Introduction

 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.

Identification

 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.

 

Axis Lubrication

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.

Axis Manifold Fitting Information

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.

Haas Liquid Grease - Reservoir Refill

AD0121

Applies to machines built from April, 2014

Introduction

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 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.

Haas Liquid Grease - Refill

1

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.

2

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.

3

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.

Axis-Lubrication System - Grease Reservoir - Prime and Test

1

If the machine has a Classic Haas Control:

  • Press [PARAMETER DIAGNOSTIC] (2) times to show the diagnostics page.
  • Press [CANCEL].
  • Go to the LUBE tab.

  • Press [WRITE/ENTER].

  • Press [F2] to start the Axis-Lubrication Test.

If the machine has a Next Generation Control:

  • Press [DIAGNOSTICS].
  • Go to the Maintenance tab.

  • Press [F2] to start the Axis-Lubrication Test.

2

Perform the Axis-Lubrication Test again until you no longer get axis lubrication alarms. Wait a minimum of (1) minute between Axis-Lubrication Test cycles.

Check the level of the grease in the reservoir.

If the grease lines were nearly empty, it may be necessary to refill the axis-lubrication reservoir after you purge the lines of air. Pour the grease into the reservoir: to about 1/2" (13 mm) below the threads on the reservoir.

Haas Liquid Grease - Purge Clogged Lines

HLG - Purge Clogged Lines - How To Video

Introduction

This procedure explains how to purge the thickened grease out of the copper lube lines on the linear axis. The illustration below showing the typical horizontal axis lubrication setup and has the castings removed for clarity. The location of the grease manifold will vary depending on the machine model and the axis. 

Note: This procedure is only applicable for the machines that are equipped with the Haas Liquid Grease system. Refer to the Axis Lubrication Systems - Identification.

Purge The Lines

1

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.

2

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. 

3

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.

HLG Pump Manifold - Clean Passages

1

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.

Haas Liquid Grease - Filter Kit

AD0429

Introduction

The grease lubrication system is a critical part of the Haas machine and it has very precise metering units at all of the lubrication points.  The slightest amount of contamination in the system can clog these fittings and will eventually cause damage to the linear motion components.  It is critical that the system stays clean every time the canister is refilled.  It is also critical that the pickup strainer is upgraded to the one currently used in production.  See detailed instructions below.

Install New Mesh Filter

1

  • 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]

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

HLG - Purge Clogged Lines - How To Video

Introduction

  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) )

System Operation Overview

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.

When a lubrication cycle is commanded, the solenoid applies air pressure to the grease reservoir for 3 seconds (specified in Parameter 2027), which forces the grease to move up the grease pick-up tube [5] and into the grease manifold. The grease flows through the lubrication lines to the lubrication points where it gets pushed through the restrictors into the components that require the lubrication (ballscrew, linear guides pads, etc). Once the cycle ends, the pressure from the grease reservoir is vented to the atmosphere, the check valve [1] traps the pressurized grease in the manifold and the grease will start to flow through the snubber and the check valve [2] back to the grease canister until the pressure in the manifold drops to 0 PSI.

During the lubrication cycle the control monitors the pressure in the lubrication manifold in order to detect a failure of the lubrication system.

When the solenoid is commanded to turn on, the control begins to monitor the status of the pressure switch [3]. The switch is expected to close within 3 seconds (specified in Parameter 1374) from the moment that the solenoid was commanded ON. Once the pressure is detected it is expected to stay for at least 15 seconds (specified in Parameter 1375). If all of the above statements were satisfied during the cycle then the lubrication cycle is considered successful.

If pressure in the system was not detected within 3 seconds (specified in the Parameter 1374) the control will stop monitoring the pressure and display the “Low Lube” warning icon until the next lube cycle. If such a condition was detected for 5 consecutive lube cycles, then the control will generate the Alarm 2073 AXIS LUBRICATION PRESSURE NOT DETECTED. The alarm will not be generated during a program execution, it will only be generated after the program execution ends or after pressing a [RESET] button.

If the pressure in the system drops below 4 PSI before 15 seconds (specified in Parameter 1375), the control will display “Low Lube” warning icon until the next lube cycle. If such a condition is detected for the next 4 consecutive lube cycles (5 total cycles) the control will generate the Alarm 2075 AXIS LUBRICATION RESERVOIR IS EMPTY. The alarm will not be generated during a program execution. It will be generated after the program execution ends or after pressing a [RESET] button.

Symptom Table

Symptom Possible Cause Corrective Action
Alarm 2082 RESIDUAL PRESSURE DETECTED PRIOR TO AXIS LUBRICATION CYCLE Clogged orifices, lube lines, or manifolds. Inspect all orifices, lube lines, fittings, and manifolds for clogs/debris.  Refer to Haas Liquid Grease - Purge Clogged Lines  procedure. 

Alarm 2073 AXIS LUBRICATION PRESSURE NOT DETECTED

 

Alarm 2075 AXIS LUBRICATION RESERVOIR EMPTY

 

 The grease is low or empty. Refill the grease. Refer to Axis Lubrication System - Grease Reservoir - Haas Liquid Grease - Refill procedure.

Always make sure you replace the grease with Haas Liquid Grease or an approved alternative. The emergency substitute can still generate alarms.
There is no check valve on the vertical axis grease tube. Make sure there is a check valve on the grease tube of the vertical axis if there was any air in the tube.
There is a problem with the grease manifold. Inspect the grease manifold, lube lines, and fittings.
There is a problem with the pressure switch for the axis grease. Inspect the pressure switch for the axis grease and check the software version.
There is a problem with the axis-lube air solenoid. Inspect the axis-lube air solenoid.
Check Valve O-rings are not seated properly inside the grease manifold assembly. Use the image in the Check Valve O-rings section to verify the o-rings are seated properly.
Grease canister is empty but no alarms are generated and the pressure gauge is holding pressure Clogged orifices, lube lines, or manifolds. Inspect all orifices, lube lines, fittings, and manifolds for clogs/debris. Blow out with air, flush with Syngear 1150, replace parts that cannot be unclogged as necessary. Upgrade the mesh filter in the pick-up tube from the previous 40 mesh filter to the new 80 mesh filter.
Machine does not appear to be using grease as much as expected

Vertical Axis Check Valve

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.

Check Valve O-rings

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

Grease Manifold

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] 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.

Pressure Switch

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.

Axis-Lube Air Solenoid

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.

Clogging and Contamination

Clearing A Clog
  • 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]
  • 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

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