Gearbox - Troubleshooting Guide · gearbox oil pump diagram 40. gearbox drive gear assy 16dp65t 41....

LAST UPDATED: 10/11/2019

Gearbox - Troubleshooting Guide

Gearbox Assembly Diagram

50-taper Gearbox

1. Gearbox oil pump2. High/low gear proximity sensors or

mechanical switches3. Spindle encoder4. Spindle drive belts

40-taper Gearbox

1. Gearbox oil pump2. High gear shifter oil tube3. Spindle drive belts4. High/low gear proximity sensors or

mechanical switches


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http://www.haascnc.com/content/haascnc/en.html

Exploded View 40T


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1. SPINDLE MOTOR 10HP LINCOLN2. GEAR 16DP 40 TOOTH 2.05"3. FITG JIC-5-F X -5 HOSE STR4. RETAINING RING 1.875 INT BASIC5. SHCS 5/16-18 X 16. GEARBOX TOP PLATE 16DP-65T7. HHB 1/2-13 X 1 3/4 GRADE 8 PLAIN8. SPRING BELVIL 1.206ID X 1.831OD X

0.0599. BEARING M17-47-14 OIL

10. GEARBOX TRANSFER GEAR ASSY16DP65T

11. NUT 7/16-20, LOCKING12. SHIFT FORK 40T GEARBOX13. BEARING M25-47-1214. RETAINING RING 1.000 EXT BASIC15. RETAINING RING 0.669 EXT BASIC16. HOUSING GEARBOX MACHINED17. FITG HOSE BARB3/8 NPT1/4M 90 BRASS18. SHCS 10-32 X 7/819. SPROCKET20. SHIFTER SHAFT21. QUAD-RING Q4-114 VITON NOT FOR

SALE22. SHIFTER BODY23. SHCS 10-32 X 224. 40T SWITCH MOUNTING BRACKET25. PICK UP TUBE DRY SUMP26. SHCS 1/4-20 X 1/2 ZINC27. SHCS 10-32 X 3/8 W/ FLAT WASHER OD

0.37-28. NIPPLE 1/2 NPT X 4 1/2 BRASS29. FITG HOSE BARB1/4 NPT1/4M STR

BRASS30. FITG PC1/4F NPT1/8M 90 STL31. ENCODER SPRING MOUNT32. S SEAL 26MM ID X 52MM OD X 8MM33. RETAINING RING 2.047 INT BASIC34. SHCS 10-32 X 1 1/435. GEARBOX GEAR LUBE MANIFLOD

16DP-40T36. GEARBOX GEAR LUBE MANIFLOD CONN

TUBE37. GEARBOX GEAR LUBE MANIFLOD

16DP-32T38. SPRING BELVIL 1.403ID X 2.028OD X

0.05939. BEARING M25-52-15 OIL40. GEARBOX DRIVE GEAR ASSY 16DP65T


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Gearbox Oil Pump Diagram

41. BEARING M30-72-19 OIL42. F SEAL 1.125 X 1.595 X 0.240 F43. VIBRATION ISOLATOR UPPER44. SPACER45. VIBRATION ISOLATOR LOWER46. OIL CATCH PAN47. HIGH GEAR TUBE 40T GEARBOX-Co

R0.438"48. PROXIMITY SENSOR49. DRAIN TUBE DRY SUMP50. F SEAL 0.875 X 1.345 X 0.350 F51. SUMP BRACKET52. SUMP TANK

50-taper spindle:

• Oil-pump motor [1].• Gearbox [2].• Scavenge Line [3].• Oil Flow Sensor [4].• Filter [5].• Oil Pump [6].• Reservoir [7].• Lubrication Tube [8].• Oil Nozzle [9].• Anti-siphon Solenoid [10].• Vent Restrictor Orifice [11].• Oil Level Switch [12].

40-taper spindle:

• Filter [1]• Oil Flow Sensor [2].• Oil-Pump Motor [3].• Sump Tank [4]


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Symptom Table


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SYMPTOM POSSIBLECAUSE CORRECTIVE ACTION

Insufficientair volume.

Make sure that air supply meets the requirements, and checkfor leaks.

The high orlow gearstatussensor isfaulty.

Troubleshoot the sensors.

The high orlow gearsolenoid isfaulty.

Troubleshoot the solenoid.

Damagedgearbox. Make sure the gearbox shifts when applying air to it.

Alarm 117 HIGH GEARFAULT

Alarm 118 LOW GEARFAULT

Alarm 2060 GEARSWITCH FAULT

Shiftdampenerinstalled.

Remove the shift dampener.

Low shoptemperature.(only in themorning)

Warm up machine.

Alarm 126 GEARBOXFAULT

Shiftdampenerinstalled.

Remove the shift dampener.

The oil levelis low.

Fix the leaks and refill with oil. After adding oil power cycle the machine totirgger oil level measurment. Overfilling the gearbox with oil will cause it toleak.

There is aclog in theoil-pumpinlet screen.

Clean the oil-pump inlet screen.Alarm 179 LOWGEARBOX OILPRESSURE

There is aproblemwith the oilflow sensoror pressureswitch.

Troubleshoot the oil flow sensor or pressure switch.


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The oil-pump motordoes notreceivepower.

Troubleshoot the oil-pump motor.

There is aproblemwith the oil-pump motorgears orcoupler.

Inspect the gears or coupler.

The oil levelis low. Fix the leaks and refill with oil.

The NGCsoftware isoutdated.

Starting in NGC software version 100.17.000.2045 to 100.19.000.1003 thecontrol only monitors the gearbox oil level condition at power-on. Once thegearbox low oil condition is detected, the icon will clear on the next poweron when a normal level condition is detected. If you are getting a LowGearbox Oil icon during machine operation, make sure you update thesoftware to 100.17.000.2045 or higher. Too much oil will cause a leak,drain the oil and fill with the correct amount.

Note: In software version 100.19.000.1102 and higher the gearbox oil levelis checked continuously when the spindle fan is off. After the spindle fanturns off, there is a delay before gearbox oil level monitoring begins. Pressthe [RESET] to clear the low gearbox oil icon.

Alarm 2011 LOWGEARBOX OIL LEVEL

Oil levelswitch isfaulty.

Troubleshoot the oil level switch.


There is aclog in theoil-pumpinlet screen.

Clean the inlet screen.

There is aproblemwith the oilflow switch.

Troubleshoot the oil flow switch.

Alarm 2012 LOWGEARBOX OIL FLOW

The oil-pump motordoes notreceivepower.

Troubleshoot the oil-pump motor.


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There is aproblemwith the oil-pump motorgears orcoupler.

Inspect the gears or coupler.

Faulty P-Techoil pump

If the machine was manufactured before August of 2019 and the gearboxoil pump was manufactured by P-Tech, replace the oil pump.

On a machine with aNGC control: A LowGearbox Oil iconappears during machineoperation.

The NGCsoftware isoutdated.

Starting in NGC software version 100.17.000.2045 to 100.19.000.1003 thecontrol only monitors the gearbox oil level condition at power-on. Once thegearbox low oil condition is detected, the icon will clear on the next poweron when a normal level condition is detected. If you are getting a LowGearbox Oil icon during machine operation, make sure you update thesoftware to 100.17.000.2045 or higher. Too much oil will cause a leak,drain the oil and fill with the correct amount.

Note: In software version 100.19.000.1102 and higher the gearbox oil levelis checked continuously when the spindle fan is off. After the spindle fanturns off, there is a delay before gearbox oil level monitoring begins. Pressthe [RESET] to clear the low gearbox oil icon.


The drivebelts areworn orincorrectlyadjusted.

Set the belt tension.

The encoderfeedback isfaulty.

See the Excessive Gearbox Noise section below.

Damaged orworn outencoderpulley orencoder belt.

Inspect the encoder pulley.

Run-out orplay withinthe encoder.

Check for runout or play.

Noisy Gearbox

The gearsaredamaged.

Perform a vibration analysis.

High Load

Badconnectionat the Wye/Deltacontactor.

Troubleshoot Wye/Delta assembly.


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Incorrectvalue forparameter150.

Verify paramter 150 using the gearbox installation procedures.

Air SupplyCorrective Action:

Refer to the "Air Requirement" section in the NEW MACHINE SETUP / PRE-INSTALLATION for information.

Drive BeltsCorrective Action:

Check for damage to the pulleys. Check the drive belts for wear and correct tension.

High/Low Gear Sensors

High/Low Gear Solenoid

Corrective Action:

Check for contamination of the connectors.Reseat the connections.

Make sure the sensor is tight on the bracket andgearbox. Image shows a 50T [1] and 40T [2].

Refer to the PROXIMITY SENSOR -TROUBLESHOOTING GUIDE.

Corrective Action:

Use a voltmeter to check for 120 VAC at thesolenoid.

The solenoid may be located on the 50T gearbox[1], the 40T gearbox [2] or in the CALM cabinet[3].

Refer to the SOLENOID - TROUBLESHOOTINGGUIDE.


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http://www.haascnc.com/info.asp

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/troubleshooting/proximity-sensor---troubleshooting-guide.html

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/troubleshooting/proximity-sensor---troubleshooting-guide.html

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/troubleshooting/solenoid---troubleshooting-guide.html



Oil Pump Gears/Coupler

Low Ambient Shop TemperatureCorrective Action:

Warm up the machine by running the spindle at high speed for 10 minutes to warm up the gearbox housing and theoil.

Corrective Action: Inspect the gears or coupler.

Remove the top assembly [1] of the oil pump.Inspect the gears [2]. Make sure they are in goodcondition. Inspect the sleeved coupler [3].Replace the sleeved coupler (P/N 93-30-5725) if itis broken.


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Oil Level

Note: Starting in NGC software version 100.17.000.2045 or higher the control only monitors the gearbox oil levelcondition at power-on. Once the gearbox low oil condition is detected, the icon will clear on the next power on whena normal level condition is detected. If you are getting a Low Gearbox Oil icon during machine operation, make sureyou update the software to 100.17.000.2045 or higher.

Note: After adding oil to the gearbox power cycle the machine to trigger the oil level measurment. Adding toomuch oil will cause the gearbox to leak.

Corrective Action:

Fix the leaks.

40 Taper Gearbox with oil fill plug: Remove theoil fill plug [1]. Make sure the spindle is stopped..Fill the sump tank to the top of the oil plug. UseMobil SHC 627 transmission oil or equivalent.Install the oil fill plug.

50 Taper Gearbox:Remove the oil fill plug [1].Operate the spindle at low RPM (500). Fill thesump tank to the top of the oil plug. Use MobilSHC 627 transmission oil or equivalent. Install theoil fill plug.

Machines with a reservoir: Add 17 oz (500 ml) ofMobil SHC 627 transmission oil to the reservoir.Some machines have the reservoir near thespindle fan [1]. Other machines have thereservoir mounted on the sump tank [2]. Removethe spindle head covers to get access to it.

Caution: Do not add more than 500 ml of oilat a time. The plastic reservoir wil completelyempty the oil into the gearbox.


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Oil Flow Switch


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Note: Starting in NGC software version 100.17.000.2045 or higher the control only monitors the gearbox oil levelcondition at power-on. Once the gearbox low oil condition is detected, the icon will clear on the next power on whena normal level condition is detected. If you are getting a Low Gearbox Oil icon during machine operation, make sureyou update the software to 100.17.000.2045 or higher. Too much oil will cause a leak, drain the oil and fill with thecorrect amount.


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Proximity Senor Oil Flow Switch:1. Fittings2. Retention clip3. Steel ball4. Oil flow sensor housing5. Proximity sensor

Corrective Action:

Remove the oil flow sensor from the oil-pumpassembly. Use a screw driver to manually operatethe switch. Navigate to the I/O tabin DIAGNOSTICS. Make sure the diagnostic bit forLow Lube Press. changes from 0 to 1.

Note: The name of this diagnostic bit in oldersoftware versions is Low GB Oil Flow.

Check Valve Style Oil Flow Sensor:

Corrective Action:

Unplug the oil flow sensor and remove it from theoil-pump assembly. Use a screw driver tomanually depress the sensor plunger. Use amulti meter to monitor continuity across theswitch leads. If continuity is made when theplunger is depressed and broken when theplunger is released the sensor is workingproperly.

If the sensor is not working properly loosen thetwo phillips head screws that attach the sensor tothe fitting. Adjust the sensor position untilactuating the plunger reliably makes continuitywhen the plunger is depressed and breakscontinuity when the plunger is released.

Plug the oil flow sensor in and monitor thediagnostic bit for Low Lube Press. as youmanually actuate the sensor.


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Oil Pressure SwitchCorrective Action:

Make sure the pressure switch connection is clean and well seated.

Use a voltmeter to check the continuity of the pressure switch when the pump is running. If the switch is open (O.L.)when there is pressure in the system, replace it.

If the diagnostic bit for Low Lube Press. does notchange from 0 to 1, disconnect the oil flow sensorfrom the connector bracket. Put an electricaljumper across the (2) pins in the connector forthe oil flow sensor [1]. Make sure the diagnosticbit for Low Lube Press. changes from 0 to 1. If theinput changes, the oil flow proximity sensor isfaulty.

If the diagnostic bit for Low Lube Press. does notchange from 0 to 1, disconnect the cable from theP12 connector [2] on the I/O PCB. Put anelectrical jumper across pins 2 and 3 of the P12connector. Make sure the diagnostic bit for LowLube Press. changes from 0 to 1. If the inputchanges, the 950 cable is defective. If the inputdoes not change, troubleshoot the I/O PCB.

Check the pressure switch with a voltmeter whenthe pump is running. If the switch is open (O.L.)when there is pressure in the system, replace it.


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Oil Level Switch

Note: Starting in NGC software version 100.17.000.2045 or higher the control only monitors the gearbox oil levelcondition at power-on. Once the gearbox low oil condition is detected, the icon will clear on the next power on whena normal level condition is detected. If you are getting a Low Gearbox Oil icon during machine operation, make sureyou update the software to 100.17.000.2045 or higher. Too much oil will cause a leak, drain the oil and fill with thecorrect amount.

Corrective Action:

Remove the oil-level switch from the gearbox.While you move the float from position [2] toposition [1], measure for continuity across pins 2and 4 of the connector for the oil-level switch.Theoil-level switch operates correctly when:

• There is not continuity when themagnet is at position [2].

• There is continuity when the magnet isat position [1].

Replace the oil-level switch if it does not operatecorrectly.

Disconnect the 950 cable from the P12 connectoron the I/O PCB. Measure for continuity acrosspins 1 and 3 of the connector for the oil-levelswitch on the 950 cable. If there is continuity,there is a short circuit in the 950 cable. Replacethe cable.

Put an electrical jumper across pins 1 and 3 of theP12 connector. Press [PARAM/DGNOS] twice.Navigate to the I/O tab. Make sure the diagnosticbit for Low GB Oil Level changes from 1 to 0. Ifthe input does not change, troubleshoot the I/OPCB.


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Oil Filter

Corrective Action:

Put a wrench [2] on the straight male-fitting [1] tomake sure it does not move. With anotherwrench [3], turn the hose and the barbed fitting[4] counterclockwise to remove them.

Put a wrench [6] on the inlet-screen housing [5]to make sure it does not move. With anotherwrench [7], turn the straight male-fitting [8]counterclockwise to remove it.

Remove the spring [1] and the inlet screen [2]from the inlet-screen housing [3]. Clean the inletscreen [4]. Reinstall the inlet screen.


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Oil-Pump Motor

Corrective Action: Troubleshoot the oil-pumpmotor.

Command the spindle to operate.

Note: There is a voltage output to the gearboxoil pump when the spindle operates.

Monitor the motor fan on the gearbox oil pump.If the motor fan on the gearbox oil pump doesnot operate, make sure the oil pump receives thecorrect voltage. Use a multimeter with needle-tipprobes to measure the voltage across the cableconnector for the gearbox oil pump.

Note: Do not measure the voltage with the oilpump cable disconnected from the 300A cable.

The measured voltage must be 120 VAC. If thevoltage is correct and the pump does notoperate, go to Section 6.

If the voltage is not correct, make sure thevoltage output from the I/O PCB is correct. Use amultimeter with needle tip test probes tomeasure the voltage between pin 1 and pin 2 onthe 300A-cable connector at P41 (Classic HaasControl) or P32 (Next Generation Control) on theI/O PCB.

Note: Do not measure the voltage with the300A cable disconnected from the P41 connectoron the I/O PCB.

The measured voltage must be 120 VAC. If themeasured voltage is correct, the 300A cable isdefective. If there is no voltage output, refer tothese troubleshooting guides:

• NGC - I/O PCB - TROUBLESHOOTINGGUIDE

• CHC - I/O PCB - TROUBLESHOOTINGGUIDE


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http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/troubleshooting/next-generation-control---i-o-pcb---troubleshooting-guide.html


http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/troubleshooting/classic-haas-control---i-o-pcb---troubleshooting-guide.html



Wye/Delta Contactor

Excessive Gearbox NoiseCorrective Action:

Determine if the problem is mechanical or electrical by commanding the spindle rpm where the noise is heard andthen turning off the power.

If the noise goes away this means that the cause of the noise may be the encoder feedback.

Damaged gears in the gearbox can cause excessive noise. Contact your local HFO for a vibration analysis to see if thegears are damaged.

A worn contactor can send unreliable power tothe gearbox motor, which can cause a high load.Check the connections at the Wye/Deltacontactor. Make sure the terminals are tight.

Corrective Action:

Refer to WYE-DELTA CONTACTOR -TROUBLESHOOTING GUIDE to troubleshoot theWye/Delta connectors.


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http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/troubleshooting/Wye_Delta_Contactor_Troubleshooting_Guide.html

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/troubleshooting/Wye_Delta_Contactor_Troubleshooting_Guide.html


Encoder Pulley/Belt

GearboxCorrective Action:

Manually actuate the High/Low gear solenoid and slowly turn the spindle by hand. The gearbox should shift and theHi Gear and Low Gear bits on the diagnostic page should change state.

If the gearbox does not shift, it may have internal damage.

If the gearbox shifts, refer to these troubleshooting guides for the high and low gear solenoids and the I/O PCB.

• SOLENOID - TROUBLESHOOTING GUIDE• NGC - I/O PCB - TROUBLESHOOTING GUIDE• CHC - I/O PCB - TROUBLESHOOTING GUIDE

Corrective Action:

Shafted encoders (top) - Check the encoder pulleyand belt for damage or wear.

“Hubbed” style encoders (bottom) - Use anindicator to check for run-out [1] or play [2] withinthe encoder and between the encoder [3] andmotor shaft [4] (“Hubbed” style encoders mountdirectly to the gearbox or spindle motor). Therunout is not to exceed 0.002".

Refer to the procedure applicable to yourmachine to set the spindle orientation after youhave installed an encoder:

• NGC - SIDE-MOUNT TOOL CHANGER -SPINDLE ORIENTATION OFFSET

• NGC - UMBRELLA TOOL CHANGER -SPINDLE ORIENTATION OFFSET

• CHC - SIDE-MOUNT TOOL CHANGER -SET PARAMETER 257 - SPINDLEORIENTATION OFFSET

• CHC - UMBRELLA TOOL CHANGER - SETPARAMETER 257 - SPINDLEORIENTATION OFFSET


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http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/how-to/ngc---side-mount-tool-changer---spindle-orientation-offset.html

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/how-to/ngc---side-mount-tool-changer---spindle-orientation-offset.html

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/how-to/ngc---umbrella-tool-changer---spindle-orientation-offset.html

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/how-to/ngc---umbrella-tool-changer---spindle-orientation-offset.html

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/how-to/umbrella-tool-changer---carousel-plate---replacement111.html










Shift Dampener

A shift dampener was installed on 40T gearboxesbetween Dec 2015 thru March 1,2016. Removethe shift dampener if equipped.

1. Remove or raise the gearbox from the spindlehead.

2. Remove the oil tank [1].

3. Remove the shift dampener [2].

4. Re-install the oil tank and gearbox.


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Gearbox - Troubleshooting Guide · gearbox oil pump diagram 40. gearbox drive gear assy 16dp65t 41....

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Transcript of Gearbox - Troubleshooting Guide · gearbox oil pump diagram 40. gearbox drive gear assy 16dp65t 41....