Gearbox - Troubleshooting Guide

Transcription

1 LAST UPDATED: 09/20/2018 Gearbox - Troubleshooting Guide Gearbox Assembly Diagram 50-taper Gearbox 1. Gearbox oil pump 2. High/low gear proximity sensors or mechanical switches 3. Spindle encoder 4. Spindle drive belts 40-taper Gearbox 1. Gearbox oil pump 2. High gear shifter oil tube 3. Spindle drive belts 4. High/low gear proximity sensors or mechanical switches Page 1 of 20 pages

2 Exploded View 40T Gearbox - Troubleshooting Guide Page 2 of 20 pages

3 Gearbox - Troubleshooting Guide SPINDLE MOTOR 10HP LINCOLN GEAR 16DP 40 TOOTH 2.05" FITG JIC-5-F X -5 HOSE STR RETAINING RING INT BASIC SHCS 5/16-18 X 1 GEARBOX TOP PLATE 16DP-65T HHB 1/2-13 X 1 3/4 GRADE 8 PLAIN SPRING BELVIL 1.206ID X 1.831OD X BEARING M OIL GEARBOX TRANSFER GEAR ASSY 16DP65T NUT 7/16-20, LOCKING SHIFT FORK 40T GEARBOX BEARING M RETAINING RING EXT BASIC 15. RETAINING RING EXT BASIC 16. HOUSING GEARBOX MACHINED 17. FITG HOSE BARB3/8 NPT1/4M 90 BRASS 18. SHCS X 7/8 19. SPROCKET 20. SHIFTER SHAFT 21. QUAD-RING Q4-114 VITON NOT FOR SALE 22. SHIFTER BODY 23. SHCS X T SWITCH MOUNTING BRACKET 25. PICK UP TUBE DRY SUMP 26. SHCS 1/4-20 X 1/2 ZINC 27. SHCS X 3/8 W/ FLAT WASHER OD NIPPLE 1/2 NPT X 4 1/2 BRASS 29. FITG HOSE BARB1/4 NPT1/4M STR BRASS 30. FITG PC1/4F NPT1/8M 90 STL 31. ENCODER SPRING MOUNT 32. S SEAL 26MM ID X 52MM OD X 8MM 33. RETAINING RING INT BASIC 34. SHCS X 1 1/4 35. GEARBOX GEAR LUBE MANIFLOD 16DP-40T 36. GEARBOX GEAR LUBE MANIFLOD CONN TUBE 37. GEARBOX GEAR LUBE MANIFLOD 16DP-32T 38. SPRING BELVIL 1.403ID X 2.028OD X Page 3 of 20 pages

4 39. BEARING M OIL 40. GEARBOX DRIVE GEAR ASSY 16DP65T 41. BEARING M OIL 42. F SEAL X X F 43. VIBRATION ISOLATOR UPPER 44. SPACER 45. VIBRATION ISOLATOR LOWER 46. OIL CATCH PAN 47. HIGH GEAR TUBE 40T GEARBOX-Co R0.438" 48. PROXIMITY SENSOR 49. DRAIN TUBE DRY SUMP 50. F SEAL X X F 51. SUMP BRACKET 52. SUMP TANK Gearbox Oil Pump Diagram 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] Page 4 of 20 pages

5 Symptom Table Gearbox - Troubleshooting Guide Page 5 of 20 pages

6 SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Insufficient air volume. Make sure that air supply meets the requirements, and check for leaks. Alarm 117 HIGH GEAR FAULT, Alarm 118 LOW GEAR FAULT, or Alarm 2060 GEAR SWITCH FAULT The high or low gear status sensor is faulty. The high or low gear solenoid is faulty. Troubleshoot the sensors. Troubleshoot the solenoid. Damaged gearbox. Make sure the gearbox shifts when applying air to it. Shift dampener installed. Remove the shift dampener. Alarm 126 GEARBOX FAULT Low shop temperature. (only in the morning) Shift dampener installed. Warm up machine. Remove the shift dampener. The oil level is low. Fix the leaks and refill with oil. There is a clog in the oil-pump inlet screen. Clean the oil-pump inlet screen. Alarm 179 LOW GEARBOX OIL PRESSURE There is a problem with the oil flow sensor or pressure switch. Troubleshoot the oil flow sensor or pressure switch. The oilpump motor does not receive power. Troubleshoot the oil-pump motor. Page 6 of 20 pages

7 There is a problem with the oilpump motor gears or coupler. Inspect the gears or coupler. The oil level is low. Fix the leaks and refill with oil. Alarm 2011 LOW GEARBOX OIL LEVEL The NGC software is outdated. Starting in NGC software version or higher the control only monitors the gearbox oil level condition at power-on. Once the gearbox low oil condition is detected, the icon will clear on the next power on when a normal level condition is detected. If you are getting a Low Gearbox Oil icon during machine operation, make sure you update the software to or higher. Too much oil will cause a leak, drain the oil and fill with the correct amount. Oil level switch is faulty. Troubleshoot the oil level switch. The oil level is low. Fix the leaks and refill with oil. There is a clog in the oil-pump inlet screen. Clean the inlet screen. Alarm 2012 LOW GEARBOX OIL FLOW There is a problem with the oil flow switch. The oilpump motor does not receive power. Troubleshoot the oil flow switch. Troubleshoot the oil-pump motor. There is a problem with the oilpump motor gears or coupler. Inspect the gears or coupler. Page 7 of 20 pages

8 On a machine with a NGC control: A Low Gearbox Oil icon appears during machine operation. The NGC software is outdated. Starting in NGC software version or higher the control only monitors the gearbox oil level condition at power-on. Once the gearbox low oil condition is detected, the icon will clear on the next power on when a normal level condition is detected. If you are getting a Low Gearbox Oil icon during machine operation, make sure you update the software to or higher. Too much oil will cause a leak, drain the oil and fill with the correct amount. The oil level is low. Fix the leaks and refill with oil. The drive belts are worn or incorrectly adjusted. Set the belt tension. The encoder feedback is faulty. See the Excessive Gearbox Noise section below. Noisy Gearbox Damaged or worn out encoder pulley or encoder belt. Inspect the encoder pulley. Run-out or play within the encoder. Check for runout or play. The gears are damaged. Perform a vibration analysis. High Load Bad connection at the Wye/ Delta contactor. Incorrect value for parameter 150. Troubleshoot Wye/Delta assembly. Verify par 150 using the gearbox installation procedures. Air Supply Refer to the "Air Requirement" section in the NEW MACHINE SETUP / PRE-INSTALLATION for information. Page 8 of 20 pages

9 Drive Belts Gearbox - Troubleshooting Guide Check for damage to the pulleys. Check the drive belts for wear and correct tension. High/Low Gear Sensors Check for contamination of the connectors. Reseat the connections. Make sure the sensor is tight on the bracket and gearbox. Image shows a 50T [1] and 40T [2]. Refer to the PROXIMITY SENSOR - TROUBLESHOOTING GUIDE. High/Low Gear Solenoid Use a voltmeter to check for 120 VAC at the solenoid. The solenoid may be located on the 50T gearbox [1], the 40T gearbox [2] or in the CALM cabinet [3]. Refer to the SOLENOID - TROUBLESHOOTING GUIDE. Oil Pump Gears/Coupler Inspect the gears or coupler. Remove the top assembly [1] of the oil pump. Inspect the gears [2]. Make sure they are in good condition. Inspect the sleeved coupler [3]. Replace the sleeved coupler (P/N ) if it is broken. Page 9 of 20 pages

10 Low Ambient Shop Temperature Warm up the machine by running the spindle at high speed for 10 minutes to warm up the gearbox housing and the oil. Oil Level Note: Starting in NGC software version or higher the control only monitors the gearbox oil level condition at power-on. Once the gearbox low oil condition is detected, the icon will clear on the next power on when a normal level condition is detected. If you are getting a Low Gearbox Oil icon during machine operation, make sure you update the software to or higher. Too much oil will cause a leak, drain the oil and fill with the correct amount. Fix the leaks. Machines with oil fill plug [1]: Remove the oil fill plug. Operate the spindle at a low RPM. Fill the sump tank to the top of the oil plug. Use Mobil SHC 627 transmission oil or equivalent. Install the oil fill plug. Machines with a reservoir: Add 17 oz (500 ml) of Mobil SHC 627 transmission oil to the reservoir. Some machines have the reservoir near the spindle fan [1]. Other machines have the reservoir mounted on the sump tank [2]. Remove the spindle head covers to get access to it. Caution: Do not add more than 500 ml of oil at a time. The plastic reservoir wil completely empty the oil into the gearbox. Page 10 of 20 pages

11 Oil Flow Switch Gearbox - Troubleshooting Guide Page 11 of 20 pages

12 Note: Starting in NGC software version or higher the control only monitors the gearbox oil level condition at power-on. Once the gearbox low oil condition is detected, the icon will clear on the next power on when a normal level condition is detected. If you are getting a Low Gearbox Oil icon during machine operation, make sure you update the software to or higher. Too much oil will cause a leak, drain the oil and fill with the correct amount. Page 12 of 20 pages

13 1. Fittings 2. Retention clip 3. Steel ball 4. Oil flow sensor housing 5. Proximity sensor Remove the oil flow sensor from the oil-pump assembly. Use a screw driver to manually operate the switch. Navigate to the I/O tab in DIAGNOSTICS. Make sure the diagnostic bit for Low Lube Press. changes from 0 to 1. Note: The name of this diagnostic bit in older software versions is Low GB Oil Flow. If the diagnostic bit for Low Lube Press. does not change from 0 to 1, disconnect the oil flow sensor from the connector bracket. Put an electrical jumper across the (2) pins in the connector for the oil flow sensor [1]. Make sure the diagnostic bit for Low Lube Press. changes from 0 to 1. If the input changes, the oil flow proximity sensor is faulty. If the diagnostic bit for Low Lube Press. does not change from 0 to 1, disconnect the cable from the P12 connector [2] on the I/O PCB. Put an electrical jumper across pins 2 and 3 of the P12 connector. Make sure the diagnostic bit for Low Lube Press. changes from 0 to 1. If the input changes, the 950 cable is defective. If the input does not change, troubleshoot the I/O PCB. Page 13 of 20 pages

14 Check the pressure switch with a voltmeter when the pump is running. If the switch is open (O.L.) when there is pressure in the system, replace it. Oil Pressure Switch 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. Page 14 of 20 pages

15 Oil Level Switch Gearbox - Troubleshooting Guide Note: Starting in NGC software version or higher the control only monitors the gearbox oil level condition at power-on. Once the gearbox low oil condition is detected, the icon will clear on the next power on when a normal level condition is detected. If you are getting a Low Gearbox Oil icon during machine operation, make sure you update the software to or higher. Too much oil will cause a leak, drain the oil and fill with the correct amount. Remove the oil-level switch from the gearbox. While you move the float from position [2] to position [1], measure for continuity across pins 2 and 4 of the connector for the oil-level switch.the oil-level switch operates correctly when: There is not continuity when the magnet is at position [2]. There is continuity when the magnet is at position [1]. Replace the oil-level switch if it does not operate correctly. Disconnect the 950 cable from the P12 connector on the I/O PCB. Measure for continuity across pins 1 and 3 of the connector for the oil-level switch on the 950 cable. If there is continuity, there is a short circuit in the 950 cable. Replace the cable. Put an electrical jumper across pins 1 and 3 of the P12 connector. Press [PARAM/DGNOS] twice. Navigate to the I/O tab. Make sure the diagnostic bit for Low GB Oil Level changes from 1 to 0. If the input does not change, troubleshoot the I/O PCB. Page 15 of 20 pages

16 Oil Filter Put a wrench [2] on the straight male-fitting [1] to make sure it does not move. With another wrench [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 another wrench [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 inlet screen [4]. Reinstall the inlet screen. Page 16 of 20 pages

17 Oil-Pump Motor Gearbox - Troubleshooting Guide Troubleshoot the oil-pump motor. Command the spindle to operate. Note: There is a voltage output to the gearbox oil pump when the spindle operates. Monitor the motor fan on the gearbox oil pump. If the motor fan on the gearbox oil pump does not operate, make sure the oil pump receives the correct voltage. Use a multimeter with needle-tip probes to measure the voltage across the cable connector for the gearbox oil pump. Note: Do not measure the voltage with the oil pump cable disconnected from the 300A cable. The measured voltage must be 120 VAC. If the voltage is correct and the pump does not operate, go to Section 6. If the voltage is not correct, make sure the voltage output from the I/O PCB is correct. Use a multimeter with needle tip test probes to measure the voltage between pin 1 and pin 2 on the 300Acable connector at P41 (Classic Haas Control) or P32 (Next Generation Control) on the I/O PCB. Note: Do not measure the voltage with the 300A cable disconnected from the P41 connector on the I/O PCB. The measured voltage must be 120 VAC. If the measured voltage is correct, the 300A cable is defective. If there is no voltage output, refer to these troubleshooting guides: NGC - I/O PCB - TROUBLESHOOTING GUIDE CHC - I/O PCB - TROUBLESHOOTING GUIDE Page 17 of 20 pages

18 Wye/Delta Contactor A worn contactor can send unreliable power to the gearbox motor, which can cause a high load. Check the connections at the Wye/Delta contactor. Make sure the terminals are tight. Refer to WYE-DELTA CONTACTOR - TROUBLESHOOTING GUIDE to troubleshoot the Wye/Delta connectors. Excessive Gearbox Noise Determine if the problem is mechanical or electrical by commanding the spindle rpm where the noise is heard and then 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 the gears are damaged. Page 18 of 20 pages

19 Encoder Pulley/Belt Gearbox - Troubleshooting Guide Shafted encoders (top) - Check the encoder pulley and belt for damage or wear. Hubbed style encoders (bottom) - Use an indicator to check for run-out [1] or play [2] within the encoder and between the encoder [3] and motor shaft [4] ( Hubbed style encoders mount directly to the gearbox or spindle motor). The runout is not to exceed 0.002". Refer to the procedure applicable to your machine to set the spindle orientation after you have 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 SPINDLE ORIENTATION OFFSET CHC - UMBRELLA TOOL CHANGER - SET PARAMETER SPINDLE ORIENTATION OFFSET Gearbox Manually actuate the High/Low gear solenoid and slowly turn the spindle by hand. The gearbox should shift and the Hi 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 Page 19 of 20 pages

20 Shift Dampener Gearbox - Troubleshooting Guide A shift dampener was installed on 40T gearboxes between Dec 2015 thru March 1,2016. Remove the shift dampener if equipped. 1. Remove or raise the gearbox from the spindle head. 2. Remove the oil tank [1]. 3. Remove the shift dampener [2]. 4. Re-install the oil tank and gearbox. Page 20 of 20 pages