-0103 Spindle Keylock Medium Gear
Sheet 4 Plug 2 Pin-e
This error indicates a 24 volt signal is absent from the medium gear proximity switch to the control interface. If the error can't be cancelled by pressing the ERROR pushbutton on the control continue with paragraph (a)
a) Gain access to the rear of the column by manually jogging X and Y axes to a convenient position. Monitor the gearchange position by the LED indicators of the three proximity switches mounted above and to the right of the spindle motor. The front one is high gear, centre one medium, and the rear one is the low gear position. If the centre one, or more than one, are illuminated refer to paragraph (e). If either the front or rear ones are illuminated refer to paragraph (b). If none of the LED's are illuminated switch-off the machine. On powering-up again, the gearchange should move to the low range position, and the rear switch LED should illuminate; if it doesn't, refer to paragraph (c).
b) Monitor the triac outputs in the rear of the control, they are numbered from 1 to 16 from left to right on the bottom row, 17 to 32 on the next row, etc. Triac 11 is the 110 volts AC output to the medium gear solenoid valve through fuse 11. The red LED should indicate if the triac is switched-on. Check for 110 volts AC each side of fuse 11, if 110 volts is present, or the fuse has failed, the gearchange solenoid valve is probably faulty; refer to paragraph (c). If there is no 110 volts output from triac 11, the triac or 'Digital Output' board is faulty; refer to paragraph (d).
c) Operate the 'Manual Hydraulic' switch to run the hydraulic power-pack independent of the control. Remove the two screws securing the gearchange proximity switches to the manifold, to monitor the position of the switch actuator. It should be positioned in-line with the rear switch hole - low gear position. Operate the valve manually by depressing the plungers at either end of the valve. Check for any end-float of the actuator, more than 2mm would indicate excessive wear of the gearchange fork and replacement will be necessary. If the fork is replaced clean the oil-sump, filter and flow switch to remove cast-iron deposits. If the actuator responds by moving to the medium and high gear positions correctly then one of the solenoid coils is suspect. Remove the plugs and compare the resistance measurements across the coil terminals with a meter. If the valve is replaced ensure the correct type is used.
d) Switch-off the control and transpose the 'DO' boards situated in the lower rack, left of centre. Power-up the machine and retry; if a different, unrelated error displays the 'DO' board is faulty and will need replacing. If the -0003, -0103 or -1103 error returns the triac is faulty; switch-off and replace triac 10, or if a spare isn't available exchange with another triac e.g. triac 5, to test.
e) Remove the cover to terminal box 12 mounted on the rear of the spindle motor. While the -0003, -0103 or -1103 error is displayed check for 24 volts DC on terminals 400 and 425. If there's zero volts on terminal 400 indicator fuse 2 in the PDP is faulty. If 24 volts is present at 400, but not at 425, the medium gear proximity switch is faulty. The switch, the centre one of 3, is mounted on a plate to the right of the spindle motor. If there's 24 volts on 425 the 'Digital Input' board is suspect; refer to paragraph (f).
f) Switch-off the control and transpose the 'DI' boards situated in the lower rack to the left. Power-up the machine and retry; if a different, unrelated error displays the 'DI' board is faulty and will need replacing. If the same -0103 error returns the fault may be with the 'Watchdog' board (WD 50x) in the control or corruption of the memory. If another control is available the 'Watchdog' boards can be exchanged to test. If the memory is to be reloaded remember to punch-out programme and tool information first (although an up to date back-up tape should always be held).