0104 Spindle Keylock Low gear
Sheet 4 plug 2 pin-f
This error indicates a 24 volt signal from the low gear proximity switch present at the control interface when there should be zero volts. If the error can be cancelled by pressing the ERROR pushbutton on the control the fault is probably a malfunction of the proximity switch; refer to paragraph (d). If the error can't be cancelled, continue with paragraph (a)
a) Gain access to the rear of the column by manually jogging X and Y axes to a convenient position. Check the position of the gear range proximity switch actuator by either monitoring the switch indicator LED's (if fitted), or checking the 24 volt DC outputs from the switches in terminal box 12 mounted on the rear of the spindle motor. High gear switch output is terminal 424, medium gear 425 and low gear 426. The proximity switches are mounted on a plate to the right of the spindle motor, low gear towards the rear, medium gear in the centre. If there is a 24 volts output from 2 switches simultaneously, the low gear switch is probably faulty, and will need replacing. An output from only the low gear switch would indicate a control command fault or a problem with the solenoid valve; refer to paragraph (b).
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, triac 10 and fuse 10 are to the high gear solenoid, low gear is selected when neither triacs 10 nor 11 are switched. The red LED should indicate if the triac is switched-on. Check for 110 volts AC at fuses 10 and 11, if no voltage is present the fuse, triac or 'Digital Output' board is faulty. Check the fuse, if it's blown the solenoid coil or the wiring in the solenoid plug may be faulty, if the fuse is O.K., refer to paragraph (c). If the output from the triacs does not correspond with the gearchange position, the solenoid valve is suspect, spool sticking, coil burnt-out, etc.
c) 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 0104, 0004 or 1104 error returns triac 10 is faulty. Switch-off and replace the faulty triac, or if a spare isn't available change with another, e.g. triac 5, to test.
d) Remove the cover to terminal box 12 mounted on the rear of the spindle motor. While the 0104, 0004 or 1104 error is displayed check for 24 volts DC on terminal 426. If 24 volts is present the low gear proximity switch is faulty. The switch, the rear one of 3, is mounted on a plate to the right of the spindle motor. If there's zero volts on 426 the 'Digital Input' board is suspect; refer to paragraph (e).
e) 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 0104 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).