valve assembly, and bracket from the old transmission, so they can be installed later on new transmission.
7. Remove the tool release piston assembly ("Tool Release Piston Assembly" section).
50 Taper mills: skip to step 12.
8. Vert: Loosen the six SHCS holding the transmission to the head casting. Slide the transmission forward
enough to release the drive belt from the transmission and spindle pulleys. Horiz: The transmission is
removed by lowering it onto blocks of wood (4”x4”) inside the column casting. The transmission is then
pulled toward the rear of the machine to separate from the spindle head. Completely remove the transmis-
sion mounting bolts and pull the transmission towards the rear of the machine until it is clear of the column
casting.
9. Remove the SHCS that attach the TRP solenoid assembly to the top of the motor lift plate. Cable tie the
assembly to the rear sheetmetal or column to prevent damage while removing the transmission/motor
assembly.

60 Mechanical Service 96-0283 rev C June 2007

 10. Disconnect all electrical lines and air lines from the transmission solenoid bracket. Disconnect the electri-
cal and oil lines from the oil pump. Plug the oil lines to prevent contamination. Most of the lines should be
marked and identified. If not marked, do so as it is removed.

Solenoid
Cable Assembly
Carrier
Transmission

Tool Release
Piston

Solenoid Bracket with All Lines Connected.

11. Remove the two SHCS holding the cable carrier to the solenoid bracket and position the cable carrier so as
to not interfere with the transmission removal. It may be necessary to tie the cable carrier back to the Z-
axis motor to keep it in place.
12. 50 taper: Remove the plug for the gear change solenoid and remove the Encoder-to-Transmission Shaft
belt. This can most easily be accomplished by removing the four SHCS that attach the Encoder bracket to
the spindle head (located inside the spindle head cavity between the drive belts). Use a universal swivel
joint and hex-head socket for these SHCS.
13. Break loose the four large SHCS that attach the transmission mount plate to the spindle head. Remove the
SHCS and set aside. Pull the transmission/motor assembly towards the front of the machine slightly. This
will remove the tension on the drive belts.
14. Remove the encoder belt and the drive belts.

CAUTION! Measure distance between the bottom of the Z-axis motor and the ballscrew
anchor mount. Cut a wood block to the proper length and put in place. This
is necessary to counteract the hydraulic counterbalance mechanism when
the transmission/motor assembly is lifted off the machine.

15. Mark and remove the power cables from the motor. Attach a heavy chain to the lifting eyeholes of the top
motor plate using hooks or C-clips of appropriate weight rating (approximately 250 lbs.).

CAUTION! Before proceeding, make sure you have appropriate lifting equipment to
safely lift 250 lbs., room to maneuver it, and a stable place to set the
transmission/motor assembly once it is removed.

16. Lift off the transmission/motor assembly.

Installation
1. 50 taper: Lower the Z-axis travel to its full negative value (full down). Position the mill table so that it is
centered on the X-axis and as close to the doors as possible (full Y) to allow the best working surface.

96-0283 rev C June 2007 Mechanical Service 61

 40 taper: If machine is equipped with Through the Spindle Coolant option, reinstall the pressure regulator,
check valve assembly, and bracket. Install two cable ties on the replacement transmission as follows:
• Place one cable tie around the limit switch cable.
• Place the second cable tie through the first one, forming a loop.
• Tighten the first cable tie.

NOTE: The loop of the second cable tie must allow the drain line to slip through.

2. 40 taper: Place cradle under new transmission and lift just enough to put tension on the cables.
3. 40 taper: Ensure new transmission is seated securely and lift. Only lift high enough to clear the enclosure
and to swing into place.
4. 40 taper: Slowly swing boom around to center the cradle and transmission over the spindle head.

NOTE: Inspect the gearbox isolators to ensure the spacer is flush with the bushing
on the underside of the housing.

50 taper: Connect the power wires and attach the electrical plug panel to the rear of the motor. Reattach
any Molex plugs to the panel, if removed during the previous procedure.
5. 50 taper: Slide on the drive belts and place and secure the TRP solenoid assembly to the top of the motor
lift plate using the removed SHCS.
6. 50 taper: Place and secure the TSC valve bracket to the right side of the motor lift plate using the removed
SHCS (if so equipped).
7. Lower the transmission carefully to just above the spindle head. Place the drive belt onto the transmission
pulley and lower. Do not crush or bind the time belt.
8. Insert and tighten down the SHCS attaching the transmission to the spindle head. If these screws include
gearbox isolators, ensure the 3/8" fender washer is not touching the gearbox housing.

3/8 - 16 x 1
SHCS (6)

Gearbox
Isolators

Gearbox Isolators

9. Adjust drive belt tension as noted in "Belt Replacement and Tensioning" section before tightening screws
down completely.
50 taper: Slip on the Encoder belt. Reattach the Encoder bracket.
10. Replace the TRP assembly. See the description in the "Tool Release Piston (TRP) Assembly" section.
11. Replace the TSC union and extension shaft. Refer to the “Through The Spindle Coolant System” section.

62 Mechanical Service 96-0283 rev C June 2007

 12. Reattach cable carrier to solenoid bracket and reconnect and secure all electrical, fluid, and air lines.
Replace any leaking lines, if necessary. 50 taper: If equipped with TSC, check drawbar for runout (see
appropriate section).
13. Fill the transmission with Mobil DTE 25 oil.

NOTE: The hoist must be disassembled before removing from the mill table. Break
down the hoist by removing the boom assembly, then the mast.

Transmission (Lathe)
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 motor's rear and place lifting straps around motor and transmission. Make
sure there is enough tension so when mounting bolts are loosened, 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.

Lathe Transmission Mounting Plate

Installation
All Haas gearbox replacements for lathes are supported using 16DP-50M gearsets. They have oil pumps, with
oil pressure switches, and use motor encoders with an M23 connector. The 16DP Haas gearbox is 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, the necessary software,
Parameter 57 bit 26 set to 1, power cable, and signal cables are already in place.
The 16DP gearbox may require changes for Parameter 150 when changing the gearbox, and must be verified.
The gearbox motor encoder connector has an attached adapter cable that converts to the previous style molex
connector in case it is needed. If the adapter cable is not needed, remove it and attach the existing M23
connector to the motor encoder.

96-0283 rev C June 2007 Mechanical Service 63

 In order for the transmission to function correctly the following 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 install CBL300A (oil pump power), 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 I/O PCB 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 connectors.
If the control cabinet cables exit through the cabinet bottom, 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 cable guide covers necessary to route CBL890 to I/O PCB P15 and place CBL890 in cable guide.
Route the other end of cable 890 in the most direct, safe path to the bracket on the side of the gearbox.
Plug the connectors into their appropriate slots in the bracket, and plug the matching Hi Gear, Lo Gear,
and Trans Lo Oil (from the pressure switch) connectors together. If there are no available slots in the
bracket, or no bracket, tie the connectorsout of the way.
6. Install CBL300A (33-8169). CBL300A connects to I/O PCB 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 same opening into control cabinet as CBL890, and connect it to I/O PCB P41.
Outside the control cabinet, route CBL300A in the most direct, safe path to the bracket mounted on the
side of the 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. If there is no
bracket, tie the connectors out of the way.

64 Mechanical Service 96-0283 rev C June 2007

 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 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 transmis-
sion oil pump is running. The oil can been seen moving through the clear line. The oil pump will run when-
ever the spindle is turning.
Check that the low transmission oil pressure alarm works by commanding a spindle speed and then
disconnecting the pressure switch. There is a 60-second pause and then Alarm 179 is generated. Recon-
nect 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 Lathe Transmission and Motor Replacement

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: Additional lifting means are needed, such as 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.

96-0283 rev C June 2007 Mechanical Service 65

 Buss

Setscrew (2)
Ratchet Wrench
w/Hex Key

2. Lift assembly and position it over the belts. Lower it into position and loosely install the 4 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 cable 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 pro-
gram. This program will run for about 2 hours.
10. Verify that the transmission oil is at the proper level. The machine is full (2 1/4 liters) when oil is visible 3/4
of the way up on the sight glass. Add Mobil DTE-25 (amber) or Mobil SHC-625 (green) as needed. Use only
the type of oil already used in the transmission; do not mix oil types.
Spindle Encoder Replacement
Please read this section in its entirety before attempting to remove or replace encoder.
Removal
1. Turn machine power on. Move the spindle head to a position that will allow you to easily work on the back
of the spindle motor. Turn the machine off.
2. a. Remove the necessary sheetmetal to gain access to the spindle encoder.
b. Horiz: Remove the fan and fan shroud, then the tool release piston to access the encoder.

4X SHCS
Motor Encoder Spindle Motor
Assembly

4X SHCS Encoder
Mounting
Bracket

Spindle
Encoder

Motor
Housing 4X SHCS

EC-300 Spindle Encoder Installation (Fan and Fan Shroud Removed)

66 Mechanical Service 96-0283 rev C June 2007

 3. a. Remove the four screws holding the encoder to the bracket.
b. Vert: Remove screws holding the encoder to the four standoffs (VF-1 thru VF-4) or mounting bracket
(Direct Drive). Remove the encoder, leaving the belt on the pulley at the orient ring.

Solenoid
Cable Assembly
Carrier
SPI
STAND
LE
WIT TUS
HO LOC
UT SWITC
KED

Transmission
GE
AR H
BO
X

TO
ST OL
AT CL
US AM
SW PE
ITCD
H

LO
JUSTATW
MP USGE
ER SWAR
GE
ARWITHITC
BO OUH
X T

STHIGH
AT
USGE
AR
SW
IT
CH

VF-1
Encoder

Tool Release
Piston
Spindle encoder installation (VF-1/VF-2) Encoder Installation for Direct Drive Machines

4. Inspect the belt and replace if necessary.

Installation

Note: Handle the new encoder with care; they are very susceptible to damage.

1. Lathe: Install the pulley onto the new encoder, aligning the setscrew hole with the flat on the encoder
shaft. Use only one setscrew and a small drop of removable grade loctite, to hold the pulley on the shaft.
Note that some pulleys may have two setscrew holes and screws; remove the unused setscrew.

Mounting bolts (2)

Lathe Encoder Belt Locations

2. Mount the new encoder and tighten the bolts

3. Apply tension to the belts. Belt tension is very critical, do not create an excessive amount of tension. The
maximum radial load (side load) for the encoder shaft is 13 1/2 lbs (60 N). Exceeding this amount may
damage the encoder. Some machines have an automatic belt-tensioning bracket. Allow the bracket springs
to properly tension the belt and then tighten the screws.
4. a. Horiz: Replace the fan and fan shroud, then the tool release piston.
b. Replace the sheet metal previously removed.

96-0283 rev C June 2007 Mechanical Service 67

 COOLANT SYSTEM OPERATION
Tool Coolant Overview
All of the Haas mills have a system that can be used at the customers discretion to provide a liquid coolant to
the tool and work piece. There is a tank at the back or side of the machine that contains the liquid coolant and
a pump that moves the coolant up to the spindle head area.
The makeup of the coolant has a wide variety of possibilities. The customer can choose to use anything from
water to oil. Typical coolant is water with some additives to improve lubrication and reduce rust and bacteria.
At the spindle area, the coolant is first circulated through a jacket around the spindle. This is done to help
maintain the spindle head at a constant temperature to improve machine accuracy. The machine is more
accurate if the spindle head temperature can be maintained within +/-5 F degrees. This cooling of the iron
casting of the spindle is a very minor effect on machine temperature and accuracy and the machine can always
be used in every type of cutting without turning on the coolant pump.
The coolant pump is electric and can be turned on and off both by the operator at the front panel and under
program control. There are codes that the CNC programmer puts into the CNC program to turn on and to turn
off the coolant. The machine can be operated normally without this coolant.
After the spindle jacket, the coolant comes out to one or more exit ports that can be aimed manually or
automatically by the machine. Typically these ports are aimed directly at the tip of the working tool.
There is an optional “thru-the-spindle-coolant” system that can be installed on most machines. It consists of a
second pump that can also be turned on from the CNC program and supply lines that bring the coolant down
the center of the spindle of thru the tool. It provides no cooling functions to the spindle.
In-Line Drive (TSC)
CVA CHECK VALVE ASSEMBLY
F1 INTAKE FILTER ASSEMBLY
100 MESH
F2 TSC FILTER, 20 MICRON
USE 20 MICRON FILTER ELEMENT
FA1 INTAKE FILTER ASSEMBLY
FA2 TSCHP FILTER ASSEMBLY
G1 SUCTION GAGE, INTAKE FILTER
G2 FILTER GAGE, TSC FILTER
OR METERING ORIFICE .040
P1 TSCHP PUMP 300 PSI MAX.
PRA PRECHARGE REGULATOR ASSY
PVA PURGE SOLENOID VALVE ASSEMBLY
TRSA TOOL RELEASE SOLENOID ASSEMBLY
S1 COOLANT PRESSURE SWITCH, 40 PSI
S2 AIR PRESSURE SWITCH, 70 PSI
SV1 SOLENOID VALVE (PURGE)
2 POSITION, 3 WAY, SP. RET.
SV2 SOLENOID VALVE (TOOL RELEASE)
2 POSITION, 3 WAY, SP. RET.
SV3 SOLENOID VALVE (PRE-CHARGE)
2 POSITION, 3 WAY, SP. RET.
V1 COOLANT CHECK VALVE
V2 PURGE CHECK VALVE
V3 SHUTTLE VALVE (PURGE)
V4 SHUTTLE VALVE (TOOL RELEASE)

VF LOCATION: (1) REAR OF MACHINE &

COOLANT TANK
(2) IN SPINDLE HEAD

EC-300/EC-400 (1) SIDE OF MACHINE AND

LOCATION: COOLANT TANK
(2) TOP OF SPINDLE MOTOR

68 Mechanical Service 96-0283 rev C June 2007

 40 Taper (TSC)
CV CHECK VALVE
CVA CHECK VALVE ASSY - TSC
F1 INTAKE FILTER, 100 MESH
F2 TSC FILTER, 100 MICRON
FA1 INTAKE FILTER ASSEMBLY
FA2 TSC FILTER ASSEMBLY
G1 DIRT INDICATOR, INTAKE FILTER
G2 DIRT INDICATOR, 100 MICRON FILTER
P1 TSC PUMP
R1 PRECHARGE REGULATOR
SET AT 3.6 - 4.4 PSI
PRA PRECHARGE REGULATOR ASSY
PS PRESSURE SWITCH
SET AT 40 PSI
PVA PURGE VALVE ASSEMBLY
SV1 SOLENOID VALVE (PRECHARGE)
2 POSITION, 3 WAY, SP. RET.
SV2 SOLENOID VALVE (TOOL RELEASE)
2 POSITION, 3 WAY, SP. RET.
SV3 SOLENOID VALVE (PURGE)
2 POSITION, 3 WAY, SP. RET.
V1 SHUTTLE VALVE

LOCATION: (1) REAR OF MACHINE & COOLANT TANK ASSEMBLY

VMC (2) SIDE OF GEAR BOX/SPINDLE MOTOR ASSEMBLY
(3) ON TOOL RELEASE PISTON ASSEMBLY
(4) REAR OF GEAR BOX/SPINDLE MOTOR ASSEMBLY
(5) AT BOTTOM REAR OF SPINDLE HEAD

50 Taper (TSC)

CVA CHECK VALVE ASSEMBLY

F1 INTAKE FILTER ASSEMBLY
100 MESH
F2 TSC FILTER, 20 MICRON
USE 20 MICRON FILTER ELEMENT
FA1 INTAKE FILTER ASSEMBLY
FA2 TSCHP FILTER ASSEMBLY
G1 SUCTION GAGE, INTAKE FILTER
G2 FILTER GAGE, TSC FILTER
P1 TSCHP PUMP
300 PSI MAX.
TRSA TOOL RELEASE SOLENOID ASSEMBLY
S1 PRESSURE SWITCH
40 PSI
SV1 SOLENOID VALVE (TOOL RELEASE)
2 POSITION, 4 WAY, SP. RET.
SV2 SOLENOID VALVE (PURGE)
2 POSITION, 3 WAY, SP. RET.
V1 COOLANT CHECK VALVE
V2 PURGE CHECK VALVE
V3 SHUTTLE VALVE

VF LOCATION: (1) REAR OF MACHINE & COOLANT TANK

(2) SIDE OF SPINDLE MOTOR
(3) TOP OF SPINDLE MOTOR

EC-1600/EC-2000 (1) SIDE OF MACHINE AND COOLANT TANK

LOCATION: (2) (3) TOP OF SPINDLE MOTOR

TSC TROUBLESHOOTING

NOTE: Abrasive swarf from grinding or ceramic machining operations will cause
heavy wear of TSC coolant pump, mill coolant tip and mill drawbar. This is not
covered by warranty on new machines. Notify Haas Service Department if
machine is being used for this application.

96-0283 rev C June 2007 Mechanical Service 69

 Coolant Overflow
Check the alarm history to determine the cause of the problem before any action is taken.
• Check the customer's tooling for through holes in the tool holder, tool, and pull stud (mill).
• Check the TSC coolant union. If failure is found, replace the coolant union.
• Check that the coolant drain and purge lines connected to the seal housing are intact. Replace the tubing if
necessary.
• Check for coolant flowing from a failed fitting or check valve.
• Check precharge pressure in accordance with "Pressure Regulator Adjustment' section and reset if neces-
sary. Mills: Low precharge pressure can cause coolant to dump into the spindle head.
• Ensure coolant pump relief valve has not been tampered with (paint band is intact). Check the coolant pump
pressure (should be 300 psi, or 1000 psi for TSC 1000 option), with a standard (no coolant through hole) tool
holder in spindle. If pump pressure is above 300 psi (or 1000 psi for TSC 1000 option), reset the pump relief
valve in accordance with the "Setting TSC Pump Relief Valve" section.

Excessive coolant flow out of drain line or pulsating flow through tool and drain line.
• Check pre-charge pressure in accordance with "Precharge Regulator Adjustment" section. Reset precharge
pressure if necessary. Low pre-charge pressure will cause heavy or pulsating flow from the drain line. Check
main air pressure regulator for 85 psi. A higher supply pressure will reduce precharge pressure. Lower supply
pressure will increase precharge pressure.
• Ensure the coolant pump relief valve has not been tampered with (paint band is intact). Check the coolant
pump pressure (should be 300 psi), using a standard tool holder. If pump pressure is above 310 psi., reset the
pump relief valve.

Low Coolant, Alarm 151

• Check coolant tank level. Check for slow coolant drainage from the machine enclosure.
• Check the filter and intake strainer for any clogging. Read filter gauges with TSC/HPC running without a tool.
Check coolant lines for any clogging or kinking. Clean or replace as needed.
• Check for overheating TSC/HPC pump motor. These three-phase motors have a thermal circuit that will
interrupt power to the relay coil.
• If received at start-up, check that the breaker has not tripped and that the pump is turning. Check the electri-
cal continuity of cables.
• Check for pressure switch failure, and replace if necessary. Check the electrical continuity of the switch cable
and the control function by monitoring the "LO CLNT" bit on the Diagnostics page (0 = pressure on, 1= pres-
sure off). Shorting the leads should cause the bit to switch from 1 to 0. Check this before replacing the pres-
sure switch. Leaking switches can give intermittent alarms.
• Check pump pressure with TSC/HPC running and without a tool; normal pressure for standard TSC is 75 - 95
psi. If the pressure is less than 60 psi, replace the pump.
• May be generated if another machine alarm occurs during TSC/HPC operation.

Pre-Charge Failure, Mill Alarm 198

NOTE: This alarm only applies to the TSC system. This alarm does not apply to 50
taper spindle machines. If this alarm is received on a 50 taper TSC machine,
check that Parameter 235 is set to zero. A non-zero value will cause the control
to act as a 40 taper TSC.

• Check for broken or disconnected pre-charge air line, and replace if necessary.
• Check if the "Tool Clamped" limit switch is sticking or out of adjustment; readjust or replace if necessary.

70 Mechanical Service 96-0283 rev C June 2007

 • Check for low pre-charge pressure and check pre-charge solenoid for proper operation.
• May be generated if another machine alarm occurs during TSC operation.

Mill Pre-Charge Regulator Adjustment

CAUTION! Extreme care must be taken in making this delicate adjustment.

Tools Required: Tool holder with small TSC drill or restrictor (with small orifice #T-1461). TSC Gauge Kit (P/N
93-9011), including 0-15 psi Precharge pressure gauge, 0-160 psi Purge pressure gauge, 0-600 Coolant
pressure gauge, and ball valve.
1. Insert a short piece of 1/4" plastic tubing into the 0-15 psi pressure gauge. Insert the short tube into the
precharge pressure regulator (located on top of the transmission) and connect the plastic precharge tube
(leading to the TRP) to the pressure gauge.
2. Manually turn on the precharge air by pushing the plunger on the precharge solenoid valve.
3. Hold down the precharge solenoid valve for at least 20 seconds to allow the pressure reading to stabilize,
then set the precharge pressure to 4.0 psi (±0.4 psi). Release the solenoid and hold it down again for 20
seconds and re-check the precharge pressure. Repeat this a few times to ensure the pressure setting
remains stable. Be sure the regulator adjustment knob is securely locked in place.
4. Remove the pressure gauge and short 1/4" hose. Reattach the precharge tube to the regulator.

Checking Pump Pressure

NOTE: If the coolant pressure with no tool in the spindle is 60 psi or less, replace the
pump assembly (30-3281A). Old TSC system uses pump head (93-3280B).

1. Insert the 0-600 psi coolant pressure gauge into the coolant line between the machine enclosure and the
TSC pump hose. Use wrenches to tighten the fittings snug. Do not overtighten!
2. Use a standard tool holder (no coolant through hole and turn on TSC.
3. Check for leaks while the system is running.
4. Turn off TSC, remove pressure gauge, and reconnect the pump to the machine.
If the pump relief valve has been changed, adjust the relief valve in the following manner:
1. Remove the sealing cap from the pump relief valve. Loosen the lock nut.
2. Start with the pressure below 300 psi. Adjust the pressure relief valve until the pressure on the gauge rises
to 300 psi. Tighten the lock nut, and replace the sealing cap. Setting range is 280-300 psi.
3. Mark across the pump and sealing cap with a paint marker. This will indicate any future tampering.
Testing the Coolant Pressure Switch
1. Insert the ball valve and pressure gauge into the coolant line between the machine enclosure and the TSC
pump hose. The ball valve must be between the pump and pressure gauge. Connect the other end to the
machine. Tighten the fittings snugly with wrenches. Do not overtighten!
2. Run the system for one minute to purge air.
3. Install a through-hole tool holder (with a small drill or restrictor) and set Parameter 236 to 100.

CAUTION! Changing tools after running TSC can cause coolant to spray out. Wear
safety glasses.

4. Turn on the coolant system. Test low coolant pressure switch by slowly shutting off the ball valve in the
coolant line (pump should shut off at 40 psi ± 5 psi). If the switch is outside this range, replace the switch.

96-0283 rev C June 2007 Mechanical Service 71

 NOTE: Test electrical continuity of switch cable and control function by monitoring the
"Lo Clnt" bit on the Diagnostics page. Shorting the leads should cause the bit
to switch from 1 to 0. Check this before replacing the pressure switch.

5. Reset Parameter 236 to the default value (1000).

TSC-1000 TROUBLESHOOTING
1) TSC 1000 pump and motor do not turn on when programmed to (M88/89 or AUX CLNT Button).
a) Check that the TSC 1000 pump has been connected to an external power supply. Power required by
default is 208-230 Volt 3-phase 50/60 Hz with a 20-Amp circuit breaker. Alternate power (240-230V 50/60
Hz @ 20 or 480V 50/60 Hz @ 10) can be connected but requires that the pump motor be rewired and the
plug replaced. See rewiring directions on the side of the pump motor housing.
b) Check inside the control that a jumper pin is in place over Pin #50 set on the I/O board. The jumper
should span pins 1 and 2 (the bottom two pins).
c) Check cable connections. The power supply cable should connect pin set 44 on the I/O board to pin
sets 20 and 16 on the power card. The signal cable should connect the TSC out port on the side panel to
pin set 45 on the I/O board.
d) Check for blown TSC fuses on the power card.
2) TSC 1000 pump motor turns on but does not pump (no coolant reaches the spindle).
a) Verify that the auxiliary filter (AF) tank on the TSC 1000 pump stand is full of coolant and sealed tightly.
Clean the upper tank ring seal each time the lid is removed.
b) Verify that the spindle is free of debris and that the tool and tool holder being used are TSC-compatible.
Some tools have a plug in place that must be removed to use TSC. Before the initial startup of the TSC
1000 system, it is recommended that tools be removed from the spindle.
c) Turn on the TSC 1000 system via a control command (M88 or AUX CLNT button), follow the pressure
regulator output hose to the high-pressure fitting, and slightly loosen the fitting.
Note: This will cause coolant leakage under pressure. Wrap a rag around the fitting before loosening.
As soon as coolant flow to the spindle is achieved, retighten the fitting to stop the leakage, then turn off the
system. Clean any leaked coolant from the hoses and fittings and turn the system back on to verify that
there are no more leaks.
3) TSC 1000 pump turns on and pumps for a time but soon fails or stops pumping.
a) Check the AF tank filter bag for clogging or excess debris.
b) Verify that the upper ring seal on the AF tank is undamaged and free of debris.
c) Verify that all fittings are tight on the inlet side of the system and that the standard coolant tank is full.
d) Verify that the drain back circuit valve T-handle is in the off position. See the following illustration.
e) Verify that the standard coolant pump has not been branched off before the check valve.

72 Mechanical Service 96-0283 rev C June 2007

 POWER PC
Drain Back Circuit
Ball Valve (Off position
for normal operation)

Out through I/O BOARD

bottom of TSC
Control Cabinet

Pin #2
Pin #1
Pressure Regulator
Output Hose

TSC 1000 Control / Electrical Connections

TSC Pressure Effects

On machines using TSC during cutting operations, tooling size will have to be taken into consideration. As
shown below, proper TSC system operation will deliver different pressures at the orifice of the tool; this depends
on the diameter and number of coolant passages in the tool.

Larger tooling has larger diameter coolant passages. Smaller tooling has smaller diameter coolant passages.
Coolant flow is higher at lower pressures This produces higher pressures at lower flow.

TSC, HPC Pump Output TSC, HPC 1000 psi Pump Output*
5.0
8.0
4.0 6.0
Volume 3.0 Volume 4.0
(GPM) (GPM)
2.0 2.0

1.0 1.0

50 100 150 200 250 300 200 400 600 800 1000
Pressure Pressure
(PSI) (PSI) *60 Hz test

96-0283 rev C June 2007 Mechanical Service 73

 A UTOMATIC TOOL CHANGER (ATC)

1. Toolchanger Trap Door

2. Loc Nut Elastic 3
3. Washer
4. Nylon Washer 1
5. Vertical Axle
6. 2 Pin Geneva Star
7. Bearing Housing 4
8. Extractor Key 5
9. Extractor Spring
6
10. Extractor Finger
11. 20 Pocket Carousel
12. Toolchanger Door Spring 7
13. Sliding Panel
14. Sliding Panel Cover 8
15. Number Ring
16. Cap, Toolchanger

11 10

12

13

14

12 9
3 4 5 6 78

15
16

Tools are always loaded through the spindle and should never be installed directly in the carousel in order to
avoid crashes. The pocket open to the spindle must always be empty in the retracted position. All wiring to the
tool changer goes through connector P8 on the side of the control cabinet.
Low air pressure or insufficient volume reduces the pressure applied to the tool unclamp piston and slows down
tool change time or will not release the tool. The air pressure is checked prior to moving the carousel on a mill
with a side mount tool changer and Alarm 120, Low Air Pressure, is generated if such a problem exists.
If the shuttle 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.
Press "Tool Changer Restore" button, to automatically reset the tool changer after a crash.
There is a fuse for tool changer motors. It might be blown by an overload or jam of the tool changer. Operation
of the tool changer can also be interrupted by problems with the tool clamp/unclamp and the spindle orientation
mechanism. Problems with them can be caused by low air pressure or a blown solenoid circuit breaker (CB2).

74 Mechanical Service 96-0283 rev C June 2007

 TROUBLESHOOTING
Refer to the alarm description when problems arise with the ATC, and see the Spindle
section for additional trouble shooting information.
Deflection
Deflection is usually caused by ATC misalignment, and sometimes caused by damaged or poor quality tooling,
a damaged spindle taper, or a damaged drawbar or poor air supply. Before beginning any troubleshooting,
observe the direction of the ATC deflection.
During a tool change, the umbrella tool changer appears to be pushed down.
• Check to see if pull studs on the tool holder are correct and tight.
• Check the adjustment of the “Z” offset (Parameter 64).

NOTE: If the offset is incorrect, a tool changer crash can occur and a thorough
inspection of the ATC will be necessary.

• Check the adjustment of the “Z” offset. Check Parameters 71, 72, and 143 against the values that are in the
documentation sent with the machine.
• Ensure the tool holders are held firmly in place by the extractor forks.
• Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release button is
pressed. If they do not move freely, the ATC will be pushed down about 1/4" before the tool holder is seated in
the taper, resulting in damage to the roller bolts on the ATC shuttle. Replace the drawbar.
• Check draw bar height adjustment.
• If TSC, check for excessive coolant tip wear.

Tool holder sticking in spindle taper causes umbrella tool changer to pull up, accompanied
by popping noise, as spindle head is travelling distance specified in Parameter 71.
NOTE: Loading a cold tool into a hot spindle (a result of thermal expansion of the tool
holder inside the spindle taper) may cause this. It may also occur in cuts with
heavy vibration (also the result of thermal expansion). If sticking only occurs
during these situations, check your application to ensure use of proper
machining techniques. If tool is pulled out of extractors due to a tool being stuck
in the taper, the unclamp switch is not adjusted correctly or is bad.

• Check the condition of the customer’s tooling, verifying the taper on the tool holder is ground and not turned.
Look for damage to the taper caused by chips in the taper or rough handling. If the tooling is suspected, try to
duplicate the symptoms with different tooling.
• Check the condition of the spindle taper. Look for damage caused by chips or damaged tooling. Also, look for
damage such as deep gouges in the spindle taper caused by tool crashing.
• Duplicate the cutting conditions under which the deflection occurs, but do not execute an automatic tool
change. Try instead to release the tool using the tool release button on the front of the spindle head. If sticking
is observed, the deflection is not caused by improper ATC adjustment, but is a problem in the spindle or tool
release piston. See the "Spindle Assembly" section for spindle cartridge replacement.
• Check for air supply pressure of 85 psi (min). An air pressure drop of 10 psi during tool release is acceptable.
A drop greater than 10 psi is caused by a supply line restriction or an undersize supply line. Use of quick
couplers (1/4") can cause restriction. Directly connecting the air hose to a barb fitting can help.
During a tool change, the umbrella tool changer appears to be pulled up; no popping
noises.
• Check the adjustment of the “Z” offset ("Setting Parameter 64" section).

96-0283 rev C June 2007 Mechanical Service 75

 NOTE: If the offset is incorrect, a tool changer crash can occurred, and a thorough
inspection of the ATC will be necessary.

• Ensure the roller bolts on the shuttle of the ATC are tight against the V-guides on the ATC holding arm. If the
lower right roller bolt is loose against the V-guide, the upper right bolt is probably bent. Bent roller bolts are a
symptom of another problem with the ATC. Repair the bent roller bolt and isolate the ATC problem.
• Check Parameter 71 against the values that are in the documentation sent with the machine.
• Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release button is
pressed. If they do not move freely, the ATC will be pushed down about ¼” before the tool holder is seated in
the taper, resulting in damage to the roller bolts on the ATC shuttle. Replace drawbar.
Tool holders twist against extractor fork during a tool change.
• Check the alignment of the ATC in the X and Y axes ("Automatic Tool Changer Alignment" section).
Tool holders spin at all pockets of the ATC when the ATC shuttle retracts.
• ATC is misaligned in the “Y” axis; realign ATC. Observe the direction the tool holder rotates, as this will be the
direction in which the “Y” axis of the ATC needs to be moved.
Tool holders spin only at certain pockets of the ATC when the ATC shuttle retracts.
• Check all the extractor forks to ensure they are centered in the pocket of the ATC. If the ATC shows this
problem, each extractor fork must be checked and centered to eliminate the possibility of the ATC being
aligned against an incorrectly-centered fork.
Noisy Operation
To isolate noise(s) in the ATC, carefully observe the ATC in operation and look for the following:
ATC makes noise as the shuttle moves.
• Check the adjustment of the roller bolts on the ATC. Loose roller bolts can cause the ATC to make a clunking
noise when the shuttle is commanded to move. Tight roller bolts can cause the shuttle motor to stall, possibly
damaging the motor or the I/O board. In this case, the shuttle may also move too slowly.
• Check for damage to the trap door on the ATC cover. See appropriate section for trap door replacement.
• Check for missing plastic riders on ATC shutter. See appropriate section for shutter replacement.
• Ensure guide pin mounted to holding plate is not bent and does not scrape ATC cover during movement.
• Listen for damage to the gear train in the shuttle motor. If the motor is the source of the noise, replace the
motor. Do not try to repair the motor or to further isolate motor noise.
• Ensure the Geneva driver on the turret motor is tight and properly adjusted. If the Geneva driver is found to be
loose, check for damage to the Geneva star. Any roughness in the slots will require that it be replaced.
• Check the adjustment of the Geneva driver in relation to the Geneva star. If the adjustment is too loose, the
carousel will vibrate heavily and make a loud clanking noise during carousel rotation. If the adjustment is too
tight, the turret motor will labor excessively and the carousel may appear to move erratically.

NOTE: If turret motor adjustment is tight for extended periods, the turret motor, Geneva
star, and I/O board may be damaged. If Geneva star adjustment appears tight
at some pockets and loose at others, the problem lies with the Geneva star.
Check concentricity of the star relative to the bearing housing on the carousel.
If it is within specification and the problem remains, replace the Geneva star.

• Ensure screws holding the turret motor to the mounting plate are tight.
• Ensure the screws attaching the motor mounting plate to the shuttle casting are tight.
• Check for excessive noise in the turret motor gear train. See appropriate section for replacement.

76 Mechanical Service 96-0283 rev C June 2007

 NOTE: If the motor is found to be the source of noise, replace the motor assembly
(motor, mounting plate, and Geneva driver). Do not attempt to repair the motor
or to further isolate the problem in the motor.

Orientation
When commanded to orient the spindle, the spindle will rotate to the position determined by Parameter 257
(spindle orient offset).
ATC out of orientation with the spindle. Incorrect spindle orientation will cause the ATC to
crash as the shuttle moves. Alarm 113 will be generated.
• Check the orientation of the spindle.
ATC will not run.
• In all cases where the tool changer will not run, an alarm is generated to indicate either a shuttle in/out or
turret rotation problem. The alarms occur either on an attempt to change tools (ATC Fwd) or to Zero Return the
machine (Auto All Axes). Use appropriate alarm to select one of the following problems:
ATC shuttle will not move; shuttle is getting power (Command a tool change and check for
power being applied to the shuttle motor).
• Disconnect the slip clutch arm from the ATC shuttle and ensure the shuttle can move freely. If not, see
appropriate section for shuttle adjustment.
• Command a tool change with the shuttle disconnected.
• If shuttle cycles, check slip clutch on the ATC. See appropriate section for slip clutch replacement.

NOTE: The slip clutch should move the shuttle with a fair amount of force, but not so
much that the shuttle cannot be made to slip when holding it back by hand. If
the slip clutch is frozen, replace it. It cannot be rebuilt in the field.

• If ATC shuttle does not cycle, motor has failed and must be replaced. Turn motor by hand and feel for
binding in the gear train, which uses a large amount of gear reduction and is hard to turn by hand.
ATC shuttle will not move; shuttle is not getting power.
• Command a tool change check for power being applied to the shuttle motor.
• Check that the TC In/TC Out LED on the I/O PCB is illuminated when a tool change takes place.
• If LED lights, check fuse FU5 on the Power PCB or FU1 on the I/O PCB. Otherwise, check I/O PCB.
• If the LED does not light, check cables I/O-P65-510 and I/O-P64-520.
• Check ATC shuttle relay
ATC turret will not rotate; turret motor is getting power.
• Command a tool change check for power being applied to the turret motor.
• If power is applied, but output shaft on motor does not turn, check for binding between turret motor assembly
and Geneva star. Check for damage to Geneva star or Geneva driver. Check for a broken turret motor.

NOTE: Do not attempt to repair the motor or to further isolate the problem in the motor.

ATC turret will not rotate; turret motor is not getting power.
• Command a tool change check for power being applied to the turret motor.
• Check that the TC CW/TC CCW LED on the I/O PCB is illuminated when a tool change takes place.
• If LED lights, check fuse FU5 on the Power PCB or FU1 on the I/O PCB. Otherwise, replace I/O PCB.
• If LED does not light, check cables I/O-P65-510 and I/O-P64-520.
• Check ATC turret relay.

96-0283 rev C June 2007 Mechanical Service 77

 Tool Changer Position Switches
Two switches are used to sense the position of the tool changer carousel. One switch is activated when the
carousel is moved full travel inward and one is activated when it is full travel outward. These switches are
normally closed so that both will be closed between in and out. The diagnostic display will show this status of
this input switch. A “1” indicates the associated switch is activated or open.

Breakage
Breakage of the ATC is caused by either very hard and repeated crashes or excessive TSC coolant tip wear.

ATC shuttle is broken off of the holding plate.

• Carefully inspect bosses on the shuttle casting (where roller bolts mount) for damage to the threads or
cracks. If any bosses are cracked, replace the casting. Realign the tool changer after repairing machine.

ATC extractor forks are damaged after breakage.

• Check the condition of the mounting holes in the carousel. If the threads are damaged, they must be repaired
or the carousel replaced. See appropriate section for extractor fork replacement.

CRASHING
If any of these crashes occur, thoroughly inspect the ATC for damage. Pay close attention to extractor forks,
sliding covers on ATC carousel, and roller bolts on the ATC shuttle. See appropriate section for extractor fork
replacement.
Crashing of the ATC is usually a result of operator error. The most common ATC crashes occur as the part or
fixture on the mill table crashes into long tooling or into the ATC double arm during a tool change
• Inspect the pocket involved in the crash for damage and replace parts as necessary.
• The machine will normally home the Z-axis as part of the tool change sequence. Check Parameter 209 bit
"TC Z No Home", and ensure it is set to zero.
The most common ATC crashes are outlined as follows:

Shuttle crashes into spindle when a tool change is commanded (tool holder is in the pocket
facing the spindle head).
This crash is fairly common and is due to operator error. If the ATC is stopped in the middle of tool change
cycle, the operator must command the ATC to an empty pocket before the machine will operate correctly.
Repeated crashes of this type can damage the I/O board, slip clutch, and shuttle motor in the ATC.
• Rotate the carousel to an empty pocket.

During a tool change spindle crashes into top of the tool holder after a turret rotation.
When the spindle head moves down over the top of the tool holder during a tool change, the pull stud will bind
inside the drawbar bore of the spindle, forcing the ATC down, breaking the carousel. Bending the upper right
roller bolt on the ATC shuttle or completely breaking it off is also possible. Tool holder is not held correctly in
the extractor fork, possibly held only in one side of the extractor and at an odd angle.
• Check all of the extractor forks on the ATC.

During a tool change spindle crashes into top of the tool holder after a turret rotation.
The balls in the drawbar do not move freely, causing the ATC to be forced down far enough to break the carou-
sel. Bending the upper right roller bolt on the ATC shuttle or completely breaking it off is also possible.
• Ensure balls on the drawbar move freely in the drawbar holes when the tool release button is pressed. If this
failure occurs, check all of the extractor forks on the ATC for damage and repair the spindle drawbar.
• Check drawbar height and set according to the appropriate section, if necessary.

78 Mechanical Service 96-0283 rev C June 2007

 ATC puts tool holder in spindle, but tools are dropped onto machine table when shuttle
retracts.
• Inspect the balls and the Belleville springs in the drawbar. Replace drawbar.

The part or fixture on the mill table crashes into long tooling or into the ATC itself when
machining.
• Reposition the tools to remove interference, or program carousel to rotate long tooling out of the way.

C ARRIAGE CASTING REPLACEMENT

Tools Required: Two-jaw puller Hydraulic jack 1-2-3 Block Cardboard
If the carriage casting is damaged in a crash, it must be replaced. Look specifically for broken bosses where
the roller bolts mount to the casting. If the carriage casting is broken off of the holding plate but not damaged,
only the roller bolts need be replaced.
1. Turn the machine power off. Remove the left side enclosure panel of the machine.
2. Disconnect all cables from the carriage casting and remove any bolts holding the ATC to the holding plate.

NOTE: If the carriage casting has been damaged, replacement is necessary; move
the ATC to a bench and remove all components from the damaged carriage
casting and place in the new casting. Skip to Step 6 for replacement.

3. Place a piece of cardboard over the machine's table, and carefully lower the carriage casting (with carou-
sel) onto the machine table.
4. If the carriage casting has crashed and/or has been broken off of the holding plate, it should be inspected
for damage before going any further.
5. Remove any damaged roller bolts from the carriage casting. Replace with new bolts.
6. With a lifting device, carefully lift the ATC assembly up and onto the holding plate.

NOTE: Ensure cam follower on the slip clutch engages slot on the carriage casting.

7. With the ATC assembly securely supported, install the lower roller bolts and adjust in accordance with
"Roller Bolt Replacement".
8. Repair or replace any cables damaged and adjust the ATC. Align the ATC assembly in accordance with the
following sections, and set Parameter 64 in accordance with "Spindle Motor and Transmission" section.

ROLLER BOLT REPLACEMENT

1. Remove the shuttle motor cover from the back of the machine (VF-1, VF-2).
2. Place a support under the center of the carousel.
3. Loosen the eccentric locks on the bottom roller bolts.

CAUTION! Ensure the ATC is securely supported, otherwise it may fall when an upper
roller bolt is removed.

4. Carefully remove the damaged roller bolt from the ATC shuttle and replace with a new bolt.

NOTE: Replace only one roller bolt at a time. Carefully inspect the V-groove rollers for
roughness or damage, and replace if necessary.

5. Tighten the eccentric locks on the bottom rollers until there is no play between the rollers and the V-guide
on the ATC holding plate.

96-0283 rev C June 2007 Mechanical Service 79

 6. Set the tool change offset (Parameter 64) in accordance with "Setting Parameter 64" section.
7. Verify the ATC alignment in accordance with the following section.
8. Reinstall the shuttle motor cover (VF-1, VF-2).

ATC ALIGNMENT
1. Verify that the spindle orientation is correct (Refer to appropriate section).
2. Command an automatic tool change, and press Emergency Stop when the shuttle is fully in.
3. Verify that the spindle dog lines up to the alignment key in the ATC, in the Y plane.

NOTE: If the spindle dog and alignment key do not line up, loosen the four HHB that
hold the ATC holding arm to the column.

Spindle Dog

Spindle

Underside Showing Centering Measurements

4. Move entire tool changer until the tool alignment key lines up with the spindle dog. Tighten the four HHB.

NOTE: Parameter 64 must be checked and adjusted when the ATC is aligned.

5. Make at least 50 tool changes after alignment is complete. Verify tools are being picked up squarely.

SHUTTLE STROKE ADJUSTMENT

1. Move the ATC away from the spindle and loosen the four HHBs in the ATC holding arm in the X-axis plane.
2. Push the cam follower to its full upward stroke, then push the entire ATC assembly in by pushing on the
tool changer holding plate until ATC is fully engaged on the tool holder.
3. Ensure the extractor is making full contact on the tool flange.

Cam Follower Tool Carriage

Tool Changer
Holding Plate

Tool #1 Standoff

Geneva Driver Geneva Star

Automatic Tool Changer - Mechanical Assembly (Side View)

80 Mechanical Service 96-0283 rev C June 2007

 EXTRACTOR F ORK REPLACEMENT

NOTE: Extractor forks that do not hold the tool holders firmly, or forks that are bent,
must be replaced. Damage to the ATC will result if not replaced.

1. With no tool holders in the spindle or in the ATC, command "ATC Fwd" until the extractor fork needing
replacement is facing the spindle.
2. Command "ATC Fwd", but press Emergency Stop after the spindle head lifts up off the carousel.

NOTE: At this point, the shuttle should be in and the spindle should be about 4½"
above the carousel.

3. Loosen the SHCS that attach the damaged extractor fork to the ATC carousel.

Tool Holding Arm

Shuttle Motor

Slip Clutch Extractor Key

Assembly

Automatic Tool Changer - Mechanical Assembly (Top View)

4. With the extractor fork removed, inspect the alignment key mounted under the extractor. If it is damaged
due to improper spindle orientation, replace it and correct the orientation (refer to appropriate section) after
the extractor fork has been replaced.
5. Put a drop of blue Loctite on each of the SHCS and attach the new extractor fork to the ATC with the
SHCS. Do not over-torque! Ensure the distance from the edge of the extractor fork to the edge of the
pocket in the carousel is the same on both sides in accordance with the following section.
6. Test run the ATC to ensure proper operation.

SLIDING COVER REPLACEMENT

NOTE: If any of the sliding covers on the ATC do not slide freely or are bent in a crash,
they must be replaced.

1. Loosen the four screws that attach the sliding panel cover to the carousel. Be careful to not lose the spring
that holds the sliding cover closed or the number plate on the ATC carousel.
2. Inspect the cover for any galling or damage. Inspect the spring for damage.
3. Loosely install the two innermost screws that attach the number plate and the cover to the carousel and
slide the spring into position in the slot in the ATC carousel.
4. Put the replacement sliding panel in place, making certain that the tongue on the panel pushes on the end
of the spring.
5. Tighten the two rear screws completely and install the two front screws.
6. Ensure the sliding panel moves freely.

NOTE: If the sliding door is bent, determine why before resuming normal operation.

96-0283 rev C June 2007 Mechanical Service 81

 SHUTTLE IN /OUT MOTOR
A motor moves the tool changer assembly (shuttle) towards and away from the spindle. The motor is geared to
a low RPM and then connected to an arm that rotates through 180o and pushes the shuttle in and out.
Removal
1. Turn the mill off, and remove the cover from the tool carriage casting.
2. Remove the hex bolt that attaches the cam follower to the slip clutch.
3. Push the tool changer in as far as it will go.
4. Loosen the set screw that secures the slip clutch assembly to the shuttle motor .
5. Using a small two-jaw puller, pull the slip clutch assembly off the shuttle motor shaft.
6. Remove the SHCS attaching the cover to the holding arm casting on the tool changer.
7. Remove cover from wire channel inside holding arm casting and unplug shuttle motor from wiring harness.

Wiring Harness

Unplug Shuttle
Motor
Shuttle Motor

Wiring Harness for Shuttle Motor

8. Remove the four FHCS attaching the shuttle motor to the holding plate on the tool changer. The FHCS are
visible from the front of the VMC. Do not remove the HHBs holding the shuttle motor gear box together.
Installation
1. Install the new motor on the tool changer holding plate using the four 10-32 x ¾" FHCS. Before inserting
the FHCS, place a drop of blue Loctite® on each screw.
2. Reattach the shuttle motor connection to the wiring harness in the holding arm casting.
3. Replace the cover on the holding arm casting.

10 - 32 x 3/4" FHCS (4)

Front View of Holding Plate Showing FHCS Location

82 Mechanical Service 96-0283 rev C June 2007

 4. Reattach the slip clutch assembly to the shuttle motor shaft. Before placing on the shaft, put two or three
drops of red Loctite® on the slip clutch hub.
5. Insert and tighten down the set screw holding the slip clutch assembly to the shuttle motor shaft. Before
inserting the set screw, put a drop of blue Loctite® on the set screw.
6. Ensure the actuating arm on the slip clutch assembly is within 0.12" of the shuttle In and Out proximity
limit switches, or makes contact with mechanical limit switches.
7. Ensure the hub of the slip clutch assembly does not interfere with the face plate on the shuttle motor.
8. Start the VMC and perform at least 30 tool changes, assuring correct operation.

CAROUSEL ROTATION MOTOR

A motor is used to rotate the tool turret between tool changes. This motor is geared to a low RPM and con-
nected to a Geneva mechanism. Each 1/2 revolution of the Geneva mechanism moves the tool turret one tool
position forward or backward.

Removal
1. Power on the mill and put it in MDI mode.
2. Zero Return all axes (Zero Ret - Auto All Axes).
3. Press ATC Fwd then the Emergency Stop after the spindle head has moved during the tool change cycle.
The tool changer should be at the full In position and the spindle head should be above the tool changer.
4. Turn the mill power off.
5. Remove the 10-32 SHCS from the carriage casting cover and remove the cover.
6. Tag both limit switch connections for reassembly, then unplug the limit switches and the power connec-
tions at the carriage casting.
7. Remove the four SHCS attaching the turret motor and mounting plate to the tool carriage casting.

Carriage Unplug Lines

Casting Here

Carriage Casting with Cover Removed

8. Carefully lift the turret motor assembly off of the tool carriage casting.

NOTE: The gear motor should never be disassembled and is not field-serviceable.
All gear motors should be returned to Haas for evaluation.

96-0283 rev C June 2007 Mechanical Service 83

 Installation

Mounting
Turret Motor Plate

0.750

Geneva
Driver Geneva
Cam

Required Spacing for Geneva Driver

1. Grease the locking element and drive pin on the Geneva driver. Also, grease the teeth on the Geneva star.
2. Rotate the Geneva driver until the cam depresses the limit switch on the turret motor assembly.
3. Place a narrow strip of paper around the locking element of the Geneva driver and install the turret motor
assembly onto the casting. Be certain that the locking element of the Geneva driver is seated against the
star with the paper strip acting as a shim.
4. Attach the turret motor assembly to the carriage casting with the four SHCS.
5. Reconnect the power and limit switch lines to the turret motor.
6. Power on the mill and Zero Return all axes (Zero Ret - Auto AllL Axes).
7. Go to MDI mode and press "T - 1 - ATC Fwd".

NOTE: The machine may alarm at this time (Alarm 115 or 127). If this occurs, Zero
Return the Z-axis (Zero Ret - Singl Axis) and repeat step 7. This step may need
to be repeated two times to clear all possible alarms.

8. Press "T - 9 - ATC Fwd". The tool changer should go to tool nine. If the tool changer travels to tool seven,
the turret motor is wired backwards. Reverse motor leads and repeat steps 7-10. The turret should run
quietly with no strain in the motor, banging, or vibration.
9. Reinstall the tool carriage casting cover.
10. Test the tool changer for proper operation.

G ENEVA STAR REPLACEMENT

NOTE: If ATC Geneva star is damaged or worn in its driven slots, it must be replaced.

1. Turn the machine power off.

2. Remove the cover from the front of the ATC shuttle.
3. Remove the turret motor assembly (Refer to previous section).
4. Place a support for the ATC under the center of the carousel.
5. Loosen the nut inside the carriage casting that attaches the ATC carousel assembly to the casting. There
is a socket head in the top of the shaft to hold it stationary while loosening the nut.
6. Place the cardboard over the mill table and carefully lower the carousel until it rests on the table.

84 Mechanical Service 96-0283 rev C June 2007

 7. Remove the six SHCS that attach the Geneva star to the bearing housing on the ATC carousel.
8. Install the Tool #1 standoff on the replacement Geneva star.
9. Install the replacement Geneva star. Check the concentricity of the star to the shaft on the carousel
assembly; it must be within 0.005". If the star is not within tolerance, loosen the SHCS and adjust the
alignment until it is acceptable.
10. Installation is reverse of removal. Grease the perimeter of the star before installation and readjust the ATC
in accordance with "ATC Alignment" and "Shuttle Stroke Adjustment", if necessary.

ATC TRAP D OOR REPLACEMENT

NOTE: If the ATC trap door is damaged in a crash, it must be replaced.

1. Turn the machine power off.

2. Remove the turret motor assembly in accordance with the previous section.
3. Place a support for the ATC under the center of the carousel.
4. Loosen the nut inside the carriage casting that attaches the ATC carousel assembly to the casting. There
is a socket head in the top of the shaft to hold it stationary while loosening the nut.
5. Place the cardboard over the mill table and carefully lower the carousel until it rests on the table.
6. Remove the two SHCS that attach the guide pin for the ATC trap door to the ATC holding plate and remove
the guide pin.
7. Slide the trap door from between the carousel cover and the shuttle casting. Be careful to not lose the two
nylon washers that sandwich the trap door between the carousel cover and the shuttle casting.
8. Installation is reverse of removal. When installing the guide pin, ensure the mounting slot is approximately
central to the mounting screws and that the pin does not interfere with the top of the ATC carousel cover.
Grease the carousel cover where the plastic standoffs ride, the slot in the ATC shutter, the guide pin, and
the nylon washers where the shutter pivots. ATC positioning may need to be readjusted after installation.

96-0283 rev C June 2007 Mechanical Service 85

 SIDE M OUNT TOOL CHANGER (SMTC)
The tool changer is driven by a single axis control mounted inside the cabinet.

TROUBLE SHOOTING
Side Mount Tool Changer Recovery Flow Chart
Press Recover
Button

Alarms Alarms exist, they must be cleared.

exist? Y Press ‘Y’ to continue, then ‘Reset’
to clear alarms, then retry.
N

Tool in N Y
arm or spindle Arm at
origin?
(Y/N)?
Y N
At origin, continue
Will arm to Pkt Restore (Y)?
prevent tool in “ATC Fwd/Rev” still
N spindle or pocket moves arm.
from being Cnc waits for ‘Y’
removed before continuing
(Y/N)? Press arrow key to
move carousel or Carousel
Y ‘Write’ to continue Y
Carousel Y between
Tool may fall during tool recovery. Place something between automatic recovery Y
pockets?
soft under tool to catch it. Don't use hands pockets? Cnc waits for ’Write’
to catch tool, and press ‘Y’ to continue. before continuing N
CNC waits for ‘Y’ before continuing. N Move to next
Restoring pockets, pocket
please wait N
Use following commands to remove all tools from
spindle and arm. Move carousel with arrows. Check current
a

ATC Fwd/Rev - Rotate arm Fwd or Rev Tool change recovery Offset page with
carousel pocket, complete! Press ‘Y’ to pockets displayed.
Tool Release - Toggle tool un/clamp enter current
Up/Down arrow - Moves Pkt up or down continue. Please update
pocket number, pocket and tool page.
Orient Spindle - Spindle orientation
a
and press 'Enter'.
To move spindle up/down, arm must be at origin,
and you must exit tool changer recovery. END
a

Are you finished using commands (Y)?

CNC waits for ‘Y’ before continuing.

Orient
spindle Y
pressed?
About to orient spindle.
N Caution! This may damage tool
arm if spindle interferes with
Use Tool Release button while holding tool and its motion. Press ‘O’ to orient,
remove all tools from arm and spindle.
a
‘N’ to cancel.
Depress tool-clamp-release stud on arm while
holding tool and slide tool out. Note a N
tool-clamp-release stud for each end of arm
a
‘N’ or ‘O’
Are all the tools removed (Y)?
Cnc waits for ‘Y’ before continuing O
Orient spindle

Arm at
origin? Use ATC Fwd/Rev to rotate arm to origin

86 Mechanical Service 96-0283 rev C June 2007

 40 TAPER CAROUSEL REMOVAL AND INSTALLATION

Carousel
12 13
10 11

ATC
14

7 8 9
1
5

Carousel

16

6
17

5
18 19
Housing

4
Assembly

3
20 21
2

Number Disc Carousel

22 23 24 1

Assembly
Tool Cover
Pockets

10
8 9 11
12

7
13 14

6
5
15 16

43
17

1 2

1
8
19
24

20 21 23
22

Carousel Base

SMTC (Horiz) SMTC (Vert)

Special Tools Required: Lifting Device (1000lb capacity for 40-pocket ATC removal, 3000lb capacity for 60-
and 70-pocket ATC removal), Spanner Wrench, Split Tools
Removal
1. Power Off machine.
2. Unscrew the BHCS from the carousel number disc and remove.

Carousel ATC Covers

Number Disc 12 1
3 10 11
14
9

1
7 8

Disc Mounting
16

6
17

BHCS
5
18 19

4
3
20 2

2
22 23 24 1
Carousel
1

Assembly
ATC Mounting
Bracket

Column
Spindle
Assembly
Double-Arm
Assembly

3. Using a spanner wrench, remove nut on the center shaft of the carousel.
4. Carefully pull the carousel assembly from the ATC center shaft. Lift carousel away from the machine and
carefully avoid hitting the sheet metal covers. Place assembly in service area.

CAUTION! Be careful not to bend the tool pocket orientation tabs when storing the
carousel assembly.

5. Unscrew the FHCS for each tool pocket. Remove the tool pocket holders from carousel as shown below.
Installation
1. Carefully lift and place carousel onto the center shaft.
2. Install new carousel retaining nut onto the ATC center shaft and torque to 85 ft-lbs (place the locking
portion of the nut toward the end of the shaft). Remove the pocket stop and slider.

96-0283 rev C June 2007 Mechanical Service 87

 Carousel Carousel
Number
Disc Slider Cam Box Carousel
Position Pulley
Carousel Carousel
Shaft Nut Pocket
Stop Cam Box
Carousel Tool Pocket Pulley
Carousel Housing Mounting
FHCS
ATC
Assembly
Mounting Backside
BHCS (8) Pocket
Orientation Tool Pocket Double-Arm
Tool Pockets Top View Tabs (Load Position)

Carousel Assembly Carousel and Tool Pocket Installation Pulley Locations and ATC Movement

3. Install each tool holder through the spindle. Attach the tool pocket to the carousel. Apply blue loctite to the
Torx and torque to 15 ft-lbs (1/4-20) / 23 ft-lbs (5/16-18). Manually rotate the carousel for each tool pocket
installation. Re-install the pocket stop and slider as shown above. The carousel can be rotated by manually
rotating the carousel pulley by hand as shown above.

50 TAPER CAROUSEL REMOVAL AND I NSTALLATION

Special Tools Required: Lifting Device (3000 lbs. capacity for Tool Changer Removal), Haas tool P/N 1357

CAUTION! Do not attempt to remove the carousel with the pockets installed.

1. Remove sheetmetal disc covering the carousel. Press Tool Changer Restore. Press Y three times to enter
Tool Changer Recover Mode.
2. Remove all tool changer pockets. See "SMTC Pocket Removal and Installation" in this section.

NOTE: The carousel can be manually rotated by turning the carousel drive motor by
hand while in E-Stop.

3. Remove the center bearing nut using Haas tool P/N 1357.
4. Remove the carousel using a suitable lifting device.

CAUTION! The carousel is extremely heavy. Ensure you have an appropriate lifting
device and straps capable of lifting the carousel weight.

Installation
1. Using a suitable lifting device, place the carousel onto the tool changer body.
2. Use a new bearing nut and thread onto the carousel shaft. Torque to 80 ft./lbs.
3. Install pockets into the carousel following the "SMTC Pocket Removal and Installation" section.
4. Rotate the carousel by hand to the next pocket. Line up the pocket mounting finger with the actuator shaft
(or micro switch) on the flat spot on the carousel cam.

88 Mechanical Service 96-0283 rev C June 2007

 ATC ASSEMBLY REMOVAL/INSTALLATION
Special Tools Required: Lifting Device (3000lb Capacity), Lifting Bracket/Bar
Removal
1. Power off machine.
2. Remove all ATC assembly sheet metal covers and fasteners.
3. Remove the tool changer amphenol connection at the control box and tool pocket air line at the top of the
carousel. Wrap and tie the amphenol connector to the top of the carousel cam box.
4. Insert an eyebolt into the threaded 1/2-13 hole at the top of the carousel housing. Note that 60-, 70-pocket
and 50-taper/50-tool tool changers require that a lifting bar be attached to the back of the carousel housing
assembly (see illustration). Attach the lifting device to the eyebolt and support the ATC assembly as
shown. Remove the five carousel mounting SHCS from the Vertical ATC mounting bracket and move ATC
assembly away from the column as shown.

Lifting Column ATC Mounting

Eye Bolt Bracket
Cam Box 1/2” Hardwasher
1/2-13 x 2”
SHCS (10)
ATC
Assembly
Backside

ATC Assembly

Horizontal ATC Assembly Lifting Position Vertical ATC Assembly Lifting Position Vertical ATC Mounting Bracket

Lifting Bar Hook here

SMTC 60/40, 70/40, 50/50Carousel Housing Assembly (Rear View)

Lifting Bar Mount Location

5. Carefully raise the ATC assembly until it is out of the machine. Avoid catching the double-arm on other
machine parts.
6. Lower the ATC assembly with the back side of the cam box towards the ground.
Installation
1. Power Off machine.
2. Clean mounting surfaces of the ATC mounting bracket and the ATC.
3. Align the ATC with the mounting bracket and attach with SHCS. Only snug the SHCS.

96-0283 rev C June 2007 Mechanical Service 89

 8X
SHCS

5X
SHCS

Horizontal Tool Changer Installation

4. Reconnect the tool changer amphenol connector to the control and reattach the air line to the carousel
assembly.
5. Align the ATC assembly according to section on ATC alignment.
6. Torque the SHCS to 100 ft-lbs.
7. Replace all carousel sheet metal covers and fasteners. Apply blue loctite to all fasteners and tighten.

ATC ALIGNMENT (HORIZ)

This procedure is to assist in the alignment of the automatic tool changer and the double arm for the EC-300,
EC-400, EC-500, and EC-1600-3000 Horizontal Mills.
Use Split Tool P/N T-2086 for 40 taper, CT type T-2088 for 50 taper, BT type
T-2087 for 40 taper, BT type T-2089 for 50 taper, CT type
Horizontal machines require three directions of alignment, as well as spindle orientation. Note that:
EC-300: The X-, Y- and Z-axis, and the spindle orientation are set by parameters
EC-400 and EC-500: The X- and Y-axis, and the spindle orientation, are set by parameters. The Z-axis is
adjusted by physically moving the SMTC.
EC-1600 - EC-3000: The Y- and Z-axis, and the spindle orientation, are set by parameters. The X-axis is
adjusted by physically moving the SMTC.
Horizontal Machine Double Arm to Tool Pocket Alignment
1. EC-300, and EC-1600-EC-3000: Go to Parameter 64, write down its value, and set it to zero. This will allow
maximum clearance to spindle. EC-400: As the alignment is checked or adjusted, ensure the tool changer
arm does not hit the spindle. Note that spindle cannot be moved in Z-axis by parameters, as other mills.
2. Without a tool in the spindle, command a tool change. Press E-Stop before the double arm reaches the
pocket. This causes the mill to move the axes to the ATC position. Do not run the double arm into the
spindle
3. Clear the E-Stop alarm.
4. Using T/C Recovery, rotate the double arm in the forward direction. Continue rotating the double arm until it
reaches the pocket, then extends approximately 4" (100mm) for the 40-taper spindle, or 6" (150 mm) for a
50-taper spindle in front of the pocket.
5. Using the dowel pin as a handle, install the tapered half of the split tool into the pocket. Be careful to not
place your hands in the pinch point between the tool and the pocket.

90 Mechanical Service 96-0283 rev C June 2007

 6. Install second half of the split tool into end of the double arm in front of pocket. It is necessary to manually
press the tool lock plunger (near center of shaft as shown in following section) for spilt tool to be inserted.
7. Using T/C Recovery in the reverse direction, move the double arm back until the halves of the split tool are
approximately 1" (25 mm) apart.
8. EC-300/EC-400/EC-500: Slightly push the double arm in the counterclockwise direction to remove back-
lash in the drive assembly.
EC-1600: Hang a 40 lb (18.2 kg) weight from the pocket side of the arm. Hang the weight from the hole
closest to the pocket. This will preload the arm.

Weight

9. Continue to move the arm toward the pocket. Watch the double arm as it approaches the pocket. Continue
moving closer until there is a maximum of 1/8" (3 mm) gap between the split tool halves, ensuring that the
halves do not touch each other.
10. Check the X and Y alignment of the double arm to the pocket by inserting the alignment dowel through
both halves of the split tool. The dowel should slide freely. If the pin does not slide freely, the direction of
the misalignment may be determined by feeling the “step” between the split tool halves, by using a steel
rule, straight edge, or similar tool.
11. If the dowel pin does not slide in freely, adjust radial alignment of the split tool to the double arm, loosen
the lock ring SHCS and adjust the double-arm, as described in “Double Arm Removal and Installation” .
12. If the double arm is not aligned in the Y-axis with the centerline of the split tool, loosen the four cam box
SHCS and insert a pry-bar between the slots. Adjust the cam box until the centerline of the split tool is
aligned with the centerline of the tool pocket.
13. Torque the cam box SHCS to 80 ft-lbs.
14. Recheck alignment.

Double-Arm Tool Release

Radial Button (2)
Alignment

Cam Box
Movement
Carousel
Double-Arm
Tool Pocket
Center

Cam Box/Double Arm Alignment, Front View

96-0283 rev C June 2007 Mechanical Service 91

 15. EC-300 and EC-1600-3000: Fully retract the Z-axis (Z+ direction).
16. Using Tool Change Recovery, press the down arrow to rotate the tool pocket to the tool change position.
17. Move the double arm in the forward direction until the arm rotates to the tool pocket. Then move away from
the pocket in the Z direction, do not crash the arm into the spindle. This distance is approximately 4" (100
mm) for a 40 taper spindle or 6" (150 mm) for a 50 taper spindle.
18. Install a toolholder into the double arm. It will be necessary to manually depress the plunger to do this.

Tool Changer
Spindle Double Arm

Tool 8 9 5 1 2 3 4 5 6 7 8 9 6 1 A Made in America

Measure This
Distance
Plunger
Double-Arm
Tool Holder
04 03

02
05

01
06
07

0
80 90

Top View

Tool to Spindle Alignment Shown. Tool to Pocket Alignment is Done the Same Way

19. Measure the distance from the front of the double arm to the front face of the toolholder and record it.
20. Press the plunger to unlock the tool and remove the tool from the double arm.
21. Using Tool Change Recovery, return the double arm to the origin (Home) position.
22. Install the same toolholder, as used in the previous step, into the tool pocket.
23. Using Tool Change Recovery, rotate the double arm in the forward direction until the arm is very close to
the toolholder, but not touching it. (The spring-loaded slide will be touching the toolholder.)
24. Using a caliper, measure the same two surface positions described in Step 5. The measurement should be
the same, +/- .01" (.254 mm), as step 5.
25. If adjustment is required, move the double arm on the output shaft as described in “Double Arm Removal
and Installation”.
26. Recheck both radial and axial positions until correct alignment is achieved.
27. Using T/C Recovery, move double arm forward, away from pocket and remove both halves of the split tool.
28. Verify the spindle is clear of the double arm. Reverse the double arm away from the spindle if necessary.
29. Return the double arm to the “Home” position and exit Tool Change Recovery.
30. Reset Parameter 64 to its original value if changed.
Double-Arm to Spindle Alignment
1. Double arm to carousel pocket alignment must be correct before setting double arm to spindle alignment.
2. With no tools in the machine, command a tool change. Press E-Stop before the double arm reaches the
spindle. This causes the machine to move the axes into tool change position. Reset the E-Stop alarm.
3. Orient the spindle; use the command in Tool Changer Recovery.
4. Advance the double arm to the spindle, watching carefully for any interference. Be sure to check orientation
of the spindle drive dogs to the double arm key.

92 Mechanical Service 96-0283 rev C June 2007

 5. If orientation is incorrect, press Reset to allow the spindle to be manually rotated to the correct position.
Correct Parameter 257 (Spindle Orientation) as described in the “Setting Spindle Orientation”.
6. Continue moving the double arm in the forward direction until the arm extends approximately 4" (100mm)
for the 40-taper spindle, or 6" (150mm) for the 50-taper spindle, in front of the spindle.
7. Using the dowel pin as a handle, install the tapered half of the split tool into the spindle. Be careful to not
place your hands in the pinch point between the tool and the spindle. The Tool Release button operates in
a Toggle On/Off mode during Tool Recovery. Press once to activate the Tool Release; press again to clamp.
8. Install the second half of the split tool into the end of the double arm in front of the spindle. It will be
necessary to manually press the tool lock plunger (near the center of the shaft, see the previous figure) to
allow the split tool to be inserted.
9. Using T/C Recovery in the reverse direction, move the double arm back toward the spindle until the halves
of the split tool are approximately 1" (25.4 mm) apart.
10. EC-300, EC 400 and EC-500: Push the double arm in a counterclockwise direction to remove backlash.
EC-1600-3000: Hang a 40 lb (18.2 kg) weight on the pocket side of the double arm as shown in “Cam Box
to Tool Pocket Alignment”.
11. Continue to move the arm toward the spindle. Watch the double arm as it approaches the spindle. The
spindle dogs and the slots in the double arm should line up. Continue moving closer until there is a maxi-
mum 1/8" (3.2 mm) gap between the split tool halves, ensuring that the halves do not touch each other.
12. Check the X and Y alignment of the double arm to the spindle by inserting the alignment dowel through
both halves of the split tool. The dowel should slide freely. If the pin does not slide freely, the direction of
the misalignment may be determined by feeling the “step” between the split tool halves. Do this by using a
steel rule, straight edge, or similar tool.
13. If misalignment is present, the method of alignment varies, depending upon the machine.
a. EC-300/EC-400/EC-500
1) Adjust Parameters 210 (X) and 211 (Y) to correctly center the spindle to the double arm.
2) Using T/C Recovery, move the double arm forward to clear the spindle dogs.
3) Put the mill in Debug mode.
4) Handle jog the X- and Y-axis to center the two halves of the split tool.
5) Record the actual values for the X- and Y-axis on the “Pos-Raw Dat” screen. Omit the decimals,
but include the “-” sign.
6) Enter the X value into Parameter 210, and the Y value into Parameter 211.
7) Remove the split tool.
8) Using T/C Recovery, return the double arm to the origin (Home) position.
9) Return the tool pocket to the tool stored position (arrow up).
10) Cycle power to the machine and recheck alignment.
11) EC-300: Parameter 64 is used to adjust the Z direction (see Setting Parameter 64). EC-400
and EC-500: If Z-axis adjustment is necessary, loosen the ATC mounting SHCS, slide the ATC as
required, retorque the SHCS to 80 ft-lbs, and recheck alignment. The screws to loosen hold the
tool changer spacer to the main base casting.

96-0283 rev C June 2007 Mechanical Service 93

 8X
SHCS
Horiz. ATC
Mounting
Bracket
5X
SHCS
6X Hex
Head Bolt

5X
SHCS

EC-400 24-Pocket Mount EC-400 40-Pocket Mount

10X
SHCS

EC-400 60 and 70-Pocket Mount

b. EC-1600-3000
1) Adjust the Y direction and spindle orientation in the same manner as for the EC-400.
2) Adjust Parameter 64 to move the spindle in the Z-axis direction.
3) If X-axis adjustment is necessary, loosen the SHCS, slide the SMTC as required, retorque the
SHCS to 80 ft-lb, and recheck alignment.

Horiz. ATC View Rotated

Mounting 1808
7X Bracket
SHCS

8X
SHCS

EC-1600 Standard Mount EC-1600 50-Pocket Mount

94 Mechanical Service 96-0283 rev C June 2007

 ATC ALIGNMENT (VERT)
For Vertical machines, the servo tool changer, like those used on super speed machines, must have the grid
offset and tool change offset set before starting the alignment procedure.
Cam Box to Tool Pocket Alignment
1. Remove all cam box sheet metal fasteners and covers. Place protective covers on the machine table.
2. Power up machine. Raise Z-axis to top of travel. Set machine control to Tool Change Recovery (TCR).
3. Push the down arrow button to activate the tool pocket down (ensure proper tool pocket operation).

Check
Valve

Air
Cylinder

Tee Fitting

Double Arm Alignment Airline Connection Location

4. Power off machine. Disconnect air supply at rear of machine. Tool pocket raises once air is disconnected.
5. At the top of the ATC assembly, reverse the two air lines going from the solenoid valve to the air cylinder as
shown above. Reconnect the air supply line at the rear of the machine. (The tool pocket holder in the tool
change position should move down.)
6. At the top of the ATC assembly, manually rotate the cam box pulley clockwise until the output shaft is
lowered and just before it begins to rotate 1800.
7. Align the double-arm underneath the tool pocket and spindle with unlocking finger buttons facing upward.
Place the double-arm onto the shaft and snug the lock ring on the double-arm bottom with the SHCS.
8. Place the split tool (P/N’s previously shown) into the double arm end beneath the tool pocket. Depress the
tool release button on top of the double-arm and insert the split tool. Slightly push the double-arm in the
clockwise direction to remove backlash in the drive assembly, as shown in the following figure.

Double-Arm

Tool Pocket
Center

Cam Box
Double-Arm Movement
Finger Center
Double-Arm
Radial
Alignment

Carousel
Tool Release
Button (2)
Cam Box to Tool Pocket Akignment (Top View)

96-0283 rev C June 2007 Mechanical Service 95

 Radial alignment of Double Arm to Carousel
9. Rotate the cam box pulley counter-clockwise to raise the double-arm into the split tool. Visually check the
centerline alignment of the split tool to the centerline of the tool pocket.
10. In order to adjust the radial alignment of the split tool to the double arm, loosen the lock ring SHCS and
adjust the double-arm as shown above.
11. If the double arm is not aligned in the Y-axis with the centerline of the split tool, loosen the four cam box
SHCS and insert a pry-bar between the slots. Adjust the cam box until the centerline of the split tool is
aligned with the centerline of the tool pocket.
12. Torque the cam box SHCS to 100 ft-lbs.

Checking Parallelism of Double-arm to Table

13. Rotate the cam box pulley clockwise to lower the double arm. Remove the split tool from the double arm.
14. Rotate the cam box pulley counter-clockwise to raise the double arm back to its home position.
15. Remove the air supply line from the rear of the machine. Switch the inlet and outlet airlines back to
their original positions at the top of the ATC assembly. Re-attach the air supply line (the tool pocket
holder should retract to its home position).
16. Power On the machine and enter TCR mode. For more information on TCR mode refer to the TCR flow
chart located in the Technical Reference section.
17. Press the ATC Forward button until the arm lowers and is parallel to the X-axis. Insert a split tool into the
double arm by pressing the tool release button located near the shaft as shown above.
18. Place a magnetic base and indicator on to the machine table. Measure the bottom of the split tool to the
nearest .001".
19. Move the split tool and indicator setup to the other end of the double-arm. Measure the bottom of the split
tool to the nearest .001". The maximum allowable height tolerance between the two ends is .030". Adjust
the alignment as necessary. Repeat this test with the arm rotated 1800 .
20. Remove the split tool from the double-arm. Return the double-arm to the home position.

Setting the Double-arm Height

21. Press the Down Arrow to command the tool pocket down. Place the split tool with the pull stud into the
tool pocket. In TCR mode, rotate the double arm near the tool pocket.
22. Visually check the height alignment of the double arm to the V-groove on the split tool. If necessary, loosen
the lock ring SHCS and adjust the height of the double arm. Torque the lock ring SHCS to 15-17 ft-lbs.
23. Repeat steps 9 & 10 to re-check radial alignment.
24. Return the double-arm to the home position.

Double-Arm to Spindle Alignment

1. Zero Return the Z-axis.
2. In TCR mode, lower the double arm and re-insert the split tool into the double arm. Orient the spindle dogs
for a tool change. (If the orientation has changed reset Parameter 257. Refer to section on setting spindle
orientation). If spindle dogs are not aligned with the tool holder slot, manually rotate the spindle dogs.
3. Raise and lower the double-arm to move the tool in and out of the spindle and check for alignment.
4. Check the X-axis alignment of the split tool to the spindle center.
5. If necessary, loosen the five ATC mounting SHCS.

96 Mechanical Service 96-0283 rev C June 2007

 ATC Mounting Loosen Mounting
Bracket
SHCS (5)
Spindle Prybar

Tool

Equalize
Gap All
Around X-Axis
Double-Arm

Spindle
Loosen xis ATC Mounting
Tool Centerline
Mounting Y-A Bracket
Centerline SHCS (5) ATC Assembly Prybar ATC Assembly

Double Arm to Spindle Center ATC Assembly X-Axis Alignment ATC Assembly Y-Axis Alignment
Alignment, Along the Y-Axis

6. Insert a pry-bar between the locating pins and the ATC mounting bracket. Adjust the bracket to align the
split tool in the double arm to the center of the spindle in the X-axis.
7. Torque the SHCS to 80 ft-lbs.
8. Check the Y-axis alignment of the split tool to the spindle.
9. If necessary, loosen the five ATC SHCS (shown above). Insert a small pry bar between the locating pins
and the mounting bracket. Adjust the ATC along the mounting slots and align the tool and spindle’s center.
10. Check the spindle tool change height. If the spindle tool change height has changed, reset Parameter 64.
11. Return to normal operation. Insert tool holders through the spindle and perform several tool changes.
Observe the tool changer during operation and make any adjustments if necessary.
12. Torque the ATC mounting SHCS to 100 ft-lbs. Replace all cam box sheet metal covers and fasteners. Apply
blue loctite to the fasteners and tighten.

D OUBLE ARM REPLACEMENT

Removal
1. In TCR mode, lower the double-arm. Power Off machine.
2. Underneath the double-arm, loosen the six SHCS from the lock ring. Insert four new jackscrews into the
lock ring (Coat the jack screw threads and tips with moly grease).
3. Slowly tighten the jackscrews in order to push the double-arm away from the lock ring. If necessary, tap
the center of the double arm from underneath with a soft mallet until the double-arm breaks free. Note that
there is a second set of jackscrews available. These use 5/16 bolts. Place a piece of steel between the
collar and the double arm and then tighten the 5/16 screws to remove the double arm.
4. Once the double-arm is loose, pull the double arm assembly off the shaft.

96-0283 rev C June 2007 Mechanical Service 97

 Drain Plug Lock Ring 8 SHCS
Lock Ring
Lock Ring

4X Double-Arm
Jack SHCS

8X Lock Ring Double-Arm

SHCS Jack SHCS (4)
Double-Arm
Double-Arm

Double-Arm Removal (Horiz) Double-Arm Removal (Vert)

Installation
1. Place the double-arm onto output shaft. Align the double-arm, as described in the previous sections.
2. Reattach the lock ring to the double-arm with eight (8) SHCS. Tighten in a star pattern to 15 ft-lbs; repeat 3
times to seat the arm lock bushing. Verify the slides are correctly adjusted on the double arm
a. With the double arm lowered, and the split tool inserted into the double arm, a feeler gauge, between
.015" and .020" should fit between the slide and the tool flange O.D. The plunger should be able to rise
fully to the locked position with the gauge between the split tool and the plunger.

Plunger Adjuster Hex Shim Insert Feeler

Spring Washers* Gauge Here

Tool
Holder

Slide
Adjuster Double Arm with Cover * Not used on
Plate Removed EC1600-3000

b. The plunger will not return reliably to the fully raised locked position when the tool is inserted if there is
insufficient clearance. The split tool will be excessively loose in the doublearm if there is too much
clearance. Either condition can cause dropped tools.
c. To adjust the clearance, remove the slide and the cover by removing the cover plate and lifting the slide
out at an angle. Be careful not to lose the spring. Loosen the adjuster and correct the clearance by adding
or removing shim washer. Apply blue Locctite and retighten. Grease the spring and the slide assembly and
reinstall them both. Reattach the cover plate and recheck the clearance. Both ends of the double arm are
separately adjusted.
3. Re-align the double-arm to the spindle and tool pocket. Refer to double arm alignment instructions in the
previous “ATC alignment” section.

SETTING SPINDLE ORIENTATION

1. Power up machine. Go to Parameters. Jog the spindle head to the tool change position. Unlock Param-
eters and change the Parameter 257 value to “0.”
2. Place a tool into the spindle. Enter TCR mode. Align the spindle dogs to the double-arm key (see the
following figure). Press the ATC Forward button until the double arm engages the tool (manually rotate the
spindle dogs if necessary).
3. Enter Debug mode. Record the encoder value under “spindle orientation position”.

98 Mechanical Service 96-0283 rev C June 2007

 4. Return to Parameter 257. Enter the spindle orientation value from Debug and lock parameters.
5. In TCR mode, press the ATC Reverse button until the double arm is in the home position. Return to normal
operation mode.
6. Manually insert tools into spindle and perform several tool changes. Observe for any misalignment.
7. Adjust the Parameter 257 setting value if necessary.

Double-Arm Key

Toolholder Slot

Align Spindle Dogs

to Double-Arm Key
and Toolholder Slot

Spindle Orientation Setting

EC-300 TOOL C HANGER DOOR OPEN S WITCH ADJUSTMENT

The tool changer door must be completely open before the sensor switch on the air cylinder changes its state.
1. With the machine on E-stop, disconnect the main air supply.
2. Clamped to the air cylinder with a hose clamp, is the tool changer door open switch. Move the sensor
switch toward the rod end of the air cylinder until it reaches the end cap of the air cylinder.
3. Open the tool changer door all the way. Watch the diagnostic screen. Slowly slide the sensor switch back
along the air cylinder until the tool changer door bit changes from 0 to 1.

TC Door
(Open)

Tool
Spring Damper Changer
View Rotated Door Open
908 Hose Switch
Clamp

TC Door
(Closed)

4. Mark the spot where the bit changes to 1 and secure the switch with a hose clamp.
5. Reconnect the main air supply, and take the machine off of E-stop.
6. Run the tool changer door and check for speed.

96-0283 rev C June 2007 Mechanical Service 99

 7. Adjust the speed at the solenoid valve on the lube panel.
8. Check the action of the spring damper that stops the tool changer door when it opens. The tension can be
adjusted by turning the adjustment screw on the back of the spring.

EC-400 T OOL CHANGER DOOR REPLACEMENT

This procedure describes the installation of the complete door assembly. It may not be necessary to start the
procedure from the beginning. Remove the damaged or inoperative parts and then rebuild the door assembly.

Installation and Alignment

Linear Guides and Air Cylinder
1. Push the top of the linear guide towards main panel wall and tighten top bolt. Push the bottom of the linear
guide towards panel wall and lightly tighten bottom bolt. Securely tighten the remaining bolts, then tighten
the top and bottom bolts. Install linear guide trucks and grease using fittings.
2. Grease shoulder bolt and slide through panel bracket, spacer, idler assembly, second spacer, and washer.
Thread the bolt into the pemnut and tighten.

Tool Changer Lock Washer

Door Top Bracket
Door Connect
Rod Aligner

Air Cylinder
Nut Washers Rod

Chain
Upper Door
Sprocket
Assembly

PEM Nut Shoulder

Bolt
Washer Lower Door
Bracket Spacers

3. Push air cylinder towards linear guide rail while tightening bolts.
4. Thread & tighten onto cylinder rod end.
Tool Changer Doors
5. Grease main panel face where the door guide will be mounted. Mount door guide to main panel, with the
guide spacer between them using 10-32 flat-head screws.

100 Mechanical Service 96-0283 rev C June 2007

 6. Grease the edges of the door that will be sliding against main panel & door guide. Slide top door into door
guide and place flange onto linear guide pad (top/right). Put the top door bracket over the door flange and
position the door between the bracket and the upper linear guide truck. Push door flush against main panel
and tighten the four bolts that hold the bracket to the linear guide. Check sliding motion of top door, bracket
and truck, this should be smooth and uniform.
7. Retract air cylinder rod. Place a 7/16 washer over rod aligner thread. Move top door bracket down to air
cylinder rod aligner. The hole in bracket should line up with rod aligner without forcing it over rod end. If not
loosen air cylinder mounting bolts, reposition and then retighten the bolts. Place flat washer and split
washer over rod end and tighten with a 7/16-20 nut. By hand, move the cylinder rod, door bracket and door,
in and out, looking for any binding. If there is any misalignment, loosen the air cylinder mounting bolts and
let it self align, then retighten the bolts.
8. Grease main panel faces where door guides will be mounted. Mount door guides to main panel, with guide
spacers sandwiched between them, via 10-32, zinc, flat head screws.
9. Attach the lower door bracket to bottom/left linear guide pad and leave bolts loose. Grease the edges of the
door that will be sliding against main panel and door guide. Slide door into door guides and attach to the
lower door bracket. Align door so it is square to panel prior to tightening the door bracket screws. Loosen 4
linear guide pad bolts and push door flush against main panel face and re-tighten.

Drive Chain
10. Place chain around idler assemblies and attach one end to bottom door bracket at the hole closest to the
lower idler assembly using a master link. Install jam nut onto threaded, right-handed side of the turnbuckle.
Attach the opposite end of the turnbuckle to the other hole in the bottom door bracket using a second
master link. Make sure chain is properly located on both idler assemblies. Tighten the chain using the
turnbuckle and lock with jam nut.
11. Retract air cylinder and top door to the closed position. Move the bottom door so the top edge is even with
the first bend line in the top door. Attach chain retainer to top connect bracket and lock it into the chain.

Door Adjustment
12. Check the motion of both doors by connecting an air supply to the cylinder, verifying that air pressure is at
85 - 95 psi. Move the top connect bracket back and forth with the cylinder stroke. The rod aligner should
prevent any binding.
Verify door motion by toggling air on and off, adjusting the chain turnbuckle as required so that the door
does not bang shut and bend. If adjustment is not possible, replace the cylinder.

SMTC POCKET REMOVAL AND INSTALLATION

Removal
1. Turn the machine on and rotate the carousel to the pocket you want to change. Remove the sheetmetal in
order to gain access to pocket limit switches. Remove the sheetmetal disc covering the carousel.
2. Press Tool Changer Restore. Press Y three times.
3. Remove the four SHCS that hold the pocket stop. Remove shoulder bolt from the back of the pocket slide.

NOTE: Don't remove set screws. It changes pocket slide and groove alignment.

96-0283 rev C June 2007 Mechanical Service 101

 Carousel Cam Follower
Groove Slider
Position
Carousel Pocket
Stop
Tool Pocket
Mounting
4X SHCS FHCS

Pocket
Orientation Tool Pocket
Tool Pocket Tool Pocket Stop Tabs (Load Position)

Horizontal Machines

Pocket Retaining
Screw
12 1
14
3 10 11
8 9

1
5
6 7
16
17

5
18 19

4
3
20 2

2
22 23 24 1
1

Pocket Down Position

Pocket Stop

Vertical Machines

NOTE: The machine must be in Tool Changer Recovery Mode to perform the next step.

4. Press v (down arrow) to retract the air cylinder shaft. Manually lower the pocket and remove the pocket
retaining screw. See the previous figure.
5. Remove the tool changer pocket by carefully maneuvering the pocket out of the carousel, taking care not to
drop the pocket slide.

NOTE: If the carousel is to be replaced, skip to the Carousel Removal and Installation.

Installation
1. Replace the damaged pocket with a new one. Apply grease to the shaft. Install the pocket slide and pocket
into the carousel. Apply a drop of Blue Loctite to the pocket retaining screw and install. Torque to 14 ft./lbs
(23 ft./lbs for 50-taper).
2. Clear all alarms. Return to Tool Changer Recovery Mode and press ^ (up arrow). This will extend the air
cylinder shaft. Install the pocket slide shoulder bolt, taking care not to pinch the microswitch roller. Ensure
that the microswitch roller rests on the shoulder bolt head.
3. Install the pocket stop, and torque the four SHCS to 40 ft./lbs (45 ft./lbs for 50-taper). Activate the pocket
up and down several times to verify the pocket slide groove matches the casting groove.

102 Mechanical Service 96-0283 rev C June 2007

 Cam Follower Pocket Retaining
Groove Screw Pocket

Pocket Slide
SHCS (4) and Groove
Alignment

Pocket
Retaining
Screw
Pocket Pocket Slide
Pocket Stop Finger
Pocket Stop

4. Restore the machine to automatic mode and perform a tool change by pressing MDI and then ATC Fwd.
Check for any binding or interference of installed parts.

TOOL POCKET SLIDER ADJUSTMENT

The slider set-screw is used to adjust the tool pocket's end-of-stroke with the circular path on the carousel
housing.
1. Rotate carousel by turning the carousel cam pulley by hand.
2. Visually check for misalignment (tool pockets should move smoothly).
3. If necessary, loosen the setscrew nut. Adjust the setscrew in or out until the tool pocket is aligned with the
circular path on the carousel housing. Advance the tool pocket and observe for proper alignment.
4. Tighten setscrew lock nut.

Air Cylinder Carousel Carousel

Housing

Pocket in
Stored Position
Tool
Pocket
Slider
Slider
Adjustment
Pocket in Set-Screw
Load
Tool Pocket Position
Assembly
Top View
Tool Pocket Orientation/Set-Screw Adjustment

PROXIMITY SWITCH REMOVAL /INSTALLATION

Removal
1. Power Off machine. Remove the carousel number disc and the top cover plate.
2. Remove the 1/4” NPT plug near the cam box output shaft and drain the cam box oil.
3. Disconnect the proximity switch connector from the bracket on the top of the assembly.
4. Loosen the double nuts retaining the proximity switch. Carefully remove the proximity switch from the cam
box assembly. Refer to following figures.

96-0283 rev C June 2007 Mechanical Service 103

 Tool Clamp Sensor Cam Box Oil Fill/Breather
Oil Fill/Breather Pulley Tool Clamp
Trigger Origin Trigger
Sensor Oil Fill Sensor
Grooves Level Grooves
Origin
Sensor

Cam Box
Pulley
Motor Stop
3X Proximity Sensor Cam Box Motor Stop
Sensors
Mounting Proximity Sensor
4X Cam Box
Oil Fill Level Mounting SHCS SHCS (4) Sensors (3)

Horizontal Machine Proximity Sensor Switch Location Vertical Machine Proximity Sensor Switch Location

Installation
The proximity trigger disk inside the cam box determines the sensor operation. The sensor must be approxi-
mately .030” away from a flat surface on the disk to function properly. An LED light will come on at the back of
the sensor when it is triggered.
1. Look through the sensor hole and rotate the cam box pulley by hand until the groove is not visible.
2. Screw two nuts to the threaded section of the proximity switch. Snug the two nuts together and apply
thread sealant to the threads. Carefully screw the switch into the cam box. Connect the proximity switch
connector to the plug on the switch bracket as shown in the following illustration.

From ATC Tool From ATC Motor

Clamp Sensor Stop Sensor
From ATC
Origin Sensor

Proximity Switch Connection Bracket.

3. Power On machine. Press E-Stop.

4. Screw the proximity sensor into the cam box an additional 1/8 turn after the LED light comes on. Loosen
both nuts then re-tighten the inner nut against the cam box housing. Tighten outer nut against inner nut.
5. Repeat this procedure for each proximity sensor switch.
6. Refill the cam box with oil to the fill level line.
7. Check for correct operation of the tool changer and alignment. Adjust as necessary.
8. Replace the carousel disc and top cover plate. Apply blue loctite to the fasteners and tighten.

104 Mechanical Service 96-0283 rev C June 2007

 SETTING P ARAMETER 64

CAUTION! The EC-400 Z-axis can crash into the pallet changer actuator if Parameter
64 is not set correctly.

For Z-axis, this is the displacement from home switch to tool change position and machine zero.
(Distance from Home in Inches) X (Line Encoder Constant) = Z-axis tool change position setting
Example:
.625 x 138718 = 861699
To reset Parameter 64 (Z-axis tool change position) if an ATC assembly has been replaced or realigned.
1. Enter Parameters page and record original Parameter 64 setting value.
2. (Make sure there are no tools in the spindle head or tool pocket positions.) Command the spindle head to
its tool change position. Enter Debug and record Z-axis spindle position value.
3. Enter TCR mode, press the Down Arrow, command a tool pocket down, and manually insert a tool into the
tool pocket.

Setting Parameter 64 for Horizontal Machines Setting Parameter 64 for Vertical Machines

4. Place a 0.0005” indicator with an extended arm base onto the machine table. Indicate the bottom of the
tool with the indicator to the nearest 0.001.” Record the measurement.
5. Remove indicator from the table and the tool holder from the tool pocket. Insert the tool into the spindle
head position. Place the measurement indicator under the spindle head.
6. Enter Debug. Jog handle the Z-axis up or down until the end of the tool is at the same height as the
measured value found when the tool was placed in the tool pocket. Record the Z-axis spindle height value.
7. Take the difference in the spindle height values found in Debug mode and add the encoder count value to
the original value for Parameter 64 setting.
Example:
(Difference in Z-axis encoder counts) + (Old Z-axis Tool Change Setting) = New Z-axis Tool Setting
20681 + 861699 = 882380
8. Enter Parameters page. Unlock settings and write new setting value for Parameter 64. Lock parameter
settings.
9. Perform a tool change and observe for misalignment. Adjust the Parameter 64 setting if necessary.

96-0283 rev C June 2007 Mechanical Service 105

 SERVO TOOL CHANGER OFFSETS
Invisible Axis Explanation
The SMTC uses an invisible axis to control the double arm. If the axis is made visible to service or adjust it, the
safety interlocks are disabled, and the automatic operation of the tool changer is prohibited. Be sure the
spindle head is out of the way before rotating the double arm.
Offsets
Both the Tool Change Offset and the Grid Offset must be set before using the tool changer. The Grid Offset
must be set first.
Setting the Grid Offset
The control calculates grid offset parameters with a ‘Grid’ command. A grid offset is an offset that is applied to
the home position of an axis so that the zero location for that axis is re-defined to be half an encoder revolution
away from the home switch. It is recommended that the Grid command be used on each axis separately.
1. Zero Return all axes.
2. Turn the machine off and back on. This will un-zero all the axes.
3. Select the Alarms screen and enter Debug mode.
4. Perform a Zero Single Axis on the Tt axis. Ignore the Zero Ret Margin Too Small alarm if it occurs. If a tool
arm fault is generated, the tool arm is out of position and must be repositioned using tool change recovery.
5. Select the Positions screen, enter “Grid TT” 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.
Setting the Tool Change Offset
1. Set the Tool changer axis to “Visible”. This is done by setting bit 18 of Parameter 462 to zero.
2. Make sure the spindle head is up out of the way
3. Go to the Discrete Inputs page and look at the cambox origin display.
4. Handle jog (rate .01) the TT (B) axis until “Origin” and Motor Stop” are “1”.
5. Handle jog in the positive direction, until both the “Motor Stop” and “Origin” are “0”. Switch displays to the
Position page and continue jogging the axis 3-5 degrees, in the same direction, past this position.
6. Handle jog the axis in the negative direction (.01 degrees per pulse) until both “Motor Stop” and “Origin” are
”1”. Note that you cannot back up if the mark is missed. If the mark has been missed go back to step 5.
7. Go to the Pos Raw Data page. Under the “Command” header the display shows the “B” axis encoder
counts. Write down the current number.
8. Go back to the Discrete Inputs page. Watch “Motor Stop” and “Origin”. Handle jog in negative direction,
until one of them changes to “0” (the first one to change).
9. Go back to the Position page and write down the current number from the same column as step 7. Add
both numbers and divide by 2, this is the amount of tool change offset, but with the wrong sign.
10. Return to the Discrete Inputs page and handle jog the axis back until the “Motor Stop” and “Origin” are “1”.
11. Enter the calculated number, as a negative number in the TT axis, Parameter 487 (not the B-axis).
12. Return the axis to “Invisible”, set Parameter 462 to 1, and cycle power.
13. Zero return the TT axis. The double arm should be in the middle of the home position.

106 Mechanical Service 96-0283 rev C June 2007

 TURRETS

TURRET CRASH R ECOVERY PROCEDURE

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, type “Debug”, and 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 Write Enter, then press Cycle Start.
This will unlock the turret by pushing it in the Z-direction.
4. Press the Handle Jog key. 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. Position Pocket #1 in the cutting position, using the coolant nozzle to align the pocket. If an overcurrent
alarm is received, press Reset and turn the Jog handle in the opposite direction.
7. Press MDI, type M44, and press Alter. Press Cycle Start. The turret should clamp in the Pocket #1
position.
8. Press Param Dgnos twice to get to diagnostics. Verify that TT LOK = 1.
9. Move to Parameter 43 on the Parameter display and change Invis Axis to “1”. Change Setting 7 back to on.
10. 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 it may be necessary to adjust the turret motor
coupling.

NOTE: The turret is now at Tool #1 and clamped.

11. Remove the sliding tool changer cover. Go to Setting 7 and turn off the Parameter Lock. Go to Parameter
43, change “Z CH Only” to “1”.
12. Loosen the turret motor coupling clamp screw on either side of the motor (refer to the following figure).
13. Press the Zero Ret key, the A key, and the Zero Singl Axis key. This will cause the motor to go to the first
encoder Z pulse.
14. With the servos on, move the turret motor coupling back and forth to find the center of its backlash, 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.

15. Change Parameter 43, “Z CH Only” back to “0” (zero), and Invis Axis to 1. Go to Setting 7 and turn on the
Parameter Lock.
16. Press the Zero Ret key, A key, and Zero Singl Axis key. This will home the turret at tool #1, or the pocket
set in Setting 81.
17. Press the Emergency Stop button and turn the turret motor coupling back and forth to verify that the
backlash is centered.

96-0283 rev C June 2007 Mechanical Service 107

 18. Replace the sliding tool changer cover.

Clamp
screw

Turret Motor Adjustment

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

TURRET CLAMP/UNCLAMP
Alarm 113 and 114 (Turret Unlock/Lock Fault)
1. Check the tool changer solenoid.
a. Does the solenoid appear to be activating?
1) No: Check power to the solenoid during a tool change. If there is voltage replace the solenoid.
2) Yes: Proceed to the next step.
b. Are the exhaust mufflers dirty?
1) Yes: Remove the muffler and do a tool change. If the alarm goes away then replace the muffler
2) No: Proceed to the next step.
c. Is there water in the airlines?
1) Yes: Insure that the air is now dry and replace the solenoid.
2) No: Proceed to the next step.
2. Check air pressure.
a. Set the main regulator set to a minimum 85 psi?
b. Does the air pressure drop more than 10 psi during a tool change?
1) No: Go to the next check.
2) Yes: The lathe has insufficient air volume. 100 psi at 4 sfm is required at the regulator. A small
diameter air supply hose, hose length, and fitting size may restrict air volume to the machine.
3. Remove the top turret cover. Confirm that the air cylinder is fully clamping (114 alarm) or fully unclamping
(113 alarm).
a. Yes: Go to the next check.
b. No: Try to push the air cylinder into position.

108 Mechanical Service 96-0283 rev C June 2007

 1) 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.
2) If the air cylinder fully clamps and unclamps then:
a) Cam balls fell out of time with each other. This would be more common on the original
style cams, which does not have a cage. Fully clamping the air cylinder by hand should
position the 3 balls correctly.
b) If this problem persists then the cams might be damaged. Replace with part number 93-
8138 “Cam Upgrade Kit”. This is a cam assembly with the cage, compatible with all
lathes.
4. Clamp switch or unclamp switch is failing or is out of adjustment.
a. Switch identification and adjustment.
1) 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 movement of the
piston, not the turret shaft.
a) 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.
b) 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, replace the switch.
2) The Clamp/unclamp switches at the rear of the turret shaft detect the position of the turret shaft
during a tool change, these switches are installed on the same bracket as the turret home switch,
also called the a-axis home switch. The amount of shaft movement or turret pop out is very impor-
tant. The switches are an 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, alarms during a tool
change will occur.

96-0283 rev C June 2007 Mechanical Service 109

 TURRET REMOVAL AND REPLACEMENT
5
3 6 18 17
7 10 11 12 13
1 14 15

14 Coupling mount bushing

(bronze)
2 15 Turret cam
16 15/16 steel ball
8 9 8 16 8 9 8 17 HHB 5/16-18 x 1
PARTS LIST 4 18 Lever cam
1 SHCS 5/16-18 x 1 19 Belleville spacer
2 Turret retaining cap 20 Belleville washers
3 SHCS 7/16-14 x 2-1/4 21 Key
4 Turret male coupling 19 20 22 Ring switch
25 24 23 21 22 23 Lock nut
5 Turret 8 Thrust washer 11 Spring retainer
6 SHCS 7/16-14 x 2-1/4 9 Thrust needle bearing 24 Spur gear
12 Die spring
7 Female turret coupling 10 Shoulder bolt 25 Turret shaft
13 Coupling mount

Pneumatic Turret
Removal
1. Position the turret for easy removal from the lathe. Index the turret to the pocket #1 position.
2. Remove the sliding tool changer and turret assembly covers.
3. Change Parameter 76 from 500 to 50000 (so you will not trip on a low air pressure alarm).
4. Remove the air line.
5. Put a 3/4" wrench on the bolt at the end of the air cylinder. Pull down (-X) until the turret is fully unclamped.
6. Place a block 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.

7. 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.

8. Remove the turret from the shaft.

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

Installation
1. Put a small amount of grease on one side of the washers.
2. Place the washer on the surface of the turret and center it using your fingers. Be sure to keep grease off
the surface facing the needle bearing.
3. Put a small amount of grease on both sides of the second washer.
4. Place the washer on the spring retainer on the lip of the turret shaft. Clean any grease on the shaft.

110 Mechanical Service 96-0283 rev C June 2007

 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, that the washer is centered on the turret,
and 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. Remove the turret and return to step 1.

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.
Hydraulic Turret
Removal
1. Clamp the turret in the pocket 1 position.
2. Remove the eight (8) bolts from the inner part of the end cap, and then remove the twelve (12) bolts from
the outer part of the end cap.

Coolant Tip

End Cap

Mounting
Screws

3. Remove the end cap.

4. Remove the turret.

CAUTION! The turret is heavy, additional lifting equipment will be necessary to safely
remove the turret.

96-0283 rev C June 2007 Mechanical Service 111

 5. Remove the coupling from the tool changer housing and replace it with the one that came with the replace-
ment turret. Center the coupler in the bolt holes then torque to 75 ft lbs. Do not loosen the front coupler
that comes attached to the turret.

Installation
1. Install the turret, lining up the coolant tip in the pocket 1 position.
2. Check and Adjust if necessary, using the Rear Coupling only, the centerline of pocket one before tightening
the bolts. It may be necessary to install a pocket on some turrets. Pocket one must be .002" TIR maxi-
mum & .001" centerline.
3. Install the end cap and snug the twelve (12) outer bolts.
4. Install the eight (8) inner bolts and snug.
5. Torque the twelve (12) outer bolts. to 30 ft/lbs.
6. Torque the eight (8) inner bolts. to 30 ft/lbs.
7. Repeat the torque process for 30 ft/lbs of torque.
8. Set Parameter 212 as described in the following section. This will correct alignment for clamping and
unclamping the turret.

TURRET C LAMP ADJUSTMENT (H YDRAULIC TURRET)

1. Enter Debug mode (type “DEBUB” in the alarms page and press enter)
2. Change parameter 43, Invis Axis to a 0 (zero)
3. Run a M43 (Turret Unlock) in MDI mode, and set parameter 212 to 0 (zero)
4. Zero-return the A-axis.
5. Reset the turret clamp failure and command a M43 in MDI mode.
6. Use the handle jog and move the A-axis (jog speed 0.0001). Line up the coolant tube to the hole on the back
of pocket 1.
7.Command a M44 and make sure the turret clamps properly. You may need to handle jog the A-axis into a
better position until it clamps properly.
8. Write down the A-axis Actual value from the Pos-Raw Dat 1 page. Enter this value in parameter 212 as a
negative value, do not include the decimal point.
9. Zero-return the A-axis. Doing this will activate the new parameter 212.
10. Return to the Pos-Raw Dat 1 screen.
11. With the turret clamped, jog the A-axis slowly (jog speed 0.0001) clockwise. Note the fuse level of the A-
axis as the turret is jogged. When the fuse level starts to climb, write down the actual position for the A-axis.
12. Jog the A-axis in the counter-clockwise direction and repeat the procedure and write down the actual
position for the A-axis.
13. Add the absolute values of each number together (ignore the minus sign), for example:
(a) -.1813 + .0113= .1926 (ignore the negative sign)
(b) Divide this value by 2= .0963
(c) Combine this number with the value in Parameter 212. As the negative value is larger (see line (a))
than the other value, subtract the calculated value (.0963) from the value in Parameter 212; this will make a
larger negative number.
For example; -410569 - .0963 = -411532 (ignore decimal point)

112 Mechanical Service 96-0283 rev C June 2007

 If the line (a) positive value is larger, add this number to the value in parameter 212 to make a smaller
negative number.
For example; -152117 + .0963 = -151154 (ignore the decimal point)

TURRET SHAFT REMOVAL AND REPLACEMENT

8
10
7
12 9
13 11
5 14 15
16
17
4
2 6
18

3
1

45 44

Turret Shaft Removal

1. Remove turret as described in previous section. Mark the retaining ring and turret casting for alignment
purposes.
2. Remove coolant tube bracket and move out of the way.
3. Remove inspection plate which will allow the gearbox oil to drain. Catch oil in a bucket.
4. Remove the bolt that holds the rod end to the lever cam. Do not adjust the rod end. Remove the lever cam
and the switch bracket.
5. 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).
6. Remove back half of curvic coupling (10-12 bolts), inspect O-ring.
7. 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. 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).
2. Install turret shaft assembly (align mark on retaining ring with the mark on the casting).
3. Align keyway facing up.

96-0283 rev C June 2007 Mechanical Service 113

 4. 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.
5. Install lever cam, and the key for limit switch cam. Install limit switch cam and the limit switch bracket.
6. Attach actuator to lever cam and install the inspection plate and coolant tube bracket.
7. Add oil to the gear box; 10 cups (2400 ml).
8. Install turret as described in previous section.

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

TURRET CROSS-SLIDE SPRING REPLACEMENT

WARNING!
Power on machine, but do not press Emergency Stop, or turret will fall
during spring removal.

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 Pivot Arm
Retainer
(Beveled)

Spring Bracket

Cross-Slide Spring Components

2. Unbolt X-axis waycover from tool changer box. Jog the turret to top of X-axis travel.
3. Insert a wood block between ballscrew support and ballscrew nut to safely block the assembly.
4. Loosen 3/8" SHCS that holds lower pivot arm to spring bracket, then loosen 3/4" nut of upper pivot arm of
spring bracket.

3/4" HHB

Pivot Arm
3/8" SHCS

Spring Tension Relief

5. 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.

114 Mechanical Service 96-0283 rev C June 2007

 NOTE: Recommend using a wrench with a cheater bar for leverage when relieving
spring tension.

6. Remove cross slide spring and remove spring retainer located inside turret housing. Use access hole
located on the opposite side of turret to remove spring retainer. Replace used spring retainer with new
beveled spring retainer.

NOTE: Old style bracket is not equipped with a cylinder spring retainer. Remove the
two mounting bolts and old style bracket then replace with new bracket
equipped with pivot arm and remount with two mounting bolts. Skip to Step 9.

7. Remove cylinder spring retainer attached to pivot arm and replace with new cylinder spring retainer.
8. Install new cross slide spring. Attach spring to spring retainer in turret housing and cylinder spring retainer
of pivot arm.
9. Place a wrench on pivot arm then pull toward rear of bracket until pivot arm locks to restore spring tension.

10. Tighten 3/8" SHCS of lower pivot arm and nut of upper pivot arm on spring bracket.
11. Remove the wood safety block.
12. Re-attach the X-axis way cover.
13. Install sliding tool changer cover.

A DJUSTING TURRET BACKLASH

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-lb.
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).

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 NOTE: While holding coupler at maximum rotational movement release pressure
and note the backlash reading falls to lesser value. By experimenting,you will
find a “spongy” area. This 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.

T URRET I N / OUT ADJUSTMENT

Extension
Sleeve

Jam
Nuts

Air Cylinder Rod

Turret Travel Adjustment Components

NOTE: Alarms 113 and 114, "Turret Unlock Fault" and "Turret Lock Fault", indicate a
turret in/out adjustment is necessary. Alarms occur when turret clamp and
unclamp switches sense a turret positioning error.

1. If turret travel is not .150", ensure no mechanical problem or obstruction affects travel. If not, air cylinder rod
travel needs adjusted. To do so, loosen the two jam nuts, and screw extension sleeve away from air
cylinder to increase turret travel, or toward air cylinder to decrease turret travel. When adjustment 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 - Production units making turret in/out adjustments with trip switches.
Section II - production units making turret in/out adjustments using air cylinder mounted reed switches.
Section I
Turret Unclamp
(Out) Switch
Clamp/Unclamp
Switch Bracket

Cam

Turret Clamp
(In) Switch

Turret Clamp/Unclamp Switches

116 Mechanical Service 96-0283 rev C June 2007

 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 side of the cam, ensuring it is flat against
the cam. The switch should trip and 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".
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."

C ENTERING I NNER T URRET COUPLING (WITHOUT BRASS PLUG )

Only perform this procedure if there is not enough adjustment to perform an outer coupling alignment.

If the turret has a 1/4" brass plug, proceed to the next section.
1. Before starting, make sure tool pocket #1 is in position.
2. Pull the turret air cylinder all the way forward (unclamp) and place something snugly between the back of
the turret shaft and the casting to keep the turret shaft from shifting.
3. Remove the four bolts from the center turret shaft cover.
4. To gain access to the rear coupling, either remove the turret or install a turret shaft extension and slide the
turret onto it.
5. Loosen the 10 bolts on the inner coupling and center the coupling to the bolt holes. Retighten them to the
required specifications. (Refer to the torque chart at beginning of the section.)
6. Install the thrust bearing and both thrust bearing washers to the shoulder of the turret shaft.

96-0283 rev C June 2007 Mechanical Service 117

 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.
All alignments could change spindle centerline. Enter new spindle centerline position in Parameter 254.

C ENTERING I NNER T URRET C OUPLING (W ITH 1/4" B RASS PLUG )

Only perform this procedure if there is not enough adjustment to perform an outer coupling alignment.
This procedure is only 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 toolholder in turret, move turret in necessary direction with a rubber or plastic mallet to align spindle.
4. Tighten all 10 inner coupling bolts (jogging the A-axis for access) and torque them to the required specifica-
tions. 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.

TURRET A LIGNMENT (X-A XIS)

Read the following sections in their entirety before starting the alignment procedures.
1. Remove the rear cover and 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.

2. Remove top plate cover to the turret housing. Be sure to check the gasket and see if it needs replacement.
3. 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.
4. Remove the black access plate. The plate may need to be pried off with a screwdriver.

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

5. Loosen all turret housing mounting bolts except for the front left bolt nearest the turret.
6. Clamp the turret (M44) and jog to the center of the X-travel.
7. 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.

Verify the turret alignment before continuing.

8. Apply Loctite and torque all turret housing mounting bolts to 50 ft/lbs.
9. Recheck the turret face to ensure the measurement did not change. Install the access cover and gasket.
10. Pour 10 cups of oil (DTE 25) into gear side of turret housing. Install the coolant adapter block.

NOTE: The turret must be in the unclamped position

11. Install the turret housing top plate, and sliding tool changer cover, then zero return the machine.

118 Mechanical Service 96-0283 rev C June 2007

 After the turret face has been realigned it is important to verify that the spindle is still in
alignment.
Proceed to “Turret Alignment Verification (Spindle )”.

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

TURRET ALIGNMENT VERIFICATION (X-A XIS)

Tools Required: Magnetic Base with a dial indicator (0.0005" or less resolution).
1. Remove all tool holders and fittings from the turret and Jog the X-axis to the center of its travel.
2. 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.
3. Jog the X-axis so the indicator is at one end of its travel, then zero the indicator.
4. Jog the X-axis to the other end of its travel and check your reading (tolerance 0.0003" TIR).
5. If the reading is greater than the tolerance specified the turret needs to be realigned.

Sweep Indicator Along

Face of Turret.

Turret Alignment Verification (X-Axis)

SPINDLE ALIGNMENT VERIFICATION

This procedure should be performed after the turret face has been realigned.
Tools Required: Spindle Alignment Test Bar (T-1312)
1. Mount a 0.0001" indicator (short setup) to face of turret.

Checking Runout

96-0283 rev C June 2007 Mechanical Service 119

 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". If the tolerance is greater than .0001, loosen the test bar mounting bolts, rotate the
spindle and tap on the mounted end of the fixture until the runout is within tolerance.
4. Tighten the bolts to the test bar, being careful not to alter the alignment.
5. Move indicator tip to 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, and 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 indicator tip
over 10" of the test bar to determine if spindle is high or low. Tolerance should not exceed 0.0004/10".

NOTE: If the measurement is greater than allowable tolerance, the spindle head
casting must be realigned. Before realignment, perform a Turret Alignment
Verification - Parallelism of X-axis (Turrets section). 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”.

T URRET A LIGNMENT VERIFICATION (SPINDLE )

This procedure should be performed after spindle alignment has been checked.
Tools Required: Spindle Alignment Tool, Dial Indicator (0.0005" or less resoultion)
1. Remove all tool holders and fittings from the turret.
2. Clean the turret pockets and tool holders.
3. Mount spindle alignment tool onto spindle retainer ring with 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.

120 Mechanical Service 96-0283 rev C June 2007

 90deg.
Spindle High

180deg. 0deg.

X-Axis
Spindle Low
270deg.
Tool Pocket

Turret Pocket Alignment

C ONVERTING S PINDLE C ENTERLINE TO ENCODER 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 X-axis Command position. This is encoder steps. Ignore the negative sign and the decimal point.
5. Copy this number to Parameter 254 as a positive number with no decimal point.
6. Press Alarms, enter "Debug", press Write, or simply turn the power off and back on. This deactivates
debug mode.

TURRET ALIGNMENT 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).

Turret Bar Sweep

96-0283 rev C June 2007 Mechanical Service 121

 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.

NOTE: For turret replacement, loosen and adjust the inner coupling.

10. Rotate the turret 180° 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 “Turret Alignment Verification (Spindle )”. If the reading is greater
than the tolerance specified, proceed to the appropriate coupling adjustment procedure.

B OLT O N TURRET ALIGNMENT

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.
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
fT
o
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.

122 Mechanical Service 96-0283 rev C June 2007

 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.

.002"
Total=.004"

.002"

The previous 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, (SL-10/SL-30) or #3 (SL-20/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 mea-
sured again to ensure they are within specifications.
14. The tool positions of the turret are now centered to the coupler. Torque all 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 from the home
position to place the pin hole in line with the spindle.

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 19. Place the indicator tip into the 3/16” indication hole in the turret or the tool holder. Sweep the hole 360°. 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.

WEDGE ALIGNMENT
Using the data from the “Service Lathe Alignment” report as this procedure is followed. It is important that the
form is filled out in its entirety before any adjustments of the wedge are attempted.
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 “Turret
Alignment Verification (Spindle )” section).
1. Mount the magnetic base on turret face and take check two positions on the spindle face (as shown in the
following figure).

Leave this bolt

snug as a pivot

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 previous figure).

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

3. Loosen the bolts on the ballscrew nut face on the Z-axis. Pivot the wedge to bring the spindle face reading to
zero.
4. Snug the wedge bolts to keep the wedge from moving during the next procedure.
5. Verify the turret alignment by completing the steps in the “Turret Alignment Verification” sections. When
moving the wedge, do not change its squareness to the Z-axis.
6. When both alignments are correct, gently snug all the Z-axis linear guide truck bolts, then torque to the
required values.
7. 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).
8. Check for binding at the start, middle and end of travel.

124 Mechanical Service 96-0283 rev C June 2007

 TOOLROOM L ATHE X AND Z-AXIS ALIGNMENT
1. 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 within
.0001” over full travel.
2. Disconnect the Z-axis ball screw nut from the nut housing.
3. 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.
4. Retighten the ballscrew SHCS to 30 ft-lb.

96-0283 rev C June 2007 Mechanical Service 125

 A XIS MOTORS

A XIS MOTOR E NCODERS

Haas machines are equipped with brushless motors, which provide for better performance, and no mainte-
nance. In addition to performance differences, the following list highlights additional benefits:
• The brushless motors have 8192 line encoders built in, with a resolution of 32768 steps per revolution.
• "In Position" Parameters 101, 102, 103, 104, and 165 affect brushless motors.
• The motor controller board has a dedicated processor which does all the servo control algorithms.
• Care should be taken, 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; only service the machine when
this light is out.
• Brushless servo amplifiers are used to control the motors.
• The servo drive assembly has a low voltage power supply module to supply required amplifier voltage.

A XIS M OTOR A MPLIFIERS

The brushless servo amplifier is a Pulse Width Modulation (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 HP. The amplifiers also have
short circuit, over temperature and over voltage protection.
There is a 32 amp (small amplifier), 45 amp (medium amplifier), and 60 amp (large amplifier) supply fuse for
failure protection. This fuse is relatively slow, therefore it can handle the 30amp peak of a small amplifier.
Continuous current limit to the motor is controlled by software.
Replace these fuses with the same type and rating. A fuse kit (93-1089) may be purchased. Make sure that the
machine is turned off and that the “High voltage present” LED light in the control cabinet is completely off.
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.

AXIS MOTOR R EMOVAL/INSTALLATION

Please read this section in its entirety before attempting to remove or replace the axis
motors.
Tool required for vertical mill Z-axis equipped with a counterbalance system: Cylinder shaft stop (P/N
99-7562 - VF-1 through 4, P/N 93-9962 - VF-6 through 11 ).

126 Mechanical Service 96-0283 rev C June 2007

 PRECAUTIONS
Mills are currently equipped with either a hydraulic counterbalance system or an electric brake motor. Care
must be taken, in either case, to avoid damaging the machine or severely injuring yourself. Heed all warnings
and cautions and read all the steps of the procedure before starting any disassembly.
If removing a vertical axis, brace the spindle head. The spindle head will fall if this is not done. Use a cylinder
Short Stop, block of wood, or shipping bolts (Horiz.) to secure the head.
WARNING! MILLS WITHOUT A COUNTERBALANCE
If debug is on and a vertical axis is disabled, the spindle head will fall.
This is extremely dangerous and must be avoided.

NOTE: When replacing the X-axis on GR-series mills, a belt must be removed from
the motor; all work is done beneath the mill.

AXIS MOTOR REPLACEMENT

Cover Plate Motor

4X 2X Adjustment
4X SHCS BHCS Dowel Pin Plate Setscrew
Coupling Motor
Mounting
Bracket

Key 4X Nut
X-Axis Motor 4X Lockwasher
Coupling Belt
Housing 4X SHCS

Typical Motor Assembly GR-Series X-Axis Motor Location

Removal
1. Power On the machine. Zero return all axes and put machine in Handle Jog mode.
2. Remove sheet metal necessary to access the axis motor (jog axes if necessary).
3. Power Off the machine.
4. Vert: Remove the Lube/Air Panel (VF-1 through VF-5).
5. Remove the motor from the motor coupling.
6. GR-series X-axis: Remove the four SHCS that secure the motor to the mounting bracket, and loosen the
setscrew on top of the motor adjustment plate. (The adjustment plate is not fastened to the motor or the
bracket, therefore it may fall off the dowel pins once the motor is removed.) Disconnect the belt from the
pulley and remove the motor.
7. Disconnect all wiring and remove the motor.

Installation
1. Reconnect all wiring to the motor.
2. Attach the motor to the coupling.
3. a. GR-series X-axis: Position the motor in the motor mounting bracket, attach the belt, reinstall the
motor adjustment plate and set proper belt tension. Tighten motor bolts and recheck belt tension.
b. VERT: Replace the Lube/Air Panel (VF-1 through VF-5).
4. Replace all removed sheet metal.

96-0283 rev C June 2007 Mechanical Service 127

 5. Power On the machine.
6. Check for backlash in the ball screw ("Accuracy/Backlash" section) or noisy operation.
7. Zero Return the axis and set the grid offset.
8. Z-axis: Reset the value for Parameter 64.

CAUTION! Work offsets will change.

COUPLING REPLACEMENT
WARNING!
MILLS WITHOUT A COUNTERBALANCE
If debug is on and the Z-axis is disabled, the spindle head will fall.

Removal
1. Remove the axis motor in accordance with "Axis Motor Removal/Installation" section.
2. Completely loosen the two SHCS on the two coupling clamp rings and remove the coupling.

45°

Motor

Coupling Flex plates

halves
Clamp ring

Front view

Motor Coupling Components

Installation
1. Visually inspect the flex plates to ensure they are parallel to the coupling halves. Slide the new coupling
onto the motor shaft until the coupling half is flush to the end of the shaft.
2. The slot in the locking collar must be positioned 450 between the bolt hole pattern of the coupler. If improp-
erly aligned, the coupler will not have enough clamping force on the ball screw or motor shaft.
3. Add one drop of blue Loctite to each screw on the coupling's clamp ring and tighten.
4. Reinstall the axis motor.

A XIS B RAKE M OTOR (M ILLS O NLY )

The servo brake motor compensates for the weight of the spindle head. The brake is released when the servo
motors are activated, however the disk brake engagement spline may produce a small noise when the head is
in motion, this is normal.
A parameter governs the ability of the brake motor; therefore, Parameter 25, Y-Axis Torque Preload, must be
set correctly, and Vertical machines without counterbalances must have Parameter 39, Z-Axis Torque Preload,
set correctly.

128 Mechanical Service 96-0283 rev C June 2007

 BEARING S LEEVE REMOVAL/INSTALLATION
Please read this section in its entirety before attempting to remove or replace the bearing
sleeve.
Vertical Tool Required: Spanner wrench, Pre-load fixture, Wood block (16" long)
Z-Axis machines with counterbalance: Cylinder shaft stop (P/N 99-7562 - VF-1 through 4, P/N 93-9962 -
VF-6 through 10)

NOTE: For machines equipped with 40 or 50 mm ball screws, the ball screw must be
removed in order to remove the bearing sleeve. Refer to the "Ball Screw
Removal/Installation" section for instructions.

NOTE: When replacing the ball screw in an older machine, always replace the bearing
sleeve with the current angular contact design bearing sleeve.

BEARING SLEEVE REPLACEMENT

Removal
1. Power on the machine. Zero return all axes and put the machine in Handle Jog mode.

Cover Plate SHCS Oil Line Fitting Axis Bumper

Bearing Motor
Housing SHCS Bumper Bracket
Sleeve
Bumper
SHCS Bearing
Locknut
Bearing Bearing
Locknut Support
SHCS Casting

Key Ball Screw Nut

Nut Housing
Servo Motor
Ball Screw
Motor Mount Casting

Motor Coupling Assy

SHCS
Typical Ball Screw Assembly

2. Remove all necessary sheet metal and jog the axis away from the bearing support. Vertical Axes: Place a
wood block beneath the spindle head and lower the spindle head until it is resting on the block to prevent it
from crashing down during servicing.
3. Power off the machine.
4. Remove the hardstop bracket from bearing support end, and remove the locknut. If necessary, manually
screw the axis away from the motor housing in order to access the motor (not possible with vertical axes).

CAUTION! Do not screw the axis too far away, since the hardstops are removed!

5. Remove the axis motor ("Axis Motor Removal/Installation" section).

6. Remove the motor coupling.
7. Loosen the SHCS on the locknut at the motor end of the ball screw, and remove the locknut.
8. Loosen the SHCS and remove the bearing sleeve from the coupling housing. Push on the opposite end of
the ball screw to loosen.

96-0283 rev C June 2007 Mechanical Service 129

 CAUTION! Do not pry the bearing sleeve away from the housing. Damage to the sleeve,
bearing, motor housing or ball screw will result.

Bearing Sleeve Motor Housing

Bearing Sleeve Mounting Location

Installation
1. Ensure all mating surfaces on the bearing sleeve and motor housing are free of dirt, burrs, grease, or other
contaminants. Failure to do so may cause misalignment.
2. Move the axis, by hand, to the support end of the ball screw.
3. Place the bearing sleeve in the motor mount. It may be necessary to align the bearings in the sleeve to
facilitate mounting on the ball screw.
4. Install the SHCS on the bearing sleeve, attaching it to the motor housing, and torque to 15 ft-lb. (Place a
drop of blue Loctite on each of the SHCS before inserting.)

CAUTION! Do not use more than one drop of Loctite. An excessive amount will cause
a film between the sleeve and housing, which could result in backlash.

CAUTION! Do not screw the axis too far away, since the hardstops are removed!

5. Screw the locknut on the motor end of the ball screw two or three turns, but do not tighten.
6. Move the axis by hand, to the motor end of the ball screw.
7. Loosen the six ¼-20 x 1" SHCS attaching the bearing sleeve to the motor housing and retighten to 15 ft-lb.
This step ensures that the ball screw is installed and runs parallel and flat to the linear guides and saddle.
8. Tighten the ball screw against the locknuts. An angular contact design bearing requires no pre-load.
Tighten the locknut on the motor housing end of the ball screw to 15 ft-lb. Tighten the SHCS on the lock-
nut. Place a spanner nut over the locknut on the support bearing end of the ball screw and slowly tighten to
4 in-lb. Remove the spanner nut. Tighten the SHCS on the locknut with Loctite, and mark it with paint.
9. Reinstall and tighten the hard stop on the bearing support and reinstall the axis motor.
10. Vertical Axis: Jog off the wood block beneath the spindle head and remove the wood block.
11. Check for backlash or noisy operation in the ball screw (see the "Accuracy/Backlash" section), zero the
axis, and set the grid offset.

130 Mechanical Service 96-0283 rev C June 2007

 B ALL SCREW R EMOVAL AND I NSTALLATION

BALL SCREW T ROUBLE SHOOTING

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. Replace the encoder on brush machines.
• Open circuit in motor (Alarms 103-106, 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 with no damage to the interior components and an Overheat alarm has been triggered.
After a thorough check of the motor (do not disassemble!), take necessary steps to eliminate the problem
and clear the alarm to resume operation. If motor is still inoperable, replace the motor assembly.
• Check for broken or loose coupling between the servo motor and the ball screw.
• Check for a damaged ball screw, and replace if necessary.

NOTE: If a ball screw fails, it is most often due to a failed bearing sleeve. When
replacing the ball screw, always replace the bearing sleeve.

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 considering other
factors; they are extremely durable and reliable. Verify that customer com-
plaints are not due to tooling, programming, or fixturing problems.

Servo motor noise

• Disconnect the servo motor from the ball screw and rotate the motor by hand. If the noise persists, replace
the motor assembly.
• Noise is caused by bearings. Grinding sound is heard coming from the motor. If bearings are making a loud
sound, replace the motor.

Ball screw noise

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. If complaints
are generated about one axis screw in comparison to another, it is possible
that the screws are simply sourced from different manufacturers.

• Ensure oil is getting to the ball screw through the lubrication system. Look for a plugged metering valve.

96-0283 rev C June 2007 Mechanical Service 131

 • 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.
• 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 ball nut may get hot. Misalignment radially at the yoke where the ball nut
mounts is indicated by the heating 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.

ACCURACY/BACKLASH
Accuracy complaints are usually related to tooling, programming, or fixturing problems. Verify that all these are
correct before working on the machine.

Poor positioning accuracy

• Check parameters for that axis. Check the parameter values with the paperwork shipped with the machine.
• Check for backlash in the ball screw as described in the following section.

Initial Preparation
1. Turn the machine On and zero return the machine.
2. Center all the axes. (For Horizontal mills move the Z-axis so the spindle and the table are the closest to
the end of travel toward the table.)
Checking X-axis
1. Set up a dial indicator and base as shown in the following figures.

4 5 6 7

X-AXIS X-AXIS

Horizontal Mill Lathe Vertical Mill

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 key on the control panel.
The “Distance to go” display in the lower right hand corner of the screen should read: X = 0 Y = 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.

132 Mechanical Service 96-0283 rev C June 2007

 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 X-axis backlash is to place the dial indicator as previously shown and
manually push the X-axis in both directions. The dial indicator should return to zero after releasing the axis.
The axis motors must be on to check backlash by this method. Do not press E-Stop.
5. If backlash is found, refer to "Backlash - Possible Causes" in this section.
Checking Y-axis
1. Set up a dial indicator and base on the mill table as shown in the following figures.

Y-AXIS Y-AXIS

Horizontal Y-axis Vertical Y-axis

2. Follow the same procedure used for checking the X-axis.

An alternate method for checking Y-axis backlash is to place the dial indicator as previously shown and
manually push the Y-axis in both directions. The dial indicator should return to zero after releasing the axis.
The Axis motors must be on to check backlash by this method. Do not press E-Stop.
3. If backlash is found, refer to "Backlash - Possible Causes" in this section.

Checking Z-axis
1. Set up a dial indicator and base as shown in the following figures.

Z-AXIS
Z-AXIS

Horizontal Z-axis Lathe Z-axis Vertical Z-axis

NOTE: For the Lathe, position the tip of the indicator on the face of the turret.

2. Follow the same procedure used for checking the X-axis.

An alternate method for checking Z-axis backlash is to place the dial indicator as previously shown and
manually push the Z-axis in both directions. The dial indicator should return to zero after releasing the axis.

NOTE: The axis motors must be on to check backlash by this method. Do not press
E-Stop.

96-0283 rev C June 2007 Mechanical Service 133

 NOTE: Do not mistake deflection for backlash in the system.

3. If backlash is found, refer to "Backlash - Possible Causes" in this section.

B ACKLASH - P OSSIBLE C AUSES

If backlash is found in the system, check for the following possible causes:
• Loosen the SHCS attaching the ball nut to the nut housing. Tighten the SHCS as described.
• Loosen the SHCS attaching the nut housing to the axis. Tighten the SHCS as described.
• Loosen the clamp nut on the bearing sleeve. Tighten the SHCS on the clamp nut.
• Loosen the motor coupling. Tighten as described.
• Broken or loose flex plates on the motor coupling.
• Loosen the SHCS attaching the bearing sleeve to the motor housing or top of the column. Tighten as de-
scribed in "Ball Screw Removal and Installation".
• Defective thrust bearings in the bearing sleeve. Replace the bearing sleeve as outlined in "Bearing Sleeve
Removal/Installation".
• Loose SHCS attaching the axis motor to the motor housing. If the SHCS are found to be loose, inspect the
motor for damage and if none is found, tighten as described in. If damage is found, replace the motor.
• Incorrect backlash compensation number in the machine parameter. Check Parameters 13, 27 (mills only),
and 41.
• Worn ball screw.

B ALL S CREWS - V ISUAL I NSPECTION

The three main causes of ball screw failure are loss of lubrication, contamination, and machine crash. Wear of
the nut balls and the screw threads is generally a non-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. Problems with the lubrication system will accelerate all wear issues.
1. Dry metal-to-metal contact following lube breakdown will create intense heat at the contact points. The nut
balls will weld to the nut races due to the heat and pressure of the preload. When movement of the 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.
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 damaged by material
fatigue are not repairable.

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.
1. If the lube is wet and clean, it 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.

134 Mechanical Service 96-0283 rev C June 2007

 3. If lube is wet and black, lube system is contaminated by metal particles. Inspect the ball screws for wear.
Contamination of lube and/or coolant systems can be caused by a wearing ball screw, or metal chips entering
the systems through open or loose way covers. Check all way covers and seals for excessive clearances.
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 ball-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 ball nut,
creating impressions on the screw surface.

B ALL S CREW C LEANING

In most cases, thorough cleaning of a suspect ball screw will resolve many issues, including noise complaints.
1. Manually jog the ball nut to one end of the screw, and visually inspect the screw threads. Look for metal
flakes, dark or thick lube, or contaminated coolant: See the previous "Contamination" section.
2. 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, they may cause rust.

3. Jog the ball nut to the other end of its travel. If metal flakes are now present on the screw threads, you may
have wear issues.
4. Re-lubricate screw threads before returning the machine to service.

H ORIZONTAL AXIS BALL SCREW R EPLACEMENT

Please read this section in its entirety before attempting to remove or replace the ball screws.
Tools Required: Horiz: Torque wrench, Spanner nut. Lathe: Spanner Wrench (32mm or 40/50mm), Shaft
Lock (32mm or 40/50mm). Vert: Spanner wrench (32 mm or 40/50 mm), 2" x 4" wood block (21"-231/2" long),
Shaft lock (32 mm or 40/50 mm), Torque tester, Z-axis if it has a counterbalance system: Cylinder shaft stop
(P/N 99-7562 - VF-1 through 4, P/N 93-9962 - VF-6 through 10)

NOTE: Certain following steps apply only to 40 and 50 mm ball screws.

Ball Nut Housing

Ballscrew
5X SHCS Support
Bearing
Housing

Motor
Support
Coupling Bearing
6X SHCS Housing 4X SHCS Locknut

Removal
1. Turn the machine on. Zero return all axes and put the machine in Handle Jog mode.
2. Remove the sheet metal necessary to access the ball screw and its components.

96-0283 rev C June 2007 Mechanical Service 135

 3. Jog the vertical axis to the bottom of its travel, and the horizontal axis to the center of travel.
4. Power off the machine.
5. If applicable, remove the hard stop from the bearing housing on the ball screw.
6. Disconnect the oil line from the ball nut.
7. Loosen the 10-32 x ½" SHCS and remove the locknut on the ball screw support bearing end.
8. Remove the axis motor in accordance with "Axis Motor Removal/Installation".
9. Loosen the SHCS and remove the bearing sleeve from the motor mount in accordance with "Bearing Sleeve
Removal/Installation". Push on the opposite end of the ball screw to loosen.

CAUTION! Do not pry the bearing sleeve away from the housing. Damage to the sleeve,
bearing, or ball screw will result.

10. Vert: Loosen the 10-32 x ½" SHCS and remove the clamp nut on the ball screw in the motor housing.
11. Loosen and remove the five SHCS attaching the ball nut to the nut housing.
12. a. Vert: Push the mill table towards the motor end until the ball screw clears the bearing support. Remove
the ball screw by pulling from the bearing support end.
b. Horiz: Pull the ball screw towards the control box side and out of the bearing in the bearing support. Lift
the ball screw up, forward, and to the side of the machine until the motor end of the ball screw is free.
Carefully remove the ball screw.
c. For 40 and 50 mm ball screws: Loosen the SHCS mounting the bearing support to the saddle and
remove. Remove the pull pins from the bearing support. Loosen the five SHCS in the ball nut and remove
the ball screw by pulling from the bearing support end.
d. For MDC-500 ball screws:
• X-axis: Jog the column to the middle of travel and turn the machine Off. Remove the eight (8)
bolts securing the nut housing to the casting. The entire casting is now free to move by hand.
• Y-axis: This procedure is most efficiently completed if the column is jogged back until the nut
housing is directly above the hole in the casting. Jog the column back until the bearing support
housing is over the hole in the saddle and Power Off the machine. From the right hand side of the
machine, remove the nut housing (8 bolts) that attach the ball screw to the saddle. The casting is
now free to move by hand.
• Y-axis with no hole in casting: Jog the column all the way forward and remove the bearing
support housing (4 bolts, 2 alignment pins). Remove the nut housing by using an allen wrench to
remove the 8 bolts. Note that at this point, the casting is free to move by hand. Take extreme
caution when moving by hand as there are no safety stops to prohibit the column from sliding off of
the linear guides. Finally remove the motor support housing and remove the ball screw through the
back of the machine.
• X & Y Axes Removal: Now remove the six (6) bolts and two (2) alignment pins on the motor
support housing and the four (4) bolts and two (2) alignment pins on the bearing support housing.
Remove the oil line fitting (X-Axis) from the side of the ball screw nut. Angle the ball screw and pull
it out the back of the machine (X-Axis) or slide the ball screw out between the bottom of the
column and the base casting to the back of the machine (Y-Axis).
If MDC-500 has to be turned On with ball screw disconnected, the corresponding Parameter bit has to be
changed to disable that axis. In Parameter 1, change bit from 0 to 1 to disable X-axis only. In Parameter 15,
change bit from 0 to 1 to disable Y-axis only. When ball screw is in place, change bit back to enable axis.

136 Mechanical Service 96-0283 rev C June 2007

 Installation
NOTE: For vertical machines, this procedure assumes that the nut and motor housing
have not been removed.

1. Center the mill table on the saddle.

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

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

affecting the proper operation of the machine.

3. Vert: Insert the ball screw through the nut housing and motor housing, taking care not to make contact
with the screw threads, which will cause possible damage.
If 40 or 50 mm ball screw:
• Mount the bearing support to the saddle with six SHCS, but do not tighten completely. Replace
the pull pins in the bearing support.
• Install the spacer ring on the motor end of the ball screw.
• Insert the 5/16-18 x 3/4" (or M10 x 25 mm) SHCS, attaching the ball nut to the nut housing, but
do not tighten completely. (Place a drop of blue Loctite on each of the SHCS before inserting.)
• Skip to Step 8.
4. Horiz: Hold the ball screw vertically with the motor end down and the nut near the support end (top) at the
front left side of the machine and lower into place, rotating the ballscrew into position, being careful not to
bump or scratch it. Gently push the bearing support end of the ball screw into the bearing in the bearing
support housing.
EC-300: Slide the motor end of the ball screw from the front of the machine over the bearing housing,
taking care not to damage the screw threads.
EC-400: Slide bearing support end of the ball screw past the rotary table towards the front of the machine.
EC-1600: Slide bearing support end of ball screw under the column, taking care not to damage the screw
threads. Position ball screw to the right side of the nut housing and slide toward the front of the machine.
5. Replace the bearing sleeve in accordance with "Bearing Sleeve Removal/Installation". It may be necessary
to align the bearings in the sleeve to facilitate mounting on the ball screw.
6. Rotate the ballscrew nut so it goes into the nut housing and start the SHCS that secure the ballscrew nut
to the nut housing. Do not tighten.
7. Reattach the oil line to the ball screw nut.
8. Replace the axis motor in accordance with "Axis Motor Removal/Installation".
9. Torque the SHCS from the nut to the nut housing to 15 ft-lb (30 ft-lb for EC-1600).
10. If applicable, replace the bearing support end hard stop.
11. The following sequence is important to ensure proper installation of the ball screw:
• Tighten the locknut, hand tight, on the motor end.
• Install and tighten locknut on bearing support. Ensure nut does not touch the bearing support.
• Install the shaft lock onto the bearing support end of the ballscrew. This will keep the ball screw
from turning while torquing the lock.

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 • Place a spanner wrench on the locknut at the motor end of the assembly.
• Vert & EC-300: Torque the locknut against the bearing sleeve to 15 ft-lb.
• 40/50 mm, EC-400, and EC-1600: Torque the ball screw locknut against the bearing
sleeve to 50 ft-lb.
• Horiz & EC-400: Torque the locknut against the bearing sleeve to 10 ft-lb.
• With a T-handle wrench hand tighten the locknut screw and mark with paint.
• (EC-300) Loosen the locknut screw and bearing locknut and tighten to 4 in-lb against the bearing.
Retighten the locknut screw.
• (EC-400/EC-1600): Loosen the locknut screw and the bearing locknut and tighten to 10 ft-lb
against the bearing. Retighten the locknut screw.
• Vert: Torque support mounting bolts to proper specifications. Loosen locknut screw and locknut
at the bearing support end and tighten to 4 in-lb against the bearing. Retighten the locknut screw.
• Remove the shaft lock for vertical machines with a counterbalance system.
For 40 and 50 mm ball screws only:
• Tighten down completely the SHCS that mount the bearing support to the saddle.
• Loosen the locknut on the bearing support end. Adjust the nut until it seats on the bearing.
Retighten the locknut hand-tight, then 1/8 turn more (4 in-lb if using a torque screwdriver).
12. Power on the machine.
13. a. Horiz: Rotate the ballscrew by hand to assure free movement.
b. Vert: Check ball screw torque at bearing support end with torque tester. Jog the table all the way to the
right. Check the ball screw torque again. It should be the same as the previous reading.
14. Jog the axis to check for free movement.
15. Check for backlash or noisy operation in the ball screw ("Accuracy/Backlash" section).
16. Replace appropriate sheet metal.
17. Zero return the axis and set grid offset.

V ERTICAL A XIS B ALL S CREW R EPLACEMENT

Removal
Machines are currently equipped with either a hydraulic counterbalance system or an electric brake motor.
Care must be taken, in either case, to avoid damaging the machine or severely injuring yourself. Heed all
warnings and cautions, and read all the steps of the procedure before starting any disassembly.

138 Mechanical Service 96-0283 rev C June 2007

 Nut Housing

Ball Nut
ECNER
EFER R
OTCEN
NOC

Ball Screw

Support
Bearing

VF-Series Ball Screw Replacement

WARNING!
If the machine is equipped with a hydraulic counterbalance, a shaft
stop block must be used to secure the spindle head. Do not move the
spindle during ball screw service.

WARNING! MILLS WITHOUT A COUNTERBALANCE

If debug is on and the Z-axis is disabled the spindle head will fall. This
is extremely dangerous and must be avoided.

1. Turn the machine on. Zero Return all axes and put the machine in Handle Jog mode.
2. Remove the sheet metal necessary to access the ball screw and its components.
3. a. Machines with counterbalances: Lower the spindle head to its lowest position. Install cylinder shaft
stop. Handle jog axis up until the shaft stop blocks the axis.
b. Machines with Brake motors: Brace the spindle head up with a 4” x 4” x 14” block of wood.
4. Power off the machine.
5. If applicable, remove the hard stop from the bearing housing on the ball screw.
6. Disconnect the oil line at the ball nut.
7. Loosen the 10-32 x ½" SHCS and remove the locknut on the ball screw support bearing end.
8. Remove the axis motor in accordance with "Axis Motor Removal/Installation".
9. Loosen the 10-32 x ½" SHCS and remove the locknut on the ball screw in the motor housing.
10. For 32 mm ball screws:
• Loosen the six ¼-20 x 1" SHCS and remove the bearing sleeve from the motor housing. Push on
the opposite end of the ball screw to loosen.

CAUTION! Do not pry the bearing sleeve away from the housing. Damage to the sleeve,
bearing, or ball screw will result.

• Hand-turn the ball screw to move the screw up until the bottom end clears the support bearing by
approximately six inches (6").

96-0283 rev C June 2007 Mechanical Service 139

 • Remove the SHCS from the ball nut remove. Lower the ball screw down and to the right of the support
bearing to remove. For the VF-6 and Horizontal machines, remove the ball screw from top of column,
being careful to not damage the threads on the ball screw.
For 40 and 50 mm ball screws:

• Loosen the SHCS that mount the bearing support to the column, and remove. Remove the pull pins
from the bearing support.

• Loosen five SHCS in the ball nut and remove the ball screw by pulling from the bearing support end.

For MDC-500 ball screw:

• Remove the column enclosure components covering the ball screw, bottom way cover, spindle head
cover and the column frame cross brace.

• Turn the machine On, zero return all axis and select Handle Jog mode. Block the spindle (using a 4"
x 4" x 14" piece of wood) on the bottom of the column or the spindle face itself (lower is better) by
lowering the spindle head on the wood and turn the machine Off.

• Loosen all screws on the bearing support housing, nut housing, and motor support housing. First
remove the four (4) bolts and two (2) alignment pins on the bearing support housing (the 10/32 pins are
threaded, insert a screw into the opening and pull out). Then remove the eight (8) bolts securing the
nut housing to the casting (these are accessed from the back of the machine through the column).
Note that at this point the spindle column will be resting entirely on the block; make sure that the
spindle is securely supported. Finally, remove the six (6) bolts and two (2) alignment pins that secure
the motor support housing to the casting and remove the ball screw assembly from the machine.

NOTE: Only when the machine is powered Off, can the motor cables be removed so
that the entire ball screw assembly can be disconnected from the machine.

If the MDC-500 has to be turned on with the ball screw disconnected, the corresponding Parameter bit has
to be changed to disable that axis. In Parameter 29, change the bit from 0 to 1 to disable the Z-axis only if
needed. When the ball screw is in place, change the bit back to enable the axis.
Installation
Oil Line Motor Housing
Fitting Bearing Cover
Coupling Bumper

Bearing Locknut
Bearing 4X
Coupling Locknut Coupling
Housing Ballscrew
Cover Nut
Ball Screw
4X BHCS Nut Housing BACK OF
SPINDLE
CASTING
Bumper Y-Axis
Ballscrew
Y-Axis lead
Support Ballscrew
Bearing
Housing 5X SHCS Bumper
Bumper
Support Bearing
Bumper Housing
Plane6

2X Dowel Pin
Plane5
Plane5

Bracket
6X
Bearing Locknut 4X SHCS Bearing
Locknut
EC-300 Ball Screw Assembly EC-400 Ball Screw Assembly

140 Mechanical Service 96-0283 rev C June 2007

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

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

affecting the proper operation of the machine.

2. Slide the ball screw up into the nut housing and gently lower it until it is resting in the support bearing.

NOTE: Correct alignment is critical to sliding the ball screw into the bearing. Binding
will not occur if it is guided carefully and correctly into the bearing.

3. Insert the ball screw into the bearing support. Screw the clamp nut on a few turns.
4. Insert the ball screw, with the bearing support attached, into place. Ensure the ball screw goes through the
ball nut housing and the bearing sleeve.
5. Mount the bearing support with SHCS, but do not tighten completely. Replace the dowel pins in the bearing
support.
6. Install the spacer ring on the motor end of the ball screw.

Hydraulic Bearing
Counterbalance
Bumper
Y-Axis Motor
2X SHCS
Coupling
Bearing
Locknut
Hydraulic 4X Lockwasher Ballscrew
Y-Axis Motor
Counterbalance Nut

4X SHCS Y-Axis
Ballscrew

2X SHCS
View Rotated
Motor Mount (looking up)
Bumper
Bearing Housing
Y-Axis Ball Screw Support Bearing
Housing

6xSHCS
Bearing
Locknut

EC-1600 EC-1600 Ball Screw and Motor Components

7. Place the bearing sleeve in the motor housing. (It may be necessary to align the bearings in the sleeve to
facilitate mounting on the ball screw.)
8. Insert the six ¼-20 x 1" SHCS attaching the bearing sleeve to the motor housing (Place a drop of blue
Loctite on each of the SHCS before inserting).

CAUTION! Do not use more than one drop of Loctite. An excessive amount will cause
a film between the sleeve and housing, which could result in backlash.

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 9. Hand-turn ball nut until it contacts nut housing mounting surface. If necessary, turn ballscrew to correctly
position lube fitting of ball nut. Insert, but do not tighten, the five ¼-20 x 1" (or ¼-20 x ¾") SHCS attaching
the ball nut to the nut housing. (Place a drop of blue Loctite on each of the SHCS before inserting.)
10. Loosely install the locknut on the motor end of the ball screw.
11. Hand-turn the ballscrew to move the spindle motor up and down, assuring free movement of the ballscrew.
12. Torque the SHCS that hold the ball nut to the nut housing.
13. The following sequence is important to ensure proper installation of the ballscrew:
• Tighten the locknut, hand tight, on the motor end.
• Install and tighten locknut on bearing support. Ensure the nut does not touch the support bearing. It will
be used to hold the ballscrew while the other end is tightened.
• Install shaft lock onto ballscrew bearing support end to keep it from turning while torquing locknut.
• Place a spanner wrench on the locknut at the motor end of the assembly.
• Torque the locknut to 15 ft-lb for Vertical machines (30 ft-lb for Horizontal machines). The 40/50 mm and
EC-400 and EC-1600 ballscrew locknut should be torqued to 50 ft-lb.
• Tighten the locknut screw and mark with yellow paint.
• Remove the shaft lock.
• Torque support mounting bolts to proper specifications.
• Loosen the locknut screw and locknut at the bearing support end and tighten to 4 in-lb (32 mm ball
screws) against the bearing (10 in-lb for EC-400 and EC-1600). Retighten the locknut.
14. Tighten down completely the five SHCS attaching the ball nut to the nut housing.
15. Reinstall the motor according to "Axis Motor Removal and Installation". Reinstall the hard stop at the
support bearing end of the ball screw.
16. Reconnect the oil line to the ball nut.
17. Reconnect electrical power.
18. a. Machines with counterbalances: Jog the spindle down and remove the cylinder shaft stop.
b. Machines with brake motors: Jog the spindle up slightly, just above the block of wood and push
Emergency stop. Watch to see if the spindle head drops. If it does, check motor installation and
electrical connections, and make proper repair.
c. For 40 and 50 mm ball screws only:
• Jog the spindle head towards the bearing support end.
• Tighten down completely the SHCS that mount the bearing support to the column.
• Loosen the locknut on the bearing support end. Adjust the nut until it seats on the bearing. Re-
tighten the locknut hand-tight, then torque the locknut to 10 ft-lb).
19. Check ball screw torque at bearing support end with torque tester. Jog the spindle head to its highest
position. Check the ball screw torque again. It should be the same as the previous reading.
20. Check for backlash or noisy operation in the ball screw ("Accuracy/Backlash" section).
21. Zero return axis and set grid offset and Parameter 64.
22. Replace appropriate sheet metal.

142 Mechanical Service 96-0283 rev C June 2007

 LATHE B ALL S CREW R EPLACEMENT - X-A XIS
Removal
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.

Oil Line

Temperature
Sensor

4. Remove the motor housing cover.

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

Brace Gearbox
Bearing Pack
Casting
Lock Nut

7. Carefully handle jog the X-axis until there is enough room to install the coupler installation tool (T-1451).
Install the coupler installation tool into the coupler to prevent damage 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.
9. Disconnect motor cables. Remove the four (4) SHCS that secure the axis motor to the motor housing. Pull
the motor away from the casting, sliding 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):

96-0283 rev C June 2007 Mechanical Service 143

 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.
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 Motor

Gear Box
Ring

Coupling

Upper
Lower Bearing
Bearing
Pack

Lower Lock Nut Wedge

13. 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
Installation
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 toward 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, toward 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-lb.
5. SL-20, 30, 40: Retighten the counterbalance spring (see Turret Cross Slide Spring Replacement section).

144 Mechanical Service 96-0283 rev C June 2007

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

LATHE B ALL SCREW R EPLACEMENT - Z-A XIS

Removal
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 hard stops from bearing support and motor end of ball screw.
3. Remove the cover from the motor housing. Disconnect the oil line from the ball screw nut.

Cover Plate SHCS Oil Line Fitting X-Axis Bumper

Bearing Motor
Sleeve Housing SHCS Bumper Bracket
Bumper
SHCS Bearing
Locknut
Bearing
Bearing
Support
Locknut SHCS Casting

Key Ball Screw Nut

Nut Housing
Servo Motor
Ball Screw
Motor Mount Casting

Motor Coupling Assy

SHCS

4. At the bearing support side, loosen the lock nut screw. Unscrew the locknut an 1/8" and retighten locknut
screw. Attach shaft lock tool.
5. 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.
6. In the motor housing, loosen the locknut screw, attach the spanner wrench to the locknut and remove the
nut from the ball screw.
32mm: Remove 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 locknut. Push the wedge all the way
toward 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 toward the
right of the bearing support. Carefully remove the ball screw.
40mm: Underneath the wedge, remove the SHCS from the ball screw nut and push the wedge towards the
motor housing. On the bearing support side, remove the shaft lock tool and locknut. 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 ball screw removal/installation, to protect surfaces.

96-0283 rev C June 2007 Mechanical Service 145

 Installation
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.

1. a. 32mm: 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.
b. 40mm: 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. a. 32mm: Hold 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-lb.
b. 40mm: 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.

CAUTION! Do not use more than one drop of Loctite. An excessive amount causes a
film 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 locknut 1/8" away from the bearing. Tighten the locknut screw.
Install the shaft lock onto the bearing support end of the ball screw.

CAUTION! Do not attach bearing locknut against bearing support until the motor side
locknut 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 locknut. Place a spanner wrench on the locknut in the motor
housing and torque it against the bearing to 15 ft-lb (50 ft-lb for 40mm).
c. Tighten the locknut screw and mark with paint.
d. At the bearing support end, remove the shaft lock.
e. 32mm: Loosen the clamp nut screw. Tighten the lock nut against the bearing to 4 in-lb. Retighten the
clamp nut screw and mark with paint.
f. Align the ball screw nut to the nut housing on the wedge, and check the 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-lb (30 ft-lb for 40mm).
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-lb.
4. Tighten the collar on the motor coupling to the ball screw and torque to 15 ft-lb. Attach bumper, and replace
motor housing cover.

146 Mechanical Service 96-0283 rev C June 2007

 40mm: Move turret to support housing end, taking care to stop before hitting the support housing. Torque
the bearing support housing SHCS to 30 ft-lb. Prevent contact with the ball screw threads, to avoid any
possible damage. Loosen the locknut screw. Tighten the locknut against the bearing to 4 in-lb. Retighten
the locknut screw and mark with paint.
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 ball screw hardstops and reconnect oil line to the ball screw nut.
7. Zero return the axis and set grid offset.

TOOLROOM L ATHE BALL S CREW REPLACEMENT

Removal
Cross Slide Lube Fitting
Ballscrew
Nut Housing
Motor
Coupling

Bearing
and
Lock Nut

Bearing Handle

1. Remove the hand wheel.

2. Remove all necessary sheet metal to gain access to the ball screw, servo motor, and coupler. Remove the
motor housing cover and loosen the coupling. Remove the lubrication line from the X-axis ball nut.
3. Remove the SHCS that secure the ball nut to the nut mount.
4. Remove the bearing locknut and the bearing support (pull the dowel pins out of the Z-axis casting).
5. a. X-axis: Remove the ball screw retaining ring from the motor end of the ball screw.
b. Z-axis: Unscrew the bearing locknut inside the motor housing.
6. a. X-axis: Slide the ball screw away from the motor. Once the ball screw nut is clear of the nut housing,
lift the ballscrew up, then toward the front of the machine, and lift it out of the casting assembly. It may be
necessary to slide the saddle toward the motor.
b. Z-axis: Unscrew the ball screw from the machine.

96-0283 rev C June 2007 Mechanical Service 147

 SHCS
Cover Plate Motor Grease Fitting Z-Axis Bumper
Housing
Bumper SHCS Bumper Bracket
Bearing Sleeve

SHCS Bearing
Locknut

Bearing Bearing
Locknut Support
SHCS

Ball Screw Nut

Key

Servo Motor Nut Housing

Ball Screw

Motor Mount Casting

Motor Coupling Assy

SHCS

Installation
1. Install the ball screw in the nut housing. Note the orientation of the lubrication fitting for the X-axis and the
machined flat on the ball screw. The fitting should be at the 7 o’clock position with the flat face down.
2. Snug bolts securing the ball nut to the nut housing and move the X-axis saddle toward the machine’s rear.
3. Torque the clamp nut on the motor support end to 15 ft-lb.
4. Torque the SHCS in the X-axis nut to 12 in-lb.
5. Lock the ballscrew (lock tool T-1601) and torque the SHCS that secure the bearing cartridge to 15 ft-lb.
Remove the lock tool.
6. Move the X-axis saddle to the front bearing support.
7. Install the bearing support over the end of the ball screw.
8. Install the Z-axis dowel pins and torque the bolts to 30 ft-lb.
9. Torque the locknut on the bearing support side to 4 in-lb and the SHCS in the nut to 15 in-lb.
10. Install the X-axis lubrication line from the ball nut to the saddle assembly.
11. Install the hand wheel.
12. Check for binding in the beginning, middle and end of travel. Check for backlash or noisy operation.
13. Reinstall the X-axis saddle covers.

M INI M ILL B ALL S CREW R EPLACEMENT

Replacement of the mini-mill ball screws follows the same procedures as for the other mills. The ball screws
are only supported at the motor end, thereby simplifing the alignment procedure.
1. Use a standard ball screw support bearing assembly to prevent the ball screw for sagging, and to allow the
use of the shaft lock for tightening the clamp nut at the motor end. Use only one screw to fasten the
support bearing assembly (no dowel pins are necessary) to prevent it from rotating while the shaft lock is in
place, and tighten the clamp nut at the motor end.

148 Mechanical Service 96-0283 rev C June 2007

 2. Remove the fastener from the support bearing assembly to allow it to float on its support surface. Position
the ball screw nut toward the motor end to allow it to self-align to the motor housing bearing assembly.
3. Tightening the five screws to the nut housing.
4. Install the ball screw bumpers.
5. Install the shaft lock on the clamp nut at the motor end, allow it to wedge itself in the coupler cavity and
torque the clamp nut to 15 ft-lb.

GR-S ERIES X-A XIS B ALL S CREW A LIGNMENT

Be sure that machine is level before starting this procedure.
1. Remove the back sheet metal cover from the top of the base and move all axes to their machine zero
locations.
2. Remove any binding in the nut by slightly loosening the ball nut and ball nut housing and retightening them.
3. Jog the saddle (X-axis) all the way to the other end (max. travel). Remove the six SHCS from the bearing
support block.
4. Remove the dowel pins from the bearing support block.
5. a. If the bearing support block is loose in this state, shim both sides of the support block evenly (see
figure) and re-tighten the six SHCS. Do not replace the dowel pins.
b. If the bearing support block is not loose in this state: replace the six SHCS (do not replace the dowel
pins), jog the X-axis to machine zero, loosen the six SHCS on the motor mount but do not remove the
dowel pins, and shim the motor mount .005” and retighten the screws. Make sure both sides are
shimmed the same.

Ball Nut Housing

Shim here Shim here

Bearing support block Motor Mount Ball Nut

6. Repeat steps 2, 3, and 5b until the bearing support block becomes loose. Once the bearing support block
is loose, tighten the six SHCS and jog the X-axis to machine zero, remove the last set of shims that were
added, tighten the motor mount, and with the X-axis at machine zero, loosen and retighten the screws on
the ball nut and the ball nut housing.

96-0283 rev C June 2007 Mechanical Service 149

 7. Check the servo motor loads by jogging the X-axis from machine zero to the maximum travel, then check
the servo motor loads on the X-axis servo motor. View the current command page. The load should not
deviate more than 5%. If necessary, repeat this process.
8. Replace the ball screw hardstops and reconnect oil line to the ball screw nut.
9. Zero return the Z-axis and set the grid offset.

BALL SCREW COMPENSATION

1. Unlock the machine parameters (Setting 7).
2. Starting at zero, move the machine across its full travel.
3. Measure the error registered on the calibration device. A laser, step gauge, or similar measuring tool is
necessary to complete this task
4. Divide the error by the travel of the machine. For example, a machine has 30 inches of travel and has an
error of +0.003" at full travel. The machine has an error of 0.003"/30" or 0.0001"/inch.
5. Multiply the error per inch calculated in the step above by 1,000,000,000. In this case above, the calculated
value would be 100,000.
6. Go to Parameter 229, 230, or 231 (depending on the axis being compensated), type the value computed
from the previous step into the display, and press “Enter”. This will compensate for any scaling error in the
machine. Note that no values will appear in the lead screw compensation tables.

150 Mechanical Service 96-0283 rev C June 2007

 TAILSTOCK 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 -PIECE T AILSTOCK ALIGNMENT VERIFICATION

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, and insert the tailstock taper alignment test bar.
3. 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.
4. 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 180 0),
proceed to the Tailstock Leveling Procedure. If this measurement is out of
tolerance from side to side (900 and 2700), 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 tailstock to the linear guide trucks, allowing the tailstock to rest
on bolts. Place the leveling stand under the bottom edge of the tailstock and manually raise the jack bolts.
(Refer to figure).
2. Attach a tenths indicator to the face of the turret. Level the tailstock 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.

Indicator

Left End Right End

Test Bar
Leveling Stand

Test Bar

Tailstock Leveling Indicator Setup

96-0283 rev C June 2007 Mechanical Service 151

 4. Raise the tailstock 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 tailstock 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 tailstock is leveled, the mounting bolts should be torqued to 50 ft-lb in a clockwise fashion (first,
the inner mounting bolts, then 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 in which direction the tailstock is out of alignment.

Flatness Measurement
End Base

Runout Measurement
at Base

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 alignment 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.

152 Mechanical Service 96-0283 rev C June 2007

 Head Alignment Tool
Mounting Nut (4)

Adjustment
Bolts
Tool Mounting Bolt (2)

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

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 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 ensuring 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.

SL10 T AILSTOCK S EAL R EPLACEMENT

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. One of the seals is inside the bore of the cylinder.

Remove (4) Nuts Stiff Single Sealing

On The Back Of The Outer Ring
Tailstock Cylinder Ring
Rubber
Inner
Ring

“O” Ring
Location

“O” Ring Location

Brown
Seal
Black This Face
Seal Down

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

T AILSTOCK INSERT R EMOVAL AND I NSTALLATION

The following procedure is for one-piece tailstocks only.
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).

154 Mechanical Service 96-0283 rev C June 2007

 Adjustment Nut
Hydraulic Press
Fixture

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 approximately 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 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 insert is removed, use a small screwdriver or chisel to remove any Devcon. Ensure 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. Mount a tenths indicator to the nose of the test bar.
4. Make sure the fill hole at the back of the tailstock casting is not clogged.
5. Install the tailstock insert and three mounting screws.
6. Insert the tailstock taper alignment bar.
7. Position the indicator tip at the base of the tailstock test bar.
8. Adjust insert until the runout at the base of the test bar is less than .0003" TIR. 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. Tighten the remaining screws.
12. Inject the Devcon and let stand overnight.

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 H YDRAULIC TAILSTOCK C YLINDER
WARNING!
Before performing any service the machine should be powered off.

Removal
1. Remove front and rear waycovers. Move the tailstock to the middle of travel and disconnect the hydraulic
lines from both ends of the cylinder.

Extended
BHCS Cylinder Rod

Encoder

Hydraulic Tailstock Adapter

Cylinder BHCS

Encoder
SHCS Rail Support Rail

Hydraulic Cylinder Replacement

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.

2. Remove the (2) SHCS that mount the cylinder rod end block to the rear of the hydraulic tailstock adapter.
3. Remove the 1/4-20 SHCS that mounts the encoder rail to the bottom of the cylinder rod end block
4. 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.
5. Remove the (2) SHCS that mount the hydraulic cylinder body to the base casting.
6. Unscrew the end block from the cylinder. Collapse the hydraulic cylinder, then push the tailstock to the
rear of travel.
7. Pull the hydraulic cylinder out from the frontside of the tailstock.

Installation
1. With the new cylinder in position, push the tailstock to the front of travel.
2. Install the (2) SHCS that mount the cylinder body to the base casting. Before tightening, move the tailstock
to the front end of travel.
3. Thread the end block onto the end of the cylinder rod and tighten.
4. Install the (2) SHCS that attach the end block, and install the 1/4-20 SHCS that hold the encoder rail to the
bottom of the mounting block.
5. Attach the hydraulic lines to both the front and rear of the cylinder. Check for leaks.
6. Reinstall waycovers. Check fluid level at hydraulic tank to determine how much fluid needs to be added.

156 Mechanical Service 96-0283 rev C June 2007

 EC-300/MDC P ALLET CHANGER

COMPONENTS
EC-300 Rotary Table - The rotary table is a Haas 210 equipped with a special platter compatible with the
pallet changer operation. The table is mounted on the pallet changer casting, and a drive shaft bearing assem-
bly is inserted into its spindle (on the brake side). A nut housing is inserted into the spindle of the table (on the
platter side), and an air blast manifold is mounted onto the table platter.
Load Station - The load station uses the 2 built-in rotary tables to index the part while in the the load station.
Hold the Pallet Index button and the pallet will rotate (in one direction only).
Power Supply Cables - The load station drawbar gearmotor and main drawbar gearmotor each have a power
supply cable. Load station motor is equipped with extension cable to aid in motor replacement. The connector
is about 12 inches from the gearmotor. Both power supplies are routed to their respective mounting locations
from the central point of the solenoid mounting bracket (at rear of machine), where disconnects are located.
Air Supply Lines - The lifting cylinder has one large air supply line for lifting the pallets and their loads. No
return line is required because the cylinder is vented to the atmosphere and the weight of the assembly and
load will cause the cylinder to lower. The rotation cylinder is double-acting and has two smaller air supply lines
for clockwise and counterclockwise rotation. The air blast system has one large air supply line, which is
connected to the lube tube adapter. Each of the four air supply lines are routed to the solenoid mounting
bracket (at the rear of the mill), where the air solenoid assembly is located. Four solenoid valves are used to
provide the responses required for the pallet change operation.
Lubrication Supply Lines - An oil supply line from the lube/air panel (on the right side of the machine)
attaches to the lube tube adapter. It provides lubrication to the rotary table drawbar, which carries oil mist from
the air blast plug up the center of the main drawbar, to the drawbar and pallet nut.

TABLE C LAMPING

Clamp Plate
Springs and
Table Clamp Air Clamp Air Clamp
Springs Pressure

Clamp Piston

Switch, Normally
Air Unclamp Exhaust Open

Operation
The table trips the clamp switch, not the clamp plate
1. Table indexes into position based on servo control parameters.
• Clamp plate is in un-clamp position; it is held there by air pressure compressing the springs.
• Clamp status switch plunger is away from the Normally Open (NO) proximity switch.
2. When table is in position, solenoid valve actuates to pressurize clamp side of piston. Air pressure and
spring force combine to clamp table (approx. 10,000 pounds of clamp force depending on air pressure).
• The table lowers and contacts the clamp status switch plunger. The plunger is pushed down and trips the
normally open (NO) status switch to close contacts.

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 3. To unclamp, the solenoid switch shuttles to exhaust the clamp side and pressurize the unclamp side of the
piston. The unclamp air pressure must compress the clamp springs to raise the clamp plate. For the first
portion of the travel the springs between the table and the H-frame aid in raising the clamp plate.
• At the top of piston travel the clamp status switch plunger raises (it is pushed up by a spring) and
comes clear of the proximity switch. The NO switch is now open and the table is ready to index.
Table Clamp Status Under Different Conditions
2 4

12 14
No Power
Sol
Safety Valve
3 1 5
2
P Sol
Ex No Power

Pressure 3 1

Blocked
Table Clamp
A. Condition is clamped when machine is normally powered off or when first powered on or when table index
is completed.

2 4

Power On
Sol
Safety Valve
3 5
Ex 1 2
P Sol
Power
Pressure On
3 1

Blocked Ex
B. Condition when machine is unclamped. Note that the same condition applies if table is unclamped and the
machine is emergency stopped in the middle of a table index. The table remains unclamped.

No Power

Safety Valve

1
P Sol
No Power
Pressure

Port Plugged Ex

158 Mechanical Service 96-0283 rev C June 2007

 C. Condition when the table is unclamped and then power is lost.
• Main valve shuttles to clamp the table but the safety valve also loses power and blocks the
exhaust port on the clamp side of the piston. This prevents the clamp plate from clamping immedi-
ately. The clamp plate will slowly move to its clamp position.

TROUBLESHOOTING
1. Failure - Clamp switch wires cut.
Result - The control see the switch as open at all times. The table can index into position and clamp. The
control will not see the switch close therefore it assumes that the pallet is not clamped; an alarm
will generate.
Comment - This is a safe condition; there is no threat of injury or machine damage. However, the machine
will not function until the switch is replaced.
2. Failure - The clamp status plunger rod is stuck in clamp position (broken rod, broken switch, stuck rod).
The same scenario if an errant piece of metal keeps the switch tripped closed.
Result - The clamp plate unclamps, raising the pallet. The machine is ready to rotate the pallet, but the
control does not receive a signal that the table has raised. Without the signal the control thinks
the pallet is clamped. After a period of time an alarm will be generated.
Comment - This is a safe condition; there is no threat of injury or machine damage. However the machine
will not function until the plunger problem is corrected.
3. Failure - Table index (pallet change) starts and then is E-Stopped in the middle of indexing
Result - The clamp plate remains in the unclamp position.
Comment - This is a safe condition. To resume machining, clear the alarms and Zero Return all axes. The
machine will automatically home all axes and the clamp plate will clamp the table.
4. Failure - Table Indexer (pallet change) starts and then the machine is E-Stopped and powered off.
Result - The clamp plate remains unclamped because the exhaust port on the unclamp side of the
piston is blocked (closed). In other words the clamp plate is being pressurized in order to clamp,
but as the exhaust port is blocked this prevents the pallet from being clamped.
Comment - This is initially a safe condition, however, due to leakage on the exhaust side of the piston the
clamp plate will eventually move to its fully clamped position. It is not safe to leave the table
partially over the table locator teeth. It should be rotated fully off of the clamp plate. This can
be done by manually rotating the pallet changer.
5. Failure - Clamp valve solenoid loses power or burns up while machine is running and table is clamped.
Result - Table remains clamped upon attempting to unclamp the clamp plate will not rise and the
clamp status switch will show the table as “clamped”. The machine will generate an alarm.
Comment - This is a safe condition. The table will remain clamped. The machine will not function until the
solenoid is replaced.
6. Failure - The solenoid on the safety valve burns out or loses power when the table is clamped and the
machine is operating.
Result - The machine will continue to function normally. It will clamp and unclamp without incident. In
the event the machine is E-Stopped in the middle of a table index, the clamp plate remains
unclamped. If power is lost or the machine is powered off during a table index, the clamp plate will
clamp.

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 Comment - A failed safety circuit valve is not detectable. This is an unsafe condition as it is found only
when the machine has already crashed.
7. Failure - Table clamped and machine loses air pressure
Result - The low air-pressure alarm will reach its time limit and alarm-out the machine. If air is lost
while the machine is cutting, the table will remain clamped via the clamp springs.
Comment - The clamp springs are adequate to prevent the table from moving grossly off of the locating
fingers.
8. Failure - Table unclamped and the machine loses air during a pallet change.
Result -The low air pressure alarm will not alarm out the machine until it has reached its time limit. At the
time of air loss the clamp plate will lower to the clamped position via the clamp springs.
Comment - This is a dangerous condition. If the table is partially on or partially off of the clamp plate;
potential damage to the indexer can result. If the table is heading towards the clamp plate and
the clamp plate lowers due to loss of air, a crash will result.

EC-300/M ILL D RILL P ALLET C HANGER D ISASSEMBLY

Pallet Changer Disassembly can be done from the Load Station of the EC 300/MDC without
removing any enclosure parts.
1. Enter M-17 in MDI mode and press Cycle Start to un-clamp the pallet (recommend 25% rapid). Wait until
the assembly has fully risen to its highest point and begins to rotate and press Emergency Stop. Rotate
the pallet as required to remove the components.
2. Remove the sheet metal guards on top of the clam shell cover.
3. Remove the clam shell by unbolting the 20 screws in the rotating door and along the bottom of the clam
shell.

CAUTION! The clam shell can be removed by simply lifting up and over the rotary table
once the sheet metal guards have been removed. Do not remove or adjust
the pallet on the rotary table.

4. Remove the two door caps on top of the door panel (rotate the door 90°).

Door Cap

Sheet Metal
Guards

Rotating
Door

Clam Shell

5. Remove rotating doors and the white plastic cable fairlead (the doors come off in 2 halves). Keep cables
out of the way. The harmonic drive assembly can be removed at this point by removing the six 3/8-24
SHCS holding the flange plate and servo motor to the frame support and lifting the entire assembly straight
out. Mark the orientation of the plate first, since it must be reassembled exactly as it was.

160 Mechanical Service 96-0283 rev C June 2007

 NOTE: If the servo motor has been removed, the grid offset has to be re-calculated
in order to assure that there is no mis-allignment after re-assembling the
motor. Refer to "Pallet Changer Grid Offset".

NOTE: Power off before disconnecting anything (and unscrew the power cables for
the rotary tables from J-box for EC-300).

Steps 6-8 apply to the EC-300 only

6. The power wires are located on top of the machine for the two rotary tables and are routed through the
table to the top of the machine via the center compartment within the rotating doors.

NOTE: There are 2 power lines and 2 air lines: one pair connected to each table. There
is also an oil line that splits to each table.

Remove the cable cover on the rotating door and pull the cables through. Disconnect the power cables from
the J-box, remove the lubrication line and disconnect and crimp air lines leading to the rotary tables with a
zip tie. There is a silk screen on the outside of the J-box that illustrates wire routing.

Electrical From Control Cabinet Air

Air Solenoids for Clamp/Unclamp Control
J-Box Cabinet
and Air Blast
J-Box Junctions
Air, Oil and Electrical to Oil Reservoir
Rotary #2
Oil Manifold 0
Air, Oil and Electrical to
Rotary #1 Pallet 2
Pallet 1
Electrical to Servo Motor Servo Motor

Rotary Table

Dowell Pin
Toe Clamp

Pallet

7. Remove the 3 toe clamps from the sides of the HRT-210 rotary tables and remove rotary tables with a lift.
8. Remove two ½" dowel pins (2 per pallet) that are seated in non-threaded holes in the pallet for proper
orientation of the rotary tables. Do not lose these pins.
9. The pallet table assembly must be rotated approximately 30° away from the home position to access the
5/8" shoulder bolts underneath.

96-0283 rev C June 2007 Mechanical Service 161

 30° Pallet Support Spring
Shoulder Bolt
Splash Shield
Spring

Clam Shell Bracket

Shoulder Bolt Frame Support

10. Remove the pallet changer tables by unbolting the four 5/8" shoulder bolts between the pallet changer and
the frame support. After removing the shoulder bolts, the pallet is loose on the pallet support springs and
can be lifted off by using 2 eye bolts. (Each table weighs approx. 160 lbs.)
11. Remove the 2 splash shields along with the bracket clam shell located under and around the table area.

NOTE: Air pressure must stay connected throughout this process. Do not initiate a
pallet change under any circumstance and only rotate assembly by hand.

Frame Support Removal: Remove the splash shields, the bracket shell, and disconnect the home switch.
The frame support can be removed with the servo motor and flange plate still connected. The frame supports
weigh approximately 195 lbs. and should be lifted out carefully.
To service the pallet clamp piston assembly, the entire pallet changer assembly must be removed.
1. Remove all front interior sheet metal pieces attached to the pallet changer.

NOTE: If enough lift capacity is available (2,000 lbs. on an extended arm) the rotary
tables, pallets, and frame support may stay in place; otherwise, they must be
removed (described in "Frame Support Removal").

Lifting Apparatus

2. Disconnect the rotary table power cables (EC-300), remove the air lines located on the lower left of the
pallet changer base, and remove the 7 bolts that attach the piston to the shaft.

NOTE: Mark the air lines for proper re-assembly.

3. Disconnect the pallet clamp switch and remove the ten 5/8 –16 socket head bolts holding the pallet
changer base to the main base casting.
4. Bolt-in lifting tools and lift out. Disconnect the Un-clamp air fitting on the bottom side of the piston cover
plate. Remove the piston cover, the pallet clamp piston and P.C. shaft to service the assembly.

162 Mechanical Service 96-0283 rev C June 2007

 To service the thrust bearing assembly, see "Frame Support Removal" and “Pallet Changer Disassembly and
Replacement” sections, and remove the support frame, exposing the thrust bearings and thrust washers.

NOTE: The weight of the table rests on the thrust bearing.

If the thrust bearing and washers have to be removed, remove the unit as a whole so as not to lose the bear-
ings. Inevitably, some bearings will fall out; therefore, it is advisable to have spare bearings for replacement.
To service the air blast assembly, the pallets must be rotated perpendicular to the home position and at least 1
pallet table must be removed. After removing the pallet, rotate the frame assembly with the empty pallet space
back over clamp plate and remove the clamp plate, followed by the air blast ring.
To service the pallet clamp switch, follow steps above for servicing the air blast assembly, then unbolt the four
socket screws and pull the assembly out.
To service the air tubing, remove the motor, motor flange plate, and the harmonic drive assembly.
Re-assembly
APC Spring Seating Procedure (Pallet 1)
1. In MDI mode write a simple program (M17; M18;M99) to clamp and unclamp pallet.
2. While P1 is clamped, loosen but do not remove shoulder bolt retaining springs
3. In single block mode, cycle the program to observe the direction of table movement.
4. Adjust spring location by gently tapping springs in the opposite direction of the table movement. Run the
program to verify adjustment.
5. Repeat the previous step until all pallet movement is gone, then torque shoulder bolts to 75 ft/lb. Run the
program again to verify the adjustment was not affected.
6. Repeat this procedure for the other pallet.

Squaring The Pallet

96-0283 rev C June 2007 Mechanical Service 163

 1. Loosen all bolts from the pallet changer to the base and align front-machined surface of pallet parallel to X-
axis (NTE 0.002" overall). Perform a pallet change and verify the other side.
2. Level the pallet along the X-axis by indicating across the pallet in the X-axis direction. Both pallets should
be parallel to within 0.002"/10" of each other.
3. If the pallets are not level, shim between the pallet changer and base as required, and tighten the pallet
changer base bolts.
4. Rotate the pallet changer and verify the other pallet.
5. EC-300: Level the pallet along the Z-axis by indicating across the pallet in the Z-axis direction.
6. MDC: Level the pallet along the Y-axis by indicating across the pallet in the Y-axis direction.
7. If necessary, adjust the shims between the pallet changer and base as required. Ensure all of the bolts are
tight before continuing.
8. Rotate the pallet changer and verify the other pallet.
Align Rotary Tables (EC-300)
1. Clean and stone pallet changer surfaces before installing rotary tables.
2. Install the 2 dowel pins into the pallets and place the rotary tables accordingly.

NOTE: Make sure the dowel pins are seated in non-threaded holes in the pallet.

3. Connect the cables, lubrication lines, and air lines to the rotary table and ensure that the oil reservoir is full.
4. Install table clamps (3 per table) and fasteners and torque to 80 ft-lb.
5. Indicate the top of the rotary table and take readings at 0, 90,180, and 270°. If necessary, adjust the shims
under the rotary table to align the rotary axis perpendicular to the XZ plane, not to exceed 0.0003".
6. Indicate across rotary table surfaces along the X- and the Z-axes. The indications should be parallel to
within 0.0005"/10".
7. Rotate the pallet changer, and indicate the other rotary table as described above.

Pallet Changer Grid Offset

1. Make sure that Bit #28 in Parameter 209 has a value of 1. The pallet will stay up.
2. Verify that the pallet changer type in Parameter 605 is 3.

NOTE: The APC is on the B-axis on machines with single Mocon PC board or the W-
axis on machines with two Mocon PC boards.

3. The grid offsets in Parameter 445 should be the W -axis, and the offsets in Parameter 170 should be the B-
axis. Respectively, tool changer offsets in Parameter 451 should be the W-axis, and the offsets in Param-
eter 213 should be the B-axis.
4. Zero return the appropriate axis, and set the grid offset for the individual axis only. Zero return again.
5. Press the Emergency stop button and manually rotate the APC so that the locators on Pallet 1 are aligned
with the locators on the APC.
6. Lower the pallet onto the locators by lowering the air pressure at the main regulator. Be careful not to
damage either the locators or the pallet.
7. Enter Debug mode, go to the Pos Raw Data page, and take the actual value from the appropriate axis.
Enter this value into the tool change offset parameter.

164 Mechanical Service 96-0283 rev C June 2007

 8. Restore the air pressure and zero return the axis.
9. Verify that the pallet is aligned over the locators.
10. Change the value of Parameter 209 to 0.

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 EC-400 P ALLET C HANGER
When the automatic pallet changer (APC) is at rest, the pallet is clamped, the pallet at the load station is at
home position, and the APC door is closed. The H-frame down solenoid is on, the safety solenoid is on, and
the H-frame is down with the H-frame lock pin engaged in the bumper mount. The APC servo has been zero
returned, using the APC home sensor.
The load station is a 90° manual indexing station that holds a pallet securely into place while maintaining the
ability to index freely. A manual indexing handle withdraws an indexing pin from the load station, which makes
it possible to rotate the turntable (and the load) by hand. Four positions are available, at 90° increments, and at
each increment the indexing pin will lock into position. Pallet must be in the home position before a pallet
change can be commanded. When a pallet change is commanded the following events occur, in this order:
1. H-frame down switch is checked to verify down status.
2. Z-axis rapids, if necessary, to a position specified by the grid offset & Parameter 64.
3. A-axis rapids to position specified by grid offset & Parameter 224 (may involve raise/lower of pallet).
4. The lifting and lowering of the A-axis platter on indexer-style machines is monitored by a sensor assembly
located on the bottom of the A-axis. There are no sensors monitoring the A-axis platter position on ma-
chines with the full 4th axis option.
5. The A-axis is allowed to rotate, once the platter lift sensor is triggered.
6. When the A-axis moves to the home position and lowers, the platter down sensor is triggered and the
platter lift sensor is turned off.
7. Power is turned on to the pallet clamp/unclamp solenoid located at the rear of the machine.
8. The clamp air pressure is released from the clamp side of the receiver piston and 100 psi of air is applied to
the unclamp side of the receiver piston.
9. The clamp plate rises.
10. When the clamp plate moves approximately .400" it will trigger the pallet unclamp sensor. The sensor
sends a signal to the CNC control that the clamp plate is in the unclamp position. A sensor assembly
located on the bottom of the A-axis monitors the clamp plate position.
11. APC door and load station lock switches are checked.
12. The H-frame down solenoid and safety solenoid turn off.
13. The H-frame up solenoid turns on.
14. Air pressure in the air cylinder rotates the top cam, by rotating the seal housing. The bottom cam does not
rotate.
15. The cage and three balls rotate at half the speed of the cam, forcing the cams to separate.
16. The top cam raises the H-frame by lifting upward on the hub, using the tapered bearing as a thrust bearing.
17. The H-frame engages and lifts both pallets as it is raised.
18. The APC shaft does not rise. The hub slides up the shaft on the four ball bearings. The flat tang of the APC
shaft slides inside a slot in the cycloid hub.
19. The H-frame up switch checks H-frame up status. As the H-frame rises, the lock pin comes out of the hole
in the bumper mount, so the H-frame can rotate.
20. Once the H-frame up switch indicates up, the air blast solenoid is turned on, and sends air blowing through
the air blast assembly at the top of the receiver.

166 Mechanical Service 96-0283 rev C June 2007

 21. The servomotor rotates the H-frame and pallets 180°, by driving through the gearbox, torque tube, and hub,
while the APC shaft, cycloid hub, and part of the gearbox remain stationary. The servomotor rotates with
the assembly.
22. The H-frame down switch gets a momentary false signal as it rotates past the tang on the APC shaft,
approximately mid-stroke, which the software ignores.
23. The safety solenoid, which is off, prevents the H-frame from suddenly lowering in the event of a power
failure by blocking the vent port of the H-frame up solenoid.
24. When it has rotated 180°, the servomotor stops, and holds position. The encoder on the servomotor
determines the rotational position.
25. The H-frame up solenoid is turned off.
26. The H-frame down solenoid and safety solenoids are turned on, pressurizing the other side of the air
cylinder while venting the side previously pressurized.
27. The top cam is rotated back to its original position, allowing the H-frame and pallets to lower. As the H-
frame lowers, a lock pin under the H-frame drops into a hole in the bumper mount. It keeps the H-frame
from being moved while the servo power is off.
28. The pallet in the machine is lowered onto the receiver and the pallet on the load station is lowered onto the
index disc pallet pins.
29. Power is turned off to the clamp/unclamp solenoid and air blast solenoids located at the machine’s rear.
30. The unclamp air pressure is exhausted from the unclamp side of the receiver piston and air blast is turned
off while simultaneously applying 100 psi of air pressure to the clamp side of the receiver piston.
31. The clamp plate moves down to clamp the pallet. The clamp plate will move approximately .400" and clamp
the pallet. It will trigger the pallet clamp sensor, indicating that the pallet is clamped. The clamp plate
position is monitored by a sensor assembly located on the bottom of the A-axis.
32. The load station lock plate prevents the load station pallet from falling off if it is rocked severely while
loading parts.
Make sure the machine is turned off and the air pressure is discharged before attempting to work on this
machine. The drive mechanism for the APC is located inside the rotating door. It can be accessed for trouble-
shooting by removing either half of the door. APC disassembly requires removing the door. Disassembly is a
top down process.

96-0283 rev C June 2007 Mechanical Service 167

 EC-400 Pallet Changer Exploded View

Servo Motor
Motor Seal
Umbrella Mount Plate (not shown)

O Ring Cycloid Mount

2-258

Torque Gearbox
Tube (99-0110 Grease
Inside)

To Following Page
.070” O Ring Cycloid Hub
stock
APC
HOME Sensor

H Frame Down Sensor O Ring 2-338

Wave Spring

Bearing Cap
Ball
Bearing Bearings
Spacer
H Frame Pins

H Frame

2X Lock Pins
Hard Stops

168 Mechanical Service 96-0283 rev C June 2007

 O Ring 2-358
Air Vent
Hub
Load Station
Index Disc Load Station (2-379 O Ring inside)
Lock Plate
Seal Housing

Tapered O Ring Inside 2-377

Pallet Roller Bearing
Pin Cam

Load
Bumper Station Shaft 3X Ball Bearings
Mount Cage
6X Dowel Pins
Bumper Cam
Table Bolt Plug Shaft Clamp
Shaft Seal
Knob Bridge
Lock Cylinder Lever
Pin
Lock Rod End, Shoulder Screw
From Preceding Page

Mount and Jam Nut & 2X Washer

Hidden
Lock HSG Shoulder Screw
(not shown)
H frame up
Operator Reed Switch
Station Lock Switch Air Cylinder and Hose Clamp
(Wired in series with
Load Station door switch) 4X Washers 2XTop & 2X Bottom
(not shown)

H Frame Down Solenoid

APC Shaft
Tapered Roller
Bearing

Bearing Locknut
Safety
Shaft Cover Solenoid H Frame Up
Solenoid

Incoming air @ 85 psi Shaft Mount

from machine regulator

96-0283 rev C June 2007 Mechanical Service 169

 PALLET P OOL MOTOR REPLACEMENT
Pallet Pool Motor Replacement is accomplished from beneath the Rotator/Slider of the EC-
400 Pallet Pool.

Access Holes

Bolt Tool
Remove SHCS
2X Install Bolt Tool
with Thrust Bearing
Bolt Tool and Washer

2X Access Holes

4X
4X Lockwasher
SHCS

Sheet Metal Rotate Key

Braces
6X SHCS Rotate
Motor
Mount

1. Enter M17 in MDI mode and press Cycle Start to un-clamp load station pallet (recommend 25% rapid).
Wait until assembly has fully risen to its highest point and begins to rotate, then press Emergency Stop.
2. Remove sheet metal attaching the Pallet Pool to the EC-400 to gain access to the interior of the Pallet
Pool.

Remove for
Pallet Pool
Access Access Holes

Bolt Tool
Hole

3. Manually rotate the rotator/slider to expose the large socket head screw access holes beneath it (two on
each side).

170 Mechanical Service 96-0283 rev C June 2007

 4. Insert a threaded bolt tool (contact Haas for tool) in the hole between the two access holes (one on each
side of the rotator/slider to keep the motor from falling later in the procedure.
5. Using a special tool (contact Haas for tool), insert it into the access holes and remove the four bolts (two
on each side of the rotator/slider) holding the motor in place.
6. Loosen the bolt tool between the access holes (one on each side) to lower the motor onto the two sheet
metal braces beneath it. Lower the motor by alternately unscrewing the bolt tool until the motor is resting
on the braces. If you fully unscrew a bolt tool on one side, it may bind.
7. Remove the two drip trays located below and to the rear of the rotary/slider.
8. Remove the drain tray gutter located below the rotator/slider, by unbolting it and pulling it out through the
open area at the left side of the pallet pool.

Right Intermediate
Drip Tray Remove 3-BHCS

8X BHCS

Remove
3-BHCS

Right Rear Drain Tray

Drip Tray Gutter

9. Enter the open area at the left side of the pallet pool by crawling into it, make your way to the motor, and
disconnect any cables and wires holding the motor to the rotator/slider.
10. To remove the motor, slide it down to the end of the sheet metal braces and lift it up and out through the
space left by the removal of the drip trays and drain tray gutter.
Reverse Steps 1 through 9 to install the motor.

NOTE: There is an extruded slot (rotate key)on the motor that fits into a slot under the
rotator/slider where the motor needs to be attached. Make sure they are fitted
together before pulling the motor into place and tightening the bolts.

PALLET CHANGER DISASSEMBLY AND REPLACEMENT

Disassembly
1. Remove the rotating door and the servo motor sheet metal cover.
2. Unplug electrical wires to servo motor. Dismount servo motor held to umbrella mount plate with four SHCS.
3. Remove SHCS that hold gearbox and cycloid tube to torque tube. Remove gearbox with the cycloid tube.
4. If the cycloid hub must be removed from the gear box, cover the gear box hole to prevent contamination.
5. Unbolt the torque tube from the bearing cap and lift it off of the dowel pins. Unbolt the bearing cap and lift it
off of the dowel pins, exposing the wave spring, four bearings, and bearing spacer.
6. Remove the two hardstops from the H-frame. Remove the eight SHCS that hold the H-frame to the hub.
Carefully lift off the H-frame from the dowel pins.

96-0283 rev C June 2007 Mechanical Service 171

 7. Lift the hub off of the APC shaft.
8. If the bearings need to be replaced, remove them from below the hub using a punch. If the bearings are
removed, replace them. Pack the new bearings with moly grease.
9. Remove the air cylinder per the instructions in the air cylinder removal section.
10. Lift the seal housing off of the bridge. The cam assembly is heavily greased and may be stuck inside the
seal housing.
11. Remove the cam assembly which consists of the cage and three balls.
12. Unbolt and remove the lower cam.
13. Remove the SHCS from the shaft clamp.
14. Loosen the tapered shaft clamp by loosening the mounting screws. Remove the shaft clamp.
15. Remove the 5/8” SHCS from the shaft mount located on the bottom of the shaft. Remove the shaft by lifting
it straight up.
Reassembly
Reassemble the pallet changer in the order by which it was removed. Align the H-frame to the receiver pallet
per the instructions in the Pallet Changer H-frame to Pallet Alignment section.

H-FRAME REPLACEMENT
1. Remove the rotating door.
2. Remove the two hardstops from the H-frame.
3. Remove the SHCS that fasten the H-frame to the hub.
4. Raise the H-frame with an appropriate lifting device until the H-frame is above the dowel pins.
5. Carefully guide the opening of the H-frame around the servo motor, connectors, and umbrella mount plate,
and remove the H-frame from the machine.
6. Replace the H-frame in the reverse order from which it was removed. Be sure that the servo motor electrical
connections are on the same side as the hard stops on the H-frame.
7. Align the H-frame per the Pallet Changer H-frame to Pallet Alignment procedure.

H-F RAME S WITCH ADJUSTMENT

H-frame up sensor
1. Remove the APC cylinder shield to access the up switch.
2. Loosen the switch clamp.
3. Find the correct position for the switch: Go to the APC diagnostics page. The status of H-Frame Up should
be 0 for most of the air cylinder’s travel, but will change to 1 when the cylinder is within 1/16" of being fully
extended. It will remain 1 for the last 1/16" of travel.
4. Slide the switch lengthwise on the air cylinder to its correct position then tighten the clamp. Replace the
APC cylinder shield.
H-frame down sensor - There is no adjustment for the H-frame down sensor.

172 Mechanical Service 96-0283 rev C June 2007

 A IR C YLINDER
1. At the APC recovery page, confirm that the H-frame is commanded down.
2. Disconnect the machine’s air.
3. Remove the APC cylinder cover.
4. Remove the H-frame up reed switch. Disconnecting it is not necessary.
5. Disconnect the two air hoses.
6. Remove the shoulder bolts and washers that retain the air cylinder and remove the air cylinder..
7. Remove the air fittings, rod end, and jam nut and assemble them on to the new air filter. Leave the rod end
loose.
8. Wrap the air fittings with teflon tape.
9. Mount the fixed end of the air cylinder to the bridge using a shoulder bolt and two washers on either side of
the spherical bearing.
10. Rotate the APC cam lever, cams, and seal housing clockwise as viewed from the top, until it stops.
11. Adjust the rod end, as required, to easily insert the shoulder bolt with the cylinder fully retracted.
12. Unscrew the rod one full turn and tighten the jam nut. The air cylinder should reach the end of its travel
before the cams do.
13. Attach rod end to the cylinder lever using the shoulder screw with one washer on each side of the rod end.
14. Torque both of the shoulder screws to 100 ft-lb.
15. Reinstall and adjust the H-frame up switch.
16. Reinstall the air lines and the cylinder shield.
17. After completion, run a sample program to test for proper operation.

PALLET C HANGER H-FRAME TO PALLET ALIGNMENT

There are two stages to properly aligning the pallet changer H-frame and the pallets. The first is to align the
pallets to the H-frame. The second is to align the pallet load station to the H-frame.

Stage 1
1. Go to the parameter page and scroll to find Parameter 76. Write down the current value. Adjust Parameter
76 to a large number (e.g. 99999999999), to delay the low air alarm.
2. Enter Debug mode (go to Alarms page, key in Debug and press Enter) and scroll to Pos Raw Data.

96-0283 rev C June 2007 Mechanical Service 173

 3. Jog the Z-axis until the pins on the H-frame are aligned with the holes in the pallet. Enter the value of Z-axis
Actual into Parameter 64.
4. Enter Pallet Changer Restore (press Tool Changer Restore and select the Pallet Changer Restore option).
5. Home the Z-axis and verify the pallet to H-frame alignment.
6. Unclamp the pallet and turn down the main air pressure regulator to approximately 10 psi.
7. Press the key to raise the pallet. Turn up air pressure (at air regulator) slowly and verify that the H-frame
and pallet are aligned. To lower the H-frame and pallet raise air pressure and press the pallet down button.
8. If the alignment is incorrect repeat the steps to set Parameter 64.
9. Once the alignment is complete, restore the main air pressure regulator to the correct pressure (85 psi)
and finish the pallet changer restore sequence.
10. Exit Debug (type Debug and press Enter from the alarms page).
Stage 2
Alignment of the pallet load station pins to the H-Frame. At this stage the H-frame has been aligned to the
rotary axis (Stage 1 has been completed).
1. Loosen the four alignment pin bolts on the load station. Rotate the pallet at the load station to access all
the bolts.

2. Rotate the pallet load station to home. Enter pallet changer recovery
3. Unclamp the pallet and raise the H-frame.
4. Reduce the main air pressure regulator to approximately 10 psi.
5. Enter pallet changer restore and command the H-frame down.
6. Increase the air pressure at the main pressure regulator until the H-frame starts to lower. Verify the pallet is
engaging the alignment pins.
7. Once the pallet is seated on the alignment pins, tighten them.
8. Increase the main air pressure regulator to 85 psi and finish the pallet changer restore sequence.
9. Close doors and command several pallet changes to verify smooth operation.
10. Set Parameter 76 to the original number.
Note that pallet changer recovery reduces rapids to 25%. The pallet at the load station must always be re-
turned to home before automatic pallet changes can occur.

174 Mechanical Service 96-0283 rev C June 2007

 EC-400 ROTARY REPLACEMENT
Warning
The indexer will crash if the following procedures are not followed.
Read all material before proceeding.

When the Indexer is replaced in the EC-400, it must have the lift switch adjusted and Parameter 212
set to zero before any other machine movement is attempted! Misalignment of the facegear at the home
position will cause malfunction. Make sure that software version 12.08 or later is loaded and the table is
initialized on the settings page. (This assures that all parameters are set for this option.)
To perform all of the procedures in this section, the Z-axis waycovers must be removed.

A- AXIS I NDEXER L IFT S WITCH S ETUP

Lift Switch Setup
1. Disconnect the main air supply, then plug the air line to the brake solenoid.
2. Release the air pressure at the table by activating the clamp release solenoid plunger.
3. Connect the test air regulator (T-2150) to the shop air supply. Connect the outlet to the rotary table at the
platter lift, air in connection (Air In). The main regulator adjustment knob must be fully unscrewed.

Air In

Solenoid
Plunger

4. Turn the regulator adjustment knob to 20-40 psi and toggle the air pressure to the clamp fittings.
5. Set an indicator on the machine with the stylus on the platter or pallet.
6. Go to the diagnostics page (Dgnos).
7. Slightly loosen the two mounting screws on the lift switch mounted on the lift switch bracket.
8. Raise and lower the pallet with the regulator adjustment knob. Note that the platter up state is at 0 when
up and 1 when down. Adjust the position of the switch so that the platter lift state becomes 0 at .052"
above the down position.
9. Tighten the switch mounting screws when this height is achieved.

S ETTING P ARAMETERS 212 AND 128 (I NDEXER A A XIS O FFSET )

1. In Debug mode, go to Parameter 212, enter “0”, then press the “Write” key. Repeat for Parameter 128.
2. Toggle air pressure to the lift piston using tool T-2150 so that the platter is at the top of its travel.
3. Zero the A-axis only by pressing the “Zero Ret” key, then the “A” key, then the “Zero Singl Axis” key.
4. Go to Parameter 128 and record the value.
5. Jog the A-axis to line up the front edge of the pallet with the X-axis as close as the coupling position will
allow. E-Stop the machine.

96-0283 rev C June 2007 Mechanical Service 175

 6. Slowly discharge the air pressure to the A-axis and lower the platter into position.
7. Rotate the worm shaft pulley to the extent of its travel and record the value. The value at the middle of this
range is the value for Parameter 212. Enter that value.
8. Remove tool T-2150 and replace the hoses.
9. To fine adjust the front edge of the pallet, it may be necessary to loosen the 16 SHCS that fasten the rotary
body to the trucks and the ten SHCS for the Z-axis ball screw mount.
10. Tap the rotary body into position within .0005"/10.00".
11. Tighten, then torque the 16 SHCS that fasten the receiver body to the trucks. Tighten the five ball nut bolts,
allowing the housing to re-align, then torque the ten housing bolts. After the housing bolts have been
torqued, loosen the five ball nut bolts and run the ball nut away from and back to the motor. If no binding
occurs, re-tighten the ball nut bolts.

EC-400 R OTARY I NDEXER A IR D IAGRAM

Safety Solenoid
Lift/Purge Assembly
Solenoid
Assembly

Air In Top View Front View

Platter Air Air in From

Purge Air Doubler
Clamp
Solenoid (140 PSI)
Assembly Lift Clamp
Solenoid
(80 PSI)

Safety
Air in From Solenoid
Air Doubler Clamp Solenoid
(140 PSI) Lift Assembly

RECEIVER REPLACEMENT
The following instructions detail the procedure for leveling and verification of the receiver geometry. Machine
level must be verified and geometry must be checked for reference before replacing the receiver.
Receiver/Pallet Verification
Leveling: The machine must be level with absolutely no twist in the Z-axis.
1. Clean the pallet and precision level of all debris. (The level can also be placed on top of the pallet clamp
plate, with the pallet off of the machine.) Center the X- and Z-axes.
2. Position the precision level on the center of the pallet parallel to X-Axis and note level.
3. Position the level in line with the Z-axis and note level. If necessary, loosen the center leveling screws and
adjust rough level before proceeding.

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 Roll
1. Position the precision level on center of the table parallel to X-Axis. Jog the Z-axis, full travel in each
direction, and note any deviation in the level.
Pitch
1. Position the precision level on center of the table parallel to Z-Axis. Jog the Z-axis, full travel in each
direction, and note any deviation in the level.
2. Adjust for any deviation of pitch or roll as necessary.
Receiver Geometry Verification
NOTE: The receiver is never adjusted to correct pallet flatness. It is adjusted for runout
and concentricity. Both need to be confirmed before the pallet is installed.

Indicate the receiver concentricity by first rotating the A-axis 45°. Then indicate the outside vertical edge, or
outermost edge of the locating key that is facing the spindle. Set the Z-axis position to zero and move the
indicator off in Z-axis to allow for A-axis rotation. Then rotate at 90° intervals until all four locating pads have
been indicated. The specification is .0003" (.00762mm) or less.
Indicate the receiver runout by indicating the top of the locating pads on the receiver. On machines with 1 or
45° indexers, move off the pad in Z-axis, rotate A-axis 90° to next pad and come back in to the same Z-axis
position and note the indicator reading. For a full 4th rotary it is not necessary to move off the pad because pop
up on the rotary will only be .0003". Rotate until all four locating pads have been indicated. The specification is
.0003" (.00762mm) or less.

Receiver Removal/Installation:
Removal
Home the A-axis before starting the removal procedure.
1. Remove the pallet from the receiver.
2. Remove the screws from the front and rear Z-axis waycovers and slide them away from the rotary base.
3. Disconnect the air supply from the machine and bump up Parameter 76 to 999999.
4. Remove the single bolt securing the switch plate assembly and remove the switch plate assembly. Set
safely aside.
5. For reference, label the three rotating union hoses. This will help when replacing them.
6. Remove the one bolt at the bottom of the rotating union. The rotary union is now loose and is pulled
straight down to remove. Note that there are shim washers between the large fender washer and the
bottom of the receiver shaft.

Receiver To
Base Bolts

Rotating
Switch Union
Bracket Bolt Rotating
Union Bolt

7. Remove the eight bolts securing the receiver to the rotary platter. The receiver is now ready to be removed
from the machine.

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 8. Working through the operator door, use lifting equipment to remove the receiver. The receiver clamp plate
has 1/2-13 tapped holes in it so that lifting eyes can be installed, or use straps to grip the top of the
receiver. Remove the receiver assembly through the operator door.
9. Remove any shims that may be present on the rotary platter and put them aside for use later, if necessary.
Installation
1. Lift the receiver assembly into the machine.
2. Position the assembly, orienting the clamp plate, over the base and lower into place.
3. Loosely install the eight bolts in the receiver.
4. Install the rotary union at the bottom of the receiver shaft.
5. Reconnect the three hoses to the rotary union.
6. Install and align the switch plate assembly. Slide the assembly toward the rotating union center of the
rotary as far as possible and tighten the mounting screw. Make sure that the proximity switches do not
contact the union but are close enough to produce a sufficient reading.
7. Connect the air supply to the machine and reset Parameter 76 to 1500.

8. Indicate the receiver using the verification procedure utilized before removing the receiver. Adjust the
receiver concentricity by snugging the eight bolts that attach the receiver to the rotary platter. If the concen-
tricity changes, the receiver runout will also change. Because of this, the concentricity should be correct
before indicating or adjusting the receiver runout.
9. If the receiver runout is not correct but the concentricity is, it will be necessary to shim under the receiver.
It will only be necessary to lift the receiver just enough to install the shims. It is only necessary to remove
the eight bolts on the receiver, there is at least 2" of travel for lifting the receiver before the union contacts
the bottom of the rotary. Shims are replaced at a 2:1 ratio for the error indicated on the locating keys.
Example: an indicated error of .001" would require a .002" shim. Install the shims as necessary and
repeat the receiver verification procedure until the geometry is correct.

Indicating the pallet

1. Install the new pallet on the receiver and indicate across the 45° angles on the receiver locating keys until
they are parallel with the X-axis. The keys must be parallel to the X-axis within .0005". If the keys are not
parallel, proceed to step 9.
2. To indicate the flatness of the pallet, attach a magentic base to the spindle nose and using a .0001" or
.0005" indicator. Indicate down the center of the pallet and note the reading at the front and back edge,
about 1" from the edge of the pallet in the Z-axis. Repeat this in the X-axis and note the reading.

178 Mechanical Service 96-0283 rev C June 2007

 NOTE: Check both pallets before making any adjustments. The pallets should be
within .0005" of each other.

3. With magnetic base still on the spindle nose, place the indicator on the face of the pallet at the center and
1" from the front edge, toward the spindle. Zero the indicator dial and set the Z-axis position to zero.
4. Jog the Z-axis off of the pallet far enough to allow rotation of the A-axis.
5. Jog the A-axis 90° and return the Z-axis to zero position.
6. Repeat step 5 until you have indicated and noted the pallet runout at 0, 90, 180, and 270°.
7. If the flatness is correct, skip to step 9.
8. Pallet flatness is adjusted by shimming under the rotary, between the rotary casting and on top of the Z-
axis linear guide pads. Note that any time adjustments are made in this area, the ball nut and ball nut
housing need to be realigned, which is also true for the next step.
9. The pallet square in relation to X-axis is adjusted on the full 4th axis, by indicating the front edge of the
pallet until parallel and adjusting Parameter 212. On the 1 and 45° indexers, the entire rotary casting needs
to be rotated until the pallet is parallel. To do this, it is necessary to loosen the Z-axis ball nut housing,
then the 16 bolts on the Z-axis linear guide pads, and physically shift the position of the casting. The
specification when indicating the front of the pallet is .0005" (.0127mm) or less. Once this is achieved it is
necessary to torque the 16 linear guide bolts, realign the ball nut housing and ball nut, and verify alignment.

96-0283 rev C June 2007 Mechanical Service 179

 A UTOMATIC P ALLET CHANGER (APC) (VERTICAL M ACHINES)

APC PALLET TROUBLESHOOTING

There are two different designs of pallets for use with the APC. This difference in design is for locating the pallet
onto the receiver. The earlier method uses two friction blocks to slow the pallet and locate it correctly as it
enters the machine (20-0053, or 20-0579 for a metric pallet). The current design uses a pin and latch to locate
the pallet (20-0053A, or metric 20-0579A). Current method pallets can be used on earlier machines by replac-
ing the location stub (20-1082), with a friction block (20-1081). See the following figures.

8X 40-1712 SHCS 5/16-18X1/2

2X 20-1081

Pallet Part number 20-0053 (metric 20-0579) Pallet Part number 20-0053A (metric 20-0579A)

The spare pallet, PAL40, is shipped with two filler blocks (20-1081) and one APC Location Stub (20-1082). If the
machine has an existing pallet with part number 20-0053 (Metric 20-0579), the two filler blocks (20-1081) will be
used and the Location Stub (20-1082) will not be used. See the figures.
If the machine has an existing pallet with a part number 20-0053A (Metric 20-0579A), one filler block
(20-1081), one Location Stub (20-1082) will be used. See the figures.

NOTE: Bolts for filler block are 40-1712 SHCS 5/16-18 X ½ ( 4). Torque to 35 ft-lb. Bolts
for Location Stub are 40-16385 SHCS 5/16-18 X ¾ (4). Torque to 35 ft-lb.

Checking pallet repeatability on to the receiver

• Maximum tolerance is .+/-0005".
• Pallets are not considered repeatable from one to the other. Pallets should use separate offsets.
• If pallet is out of tolerance, check alignment pins on receiver base and bushings on bottom side of clamp rails
for damage.
• Check the height of the alignment pins on the receiver base. The top of the pin should be .450" to .490" (11 to
12.5mm) above the receiver base.
• If alignment pins are out of receiver body, check depth of hole. Depth should be .510" to .550" (13 to 14mm).
Sticking Pallet
• Check for chips around the alignment pins or pallet clamp rail bushings.
• Check the torque on bolts that fasten the clamp rails to the pallet. If the bolts are loose, realign the pallet.
APC not responding to controller commands
• If the APC does not run, but the mill does, check the APC control cable.
• Be sure the E-Stop jumper is removed and the APC control cable is plugged tightly into the 5th axis port.
The receiver is on the APC and engaging the pallet home switch under the control panel. Note that the align-
ment pin and receiver bushing alignment must be verified when manually positioning a pallet on the receiver.

180 Mechanical Service 96-0283 rev C June 2007

 Pallet
Receiver

Pallet Clamp Switch

Alignment Pin Receiver Bushing

Alignment Pin

Recovery from an E-Stop or power outage during a pallet change

Not used for MDC Pallet Changer.
Troubleshooting a Power Outage or E-Stop condition with CAUTION!
a Pallet in transition between the Receiver and the APC. With the pallet stopped between the APC and receiver the
drive pin on the chain will be engaged with the pallet drive
arm. Severe damage may occur if the “X” or “Y” axes are
moved automatically.
Is Power ON?

YES NO **
Has power been turned off since
the pallet motion was stopped? Power ON the VMC. Do not push Power
*** Up Restart. Do not Zero Return, auto all
NO YES ** axes. Do not Zero a single axis. Do not
Jog or otherwise move the X and Y axes.

Is the receiver Unclamped?

With power and air supply ON, have an assistant manually
YES NO
actuate the solenoids on the lube panel to open the APC
door and unclamp the receiver. Constant pressure must be
maintained on the actuators to provide a continuous air flow.
* Manually move the pallet to a known location,
either on the receiver, or on the APC to engage
Run M17 to open the
door and unclamp
the associated switch. Verify alignment of pin the receiver.
and bushing.
Manually move the pallet to a known location,
* either on the receiver, or on the APC to engage
the associated switch. Verify alignment of pin
and bushing.
* If needed, rotate the chain to a known location
that compliments the pallet locations. Use the
sprocket rotation tool to move the chain.

* Ifthatneeded, rotate the chain to a known location

compliments the pallet locations. Use the
sprocket rotation tool to move the chain.
Run M18 to close
the door and clamp
the receiver.
Release the solenoid
actuators.

Run M50 to complete a pallet

cycle. The completed M50 Zero the axes.
will clear the Pallet Change
Incomplete variable. ****
Flowchart Notes
* There are 5 switches involved in the location of the pallets and chain.
1 pallet switch on the receiver (pallet clamp switch).
2 pallet switches on the APC (pallet home switches).
2 chain switches on the APC (pin clear switches).
** If the power to the mill has been shut down either intentionally or by power outage, damage may occur
to the APC pallet, the receiver, or the drive chain if the X- or Y-axis is moved at power on.
*** At power on the mill will alarm if either an unknown chain location or unknown pallet location are detected.
**** At the beginning of the APC M50, a Pallet Change Incomplete variable is set to 1 and reset to 0 at the
end. The mill will not operate properly if a pallet change (M50) has not been completed.

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 PALLET REPLACEMENT
Disconnect the APC motor wire on the left side of the Quad APC mills. The pallets will be difficult to manually
move if this is not done. The motor cable is located under the APC base.
Tools Required: Hoist, Straps or Chains, Eyebolts (2)

CAUTION! Be careful when changing out pallets, each pallet weighs approx. 300lbs.

NOTE: Replaced pallets must be re-aligned to receiver. Pallets shipped with mill from
the factory are machined perpendicular to the spindle. It is recommended that
replacement pallets be machined after aligning them to the receiver.

1. Remove the old pallet from the APC using the supplied eyebolts and a hoist.
2. Set the new pallet on the APC, aligning roller grooves on the bottom of the pallet with rollers on the APC.
3. Loosen the clamp rail bolts on the new pallet (the bolts should be snug, but not overtightened).
4. Run new pallet into the receiver. Clamp and unclamp the pallet a few times (to allow the pallet to center on
the guide pins). Torque the clamp rail bolts to 50 ft-lb while the pallet is clamped to the receiver.

Receiver Alignment pins

(2) pins in opposite corners
Clamp rail bolts
Pallet

Clamping Bar
Receiver Base

Wiper
Alignment bushing (2)

Pallet Replacement

P ALLET CLAMP RAIL REPLACEMENT

Tools Required: Hoist, Straps or Chains, Eyebolts (2)

NOTE: This procedure must be performed with the pallets on the APC.

1. Loosen the clamp rail bolts. Screw the eyebolts into place and lift the pallet carefully.
2. Remove the clamp rails from the pallets.

182 Mechanical Service 96-0283 rev C June 2007

 3. Verify the condition of the wipers and determine if they need replacing.
4. Re-install the new rails leaving the bolts loose.
5. Carefully place the pallet back onto the APC, using the hoist.
6. Position the pallet back onto the receiver, and clamp/unclamp the pallet several times to allow the rails to
center themselves on to the guide pins.
7. Finish torquing the clamp rail bolts.

ALIGNMENT PIN REPLACEMENT

Tools Required: Hoist, Straps or Chains, Eyebolts (2)

CAUTION! Be careful when changing out pallets, each weighs approx. 300lbs.

NOTE: The receiver must be removed in order to access the alignment pins.

1. Both pallets must be on the APC in order to access the receiver.

2. Position the receiver to the front of the machine.
3. Disconnect the air from the machine.

Alignment
Bushing

Alignment
Pin

Alignment Pin Removal

4. Remove the six receiver mounting bolts.

5. Use a hoist and the two eyebolts supplied with the APC, and lift the receiver off the table.
6. Use a punch to remove the alignment pins.
7. Install the new pins using a brass hammer. The pins should bottom out in the holes. Pin height from the
base of the receiver to the top of the pin should be within .450" to .490".
8. Position the receiver back onto the table.
9. Install the six mounting bolts.
10. Reconnect the air to the machine.
11. Position a pallet onto the receiver and clamp/unclamp the pallet to the receiver several times. Check for the
pallets sticking during this process. If the pallets are sticking, loosen the clamp rail bolts and clamp/
unclamp the pallet several times to center the alignment pin to the rails.

NOTE: Because the receiver has been removed from the mill, any tooling on the
pallets must be re-aligned.

96-0283 rev C June 2007 Mechanical Service 183

 D RIVE PIN REPLACEMENT

NOTE: If the drive pin assembly is damaged due to a crash or from excessive wear,
all components should be checked for damage and replaced.

NOTE: The chain must be loosened in order to remove the entire drive pin assembly.

1. Power off the machine.

2. Remove the drive pin retaining clip.

Retaining Clips (2)

Top clip

Bottom clip

Drive Pin Assembly

3. Remove 5/16" washer.

4. The cam follower is lightly pressed onto the pin. The spacer should slide off easily.

Loosening the Chain

5. Remove the two screws that mount the coverplate over the sprocket located at the far end of the APC.

Chain/Sprocket
Rotation Tool

Trip Block
Pin Clear
Switch

Pin Clear
Switch

Pallet Home Pallet Drive

Switches Leg

Loosening Chain Sprocket With the Pallet Clamped, the Trip Block Must Engage the Switch

6. Loosen the four bolts that mount the sprocket bracket to the casting.
7. Loosen the chain sprocket tensioner screw slightly.
8. At this point there should be enough slack in the chain to slide the drive pin out.
9. Re-assemble the drive pin assembly according to the assembly drawing.
10. Re-tension the chain in the reverse order. Note that the trip block must be engaging the switch as shown.

184 Mechanical Service 96-0283 rev C June 2007

 S ETTING THE G RID O FFSET
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. Do not use the Grid command on
axes with linear scales or on a rotary axis.
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 that if a Servo Error Too Large alarm was generated, it 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, it
indicates that none of the axes were zeroed.
5. Perform Auto All Axes 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 be calculated by hand.
Calculating the Offset
These instructions only work on machines with 6mm pitch ballscrews. 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 .118. (This equals ½ of a revolu-
tion of the encoder.) For the Lathe series, these values are: X-axis = .236, Z-axis = .118, B-axis (TL-15) = .118.
HL-series machines with ball screw tailstocks will have the grid offset set to .050.
Setting the Offset
1. Set the grid offset to zero. (Parameter 125,126, 127, 128, or 170, 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, Y, Z, A, or B).
3. Calculate the grid offset using the following formula, and write the result in Parameter 125 (X-axis),126 (Y-
axis), 127 (Z-axis), 128 (A-axis), or 170 (B-axis) (depending on the axis being set).
Horiz. & Vert: (Distance to Go - .118) x Ratio = Grid Offset.
Lathe: (Distance to Go - .236) x Ratio = Grid Offset
The Ratio (steps/unit) for the X, Y, Z, A, and B axes are the values in Parameters 5, 19, 33, 47, and 155,
respectively.
4. Zero Ret the axis again to use this offset.

NOTE: If Z-axis grid offset is reset, Parameter 64 should be checked and adjusted
accordingly.

96-0283 rev C June 2007 Mechanical Service 185

 H YDRAULIC COUNTERBALANCE

TROUBLESHOOTING
Spindle head weight is balanced by upward pull of hydraulic cylinder on machines without a Z-axis brake motor.
Hydraulic oil forces piston to retract into the cylinder body. The oil is then pressurized by a nitrogen reservoir.
System is self-contained and passive (no pump required to maintain lift). Normal Z-Axis of gas/oil counter
balance has initial pressure to balance weight at full system volume, plus an additional 50-75 psi overcharge for
longevity. A list of observable machine conditions, probable cause, and corrective action is shown below.
1. Machine alarms, pressure reading low.
Cause: Cylinder or Fitting leaks
Corrective Action:
a. Check for sufficient oil in system: Block spindle head at top of travel. Attach charge/discharge kit to
schrader valve, slowly turn T-handle clockwise to begin releasing pressure and look for the following:
1) If oil is immediately present stop discharging, there is sufficient oil in the system. There are two
courses of action, the first is to add nitrogen to the system to obtain top of travel pressure specifica-
tion. Proceed to Corrective Action 2 if it is felt that the leak is substantial.
2) If nitrogen gas is immediately present stop discharging; there is not enough oil in the system.
b. Block spindle head at bottom of travel (if the cylinder is being replaced, block the head in the lowest
position that will permit access to the rod attachment).
1) Carefully drain remaining gas and oil.
2) Replace faulty component(s). Note SAE straight thread O-ring fittings are lubricated with hydraulic
oil prior to install. Machines built after August, 1999 use straight thread fittings with O-rings and sealed
connectors on switch wires. Earlier machines have pipe thread connections. Replace all counterbal
ance components when changing old style with new style system, including counterbalance cable.
3) Fill tank with CASTROL HYSPIN AW46 (Anti-wear hydraulic oil) or MOBIL DTE 25 (Hydraulic oil)
(see chart for qty.) into system using Hydraulic Hand Pump Kit.

NOTE: Make sure its mixed with the red dye 99-4839). Use only 20ML of dye per drum.
Mix the Oil for about 1 minute.

Machine Tank Size Tank Height Quarts of Oil # of Pump Strokes

40 cubic feet 23” 2 per tank 93
80 cubic feet 36” 3 per tank 140
110 cubic feet 42” 3 per tank 140
4) Pressurize with nitrogen using charge/discharge kit to specification at top of travel.
2. Machine alarms, pressure reading OK, alarm does not reset.
Cause: I/O Board failure, bad cable or dirty contacts, switch setting too high and/or system is under-
pressurized due to inaccurate gauge.
Corrective Action:
a. Check I/O board and replace if necessary.
b. If the counter balance system pressure is correct and there is an E-Stop alarm that will not reset, check
the cable for dirty contacts. Loose connections or a broken wire is tested by disconnecting the cable at the
switch and adding a jumper across the connector pins of the cable and clear the alarm. If the alarm does
not clear the cable is defective; repair or replace the cable if necessary.

186 Mechanical Service 96-0283 rev C June 2007

 3. No alarm, pressure reading low (at or below switch setting).
Cause: Cylinder or Fitting leaks, shorted cable, switch setting too low and/or inaccurate system gauge.
Corrective Action: As described for leaks in 1.
a. Test for short in cable. Repair or replace if necessary.
4. Spindle Head drifts up.
Cause: Over-pressurized due to inaccurate gauge.
Corrective Action:
a. Invert tank to bleed about 50 psi of nitrogen gas. Re-evaluate machine condition.
5. Spindle Head drifts down, no alarm.
Cause: Cylinder or fitting leaks, switch setting too low and/or system under-pressurized due to bad gauge.
Corrective Action: As described for leaks in 1. above.
a. Add 50 psi of nitrogen to the system at top of travel. Does the alarm clear?
1) Yes: Check if the spindle head drifts up more than 1" upon E-Stop at the bottom of travel. If it
does, replace the switch.
2) No: Add another 50 psi to the system at top of travel. If the alarm still does not clear, replace the
switch. If the alarm clears, check if the head drifts up more than 1" upon E-Stop at the bottom of
travel. If it does, the switch is faulty.
b. Does spindle head drift down from top of travel upon E-Stop?
1) Yes: Replace the switch.
2) No: Replace the pressure gauge.
Tools Required: (1) 4 x 4 x 14" head support block.
Hydraulic counterbalance service kit, consisting of:
Pressure tank with manifold assembly, prefilled with (2) quarts DTE-25 hydraulic oil.
Hydraulic cylinder with hose attached (if necessary).

Hydraulic
Tank
Pressure
Switch
Cable
Fill Valve
Pressure Pressure
Gauge Switch
120

140
100

160
psi
80
60

0
20
40

Pressure
Outlet Manifold

Hydraulic Tank Assembly

A placard on each machine states the correct pressure for each machine/system. Use this as a guide when
troubleshooting the counterbalance system. The pressure must be set accurately in order for the system to
function properly.

96-0283 rev C June 2007 Mechanical Service 187

 LEAK F AILURES
Leaks can occur at any fitting connection, at the hydraulic cylinder’s rod seal (where the rod enters the cylin-
der), at the cylinder’s piston seal, or through hose failures. Inspections for leaks are visual, although rod seal
leaks may be inconclusive because of way-oil spatter. Piston seal leaks, if advanced, exit the top end of the
cylinder and oil can be seen at the vent area. Early piston leaks accumulate over time on top of the piston to
about ¾" high before they are pushed out the cylinder at top of travel. Leaks are normally very slow and
machines can operate until the pressure switch sends an E-Stop alarm.

MECHANICAL DIAGNOSIS
Important! Hydraulic counterbalance oil contains red dye for easier recognition.
Noise in the system
• Slight moan or creaking at slow speeds is normal for rubber seals.
• While Z-axis is in motion, a whistle sound at tank location is normal fluid flow.
• Verify cylinder is seated correctly in counterbore. If not, reseat the cylinder.
• Bumping or grinding noise indicates a mechanical cylinder failure. Replace cylinder assembly.
• Look for galling and wear on cylinder shaft. If so, replace the cylinder assembly.
System is not holding pressure and/or has an E-Stop (Alarm 107) that cannot be reset. Check for
accurate pressure readings. If low, the following items need to be checked:
• Check for leaks at all cylinder fittings. If leaking, replace cylinder assembly.
• Collapse the lower Z-axis waycover and look for any red oil pooled at the bottom of the base. If so, fittings
or seals could be damaged. Replace cylinder assembly.
• Remove cylinder vent fitting. If there is red oil inside the vent cavity, cylinder assembly needs replace
ment.
• Check for leaks at all hydraulic tank fittings. If leaking, tank assembly needs replacement.
Over Current alarms
• Pressure is set too high.
• Pressure is set too low.
• Too much oil has been added (insufficient gas volume causes large pressure rise).
• Hydraulic cylinder is binding or is misaligned. Replace cylinder assembly.
• Length of replacement cylinder incorrect.

H YDRAULIC TANK R EPLACEMENT

Removal
CAUTION! While performing this procedure, the spindle head may drop if the control
loses power or alarms.

1. Handle jog spindle head up to 14.5" above the table. Insert wood block and lower head casting onto it.
Emergency Stop the machine. Head should rest securely on table block. Power off the mill.

NOTE: Do not lower spindle onto block.

2. Disconnect the two-pin end of the pressure sensor cable(s) to the pressure sensor(s), if equipped.

188 Mechanical Service 96-0283 rev C June 2007

 Shrader Filler
Valve CONNECTOR REFERENCE

Gas
chuck

LEVEL
OIL
MAX

BIJUR

LEVEL
OIL
MIN

Charge/Discharge
CGA 580 Kit
Fitting P/N 35-4050A
Hydraulic Counterbalance Charge/Discharge Kit (Shown in Place to Discharge System)

3. Remove cap to Schrader filler valve.

4. Ensure T-handle of the gas chuck is turned completely counterclockwise. Attach charge/discharge kit by
tightening gas chuck to the Schrader valve finger tight, then wrench lightly to tighten (see previous figure).
5. Place CGA 580 end of charge/discharge kit into bucket to contain hydraulic oil while discharging system.
6. Slowly turn the T-handle clockwise until the system begins to discharge. Complete discharge may take up
to 10 minutes. Verify tank gauge reads 0 psi.
7. Turn T-handle completely counterclockwise and remove the charge/discharge kit from the Schrader valve.
8. Disconnect the hydraulic hose from the tank assembly.
9. Remove the tank assembly from the column by removing the four SHCS from the tank mount.

Installation
1. Connect the hose to the tank before mounting the tank in the inverted position. This prevents oil spillage.

NOTE: For a positive seal, ensure hose-to-tank connection is straight, not skewed.

2. Mount tank assembly to column with tank mount and four SHCS. Ensure hydraulic hose is not twisted.
3. Connect the two-pin end of the pressure sensor cable(s) to the pressure sensor(s).
4. Use cable ties to secure the cable to the hydraulic hose.

NOTE: For this step, use regulated dry nitrogen gas (welding grade acceptable) that
accepts a right-hand thread CGA 580 fitting.

5. Attach the CGA 580 fitting end of the charge/discharge kit to the source pressure. Ensure T-handle of the
gas chuck is turned completely counterclockwise. Attach charge/discharge kit by tightening gas chuck to
the Schrader valve finger tight, then wrench lightly to tighten. Pressurize the system to required pressure
as listed in the following tank pressure requirements chart.

NOTE: For VF-6/8, follow installation procedure for each hydraulic tank.

NOTE: Do not use compressed air, oxygen, or flammable gas. Refer to the table below
and verify pressure according to machine and spindle head position, and verify
cylinder is seated in counterbore.

96-0283 rev C June 2007 Mechanical Service 189

 VF-6/7/10 VF-8/9/11 VF-5 VF-5
VF-3/4 VF-6-11 VR VS
w/50T Spindle w/50T Spindle w/40T Spindle w/50T Spindle

Machine at Top of Travel 1150 psi 7 5 0 p si 1150 psi 1 5 5 0 p si 8 7 5 p si 1100 psi 1 8 0 0 p si 1 2 5 0 p si

Tank Pressure Requirements

6. Power on the machine and zero return (Zero Ret) Z-axis only. Check for any leaks or abnormal noises.
Verify tank pressure at top of travel. Remove charging system and replace valve cap.

NOTE: If E-Stop alarm won’t reset, check system pressure and tank assembly.

H YDRAULIC C YLINDER R EPLACEMENT

Removal
1. Remove the hydraulic tank as described in previous section.
2. To gain access to the cylinder rod, remove the three SHCS holding Z-axis way cover to spindle head.
3. Remove the cotter pin and lock nuts from the threaded end of the cylinder rod.

Extended
Cylinder
Rod
Extended Rod

Washer
Cotter Pin
Jam Nut
Lock Nuts
Clevis Pin

Clevis

Spindle
Safety Cotter Z-Axis Head
Pin Ball Screw Brackets
Hydraulic Cylinder Rod Installation for VF-1 through 4 and (VF-6/8)

NOTE: For VF-6/8 loosen jam nut from clevis and remove cotter pin, clevis pin, clevis,
and jam nut.

4. Remove band clamp holding cylinder to stabilizer bracket. Loosen SHCS that attach bracket to column.
5. Remove the hydraulic cylinder from the top of the column.

Hydraulic Cylinder Hydraulic

Cylinders
Hydraulic Hose
Hydraulic Cyl.
Hydraulic Brackets
Hydraulic Fluid
Cylinder Tank Hydraulic
Bracket Tank Fluid
Mount Tanks
Spindle
Extended Head
Cyl. Rod Brackets

VF-Series Hydraulic Counterbalance - Right Side View VF-Series Hydraulic Counterbalance - Left Side View

190 Mechanical Service 96-0283 rev C June 2007

 NOTE: Do not disassemble unit. Keep the hose attached to the cylinder.

6. Return complete assembly to the Haas factory.

Installation
1. Install cylinder with cylinder rod extended from top of column.

NOTE: Cylinder rod should pass through column bracket and spindle head bracket.
Cylinder body must rest in column bracket counterbore.

2. Orient cylinder body with hydraulic hose facing away from ball screw.

NOTE: For VF-6/8, orient cylinder bodies with hydraulic hose facing the ball screw.

3. Install lock nuts, at threaded end of cylinder rod, wrench tight. Install safety cotter pin.

NOTE: For VF-6/8, install jam nut and clevis at end of cylinder rod, then attach to
spindle head bracket with clevis pin. Install safety cotter pin and lock the clevis
by tightening the jam nut.

4. Install the hydraulic tank as described in the previous section, but do not power up the machine.
5. Power on the machine and zero return (Zero Ret) Z-axis only. Observe cylinder body for motion or abnormal
noises. Check for fluid at manifold, cylinder hose connection and cylinder rod. Verify tank pressure at top of
travel. Remove charging system and replace valve cap.
6. Loosely install the band clamp and tighten the two SHCS that attach the stabilizer bracket to the column.
7. Place a mag base with a dial indicator on top of the column (not the spindle head). Position the tip of the
indicator on the front of the cylinder and jog the Z-axis up and down to verify alignment. Note that when
jogging the Z-axis the counter balance will shift in the bracket. The cylinder shift should not exceed .015 in.
Cylinder
Stabilizing
Cylinder Stabilizing Bracket
Bracket Bolts (2 SHCS)

Clamp
Hydraulic
Cylinders
Hydraulic
Front of Machine Cylinder View Rotated for Clarity
Cylinder Brackets
Dial
Indicator
Hydraulic Extended
Rod (2)
0 1

Fluid
1 2

2 3

3 4

Tanks Spindle
Head Jam
Brackets Nut (2)
Rear of Machine

Clevis (2)
Cotter Pin (2)
Spindle Head
Bracket (2)
8. If spindle head brackets have been moved from the original location it will be necessary to check for side to
side alignment. Place a dial indictor the same as in step 7 and position the tip of the indicator on the side
of the cylinder. Jog the Z-axis up and down to verify alignment. The cylinder shift should not exceed .015 in.

96-0283 rev C June 2007 Mechanical Service 191

 9. When the side to side alignment of the cylinder is correct, tightening the spindle head brackets. Be careful
not to move the cylinder out of alignment while tightening the spindle head brackets.
10. When the cylinder has been aligned correctly, finish tightening the band clamp. Be careful not to move the
cylinder out of alignment while tightening the band clamp.
11. Zero return (Zero Ret) machine. Handle Jog Z-axis in 0.1 increments. Verify full Z travel.
12. Cycle Z-axis, using the following program, for five minutes, and check for oil leaking at top of cylinder and
cylinder rod.
G28, G54, Z-14.
M99
50% Rapid
13. If Z-axis overcurrent alarms occur during travel, verify and correct system pressure.

NOTE: If Z-axis overcurrent alarm at top or bottom of travel, call Haas Automation
Service Department immediately for assistance. If fluid leaks from hydraulic
fittings, check that fittings are tight. If leaking continues, call Haas Automation
Service Department for assistance.

14. Reinstall Z-axis way cover with three SHCS that hold it to the spindle head.

192 Mechanical Service 96-0283 rev C June 2007

 H YDRAULIC P OWER U NIT (HPU) (L ATHE )

TROUBLESHOOTING
Hydraulic Pressure - “Low hydraulic pressure” Alarm (134)
• Check for any leaks.
• Check that the oil level is above the fill line.
• Check that the temperature is less than 150°.
• Voltage phasing changes cause the HPU 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.
Hydraulic Chuck - Chuck won’t clamp/unclamp.
• Check for alarm condition.
• Check display for “Low Hydraulic Pressure” Alarm (134).
• Use a voltage meter to check the solenoid circuit breaker; replace if faulty.
Noise in HPU

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

• Check for leaks in hose.

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

HPU R EMOVAL/I NSTALLATION

CAUTION! Power off the machine before removal or installation.

Removal
1. Remove necessary panels to access the HPU and Drain the hydraulic fluid.
2. Disconnect hydraulic hoses. Be sure to mark positions of hoses so they can be put back to original fittings
3. Disconnect the cables.
4. Remove the four bolts from base of unit, then slide HPU out.

Installation
1. Position the HPU 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 HPU with DTE25 to the top of the sight glass.
5. Replace any panels that were removed to access the HPU.

96-0283 rev C June 2007 Mechanical Service 193

 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

194 Mechanical Service 96-0283 rev C June 2007

 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

96-0283 rev C June 2007 Mechanical Service 195

 4 TH A XIS R EPAIR (H ORIZ .)

R ING G EAR INSTALLATION

1. Lubricate and stone the mating surfaces of the platter and ring gear. Wipe clean to remove grease and
contaminents.
2. Clean the mating surfaces of the platter and ring gear with alcohol.

CAUTION! The ring gear is a precision-machined piece. Take care in handling it. Do
not drop it or set it heavily on the teeth.

3. Install eyebolts into the top of the ring gear. With an assistant, lift the ring gear by the eyebolts and place
over the platter.
4. The ring gear is an interference-fit item and will need to be clocked properly prior to the next step. If
necessary, adjust the position of the ring gear so that all the bolt holes line up exactly.
5. Apply a drop of Loctite to each of the 16 SHCS and insert into the holes in the ring gear. Start each SHCS
by hand to ensure proper alignment of the ring gear and to prevent crossthreading tapped holes.
6. Tighten the SHCS incrementally in a star pattern to slowly pull the gear down onto the platter. Do not
tighten each SHCS completely in one attempt. This will foul the location of the ring gear.
7. When the ring gear is fully seated on the platter, tighten the SHCS to full torque value.

P ALLET R ECEIVER D ISASSEMBLY (EC-630)

1. Remove the pallet and all fixtures from the rotary body.
2. Disconnect air supply. Ensure that the rotary table is in the home position (arrow points toward pinion gear
in the platter drive motor assembly) and that the rotary assembly is in the clamped position.
3. Remove the four shaft guide bushings from the top of the pallet receiver by removing the ball clamp retainer
spring and the three clamping balls from each bushing. Remove the six 5/16 x .75" SHCS to remove each
bushing.

NOTE: When reinstalling these bushings, check for and clear the air blast holes of
any debris.

4. Remove the 12 5/8 x 2" SHCS from the receiver cap and lift it using two eye bolts in the holes in the top of
the cap. This exposes the piston assembly.
5. Remove the piston assembly by first removing the rotary union from the bottom of the piston shaft (see the
following instructions). Using two eye bolts in the top of the piston, lift it out with its four guide shafts and
main shaft attached. This exposes the rotary platter.

R EMOVING THE R OTARY U NION (EC-630)

1. Ensure that the rotary table is in the home position and that the rotary body is in the clamped position
(down). Disconnect air supply.
2. Remove the bottom splash cover.
3. Disconnect the two pneumatic lines from the union.
4. Remove the bolt and hard washer from the bottom of the rotary union, and lower the union off of the piston
shaft.

196 Mechanical Service 96-0283 rev C June 2007

 1° I NDEXER P LATTER A SSEMBLY (EC-630)
With the pallet receiver removed and the platter exposed (see the previous procedures), remove the center seal
plate for access to the piston adapter plate.

NOTE: The piston adapter plate is precisely concentric to the platter and piston
assembly. If it is ever removed, it must be recentered.

To remove the piston adapter plate:

1. Remove ten (10) 1/2-13 x 1.5" SHCS in the piston adapter plate that are exposed when the center seal
plate is removed.
2. Lift the rotary platter using two eye bolts placed in any two opposing holes on the top edge of the platter.
The piston adapter plate will come up with the platter.
3. Remove sixteen (16) 3/8 x 1.25" SHCS from the underside of the platter to remove the piston adapter plate.
The hydraulic clamp assembly should be replaced as a unit.

R EPLACING THE 4 TH A XIS BRAKE A SSEMBLY

1. Command the A-axis brake to disengage. Enter MDI and command an M11. Do not disconnect air to
machine. Power-down the machine.
2. Remove the rotary platter from the table using a suitable lifting device, chains and lifting plates. Do not use
synthetic lifting straps or eyebolts.
3. Disassemble existing brake assembly, hoses, and air/hydraulic booster. Leave air lines that were attached
to the booster to be reused. Remove all fasteners and dowel pins that were used with the old brake assem-
bly.
4. Clean the brake mounting surface, verifying that there are no chips or burrs before proceeding. Stone the
surface if necessary.
5. The brake/booster sub-assembly is assembled and bled at the factory. Do not attempt to bleed. After
installing the brake and replacing the booster and regulator, all that is necessary is to connect the hose at
the quick disconnect. The system should not need further bleeding. Do not loosen fittings at either the
brake or the booster or the factory bleeding will be lost.
6. Separate the brake/booster hose at the quick disconnect fittings. Install the new brake assembly onto the
table, making sure the hose is routed through the hole in the bottom of the table.
7. Install and hand-tighten sixteen (16) 3/8-16 bolts to secure the brake.
8. Replace the old booster and fittings with the new booster assembly. Trace the air line back to the solenoid
and replace the regulator with the new regulator.
9. Power up the machine and reconnect air.
10. When the platter is reassembled, actuate the brake to center the assembly. Torque the sixteen (16) bolts
to 50 ft-lbs. in a star pattern through the access holes in the platter. Plug the access holes when torquing
is complete to prevent chips and coolant from contaminating the encoder/brake area under the platter.

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 B LEEDING THE H YDRAULIC B RAKE
It will take about 1 hour to properly bleed the hydraulic brake assembly.
1. Power off the machine and remove the indexing platter from the table using a proper lift and lifting plates.
The brake assembly and fly-wheel will be exposed underneath.
2. Disconnect all oil/air lines and remove the fly-wheel and clamp ring from the table. Set the clamp ring on a
firm work surface and reconnect the air/oil lines.
3. Slightly loosen bleed valve on clamp ring and elevate brake assembly to let air bubbles escape.
4. Set air pressure to 1000 psi or less. If air pressure is set to more than 1000 psi, the clamp will become
permanently damaged.
5. Pressurize the clamp ring, forcing air and air bubbles out of the oil through the bleed valve. Re-pressurize
every five minutes for about 10 - 12 cycles or until the oil is completely clear of any air bubbles. Re-
tighten the bleed valve.
Ring Gear
Oil Line Oil Bleed Valve
Hydraulic
Brake Assy

Air Lines Brake Booster

4 TH A XIS A IR V ALVE A SSEMBLY

This section applies to machines with serial number 51004 and later.
The Air Valve Assembly has three main components: 3-Way Air Valve, High-Pressure Fixed Regulator, and
Low-Pressure Regulator.
The air valve assembly actuates the rotary table brake. Supplied air flows though the high-pressure regulator
(45 psi) to supply the high-side of the brake valve pressure booster. This supplies 40:1 hydraulic pressure boost
to expand the hydraulic pump. When the clamp is released, a valve switches the supplied air into the low-side
of the pressure booster. This action returns the pressure booster piston to its original position and refills the
hydraulic cylinder from the reservoir. This is a closed hydraulic system. A 45/20 psi pressure differential is used
to prevent air leaking into the pressure booster.

Assembly
Individual assembly of the 3-Way Air Valve, the High-Pressure Regulator, and the Low-Pressure Regulator
component parts is necessary and is not detailed in this Service Manual.
1. Apply a small amount of thread sealant to the threads of the high-pressure regulator assembly and attach
to the 3-way air valve. Orient the regulator to match the position of the part removed.
2. Apply a small amount of thread sealant to the threads of the low-pressure regulator assembly and attach to
the 3-way air valve. Orient the regulator to match the position of the part removed.
3. Attach this assembly to the mounting plate using Loctite and supplied SHCS.

Installation
1. Place the air valve assembly at its air-lube panel mounting location. Route all air tubing to the air valve.
2. Cut each air tubing line to fit and insert into the appropriate regulator/outlet on the air valve assembly.
3. Position the air valve assembly properly, then thread four SHCS into the mounting holes and tighten.

198 Mechanical Service 96-0283 rev C June 2007

 4TH AXIS B RAKE C YLINDER PRESSURE B OOSTER
The pressure booster gives the ability to develop and use high hydraulic pressure without incurring the cost of
an on-board HPU. The pressure booster has a high-pressure side, a low-pressure side, and a fluid fill-port on
the front of the unit. The pressure booster assembly is located in the bottom of the rotary table. There is a
cutout underneath the rotary table to provide access for service and replacement of the pressure booster and
component parts.
Pressure Booster Assembly
Prior to installation of the pressure booster assembly, a test of this system should be performed. This will
identify leaks and allow for the system to be bled while it is still easily accessible. Set the air valve assembly
on top of the table or other high work surface. Set the pressure booster assembly onto the floor.
Bleed the Pressure Booster:
• The booster should be filled to the top fill line before starting.

• Use a manual vacuum pump to draw the air bubble out of the hose. Stop before the fluid reservoir is full.

• Release the pressure valve on the pump (depress small needle-like feature on the bottom), empty the
reservoir, and repeat procedure.
It can take 5 to 8 vacuum cycles to remove all the air from the hose. Take caution to refill the booster before the
fluid level falls below the lower fill line, or air will be introduced into the system. It is critical to remove all air
from booster hose, failure to do so will introduce air into the clamp ring.
1. Identify the low and high pressure tubing lines coming from the pressure booster. Connect them to the
respective low and high pressure ports on the air valve assembly regulator.
2. Attach an air supply line (45 psi) to the air valve assembly. Supplied air is preset to 45 psi.
3. Using appropriate regulator adjuster on the air valve assembly, set the low-pressure regulator to 20 psi and
the high-pressure regulator to approximately 5-10 psi. Remember that the pressure booster provides 40:1
pressure boost.

CAUTION! During the following steps, spillage of hydraulic oil may occur. Wear eye
protection and have sufficient rags on hand to clean up any leaked oil.

4. Apply air pressure to the pressure booster by pressing the yellow pin-button on the air valve assembly. Do
not activate the pressure booster for more than five seconds at a time.
5. If any air leaks have been noticed during this operation, take appropriate measures to fix them before
installing the assembly.
The pressure booster comes packaged with extra components not needed for its proper operation in this
application. Where applicable in the following steps, use a small amount of thread sealer on all pipe threads.
1. The pressure booster is shipped full of hydraulic oil. Tilt the pressure booster on end before removing the
plug from the container.
2. Thread the adapter into the pressure booster and tighten.
3. Thread the nipple (new part) into the adapter.
4. Thread the T-fitting onto the nipple and tighten so that it is oriented as shown in the following figure.

96-0283 rev C June 2007 Mechanical Service 199

 Nipple Muffler Assembly
Street Elbow (2)
T-Fitting

Adapter

Hose Barb Hydraulic Hose Braided Hose

5. Thread nipple into right side of T-fitting. Thread street elbow into left side of the T-fitting. Tighten all parts.
6. Thread the 90° elbow onto the nipple, and add another nipple to the elbow, as shown.
7. Thread the hose barb into the last 90° elbow and attach it to the pressure booster assembly as shown.
8. Attach the braided hose to the hose barb using the supplied hose clamp. Use caution when moving the
pressure booster assembly, since the internal hydraulic fluid can spill from the braided hose.
9. Remove the plug in the center hole of the pressure booster. Thread a #4 SAE to NPT female adapter (new
part) into the center hole.
10. Thread the hydraulic hose into the adapter.
11. Thread the reducer into the street elbow. Thread the muffler and reducer together, then attach to the street
elbow. Tighten all parts. This will act as a snorkel for the system.

Final Assembly
Orient the plate as shown and attach to the bottom of the pressure booster.

Pressure Booster
Assembly
Low Side Port
Tubing
Elbow

Plate

Pressure Booster Final Assembly (Bottom View)

Pressure Booster Installation

Position the pressure booster and air valve assemblies near the working areas.
1. Thread the 3/4 NPT elbow (new part) into the fill port machined into the right side of the table. The elbow
must be installed from the inside. Orient the elbow so that it points down.
2. Thread a hose barb into the elbow. Tighten with a 1-1/16" socket.
3. Lift the pressure booster assembly into the area underneath the right front of the table. See the following
figure for the approximate location. Route the hydraulic hose and high- and low-pressure tubing through the
mouse hole. Secure to the table with four 1/2" SHCS using the outermost holes in the plate.
4. Cut the braided hose to length and attach to the hose barb with a clamp.

200 Mechanical Service 96-0283 rev C June 2007

 BEARING INSTALLATION
1. Place the bearing retainer ring onto the rotary table, flat side down. Orient the holes in the ring so that they
line up with the threaded holes in the rotary table.
2. Stone the table mating surface. Clean with a lint-free rag.
3. With an assistant, lift and place the bearing onto the table, on top of the spacer.
4. Align the bolt holes in the table with the countersunk holes in the outer bearing race. Make sure the spacer
will pull up into the inner bearing diameter. There should be no interference-fit problems.
5. Insert the SHCS by hand through the bearing and into the table.
6. Tighten the SHCS in a star pattern until the screws are snug. Evenly tighten the screws to seat the
bearing, then back off each SHCS 1/16 turn.

NOTE: If installing the bearing by yourself, it will be useful to have a mirror positioned
to see the indicator when it is on the far side.

7. Remove four of the SHCS that lie along the X- and Y-axis.
8. Attach a magnetic indicator stand (MIS) to the inner bearing race. Adjust the indicator to point to the side
of the outer bearing surface as shown in the following figure.

Magnetic Inner Bearing

Stand

Indicator

Outer Bearing

9. Turn the inner race to find high and low spots. To ease this procedure, place a long bolt into one of the
holes in the inner race. Do not use the MIS to rotate the bearing.

NOTE: The acceptable tolerance for the bearing is .0002”. This is due to the 3:1
distance differential between the platter diameter and the bearing diameter.

NOTE: During the following adjustment procedure, adjust the bearing runout only
from the high spots, adjust out only 1/2 of needed measurement. The high side
will shrink by half, the low side will grow by half, and periodically rotate the
bearing to realign the bearing rollers after adjustment.

10. Turn the bearing until the lowest spot is encountered. Zero the indicator. Turn the bearing until the high spot
is encountered (this should be 180° opposite the low spot).
11. Insert a long T-handle hex wrench into the bolt hole in the outer bearing nearest the high spot. Place
pressure on the hex wrench towards the low side to adjust the bearing.

NOTE: This will move the top part of the outer bearing in the direction pressed, placing
leverage against the bottom part of the outer bearing.

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 NOTE: During this procedure, it will be necessary to tighten selected bolts in the outer
race to keep your adjustments. This is not exactly defined, depending upon
adjustments necessary during this process.

12. Perform Steps 9 through 11 until the bearing reads within .0002" of true. Torque the SHCS to 20 ft-lb in a
star pattern (there should be very little effort needed to reach this value if you have tightened bolts during
the previous steps). Torque the SHCS in sets of four, rotating the bearing between each screw. Each SHCS
of the set should be 90° from each other.
13. Recheck bearing runout. Ensure the bearing remains within at least .0002" of true. If the bearing has
slipped out of true, repeat Steps 9 through 11.
14. Torque the SHCS in 5 ft-lb increments to 45 ft-lb. Recheck bearing runout after each torque sequence.
15. Recheck bearing runout. Make sure the bearing has not shifted after the final torque sequence.

R OTARY TABLE PLATTER REMOVAL AND I NSTALLATION

Removal
1. Command the A-axis brake to disengage. Enter MDI and command an M11. Do not disconnect air to
machine.
2. Remove the encoder cover plate. Remove the encoder shaft plate. Important: There are two set screws in
the encoder shaft plate.
3. Remove the plastic bolt cover plugs and the bolts that secure the table to the bearing.

NOTE: Damage to the encoder will result if the plugs and bolts are not removed.

4. Fasten lifting plates to the platter. Do not use T-nuts and eyebolt; slippage can occur and the platter could
fall. Use chains to lift the rotary table. Do not use synthetic lifting straps, since these have a tendency to
stretch, which will cause the platter to be lifted off unevenly. An unevenly lifted platter may cause damage
to the components beneath it.

Installation
1. Generously apply red grease to the outer ring of the brake, completely filling the two grooves. Apply moly
grease around the stud flex nuts filling the counterbores on the brake rin. Apply moly grease to the pinion
gear and ring gear if present.
2. Stone and clean the platter where it will mate with the bearing. Rotate the inner bearing holes so they line
up on the X- and Y-axis.
3. Use the backlash adjusting screws to fully retract the pinion gear/harmonic drive assembly.
4. Cut the heads off of two 3/8-16 x 7" threaded rods (40-0021). Insert each through a bearing mounting hole
in the platter so that they are 180° apart. Use these to rotate the platter to align it with the holes in the
inner bearing. Install the threaded rods into the bearing, use them as a guide when lowering the platter.

202 Mechanical Service 96-0283 rev C June 2007

 5. Hoist the platter over the table using a chain fall. Do not use synthetic lifting straps to move or position the
platter.
6. Carefully lower the platter over the pilot rods and onto the bearing. Thread the rods (from step 4) into the
bearing retaining ring. Ensure the bolt holes in the platter line up with the bolt holes in the bearing.
7. When the ring gear attached to the platter contacts the pinion gear, manually jog the A-axis so that the
teeth mesh and the pinion gear does not force the platter into position.
8. Slowly guide the platter down the remaining distance.

CAUTION! Do not crash the platter against the table. These components are ma-
chined to very close tolerances and can be easily damaged by hard metal-
to-metal contact.

9. Remove the threaded rods from Step 4.

10. Install the 12 3/8-16x4" (40-16430) SHCS to fasten the platter to the bearing.

NOTE: You will need a T-handle wrench or a 6" long hex socket to tighten the SHCS
in the platter. Socket extensions will not fit.

11. Tighten the SHCS incrementally in a star pattern to avoid misaligning the Bearing. Torque the SHCS in
stages up to a final torque of 45 ft./lbs.
12. Before replacing the encoder shaft plate, make sure the set screws are loose.
13. Tighten the screws securing the encoder shaft plate to the platter. Tighten the set screws to clamp the
shaft plate to the encoder shaft
14. Replace the encoder cover plate.

ENCODER INSTALLATION
Pre-assembly Verification
Before assembling the encoder mounting parts, perform the following checks:
1. Verify that the encoder mounting plate can be inserted into the encoder mounting cup without binding. The
contacting surfaces must be burr-free.
2. Verify that the encoder shaft has no detectable side-to-side play. Perform this test by hand.
3. Verify that the encoder boss can be inserted into the encoder mounting plate without binding. The contact-
ing mating surfaces must be flat and free of burrs.
4. Verify that the encoder shaft can be inserted into the encoder shaft plate to the full depth of the bore in the
encoder shaft plate without binding.
5. Verify that the encoder shaft plate can be inserted into the platter bore without binding. The contacting
surfaces must be flat and burr-free.

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 4.175" 3.700"
Measure from Shaft
this surface Length
Encoder Cover
Plate
Encoder Set Screws
Mounting Encoder Shaft
Plate Plate
Encoder Shaft
Encoder Flex Coupling
Coupler Tube
Encoder
Encoder Mounting Cup
Mounting
Plate (O.D. is
precision ground Encoder
for measuring
concentricity)

Assembly
1. Install the encoder mounting cup with one 0.005 shim washer (45-0057) under each screw location.
2. Install the encoder onto the bottom of the encoder mounting plate. Install the encoder mounting plate
assembly onto the top of the encoder mounting cup. Use three screws at 120° spacing to mount plate. The
remaining three threaded holes are for the encoder coupling tube.
3. Attach a magnetic base and indicator to the inner race of the cross-roller bearing and indicate off the top
face of the encoder mounting plate. Add or subtract shims to adjust the face run-out of the top face of the
encoder mounting plate, flatness NTE 0.0005". Shims are available in the following thickness: 0.001 (45-
0054), 0.002 (45-0055), 0.003 (45-0056), and 0.005 (45-0057).
4. Adjust the indicator to indicate off the outer diameter of the encoder mounting plate. Sweep the outer
diameter of the encoder mounting plate concentric to the cross-roller bearing, concentricity NTE 0.0005".
5. Before proceeding, test fit the encoder shaft into the encoder shaft plate to ensure that it fits in completely
without binding, and that the set screws have been completely backed out or removed. Install flex coupling.
Install encoder shaft to the dimension shown in the assembly*. Install encoder coupling tube.
*Failure to install encoder shaft to correct height will result in damage to flex coupling.

204 Mechanical Service 96-0283 rev C June 2007

 80
70
60

90
50

0
40

10
30

20
Encoder Shaft
Coupler (52-4471)
1.03 + 0.03

Encoder Mounting
Encoder Plate (20-6114B)
(32-1459)

6. Install the rotary table platter and indicate its bore concentric with the cross-roller bearing, concentricity
NTE 0.0005".

NOTE: Be careful not to deflect the encoder shaft - damage to the flex coupling may
result.

7. When installing the encoder shaft plate, ensure that the flats on the encoder shaft are lined up with the set
screw holes in the shaft plate. Set screws must be removed before performing this operation.
8. After seating the encoder shaft plate, tighten the screws securing the encoder shaft plate to the platter.
Then install and tighten the set screws. Install O-ring onto the top of the encoder shaft plate.
9. Install the encoder shaft plate by greasing O-rings and installing them onto the encoder cover plate. Install
the encoder cover plate into the platter bore.

A-AXIS A LIGNMENT AND P ARAMETER SETTINGS

1. In Debug mode, go to parameter 212 (224 for EC1600 and HS series) and enter "0" then press the "Write"
key. Repeat for parameter 128. For a 5-degree indexer table, on an EC-1600, leave the sixteen (16) SHCS
that hold the platter to the rotary body loose.
2. Toggle air pressure to the lift piston using Haas tool P/N T-2150 so that the platter is at the top of its travel.
To lift the EC-1600 indexer, select the A-axis, doing so will raise the platter
3. Zero the A-axis only by pressing the ZERO RET key, then the A key, then the ZERO SINGL AXIS key.
4. Jog the A-axis to line up the front edge of the pallet with the X-axis as close as the coupling position will
allow. For a 5-degree indexer table, align the T-slots on the platter with the T-slots on the table as close as
possible.
5. Slowly discharge the air pressure to the A-Axis and lower the platter into position.
6. Rotate the worm shaft pulley to the extents of its travel and record the values. The value at the middle of
this range is the value for parameter 212. Enter that value.
7. Remove tool T-2150 and replace the hoses. To lower the EC-1600 indexer, select an axis, other than the
A-axis to jog and the platter will lower.

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 EC-400/500 1-degree Indexer Fine Adjustment
1. To fine adjust the front edge of the pallet, it may be necessary to loosen the sixteen (16) SCHS that fasten
the rotary body to the trucks and the ten (10) SHCS for the Z-axis ball screw mount.
2. Tap the rotary body into position within .0005/10.00". EC-400/500: The keys on the reciever will be parallel
to the X-axis. See the “Receiver Replacement” section
3. Tighten then torque the sixteen (16) SCHS that fasten the rotary body to the trucks. Tighten the 5 ballnut
bolts allowing the housing to re-align, then torque the 10 housing bolts. After the housing bolts have been
torqued, loosen the 5 ballnut bolts and run the ballnut away from and back to the motor. If no binding
occurs, re-tighten the ballnut bolts.
EC-1600/2000/3000 5-degree Indexer Fine Adjustment
1. Tap the platter into position within .001" alignment between the platter and the table T-slots.
2. Torque the sixteen (16) SHCS to 45 ft-lbs in a star pattern and re-verify alignment.
3. Place plugs in the fastener holes in the platter to prevent coolant and chips from contaminating the en-
coder/clamp area.
Full 4th A Axis Offset (EC-400/500/1600/2000/3000, HS-3R/4R/6R/7R)
1. In Debug mode (POS-RAW DAT screen), go to parameter 212 (224 for EC-1600/2000/3000), enter "0" and
press the "Write" key.
2. Zero the A-axis only by pressing the ZERO RET key, then the A key, then the ZERO SINGL AXIS key.
3. Go to debug mode and type "GRID" followed by a space and then "A".
4. Jog the A-axis to line up the front edge of the pallet (EC-400/500) or the T-slots (EC-1600/2000/3000,
HS-3R/4R/6R/7R) with the X-axis to a value of .0005/10.00".
5. Enter acual value from POS-RAW DAT screen into parameter 212 (224 for EC-1600/2000/3000).

A-A XIS ALIGNMENT AND P ARAMETER S ETTINGS (EC-630)

Prior to aligning an A-Axis, verify and record Setting and Parameters for the appropriate configuration.
• Run Parameter Checker to call out any incorrect parameter settings for the machine’s configuration.
• Verify that the Setting 30 value is USER1 for all configurations (1 and 45 deg. indexers and Full 4th).
• Verify Parameter 647 for Indexers (1 deg. = 1000; 45 deg. = 45000).
• Set Parameters 128 & 212 to zero for all configurations.
Indexer Rotary Axis Alignment
1. Attach the Lift Fixture
• Tool 15-1304 is required to manually raise and lower the platter.
• Disconnect the Oil Booster Solenoid cable from under the front of the machine and connect it to the tool,
using the adapter cable supplied with the lift tool.
• Disconnect the Hydraulic Valve cable from the cable tray alongside the pallets and connect it to the tool.
2. Set GRID (Parameter 128).
• Change Parameter 605 - Pallet Type from 5 to 0.
• Raise the platter with the lift tool.
• Place the machine in ‘DEBUG’ mode.
• Perform a Single Axis Zero Return on the A-Axis.
• Display the Posit screen, type ‘GRID A’ and press Write/Enter.

206 Mechanical Service 96-0283 rev C June 2007

 • Perform a Single Axis Zero Return on the A-Axis.
• Verify that a value was automatically entered into Parameter 128.
• Leave the platter in the raised position.
3. Set TOOL CHANGE OFFSET (Parameter 212).
• Handle jog the A-Axis so the cones (pallet if installed) are square to the X-Axis.
• Press E-Stop.
• Lower the platter with the lift tool and verify that it seats properly.
• Draw an alignment line on the platter and rotary body, using a fine-tipped black marker. This is used later
in the alignment process.
• Display the Pos Raw Data screen, read the A-Axis actual encoder count and enter that value into Param-
eter 212.

NOTE: Change the value to the opposite sign, i.e., if (+) value, enter (-) and vice versa.

• Raise the platter with the lift tool and perform a Single Axis Zero Return on the A-Axis.
• Verify that the lines marked on the platter and rotary body are still aligned, and lower the platter.
• If the coupling is fully meshed, the fuse reading should stay constant and begin to drop. Verify this in the
Pos Raw Data screen (fuse level for A-Axis).
• If the fuse level is climbing, immediately press E-Stop and repeat the previous steps for TOOL CHANGE
OFFSET.
4. Set PINION GEAR POSITION to middle of mechanical backlash.
• Change Parameter 647 - Indexer Increment from 1000 to 0.
CAUTION! This allows platter rotation in lowered position and can damage the motor.

• Change Parameter 52 - Fuse Level from 3000000 to 500000.

• Go into Handle Jog mode for the A-Axis and set the jog increment to its lowest value.
• Display the Pos Raw Data screen and monitor the A-Axis fuse level before jogging the axis.
• Handle jog the A-Axis slowly ‘clockwise’ watching the value of the fuse for the A-Axis.
• When the value begins to increase, stop and back up until the fuse value stays constant and record the
A-Axis actual encoder count.
• Handle jog the A-Axis slowly ‘counterclockwise’ watching the value of the fuse for the A-Axis.
• When the value begins to increase, stop and back up until the fuse value stays constant and record the
A-Axis actual encoder count.
• Add the two readings, divide the sum by two, and subtract or add this value as required to the value in
Parameter 212.
• Repeat the handle jogging until the difference between encoder error counts is less than 100.
• Reset Parameter 605 to 5, Parameter 647 to 1000 and Parameter 52 to 3000000.
• Indicate the front edge of the pallet in the X-Axis.
• If the pallet is off by a full degree, add or subtract 4511.1 to the value in Parameter 212.
• Disconnect the lift tool.
• Connect the Oil Booster Solenoid cable to the connector bracket under the front of the machine.
• Connect the Hydraulic Valve cable to its mating cable in the cable tray alongside the pallets.

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 A- AXIS BACKLASH
1. Command A-axis brake to disengage. Enter MDI and command an M11. Do not disconnect air to machine.
2. Set Parameter 269 bit 0 (lin scale en) to 0. This disables the rotary table position encoder and enables the
drive motor encoder. The drive motor gear now holds position, allowing backlash to be measured between
the ring and pinion gear. (Power must be cycled when enabling and disabling any scale parameters.)
3. Verify the brake is disengaged, by ensuring the platter can be rotated a slight amount.
4. Set up an indicator on the non-rotary part of the table and set the needle against a T-slot on the rotary
portion of the table (see the following figure).

5. Manually rotate the platter back and forth. At times additional force is required to overcome the friction. Use
platter lifting plates or a fixture on the platter with a bar between them, if necessary, to move the platter.
6. Take readings from the indicator every 10° for 360°. Reposition the indicator each time. Backlash should be
between .0005" and .0007". If it is not within this range, perform the following adjustment procedure.
Backlash Adjustment (EC630-1600-3000)
1. Command A-axis brake to disengage. Enter MDI and command an M11. Do not disconnect air to machine.
2. Disable the A-axis encoder by setting the Parameter 43 bit 3 to 1. Note that this will disable the rotary
table position encoder and enable the drive motor encoder. The drive motor gear will now hold position
allowing backlash to be measured between the ring and pinion gear.
3. Loosen the 3/4-11 hex head bolts that secure the cam backlash adjuster (motor plate) to the underside of
the table. It is not required to remove these bolts completely, only loosen them. The SHCS that bolts
through the plate is a shoulder bolt and does not need to be loosened.
4. Loosen the one adjustment set screw and thread it back away from the pin. Tighten the other screw. This
will alter the backlash between the drive and ring gear.

Increase Decrease
Backlash
3/4-11 HHB Adjusting
Set Screws

Backlash Adjusting Set Screws (HS3-7R)

208 Mechanical Service 96-0283 rev C June 2007

 5. Verify the brake is disengaged and that backlash exists by manually moving the platter back and forth. At
times additional force is required to overcome friction. Use platter lifting plates or a fixture on the platter
with a bar between them, if necessary, to move the platter within the allowable backlash.
6. Back the right set screw all the way out.
7. Set up an indicator on the non-rotary part of the table and set the indicator needle against a T-slot as
shown in the previous figure. For the EC-630, place the magnetic base on the rotary body and set the
indicator needle against the flat front surface of the pallet.
8. Begin tightening the left adjusting set screw and check the backlash. Using the bar between the lifting
plates or fixtures, nudge the table CW and CCW. Take readings from the indicator. Once the readings
come close to .003", rotate the table and take readings every 10° for 360°. Find the tightest of these spots
and set the indicator up as in the previous step.
9. Tighten the left adjusting set screw until the backlash is between .0005" and .0007".
10. Snug the right adjusting set screw against the pin.

NOTE: Be sure that each set screw is tightened snugly against the pin.

11. Tighten the 3/4-11 hex bolts that mount the cam backlash adjuster (motor plate).
12. Recheck backlash. If adjustment is necessary, loosen the plate’s hex bolts and adjust with the set screws.

EC-400 A-A XIS B ACKLASH A DJUSTMENT (F ULL 4 TH )

1° indexer instructions are different, see the instructions at the end of this section.
1. Remove all parts and fixtures from the platter.
2. Check and record backlash near the outer edge of the platter face, using approximately 15-20 ft-lb. The
factory specification is 0.0003" to 0.0007".

NOTE: Check backlash in each of the four quadrants (every 90°).

3. Remove four 10-32 BHCS that retain the worm housing cover. Place a drip pan beneath the black bearing
housing cover to catch any gear oil (keep this pan in place for step 4). Remove the bearing housing cover. It
may be necessary to apply channel lock pliers to the bearing housing in order to remove it; if this is
necessary, use a rag to prevent marring.
4. Note position of the dimple located on the flange of the bearing housing. Mark this position on an adjacent
part of the casting for reference. Remove the four 5/16-18 cap screws. Do not pull the housing out or gear
oil will pour out of the housing. Put two screws part way in housing holes and turn housing with lever.
5. Index the bearing housing one set of holes. Move to the next set of holes by rotating the hole set upward
(toward the platter), either CW or CCW. Bolt the bearing housing flange down. Torque the bolts to 25 ft-lb.
Check the backlash in each of the four quadrants. The factory specification is 0.0003" to 0.0007". If
necessary, repeat Steps 4 and 5.
6. Replace the bearing housing cover. Replace the side cover sheetmetal and reattach with the four BHCS
removed in step 3.
7. Remove the oil filler pipe plug. If the oil level covers less than half of the sight glass, add as follows.
8. Refill the gear case with Mobil SHC-630 gear oil to the midpoint of the oil level eye.
9. Reinstall the oil filler pipe plug from step 7.

96-0283 rev C June 2007 Mechanical Service 209

 A-axis backlash adjustment for optional 1° indexer
The facegear must be disengaged before checking backlash. First raise the platter by applying air to the lift
piston with tool T-2150. Disconnect the A-axis and connect tool T-2150. Toggle air to the lift piston with the
regulator set between 20 to 40 psi [138-276 kilopascals]. Check backlash at each quadrant (every 90°).
Backlash on the 1° indexer option is .0007"-.0015" (nonstandard). Adjust as necessary. See the previous
adjustment description.

EC-630 A-A XIS S ERVICE

Motor Assembly Removal

1. Intiate a pallet change and remove the pallet and all fixtures from the rotary body.
2. Remove the rear cover (25-8083) at the spindle side of the rotary body. If necessary, the waycovers can be
released and moved aside by removing the three screws on each side of the rotary body.
3. The motor, gearbox (1-degree indexers only), harmonic drive assembly (full 4th rotary only), backlash plate
and pinion gear are removed as a unit along with the platter drive motor mount. Disconnect the motor
cables, remove the eight 1/2-13 x 1.75" SHCS that hold the motor mount in place, and slide the assembly
back, off of the alignment dowel pins.

CAUTION! This assembly weighs over 100 lbs. Do not attempt to remove it without
assistance.

Pallet receiver clamp/unclamp solenoid (52-0159) (1° indexer only)

This solenoid is mounted to the main casting of the rotary body, to the right of the platter drive motor assembly.
The hydraulic flow control valve, mounted between the hydraulic pressure line and the solenoid, is factory-set
and should not require adjustment.
Replacing the solenoid:
1. Shut off hydraulic power and ensure that no pressure remains in the system.
2. Disconnect the pressure and return lines from the solenoid.
3. Remove the two 1/4-20 x .75" SHCS that secure the solenoid to the mounting bracket. Install the new
solenoid.
4. Reattach hydraulic lines and bleed the hydraulic system (See EC-1600 procedure).

210 Mechanical Service 96-0283 rev C June 2007

 Platter Up/Down Switch (69-1601 switch) (20-2533 plunger) (1° indexer only)
This switch is located beneath the ring gear, to the right of the index drive assembly. It indicates to the control
that the rotary table has been lifted for indexing or lowered to the clamp position by sensing the position of the
plunger mounted to the switch assembly bracket.
The switch itself is held by its own bracket to the switch assembly.
Pallet Clamp/Unclamp Trip Switch Assembly
This switch is located at the bottom end of the pallet receiver shaft. Two switches are activated by a trip flag
attached to the rotary union at the end of the shaft to indicate pallet clamped or unclamped conditions.
Adjust the switch trip flag by loosening the two 1/4-20 x 0.5" BHCS, moving the trip flag, and then re-tightening
the BHCS.
When replacing switches, make sure that the clamped (lower) and unclamped (upper) switches are in the
appropriate positions, and that they are plugged into their appropriate locations at the control.

H ARMONIC D RIVE (H ORIZ )

The Harmonic Drive unit is used to drive the rotary table on machines such as the HS 3, 4, 6, 7 and the EC630-
1600-3000. It is a self-greasing unit, prepacked with appropriate grease, and requiring no maintenance.
The Harmonic Drive Assembly is made up of the following components:
Housed Harmonic Drive Gearbox Adapter
O-Ring Pack Pinion Gear, 22 Tooth
Wave Generator Cam Backlash Adjuster
Yaskawa Sigma Motor
Backlash Tube and Plate Assembly
1. Place the tube backlash adjuster onto the cam backlash adjuster plate. Turn the tube so that the holes line
up with the holes in the plate. This is an interference-fit item. Insert the 12 SCHS into the tube and thread
into the plate. Tighten the SCHS in a star-pattern to ensure proper positioning of the tube.
2. Attach one push block to each side of the plate, using existing drilled holes and six supplied SCHS.

NOTE: The backlash plate assembly is not attached to the motor at this point to ease
assembly into the table during installation.

Tube Backlash
Adjuster
Cam Backlash
Adjuster

Push Block

SHCS

Spring Washers

Installation
1. Apply grease to the outer side of the tube and top side (as installed) of the plate. Also apply grease to the
counterbore for the tube and the machined surface underneath the table the plate will move against.
2. Assemble four Spring Washers in series and one 3/8" hard washer onto each shoulder screw. They should
be assembled so that a small space appears between the top and bottom pairs of washers.

96-0283 rev C June 2007 Mechanical Service 211

 3. Orient the backlash plate so the push blocks face the access holes of the table. Insert the backlash tube/
plate assembly into the counterbore from under the table. Be careful to not mar the tube surface.
4. Insert the shoulder screws through the slots in the plate closest to the tube (place the hard washer against
this plate) and thread into the table. Tighten with a hex wrench to standard torque.
5. Place a flat washer (45-1725) and a lock washer (45-1720) onto each HHB. Thread the HHB up into the
table through the outer slots of the plate. Leave loose until final adjustment.

MOTOR/WAVE GENERATOR ASSEMBLY

1. Sweat pinion gear (positioned so groove is away from flange) over shaft of sigma adapter and set aside.
2. Examine the spindle of your Yaskawa sigma motor. If your motor has the motor shaft spacer already
sweated onto the shaft, skip to step 4.
3. Sweat the motor shaft spacer over the shaft of the motor. Ensure the chamfer on the inner diameter spacer
faces the motor.
4. Turn the motor so that the shaft faces upward. Place the gearbox adapter over the motor shaft. Insert the
four SHCS through the tabs of the motor case into the gearbox adapter and tighten.
5. Place the wave generator over the motor shaft. Align the keyway in the wave generator with the keyway in
the motor’s shaft.
6. Insert the Yaskawa motor key into the combined keyway. Use a press to fit the key into the keyway. Do
not use the Haas motor key.

CAUTION! Do not use a hammer or other forceful method of inserting the key. You will
damage the fragile bearings and components of the wave generator.

7. Place the shoulder washer over the motor shaft. Apply Loctite, insert the MSHCS and tighten.

MSHCS
Shoulder Washer
Yaskawa Motor Key
Wave Generator
Gearbox Adapter

Yaskawa Sigma
Motor
SHCS

H ARMONIC D RIVE ASSEMBLY

1. Cover your work area with a clean shop rag and place the harmonic drive with the smaller-diameter end
down on the work surface. You should see the grease cavity of the harmonic drive.
2. Remove the large O-Ring from the included package and lightly grease. Place in the groove in the face of
the harmonic drive.

NOTE: For proper operation of a harmonic drive, it is essential that the ring of the wave
generator be concentric with the ring of the harmonic drive. The rings of the
wave generator and harmonic drive are ellipses; they are not circular. Incorrect
assembly will result in an off-center or “dedoidal” condition, resulting in poor
performance and reduced service life.

212 Mechanical Service 96-0283 rev C June 2007

 3. Place the motor/wave generator assembly next to the harmonic drive. Turn the harmonic drive elliptical ring
until the ring is closest to the front of the harmonic drive. Orient the wave generator elliptical ring until it
matches the positioning of the harmonic drive exactly.

A
A
Motor/ Harmonic
Wave Generator Drive
Assembly
Flexspline
Wave Generator
Shoulder Washer
(20-6112)
MSHCS
(43-1651)
Circlular
Spline

Phasing the Wave Generator to the Harmonic Drive (View from Above)

4. Turn the motor/wave generator assembly over and set lightly on the harmonic drive. If the two elliptical rings
are in phase, they will mesh. If they do not mesh easily, remove the motor/wave generator assembly and
verify correct alignment of the elliptical rings and repeat this step.
5. Bolt gearbox adapter to harmonic drive by inserting four SHCS into countersunk holes in gearbox adapter.

NOTE: Test for dedoidal (out of phase) condition, by turning harmonic drive/motor
assembly over and setting it on motor casing, harmonic drive up. Insert 5mm
hex wrench through center hole in harmonic drive into MSCHS. Turn hex
wrench with a drill. For one complete revolution of input there should be two
equal deflections, or pulses, felt through drill.

6. Turn complete assembly over to expose harmonic drive. Keep this free of contaminents. Lightly grease and
install remaining O-Ring into groove. O-Ring seals harmonic drive from coolant during machine operation.
7. Install the pinion assembly (“Motor/Wave Generator Assembly”) onto the harmonic drive. Be sure to orient
the pinion assembly so that the bolt holes line up with the holes in the harmonic drive (interference-fit item).
8. Place sealer on the eight MHHB and thread into the holes of the pinion assembly. Tighten in a star pattern.

MHHB

Pinion
Assembly

O-Ring

Harmonic
Drive
Assembly

Installation
1. Thread an eyebolt into the pilot hole in the shaft of the harmonic drive assembly.
2. Connect a rope or hoist line to the eyebolt. Have an assistant lift the rope up through the counterbore and
raise the harmonic drive.

96-0283 rev C June 2007 Mechanical Service 213

 3. Orient the harmonic drive so that the motor connectors can be accessed from the right of the table. Insert
eight 70mm SHCS through the gearbox adapter into the table. Torque to 35 ft-lb.

CARRIER M OUNT BRACKET INSTALLATION

1. Orient the carrier mount bracket so the edge side faces forward and the flush side is toward the center of
the table. Turn the carrier bracket so the mounting holes face the table’s bottom surface (shown below).

(Front View) (Right Side View)

Table
Limit
Bracket
Access Ports Limit Bracket
Cable Carrier

Cable Carrier and Bracket Installation

2. Place the carrier bracket against the bottom side of the table where indicated and insert the four SHCS
through the bracket, to the table, and tighten.
3. Orient the limit bracket so that the angled bottom edge faces to the right and the mounting tab faces
toward the rear of the table as shown in the previous figure. Mount using two SHCS.

C ABLE BOX E NCODER I NSTALLATION

1. Place the cable box encoder into the left rear corner of the accessory box of the table. Orient the cable box
with the open sides against the casting of the table for the encoder cable.
2. Install the three SHCS and insert through the cable box into the table. Tighten.
3. Apply Sikaflex around any gaps to prevent the encoder cable from popping out when it is pushed down into
the box after installation.

214 Mechanical Service 96-0283 rev C June 2007

 LUBRICATION SYSTEM
The lubrication system is a resistance type system which forces oil through metering units at each of the
lubricating points within the machine. The system uses one metering unit at each of the lubricating points: one
for each linear guide pad, one for each lead screw and one for spindle lubrication. A single oil pump is used to
lubricate the system. The pump is powered only when the spindle and/or an axis moves. Once powered the
pump cycles approximately 3 cc of oil every 30 minutes throughout the oil lines to the lube points. The control
monitors this system through an internal level switch in the reservoir and and external pressure switch on the
lube panel.

VF, 40 TAPER AIR LINE & OIL LINE DIAGRAM

PURGE VALVE ASSEMBLY
IN
TO TSC
PRESSURE AIR MUFFLER EXH AIR MUFFLER A CHECK VALVE
PORT EXH
A ASS'Y
SHOT PIN
*
3-WAY
S3 B MECHANISM VENT
DIRECTIONAL SOLENOID
AIR VALVE A VALVE
S2 B
SOLENOID
A IN
S1 GEAR CHANGE TOOL RELEASE
B AIR SHUTTLE PISTON MECHANISM
MECHANISM REGULATOR VALVE OUT
IN WITH PRECHARGE
AIR MUFFLER EXH 3 IN
COMPRESSED 2
AIR IN 1
SOLENOID PILOT
AIR FILTER PRESSURE SWITCH OPERATED VALVE
REGULATOR
LOCATED AT
IN B
B
A TO TOP OF SPINDLE SPINDLE HEAD
NOZZLE EXH FOR BEARING LUBE
4-WAY
SOLENOID AIR FILTER
VALVE REGULATOR
A AIR CHECK VALVE
(15 PSI)
LOCATED AT LOCATED AT COLUMN ASSEMBLY
AIR REG & LUBE OIL RESTRICTOR
LINEAR GUIDE RAILS LINEAR GUIDE RAILS
BACK PANEL BALL SCREW
(BALL NUT)

PRESSURE SWITCH OIL

OIL TANK
RESTRICTERS
& PUMP OIL FILTER
P
COLUMN'S
PRESSURE GAGE OIL LINE

NOTES: BASE'S LOCATED AT SADDLE ASSEMBLY

LOCATED AT BASE ASSEMBLY OIL LINE
COMPRESSED BALL SCREW
AIR LINE LINEAR (BALL NUT)
LINEAR BALL SCREW GUIDE RAIL LINEAR
LUBRICATING GUIDE RAIL (BALL NUT) GUIDE RAIL
OIL LINE LINEAR GUIDE RAIL SADDLE'S
OIL LINE
NOT USED ON OIL
RESTRICTERS
* VECTOR DRIVE
OIL OIL
MACHINES RESTRICTERS RESTRICTERS
LINEAR LINEAR
GUIDE RAIL GUIDE RAIL
LINEAR GUIDE RAIL LINEAR GUIDE RAIL

The lube pump and spindle fan are on the same circuit, which is turned on whenever a program is running, and
remains on after a program is stopped for the time specified by Spin Fan Off Delay (Parameter 208).

Low Lubrication/Pressure Sense Switches

There is a low lube sense switch in the oil tank. When the oil is low, an alarm will be generated. This alarm will
not occur until the end of a program is reached. There is also a lube pressure switch that senses the lube
pressure. Parameter 117, Lube Cycle Time, controls the lube pressure check. If Parameter 117 is not zero, the
lube pressure is checked for cycling high within that period. Parameter 117 has units of 1/50 seconds; so 30
minutes gives a value of 108000 (at 60Hz - the time interval will be 36 minutes at 50Hz). Parameter 57, bit Oiler
on/off, indicates the lube pump is only powered when the spindle fan is powered. The lube pressure is only
checked when the pump is on.

96-0283 rev C June 2007 Mechanical Service 215

 Air Supply Lines
The lifting cylinder has one large air supply line for lifting the pallets and their loads. No return line is required
because the cylinder is vented to the atmosphere and the weight of the assembly and load causes the cylinder
to lower. The rotation cylinder is double-acting and has two smaller air supply lines for clockwise and counter-
clockwise rotation. The air blast system has one large air supply line, connected to the lube tube adapter.
Each of the four air supply lines is routed to the solenoid mounting bracket where the air solenoid assembly is
located. Four solenoid valves are used to provide the responses required for the pallet change operation.
Lubrication Supply Lines
An oil supply line from the lube/air panel (on the right side of the machine) attaches to the lube tube adapter. It
provides lubrication to the rotary table draw bar, which carries oil mist from the air blast plug up the center of
the main draw bar, to the draw bar and pallet nut.

COMPONENTS

8 9
7
11
10 AIR

1
AIR

2
5
3
MIN

6 4

Lube Air Panel (Front View)

The following is a list of the Lube Air Panel assembly components.

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 3 cc of oil (at approximately 20 psi).
3. Oil Filter - Filters the oil from the reservoir before it is pumped to the necessary areas.
4. 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.
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.

216 Mechanical Service 96-0283 rev C June 2007

 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.
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 bearings.
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 pressure of 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 for 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.

LUBE PANEL R EMOVAL

CAUTION! Power off the machine before performing the following procedure.

1. Remove the rear panel and disconnect the main air line.
2. Disconnect limit switches from lube panel, the spindle air lines, and disconnect oil line at lube panel.

NOTE: All plastic ties must be cut in order to remove the lube air panel.

3. Remove all conduits.

4. Disconnect main oil line.
5. Remove the mounting screws located at the top of the lube panel.

96-0283 rev C June 2007 Mechanical Service 217

 A IR R EGULATOR S ERVICING

CAUTION! Disconnect or shut off air supply and exhaust the primary and secondary
pressure before servicing unit. Turning the adjustment knob counterclock-
wise does not vent downstream pressure. Downstream pressure must be
vented before servicing the regulator.

NOTE: Use mineral based grease or oil only. Do Not use synthetics or silicones.

NOTE: After servicing unit, turn on air supply and adjust regulator to the desired
downstream pressure. Check for leaks. If leakage occurs, do not operate –
conduct repairs.

Servicing the Filter Element and Cleaning the Bowl Assembly

1. Unscrew the bottom threaded collar and remove the bowl assembly. Use care as not to lose the O-ring.
2. Unscrew the baffle and then remove the element.
3. Clean the internal parts and bowl assembly before reassembling. To clean the bowl assembly use mild
soap and water only! Do not blow with air as loss or damage may occur to O-rings.
a. Remove the drain nut from the dump valve and remove it from the bowl assembly. Use care to not lose
the O-ring.
b. Soak the dump valve in a mild soap and water mix to clean. Rinse in water and allow to air dry.
c. After cleaning the bowl assembly, reassemble the dump valve in the bowl assembly. Care should be
taken to not pinch the O-ring. Do not over tighten the plastic drain nut.
4. Install the new element.
5. Attach the baffle and finger tighten firmly.
6. Inspect/replace O-ring. Lightly lubricate O-ring to assist with retaining it in position.
7. Install the bowl assembly into the body and tighten the collar; hand tight, plus ¼ turn.

O-ring (a)

Element

Baffle

Dump Valve

O-ring (b)

Collar

Bowl Assembly

Drain Nut

218 Mechanical Service 96-0283 rev C June 2007

 PARTS CATCHER (LATHE )
Removal
CAUTION! Power off the machine before performing the following procedure.

1. Disconnect the main air line. Remove necessary panels to access the parts catcher unit
2. Loosen 1 1/2" shaft collar that locates the parts catcher tray, and slide out tray and inner shaft.
3. Unclamp outer retaining ring that retains the shaft collar on the outer shaft, remove shaft collar and inner
retaining ring. Remove rubber seal from outer shaft.
4. Detach 5/32" airlines attached to the barrel end and rod end ports of the air cylinder.
5. Remove 7/16" hex nut that attaches the air cylinder to the parts catcher shaft.
6. Loosen and remove 1/4" SHCS and washer that attaches air cylinder to cylinder mount and remove air
cylinder.
7. Remove 3/8" SHCS holding the parts catcher pivot mount assembly to the spindle head casting and slide
out mount assembly.

5/32" Airline (2) 1/4" SHCS

Air Cylinder Parts Catcher

Tray
Hex Nut
Parts Catcher

Parts Catcher
Shaft
Parts Catcher Pivot
Mount Assembly

Parts Catcher/Tray (Front View)

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. Attach air cylinder rod, in its fully
retracted position, to parts catcher shaft with the hex nut. Connect air lines to air cylinder ports.
3. Install rubber seal on outer shaft. Place inner retaining ring on outer shaft, slide shaft collar on and attach
outer retaining ring. Connect the main air line.
4. Power on the machine and program an M36, in MDI mode, to fully extend the air cylinder. 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.
5. 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
6. Install necessary panels that were removed.

96-0283 rev C June 2007 Mechanical Service 219

 LATHE T OOL PROBE

PROBE SETTING
1. Power off the machine and remove the forward end panel on the left side of the machine.
2. Loosen all fasteners and the 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. Adjust the height of probe so the tip of the turning tool touches the middle of the side of square tip by
tightening 1/4-20 set screw on the mounting block. 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.
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 BHS and
let the 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 the probe. The speaker should beep and diagnostics
input should change from 0 __> 1 __> 0. Using the slow jog button, move X or Z clear of the part, and tap the
probe. The motion in current direction should stop, and the offset should update.

PROBE TIP R EPLACEMENT

1. Install stylus tip with supplied wrenches. Additional information is found in the 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 S ETUP (LTP)

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. Select YASNAC for Setting 33 coordinate system.
Offset G54 must be set X = 0, Z = 0. Tool wear #1 must be set to 0.
3. Handle jog to a position for clear X travel. In Offset page, use F2 to set tool 1 work shift to centerline.
4. Enter this program in MDI: G54
G50 T5100
X0
Run the MDI program; the tool will move to spindle center
5. Select handle jog mode, Distance to go will read X = 0.0000, Z = 0.0000. Manually jog in Z to a position
clear of the LTP arm. Don’t move the X-axis.
6. Lower the LTP arm, the display will switch to Offsets. Select Position display again in order to view Dis-
tance to Go Display.

220 Mechanical Service 96-0283 rev C June 2007

 7. Manually jog to probe tip and “probe” the 1"dia reference tool in the -X direction (move down) using 0.0001
feed rate. Record the X distance to go. (e.g.; 4.9993). Subtract 1" from the number (e.g.; 4.9993 - 1.0000 =
3.9993). Enter this number in Setting 59 (Probe Offset X+).
8. Manually jog the tool and “probe” the 1" reference tool in the X+ direction (move up) using 0.0001 feed rate.
Record the X distance to go for this position. (e.g. 2.2309). Add 1" to the number (e.g. 2.2309 + 1.0000 =
3.2309). Enter this number in Setting 60 (Probe Offset X-).
9. Subtract the number in Setting 60 from Setting 59 (e.g. 3.9993 - 3.2309 = 0.7684). Divide this number by 2
(e.g. 0.7684/2 = 0.3842 ). This is the effective width of the probe head; the actual width is 10mm or 0.3937.
Enter this number (effective probe width, not actual) in Setting 62 and Setting 63.

VERIFICATION
( Method assumes cut geometry is smaller than tool probe setting diameters.)
O.D.
1. Using Handle jog and an OD turning tool, OD turn a diameter. Set Distance to Go to X = 0.000. Measure
the diameter (e.g. 2.125).
2. Jog away in Z direction and lower tool presetter. Jog to probe OD tool in X direction using 0.0001 feed rate.
3. Record X Distance to Go number (e.g. 1.8743). Add number to the measured diameter from step 1 (e.g.
2.125 + 1.8743 = 3.9993). The sum should equal the number in Setting 59 (Probe Offset X+) +/- 0.0020".

I.D.
1. Using Handle jog and an ID boring tool, ID bore a diameter. Set Distance to Go to X = 0.000. Measure the
bore diameter (e.g. 1.750).
2. Jog away in Z direction and lower the tool presetter. Jog to probe the ID tool in the X+ direction using the
0.0001 feed rate.
3. Record the X Distance to Go number (e.g. 1.4809). Add this number to the measured diameter (e.g. 2.125
+ 1.4809 = 3.2309). The sum should equal the number in Setting 60 (Probe Offset X-) +/- 0.0020".
4. 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 appropriate X +/- Setting (59 or 60).

C-AXIS (L ATHE )

LUBRICATION
The C-axis gears are lubricated by the automatic 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. 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.

Oil Adjustment

96-0283 rev C June 2007 Mechanical Service 221

 S ETTING G RID O FFSET

NOTE: This option uses a second MOCON PCB; take care tracing signals.

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.

Air To Pivot Block

Cut Off Valve
C-Axis Pinnion

Driven Pivot
Gear Block

2. Press Setng/Graph and turn Setting #7 off. Press Alarm/Mesgs, type Debug, and press Enter. Change
parameter 517 to zero.
3. Press Zero Return, type “C” and press Zero Single Axis.
4. Set Parameter 278 (C-axis drive) to zero, which will prevent the actuator block from engaging the C-axis.
Set Parameter 498 (C-axis Disable) to one.
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. Observe
the mesh gear contact, ensuring full contact and smooth mesh of gears. If necessary, move the drive gear
by hand to ensure full gear mesh.
7. Press Posit, and 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.
8. Release the air from the actuator block and set Parameter 498 back to zero. Zero return the C-axis; the
value in the raw-data page Actual column should now read zero.
9. Engage and disengage the actuator block several times and insure that the gears are meshing smoothly,
observe the raw data Actual column to ensure it remains at zero.
10. Disconnect the regulator from actuator block and reconnect normal air supply, enable Parameter 278 bit 27
C-axis drive.
11. Press MDI/DNC and enter the following program:
M154;
M155;
M99;
12. Press Reset then Cycle Start. The machine should orient the spindle, and engage and disengage the C-
axis without fault. If the machine displays an alarm, double check the grid offset and spindle encoder pulley
for proper operation.

222 Mechanical Service 96-0283 rev C June 2007

 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.
2. Loosen the two 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. Place a magnetic base indicator on top of
the spindle head and rest the indicator finger on top of the pivot block.
4. 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.
5. Once the proper runout is achieved, set the indicator finger to zero at the lowest point of the runout. Screw
down the adjustment set screw until the pivot block is .0005" from the gear mesh contact point.
6. Tighten the two SHCS stop block lockdown screws, located on the side of the pivot stop block. Torque to
35 ft-lb. Reconnect the C-axis air supply from the C-axis solenoid.

A UTO D OOR R EMOVAL AND R EPLACEMENT (L ATHE & V ERT .)

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 for Lathe, 33-1320 for Vert.).
3. a. Lathe: Loosen the front two FBHCS on the door drive mount. This will loosen the tension on the chain.
b. Vert: Rotate the turn buckle to loosen the tension on the chain and remove the chain from the clutch
sprocket.
4. Detach the clutch and shaft adapter from the motor shaft by loosening the two SSS on the shaft adapter.
5. Remove the four SHCS and lock washers that mount the motor to the door drive motor mount and remove
the motor.

96-0283 rev C June 2007 Mechanical Service 223

 Door Drive Door Drive Door Drive Door Drive
Door Drive Motor Mount
Motor Motor Mount Mount Motor
Door Drive
Mount

SHCS Motor
Chain Mounting
Clutch Chain
Motor Mounting
SHCS
Lathe Vertical Mills

Motor Replacement
1. Remount the motor to the motor mount in the same manner in which it was removed.
2. Remount the clutch with the shaft adapter to the new motor. Lathe: Hook the stabilizing arm of the clutch
to the prong on the door drive chain retainer.
3. Reassemble the chain to the motor assembly (see the Chain Replacement and Adjustment section).
4. Reattach the motor cable to the extension cable (33-1312 for Lathe and 33-1320 for Vert.).

CLUTCH REPLACEMENT
Clutch Removal
1. Turn off power to machine. Unplug both of the clutch cables from the bridge rectifier on the motor mount.
2. Lathe: Loosen the front two FBHCS on the door drive mount. Vert: Turn the turn buckle. This will loosen
the tension on the chain. Remove the chain from the sprocket on the clutch assembly.
3. Cut the cable ties that fasten the clutch cable to the motor mount. Loosen the two set screws on the shaft
adapter and remove the clutch assembly.
4. 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.
5. Remove the three SHCS that fasten the sprocket and cog hub to the clutch (the clutch is in two parts).

2X Setscrew

Woodruff Key

3X SHCS

Setscrew

Shaft
Adapter

Cog Hub

Sprocket
Clutch

Stabilizing Arm

Vertical Machine Clutch Replacement

224 Mechanical Service 96-0283 rev C June 2007

 Bridge Rectifier Cable Ties
Cable Tie

Cable Ties

Clutch Cabling
Stabilizing Clutch
Arm Stabilizing Arm

Bridge Rectifier and Cable Ties Vertical Machines Lathe

Clutch Replacement
1. Replace the clutch in the same manner as which it was removed. When tightening the set screw on the
clutch, make sure that the sprocket turns freely.
Lathe: Hook the stabilizing arm of the clutch to the prong on the door drive chain retainer.
Vert: Hook the stabilizing arm of the clutch to the flange on the right side of the door drive mount.
2. Lathe: The clutch sprocket should be aligned with the nylon derailers (sprockets) on the chain rail.
3. Fasten the clutch cable with ties.
4. See the Chain Replacement and Adjustment section to reattach the chain.
5. The clutch must be run-in after the clutch has been installed and the chain adjusted properly. To do so,
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; this will seat the clutch.

CHAIN REPLACEMENT AND ADJUSTMENT

Chain Removal
1. Shut off power to the machine.
2. a. Lathe: Loosen the front two FBHCS on the door drive mount. This will loosen the tension on the chain.
b. Vert: Remove the two FBHCS that fasten the chain retainer to the right door connector.
3. a. Lathe: Detach the master chain link from both sides of the chain rail and remove the chain.
b. Vert: Detach master chain link from left door connector and from turn buckle, and remove the chain.

Door Drive
Door Drive Door Drive Door Drive Mount
Motor Motor Mount Mount
Master
Links

` Chain
Chain Turnbuckle
BHCS
Chain Chain Retainer
Tension Left Door Connector

Lathe Chain Vertical Chain

96-0283 rev C June 2007 Mechanical Service 225

 Chain Replacement
1. a. Lathe: Replace the chain by fastening the left and right master links to the chain rail on both ends.
b. Vert: Reattach the chain to the left door connector and to the turn buckle. Make sure that the chain is
placed over the sprocket on the left end of the rail and over the sprocket on the motor assembly.
2. Lathe: Run the chain under the nylon derailers (sprockets) and over the sprocket on the motor assembly.
3. Vert: Replace the chain retainer.
4. a. Lathe: 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.
b. Vert: Adjust the tension with the turn buckle.
5. 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.

AUTO DOOR PARAMETERS

The movement of the Auto-Door is controlled by Parameters 235, 236, and 251 for the Lathe, and Parameters
292, 293, and 251 for the mill. See the Parameters chapter in the Electrical Service Manual.
Adjust the parameters to assure that the door opens and closes properly:
1. Be sure that Setting 131 is set to on.
2. Set Parameters 235, 236 (lathe) or 292 and 293 (mill) to a value of 3 (50ths of a second).
3. Set Parameter 251 to a value of 3000. This number means that the door travel time will be 3 seconds. The
time needed to fully open or close the door depends on the size of the machine.
4. Test the door by running a short program: G04 P3.;
M30;
5. When closing, the door should stop about one inch [2.54cm] before reaching the end. Adjust Parameter
251 as necessary.
6. Adjust parameters 292 and 293 (mill), 235 and 236 (lathe) or as necessary for proper closure.

ENCLOSURE REPLACEMENT (VERT.)

Please read this section in its entirety before attempting to replace the doors or windows.
Tools Required: Trim installation tool (dull-edged knife or caulking spatula).

DOOR REPLACEMENT

CAUTION! Doors are heavy; have two people performing this operation, if possible.

Removal
1. Turn the machine power off.
2. Slide the doors to the full open position.
3. Remove the tension springs (2) connecting the two swivel roller brackets at the top and bottom of the door.
4. Slide the door to the fully closed position. Loosen the two upper roller hex nuts, and disengage the upper
swivel roller brackets from the top roller guide.
5. Lift the door from the bottom roller guide and remove.

226 Mechanical Service 96-0283 rev C June 2007

 Installation
1. Ensure that the lower roller hex fasteners are tight and the upper roller fasteners are loose and in the
middle of their adjusting slots. Place the door into the enclosure, and position with the lower rollers resting
on the lower roller guide.
2. Rotate the door to the upright position, and engage the top rollers onto the top roller guide.
3. Replace the tension springs onto upper and lower roller swivel brackets. Tighten the upper roller fasteners.
4. Verify that the door travels smoothly. If it does not:
• Check that all roller wheels are seated and roll on their tracks.
• If all roller wheels are seated on their tracks, it will be necessary to adjust the door travel by
loosening the upper and lower roller hex fasteners.

2X Shoulder Bolt Roller Wheel Assy

2X Roller Wheel
Roller Guide
4X Washer
2X Nut

Tension Spring
Door Swivel Roller
Bracket

Roller/Roller Guide Assembly

Door Adjustments
5. Close both doors and check that the vertical gap between them is uniform. If it is not:
• Determine which door must be adjusted.
• Loosen the door's outer lower roller attachment and pivot the door on the inner lower roller wheel.
• When door is in the desired position (the vertical gap is uniform), tighten the lower outer roller
fastener.

Door Gap

Outer Lower
Roller Attachments

Vertical Gap Between Front Doors Gap Between Front of Door and Front Panel Flange

6. Check the gap between the door and the front panel flange, and verify it is 5/8" throughout the travel of the
door. If it is not, loosen door's upper roller fasteners and tilt door forward or back, as necessary, to adjust
position.

96-0283 rev C June 2007 Mechanical Service 227

 D OOR O PEN S ENSE SWITCH
The Door Open sense switch is a magnetic reed switch type. These switches are normally closed and wired in
series. When a door is open, the switch(es) will open and the machine will stop. When the door is closed
again, operation will continue normally.

CAUTION! A 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 750 RPM (500 RPM for lathes).
The Door Hold function can be temporarily disabled with 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.

Switch Adjustment
1. Move the door to the fully closed position. Go to the Diagnostics page on the control panel, and ensure
Door S reads 0. Open the door, and ensure Door S reads 1. If either reading is incorrect:
• Loosen the SHCS that mounts the switch actuator bracket to the top of the door. Note that it is
possible to access this bracket from the side window.
• Move the bracket in its slot to the proper position and tighten the SHCS.

STEADY R EST ALIGNMENT 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) posi-
tion.
2. Grip the tension bar and adjust in a counterclockwise 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.

228 Mechanical Service 96-0283 rev C June 2007

 HORIZONTAL MILL ASSEMBLY DRAWINGS AND PARTS LISTS

EC-300 FRONT PANELS

31 32
30

33

34
1
2
3 39
20

4 35
19
5 36
38 37
18

17
7
16 21
29
8
15
14 9
13 10
12 11
22

23
View Rotated for Clarity

28
27 26 25 24
1. 25-5682 Tool Trays Panel
2. 25-5683 Intermediate J-Box Top Cover 22. 25-0563 Tool Box Assembly
3. 25-5681 Intermediate Top Cover 23. 25-5738 Left Intermediate Pan
4. 25-5678 Front Right Panel 24. 25-5786 Left Chip Shield Pan
5. 59-0123 Sanders K 18 Wire Clip 25. 25-5742 Center Bottom Pan
6. 25-0440 Tool Tray (2x) 26. 25-5784 Front Left Chip Shield Pan
7. 25-6182 Front Table 27. 25-5785 Front Right Chip Shield Pan
8. 25-5740 Front Right Pan 28. 25-5806 Operator Door Tunnel
9. 59-0278 Knob Head 3/8-16 x 1-1/4 Dog Point Screw 29. 25-5893 Panel Top Partition
10. 20-1341 Tool holder Block 30. 32-2300 Proximity Limit Switch –Door Open
11. 25-0798 Tool Holder Bracket 31. 20-2696 Front Door Guide Bar
12. 58-1671 Nipple 1/8 NPT x2 32. 20-2317 Rail Load Station (2x)
58-3618 Street Elbow ¼, 90 degree 33. 28-0165 Front Door Window
13. 25-5412 Nozzle Holder Bracket 34. 25-0668 Side Window Retainer (2x)
14. 25-1257 Front Panel Switch Box 35. 59-6400A Guide Wheel
15. 25-5741 Front Center Pan 49-2015 PTHS ¼-20x7/8
16. 25-5739 Front Left Pan 49-0015 NVT
17. 25-1292 Door Handle 45-16390 Washer
18. 25-5809 Center Front Panel 36. 25-0669 Top-Bottom Window Retainer (2x)
19. 30-7148 Front Door Assembly 37. 59-9743 Front Door Spring
20. 25-5680 Front Panel Top Cover 38. 30-2009 Lower Right Corner Roller Assembly
21. 25-5679 Front Left Panel 39. 25-5810 Front Door

96-0283 rev C June 2007 Mechanical Service 229

 EC-300 O PERATOR DOOR P ANELS
1 2 6 8
3
4

9
5
19
18
17
16
10

11
12

13
14

15 20
26

1. 25-5888 Center Channel Cover Plate

2. 25-5891 Cable Channel Cross Top 25
3. 25-5799 Top Operator Side Cables Tray 21
4. 25-5892 Cable Channel Cover Plate
5. 25-5792 Right Intermediate Top Panel
22
6. 20-2685 Operator Door Upper Door Rail
7. 25-2684 Operator Door Lower Door Rail
8. 25-5798 Operator Door Trip Bracket
9. 25-5791 Operator Door
10. 59-6210 Red Door Handle 23
11. 30-7359 Operator Door Right Roller Assembly (2x)
12. 30-7358 Operator Door Left Roller Assembly (2x)
13. 25-5796 Left End Hinge Assembly 24
14. 25-5926 Auger Motor Cable Tray View Rotated 1808 (Looking Up)
15. 25-5788 Right Intermediate Pan
16. 25-4521 Cover Lamp Connector
17. 25-5889 Operator Side Top Cover
18. 25-5887 Top Center Channel
19. 25-5890 Tool Changer Side Top Cover
20. 32-0227 Mylar Reflector Lamp Assembly
25-4789 Adjust Work Light Bracket
21. 25-5793 Operator Door Side Z-Frame
22. 28-0151 Operator Door Side Window
23. 25-5787 Right Chip Shield PC Wing
24. 25-5789 Operator Side Lower Chip Shield
25. 25-5228 Door Window Z-Frame (2x)
26. 25-5800 Operator Side Top Chip Shield

230 Mechanical Service 96-0283 rev C June 2007

 EC-300 REAR P ANELS
1

5
7
8

14

13

10 1. 25-5720 Rear Header

12 11 2. 25-5666 Rear Control Box Panel
View Rotated 908 CCW 3. 25-5722 Control Support Mounting Bracket
4. 25-5924 Control Intermediate Pan
5. 25-5665 Front Control Pan
6. 25-5667 Front Control Box Panel
7. 25-5721 Top Panel Support Brace
8. 25-5912 Control Top Panel Tray
9. 25-5896 Control Box Panel Tray
10. 25-5925 Rear Control Pan
11. 25-5897 Rear Panel Support Bracket (2x)
12. 25-5664 Rear Left Pan
13. 25-7581 TSC Filter Bracket
14. 25-5718 Rear Left Panel

96-0283 rev C June 2007 Mechanical Service 231

 EC-300 TOOL CHANGER PANELS
1

10

9 2

8
3
7
6
5

11 12
4

13
23

22

21

20

19 14

18 17 16 15
View Rotated 908 CW

1. 25-5881 Tool Changer Top Cover 13. 25-5709 T.C. Rear Panel
2. 25-5706 T.C. Front Panel 14. 25-6730 Separator Return Line Bracket
3. 25-5779 T.C. Side Panel 15. 25-5705 T.C. Rear Pan
4. 25-6682 Removal Tool 40T Holder 16. 25-5707 T.C. Front Pan
5. 25-9248 Plate Window Handle 17. 25-5804 T.C. Top Chip Shield
6. 25-5885 T.C. Access Panel 18. 25-5716 T.C. Front Chip Shield
7. 32-0097 Remote Switch Box 19. 25-5957 T.C. Access Bottom Bulkhead
8. T.C. Access Window 20. 25-5706 T.C. Front Panel
9. 25-9262 Wash Handle Holding Bracket 21. 25-5776 Lower Bulkhead
10. 25-5927 T.C. Header Panel 22. 26-0155 Nylon Strip Brush (2x)
11. 25-5777 Top Bulkhead 23. 25-5956 T.C. Access Top Bulkhead
12. 25-5778 Mounting Bulkhead

232 Mechanical Service 96-0283 rev C June 2007

 EC-300 COLUMN AND F RAME PANELS

1 2 3 4

13 6
14

24 7

12

23 11

22
8

21 15
10
16 9

20 17
19 18

1. 59-0706 Shade Roller- 70.5" x 21" (2x) 13. 25-5826 Column Top Cover
2. 25-5833 Shade Roller Left Frame 14. 25-5825 Column Top Side Cover
3. 25-5837 Top Column Clamp Wiper 15. 25-5831 Gordillo Top Bracket
26-0173 Top Column Wiper Felt 16. 25-5823 Column Right Cover
4. 25-5834 Shade Roller Top Frame 17. 25-5827 Gordillo Right Guide
5. 25-5832 Shade Roller Right Frame 18. 25-5829 Bottom Chip Cover Plate
6. 30-7214 Column Frame Roller Assembly 19. 20-2615 Bottom Plate Bar (2x)
7. 25-5773 Shade Roller Frame Brace (2x) 20. 25-5830 Bottom Gordillo Cover
8. 25-5767 Right Corner Seal 21. 59-0714 Y-Axis Gordillo (2x)
9. 25-5765 Saddle Cover Front Seal 22. 25-5911 Y-Axis Waycover Center Cover
10. 25-5766 Wiper Backing Plate 23. 25-5828 Gordillo Left Guide
25-0169 Saddle Wiper Felt 24. 25-5824 Column Left Cover
11. 25-5768 Left Corner Seal
12. 25-5836 Column Felt Wiper Clamp (2x)
26-0172 Column Felt Wiper

96-0283 rev C June 2007 Mechanical Service 233

 EC-300 B ASE ASSEMBLY 5
4 6
2 3 7

1
8
9
12
10
11

15 16
14 18
13
17 19
20
33 34 21
22

31 32

30

29

27 24
23
28 25
26
1. 50-9011 Linear Guide (truck) 19. 20-2593 X-Axis Ship Block
2. 50-0017 Linear Guide (35mm truck) 20. 20-2676 Ballscrew Bumper
3. 20-2587 Saddle Casting 21. 20-0152 Bearing Housing
4. 58-3600 3/8" Nipple 22. 50-9011 Linear Housing
5. 20-7008 Nut Housing 23. 58-1680 Parker Fitting
6. 25-7267 Prox. Switch Bracket 24. 58-0097 90° Fitting
7. 25-5780 Y-Axis Trip Bracket 25. 57-9265 Chip Conv. Bracket
8. 25-5919 Cable Carrier Bracket 26. 32-6626 Chip Conv. Motor
9. 20-2593 Prox. Switch 27. 25-5669 Auger Box
10. 20-0150 Nut Housing 28. 57-0360 Box Gasket
11. 30-7140 Base Lube Assembly 29. 20-2586 Base Casting
12. 30-7138 Saddle Lube Assembly 30. 57-9265 Conveyor Gasket
13. 25-5953 Chip Shield 31. 20-2592 Chip Auger
14. 20-2687 ATC Mount 32. 25-5670 Auger Box Cover
15. 62-0014 Servo Motor 33. 25-5673 Strainer Base
16. 25-9203 Motor Mount Cover Plate 34. 58-0807 Coolant Nozzle Base
17. 20-2733 X-Axis Bumper
18. 30-3107 Ballscrew Assembly

234 Mechanical Service 96-0283 rev C June 2007

 EC-300 COLUMN ASSEMBLY

2 4
1

17
16
9

15 7

14 10

10
13
12 4 11

1. 25-2767 Mounting Bracket

2. 32-2130 Prox. Switch
3. 62-0017 Servo Motor
4. 25-7042 Cover Plate
5. 20-2686 Ballscrew Bumper
6. 20-2588 Column Casting
7. 20-6361 Y-Axis Bumper
8. 25-5732 Column Cover
9. 20-7009 Bearing Housing
10. 21-2131 Prox. Switch
11. 62-0014 Servo Motor
12. 20-2734 Bumper Cover
13. 24-0023 Ballscrew Assembly
14. 25-7080 Bracket
15. 50-3400 Linear Guides
16. 24-0041 Ballscrew
17. 30-6403 Y-Axis Lube Line Assembly

96-0283 rev C June 2007 Mechanical Service 235

 EC-300 S PINDLE H EAD A SSEMBLY

5
6

4
3
17
2 16
18
19
7 15
1
14

8
13

9 23
16 20
22
12
14 21
11 10

1. 20-7016 Spindle Housing 15. 20-1691 Shaft Inline

2. 50-0017 Linear Guide (35mm Truck) 16. 25-4648 Bracket Switch Mounting
3. 30-7441 TRP 17. 20-1693 Cylinder Inline
4. 73-3055 Terminal Buss 18. 30-2200 Prox. Switch “Unclamp”
5. 25-5242 Shroud Bracket 19. 20-1696 Spring Retain Inline
6. 30-6465 TSC Fitting Assembly 20. 30-2233 Prox. Switch “Clamp”
7. 25-6733 Motor Shroud 21. 20-2520 Standoff Inline
8. 62-3013 Spindle Motor 22. 20-1692 Piston Inline
9. 20-2520 Stand Off 23. 20-2521 Striker Plate Inline
10. 20-2674 Spindle Head
11. 25-6592 Junction Bracket
12. 20-7022 Spindle Lock
13. 20-2512 Incline Spindle Shaft
14. 25-5970 Shim

236 Mechanical Service 96-0283 rev C June 2007

 EC-300 PALLET C HANGER

5
14

13
1
5
12

2
P1
4
6

8
6
1. 25-5880 2X Rotating Door Cap
2. 25-5878 2X Rotating Door
3. 59-0580 Name Plate P2
4. 25-5874 2X Clamshell Cover Access
5. 25-5875 2X Clamshell Cover Access
9 6. 25-5873 2X Clamshell Pallet Cover
7. 20-2782 Pallet
10 8. 30-7011 HRT210 No. 1
30-7012 HRT210 No. 2
11
9. 20-2688 Pallet Changer Table
10. 20-2218 6X Toe Clamps
11. 22-9087 Table Bolt Plug (Dowel Pin)
9
12. 59-0579 Name Plate P1
13. 25-5883 2X Rotating Access Cover
14. 20-2695 2X Rotating Door Fairlead

96-0283 rev C June 2007 Mechanical Service 237

 EC-300 PALLET CHANGER
1. 25-6845 Motor Cover
2. 62-0014 Servo Motor
3. 20-2724 Motor Flange 1
4. 20-2812 Stabilizer Plate 2
5. 25-5934 Retainer Button
52
6. 40-1640 SHCS 10-32 x ½
7. 20-2814 Stabilizer Button 3
4 5
8. 20-2729 Pallet Support Frame (2x) 6
9. 25-5876 Clamshell Splash Shield 50
51 7
10. 25-5877 Clamshell Splash Shield 49 8
11. 59-0724 Harmonic Drive
12. 25-5916 Thrust Washer (2x)
13. 25-5915 Roller Cage
14. 51-0018 Bearing Roller 9
15. 25-5900A APC Skirt (2x)
16. 20-2813 Stabilizer Spacer
17. 25-6793 Right Clamp Shield 10
18. 25-6794 Left Clamp Shield
19. 20-2783 Drive Plate 8
20. 25-6827 Switch Cable Cover 11 15
21. 58-0779 Air Blast Tube 48
22. 20-2726 Bulkhead
17 16
23. 58-1693 LBO Fitting 47 12 17
24. 58-0778 Clamp Tube 46
13
25. 58-0777 Unclamp Tube 45
44 14
26. 58-3087 Comp Fitting
42 43
27. 58-3052 90° Comp Fitting 41 36 19
28. 25-5899 APC Cable Strap
40 38

29. 20-2719 Clamp Cylinder Cover 37

35
30. 57-2986 Piston “O” Ring 39
31. 20-2700 Pallet Clamp Piston
32. 20-2716 Pallet Clamp Shaft A 18

33. 59-0727 Die Spring 34 20

34. 20-2690 Pallet Changer Base
21
25
33 22

27
32

31 23
24

26
30
28 Note: The “A” locations illustrate
29
35. 20-2785 “H” Frame Pad lifting points.
36. 20-2809 Frame Button
37. 59-0725 Bumper 45. 20-3073 Clamp Switch Housing
38. 20-2728 Stop Block 46. 32-2236 Prox. Switch Unclamp
39. 20-2727 Air Blast Ring 47. 20-2698 Pallet Flag
40. 20-2582 Air Blast Nozzle 48. Shoulder Bolt (2x)
41. 40-1705 FHCS 49. 59-0726 Pallet Support Spring
42. 58-2070 Hex Fitting 50. 20-2715 Pallet Clamp
43. 58-0780 90° Fitting 51. 25-5903 Prox. Pallet Mount
44. 20-2699 Pallet Up Plunger 52. 32-2130 Prox. Home 1.5’

238 Mechanical Service 96-0283 rev C June 2007

 EC-300 40-40 T OOL CHANGER

11
12
10 13
9 14
15
3 8

5
4 7 16
6
37
2 22
23
1

24 25 26 17 18
27

35

30
34 29
32 31 28
36 18
33 21 20
19

1. 25-4153 Rear Cover 23. 20-0226 Bearing Housing

2. 20-0731 Carousel 24. 32-2251 Prox. Pocket Down
3. 25-4152 Front Cover 25. 32-2252 Prox. Pocket Up
4. 32-2295 Prox. Carousel Mark 26. 20-2732 SMTC Shaft Support
5. 32-1875 Carousel Motor 27. 20-2731 SMTC Support Plate
6. 20-0809 Carousel Shaft 28. 20-2730 Pocket Stop
7. 20-2759 Mounting Plate 29. 20-0807 Tool Pocket Slide
8. 62-0014 Servo Motor 30. 32-2253 Prox. Switch Tool One
9. 20-0772 Motor Mount 31. 59-0078 Air Cylinder
10. 54-0036 Drive Belt 32. 20-2735 ATC Housing
11. 22-0001 Output Shaft Cad 33. 25-0800 Shroud Corner
12. 20-0224 Star Bearing Housing 34. 20-0458 Tool Pocket
13. 20-0223 Star Gear 35. 59-0290 Lock Nut
14. 20-0225 Bearing Housing 36. 20-0392 Carousel Washer
15. 30-4008 Cam Box 37. 54-0045 Belt Drive
16. 20-2694 Output Shaft
17. 57-0059 Seal
18. 25-5805 Cover Plate
19. 20-0240 Arm Hub
20. 20-0245 Arm Cap
20-0246 Arm Cap
21. 30-7234 Double Arm Assy.
22. 20-0238 Bearing Cap

96-0283 rev C June 2007 Mechanical Service 239

 EC-400 E NCLOSURE SHEET METAL

1
2
Tool Changer 3
Enclosure 9
4 10
See Sheet 2
66 7

65 6
5 8
11

12

16 17
15
14
13

64 30

21

20

61 62

58 19
57 60 37 18
63 23
59 22
38
39
EC 36 35
400 40
56 32
41 31
42
44
43 EC

400
55 33
34
54
53 45
24
46 25
47 26
52
50 27
51 29

49 28

Sheet 1 of 2

240 Mechanical Service 96-0283 rev C June 2007

 EC-400 E NCLOSURE SHEET METAL

67
68

84 69

83
71 70
72
7
79
80
81 77
82 73

74
78

77 75

View Rotated 908 CCW

76

72
85
Ref

88
86 87
106

33
105

104
89
103

102
90

98
91

99
92
97
95 94
100 96
101 93

Tool Changer Enclosure

Sheet 2 of 2

96-0283 rev C June 2007 Mechanical Service 241

 EC-400 E NCLOSURE SHEET METAL

1. 25-4984 Wire Channel Top Cover 51. 25-5402A

2X Door Hook
2. 25-4965A Left Top Cover 52. 25-4043Door Stop
3. 25-4964A Right Top Cover 53. 25-4950B
Front Upper Pan
4. 25-4953B J-Box Top Cover 54. 20-1433Door V-Track
5. 25-4952 Front Top Cover 20-6016Rail Spacer
6. 25-4980 Wire Channel Top Cover 55. 59-6210Front Door Handle
7. 25-5253 Brace Top Cover 25-1292Door Handle Mount
8. 25-4963 Intermediate Top Brace 56. 25-52602X Front Door Window Z-Frame
9. 25-4957 Rear Center Panel 57. 28-0152Front Door Window
10. 25-4977 Rear Panel Access Cover 58. 25-4997A
Front Door
11. 25-4958 Rear Pan 59. 25-4947A
Front Left Panel
12. 25-5035 Rear Apron 60. 20-2410Door Guide Block
13. 25-6661 Pendant Levelling Assy 61. 25-5420Left Panel Stiffener Bracket
14. 20-1592 Pendant Arm 62. 25-5415Door Guide Bracket
15. Regen Assy 63. 32-5074A
Front Door Close Switch
16. 25-5261 J-Box 64. 25-4971Left Front Apron
17. Control Box Assy 65. 25-4949A
Left Top Side Panel
18. 25-5421 Control Box Skirt 66. 25-4979Left Intermediate Panel
19. 25-1133 Connector Door 67. 25-5030TC Top Door
20. 2X Door Hinge 68. 25-5032Top Connect Bracket
21. 25-1132 Door Mounting Bracket 69. 59-0641Rod Aligner
22. 25-4956 Right Intermediate Panel 70. 25-0974Chain Retainer
25-5200 Operator Door Rear chip Shield 71. 50-0012A
Linear Guide
23. 25-4938 Right Rear Corner Panel 72. 54-0072Chain 96 in.
24. 59-6210 Door Handle 73. 59-0612Air Cylinder
25. 25-4966 Operator Door 74. 25-5033Bottom Connect Bracket
30-7653 4X Door Roller Assy 75. 25-5029TC Internal Panel
59-0604 Door Spring 76. 25-5031TC Bottom Door
26. 25-5198 Operator Lower Panel 77. 25-50343X Door Guide Spacer
27. 25-4982 Right Rear Apron 78. 20-20873X Door Guide
28. 25-4970 Right Front Apron 79. 20-10052X Sprocket Adapter
29. 25-0563 Tool Box 80. 54-00742X Chain Cog 16T
30. 25-6182 Tool Tray 81. 20-05482X Cog Hub
31. 25-4948B Right Side Panel 82. 22-96734X Spacers
32. 20-2036 Upper Operator Door Track 83. 2X Shaft
20-2038 Lower Operator Door Track 84. 50-0075 2X Bearing
33. 25-0440 Tool Crib 85. 25-4960B TC Panel Header
34. 25-5228 2X Operator Door Window Z-Frame 86. 25-5284 Left Chip Shield
35. 28-0151 Operator Door Window 87. 25-4976 Coolant Drip Pan
36. 25-4954 Right Side Header 88. 25-5283A TC Front Chip Shield
25-4973 Header Chip Shield 89. 25-4961 TC Pan
32-2313 Door Close Switch 90. 25-4985 Chip Shield Lower Panel
25-4990 Door Trip Bracket 91. 25-4979 TC Intermediate Left Panel
37. 25-4999A Enclosure Header 92. 25-4987 Lower Left Panel Chip Shield
38. 25-4951 Front Corner Panel Stiffener Bracket 93. 25-4962 TC Panel
39. 25-5456 Front Door Guide Rail 94. 28-0151 TC Window
40. 20-2411 Door Stop Block 95. 25-5228 2X TC Window Z-Frame
41. 59-0053 2X Edge Trim 96. 25-4972 Right Rear Apron
42. 25-4969A Front Right Panel 97. 25-5247 Left Rear Apron
43. 25-1257A Switch Box 98. 32-1114 TC Remote Switch Box
25-1258 Switch Box Cover 25-6719 Switch Box Cover
57-0195 Switch Box Cover Gasket 99. 25-4220 Window Rest
44. Switch Assy 100.25-5991 TC Side Panel
45. 20-1341 Tool Holder 101.28-0167 TC Window Extrusion
59-0278 Knob and Screw 102.25-4221 Window Rest Opposite
46. 25-0798 Tool Holder Mounting Bracket 103.25-9248 Window Plate Handle
47. 25-5412 Nozzle Holding Bracket 104.28-0168 TC Access Window
49. 25-4969 Front Apron 105.25-4978 TC Rear Panel
48. Not Used50. 54-00302X Guide Wheel 106.25-4959C Left Rear Corner Panel

242 Mechanical Service 96-0283 rev C June 2007

 EC-400 INTERNAL SHEET METAL

67 68 69 11 12 1
66 2
13 10
65
9
3
64
70
63 14 8

62 15 7 4

6
61
View Rotated
60 908 CCW
5
59 58
57

56
55 16

54 50
51
52 17
53 28

48 29
18
49
47 19
46 20
30

31
45
27
26
44
32 21
25 22
43 34

42
23
24
41 35

40
36
39 3
38 37
View Rotated 908 CW

96-0283 rev C June 2007 Mechanical Service 243

 EC-400 INTERNAL S HEET METAL

1. 25-5007 Y-Axis Frame Top Bracket 53. 25-5231 Z-Axis Front Waycover
2. 25-5001 Y-Axis Right Guide 54. 25-5229 Right Bridge Chip Shield
3. 59-0608 Right Roll-up Waycover 55. 25-5230 Left Bridge Chip Shield
4. 25-5008 Y-Axis Frame Bottom Bracket 56. 25-5235 2X Rotating Door Right Step Shield
5. 25-5006 X-Axis Bottom Shield 57. 25-5046 APC Cylinder Shield
6. 59-0606 Y-Axis Lower Waycover 58. 25-5237 4X Z-Axis Rotating Door Shade Seal
7. 25-5000A Y-Axis Left Guide 59. 20-2283A 2X Rotating DF Support Bar
8. 25-5002 Spindle Cover 60. 25-5233 2X Rotating Door Z-Channel
9. 25-5327 P-Cool Mounting Bracket 61. 25-1262 4X Partition Top z-Frame
10. 59-0607 Left Roll-up Waycover 62. 28-0043 2X Window
11. 59-0605 Y-Axis Upper Waycover 63. 25-4149 4X Window Z-Frame
12. 20-2319A Y-Axis Frame Plate Filler 64. 25-5232 Rotating Door Panel
13. 25-4152A SMTC 40-40 Front Cover 65. 25-5234 Rotating Door Cover
14. 25-0800 SMTC 40-40 Corner Shroud 66. 20-2284 2X Rotating Door Cable Fairlead
15. 25-4153A SMTC 40-40 Rear Cover 67. 25-5239 2X Rotating Door Retainer Seal
16. 20-3035 GR Ram Machined 68. 57-0330 2X Rotating Door Cover Seal
17. 20-2031 Control Box Support Bar 69. 25-4983 2X Rotating Door Splash Shield
18. 30-6316 Lube Panel Assy 70. 25-5238B 2X Rotating Door Top Shade
19. 25-4942 Wire Channel Panel
20. 25-4940A 2X Panel Side Brace
21. 25-5360 Auger Keeper Right Bracket
22. 25-4967 lower right Front Chip Shield
23. 25-4994 Right Front Pan
24. 25-4981 Lower Front Pan
25. 25-4995 Left Front Pan
26. 25-4987 Lower Left Panel Chip Shield
27. 25-5361 Auger Keeper Left Bracket
28. 25-0548 Auger Chute
29. 25-5301 Coolant Trough Extension Cover
30. 25-5300 End Chute Cover
31. 57-9846 Auger Chute Gasket
32. 25-5025 Coolant Trough Extension
33. Not Used
34. 57-0334 Coolant Trough Extension Gasket
35. 25-5288 Coolant Trough
36. 25-4944 2X Auger Trough Brace
37. 57-0333 Extension Box Gasket
38. 20-2322 Auger Coupler Extension
39. 57-9265A Conveyor Motor Gasket
40. 25-5289 Auger Motor Extension Box
41. 57-0332 Extension Box Top Gasket
42. 25-5290 Extension Box Top
43. 25-5024 Auger Trough
44 25-5299 Auger Trough Screen
45. 25-5297 Coolant Channel
46. 25-5291 Chip Basket
47. 25-5521 Rear Auger Trough Seal
48. 25-5256 Front Left Auger Guard
49. 25-5255 Front Right Auger Guard
50. 57-0304 Bulkhead Waycover Gasket
51. 25-5011 Bulkhead Waycover
52. 57-0327 Waycover Gasket

244 Mechanical Service 96-0283 rev C June 2007

 EC-400 60-40 T OOL C HANGER

18 19 20
17 21 22

14

11 12

24 23
6
4 5 ATC Assembly
25

Load Position

15 16

1 2 3 7 8 9 10 13

14. 20-2864A Pivot Packet

1. 40-0226 SHCS ¾”x3"
15. 51-0045 Cam Follower
2. 59-0737 Plug Hole
16. 20-2913 Plate Index
3. 20-2911A Hub Index Plate
17. 20-0458A Tool Pockets
4. 20-2911A Hub Index Plate
18. 20-2828 Pocket Carousel
5. 20-2868A Shaft Assembly
19. 30-0145 Cambox Assembly
6. 40-1663 SHCS ½”-13x1¾”
20. 20-0455 ATC Cambox
7. 25-6029 Panel Tools (31-45)
21. 20-0238 Bearing Cap
8. 25-6030 Panel Tools (46-60)
22. 20-2825A Machining Mount
9. 25-5998 Disk Section (1)
23. 20-2121 Double Arm
10. 25-6021 Panel Tools (1-15)
24. 20-0240F Hub Arm
11. 25-6022 Panel Tools (16-30)
25. 20-2867 Stop Pocket
12. 25-5998 Disk Section (2)
13. 20-2966 Carousel Ribs

96-0283 rev C June 2007 Mechanical Service 245

 EC-400 B ASE C ASTING

1 2 3 4 5 6 7 8

15

10
1

3
14

11
6

12

13 8

9
1. 62-0016 Motor
2. 32-2130 Limit Switch
3. 30-1215 Ball Screw Coupling
4. 20-9212 Bearing Housing
5. 20-2042 Casting
6. 24-0026 Ballscrew
7. 20-2084 Hard Stop X-Axis
8. 20-0152 Bearing Housing
9. 50-3400 Linear Guides
10. 20-0151 Motor Mount Assy.
11. 32-2134 Limit Switch
12. 20-2450 Z-Axis Bumper
13. 30-6336 Z-Axis Lube Assy.
14. 20-1992 Bumper
15. 30-6337 X-Axis Lube Assy.

246 Mechanical Service 96-0283 rev C June 2007

 EC-400 O PERATOR ' S D OOR

16 17 1
15

14

2
13
3

4
12
5

11

6
10

9 8

1. 25-4954 Right Side Header

2. 20-2036 Operator Door Upper Track
3. 25-5228 2X Operator Door Window Z-Frame
4. 28-0151 Operator Door Window
5. 25-4966 Operator Door
6. 20-2038 Door Track Lower
7. 25-5198 Operator Lower Panel
8. 25-4955 Right Intermediate Pan
9. 25-4982 Right Rear Apron
10. 25-5246 Chip Shield
11. 25-5245 Chip Shield Lower Operator Panel
12. 25-5200 Chip Shield Rear Operator Door
13. 25-4973 Chip Shield Header Operator Door
14. 25-4956 Right Intermediate Panel
15. 25-4990 Trip Bracket Operator Door
16. 32-2313 Operator Door Close Switch
17. 30-7653 Door Roller Assembly
59-0604 Operator Door Spring

96-0283 rev C June 2007 Mechanical Service 247

 EC-400 IN -LINE S PINDLE A SSEMBLY
1 2

12
11
3

4
10 5

9
8 7

13 16

14

15

1. 20-1686A Key Drawbar Inline 12. 20-1687A Guide Release In-line

2. 20-1693B TRP Cylinder In-Line 13. 25-4648B 2X Bracket Switch Mounting In-line Spindle
3. 20-1688 Transfer-Tube In-line 14. 20-1696A TRP Spring Retain Inline
4. 25-4761 2X Shim TRP In-Line 15. 20-1691 TRP Shaft In-Line
5. 20-1694A Standoff Motor In-Line 16. 52-0040 Shaft Coupling
6. 20-1690 Striker Plate Inline
7. 20-7422D Oil Injector Cover
8. 20-7016C Spindle Houseing 40T
9. 20-9763C Spindle Lock Tapered
10. 20-7018M Spindle Shaft 40T
11. 20-1684A Adapter Shaft In-line

248 Mechanical Service 96-0283 rev C June 2007

 EC-400 SPINDLE H EAD ASSEMBLY 1
2
3

16 7
15
14
13
12
11 8
10 9

34
18 19 20
17 21
22
23

24
33
25
26
27

28
32 29
31
30
View Rotated 1808 Looking Up
1. 58-1680 Fitting Bkhd NPT 1/2x1.125 Dia. 18. 30-4095 TRP Soleniod Assembly
2. 20-7381A Plate, Prog Coolant 19. 25-5241 Bracket Clamp TSC
3. 32-0199 Condit Assembly P-Cool 20. 30-6465 TSC Switch Assembly
4. 20-7384A Nozzle Body 21. 25-5242 Bracket Shroud
5. 14-1905 P-Cool Cover 22. 36-3035 Fan Assembly Spindle
6. 25-5327 P-Cool Mounting Bracket 23. 25-5264 Brkt Cable Carrier Y-Axis
7. 58-3694 1/4 Valves Loc-Line 24. 59-0144 Fan Guard 8.75 in.
8. 58-1722 Fitting NPT 3/8F x NPT 3/8M 90 Degree 25. 25-5215 Bracket Fan In-Line Spindle
9. 58-1686 Fitting NPT 1/4M x NPT 3/8F 26. 25-5213 Shroud Motor In-Line
10. 58-0326 3/8 Full Pivot Ball Valve 27. 25-5017 Cable Tray Spindle Head
11. 58-3052 Fitting Comp 1/2 x NPT 3/8M 90 Degree 28. 73-3055 Therm Blk 6-Pole
12. 30-6460 Spindle Assmbly 12K in-Line 29. 25-5216 Strap Spindle Motor Lift
13. 58-0674 Tube Coolant P-Cool 30. 20-2248 Plate Motor
14. 52-0035 P-Cool Hose 31. 20-1694A Stand Off Motor In-Line
15. 58-3049 Fitting Comp 1/2xNPT 3/8 Str 32. 20-2044 Spindle Head Machined
16. 25-5366 Brkt Mounting Air Soleniod Assembly 33. 20-2063 Coolant Block
17. 25-5012 Trip Bracket Y-axis 34. 30-6338A Oil Line Assembly Y-Axis

96-0283 rev C June 2007 Mechanical Service 249

 EC-400 T OP C OVER

3 8

4 9

6
10

1. 25-4952 Top Cover Front

2. 25-4963 Brace Top Intermediate
3. 32-0196 Worklight Assembly
4. 25-4964 Top Cover Right
5. 25-4980 Wire Channel Top Cover
6. 25-4965 Top Cover Left
7. 25-4983 Splash Shield Rotating
8. 25-5253 Cover Brace Top
9. 25-4953 J-Box Top Cover
10. 25-4984 Cover Wire Channel Top

250 Mechanical Service 96-0283 rev C June 2007

 EC-400 60 AND 70-T OOL T OOL C HANGER PANELS

1
2
17

18
3
19
4
48 20
16 21
5
15
14 6

13
7
12

22
8
9 23
10 24
11
49 25

3 27
28 19
1 26
SMTC 60 Pocket Only

18
29
42 37 TC Door Assembly

36
48 38
30
43
31

32

35 33
39
34

41
40
44

45
47 46
SMTC 60 Pocket Only TC Door Assembly
(View Rotated 1808) (View Rotated 1808)

96-0283 rev C June 2007 Mechanical Service 251

 EC-400 60- AND 70-TOOL TOOL C HANGER P ANELS

1. 25-4979 Left intermediate panel

2. 25-4962B Tool changer panel
3. 28-0168 TC access window
4. 25-9248 Plate window handle
5. 25-6718A SMTC switch box
25-6719 SMTC switch box cover
6. 25-5991A SMTC side panel
7. 25-4961A TC pan
8. 25-4972 Left rear apron
9. 55-0671 Coolant drain tube
10. 25-5247 TC panel rear apron
11. 58-1679 Bulkhead fitting
58-1693 LBO fitting (2)
12. 52-6042 TSC filter
13. 25-7581B TSC filter bracket
14. 25-4978A TC rear panel
15. 25-0440A Tool tray
16. 25-4959C Left rear panel
17. 25-4960B TC panel header
18. 22-9673 Spacer (2)
19. 30-2464 Idler assembly
20. 25-0974 Chain Retainer
21. 25-5032 TC door top connect bracket
22. 54-0072 Chain
23. 50-0012A Linear guide
24. 59-0641 Cylinder rod aligner
25. 59-0612 Air cylinder
26. 25-5033 TC door bottom connect bracket
27. 25-4221A Opposite window rest (2)
28. 28-0167 TC window extrusion (2)
29. 25-5284A TC left chip shield 24TL
30. 25-5295 TC left chip shield 40TL
31. 25-4976 TC coolant drip pan
32. 25-4961 TC pan
33. 30-6753 Coolant fitting assembly
34. 25-4985 TC panel lower chip shield
35. 25-5283 TC front chip shield
36. 28-015 Window TC panel operator door
37. 25-5228 TC operator door window Z-frame
38. 25-5030 Top door
39. 20-2087 Door guide
25-5034 Door guide spacer
40. 25-5031 Bottom door
41. 25-5029 TC internal panel
42. 25-5992A SMTC60 top panel
43. 25-5994A SMTC70 rear panel
44. 25-5996A SMTC70 rear chip shield
45. 25-5995 SMTC60 front chip shield
46. 25-5283A TC front chip shield
47. 25-4987 Left lower panel chip shield
48. 25-4986 Left upper panel chip shield
49. 25-5993B SMTC70 bottom pan

252 Mechanical Service 96-0283 rev C June 2007

 EC-400 FRONT TROUGH ASSEMBLY (AUGER SYSTEM )

20 21 24
19 2
22 3
18

17 4

23 5

6
16
15
14
13

12

11 10

1. 57-0334A Gasket Coolant Trough 17. 59-0661 Nozzle Assembly Screen Washdown
2. 25-0548 Chute Discharge 18. 58-2071 Fitting Comp 1/2 x NPT 1/2M
3. 25-5300 End Chute Cover 19. 58-1679 Fitting BKHD NPT 3/8 x 1 Dia
4. 25-5301 Coolant Trough Extension Cover 20. 58-1722 Fitting NPT 3/8F x NPT 3/8M 90 Brass
5. 25-5025 Extension Box Front Trough 21. 58-3644 Nipple 3/8 NPT x 2 1/2 Brass
6. 57-9846C Gasket Discharge 22. 25-5291A Chip Basket
7. 25-5297A Coolant Channel 23. 58-1693 Fitting LBO 1/2 NPT 3/8M STR
8. 20-2039 Auger Front 24. 58-1693 Fitting LBO 1/2 NPT 3/8M STR
9. 25-4944 (2X) Brace Auger Trough
10. 25-5289 Extension Box Auger Motor
11. 62-0050 Motor 115V 1/4HP 15 RPM
12. 57-0332 Gasket Extension Box Top
13. 25-5290 Extension Box Top
14. 25-5024A Front Auger Trough
15. 25-5288A Coolant Trough
16. 25-5299A Auger Trough Screen

96-0283 rev C June 2007 Mechanical Service 253

 EC-400 FRONT TROUGH ASSEMBLY (CHIP CONVEYOR SYSTEM)

10
9

7 2
3
4

6
5

1. 30-6477B Chip Conveyor

2. 25-5309 Chip Conveyor Extension Cover
3. 25-5025A Coolant Trough Extension
4. 57-0334A Coolant Trough Gasket
5. 25-4944 2X Auger Trough Brace
6. 25-5292 Motor Access Cover
57-0333 Extension Box Gasket
7. 25-5288A Coolant Trough
8. 58-0336 Pipe Plug 3/8 Brass
9. 58-1679 Fitting Bulkhead NPT 3/8 x 1
10. 25-5308A Conveyor Chip Shield

254 Mechanical Service 96-0283 rev C June 2007

 EC-400 B ULKHEAD

1 2

3
1

10
2
9
6
1
7
8

1. 58-3680 3X Fitting, LBO 3/8 x NPT 1/4 M STR

2. 58-3618 2X Fitting, NPT 1/4F x NPT 1/4M 90 Brass
3. 58-1677 Fitting, BKHD NPT 1/4 x .750 Dia
4. 25-5009 Base Cover Bracket
5. 25-5006 X-Axis Bottom Shield
6. 25-5003 Base Cover
7. 25-5004 Right Trough Cover
8. 20-6413A Manifold Washdown
9. 25-5005 Left Trough Cover
10. 25-5010 Left Base Cover Shield

96-0283 rev C June 2007 Mechanical Service 255

 EC-400 COLUMN A SSEMBLY

14
1 2
13
3
4
12 3

11 5
15
10 29 16
17

27 18

28 19
20
27
6
9 21

22
26
8 23

25

7 24

Back View (Looking Up)

1. 20-2043 Column Machined 20. 25-5294 Bracket TRP

2. 25-4996 BRKT Carrier Column 21. 58-1680 Fitg Bkhd
3. 58-3045 Lube Fitg Adaptor 22. 58-2066 Fitg Hose Barb
4. 58-3045 Lube Fitg Adaptor 23. 25-4937 Trip Bracket X-Axis
5. 58-0634 Copper Tubing Column 24. 20-0150 Nut Housing
6. 22-7458 Cam Linear Guide 25. 30-6337 Oil Line Assembly X-Axis
7. 58-3031 Lube Fitg Adaptor 26. 58-0634 Copper Tubing Column
8. 20-0166 Bumper 27. 58-0029 Fitg Hose Barb
9. 50-3400 Linear Guide 28. 58-1679 Fitg Bkhd
10. 20-2058 Hardstop Y-axis 29. 59-0640 Cable Carrier Y-Axis
11. 25-7267 Mounting Bracket
12. 32-2131 Home Switch
13. 30-6338A Lube Line Assy.
14. 62-0017 Servomotor YASK 13
15. 58-1693 Fitg LBO
16. 58-3625 Fitg Reducer
17. 58-3650 Fitg
18. 58-0097 Fitg LBO
19. 58-0287 Hex Nipple

256 Mechanical Service 96-0283 rev C June 2007

 EC-400 PALLET CHANGER ASSEMBLY

27 1 2

26

25 3

24
4

23 6

8
9

10

22 11

21
12
13

20 14
18 17 16 15
19

1. 25-5238B Shade Rotating Door Top 14. 20-2249 Load Station Pallet Pin
2. 25-4149 Z-Frame Window SMTC 15. 20-2256 Load Station Index Disc
3. 28-0043A Window Partition 16. 20-2258 Load Station Shaft
4. 25-1262A (2X) Z-Frame Partition Top 17. 20-2154B APB H-Pin
5. 25-5233A (2X) Z Channel Rotating Door 18. 20-2115 H-Frame APC
6. 20-2283A (2X) Support Bar Rotating Door 19. 20-2046 Bridge Machined
7. 25-5237 (4X) Shade Rotating Door Seal 20. 25-5230 Chip Shield Bridge Left
8. 20-2048 Pallet 21. 25-5235 Step Right Rotating Door Seal
9. 25-5229 Chip Shield Bridge Right 22. 20-3208 Pin Short APC H-Frame
10. 20-2254 Load Station Lock Housing 23. 25-5232B (2X) Panel Rotating Door
11. 59-6225 Knob 24. 25-5239A Retainer Seal Rotating Door
12. 20-2255 Load Station Lock Pin 25. 57-0330 (2X) Seal Rotating Door Cover
13. 20-2253 Load Station Lock Mount 26. 25-5234B Rotating Door Cover
27. 20-2284B (2X) Cable Rotating Door

96-0283 rev C June 2007 Mechanical Service 257

 EC-400 RECEIVER ASSEMBLY

1
2

3
4
5 6
7

8
9
10 11 18
12
49 19
13 22 23 24
20

14
15 25
16
46 17
26 21
27
48
47 28
45 44
29
30
32
33
36 34
35 31
43
37
42 10
38
39
40
41

258 Mechanical Service 96-0283 rev C June 2007

 EC-400 RECEIVER A SSEMBLY

1. 20-1123A Pallet plug 36. 20-4213 Disc brake

Parker O-ring 2-135 57-2144 O-ring 2-256
2. 20-2048A Pallet machined 57-4288 Thrust bearing
3. 40-1639 SHCS 3/8-16x1 (8) 37. 20-4236 Spindle spacer
4. 20-1995 Receiver clamp plate 40-1636 SHCS (6)
5. 30-6551 Air blast assembly 38. 20-1998A Receiver rotary union
6. 48-1667 Dowel pin 1/2x3 ½ (2) 39. 20-2344 Rotary union lower washer
7. 20-2041 Receiver body machined 40. 45-0075 Steel washer 5/16
57-0328 O-ring 2-339 viton (2) 41. 43-0023 HHB 5/16-18x1 ½ pltd
25-5252 Receiver wear surface (2) 42. 25-5231 Front way cover Z-axis
57-0337 V-ring seal 43. 57-0327 Fixed way cover gasket
40-16575 SHCS (8) 44. 30-6336 Oil line assy Z-axis
8. 20-1994 Receiver piston 45. 20-0150 Ballnut housing machined
25-5250 Piston wear surface 46. 20-2330B Rotary axis switch arm
9. 57-0329 O-ring (2) 47. 20-2473 Bar-spring mount assy
10. 20-1996A Receiver shaft 48. 20-2023A Ballnut spacer Z-axis
57-0328 O-ring (3) 49. 69-1700 Proximity switch (2)
57-5148 O-ring
11. 20-1997 Receiver nut
12. 20-1999A Receiver seal plate
40-1500 SHCS (16)
13. 20-2022A Rotary table platter
43-1600 SHCS (8)
45-0114 Washer (8)
40-1646 SHCS (8)
45-0038 Washer (8)
14. 2-4285 Face Gear (2)
15. 57-0337 O-ring
16. 35-4284A Spindle gear assy
48-0035 Dowel pin 3/8 x ¾
57-2121 O-ring 2-161
17. 57-0337 O-ring
18. 25-5011 Right tele Z-axis way cover
19. 57-0326 Right tele way cover gasket
20. 25-6305 Z-axis Cable tray
21. 25-6304 Cable tray bracket
22. 20-2071 Rotary motor mounting plate
23. 25-5018A Receiver solenoid mount
24. 62-0016 Servo motor
25. 54-4505 Drive belt PGGT 5Mx15
26. 20-4506 Driven pulley 310-64T
20-4229 Driven pulley lockring
27. 30-6774A Rotary index solenoid assy
28. 25-5027 Z-axis cable carrier bracket
29. 20-1991 Z-axis shipping pin
30. 25-4968 Rotary table side chip shield
31. 35-4210 Worm shaft assembly
32. 20-2045B Rotary table index machined
33. 57-4282 O-ring 2-248
34. 20-4286 Lift piston
51-4285 Thrust washer (2)
51-4286 Thrust bearing
35. 57-0139 O-ring 2-263

96-0283 rev C June 2007 Mechanical Service 259

 EC-1600 B ASE A SSEMBLY

1. 20-2509 Casting
2. 30-6953 Lube Line Assy
3. 30-0472 Bearing Assy
4. 32-2133 Limit Switch
5. 30-1222 Bearing Assy
6. 30-3988 Coupling
7. 20-0151 Motor Mount Assy
8. 62-0008 Motor
9. 50-9010 Linear Guides
10. 24-9960A Ballscrew Assy
11. 20-0150 Nut Housing
12. 20-0156 Bumper

260 Mechanical Service 96-0283 rev C June 2007

 EC-1600 COLUMN ASSEMBLY

1. 20-2506 Casting
2. 62-0017 Motor
3. 30-1517 Coupling
4. 30-0764 Bearing
5. 32-2131 Limit Switch
6. 24-0003A Ballscrew
7. 30-0472 Bearing Assy
8. 20-0156 Bumper
9. 30-6954 Lube Line Assy
10. 20-267 Bumper
11. 50-9010 Linear Guides
12. 25-7267 Switch Brkt

96-0283 rev C June 2007 Mechanical Service 261

 EC-1600 SADDLE ASSEMBLY

1. 20-2536 Casting
2. 20-0151 Motor Mount Assy
3. 32-2133 Limit Switch
4. 25-7267 Switch Brkt
5. 30-7410 Lube Line Assy
6. 20-0150 Nut Housing
7. 20-0152 Bearing Housing
8. 20-9822 Guide Bar
9. 24-9961C Ballscrew
10. 50-9806 Linear Guides
11. 30-1222 Bearing Assy
12. 30-1215 Coupling Assy
13. 20-0166 Bumper
14. 62-0016 Motor

262 Mechanical Service 96-0283 rev C June 2007

 EC-1600 ENCLOSURE ASSEMBLY
7 8 2
9
34 35
33 36
6 1 32
37
5
38
4

10

40

2 46
43
11
45 44 39
1
41
42
16
17
15 18

14

11 47
13
21

12

48

19 20

31 50 49
25

29
22
30
30. 25-5609 Saddle End Cover LT
23 31. 25-5613 Saddle Back LT
32. 25-5597B Panel Encl
33. 25-5596B Panel Encl
24 34. 25-5585B Dip Pan T/C
25 35. 25-5601C Panel Encl L R
28 13. 25-5619 Front Door
27 36. 25-5594B Panel Encl Top
14. 28-0020 Window 37. 25-5588B Panel Encl R Upper
15. 59-6210 Door Handle 38. 25-5587C Panel Encl Rear Mid
16. 54-0030 Guide Wheel 39. 25-5590 Panel Cbl Encl
26
17. 25-5653 Retainer 40. 25-5592B Panel Encl RT Rear
1. 25-5615 Panel Encl Top 18. 20-2579 Stand-off Bumper 41. 25-5593A Panel Encl RT Side
2. 25-5621 Post Encl Top Cross 19. 20-2573 Track, Front Door 42. 25-5591A Door, Operator
3. 25-5622 Track Encl Door Roll 20. 25-5608 Saddle Back RT 43. 25-5600B Panel Encl Left Side
4. 25-5623 Post Encl LT Top 21. 25-5638 Saddle End Cover 44. 25-5599B Panel Encl LT Side F
5. 25-5625 Cover Encl Top LT 22. 25-5610 Saddle Front RT 45. 25-5582B Drip Pan T/C Bottom
6. 25-5627 Cover Encl Top RT 23. 25-5611 Saddle Front Mid 46. 25-5598B Panel Encl R L
7. 25-5624 Post Encl RT Top 24. 25-5612 Saddle Front LT 47. 25-5595B Panel Encl T/C Fillet
8. 25-5629 Header Support 25. 25-5643 Silt Plate 48. 25-5642B Panel T/C Back
9. 25-5618 Panel Encl Top Door 26. 25-5640 Trough Drain 49. 25-5586B Support, T/C D Pan
10. 25-5614 Panel Encl Top 27. 25-0548 Discharge Chute 50 25-5581B Retainer
11. 25-5616 Panel Encl Side 28. 19-8612 Screen, Chip Tray
12. 25-5617 Main Post Encl 29. 25-5639 Plenum Drain

96-0283 rev C June 2007 Mechanical Service 263

 EC-1600 SPINDLE A SSEMBLY

4
3 5

13
2 30
12 14
1
11 15
31
32 16
10 17
18
6
9
7
8 19

22 20
23 21
28 27 24
29
26 25

1. 20-0011A 50T Shaft Spindle 27. 20-2962 Read Head Mount

2. 20-0001A Spindle Lock 28. 50-9010 Linear Guide
3. 30-7395 EC-1600 P Cool 29. 20-2507 Spindle Head
4. 30-7394 Plumbing Assembly 30. 57-0372 Head Cover
5. 20-0004 50T spindle Housing 31. 57-0372 Encoder Cover Gasket
6. 30-6954 Lube Line Assembly-Y Axis 32. 25-5565 Encoder Cover
7. 32-1457 Encoder
8. 60-1813 Encoder M23 Short
9. 20-2965B Standoff Rod
10. 20-0726 Transmission Subplate
11. 20-0017 Air Cylinder Subplate
12. 20-6097 Coolant Manifold
13. 25-6096 Manifold Cover
14. 58-3062 3/8 NPT Elbow
15. 58-1725 3/8 NPT Tee
16. 30-0013 TRP Assembly
17. 59-0144 Fan Guard
18. 25-5649 Fan Mounting Shroud
19. 62-4010 20HP Spindle Motor
20. 30-3260C Gear Oil Pump Assembly
21. 25-5647 Spindle Motor Shroud
22. 30-7255 Check Value Assembly
23. 30-7280 TRP/TSC Solenoid Assembly
24. 20-2549 Trans Plate
25. 25-6292 Spindle Sound Shield
26. 20-1455 50T Pully

264 Mechanical Service 96-0283 rev C June 2007

 EC-1600 TOOL RELEASE PISTON

18
8 11 12 16 17
7 10 15
TSC
27
4 19
29 8 13
28 3 6
7 11
26
4 14
3 6
9
2
24
5
23
9
22
1 6

25
Standard 50T
21 Sub Plate
20 9

1. 20-0018 Air Cyl. Shaft

2. 57-0027 O Ring 2-121 (4X)
3. 57-0082 O Ring 2-448 (2X)
4. 20-0019 Air Cyl. Piston (2X)
5. 20-0020 Lower Air Cyl. Spacer
6. 57-0095 O Ring 2-327 (3X)
7. 48-1662 Dowel Pin (6X)
8. 20-0022 Air Cyl. Housing
9. 58-1695 90 Degree Elbow (3X)
10. 20-0021 Upper Air Cyl. Spacer
11. 25-0009 Switch Bracket (2X)
12. 32-2204 Clamp Prox Switch
13. 32-2203 Unclamp Prox Switch
14. 40-0006 SHCS ½-13x5 (8X)
15. 59-0049 Compression Spring
16. 20-1657 Spring Retainer
17. 52-0003 Shaft Clamp
18. 58-3631 Reducer
19. 58-3050 90 Elbow
20. 20-0015 Spindle Fork Lift
21. 20-0013 Spindle Fork Spacer (4X)
22. 20-0014 (22-0014) Spacer (4X)
23. 45-0014 Washer .010
24. 45-0015 Washer .018
25. 20-0017 Sub Plate (EC-1600)
26. 20-2988 Sub Plate
27. 20-7655 Bearing Holder
28. 20-7654 Extension Tube
29. 52-6200 Rotating Union

96-0283 rev C June 2007 Mechanical Service 265

 EC-1600 T ABLE A SSEMBLY

(5° Indexer)
13

14

12
15
11
16
10
9 17

18

8 7 19 20

5 6
3
1 2 4
27
28 21

24
29
25

35 26
22
34 30 31

32
33 23

1. 25-5541 Left Shroud 21. 20-2508 Table

2. 25-5542 Top Shroud 22. 30-7410 Saddle Oil Line
3. 25-5544 Pump Cover Access 23. 30-7510 Haskel Pump
4. 57-0373 Pump Cover Gasket 24. 25-55545 Pump Sound Wall
5. 32-6929 Hydraulic Solenoid 25. 69-1700 Prox. Sensor
6. 25-5546 Hydraulic Valve Bracket 26. 20-2532 Sensor Bracket
7. 20-2528 Zero Ref. Sensor Mount 27. 20-2527 Pinion 22T Indexer
8. 20-6103 Ring Gear 28. 20-1400 Backlash Plate
9. 20-2523 Hydraulic Clamp Cylinder Housing 29. 20-2526 Indexer Mount
10. 51-0162 160mm Thrust Bearing 30. 25-5539 Shroud Support
11. 20-2524 Hydraulic Clamp Piston 31. 20-2531 Platter Drive Mount
12. 20-2529 Face Gear 32. 59-0695 Alpha Ip 120
13. 20-0973 Table Cover Center 33. 62-0024 Servo Motor
14. 20-2980 Indexing Platter 34. 25-5540 Right Shroud
15. 20-2530 Piston Adapter 35. 25-5543 Bottom Shroud
16. 51-0168 Thrust Washer 160200 (2)
17. 20-2522 Hydraulic Clamp Cylinder Cap
18. 69-1700 Prox. Sensor
19. 25-5538 Retainer Platter Seal
20. 25-9817 X-Axis Chip Guard

266 Mechanical Service 96-0283 rev C June 2007

 EC-1600 TABLE A SSEMBLY (F ULL-F OUTH I NDEXER)

17
18
16
15
14
13
19
12
11
10
8 9
7 20
21
6

5
3
2
1 34
4 22
35 23
36
24
37 25 26
33
38
43 39
40 27
42 32 31
28
41 30 29

1. 25-5541 Left Shroud 22. 20-2508 Table

2. 25-5542 Top Shroud 23. 30-7410 Saddle Oil Line
3. 25-5544 Pump Cover Access 24. 30-7881 Brake Booster Assembly (with Sensor)
4. 57-0373 Pump Cover Gasket 25. 58-2267 Muffler
5. 30-7398A Hydraulic Solenoid Assembly 26. 59-0216 Booster
6. 32-1459 Encoder Assembly 27. 58-1696 Elbow
7. 52-4471 Coupling 28. 58-0051 Connector
8. 20-6115 Encoder Shaft 29. 59-0047 Quick Exhaust Valve
9. 20-6114B Encoder Mounting Plate 30. 58-3658 Elbow (2x)
10. 20-6027 Coupling Tube 58-1671 Nipple
31. 58-0315 “T”
11. 20-6103 Ring Gear
32. 52-0014 Pressure Guage
12. 30-7754 Hydraulic Brake Assembly 33. 25-5547 Booster Mounting Bracket
13. 20-6113 Bearing Retainer Ring 34. 20-6102 Pinion Gear
14. 51-2038 Cross Roller Bearing 35. 20-6100 Cooling Jacket Inlet Plate
15. 20-2534 Encoder Shaft Plate Adapter 36. 20-1400 Backlash Plate
16. 20-6116 Encoder Shaft Plate 37. 59-2930 Harmonic Drive (50:1)
17. 20-0973 Table Cover Center 38. 20-2531 Platter Drive Mount
18. 20-2510A 4th Axis Platter Machined 39. 20-6110 Motor Shaft Spacer
19. 69-1700 Prox. Sensor 40. 20-6109 Motor Adapter
20. 25-5538 Retainer Platter Seal 41. 62-0014 Motor
21. 25-9817 X-Axis Chip Guard

96-0283 rev C June 2007 Mechanical Service 267

 HS3-7R HARMONIC DRIVE A SSEMBLY

1. 20-6047 Tube Backlash Adjuster (HS3R) 1

2. 20-6048 Cam Backlash Adjuster (HS3R)
3. 20-6005 Push Block (HS3R)
4. 20-6102 Pinion Gear (HS3R) 2
5. 20-6109 Sigma Adapter (HS3R)
6. 59-2930 Harmonic Drive
7. 20-6112 Shoulder Washer (HS3R)
8 22-2627 Yasakawa Motor Key 3
9. 59-2930 Harmonic Drive Assy
10. 20-6108 Gearbox Adapter (HS3R)
11. 62-0014 Yaskawa Sigma Motor

5
7

6
9

10
8

11

12

268 Mechanical Service 96-0283 rev C June 2007

 HS3-7R T ABLE A SSEMBLY

1
1. 20-6101 Machined Platter
2. 20-6103 Ring Gear
3. 30-7754 Brake Assy
4. 51-2038 Bearing Crossroller
5. 20-6113 Bearing Retainer Ring
6. 20-6100 Table Machined (HS3R)
20-1511 Table Machined (HS6R-7R)

5
6

96-0283 rev C June 2007 Mechanical Service 269

 HS3-7R ENCODER ASSEMBLY

20-6006
Encoder Cover Plate

20-6116
Set Screws Encoder Shaft Plate

20-6027
20-6115
Encoder Coupler Tube
Encoder Shaft

20-6114
52-4471 Encoder Mounting Plate
Encoder Shaft Coupling

20-6025
Encoder Mounting Cup

32-1459
Encoder

270 Mechanical Service 96-0283 rev C June 2007

 HS-3 S HEET METAL AND P ARTS L IST 1
2
4 5

3 7

6 11
9 8 10
15
2

0
12
13
14

16 17
18
19 21
19
25 23
24
22
26

34 27 28 30
32
29

35 31
34
36
33

36
35

1. 25-0528 Back panel sheet metal 20. 25-0448 Z-Axis chip conveyor tray, left
2. 25-0163 Y-Axis bellows top edge cover 21. 25-0449 Z-Axis chip conveyor tray, right
3. 59-0268 Y-Axis upper bellows 22. 25-6043 Z-Axis chip conveyor brace (6)
4. 25-6017 Y-Axis splash cover 23. 57-0085 Z-Axis chip conveyor tray gasket (2)
5. 25-6051 Door enclosure 24. 25-6054 X-Axis splash guard
6. 25-6017 Y-Axis chip guard 25. 25-0450 X-Axis chip conveyor tray, left
7. 25-6057 Conduit enclosure 26. 25-0548 Chip conveyor chute
8. 25-6026 Head cover, right 27. 57-0086 X-Axis chip conveyor tray gasket
9. 25-6025 Head cover, left 28. 25-0451 X-Axis chip conveyor tray, middle
10. 25-6057 Conduit enclosure access plate. 29. 25-0452 X-Axis chip conveyor tray, right
11. 25-6571 “L” bracket 30. 57-0087 Center Trough Gasket
12. 25-0446 Center bottom sheet metal 31. 25-6008 Z-Axis way covers
13. 25-6052 Door 32. 25-6063 X-Axis chip conveyor brace (4)
14. 59-0267A Y-Axis lower bellows 33. 25-0447 Z-Axis way cover end support
15. 22-6056 Fence panel (6) 34. 25-6007 X-Axis way covers (2)
16. 25-0626 Left table gutter 35. 25-0645 X-Axis extension
17. 25-0630 Front table cover 36. 25-0679 X-Axis extension access cover
18. 25-6003 Access cover (2)
19. 25-0627 Right table gutter

96-0283 rev C June 2007 Mechanical Service 271

 VERTICAL MILL ASSEMBLY DRAWINGS AND PARTS LISTS

VF E XTERIOR S HEET METAL

1 3

2
5

24

6 10

7
11

23 8
9

12

13

22

15

14

16

21

18
20
17

29
25
19

28

26
27

VF6 - 8 Extended Column - Riser Sheet Metal

(Optional)

272 Mechanical Service 96-0283 rev C June 2007

 VF E XTERIOR S HEET METAL

1. Plate, Top Left

2. Back Panel Spacer
3. Top Left Panel
4. Upper Door Brace
5. Plate, Top Right
6. Back Right Panel
7. Spindle Head Cover
8. Spindle Head Cover, Bottom
9. Bottom Head Cover Inspection Panel
10. Left Door Assembly
11. Right Door Assembly
12. Panel, Right Side
13. Panel, Front Right
14. Apron Extension, Right
15. Middle Front Panel
16. Apron, Left and Right
17. Access Panel
18. Pan, Chip Enclosure
19. Front Left Panel
20. Chip Chute
21. Apron Extension, Left
22. Side Panel, Left
23. Back, Left Panel
24. Side Window (handle not included)
25. Right Side Riser
26. Front Riser
27. Left Side Riser
28. Left Rear Riser
29. Right Rear Riser

96-0283 rev C June 2007 Mechanical Service 273

 VF E XTERIOR S HEET METAL

5
4

8
8

7 6

1. Front Left Panel

2. Front Right Panel
3. Floor Pan Left
4. Floor Pan Right
5. Pan Right, Outrigger
6. Pan Support
7. Pan Support
9 12 8. Pan Left, Outrigger
11

10

13

VF(10&11) 14

9. Back Right Panel Extension 16

10. Inner Back Panel, Right 15 17
18
11. Inner Back Panel, Left
12. Back Left Panel Extension
13. Apron Extension Right 19

14. Apron Extension Left

15. Support Beam
20
16. Support Beam
17. Tool Changer Bracket
18. Tool Changer Cover
19. Tool Changer Pan
20. Back Panel Left 13 VR11
14

274 Mechanical Service 96-0283 rev C June 2007

 VF INTERIOR REPLACEABLE PARTS

1. Y-axisGutter
2. Y-axis Waycover
3. Y-axis Guide Rails
4. Way Cover Bracket
5. Saddle Cover
6. X-axis Gutter
7. X-axis Gutter
8. Saddle Cover
9. X-axis Waycover
10. X-axis Guide Rails
11. X-axis Guide Rails
12. Way Cover Bracket
13. Y-axis Wiper
14. Y-axis Rear Waycover
15. Z-axis Waycover Support
16. Z-axis Chip Guard
17. Z-axis Waycover
18. X-axis Waycover
19. Table Gutter
20. Table Cover

96-0283 rev C June 2007 Mechanical Service 275

 VF-1 B ASE

1. 50-3300 Linear guide

2. 30-0171 Oil line assembly
3. 32-2030 Switch assembly
4. 62-0014 Motor (except XRT)

276 Mechanical Service 96-0283 rev C June 2007

 VF-1 C OLUMN

VIEW B
WITHOUT 20-7005
OUT OF POSITION

1. 30-0170 Oil line assembly

2. 62-0009 Motor (except XRT)
3. 32-2040 Switch assembly
4. 50-3300 Linear guide

96-0283 rev C June 2007 Mechanical Service 277

 VF-1 S ADDLE

1. 30-0173 Oil line assembly

2. 32-2050 Switch
3. 50-3300 Linear guide
4. 62-0014 Motor (except XRT)

278 Mechanical Service 96-0283 rev C June 2007

 VF-3 B ASE

1. 30-0221 Oil line assembly

2. 32-2031 Switch assembly
3. 50-9011 Linear guide
4. 62-0014 Motor assembly (except XRT)

96-0283 rev C June 2007 Mechanical Service 279

 VF-3 C OLUMN

2
4

1. 30-0687 Oil line assembly

2. 32-2041 Switch assembly
3. 50-9011 Linear guide
4. 62-0014 Motor (except XRT)

280 Mechanical Service 96-0283 rev C June 2007

 VF-3 S ADDLE

1. 30-0223 Oil line assembly

2. 32-2050 Switch assembly
3. 50-9010 Linear guide
4. 62-0014 Motor (except XRT)

96-0283 rev C June 2007 Mechanical Service 281

 VF-6 B ASE

1. 32-5056 Limit switch assembly

2. 30-0221 Oil line assembly
3. 50-9010 Linear guide
4. 62-0014 Motor (except XRT)

282 Mechanical Service 96-0283 rev C June 2007

 VF-6 C OLUMN

1. 32-2050 Limit switch assembly

2. 62-0014 Motor (except XRT)
3. 30-0464 Oil line assembly
4. 50-9010 Linear guide

96-0283 rev C June 2007 Mechanical Service 283

 VF-6 S ADDLE

1. 62-0014 Motor (except XRT)

2. 50-9806 Linear guide
3. 30-0463 Oil line assembly
4. 32-2051 Limit switch assembly

284 Mechanical Service 96-0283 rev C June 2007

 VF-8 B ASE

1. 62-0014 Motor (except XRT)

2. 50-9010 Linear guide
3. 30-0461 Oil line assembly
4. 32-5056 Limit switch assembly

96-0283 rev C June 2007 Mechanical Service 285

 VF-8 C OLUMN

1. 32-2050 Limit switch assembly

2. 62-0014 Motor (except XRT)
3. 30-0464 Oil line assembly
4. 50-9010 Linear guide

286 Mechanical Service 96-0283 rev C June 2007

 VF-8 S ADDLE

1. 62-0014 Motor (except XRT)

2. 50-9806 Linear guide
3. 30-0463 Oil line assembly
4. 32-2051 Limit switch assembly

96-0283 rev C June 2007 Mechanical Service 287

 VF-10 B ASE

1 2 3 4 5 6 7 8

14 13 12 11 10

1. 59-6655 Rubber plug guide rail

2. 22-7458 Cam, linear guide
3. 20-9218 Y-axis bumper, motor end
4. 20-0150 Nut housing
5. 58-3031 Banjo elbow 5/16 female x M6 male
6. 58-1560 Adapter 1/8m (NSK and THK Linear guides) 59-0001 (Star linear guides)
7. 30-0461 Oil line assembly
8. 20-0156 Bumper for 40 and 50 mm ballscrews
9. 32-5056 Limit switch assembly
10. 25-7268 Bracket mounting Y-axis
11. 50-9010 Linear guide
12. 24-9960 40mm ballscrew (except XRT)
13. 25-9203 Cover plate motor mount
14. 62-0014 Servo motor (40 taper) 62-0016 servo motor (50 taper)*

*Except XRT

288 Mechanical Service 96-0283 rev C June 2007

 VF-10 COLUMN

21
1 2 3 4

5 22
20

19 23

18
24
17

16

15

14

13

11 12
25

7
26 27

10

1. 25-7267 Bracket mounting Y-axis 16. 48-1699 Dowel pin 5/8 x 2 1/4
2. 25-9929 Stabilizer bracket hyd. cyl. 17. 20-9216 Z-axis bumper, motor end
3. 32-2050 Limit switch Z-axis 18. 48-10045 Dowel pin 3/8 x 1 1/2
4. 59-4002 Hose clamp 13/16 x 1 3/4 19. 59-6655 Rubber plug
5. 50-9010 Linear guide 20. 22-7458 Cam
6. 22-9826A Counterweight head bracket 21. 25-9929 Stabilizer bracket
7. 20-9217 Z-axis bumper, support end 22. 20-0365 Clevis counterbalance
8. 48-0045 Dowel pin 3/8 x 1 1/2 pull 23. 48-0017 Clevis pin 3/8 dia. x 1 1/4 and
9. 25-9813 Z-axis waycover 49-0026 Cotter pin 1/8 x 1 1/4
10. 40-2021 FHCS 1/4-20 x 3 24. 20-0150 Nut housing
11. 25-7560B Tank cover 25. 22-9927 Bracket cylinder counter
12. 30-1420 (40 taper) 30-1421 (50 taper) 26. 24-9960 40mm ballscrew (except XRT)
Counterbalance tank assembly 27. 62-0014 Motor (except XRT)
13. 58-3031 Banjo elbow 5/16 F x M6 M
14. 30-0464 Oil line assembly
15. 58-1560 Linear guide adapter 1/8m (NSK
and THK) 59-0001 (Star)

96-0283 rev C June 2007 Mechanical Service 289

 VF-10 S ADDLE

1 3 4 5 6 7 8
2

15 14 13 11 10 9
TOP 12

BOTTOM 16 17

1. 20-0152 Bearing housing 40mm and 50mm ballscrew

2. 20-0156 Bumper
3. 59-6655 Rubber plug
4. 22-7458 Cam, linear guide
5. 30-0534 Oil line assembly
6. 58-1560 Linear guide adapter 1/8m (NSK and THK) 59-0001 (Star)
7. 58-3031 Banjo elbow 5/16 F x M6 M
8. 20-0156 Bumper 40 and 50mm ballscrews
9. 62-0016 Motor (except XRT)
10. 48-0045 Dowel pin 3/8 x 1 1/2 pull
11. 32-2055 X-axis limit switch
12. 25-9219 Bracket, limit switch
13. 20-0150 Nut housing
14. 24-0002C Ballscrew 50mm (except XRT)
15. 50-0001 Linear guide
16. 25-7459 Bracket trip table
17. 25-9220 Bracket, trip X-axis

290 Mechanical Service 96-0283 rev C June 2007

 10 POCKET T OOL CHANGER
1

2
1. 32-1875 Motor Assembly
4
2. 22-7263 Block Switch Mounting 5
3. 32-2010 Limit Switch
4. 32-2000 Limit Switch 6
5. 25-4146 Cover T/C Switch 3
6. 20-0682 Tool Holding Plate
7
7. 22-7034 Spacer Cam Follower 11
10
8. 54-0010 Cam Follower T/C 9 12 26
14
9. 30-7200A Actuating Arm 8
13
10. 54-0030 Guide Wheel
11. 25-0466 Door Opener Bracket
12. 22-2065 Locating Pin
13. 54-0020 Bushing Guide Wheel 15

14. 25-7162 Connector Bracket 21

15. 20-1354A T/C Carriage 16 17 18
16. 54-0040 Standard Bushing Gd Wheel
19
17. 30-1679 Turret Motor Assembly
20
18. 20-0680A Plate Motor Mtg 10 pkt
19. 25-0634 T/C Cover
20. 32-1999 Limit Switch
22
21. 22-7163 Rider Trap Door
22. 25-0633 T/C Shroud
23. 25-0636A Trap Door 23
24. 20-0681 Vertical Axle
25. 22-7255A Tool #1 Standoff
26. 20-0678 Geneva Star
27. 20-0679 Bearing Housing
28. 51-2022 Bearing Radial
24
29. 51-2041 Bearing Locknut BH-05
30. A 22-9574A CT Extractor
B 22-7067F Extractor Key
C 22-9256 Extractor Bushing
D 24-9257 Extractor Spring 25
31. 93-0403 Carousel
26
32. 25-0638 Number Ring
33. 25-0635 Bearing Cover 27
34. 20-1118A (TRM)
35. 20-1263 (MM) 28
29
36. 25-4030 (TRM) 30
30A
30B
37. 25-9912 (MM)

30C

30D 31

34

36
35
10 6
9 8 7
32
37
33

96-0283 rev C June 2007 Mechanical Service 291

 20 POCKET T OOL CHANGER
27

26

25
1 2

23 24
3 4
21 22

19 20

18
6

17
7

16 8

14 15
9
13
10
12

11

32
28 29 30 31 33 34 35 36 37 38

66 39

65

64

63

40

41

42 43
62
44

61 45
60

59

58 46
57 56 55 54 53 52 51 50 49 48 47

292 Mechanical Service 96-0283 rev C June 2007

 20 POCKET T OOL CHANGER

1. 20-7029B Holding arm 49. 20-7038A Bearing housing

2. 57-7379 Tool holding arm gasket 50. 20-7035G Vertical axle
3. 79-1000 Wire channel 1in. x 2in. 51. 54-0040 Standard bushing guide wheel
4. 79-1001 Cover wire channel 1" 52. 25-7036 Cap, tool changer
5. 54-0030 Guide wheel 53. 51-0012 Bearing locknut BH-06
6. 22-7263 Block switch mounting 54. 26-7239 Spacer ring
7. 54-0020 Bushing guide wheel 55. 32-2000 Limit switch 4 wire 12"
8. 48-0019 Dowel pin 1/4 x 5/8 56. 25-7570 Number ring
9. 24-9257 Spring, extractor 57. N/A
10. 22-7067F Key extractor spring 58. 20-7352B 20 tool carousel
11. 48-0002 Roll pin 7/32 x 7/8 20-1524 20 Tool carousel BT
12. 22-9574A CT extractor spring load 59. 51-0001 Bearing 3/4 cam follower
22-7166A BT Extractor 60. 20-9332 Driver geneva 2 pin
13. 22-9256 Bushing extractor 61. N/A
14. 20-7476 Hub slip clutch 62. 25-7237C 20 pocket T/C cover
15. 48-0005 Dowel pin 3/16 x 3/8 63. 20-7236A Motor mounting plate
16. 22-7034 Spacer, cam follower 64. 32-7618 TL Carriage cable 40T (VF 6-11)
17. 20-7475 Arm slip clutch 65. 57-7378 Tool Carriage gasket (VF6-10)
18. 54-0040 Standard bushing guide wheel 66. 78-1996 Split flex tubing 1/2 I.D.
19. 22-9256 Bushing extractor
20. 45-2020 Washer 1 1/4 nylon
21. 51-6000 Bearing locknut NT-05
22. 55-0010 Spring washer B2500-080
23. 22-2065 Locating pin
24. 25-7168 Bracket, door opener
25. 70-0050 PLT4S-M cable ties
26. 25-9253 Conduit mounting plate
27. 32-1800 Shuttle motor assembly
28. 54-0010 Cam follower T/C
29. 20-7030E Tool carriage
30. 32-1900A Turret motor assembly
31. 32-7011A Molded T/C cable assembly (VF 0-5)
32-7012B Molded T/C cable Assembly (VF 6-11)
32. 75-15721 MLX 2 pin M 7.11 LSW/Earmolex
33. 25-7162 Connector bracket
34. 46-1705 Nut 3/4-10 nylon lock
35. 32-2010 Limit switch shuttle In/Out 24"
36. 63-1031 Cable clamp 1/4
37. 48-1750 Dowel pin 1/2 x 1 1/2
38. 22-7106 V track
39. 20-7033 F hold plate
40. 51-0010 Bearing deep groove
41. 22-7163 Rider trap door
42. 20-9336 20 pocket geneva star
43. 48-0020 Dowel pin 1/4 x 1
44. 25-7238C Tool trap door
45. 25-7249 Sliding panel
46. 25-7250B Sliding panel cover
47. 24-2010A Compression Spring
48. 22-7255A Tool #1 standoff

96-0283 rev C June 2007 Mechanical Service 293

 SIDE MOUNT T OOL C HANGER ASSEMBLY

38 39
37
40 1
36
41
33 2
35
42
12 1 32 34 3
14
3 10 11
7 8 9

44
1
5

30 43
16

6
6
17

4
5
18 19

29
4
3
20 2

2
22 23 24 1
28 7
1

8 5
27

31

22 * 9 **
26
11
24 10

23
21
*
20
25
17
19 16
15
18
14
13

12

294 Mechanical Service 96-0283 rev C June 2007

 SIDE MOUNT TOOL C HANGER ASSEMBLY

* Back Side
** Hose, on Horizontal Applications
1. Cam Box Motor
2. Key
3. Cam Box Motor Mount
4. Cam Box Pulley
5. Drive Belt
6. Key
7. Pulley
8. Cam Box Motor (High Speed)
9. Oil Fill/Breather
10. Cam Box Assembly
11. ATC Enclosure
12. Double Arm Assembly
13. ATC Mount
14. Shoulder Bolt
15. Hex Nut
16. Lockwasher
17. Air Cylinder
18. Slide Roller
19. Tool Pocket Slide
20. Pocket Stop
21. Proximity Switch (Pocket Up)*
22. Proximity Switch (Pocket Down)*
23. Carousel Housing
24. Proximity Switch (Tool One)
25. Pocket Retaining Screw
26. Tool Pocket Shaft
27. Proximity Switch (Tool Mark)
28. Carousel Shroud
29. Bearing
30. Carousel
31. Bearing Nut
32. Tool Pockets
33. Carousel Number Disc
34. Bottom Cam Support
35. Carousel Cam
36. Top Cam Support
37. Key
38. Pulley
39. Timing Belt
40. Pulley
41. Motor Mounting Plate
42. Key
43. Motor Mounting Block
44. Carousel Motor

96-0283 rev C June 2007 Mechanical Service 295

 96-0283 rev C June 2007
58
59
52 57
60
56
1
51 61
52
16 17 18 19 55 62
20 15 2 66
14

21
54
12 13

22
6 7
23

11

53
24

64 63
10

8 9
25

10 52
26

67
8

51
27 28

7
6 3 50 49
30
29

5
1 2 3 4 25 68
26
65
24 69
4 27

Mechanical Service
35
4 38
23 34
5
50 TAPER SIDE MOUNT TOOL CHANGER A SSEMBLY

37
39 41
28
42
11 43
13
12 *
22
14 2 44
22 *
21
21 40
31 36
20
15 29
16 17 18 19 30
46
45
47

296
48
 50 TAPER SIDE MOUNT TOOL CHANGER A SSEMBLY

1. 25-0284A Carousel Cover 53. 20-0439 Carousel Cam

2. 20-0490B Tool Pocket 50T 54. 20-0231 Carousel Shaft
3. 51-2043 Bearing Lock Nut 55. 22-2629 Key Stub
4. 51-0020 Bearing 56. 20-0268 20-7239 Carocam Support
5. 20-0438 Carousel 50T 57. 54-0039 Bushing
6. 46-1663 Jam Nut 58. 54-0044 Pulley
7. 45-0068 Flat Washer 59. 54-0045 Belt
8. 20-1239A Tapered Bushing 60. 54-0043 Pulley
9. 45-0070 Washer 61. 54-0017 Bushing
10. 51-0045 Cam Follower 62. 20-0272A Motor Mount Plate
11. 20-0385 Pocket Roller Shaft 63. 32-1875 Motor Assy.
12. 56-0020 Retaining Clip 64. 20-0273 Motor Mount Block
13. 40-1715 SHCS 65. 54-0043 Pulley
14. 45-1739 Washer 66. 32-1880B Motor Assy.
15. 40-1919 Screw 67. 20-0772 Motor Mounting Base
16. 20-0384 Arm Key 68. 54-0037 Pulley
17. 29-0382 Pocket Plunger 69. 54-0036 Belt
18. 59-0114 Spring
19. 20-0383 Tool Pocket Rollers
20. 20-0386 Tool Pocket Shaft
21. 51-0051 Cam Follower
22. 46-1810 Nut
23. 20-0392 Press Fit Washer
24. 20-0621A ATC Housing
25. 32-0039 Solenoid Assy.
26. 32-2295 Prox. Switch
27. 32-2253 Prox. Switch
28. 20-0390 Pocket Slide
29. 20-0393 Pocket Stop
30. ¾ 16 Jam Nut
31. 59-0116 Air Cylinder
32. 32-2252 Prox. Switch
33. 32-2251 Prox. Switch
34. 20-0387A T/C Shaft
35. 25-0286B Shroud
36. 25-0291B Corner Shroud
37. 20-0456A Cam Box Cover
38. 58-3069 Muffler
39. 20-0455B Cam Box Case
40. 30-1150 Cam Box Assy.
41. 25-0288A Motor Cover
42. 25-0287A Top Plate
43. 25-0290A Front Cover
44. 25-0289A Right Cover
45. 25-0292A Bottom Cover
46. 20-0388A Double Arm Assy.
47. 20-0240 Arm Hub
48. 40-1610 (8X) SHCS ¼-20-1"
49. 51-2012 Bearing Lock Nut
50. 20-0268 Carousel Cam Bottom Support
51. 51-2025 Bearing
52. 51-2041 Bearing Lock Nut

96-0283 rev C June 2007 Mechanical Service 297

 VF 1-11 G EARBOX A SSEMBLY 15 HP

1 2

4
3

6 5
VIEW A

8 42 43

44
7 9

10 45

23 41 46
40

11 47
24
48
25
22
49
21 39
12

38
50
26
37 51
20 27

28 36

35 52
53

34
33 54
19
32 55
13 29
VIEW A 31 56
14

15 30

16 57

17 58 59
18

298 Mechanical Service 96-0283 rev C June 2007

 VF 1-11 G EARBOX A SSEMBLY 15 HP

1. 25-0108 Fan bracket motor shroud 53. 58-2110 Sleeve nuts lube assembly
2. 36-3035 Spindle fan assembly 54. 22-7520A Isolater trans
3. 59-7130 Protective strip 55. 22-7521A Spacer trans
4. 32-2011 30" limit switch 56. N/A
5. 32-2010 24" limit switch 57. 58-7636 High gear tube VF-3
6. 25-7264 Switch mounting bracket 58. 58-7635 Low gear tube VF-3
7. 29-0022 Shroud caution decal 59. 63-0001 Nylon cable clamp 1/2
8. 59-1482 Nylon finish plug, 13/16
9. 25-01074 Motor shroud
10. 20-0064 Adapter encoder pulley
11. 62-3010 Spindle motor, 10HP
12. 59-0046 Soundcoat shroud RT/LT
13. N/A
14. N/A
15. 25-7433 Sump bracket
16. 22-7445A Drain tube dry sump
17. 22-7446 Pick up tube dry sump
18. 58-2745 Magnetic oil plug
19. 57-0001 Oil seal
20. 58-3657 1/4 female 1/8 male adaptor
21. 54-2125 Drive belt HTD 300-3M-09
22. 54-1013 Drive sprocket .250 RTAP
23. 59-2040 Cable clamp 7/16
24. 58-2001 Polyu hose 1/2OD x 3/8ID
25. 32-1455D RTAP encoder cable
26. 60-1810 Shaft encoder 2000 line
27. 54-7127 Drive sprocket .375 RTAP
28. 22-7260 Encoder standoff
29. 57-0002 Oil seal
30. 25-7434 Sump tank
31. 63-1031 Cable clamp 1/4
32. 59-4006 Hose crimp, 35/64
33. 59-2040 Cable clamp, 7/16
34. 58-3616 3/8 90 deg. elbow 1/4 NPT
35. N/A
36. 58-7377 Air reg/solenoid tube
37. 76-2420 Crimp ring, 12-10 10 stud
38. 77-8011 Wire nut, ideal #30-076
39. 30-3270A Precharge regulator assy
40. 30-3260B Oil gear pump assy
41. 59-0027 Hose clamp 1/2 hose
42. 58-2020 3/8OD natural tubing
43. 22-7487 Oil fill cap modified
44. 58-2065 Coupling, 1/4NPT
45. 58-2070 1/4NPT male to 3/8 comp
46. 58-9114B Trans fill tube
47. 25-7336 Solenoid mounting bracket
48. 33-3200 Solenoid bracket cable assembly
49. 33-5088 Ground strap spindle motor shroud
50. 30-3146 Air solenoid assy mac TP
51. N/A
52. 58-2100 Sleeve lube assembly

96-0283 rev C June 2007 Mechanical Service 299

 VF 1-11 G EARBOX A SSEMBLY HT10K

1 2

5
4
VIEW A

6 64 63

62
21 37
7
38
20 61
39

36 40 60

41
19

18 59
35
8
58
9 34
57
22 42
17

10 43
56
33
44
23 32

31 45
24

25
55
26
54

30

46
53
27 47
52
16 29 48

VIEW A 15
36

28
14

13 51

12 50

11 49

300 Mechanical Service 96-0283 rev C June 2007

 VF 1-11 G EARBOX A SSEMBLY HT10K

1. 25-0108 Fan bracket motor shroud

2. 36-3035 Spindle fan assembly
3. 32-2011 Switch assembly (30" cable length)
4. 32-2010 24" limit switch
5. 25-7264 Switch mounting bracket
6. 59-1482 Nylon finish plug, 13/16
7. 29-0022 Shroud caution decal
8. 55-0035 Spring washer, BS-204
9. 56-2087 Snap ring, N5000-206
10. 29-7399 Transmission motor label
11. 58-2745 Magnetic oil plug
12. 22-7446 Pick up tube dry sump
13. 22-7445A Drain tube dry sump
14. 25-7433 Sump bracket
15. 22-7376 Sprocket flange
16. 20-7374 1 1/8 sprocket
17. 20-0125 Drive sprocket encoder
18. 57-7573A Trans motor gasket
19. 36-3078 10K 10HP motor kit
20. 59-0046 Sound coat shroud RT/LT
21. 25-0107 Motor shroud
22. 54-2125 Drive belt HTD 300-3M-09
23. 58-3657 1/4 female 1/8 male adapter
24. 55-0036 Spring washer, BS-205
25. 56-0070 Snap ring, N5000-187
26. 58-7357 Top plate tube-A
27. 57-0001 Oil seal
28. 25-7434 Sump tank
29. 57-0002 Oil seal
30. 58-7358A Top plate tube-B
31. 22-7260 Encoder standoff
32. 54-7127 Drive sprocket .375 RTAP
33. 60-1810 Shaft encoder 2000 line
34. 32-1455D RTAP encoder cable
35. 58-2001 Polyu hose 1/2OD x 3/8ID
36. 59-2040 Cablt clamp, 7/16
37. 59-0027 Hose clamp 1/2 hose
38. 57-0049 Rubber stud bumper
39. 46-1625 Nut hex blk ox 1/4-20
40. 45-1800 Washer split lock 1/4 med
41. 30-3260B Oil gear pump assembly
42. 30-3270A Precharge regulator assembly
43. 77-8011 Wire nut, ideal #30-076
44. 76-2420 Crimp ring, 12-10 10 stud
45. 58-7377 Air reg/solenoid tube
46. 58-3616 3/8 90 deg elbow 1/4 NPT
47. 59-4006 Hose crimp, 35/64
48. 63-1031 Cable clamp 1/4

96-0283 rev C June 2007 Mechanical Service 301

 VF 1-11 G EARBOX A SSEMBLY HT10K TSC

1 2

6 5
VIEW A

7 73 72

71
28
8

27 70

44 45 69

46
26

25 68
43
67
42
29
66
30 47
24
9

48
10
23 65
41
49
11
31 40
50
12
32 39
22 51
33
21 52 64
34
63

20

19

38 53
62
35 54
61
18 37 55

VIEW A 17
56

36
16

15 60

14 59
58
13 57

302 Mechanical Service 96-0283 rev C June 2007

 VF 1-11 G EARBOX A SSEMBLY HT10K TSC

1. 25-0108 Fan bracket motor shroud 52. N/A

2. 36-3035 Spindle fan assembly 53. 58-3616 3/8 90 deg. elbow 1/4NPT
3. 59-7130 Protective strip 54. 59-4006 Hose crimp, 35/64
4. 32-2011 Switch (30" cable lenght) 55. 59-2040 Cable clamp 7/16
5. 32-2010 24" limit switch 56. 63-1031 Cable clamp 1/4
6. 25-7264 Switch mounting bracket 57. 63-0001 Nylon cable clamp 1/2
7. 59-1482 Nylon finish plug 13/16 58. 58-7635 Low gear tube VF-3
8. 29-0022 Shroud caution decal 59. N/A
9. 57-0006 O-ring 2-328 buna 60. 58-7636 High gear tube vf-3
10. 29-7399 Transmission motor label 61. 22-7521A Spacer trans
11. 29-9128 Label, transmission 62. 22-7520A Isolater trans
12. 48-0020 Pin, dowel 1/4 x 1 63. 58-2110 Sleeve nuts lube assembly
13. 58-2745 Magnetic oil plug 64. 58-2100 Sleeve lube assembly
14. 22-7446 Pick up tube dry sump 65. 30-3146 Air solenoid assy mac tp
15. 22-7445A Drain tube dry sump 66. 33-5008 Ground strap spindle motor shroud
16. 25-7433 Sump bracket 67. 33-3200 Solenoid bracket cable assembly
17. 22-7376 Sprocket flange 68. 25-7336 Solenoid mounting bracket
18. 20-7374 1 1/8 Sprocket 69. 58-9114B Trans fill tube
19. N/A 70. 58-2070 1/4NPT male to 3/8 comp
20. N/A 71. 58-2065 Coupling, 1/4NPT
21. N/A 72. 22-7487 Oil fill cap modified
22. N/A 73. 58-2020 3/8OD natural tubing
23. 20-7435 Oil plate
24. 20-0064 Adapter encoder pulley
25. 57-7573A Trans motor gasket
26. 36-3078 10K 10HP motor kit
27. 59-0046 Soundcoat shroud RT/LT
28. 25-0107 Motor shroud
29. 54-1013 Drive sprocket .250 RTAP
30. 54-2125 Drive belt HTD 300-3M-09
31. 58-3657 1/4 female 1/8 male adapter
32. 55-0036 Spring washer, BS-205
33. 56-0070 Snap ring N5000-187
34. 58-7357 Top plate tube-A
35. 57-0001 Oil seal
36. 25-7434 Sump tank
37. 57-0002 Oil seal
38. N/A
39. 22-7260 Encoder standoff
40. 54-7127 Drive sprocket .375 RTAP
41. 60-1810 Shaft encoder 2000 line
42. 32-1455D RTAP encoder cable
43. 58-2001 Polyu hose 1/2OD x 3/8 ID
44. 59-2040 Cable clamp 7/16
45. 59-0027 Hose clamp 1/2 hose
46. 30-3260B Oil gear pump asssembly
47. 30-3270A Precharge regulator assembly
48. 30-3276 Purge solenoid valve assembly
49. 77-8001 Wire nut, ideal #30-076
50. 76-2420 Crimp ring, 12-10 10 stud
51. 58-7377 Air reg solenoid tube

96-0283 rev C June 2007 Mechanical Service 303

 50 T APER GEARBOX A SSEMBLY

34 21 1
3
1
33
2 4 22

32

23

31
3 5
20

24
30
19 6
18 7 6
2 29
8
25
28
17 9 27

10
16
11 26
15
14 13 12

1. 25-4420 Oil Pump Bracket

2. 20-1452 Transmission Plate 26. 32-1457 Rtap Encoder
3. 25-4419 Solenoid Bracket 27. Dipstick
4. 22-7487 Oil Fill Cap 28. 20-1396 Transmission Spacer Plug
5. 30-3275 TSC Check Valve 29. Oil Sight Level
6. 58-0609 Oil Pickup Tube 30. 20-1526 Housing Gearbox
7. 20-1440 Out put Gear 31. 30-3275 Check Valve Assembly
8. 51-0089 Bearing Locknut 32. 30-3642 TRP TSC Solenoid Assembly
9. 20-1459 Oil Pan 33. 25-4421 Spindle Connector Bracket
10. 35-0017 Output Shaft 34. 20-1147 X-Axis Support Bumper
11. 20-2965 Encoder Stand Off
12. 20-1454 Encoder Pulley
13. 25-6298 Encoder Spring Clamp
14. 25-6299 Encoder Spring Plate
15. 20-2964 Encoder Spring Mounting Plate
16. 20-1455 Pulley
17. 51-0088 Deep groove Bearing
18. 51-0087 Bearing
19. 20-2393 Bearing Ring
20. 20-1458 Oil Manifold
21. 62-4010 Spindle Motor
22. 30-3644 Shift Valve
23. 30-3260 Oil Pump Assembly
24. 20-1448 Cylinder Shifter
25. 20-1782 Housing Cover Plate

304 Mechanical Service 96-0283 rev C June 2007

 SPINDLE ASSEMBLIES

SPINDLES
30-0319A 7.5 Spindle Assembly
30-2132 10K Spindle Assembly
30-1360 15K Spindle Assembly
30-1468 15K spindle Assembly VF5-11
30-0449 50 Taper Spindle Assembly

DRAWBAR
30-3410E 7.5k spindle with or without TSC
30-0067 50 Taper

96-0283 rev C June 2007 Mechanical Service 305

 M ILL DRILL S PINDLE H EAD A SSEMBLY

3
5 12 13
4

59 6
10 14
15
7
11
8
9 16

18
17

22 21

23 20
19
50
21
24 29
26 30
25 36
31 35
27
28 34
32 37
33

41
38

34
39
40

43 42 41
58

44
45

52
57
53 50
46
48

56 54 49
47
51
55

306 Mechanical Service 96-0283 rev C June 2007

 M ILL D RILL S PINDLE H EAD A SSEMBLY

1. 25-6804 Fan racket 48. 25-7284 Inspection plate

2. 59-0091 Cable carrier 49. 30-6656 Spindle
3. 59-0144 Fan guard 50. 59-9132 Side sound foam
4. 36-3035 Fan Assembly 51. 30-7365 P-cool assembly
5. 25-7336 Solenoid bracket 52. 58-5173 Conduit
6. 60-1815 Encoder 53. 52-0026 P-cool hose assembly
7. 22-7260 Encoder stand-off 54. 25-5820 P-cool mounting bracket
8. 54-7127 Drive sprocket 55. 61-1040 Switch
9. 25-9667 Encoder mounting plate 56. 30-7459 Manifold assembly
10. 54-2121 Drive belt 57. 25-7600 Spindle head cover
11. 20-0276 Drive sprocket 58. 59-9131 Front sound foam
12. 53-3001 Pressure switch 59. 25-6805 Top chip cover
13. 30-3156 Air solenoid
14. 58-2736 Air regulator
15. 59-2780 Solenoid
16. 25-7440 Rear sound shield
17. 62-3016 Spindle motor
18. 25-5748 Left chip shield
19. 25-5747 Right chip shield
20. 20-1656 Spring retainer
21. 32-2010 Limit switch
22. 32-5620 Solenoid valve assembly
23. 30-3201 TRP assembly
24. 59-2832 Quick exhaust
25. 59-2760 Compression spring
26. 20-7626 TRP shaft
27. 22-7520 Isolator
28. 22-7521 Spacer
29. 20-1514 Cylinder housing
30. 20-7429 Motor sub plate
31. 20-7376 Sprocket flange
32. 20-9672 Sprocket
33. 54-2660 Drive belt
34. 25-0982 Retaining bracket
35. 30-7494 Upper oil line assembly
36. 20-7008 Nut housing
37. 24-0041 Ball screw assembly
38. 30-7525 Oil line assembly
39. 50-0017 Linear guide assembly
40. 58-2071 ½ x ½ weatherhead
41. 25-0957 Coolant jacket
42. 58-0204 Coolant jacket tube
43. 20-7005 Spindle head
44. 59-9134 Bottom sound cover
45. 25-7096 Bottom spindle head cover
46. 58-1680 Anchor connector
47. 25-5737 Gordillo adapter plate

96-0283 rev C June 2007 Mechanical Service 307

 VR-S ERIES HEAD ASSEMBLY

308 Mechanical Service 96-0283 rev C June 2007

 VR-S ERIES HEAD ASSEMBLY

96-0283 rev C June 2007 Mechanical Service 309

 TOOL RELEASE P ISTON ASSEMBLY
B

A A

2 3 4 5 6 7 8 9

10 11 12 13 14

18 17 16 15

VIEW B
OUT OF POSITION SECTION A-A
OUT OF POSITION
1. 58-3613 1/4 Street elbow
2. 58-3050 Elbow 1/4 bylon tubing
3. 58-3670 1/4NPT M 1/8F reducer
4. 58-3727A 1/4NPT x 4 nipple brass
5. 59-2832B Quick exhaust 1/4
6. 58-2165 Fitting close nipple 1/4
7. 32-5620 TRP solenoid valve assembly
8. 58-2265 Air muffler 3/8 flat 40 Taper Complete Assembly Non-TSC 30-3201A
9. 58-3685 1/4NPT M 3/8 tube swivel elbow Mini Mill TRP Assembly 30-1668
10. N/A
11. 22-4045 Spring retainer TRP 30 degree
12. N/A TRP base XHC 30-3207
13. 32-2010 Limit sw shuttle in/out 24" TRP base 30-3205
14. 25-4050C Switch mounting bracket
15. 59-2760 Comp spring/large wire
16. 57-0040 O-ring 2-111 Buna
17. 56-0040 Retaining ring N5100-62
18. 57-0018 O-ring 2-446 buna

310 Mechanical Service 96-0283 rev C June 2007

 IN -LINE SPINDLE T OOL RELEASE PISTON

2
3
1 4

1. 32-2201 Proximity Switch

2. 20-1692A TRP Piston, In-line
3. 20-1691 TRP Shaft
4. 20-1696A TRP Spring Retain, In-line
5. 25-4648A Bracket Switch Mounting
6. 20-1693A TRP Cylinder In-line
7. 20-1690C Striker Plate

96-0283 rev C June 2007 Mechanical Service 311

 50 TAPER TOOL R ELEASE PISTON

1 2 3 4 5 6 7

25

8
24

23

22 9

10

21
11
20

12
19

18
17 16 15 14 13

1. 59-0049 Spring compression 19. 48-1662 Dowel pin 1/2 x 1

2. 52-0003 Shaft clamp 20. 20-0017A Sub plate TRP 50T
3. 58-3050 Elbow 1/4 nylon tubing 21. 59-0016 Spring compression
4. 58-3631 Reducer bushing 1/2M-1.8F 22. 49-0003 Shoulder bolt 5/8 x 3 1/2
5. 20-0016B Switch plate 23. 20-0020A Spacer lower TRP 50T
6. 20-0021 Spacer upper TRP 50T 24. 20-0022A Housing air cylinder
7. 32-2013 Limit switch shuttle assembly 25. 25-0009 Switch mounting bracket
8. 20-0019A Piston TRP 50T
9. 57-0092 O-ring 2-448 Viton
50 Taper complete assembly 30-3202A
10. 57-0027 O-ring 2-121 Buna
11. 57-0095 O-ring 2-327 Viton
12. 58-1695 Elbow 1/4MPT
13. 58-1627 1/8-27 pipe plug
14. 20-0013 Spacer fork spindle
15. 20-0015 Fork lift Spindle
16. 20-0018A Shaft TRP 50T
17. N/A
18. 22-0014 Spacer .62ID x 1.25OD.857

312 Mechanical Service 96-0283 rev C June 2007

 TSCHP TOOL RELEASE PISTON ASSEMBLY
B

A A

2 3 4 5 6 7 8 9

16

10 11 12 14 15

23 22 21 20 19 18

SECTION A-A
OUT OF POSITION
VIEW B
OUT OF POSITION

93-30-3206 Complete assembly 14. 32-2010 Limit switch shuttle in/out 24"
15. 25-7050C Switch mount tool release
16. 30-6733 Hose Assy Ck Vlv/TRP
1. 58-3618 1/4 Street elbow 90 deg. VF1-11/40T QAPC
2. 58-3727A 1/4NPT x 4 nipple brass 30-6734 Hose Assy Ck Vlv/TRP
3. 58-3050 Elbow 1/4 nylon tubing VF5-11/50T , VF-SS, VS-3
4. 58-3670 1/4NPT M 1/8 F reducer 30-6733 Hose Assy Ck Vlv/TRP
5. 59-2760 Compr spring/large wire VR-8, VR-9, VR-11
6. 58-2165 Fitting close nipple 1/4 18. 20-7640 Tool Release Bolt, 3/8-LH
7. 32-5620 TRP solenoid valve assembly 19. 30-3298 Seal Housing Assembly
8. 58-2265 Air muffler 3/8 flat 20. 56-0040 Retaining ring N5100-62
9. 58-3685 1/4NPT M 3/8 tube swivel elbow 21. 20-7630A TRP rectangle TSC
10. 22-7045A Spring retainer TRP 30 degree 22. 57-2156 Quad-ring Q4-440 buna
11. 20-7626A Shaft TRP hex 23. 20-7007A Cylinder housing
12. 58-3614 1/4F 1/8M street elbow

96-0283 rev C June 2007 Mechanical Service 313

 B ALL SCREW ASSEMBLY

COUPLING ASS'Y

MOTOR MOUNT

BALL SCREW

SNAP LOCK RING BMPR

BALL SCREW ROTATED 90°

Mini-mill VF 0-1 VF 2 VF 3 VF 4-5 VF-5XT

Base 24-3006 30-0157 30-0157 30-0196 30-0196 30-0196
Saddle 24-3006 30-0157 30-0194 30-0195 30-0197 30-2152
Column 24-3006 30-0157 30-0157 30-0196 30-0196 30-0196

VF-6/8 VF-7/9 VF-10/11

Base 30-0474 30-0474 30-0474
Saddle 30-0470 30-0473 30-0516
Column 30-0474 30-0474 30-0474

50 Taper
VF5 VF-5XT VF-6/8 VF-7/9 VF-10/11
Base 30-0202 30-0202 30-0895 30-0895 30-0895
Saddle 30-0198 30-2152 30-0896 30-0897 30-0516
Column 30-0202 30-0202 30-0895 30-0895 30-0895

*Except XRT

314 Mechanical Service 96-0283 rev C June 2007

 APC ASSEMBLY

96-0283 rev C June 2007 Mechanical Service 315

 APC ASSEMBLY

ITEM QTY. PART NO. TITLE

1. 3 14-7068 CASTING, LEVEL PAD
2. 1 20-0046 SUPPORT, IDLER SPROCKET
3. 2 20-0048 DRIVE LEG, APC
4. 2 20-0049 DETENT, APC
5. 1 20-0050 SUPPORT, MOTOR, APC
6. 2 20-0051 GUIDE, CHAIN, APC
7. 1 20-0052 TENSIONER BLOCK
8. 2 20-0053 PALLET
9. 4 20-0054 CLAMPING RAIL
10. 1 20-0057 IDLER SPROCKET
11. 1 20-0060 JOURNAL, IDLER SPROCKET
12 2 20-0065 FRICTION BLOCK
13. 2 20-0066 PALLET STOP, APC
14. N/A
15. 1 20-0193 BASE, MACHINED
16. 1 25-0066 SHIELD, SPLASH, LOW PROFILE
17. 3 25-0072 LEG, APC
18. 2 25-0077 PALLET, SKIRT, REAR
19. 1 25-0082 SWITCH BRACKET, CHAIN, LOW
20. 4 26-8964 WIPER APC
21. 2 25-0095 PALLET DRIP PAN
22. 4 25-0100 BRACKET, WIPER
23. 1 25-0101 SWITCH BRACKET ARM #2
24. 1 25-0102 SWITCH BRACKET, CHAIN, HIGH
25. 2 25-0105 PALLET SKIRT, FRONT
26. 1 30-0054 CHAIN ASSEMBLY, APC
27. 1 30-0055 SLIP CLUTCH ASSEMBLY
28. 1 32-1800 SHUTTLE MOTOR, 507-01-110AH
29. 8 40-0017 FHCS, 5/16-18 X 3/4”
30. 8 40-16081 BHCS, 6-32 X 5/16”
31. 1 40-1614 SHCS, 1/4-20 X 1 1/4
32. 2 40-1617 FHCS, 1/4-20 X 1”
33. 4 40-1636 SHCS, 3/8-16 X 1 1/4
34. 13 40-1654 SHCS, 1/2-13 X 1”
35. 4 40-1667 SHCS, 5/16-18 X 1 1/4
36. 124 40-1703 FHCS, 10-32 X 1/2
37. 8 40-1850 SHCS, 10-32 X 3/8”
38. 8 40-1920 FHCS, 1/4-20 X 5/8
39. 2 40-1950 SHCS, 10-32 X 3/4
40. 32 40-1961 SHCS, 3/8-16 X 2”
41. 4 40-1970 FHCS, 1/4-28 X 1”
42. 3 40-1981 FBHCS, 1/4-20 X 1/2
43. 3 44-1700 SSS, CUP PT. 3/4-10 X 4:”
44. 12 45-1666 WASHER, FLAT 1/2 I.D.
45. 1 46-1625 NUT, HEX, BLACK OX, 1/4-20
46. 20 48-0012 DOWEL PIN, 12mm X 30 mm LG.
47. 32 49-16201 BHCS, 10-32 X .38
48. 4 51-0030 BUSHING, DRILL .6260 I.D.
49. 2 51-2836 BEARING, RADIAL, #60052RS
50. 20 51-4000 BEARING, RADIAL 12 X 32 X 10MM
51. 1 56-0085 RETAINING RING 5100-100
52. 2 59-1057 BUMPER, PALLET

316 Mechanical Service 96-0283 rev C June 2007

 G ANTRY ROUTER BRIDGE A SSEMBLY P ARTS L IST

1
4
5
6
3
2

16
15

14

7
11

13 10 9 8

12

1. 25-1147 Y-axis Servo Motor Cover 10. 50-0110 Linear Guide 2x (GR 408)
2. 20-0151 Ballscrew Motor Mount 50-0024A Linear Guide 2x (GR 510-512)
3. 29-9211 Ballnut Housing (40mm) 50-0107A Linear Guide 2x (GR710-712)
20-9212 Bearing Housing (40mm) 11. 28-0215 Bumper .500 40-50mm
4. 25-1304 Cable Hole Covers (2x) 12. 25-1164 Y-axis right bellow mount (GR 510-712)
5. 25-1360 Y-axis Cable Carrier Cover 25-7436 Y-axis right bellow mount (GR-408)
6. 20-3256A Bridge (GR 408 only) 13. 59-0817 2x Y-axis bellows (GR-408)
20-3238 Bridge (GR 510-512) 59-0360 2x Y-axis bellows (GR 510-512)
20-2829 Bridge (GR 710-712) 59-0718 2x Y-axis bellows (GR 710-712)
7. 20-0152 Bearing Housing (40-50mm) 14. 25-9203 Motor mount cover plate
8. 28-0195 Bumper 1.25 40-50mm 15. Servo motor
Bumper .500 (GR-408) 16. 25-7435 2x Y-axis bellows guide (GR408)
9. 24-0118 Y-axis Ballscrew (GR 408 only) 25-1163 2x Y-axis bellows guide (GR 510-512)
24-0030B Y-axis Ballscrew (GR 510-512) 25-5960 2x Y-axis bellows guide (GR 710-712)
24-0111B Y axis ballscrew (GR710-712)

96-0283 rev C June 2007 Mechanical Service 317

 GR-408 B ASE & TABLE ASSEMBLY P ARTS L IST

2 5
1
6

37 7
4 A

8
20
18 10
19

11
12
17
16 13
15
14

35 21 22
34 23
24
25

32
30
33

31 36 27 26
29 28
Detail A

318 Mechanical Service 96-0283 rev C June 2007

 GR-408 B ASE & TABLE ASSEMBLY P ARTS L IST

1. 25-7720A MOM-408 Bracket

2. 20-3254 2X Bridge Support
3. 25-7427A 2X Chip Tray
4. 25-7429 X-Axis Ballscrew End Cover
5. 20-3268 Table
6. 20-3267A Sub-Table
25-7552 Proximity Switch Trip Bracket
7. 25-7428 X-Axis Ballscrew Cover
25-7801 Cable Cover
8. 25-7417 Rear Chip Pan Support
9. 25-7416A Rear Chip Pan
10. 25-7413 4X Front Chip Pan Support
11. 25-7415A 2X Left and Right Side Chip Pan Drain
12. 20-3261 Control Side Foot
13. 46-1027 8x Adjusting Screw
14. 14-7068 8x Leveling Pad
15. 25-7441 Bed Support Panel
16. 25-7721 Right Side Reflector Bracket
17. 25-7418A Front Chop Pan Drain
18. 25-7722 Left Side Reflector Bracket
19. 20-3259A Base
20. 20-3262 TC Side Door
21. 30-1222 Ballscrew Support Bearing Assembly
22. 20-0151 Ballscrew Motor Mount
23. 62-0016 Servo Motor
24. 25-7571A 4x Chip scraper
25. 50-0024A 4X Linear Guide
26. 25-7567 2X Right Chip Scraper
27. 30-8356A X-Axis Right Lube Line Assembly
28. 30-8412 X-Axis Ballnut Lube Assembly
29. 24-0116 X-Axis Ballscrew
30. 20-3269 X-Axis Ballnut Support
31. 30-0472 2x Ballscrew Bearing Housing
32. 28-0215 3x Bumper (.500")
33. 25-7568 2x Left Chip Scraper
34. 25-7569 4x Chip Scraper Mount
35. 30-8357A X-Axis Left Lube Line Assembly
36. 20-0150 X-Axis Ballscrew Nut Housing
37. 25-7705 2x Sensor Mount

96-0283 rev C June 2007 Mechanical Service 319

 GR-408 C ONTROL A SSEMBLY P ARTS L IST

8 9
3
1 2
6 7
5
4

18 19
10
11

17
16

15 12
14 13

1. 25-7580A Operator Shield Bracket

2. 25-7574A Control Support Bracket
3. 20-3679 Control Box Mount
4. 25-6661A Arm End Cap
25-6659A Swivel Mounting Plate
5. 14-2135 Pendant Arm
6. 25-6380 Control Arm Top Stiffener
7. 25-6381 Control Arm Bottom Stiffener
8. 25-4311A Front Regen Cover
25-0462A Back Regen Cover
9. 32-9654B Control Box Assembly
10. 93-0282 Swivel Control Assembly
11. 25-1129 Pendant Hard Stop
12. 25-7442A Control Junction Box
13. 25-7443A Wire Cover Junction Box
14. 32-6006C Control Pendant Assembly
15. 25-1136 Control Skirt Bracket
16. 25-1137 Control Skirt Bracket
17. 59-0023 2X Door Positioning Hinge
18. 25-1132A Control Box Cover Bracket
19. 25-1133A Control Box Cover Door

320 Mechanical Service 96-0283 rev C June 2007

 GR-408 R AM A SSEMBLY P ARTS L IST

17 18
19
20 21
22
9 10
16
8 23 36
15
7 39
38
6 37
11
5 26 24
12
27
1 4
2 40
3
13 41
14 28
29
30
42
31
32

43
44 45
35
33 34

51 46
53 50
52
49
58 47
48
57

54

56 55

Runner Block Assembly (Optional)

96-0283 rev C June 2007 Mechanical Service 321

 GR-408 R AM A SSEMBLY PARTS L IST

1. 59-0144 Fan Guard 45. 30-3778 Y-Axis Lube Line Assembly

2. 25-1157 Spindle Fan Cover 46. 20-0150 Ballnut Housing (40-50mm)
3. 25-1162 Head Cover 47. 30-3786B Y-Axis Lube Line Assembly
4. 22-7376 2x Sprocket Flange 48. 25-1165A Y-Axis Bellows Moving Mount
20-0997 Pulley 49. 30-3788 Z-Axis Lube Line Assembly
5. 62-1015 Spindle Motor 50. 20-1532 Ballnut Housing (32mm)
6. 25-6181 Encoder Mounting Plate 51. 59-0058 Air Cylinder (1.25x26)
7. Encoder Bracket 52. 50-30007 Linear Guide
8. 30-9569 Encoder Assembly 53. 25-7659 Curtain Lift Inside Mount
9. 22-0125 Encoder Drive Sprocket 54. 25-7662 Rear Curtain Lift Mount
10. 25-6180A Solenoid Motor Plate 55. 59-0845 Rear Curtains
11. 20-2415 Spindle Motor Plate 56. 59-0844 Front Curtains
12. 54-2121 Belt 57. 20-3463 Curtain Lift Rod
13. 22-7520A 8x Isolator 58. 25-7660 Curtain Lift Cover
14. 25-1153 Z-Axis Ballscrew Cover
15. 58-0004 Nipple ¼ NPT x2
16. 58-3613 Street Elbow 1/4F x NPT 1/4M
17. 32-5620 TRP Solenoid Valve Assembly
18. 58-3691 Nipple ¼ NPT Hex
19. 59-2832 Quick Exhaust
20. 58-3685 90° Elbow 3/8 x NPT ¼-M
21. 25-5516 2x Clamp/Unclamp Bracket
22. 25-7050 2x Switch Mounting Bracket
69-1700 2x Proximity Switch
23. 20-1491A Cylinder Housing Casting Machined
24. 25-6777 Z-axis Ballscrew Shield
26. 62-0036 Servo Motor
27. 20-7010A Motor Mount
28. 20-1114 Ballscrew Cover Spacer
20-7416 Bearing Cartridge Housing
22-7417 Bearing Cartridge Spacer
20-7418 Bearing Cartridge Lock
29. 24-0031 Ballscrew (32mm)
30. 28-0242 Z-Axis Bumper
31. 51-2012 Bearing Locknut
32. 25-1154A Head Vent Cover
33. 20-1548 Ram Motor Base
34. 20-1549B Ram Casting
35. 50-0025 2x Linear Guide
36. Cable Carrier Assembly
37. 25-1150A Z-Axis Cable Carrier
38. 25-1151 Z-Axis Cable Carrier Mount
39. 25-1152 Z-Axis Cable Carrier Mount Cover
40. 25-1148A Y-Axis Right Cable Carrier Bracket
41. 25-1149A Y-Axis Left Cable Carrier Bracket
42. 25-1156 Right Sub Plate Cover
43. 25-1155 Left Sub Plate Cover
44. 20-1525B Router Sub Plate
25-5937 Sub Plate Cover

322 Mechanical Service 96-0283 rev C June 2007

 GR-510/512/710/712 B ASE & T ABLE A SSEMBLY P ARTS L IST

1 2

25
24 23 4 5
20 3 6
7

22 21

9
10
16

19

28 29 30 31
18 27
15 11 26
12
17
13
14 15 32
1. 20-1531B GR-510 Table Assembly
34 33
20-1963B GR-512 Table Assembly
20-5846A GR-710 Table Assembly 35
36
20-2860B GR-712 Table Assembly
2. 25-1145 GR 510/512 Back Cover 37
34 38
25-6763 GR 710/712 Back Cover
3. 20-1828A Vacuum Table Pipe
4. 50-0023C 2x GR 510, 710 Linear Guide 15. 24-0029 Ballscrew 40mm (GR510, 710)
50-0029C 2x GR 512, 712 Linear Guide 24-0037 Ballscrew 50mm (GR512, 712)
5. 25-4796D 2x Light Sensor Bracket 16. 25-4795A 2x Reflector Mount
6. 25-4798B Left Safety Arm Mount 17. 20-1556A 3x Cable Carrier Track
7. 25-4797B Right Safety Arm Mount 18. 20-1530 2x Ballscrew Mount Extension
8. 32-7455 2x Light Sensor 19. 20-1552A GR510 Base
9. 46-1027 4x Adjusting Screw 20-1860 GR512 Base
10. 14-7068 4x Leveling Screw 20-2993 GR710 Base
20-2998 GR712 Base
11. 25-5187 Table Trip Bracket
25-7267 Y-Axis Mounting Bracket 20. 25-1373 Front Ballscrew Shield
69-1700 Proximity Switch 21. 58-2066 4x Hose Barb Fitting
12. 25-1348 GR 510, 512 Base Cable Trough 22. 58-0511 Valve
25-6767 GR 710, 712 Base Cable Trough 23. 58-0287 4x Hex Nipple
13. 25-1159 Cable Carrier Fixed End Bracket 24. 25-1144 GR510, 512 Front Gutter
14. 59-0395 Cable Carrier X-Axis (GR-510/710) 25-5965B GR710, 712 Front Gutter
59-0603 Cable Carrier X-Axis (GR-512/712) 25. 20-1814 Vacuum Table Manifold

96-0283 rev C June 2007 Mechanical Service 323

 GR-510/512/710/712 C ONTROL A SSEMBLY P ARTS L IST

2
1 3

6
5

7 8

11
10 9

13
12

1. 14-1550A Control Box Mount

2. 25-4311A Front Regen Cover
25-0462A Back Regen Cover
3. 32-9654B Control Box Assembly
4. 20-1593A Fixed End Control Arm
5. 20-1560A Control Arm
6. 25-6661A Arm End Cap
25-6659A Swivel Mounting Plate
7. 93-0282 Swivel Control Assembly
8. 25-1129 Pendant Hard Stop
9. 32-6006C Control Pendant Assembly
10. 25-1245A Regulator Mounting Bracket
11. 25-1246 Control Cabinet Back Cover
12. 25-1228 Control Cover Junction Box
13. 25-1227A Control Junction Box

324 Mechanical Service 96-0283 rev C June 2007

 GR-510/512/710/712 R AM A SSEMBLY PARTS L IST

11 12 22 23
24
10 13 25
26
9 27
21 28
8 40
20
7 29
6 41 42
30
14 31
5
15 39
32
1
2 19
3 43
16

33 44
34
45
35

36
18
37

46
38
49
59
47
57 48
50
60 56
62

61 54
55

51
63
53 52
64

67
65
68 66
76

75 72 69
70
71
74 73
Dust Shroud Assembly (Optional)

96-0283 rev C June 2007 Mechanical Service 325

 GR-510/512/710/712 R AM ASSEMBLY PARTS L IST
1. 59-01544 Fan Guard 38. 50-0025 2X Linear Guide
2. 25-1157 Spindle Fan Cover 39. 25-6777 Z-Axis Ballscrew Shield
3. 25-7910 Head Cover 40. 59-0393 Cable Carrier Assembly Z-Axis
4. Not Used 41. 25-1150A Z-Axis Cable Cover
5. 20-2415 Spindle Motor Plate 42. 25-6774 Z-Axis Cable Carrier Bracket
6. 62-1015 Spindle Motor 5HP 43. 25-1149A Y-Axis Left Cable Carrier Bracket
7. 25-6181 Encoder Mounting Plate 44. 25-1148A Y-Axis Right Cable Carrier Bracket
8. 20-0276A Encoder Drive Sprocket 45. 25-1156 Right Sub-Plate Cover
9. 25-6297 Encoder Spring Spacer 46. 25-1155 Left Sub-Plate Cover
10. 25-6293A Encoder Spring Mounting Box 47. 20-1532 Ballnut Housing 32mm
11. 30-9569 Encoder Assembly 48. 25-1165A 2X Y-Axis Bellows Moving Mount
12. 25-6761 Terminal Block Bracket 49. 30-3778 Y-Axis Lube Line Assembly
13. 25-6180C Solenoid Mounting Bracket 50. 20-0150 Ballnut Housing 40-50mm
GR-510 (10 HP) 51. 30-3786B Y-Axis Lube Line Assembly
25-7913 Solenoid Mounting Bracket
52. 20-1525B Router Sub-Plate
GR-510 (5 HP)/512/710/712
53. 25-5967 Sub-Plate Bottom Cover
14. 20-0997 Pulley
54. 30-3788 Z-Axis Lube Line Assembly
15. 54-0221 Belt
55. 14-2149 P-Cool Cover Casting
16. 22-7520A 8X Isolator
56. 25-7850 Programmable Coolant Bracket
17. Not Used
57. 20-0714A Air Cylinder Bracket
18. 20-3037A Motor Mount
58. Not Used
19. 20-3477A RAM
59. 58-2071 Fitting ½ x NPT - 1/2M
20. 58-0004 Nipple ¼ NPT x 2
60. 25-5654 Pipe Fitting Bracket
21. 58-3613 Street Elbow 1/4F x NPT 1/4M
61. 30-2738 Air Cylinder Assembly
22. 32-5620 TRP Solenoid Valve Assembly
62. 25-7707A Dust Shroud Bracket
23. 58-3691 Nipple ¼ NPT HEX x 1
63. 59-0929 Duct to Hose Adapter
24. 59-2832 Tool Changer Quick Exhaust
64. Pipe
25. 58-3685 90 Degree Elbow 3/8 x NPT 1/4M
65. 59-0359 Flange Adapter 6 inch
26. 25-5516 2X Clamp Unclamp Bracket
66. 25-7642C Dust Shroud Plenum
27. 25-7050C 2X Switch Mounting Bracket
69-1700 2X Proximity Switch 67. 25-7666B MTR DEP Top Cover
28. 20-1491A Cylinder Housing Casting 68. 32-0280B Turret Motor Assembly
29. 20-3724A TRP Mounting Plate 69. 25-7638B Dust Shroud Hinge
20-3372 Motor to Shaft Coupling
30. 20-3787 4X TRP Plate Spacer
69-1700 2X Proximity Switch
31. 62-0036C Yaskawa Servo Motor
70. 20-3371A Shroud Door Shaft
32. 20-7010A Motor Mount 20-0356 Flange Bushing 1 inch
33. 20-3531 Ballscrew Cover Spacer 71. 25-7639 2X Shroud Door Hinge Bracket
51-1011 Bearing
72. 26-0196A Left Rear Brush
20-7416 Bearing Cartridge Housing
22-7417 Bearing Cartridge Spacer 73. 26-0195A 3X Dust Shroud Front Brush
20-7418 Bearing Cartridge Lock 74. 26-0197 X-Axis Rear Chip Guard
34. 24-0031 Ballscrew 32mm 75. 25-7640C Dust Shroud Door
35. 28-0242 Z-Axis Bumper 76. 25-7641C Dust Shroud Hood
36. 51-2012 Bearing Locknut
37. 25-1154A Head Vent Cover

326 Mechanical Service 96-0283 rev C June 2007

 GR-510/512/710/712 S ADDLE A SSEMBLY P ARTS LIST

1
3

4
5
10
6

8
9 7

1. 20-2830A Left Column

2. 20-1544B 2x Saddle Spacer
3. 20-2831A Right Column
4. 20-0150 Ballnut Housing (40-50mm)
20-1964 Ballnut Housing (50x50mm)
5. 25-1158 X-Axis Moving Cable Carrier Bracket
6. 50-0029C 6x Linear Guide Trucks
7. 30-3789B 2x X-Axis Lube Line Assembly
8. 30-3957A X-Axis Lube Line Assembly
9. 20-3070 Saddle (GR510, 512)
20-3062 Saddle (GR710, 712)
10. 25-1304 Cable Hole Cover

96-0283 rev C June 2007 Mechanical Service 327

 M INI M ILL EXTERIOR S HEET M ETAL

1
15 16 19
13
20
12

11 14 21
25
24 22
23

18

17

4 2
6 5
3
7

10
9
1. 25-0754 Enclosure Side 14. 20-3009 Box Bar
2. 25-0386 Door Assembly 15. 25-0384A Back Panel Left
28-0011 Window 16. 25-0385A Back Panel Right
3. 20-0712 Guide Block 17. 14-1962 End Cap
4. 25-0753 Panel Front Enclosure 25-5394 End Cap Mounting Clip
5. 25-0958 Keybracket 18. 20-3008 Pendant Arm
6. 25-7050C Switch Mounting Bracket 19. 25-6661 Pendant Arm Knuckle
7. 25-0757 Door Keeper 20. 44-0018 Leveling SHCS
8. 22-7616 Lower Door Rail 21. 25-6660 Knuckle Cover
9. 25-7195K Lube Panel Mounting 22. 20-7109A Pendant Arm Mount
10. 25-0754 Enclosure Side Mirror 23. 20-7110A Pendant Mount
11. 25-0025D Main Electric Control Box 24. 55-0020 Wavy Washer
12. 25-7198B Junction Box 25. 25-6659 Knuckle Swivel Plate
13. 25-0461 Regen Cover (Front)
25-0462 Regen Cover (Back)

328 Mechanical Service 96-0283 rev C June 2007

 M INI MILL I NTERIOR SHEET M ETAL

1
Optional Chip Auger
2 Gasket Trough
57-0302 25-4915

17 5
6

16
7

8 9

14 15

13
10

12
11

1. 59-0144 Fan guard 10. 25-0378 Tab side cover (2)

2. 25-0389 Fan bracket top 11. 25-0374 Front Y-axis motor cover
3. 25-0382A Head Cover 12. 25-0372 Y-axis Waycover, Front
4. 25-0388 Back Head Cover 13. 25-0376 Motor Cover, X-axis
5. 25-0381 Z lower cover 14. 25-0379 Table End Cover (2)
6. 25-0380 Z upper cover 15. 25-0633 Tool Changer Shroud
7. 25-0373 Y-axis way cover, rear 16. 25-0636A Trap Door
8. 25-0377 Support Cover 17. 25-0634 Tool Changer Cover
9. 25-0375 Saddle cover (2)

96-0283 rev C June 2007 Mechanical Service 329

 M INI-MILL BASE

10
3

7 5
6
1. 20-3005 C Base
2. 20-3000 Casting
3. 50-0011 Y-axis runner block
4. 30-1752 Lube line assy
5. 62-0014 Y-axis motor
6. 32-2131 Limit switch
7. 50-3007 Linear Guide
8. 20-7008F Nut housing
9. 24-3006 Ballscrew
10. 20-3018 Bumper Y-axis

330 Mechanical Service 96-0283 rev C June 2007

 M INI-MILL C OLUMN

2 4

10

1. 20-3001 Column casting

2. 30-3048 Oil line assembly
3. 62-0009 Z-axis motor
4. 30-3049 Oil line assembly
5. 32-2130 Limit Switch
6. 50-0010 Runner block
7. 20-7008F Nut housing
8. 20-3019 Bumper Z-axis
9. 25-7273 Ballscrew assembly
10. 50-3007 Linear guide

96-0283 rev C June 2007 Mechanical Service 331

 M INI -MILL SADDLE
3 6
1 2 4 5 7 8

9
11
10

14
13

12
16 15

17
1. 50-3007 Linear guide
2. 30-1220 Coupling assembly
3. 50-0010 Runner block
4. 20-0505 Floating bumper
5. 30-1751 Lube line assembly
6. 25-0659 Carrier tray
7. 24-3006A Ballscrew
8. 20-7008F Nut Housing
9. 20-3017 Bumper, X-axis
10. 30-1750 Lube line assembly
11. 30-0154 Motor bearing assembly
12. 62-0014A X-axis motor
13. 32-2131 Limit switch
14. 50-0011 Runner block
15. 30-1752 Lube line assembly
16. 20-7008F Nut housing
17. 32-2130 Limit switch

332 Mechanical Service 96-0283 rev C June 2007

 OM-1/OM-2 E XTERIOR S HEET M ETAL

24 25
5 6
23

20 21 22 31
26 30
29
4 7
19 28
Door Open 17
8
16 18
3
9 15 32

14 33
2
13 27
1 10 12
11
34
OM
35

36

69
68
67

37
65 66
64 44 39
62 40
63
43
38
61
60 41
59
57 56
50
53 49 48 47 46 45
51
54 52 42
58 55

96-0283 rev C June 2007 Mechanical Service 333

 OM-1/OM-2 E XTERIOR SHEET M ETAL

1. 25-7231Bottom Front Panel 43. 25-7348A Base Right

2. 59-8210Door Handle 44. 25-7351A Base Rear
3. 25-7317Enclosure Door 45. 59-0837 2X Drawer Slide
4. 25-7393Gas Spring Door Bracket 46. 25-7350 Base Bottom
5. 59-00082X Gas Spring Ball Stud 47. 25-7072 Coolant Tank Support
6. 25-7394Gas Spring Enclosure Bracket 48. 25-7672 Tank Shipping Bracket
7. 59-0839Gas Spring Assy 49. 14-7068 4X Casting Level Pad
8. 25-7331Op Door Guide Bracket 50. 44-0018 4X Casting Level Bolt
9. 28-0174Window Top Guide 51. 59-0023 4X Door Hinge
10. 25-7673Shield Support Bracket 52. 25-5856A Right Front Lower Door
11. 20-3241Op Door Bottom Guide 53. 58-0227 2X Door Latch Assy
12. 25-7341Bottom Window Frame 54. 25-5855A Left Front Lower Door
13. 25-73372X Window Frame Sides 55. 32-0189A Coolant Pump Assy
14. 25-7333Door Switch Trip Flag Bracket 56. 25-6838 Coolant Tank Filter
15. 59-0162Chip Basket Handle 57. 25-7070 Pump Assy Bracket
16. 25-7338Top Window Frame 58. 25-7069 Coolant Tank
17. 28-0182Window 59. 25-7071 Chip Tray
18. 20-3239Door Hinge Stud 60. 58-1721 45 Degree Elbow 3-8npt
20-3240Door Hinge Bushing 58-3600 Nipple 3-8 Hex
20-3242Hinge Bottom 61. 59-2228 Swing Check Valve
19. 25-7392Operator Door Shield 62. 58-3662 Garden Hose Conn. .372" to .75"
20. 20-3244Top Hinge 63. 25-7346A Base Front
20-3243Top Hinge Bracket 64. 59-0814 Auto Lube Pump
21. 25-7319Left Panel 65. 30-8572 Air Regulator Assy
22. 25-7325Left Back Panel 66. 25-7347 Base Left
23. 25-7326Left Top Back Panel 67. 25-7390 Tool Tray
24. 25-7322A
Top Panel (OM-2) 68. 25-7490A Base Basin
25. 25-6914Top Panel (OM-1) 69. 25-7354A Short Machine Support
26. 25-4789A
Work Light Bracket Adjust
27. 25-7330Door Switch Bracket
69-1700Proximity Switch
28. 25-4788Work Light Housing
29. 25-7320Right Panel
30. 25-7323Right Back Panel
31. 25-7353Horiz. Cables Back Cover
32. 25-7352Vert. Cables Back Cover
33. 25-7329Back Cover Panel
34. 20-7109Swivel Arm Mount
20-7110Swivel Mount
35. 28-0024Beacon
36. Control Pendant Assy
37. 14-1962 2X End Cap
38. 20-3263 Pendant Arm
39. 25-6946A Pendant Arm Support
40. 25-6948 Control Cable Box Cover
41. 30-7286 Control Box Assy
42. 30-7741 Swivel Caster Assy (Left Side) (Optional)
30-7742 Swivel Caster Assy (Right Side) (Optional)

334 Mechanical Service 96-0283 rev C June 2007

 OM-1/OM-2 INTERNAL S HEET METAL

51

31
OM-1A_-2A
ATC Only
30
32 41
42 40

33 43
5
44
2 45
1
4 34 46
3 47
35 38
36 48

7 6
8 10
11 49

9 37 29
50
39
12
15 13 14
16 17
18 OM-1, -2 Shown
19
20 2
13 14
21
7 10 25
27
28
22 26
23 24

96-0283 rev C June 2007 Mechanical Service 335

 OM-1/OM-2 INTERNAL S HEET M ETAL

1. 25-6831 X-Axis Short Waycover

2. 25-6848 X-Axis Floater Waycover
3. 20-2743 Table
4. 20-2775 2X Riser Rail
5. 25-5841 Y-Axis Rear Waycover
6. 20-3082 Nut Housing
7. 50-0106 2X Linear Guide
8. 25-5840 Y-Axis Front Waycover
9. 20-2749 Ball Screw Bumper
10. 24-0110 Ball Screw
11. 20-2748 Bumper (Motor End)
12. 20-2741 Saddle Spacer
13. 20-2747 Motor Mount
14. 62-2495 Servo Motor
15. 30-7541 X-Axis Lube Line Assy
16. 20-2834 Switch Spacer
17. 69-1700 Proximity Switch
18. 20-2742 Saddle
19. 59-0672 Spring
20. 49-1015 Shoulder Bolt
21. 30-7542 Y-Axis Lube Line Assy
22. 20-2751 Ball Screw Bumper
23. 20-2746 Nut Housing
24. 20-2750 Pocket Stop
25. 25-5842 X-Axis Side Waycover
26. Not Used
27. 25-5846 Home Switch Bracket
69-1700 Proximity Switch
28. 20-2739 Base (Bed)
29. 20-2740 Column
30. Cable Carrier Bracket
31. 59-0882 Z-Axis Cable Carrier (OM-1, -2 only)
59-0821 Z-Axis Cable Carrier (OM-1A, -2A only)
32. 25-5989A Z-Axis Top Waycover
33. 25-5990 Z-Axis Upper Mid Waycover
34. 25-5844 Z-Axis Upper Bottom Waycover
35. NR-402E Spindle
36. 20-2745 Spindle Head Adapter
37. 20-1580 30mm Toolholder
38. 20-2744 Spindle Head
39. 25-6874 Z-Axis Lower Waycover (40K Spindle Option)
25-5845 Z-Axis Lower Waycover
40. 69-1700 Proximity Switch
41. 62-0048 Servo Motor
42. 25-5848 Switch Bracket
43. 59-0210 Plug
44. 50-0106 2X Linear Guide
45. 20-2747 Motor Mount
46. 20-2748 Bumper (Motor End)
47. 24-0110 Ball Screw
48. 20-2746 Nut Housing
49. 20-2749 Ball Screw Bumper
50. 30-7540 Z-Axis Lube Line Assy
51. 30-7868 ATC

336 Mechanical Service 96-0283 rev C June 2007

 OM-1/OM-2 TOOL C HANGER
8 9 14 15 18
7 19 18
6 13 12 3
20
21
4
16 17
12 24
10 11
3 25

5 26
2
27
28 23 22
1
29
30

3
1. 25-6953 Carriage Cover 31
2. 20-0680A Motor Mounting Plate
3. 32-2205 4X Proximity Switch TC Mark
4. 32-1911 2X Turret Motor 32
5. 25-7162 Connector Bracket
6. 43-0109 HHB 5/16 x 1.25 35 33
7. 45-1600 Split Lock Washer 5/16 36 34
8. 54-0010 Cam Follower
9. 45-1739 Flat Washer 5/16 37
10. 20-3124 Slip Clutch Hub 38
39 40
11. 40-1805 SHCS 8-32 x 5/8
12. 45-2020 2X Nylon Washer 1 1/4 41
42
13. 20-3123 Slip Clutch Arm 43
14. 20-7477 Pressure Plate
15. 55-0010 Spring Washer
16. 45-0050 Washer 1.00 44
17. 51-6000 Bearing Locknut
18. 25-1392 2X Felt Retainer 45
46 34
26-0083 2X Carrier Rail Wiper Felt
19. 20-3120A 2X V-Track 33
20. 32-1911 Turret Motor
21. 20-3122 TC Mount
22. 20-3119A V-Track Mount
23. 43-16011 HHB 1/2-13 x 1 34. 45-1600 12X Split Lock Washer 5/16
45-1740 Hard Washer 1/2 35. 20-3118 Geneva Driver
24. 46-1705 Nylon Lock Nut 3/4-10 36. 54-0222 2X Track Roller
45-1725 Washer 3/4 37. 20-3117 Geneva Star
25. 54-0040 4X Guide Wheel Std Bushing 38. 20-3116 Bearing Housing
26. 54-0030 4X Guide Wheel 39. 51-2022 2X Radial Bearing
27. 20-3114 Carriage Machined 40. 24-0113 20X Compression Spring
28. 25-0466 Door Opener Bracket 41. 20-3113 20X Extractor
29. 20-2065 Locating Pin 42. 48-0025 19X Roll Pin 1/8 x 5/8
30. 25-6952 Trap Door 43. 20-3112 Carousel
31. 25-6951 Shroud 44. 25-6949 Number Ring
32. 20-3115 Vertical Axle 45. 51-2041 Bearing Locknut
33. 40-16385 12X SHCS 5/16-18 x 3/4 46. 25-0635 Bearing Cover

96-0283 rev C June 2007 Mechanical Service 337

 OM-1, -2 SPINDLE H EAD A SSEMBLY

62
63
64

58 59 65
60 66
57
61

55 56 67
76
77 75 68
54 78
79 69
70
80 71
81 82
53 83
52 84
85 87
86 88
92
89
90
91
93
72

94
95 96 73
97
98 99
100 102 101
103
104
105 74

107 106
108
109
110
111
99
112

338 Mechanical Service 96-0283 rev C June 2007

 OM-1, -2 SPINDLE H EAD A SSEMBLY

52. 25-7461A Spindle Head Cover 98. 57-0070 O-Ring 2-114

53. 66-1480 Fan 99. O-Ring 2-012
54. 25-7462A Top Head Cover 100. 20-3202 Draw Bar Retainer
55. 59-0144 Fan Guard 101. 3MR-635-15 Polychain GT2 Belt
56. 59-2832B Quick Exhaust 102. 20-3226 Pulley 90T
58-3729 Nipple 103. 57-4120 O-Ring 2-226
57. 36-30675 Solenoid 104. 20-3192A Spindle Housing
58. 53-3012 Pressure Switch 105. 20-3197 Spindle Lock Ring
59. 58-2743 Branch Tee 106. Spring 4.51g_Comp. 1_15
60. 58-2736 Air Regulator 0-10 B-1 107. 2X Bearing 25_42_9mm
61. 36-30670 Solenoid 108. 20-3196 Spindle Outer Spacer
62. 60-1813 Encoder 109. 20-3195 Spindle Inner Spacer
63. 25-6298 Encoder Spring Clamp 110. O-Ring 2-033
64. 25-6293 Encoder Spring Box 111. 20-3193A Spindle Cap
65. 20-3323 Encoder Drive Sprocket 112. 20-3194A Spindle Shaft
66. HDT_Wb1 Encoder Drive Belt 113. 20-3201 Spindle Draw Bar
67. 20-0276A Drive Sprocket
68. 25-7463 Terminal Block Mount
69. 25-7469 Spindle Connector Bracket
70. 73-3054 Terminal Block
71. 25-7460A Head Back Cover
72. 57-0401 2X Coolant Gasket Jacket
73. 25-7432 2X Coolant Gasket Cover
74. 25-6874 Z-Axis Lower Waycover
75. 62-0300 Spindle Motor 1.5 HP
76. Not Used
77. 20-1656 TRP Spring Retainer
78. 59-2760 TRP Spring
79. 45-1730 Hard Washer 3_8
80. Spring C0850_092_0880_M
81. 49-0130 Shoulder Screw 3/8 x 2 3/4
82. 69-1700 2X Proximity Switch
83. 25-7227 2X Switch Mounting Bracket
84. 20-3204 TRP Cylinder
85. 20-3205 TRP Piston
86. 20-3216 TRP Sub-Plate
87. 20-3207 4X TRP Support Spacer
88. 20-3206 TRP Support Finger
89. 20-7626C TRP TSC Shaft
90. 45-0063 5X
91. 20-7640 Tool Release Bolt
92. 20-3260 Washer 3/8 Steel
93. 20-3121 Head Machined
94. WHM75 Spiral Retaining Ring
95. 20-3199 2X Sprocket Flange
96. 20-3198 Sprocket GT2 5M-30S-15
97. 54-0101A Shaft Collar 5/16

96-0283 rev C June 2007 Mechanical Service 339

 TOOLROOM M ILL E XTERIOR S HEET METAL

2 3 5 6

4
7

10 11 12

23
22

13
21

20

14

19
18
15

17 16

1. 25-7198 Junction Box 12. 25-6596 Right Chip Pan

2. 59-0385 Corrugated Tubing Assembly 13. 25-0440A Tool Crib
3. 32-0043 Regen Cover 14. 25-4006 Right Side Pan
4. 25-4044A Control Box Top Mounting Bracket 15. 25-6656 Trough
5. 59-0144 Fan Guard 16. 20-1117A Front Leg
6. 25-0389 Top Fan Bracket 17. 20-1116A Rear Leg
7. 25-4003C Spindle Head Cover 18. 25-4007 Left Side Pan
8. 25-4008 Safety Shield 19. 25-6597 Left Chip Pan
9. 25-1097 Pendant Arm 20. 25-4000A Table Motor Cover
10. 14-1962 End Cap (2) 21. 25-4010 Spindle Waycover
25-5394 End Cap Mounting Clip 22. 25-1091 Control Box Bottom Mount (2)
11. 25-0563 Storage Box 23. 25-0025 Control Box

340 Mechanical Service 96-0283 rev C June 2007

 TOOLROOM MILL I NTERIOR P ARTS

1 6

2 5 7

3 8

4 9

26 10

11
17 18
12 16
54 14 13 19
32
53 33
15
34
52

15
32
51
33
50 20
34 32
21 26
33
36 37 22
34 35
36 26
26
49
28
23 24
48
25
26

29 27

47

46 38 30
31
39
19
22
44
45 43
41 42
42 41
40

96-0283 rev C June 2007 Mechanical Service 341

 T OOLROOM MILL INTERIOR PARTS L IST

1. 62-0024 Motor 50. 20-3017 Bumper

2. 30-1220A Coupling Assembly 51. 30-2042 Z-Axis Oil Line Assembly
3. 32-5060 Z-Axis Limit Switch 52. 50-0014A Z-Axis Linear Guides (2)
4. 25-4024 Z-Axis Limit Switch Mounting Bracket 53. 24-0021 Z-Axis Ball Screw
5. 20-7008F Z-Axis Ball Screw Nut Housing 54. 20-1303A Base Machined
6. 30-2465A Air Solenoid Assembly
7. 30-1674 Linear Motor 5HP
8. 25-6578 Z-Axis Limit Switch Trip Bracket
9. 30-1668A TRP Assembly
10. 20-7373 Pulley 1_7_8
11. 20-7442 Oil Injection Cover
12. 20-1330 Spindle Head Housing Machined
13. 30-1337 Spindle Assembly CT30
14. 20-3003A Spindle Mounting Plate
15. 62-0014 Motor
16. 25-4001A Table Side Covers (2)
17. 20-1302A Table
18. 25-4002A Table End Cover
19. 20-1256 Handwheel (2)
20. 25-4014 X-Axis Proximity Switch Bracket
21. 32-2133 X-Axis Proximity Switch
22. 20-1093 X and Y Axis Ball Screw Nut Housing (2)
23. 20-1147 X-Axis Support Bumper
24. 30-2780 Bearing Housing Assembly
25. 51-2025 Ball Bearing
26. 51-2012 Bearing Locknut (6)
27. 50-0012A X-Axis Linear Guides (2)
28. 30-2767 X-Axis Oil Line Assembly
29. 25-4013 X-Axis Proximity Switch Trip Bracket
30. 20-1304B Saddle
31. 25-5191 Y-Axis Proximity Switch Trip Bracket
32. 20-7416 Bearing Cartridge Housing (3)
33. 51-1011U Ball Bearing (3)
34. 20-7418 Bearing Cartridge Lock (3)
35. 20-1146 Bumper (Motor Side)
36. 30-1220 Coupling Assembly (2)
37. 24-0019 X-Axis Ball screw
38. 30-2780 Bearing Housing Assembly
39. 51-2025 Ball Bearing
40. 20-1158 Y-Axis Support Bumper
41. 59-0264 Ball Screw Cover (2)
42. 20-1113 Ball Screw Cover Retainer (2)
43. 20-1114 Ball Screw Spacer
44. 24-0020 Y-Axis Ball Screw
45. 20-1148 Y-Axis Motor Bumper
46. 32-2133 Y-Axis Proximity Switch
47. 25-4012 Y-Axis Limit Switch Bracket
48. 50-0013A Y-Axis Linear Guides (2)
49. 30-2794 Y-Axis Oil Line Assembly

342 Mechanical Service 96-0283 rev C June 2007

 VS-3 S HEET M ETAL ASSEMBLY

96-0283 rev C June 2007 Mechanical Service 343

 VS-3 SHEET METAL A SSEMBLY P ARTS L IST

1. Fan guard 31. Center, left door

2. Head cover, top plate 32. Center, right door
3. Head cover, left rear cover 33. Right splash tray
4. Head cover, left front cover 34. Left, splash tray
5. Head cover, right rear cover 35. Table splash guard
6. Head cover, right front cover 36. Pedant arm shroud
7. Head cover, rear bottom 37. Pendant arm
8. Bottom head access plate 38. Z-Axis, right chip conveyor tray
9. Head cover, front bottom cover 39. Z-Axis, left chip conveyor tray
10. Head cover, front 40. Brace
11. Tool changer housing 41. Z-Axis chip conveyor gasket
12. Tool changer shroud 42. X-Axis splash guard
13. Head cover access plate 43. Chip conveyor chute
14. Left rear enclosure panel 44. X-Axis chip conveyor tray, left
15. Rear enclosure panel 45. X-Axis chip conveyor tray gasket
16. Center bottom sheet metal panel. 46. X-Axis chip conveyor tray, middle
17. Right rear enclosure panel 47. X-Axis chip conveyor tray, right
18. Conduit box 48. X-Axis way cover end plate
19. Conduit enclosure 49. X-Axis way covers
20. Conduit access plate 50. X-Axis wiper
21. “L” bracket 51. Z-Axis way cover wiper cover
22. Right front sheet metal 52. Z-Axis way cover wiper
23. Right forward sheet metal 53. Z-Axis way covers
24. Left forward sheet metal 54. Z-Axis way cover end plate
25. Left front sheet metal 55. Z-Axis way cover end support
26. Support brace 56. X-Axis extension
27. Left corner, door assembly 57. X-Axis extension access cover
28. Left door
29. Right door
30. Right corner, door assembly

344 Mechanical Service 96-0283 rev C June 2007

 LATHE ASSEMBLY DRAWINGS AND PARTS LISTS

SL-10 C ASTING ASSEMBLY AND P ARTS L IST

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

96-0283 rev C June 2007 Mechanical Service 345

 SL-10 T AILSTOCK A SSEMBLY AND P ARTS L IST
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

346 Mechanical Service 96-0283 rev C June 2007

 SL-10 WEDGE ASSEMBLY AND PARTS L IST

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

96-0283 rev C June 2007 Mechanical Service 347

 SL-10 TOOL CHANGER ASSEMBLY AND PARTS L IST

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

348 Mechanical Service 96-0283 rev C June 2007

 SL-20 C ASTING ASSEMBLY AND P ARTS L IST
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

96-0283 rev C June 2007 Mechanical Service 349

 SL-30 CASTING ASSEMBLY W/T AILSTOCK

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

350 Mechanical Service 96-0283 rev C June 2007

 SL-30 C ASTING ASSEMBLY W /T AILSTOCK P ARTS L IST

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

96-0283 rev C June 2007 Mechanical Service 351

 SL-40 C ASTING A SSEMBLY W /TAILSTOCK AND P ARTS L IST
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

352 Mechanical Service 96-0283 rev C June 2007

 SL-40L C ASTING ASSEMBLY AND PARTS L IST

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

96-0283 rev C June 2007 Mechanical Service 353

 TL-25 C ASTING ASSEMBLY AND P ARTS L IST

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

354 Mechanical Service 96-0283 rev C June 2007

 TL-25 SUB-S PINDLE ASSEMBLY AND P ARTS L IST
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

96-0283 rev C June 2007 Mechanical Service 355

 SL-20 W EDGE ASSEMBLY AND PARTS L IST

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 13. 50-8549 Linear Guide

2. 22-2629 Stub Shaft Key 14. 20-7008F Nut Housing Machined
3. 30-1044 Oil Line Carrier 15. 24-7325 Str Fit Metric Linear Guide
4. 41-1717 Long Stud/Set Screw 16. 30-8716 Lube Line Assembly
5. 58-2110 Sleeve Nuts Lube Assembly 17. 22-7458 Linear Guide Cam
6. 25-7042A Snap Lock Motor Mount Cover Plate 18. 25-7266 X-Axis Mounting Bracket
7. 26-7233A Deflector Shield Gasket 19. 30-1220A Coupling Assembly
8. 20-7185 Z-Axis Motor End Bumper 20. 20-8535 Tool Changer Access Plate
9. 58-3031 Banjo Elbow 5/16 F x M6 M 21. 57-8546 TC Access Plate Gasket
10. 30-0616B X-Axis Ball Screw Assembly 22. 57-8576 TC Cover Gasket
11. 20-7185 Z-Axis Support End Bumper 23. 20-8545 TC Housing Cover
12. 48-0045 Dowel Pin 24. 20-8364 Spacer
23. 25-7459 Trip Table Bracket

356 Mechanical Service 96-0283 rev C June 2007

 SL-30 WEDGE ASSEMBLY AND PARTS L IST
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

96-0283 rev C June 2007 Mechanical Service 357

 SL-40 W EDGE ASSEMBLY AND PARTS L IST

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

358 Mechanical Service 96-0283 rev C June 2007

 SL-20 TOOL CHANGER ASSEMBLY

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
60
61 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

96-0283 rev C June 2007 Mechanical Service 359

 SL-20 T OOL CHANGER ASSEMBLY P ARTS L IST

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 Retainer 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 Retainer 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. 58-8657 Copper line
35. 57-1045 Seal
36. 20-8539 Bearing rear
37. 20-8511A Gear cluster T/C
38. 46-7016 Locknut
39. 20-8522A Gear spur T/C
40. 22-8544 Key gear spur T/C
41. 24-4010 Bellville washer
42. 22-8550A Spacer Bellville T/C
43. 20-8516 Lever cam T/C
44. 93-8138 Cam Turret T/C
45. 30-3660A 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

360 Mechanical Service 96-0283 rev C June 2007

 SL-30 TOOL CHANGER ASSEMBLY

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

96-0283 rev C June 2007 Mechanical Service 361

 SL-30 T OOL CHANGER ASSEMBLY P ARTS L IST

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 Retainer 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

362 Mechanical Service 96-0283 rev C June 2007

 SL-40 TOOL CHANGER ASSEMBLY

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

96-0283 rev C June 2007 Mechanical Service 363

 SL-40 T OOL CHANGER ASSEMBLY P ARTS L IST

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

364 Mechanical Service 96-0283 rev C June 2007

 SL-40 HYDRAULIC TOOL C HANGER
3
5

1
2

4
7
1
6

9 10 11 30 31
12 13 32
27 29
14 28 33
15 27
8 26
34

24 25
21 35

23 42
22
21
16 17
20 43

20 41
20 40 44
49
18 39
19
38
45
37

46

36 47

48

96-0283 rev C June 2007 Mechanical Service 365

 SL-40 H YDRAULIC TOOL C HANGER PARTS L IST

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

366 Mechanical Service 96-0283 rev C June 2007

 B ALL SCREW ASSEMBLY
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)

96-0283 rev C June 2007 Mechanical Service 367

 COUPLING ASSEMBLY

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)

368 Mechanical Service 96-0283 rev C June 2007

 PENDANT LEVELING ASSEMBLY

Levelling Screw
(40-164391)
Pendant Arm
Knuckle
(25-6661)

Knuckle Cover
(25-6660)

Knuckle Swivel
Plate (25-6659)

Pendant Arm
Mount (20-7109)

Wavy Washer
Pendant Mount
(55-0020)
(20-7110)

96-0283 rev C June 2007 Mechanical Service 369

 LATHE TOOL S ETTING A RM

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)

370 Mechanical Service 96-0283 rev C June 2007

 SL-30 AND SL-40 S TEADY R EST

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)

96-0283 rev C June 2007 Mechanical Service 371

 FOOT SWITCH ASSEMBLY

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)

372 Mechanical Service 96-0283 rev C June 2007

 P ARKER HYDRAULIC P OWER UNIT

96-0283 rev C June 2007 Mechanical Service 373

 R EXROTH HYDRAULIC P OWER UNIT
58-0741 Chuck
93-0531
Low Pressure
Cartridge

93-9137
Filter

93-0460/61
T/S Rapid
Solenoid

58-0741 T/S

59-0703 93-0458
Pressure T/S Solenoid
Adjusting Valve Valve
(59-0439
for SL-10)

58-0086
Sight Gauge

93-0459
Chuck Solenoid Valve

374 Mechanical Service 96-0283 rev C June 2007

 H AAS H YDRAULIC 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
Filter Replacement
Filter Manufacturer Oil Filter Part Number Replacement Element Part Number
Pall 58-1064 58-1065
Hydac 58-1064 58-1066
Flow Ezy 58-1064 58-1067

96-0283 rev C June 2007 Mechanical Service 375

 M INI L ATHE EXTERNAL SHEETMETAL AND P ARTS 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

376 Mechanical Service 96-0283 rev C June 2007

 M INI L ATHE I NTERNAL S HEETMETAL AND P ARTS L IST

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

96-0283 rev C June 2007 Mechanical Service 377

 O FFICE LATHE EXTERNAL S HEETMETAL AND P ARTS L IST

7 22
8 23 25 26 28
21 24
11 12 13 27
6 9 14
10
5
4 15
3
11

18 16 30
29
17
2 19 20

31
1
32

OL

34
35
37
36 38
65 66
64
40

63 46 39
45 41
58
62 44 42

43
57 47
54 50
61 56 55 48
59
60 51
52
49
53

378 Mechanical Service 96-0283 rev C June 2007

 O FFICE L ATHE EXTERNAL S HEETMETAL AND P ARTS L IST

1. 59-0754 Chrome Handle 41. 25-6946A Pendant Arm Support

2. 25-6905 Set-Up Door Panel 42. 32-9841 Electrical Control Box Assy
3. 25-6070A Window Rail 43. 30-7741 Right Swiveling Caster
4. 28-0175 Bottom Window Guide 30-7742 Left Swiveling Caster
5. 25-6247A Bottom Window Frame 44. 25-7348A Base Right Panel
6. 28-0173A Window 45. 25-7072 Coolant Tank Support
7. 25-7549 Operator Door Panel 46. 25-7350 Base Bottom
59-0901 Small Handle 47. 30-0857B Pendant Mount Assy
8. 25-6081 Window Guide Bracket 48. 28-0024 Top Beacon Light Assy
28-0174 Top Window Guide 49. 25-1125A Front Pendant Enclosure
9. 25-6084A Left Window Side Frame 50. 58-3662 .375 Garden Hose Fitting
25-6108 Right Window Side Frame 51. 59-2228 .375 Swing Valve Brass
10. 25-7198 Junction Box Cover 52. 58-3600 .375 Hex Nipple
11. 59-0101 2X Gas Spring 53. 58-1721 45 Degree Elbow
12. 25-6907 Left Panel 54. 32-5005 Coolant Pump Kit
13. 59-2746 Reverse Acting TV-4DMP Model CS-1781 55. 25-6838 Coolant Tank Filter
25-7579 Drawbar Relief Bracket 56. 25-7070 Pump Assy Bracket
14. 32-1210A Chuck Release Button 57. 25-7069 Coolant Tank
25-6924 Chuck Release Bracket 58. 25-7071 Chip Tray
15. 25-7553 Door Switch Bracket 59. 59-0023 4X Door Hinge
32-2305 Proximity Switch 60. 25-5856A Right Base Door
16. 25-6912 Spindle Partition 61. 25-5855A Left Base Door
17. 25-7573 Coolant Splash Shield 62. 58-0227 2X Push Close Latch
18. 59-0712 3X AKROBIN AKRO-Mils 30-210 Red 63. 25-7346A Base Front Panel
19. 25-7916 Tool Tray 64. 59-0814 Auto Lube Pump
20. 25-6908 Right Panel 65. 30-8257 Air Regulator Assy
21. 58-1679 Bulkhead Fitting NPT-3/8 x 1.000 Dia. 66. 25-7347A Base Left Panel
22. 25-6796A Coolant Manifold Bracket
23. 30-8487 Spindle Head Manifold Assy
24. 25-6909 Top Panel
25. 32-0229 Work Light Housing
26. 25-4789A Work Light Adjust Bracket
27. 66-1480 Fan 5.91 x 6.78 in. 200 cfm
25-6923 Fan Bracket
66-1485 Fan Guard
28. 25-6910 Back Panel
29. 25-7500 Horizontal Cables Back Cover
30. 25-7501 Vertical Cables Back Cover
31. 25-6911 Bottom Back Panel
32. 25-6906 Bottom Front Panel
33. NOT USED
34. 25-7355A Long Machine Support
35. 25-7491A Base Basin
36. 25-7499 Back Cables Trough
37. 25-7351A Base Rear Panel
38. 14-1962 2X End Cap Assy
39. 20-3263A Pendant Arm
40. 25-6948A Pendant Arm Cover

96-0283 rev C June 2007 Mechanical Service 379

 O FFICE LATHE I NTERNAL SHEETMETAL AND P ARTS L IST
3 4
2 5 6 7
1
8

17 9
19
10
11 12 22
13 14 23 24
15 16 25
18
26
27
21
20

29
30
32

33

55
34
53 54 31

32
35
33 39
51 37 36
44

40
38 41 42
50
52 49

48 43

44
40

39
47 45
46
35

380 Mechanical Service 96-0283 rev C June 2007

 O FFICE L ATHE INTERNAL S HEETMETAL AND PARTS L IST
1. 49-0122 2X Track Roller 32. 25-6848 2X X-Axis Floater Waycover
2. 20-3088A Lever AAC 33. 59-0883 4X Spring - Ext - 3/8 x 2.50 lg x .035
3. 59-0789 Air Cylinder AAC 34. 25-5842A X-Axis Waycover
4. 25-6828A Spindle Belt Cover 35. 50-0106 4X Linear Guide
5. 20-3090 Cylinder Mount AAC 36. 25-6068B Z-Axis Right Waycover
6. 54-0214 Belt 37. 20-3082 X-Axis Nut Housing
7. 20-2766A Pulley 180T 3mm 38. 20-2748 X-Axis Bumper
8. 62-0014 Servo Motor 20-2754 Ball Screw Bearing Cap
9. 30-8277 Solenoid Assy 39. 20-2747 2X Motor Mount
10. 20-3087 Drawbar AAC (30-7451 Air Collet Closer) 59-1086 Plug
11. 20-3107 Locking Collar AAC (30-7451 Air Collet Closer) 40. 62-2495A 2X Servo Motor
12. 20-2056 Coolet Closer Cone (30-7451 Air Collet Closer) 41. 32-2193 Proximity Switch
13. 20-2055 Detent Ring (30-7451 Air Collet Closer) 20-2834 Switch Spacer
14. 57-2057 Fiber Washer 42. 25-6847 X-Axis Bottom Waycover
15. 20-3091 Drawbar Bushing 43. 30-7542B Y-Axis Lube Line Assy
16. 20-2921 2X Pulley Flange 90T 3mm 44. 24-0110 2X Ball Screw
17. 20-2765A Pulley 90T 3mm 45. 20-2751 Y-Axis Ball Screw Bumper
18. 20-2764A Spindle Lock 60mm 46. 20-2746A Y-Axis Nut Housing
19. 20-2773A Motor Mount Plate 47. 20-2750 Y-Axis Bumper
20. 25-7548A Spindle Cable Shield 48. 20-2742B Saddle Machined
21. 51-0165 2X Bearing 49. 30-7541C X-Axis Lube Line Assy
22. 20-2767 Spacer Set 60mm 50. 20-2749 Ball Screw Bumper
23. 20-2762A Spindle Shaft 51. 20-2741 2X Saddle Spacer
24. 22-4052 5C Lock Screw 52. 25-6831 X-Axis Short Waycover
25. 20-2761A Spindle Head Machined 53. 25-6067A Z-Axis Left Waycover
26. 57-2875 O-Ring 54. 20-2743A Table Machined
27. 20-2918 Spindle Cap 55. 20-2775 2X Riser Rail
28. NOT USED
29. 32-2195 Proximity Switch
30. 25-5846 Switch Bracket
31. 20-2739A Bed Machined

96-0283 rev C June 2007 Mechanical Service 381

 O FFICE LATHE EXPLODED S PINDLE HEAD

20-2764A
Spindle Lock
20-2765A 54-0214
Pulley 90T Belt
20-2921
20-2767 Flange,
Spacer Set Pulley
2X 51-0165
Bearing

20-2762A
Spindle Shaft

20-2766A
Pulley 180T

Spindle Cartridge

20-2773A
Motor Plate

20-2761A
62-0014 Spindle Head
20-2918
Spindle Cap Motor

382 Mechanical Service 96-0283 rev C June 2007

 SL-10 EXTERNAL S HEETMETAL AND P ARTS L IST

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

2. 25-0876 Pendant Back Cover 19. 25-0860 Door Inner Liner
3. 25-0879 Z-Axis Right Bottom Wiper Retainer 20. 25-0862 Front Skirt
4. 26-0030 Z-Axis Right Bottom Wiper Felt 21. 25-0865 Lower Door Rail
5. 59-0009 R-Type Hinge Half 22. 22-6506 Door V-Track
6. 25-0868A Right Side Panel Weldment 23. 20-6016 Door V-Track Spacer
7. 25-1002 Tailstock Pan 24. 25-6190 Bottom Left Side Panel
8. 25-0890 NOTS Tray 25. 25-0398 Tramp Lube Oil Bottle Panel
9. 25-1023 Motor Pump Coolant Tray 26. 25-6185 Coolant Collector
10. 25-0889 Coolant PM Tray 27. 25-0606 Coolant Collector Door
11. 25-0548 Discharge Chute Weldment 28. 25-6150 Coolant Collector Enclosure
12. 25-0887 Auger Pan Weldment 29. 25-6189A Top Left End Panel
13. 25-6551 Auger Mount 30. 26-0869 Upper Door Rail
14. 25-0888 Chip Tray Extension 31. 25-0025D Main Electrical Control Box
15. 25-0878B Chip Tray Right 32. 25-8709 J-Box
16. 25-0877B Chip Tray Left 33. 32-0042 Regen Assembly
17. 25-6574 Chip Tray Bottom 34. 25-0857 Control Box Bracket
18. 25-0858 Door Weldment (25-0016 Window) 35. 25-0867 Rear Panel
36. 25-0863 Hydraulic Pump Mount Weldment

96-0283 rev C June 2007 Mechanical Service 383

 SL-10 INTERNAL S HEETMETAL AND PARTS LIST

1. 25-0870 X-Axis Top Cover 13. 25-0885 Belt Cover

2. 25-0871 X-Axis Front Cover 14. 25-0886 Fan Mount
3. 25-0983 X-Axis Wiper Retainer 15. 36-3035 Spindle Motor Fan
4. 26-0038 X-Axis Way Cover Felt 16. 25-0861 Fixed Bulkhead
5. 25-0872 X-Axis Way Cover 17. 25-0880 Z-Axis Left Bottom Wiper Retainer
6. 26-0034 X-Axis Top Wiper Felt 18. 26-0032 Z-Axis Left Bottom Wiper Felt
7. 25-0866 Moving Bulkhead 19. 25-0881 Z-Axis Left Top Wiper Retainer
8. 26-0035 X-Axis Side Wiper Felt 20. 26-0033 Z-Axis Left Top Wiper Felt
9. 25-0873 Z-Axis Sliding Cover 21. 25-0859 Door Drain
10 26-0036 Cover, Z-axis Right 22. 26-0039 Door Wiper
11.25-6138A Chip Shield Wedge SL-10 23. 25-0947 Top Wiper Retainer
12. 25-7195 Lube Rack Bracket

384 Mechanical Service 96-0283 rev C June 2007

 SL-20 EXTERNAL S HEETMETAL AND P ARTS L IST

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)

96-0283 rev C June 2007 Mechanical Service 385

 SL-20 INTERNAL S HEETMETAL 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)

386 Mechanical Service 96-0283 rev C June 2007

 SL-30 EXTERNAL S HEETMETAL AND P ARTS L IST

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

96-0283 rev C June 2007 Mechanical Service 387

 SL-30 INTERNAL S HEETMETAL 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
* For Lifting Only
11
**

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

388 Mechanical Service 96-0283 rev C June 2007

 SL-40 EXTERNAL S HEETMETAL AND P ARTS 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

96-0283 rev C June 2007 Mechanical Service 389

 SL-40 INTERNAL S HEETMETAL 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

390 Mechanical Service 96-0283 rev C June 2007

 SL-40L E XTERNAL S HEETMETAL (S HEET 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

96-0283 rev C June 2007 Mechanical Service 391

 SL-40L E XTERNAL S HEETMETAL (S HEET 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

392 Mechanical Service 96-0283 rev C June 2007

 SL-40L E XTERNAL S HEETMETAL P ARTS L IST

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

96-0283 rev C June 2007 Mechanical Service 393

 SL-40L I NTERNAL 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

394 Mechanical Service 96-0283 rev C June 2007

 SL-40L I NTERNAL S HEETMETAL P ARTS 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

96-0283 rev C June 2007 Mechanical Service 395

 TL-15 LIVE T OOLING AND S UB-S PINDLE SHEETMETAL

1 2
3

5
7 6

Live Tooling

9
10 11
1981_F40
BHCS
45-0022
Washer

12 20-0170A
Drive Castle

45-0025
14 Washer

21 59-0069
13 Spring

20 51-2042
Locknut

19 16 15
20-0168A
Shaft
17
18
Sub-Spindle Bearing
SL-20/30 Live Tooling
Nose

20-0277
Pulley

396 Mechanical Service 96-0283 rev C June 2007

 TL-15 SHEETMETAL P ARTS 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

96-0283 rev C June 2007 Mechanical Service 397

 TL-25 E XTERNAL S HEETMETAL AND P ARTS L IST

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

398 Mechanical Service 96-0283 rev C June 2007

 TL-25 INTERNAL S HEETMETAL

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

96-0283 rev C June 2007 Mechanical Service 399

 TL-25 INTERNAL SHEETMETAL PARTS L IST
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

400 Mechanical Service 96-0283 rev C June 2007

 B ARFEEDER S HEETMETAL AND PARTS LIST

1 2

4
3

300
AR
OB
5 ERV
S

7
8

11

9
1. 25-6516A Base Position Control 8 10
2. 25-6537B Barfeeder Door
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

96-0283 rev C June 2007 Mechanical Service 401

 B ARFEEDER EXTERNAL PARTS

402 Mechanical Service 96-0283 rev C June 2007

 B ARFEEDER E XTERNAL P ARTS L IST

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

96-0283 rev C June 2007 Mechanical Service 403

 B ARFEEDER INTERNAL P ARTS

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

o
View Rotated 180
29
16
66 17
65 18
1
3 27
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

404 Mechanical Service 96-0283 rev C June 2007

 B ARFEEDER 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. 25-6531 Motion control intermediate 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

96-0283 rev C June 2007 Mechanical Service 405

 D ETAILED B AR 300 P ARTS
30-1389 – 3/8" Pushrod
20-6484 – 3/4" Pushrod

CURRENT

20-1033 Push 20-1034 Push Rod Control 20-1035 Push Rod Control 20-1923 Spacer 30-1336 Switch Hold
Rod End Clamp Bushing Holder 3/4” Bushing Holder 3/8” Down Assembly

PREVIOUS

51-0055 20-0357
Nylon Flange Push Shaft
Bushing 3/8" Bushing 3/4"
20-6483 Push Rod 20-6032 Push Rod Control 20-6044 Push Rod Control
Connector Adapter Bushing Holder 3/4” Bushing Holder 3/8”

406 Mechanical Service 96-0283 rev C June 2007

 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 10. 25-4932 X Axis Motor Cover

2. 45-4301 25-4307 Control Cabinet 11. 25-6351 Wiper Retainer
3. 25-4794 Control Box Isolator (4) 12. 26-0372 Wiper Felt
4. 59-0515 Contorl Box Gasket (4) 13. 25-4931 Rear Ballscrew Left Cover
5. 20-2672 Pendent Arm 14. 25-6352 Saddle Chip Guard
6. 25-6661 Arm End Cap (leveling) 15. 25-4930 Rear Ballscrew Right Cover
7. 25-5524 Control Pendant Shell 16. 20-1938 TS Quill
8. 20-1936 Control Box Support Frame 17. 20-1957 Quill Drive Nut
9. 25-5449 TL-2 Control Support 18. 20-1939 Drive Screw
25-6354 LT-1 Control Support Cover 19. 20-2453 TS Bearing Spacer

96-0283 rev C June 2007 Mechanical Service 407

 T OOLROOM L ATHE (TL-1) PARTS L IST

20. 51-2033 Radial Bearing 66. 20-9062 Tool Mat

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

408 Mechanical Service 96-0283 rev C June 2007

 TL 1-2CE

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)

96-0283 rev C June 2007 Mechanical Service 409

 TL 1-2CE P ARTS L IST

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

410 Mechanical Service 96-0283 rev C June 2007

 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

96-0283 rev C June 2007 Mechanical Service 411

 LATHE APL P ARTS L IST

1. 25-0704 Carriage Cover 56. 51-4000 Radial Bearing

2. 59-0197 Cable Carrier 57. 20-0741 Drive Shaft
3. 25-0705 Cable Carrier Mount 58. 20-5164 Pinion
4. 25-0703 B-Axis Ram 59. 20-0742 W-Axis Spacer
5. 59-0196 Cable Carrier 60. 20-0740 Carriage Plate
6. 50-0008 Linear Guide 61. 20-0739 Hard Stop
7. 20-0739 Hard Stop 62. 25-0693 Beam
8. 50-0009 Linear Guide 63. 20-0738 Horizontal Rack
9. 20-0749 B-Axis Rack 64. 25-0082 Switch Bracket
10. 25-0768 Rotator Housing 65. 32-2010 Limit Switch 24"
11. 25-0769 Rotator Cover 66. 25-0715 Trip Bracket
12. 87-6535(6700,6710) Light 67. 25-6826 Home Bracket
13. 30-6466 Gripper Assy 68. 25-0696 Cable Junction
14. 20-2299 Jaw 69. 20-0760 Trip Block
15. 20-2297 Gripper Finger 70. 25-0714 Limit Switch Bracket
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
45. 46-0007 Jam Nut
46. 51-0081 Collar Clamp
47. 20-0743 A-Axis Motor Spacer
48. 20-4519 Drive Pulley
49. 62-0009 Servo Motor
50. 20-0744 Bearing Support
51. 20-0745 Bearing Spacer
52. 20-4264 Lock Ring
53. 20-4509 Driven Pullet
54. 54-0218 Belt
55. 20-0758 Idler Shaft

412 Mechanical Service 96-0283 rev C June 2007

 COMMON ABBREVIATIONS

AC – Alternating Current MB – Megabyte (1 million)

AMP – Ampere MCD RLY BRD – M -Code Relay Board
APC – Automatic Pallet Changer MDI – Manual Data Input
APL – Automatic Parts Loader MEM – Memory
ASCII – American Standard Code for Information Interchange M-FIN – M -code Finished
ATC – Automatic Tool Changer MM – MilliMeter
ATC FWD – Automatic Tool Changer Forward MOCON – Motor Control
ATC REV – Automatic Tool Changer Reverse MOTIF – Motor Interface
AWG – American Wire Gauge MSG – Message
BHCS – Button Head Cap Screw MSHCP – Metric Socket Head Cap Screw
BT – British Tooling (Common usage) NC – Numerical Control
CAD – Computer Assisted Design NC – Normally Closed
CAM – Computer Assisted Manufacturing (Assisted Machining) NO – Normally Open
CAT-5 – Category 5 Cable OD – Outside Diameter
CB – Circuit Breaker OPER – Operator
CC – Cubic Centimeter P – Pocket
CCW – Counter Clock Wise PARAM – Parameter
CFM – Cubic Feet per Minute PCB – Printed Circuit Board
CNC – Computerized Numeric Control PGM – Program
CNCR SPINDLE Concurrent Spindle with axis motion POR – Power On Reset
CRC – Cyclic Redundancy Check digit POSIT – Positions
CRT – Cathode Ray Tube PROG – Program
CT – Caterpillar Tooling PSI – Pounds per Square Inch
CTS – Clear To Send PST – Pallet Schedule Table
CW – Clock Wise PWM – Pulse Width Modulation
DB – Draw Bar RAM – Random Access Memory
DC – Direct Current RET – Return
DGNOS – Diagnostic REV CNVR – Reverse Conveyor
DHCP – Dynamic Host Configuration Protocol RJH – Remote Jog Handle
DIR – Directory RPM – Revolutions Per Minute
DNC – Direct Numerical Control RTS – Request To Send
DOS – Disk Operating System RXD – Receive Data
DTE – Data Terminal Equipment SDIST – Servo Distribution PCB
ENA CNVR – Enable Conveyor SFM – Surface Feet per Minute
EOB – End Of Block SHCS – Socket Head Cap Screw
EOF – End Of File SIO – Serial Input/Output
EPROM – Erasable Programmable Read Only Memory SKBIF – Serial Key Board Inter Face PCB
E-STOP – Emergency Stop SMTC – Side Mount Tool Changer
FHCS – Flat Head Cap Screw SP – Spindle
FT – Foot T – Tool Number
FU – Fuse TC – Tool Changer
FWD – Forward TIR – Total Indicated Runout
GA – Gauge TNC – Tool Nose Compensation
HHB – Hex Head Bolts TRP – Tool Release Piston
HP – Horse Power TS – Tail Stock
HS – Horizontal Series of Machining Centers TSC – Thru the Spindle Coolant
ID – Inside Diameter TXD – Transmit Data
IGBT – Isolated Gate Bipolar Transistor VDI – Verein Deutscher Ingenieure
IN – Inch VMC – Vertical Machining Center
I/O PCB – Input Output Printed Circuit Board WAN – Wide Area Network
LAN – Local Area Network
LB – Pound
LCD – Liquid Crystal Display
LED – Light Emitting Diode
LO CLNT – Low Coolant
LOW AIR PR – Low Air Pressure
LVPS – Low Voltage Power Supply

96-0283 rev C June 2007 Mechanical Service 413