Note: The location of the grease reservoir is different on some machines.

The CALM - Haas Liquid Grease (HLG) lubrication system is a restrictor grease flow system that pumps grease through flexible plastic tubing and copper tubes to the axes.

 Note: For recommended lubricant types, see Lubricant Table for Haas Machine Components.

Use the illustration to identify the parts of the lubrication system.

1. Grease Pressure Switch - Monitors the grease system pressure and sends a signal to the control to generate an alarm if the pressure drops below the minimum level too quickly.
2. Grease Pressure Gauge - Shows the pressure (in psi and bar) of the grease system.
3. Grease Filter Wrench - Removes the grease reservoir.
4. Grease Reservoir Assembly - Stores the grease.
5. Air-Lube Panel Decal - Shows the color-coded cables that connect each solenoid.
6. Oil Reservoir - Stores the oil that lubricates the spindle.
7. Air Manifold Assembly - Supplies air to the machine.
8. Axis-Lube Air Solenoid - Pressurizes the grease reservoir.
9. Air Pressure Gauge - Shows the pressure (in psi and bar) at which the air is supplied.
10. Electronic Analog Air Pressure Sensor - Monitors the air system pressure and sends a signal to the control to generate an alarm if the pressure drops below the minimum level for a set period of time.

The grease reservoir [1] lubricates the axes at a rate of (1) grease cycle for every 24 hours of axis travel.

• Grease moves from the grease reservoir [1] through flexible plastic tubing [2] to the axis manifolds [3]. 
  • The number of axis manifolds may be different on some machines.
  • Each axis has (1) ballnut [4] and (4-6 ) linear guide trucks [5].
• Grease moves from the axis manifolds [3] through copper tubes. The copper tubes lubricate the ballnuts [4] and the linear guide trucks [5].
  • There is (1) copper tube that goes to the ballnut and (1) copper tube that goes to each linear guide truck.

The Haas Liquid Grease canister lasts approximately 10 months to a year under normal machine operation, 8 hours a day and 5 days per week.

The Haas Liquid Grease lubrication system uses adapter fittings [1] in the axis manifolds. The linear guide trucks and ballnuts use restrictor fittings [2]. The restrictor fitting has a gap [4] between the threads and the set screw [3]. This forces the manifold-fed grease to pass through the gap [4] to lubricate the axes.

 Note: The copper tubes on this system may or may not be equal length.

 Caution: Do not change the length of the copper tubes or flexible plastic tubing. This changes the flow of grease.

The Haas Liquid Grease reservoir has a gauge [1], and is either plastic [2] or metal [4]. Do not use Haas Liquid Grease on a machine that uses red Mobil SHC007 [3].

If the reservoir for the liquid grease does not have a pressure gauge and the grease is red, do not use purple/brown Haas Liquid Grease. This grease will not work in the red grease system. Perform the Axis Lubrication System - Grease Reservoir - SHC-007 - Refill procedure.

If you get an axis lubrication alarm, perform the "Axis Lubrication System - Grease Reservoir - Haas Liquid Grease - Prime and Test" at the end of this procedure. This removes the air from the grease supply system after you fill the reservoir.

 Caution: Do not operate the machine if air is in the system. Damage to the ballscrews and guideways is possible without correct lubrication.

If Haas Liquid Grease, (P/N 93-3168), is not available refer to the Lubricant Table for Haas Machine Components.

 Note: To upgrade the plastic grease canister with a metal canister use P/N 93-2601A.

Power off the machine. Close the primary air valve. This stops the air supply to the machine.

Pull the ring on the pressure relief valve on the air and lubrication manifold. This releases the air pressure from the system.

If the machine has a metal reservoir, go to Step 3.

Place shop towels under the reservoir to catch any grease that may fall.

If the machine has a plastic reservoir, use the supplied wrench to loosen and remove the grease reservoir.

Inspect the reservoir for cracks or damage. Replace the reservoir if it is damaged, chipped, or cracked.

Pour the HAAS LIQUID GREASE (HLG) [A] into the reservoir to about 1/2" (13 mm) below the threads on the reservoir.

 Note: It can be necessary to fill the reservoir again after you remove air from the system.

 Note: To prevent spills, do not overfill the reservoir.

Install the reservoir and tighten it with the wrench.

 Caution: The reservoir head has a stop. When you tighten the reservoir, do not try to tighten the reservoir after you feel it stop.

If the machine has a metal reservoir:

Place shop towels under the reservoir to catch any grease that may fall.

Remove the empty reservoir. Use an automotive oil filter wrench to loosen it if the reservoir is too tight to loosen by hand.

Pour the HAAS LIQUID GREASE (HLG) [A] into the reservoir to 1/2" (13 mm) below the threads on the reservoir.

Install the reservoir [B]. Use your hand to tighten it until the gasket makes contact with the reservoir head. Tighten another 3/4 turn.

Identify the axis that has a clogged grease lines. Refer to the Haas Liquid Grease - Troubleshooting Guide.

Remove the sheet metal panels/waycovers to gain access to the axis lube manifold.

A liquid pump is used to drive oil through the lube lines to clear the obstructions. We recommend using the Haas Pump 30-7510. This is an air driven pump that can build enough pressure to clear the lube lines. An air driven pump from your local hardware store can also be used. Be sure to not exceed 3000 PSI when pressurizing the copper lube lines or you can cause them to fail. Use a pressure gauge to ensure you are at a safe pressure when operating the pump. 

Remove the barb fitting [1] from the manifold. Install the 58-3657 reducer [2] and the 58-1684 JIC fitting [3] onto the manifold. Connect one end of the 59-8621 hydraulic hose to the JIC fitting [3] at the grease manifold. Connect the other end of the 59-8621 hydraulic hose to the JIC fitting [4] at the 30-7510 pump. Make sure that the ball valve [6] is in CLOSED position and connect the air supply [5]. Fill up the 30-7510 pump tank with the Mobil DTE24 oil. Open the ball valve [6] to turn ON the pump. Run the pump untll there is a steady oil flow out of each linear guide truck and the ballscrew ballnut [7]

NOTE: If any point on the system will not unplug, disconnect and plug the outputs of the points that are flowing oil using P/N 58-3015.  Apply pressure only to the points that will not unplug.  Repeat this as necessary.  If a point will not unplug after this sequence, the restrictor will have to be removed from this point to allow it to unplug.  Remove and replace the clogged restrictor.

 IMPORTANT:  Do not connect the hydraulic hose directly to the linear guide truck or ballscrew ballnut. Direct pressure can cause damage.

Once you get the steady flow of oil out of each lubrication point, stop the oil pump, remove the fittings [2] and [3] and reconnect the barb fitting [1] with the lubrication line back to the manifold.

Reinstall previously removed sheet metal panels/waycovers.

Repeat the same process for each axis.

Remove the HLG pump assembly from the CALM cabinet.

Remove the HLG reservoir, clean the grease out and wash it with the degreaser.

Remove the pressure gauge [1].

Remove the 1/4" fittings [2].  NOTE: The amount of fittings will depend on the machine model and configuration.

Remove the pressure sensor [3]

Remove all of the NPT plugs [4] from the manifold.

There are two check valves within the HLG pump manifold. 

The main check valve [5] located on the bottom of the HLG manifold and prevents the pressurized grease to flow from the pressurized lines back into the HLG reservoir. remove the spring and the ball. Inspect the o-ring inside the check valve cavity, replace with 57-22201 if necessary.

The bleed back circuit check valve located on the top of the HLG manifold and shuts off the bled back circuit when the HLG canister is under pressure. Besides the spring and the ball [6] there is a snubber setscrew [7] under the check valve ball. Remove the snubber setscrew when cleaning the manifold passages.

Clean the HLG manifold ports out with degreaser and compressed air.

Reassemble the HLG manifold in the reverse order.  IMPORTANT:  Torque the snubber setscrew [7] to 2 in-lbs (0.226 Nm).

Install the HLG pump into the CALM cabinet and reconnect the grease lines. 

Verify that the pickup tube has an updated 80 mesh filter screen. Replace if nesessary. Refer to the Haas Liquid Grease Filter Kit for more information.

Fill the HLG reservoir with compatible lubricant to 1/2" (13 mm) below the threads on the reservoir. Refer to the Lubricant, Grease, and Sealant Tables for Haas Machine Components.

Prime the lube lines as described in the Minimum Lubrication - Axis - Grease Reservoir - Haas Liquid Grease - Refill instruction.

• Replace the filter if the pick-up tube has the 40 mesh 0.625" diameter filter [1]
• Replace with 80 mesh 0.625" diameter filter (P/N 58-1993A) [2]

• Remove grease canister [4]
  
• Remove brass fitting [3] on end of pick-up tube [1]
• Discard old 40 mesh filter [2]
• Clean brass fitting
• Clean any debris from the inside of the pick-up tube and any brass from the threads
• Install new 80 mesh filter to the fitting [2]
• Install fitting to the pick-up tube
• Fill the HLG reservoir with compatible lubricant to 1/2" (13 mm) below the threads on the reservoir.
• Prime the lube lines and verify each axis is getting grease

Note : The HLG grease system has been discontinued. Machines should be updated to Haas Oil System refer to AD0659. This procedure is for reference only

This procedures tells you how to convert a machine with red SHC 007 axis lubrication grease to Haas Liquid Grease. The Haas Liquid Grease system uses a different reservoir assembly and different fittings at the linear guide trucks and ballscrew.

This applies to the following service kits:

• 93-2755: RETROFIT, HAAS LIQUID GREASE CONVERSION

Remove the existing lubrication system.

Remove the waycovers necessary to get access to the axis manifold [3] and ballscrew [2] for each axis.

Get access to the lubrication housing box [1] between the column and base casting.

Disconnect the copper tubes from the ballnut and linear guide trucks [4]. Use shop air to blow the remaining red grease out of the copper tubes.

Remove and discard the grease tubes to each axis and everything inside the lubrication housing box [1].

Install fittings and new reservoir.

Install the brass nipple fitting [1], check valve [2], and hose fitting [3] to one of the ports on the grease manifold.

Install the other two hose fittings [3] to open ports on the grease manifold.

Install the two plugs [4] in the remaining two open ports.

Remove the red grease reservoir assembly.

Install the Haas Liquid Grease reservoir assembly and air tube. Use the bracket [5] to install the assembly to the lubrication cabinet. Install the metal reservoir with Haas Liquid Grease [6].

Connect the pressure switch cable to the pressure switch behind the grease manifold.

Install new clear lubrication tubes.

Install new tubes from the ports [1] on the grease manifold to each axis.

Note: The tube that supplies the vertical axis must be plugged into the port with the check valve. This is the z-axis in a VF or MM, the y-axis in an EC, or the x-axis in an ST.

Connect the air hose [2] from the solenoid on the air manifold to the Haas Liquid Grease reservoir assembly.

Install the banjo and restrictor fittings.

Remove the fittings at the ballscrew and at each linear guide truck.

Install the banjo fitting [1] at the ballscrew port. Torque the banjo fitting to 10 in-lbs. Be very careful here; if you exceed 10 in-lbs you will break the banjo bolt.

Install the restrictor fittings [2] at each linear guide truck port.

Torque the restrictor fittings as follows:

• For linear guide brand Rexroth: 15 in-lbs
• For linear guide brands INA, NSK, and THK: 12 in-lbs

1. Axis-Lube Air Solenoid
2. Metal Canister Grease Reservoir
3. Plastic Canister Grease Reservoir
4. Air Pressure Gauge
5. Grease Manifold
6. Ballnut
7. Linear Guide Truck
8. Axis Grease Manifold
9. Orifice Fitting - grease flows in a helical shape around a set screw and oversize drilled thread. Do not remove the set screw from the orifice fitting.
10. Pressure Sensor: 4 PSI switch, normally open (not shown, located behind (5) )

The Haas Liquid Grease (HLG) system utilizes shop air pressure to pressurize the HLG reservoir via a 120VAC solenoid. Both components are located inside the air/lube cabinet

The lubrication cycle will be initiated when:

1. The axes have been in motion for the time specified in Setting 277 (6 hours by default).
2. The machine has been idle for 24 hours (specified in Parameter 1401).
3. If the user presses [F2] while in the LUBE MAINTENANCE section of the DIAGNOSTIC display.

The HLG manifold has two internal check valves [1] and [2]; internal snubber before the check valve [2]; the pressure gauge and the 4 PSI normally open pressure switch [3]. There are multiple lubrication lines coming out of the grease manifold depending on the machine type and configuration. The lubrication lines that are routed above the air/grease pump will have a check valve [4] at the grease manifold to prevent the grease from draining from the lines back to the reservoir between the lubrication cycles.

Corrective Action: Check for the presence of a check valve on the grease tube of the vertical axis.

If there is air in this tube or no grease, install the check valve (P/N: 58-2754) to this port on the manifold. Make sure the arrow is pointing down as shown in the image.

The machine does an Axis Lubrication cycle every 24 hours of axis feed time. In some cases it is possible that the machine can go a prolonged period of time without an Axis Lubrication cycle. If this happens and the machine's Z-Axis grease tube does not have a check valve, the grease may come back down the tube. When the machine does its next lubrication cycle, only air gets pushed through the tube. The horizontal axes get lubricated correctly while the vertical axis only gets air. Over time this damages the vertical axis ballscrew, linear guides, and trucks.

The check valve on the grease tube of the vertical axis prevents the grease from coming back down the tube. Install a check valve if the machine does not have one.

Verify that the check valve o-rings [1] & [2] are seated properly.

Corrective Action: Inspect the grease manifold.

Follow these steps to make sure the grease manifold operates correctly.

Disconnect all of the axis-grease tubes [1] from the grease-pressure manifold and connect a plug [2] (P/N: 58-1365) to each connector on the manifold.

Do the Axis Lubrication Test. If the Check-Lube icon shows, the grease manifold is faulty. Replace the grease manifold.

If the Check-Lube icon does not show follow these steps.

Disconnect the plug [1] from the grease manifold and connect the axis-grease tube [2].

Do the Axis Lubrication Test. If the Check-Lube icon shows, there is a leak in that axis. Examine the entire length of tube and associated fittings and manifolds and fix the leak.

Repeat this test with the other axes.

Corrective Action: Inspect the pressure switch for the axis grease.

Machines with the Next Generation Control:

Check the software version on the machine. The machine must have software version 100.16.000.1020 or higher. Update the machine software if necessary.

Do the Axis Lubrication Test and monitor INPUT 68, LOW_AXIS_GREASE_PRESSURE in the I/O tab in Diagnostics.

Machines with the Classic Haas Control:

Do the Axis Lubrication Test and monitor the Ax Grease Press. input in the I/O tab.

If the input changes from a 1 to a 0, the pressure switch operates correctly.

If it does not, disconnect the cables from the pressure switch and use a jumper to connect them as shown. The pressure switch is behind the grease manifold. If the input changes from a 1 to a 0, the pressure switch is faulty. Replace the pressure switch.

 Note: If the grease reservoir is empty or has been recently refilled, warnings/alarms 2073 and 2075 can occur until the axis lubrication system purges some air from the system.

Corrective Action: Inspect the axis-lube air solenoid.

Do the Axis Lubrication Test and make sure the voltage to the min. lube solenoid is 120 VAC.

 Note: Do not measure the voltage with the min. lube grease solenoid disconnected from the connector.

Refer to the I/O PCB - Troubleshooting Guide (Classic Haas Control) to troubleshoot the I/O PCB.

Refer to the Solenoid Troubleshooting Guide to troubleshoot the solenoid.

If the solenoid is not activating when commanded, check for:

• the connector being in the correct location.
• loose or broken wires.
• air coming out of the solenoid without the tube connected.
• firm solenoid cable connection at the I/O board.

• Inspect linear guides and ball screws for fresh grease
• If there doesn't appear to be grease, move to the orifices
• Ensure there is enough grease in the canister to run a test
• Disconnect the orifices from the linear guide pads and manually & continuously fire the solenoid
• If no grease comes out of the orifice they are likely clogged
• Remove the orifices from the copper lines and inspect the copper lines for clogs
• Fire the solenoid again with the orifices removed
• If no grease exits the lines there could be a clog in one of the manifolds
• Go to the lube cabinet and disconnect the plastic tube for the axis you are testing
• Blow pressurized shop air into the tube and see if this will clear the clog
• If the clog does not clear refer to the Haas Liquid Grease - Purge Clogged Lines procedure.

Eliminating Contamination

• If you were able to clear a clog just by using air pressure and did not replace any copper lines or manifolds, you may have contamination in the lines that could cause a new clog in the future.
• Check for contamination in the pick-up tube within the canister assembly [1]
  • Un-screw the grease canister [4]
  • Remove the brass fitting [3] that holds the mesh screen [2] in the pick-up tube and clean with a rag and alcohol
  • Dry with compressed air
  • Replace the mesh screen with a new finer 80 mesh screen provided in our service kit (P/N 58-1993A)  [2]
  • Re-install the fitting and screen
• To ensure a new clog does not occur, flush the lines without the orifices installed with Syngear SH1150 oil (93-2626)
• Install new orifices
• Re-fill can with Haas Liquid Grease or Syngear SH1150 oil
• Prime the lines and run as usual