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Push [POWER OFF]. Set the main circuit breaker to the OFF position.

Lock the main circuit breaker. Use an approved lock with an approved safety tag. Close the primary air valve.

Remove all the electrical [1] and pneumatic [2] connections from the gearbox assembly. Put marks to record their locations. Put labels on all cables and hoses.

Record the wiring configuration for the spindle motor [3]. Disconnect the wires. Remove the tool release piston (TRP) [4]. If the machine has through-spindle coolant (TSC), disconnect the necessary plumbing.

If the gearbox has a mid belt shield [1], remove it.

Make sure no cables are connected to the gearbox. Remove the gearbox from the machine.

Remove (5) of the (6) bolts from the gearbox assembly. Do not remove (1) of the bolts near the rear of the machine. Loosen this (1) remaining bolt. With your hands, pull the gearbox toward the spindle. This loosens the tension on the spindle belt [3]. Connect the hoist to the gearbox [2]. Lift the hoist until it supports the gearbox. Remove the (1) remaining bolt from the gearbox assembly. Slowly lift the gearbox.

Remove the gearbox from the machine. Move the transmission oil pump assembly [4] and the spindle encoder [5] to the new gearbox.

Connect the high-gear air hose [1] from the CALM cabinet to the fitting on top of the air-over-oil assembly.

Connect the low-gear hose [2] to the fitting on the top plate of the gearbox labeled LOW.

If you have a 35-psi air regulator [3] on the input of the shift solenoid in the CALM cabinet, you must remove it. Replace the 35-psi air regulator [4] with the tee fitting [5].

If you have an adjustable air regulator on the input of the shift solenoid, set the air regulator to 80 psi.

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

1. SPINDLE MOTOR 10HP LINCOLN
2. GEAR 16DP 40 TOOTH 2.05"
3. FITG JIC-5-F X -5 HOSE STR
4. RETAINING RING 1.875 INT BASIC
5. SHCS 5/16-18 X 1
6. GEARBOX TOP PLATE 16DP-65T
7. HHB 1/2-13 X 1 3/4 GRADE 8 PLAIN
8. SPRING BELVIL 1.206ID X 1.831OD X 0.059
9. BEARING M17-47-14 OIL
10. GEARBOX TRANSFER GEAR ASSY 16DP65T
11. NUT 7/16-20, LOCKING
12. SHIFT FORK 40T GEARBOX
13. BEARING M25-47-12
14. RETAINING RING 1.000 EXT BASIC
15. RETAINING RING 0.669 EXT BASIC
16. HOUSING GEARBOX MACHINED
17. FITG HOSE BARB3/8 NPT1/4M 90 BRASS
18. SHCS 10-32 X 7/8
19. SPROCKET
20. SHIFTER SHAFT
21. QUAD-RING Q4-114 VITON NOT FOR SALE
22. SHIFTER BODY
23. SHCS 10-32 X 2
24. 40T SWITCH MOUNTING BRACKET
25. PICK UP TUBE DRY SUMP
26. SHCS 1/4-20 X 1/2 ZINC
27. SHCS 10-32 X 3/8 W/ FLAT WASHER OD 0.37-
28. 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 2.047 INT BASIC
34. SHCS 10-32 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 0.059
39. BEARING M25-52-15 OIL
40. GEARBOX DRIVE GEAR ASSY 16DP65T
41. BEARING M30-72-19 OIL
42. F SEAL 1.125 X 1.595 X 0.240 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 0.875 X 1.345 X 0.350 F
51. SUMP BRACKET
52. SUMP TANK

Corrective Action:

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.

Corrective Action:

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.

Corrective Action: 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 93-30-5725) if it is broken.

1. Fittings
2. Retention clip
3. Steel ball
4. Oil flow sensor housing
5. Proximity sensor

Corrective Action:

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.

Check Valve Style Oil Flow Sensor:

Corrective Action:

Unplug the oil flow sensor and remove it from the oil-pump assembly. Use a screw driver to manually depress the sensor plunger.  Use a multi meter to monitor continuity across the switch leads.  If continuity is made when the plunger is depressed and broken when the plunger is released the sensor is working properly.

If the sensor is not working properly loosen the two phillips head screws that attach the sensor to the fitting.  Adjust the sensor position until actuating  the plunger reliably makes continuity when the plunger is depressed and breaks continuity when the plunger is released.

Plug the oil flow sensor in and monitor the diagnostic bit for Low Lube Press. as you manually actuate the sensor.

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.

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.

Corrective Action:

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.

Corrective Action:

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.

Corrective Action: 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 300A-cable 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

Cause:

Sump tank missing weep hole and a change to foam gasket. 

Corrective Action:

Drill the weep hole on the backside (encoder side) of the sump tank.

1. ø.094 THRU ONE WALL 0.20” From Top Of The Tank.

Clean thoroughly after drilling to not introduce debris.

Note: Do not drill a hole on the front side (spindle side) as coolant can enter the sump.

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.

Corrective Action:

Refer to Wye-Delta Contactor - Troubleshooting Guide to troubleshoot the Wye/Delta connectors.

Remove the spindle head covers to gain access to the transmission.

Disconnect the oil return line on the top of the gearbox [3].

Put the oil return line in the container to collect the oil.

Run the spindle at 5 RPM until the oil pump pumps all the oil out of the gearbox into the container.

Note: The control will generate the alarm 2012 INSUFFICIENT SPINDLE GEAR BOX OIL FLOW or 179 LOW GEARBOX OIL PRESSURE. Reset the alarm and keep running the spindle until gearbox is empty.

Once gearbox is empty, stop the spindle and reconnect the oil return line.

Remove the access cover on the bottom of the spindle head to gain visual access to the oil sump tank and locate the overflow hole. Gearbox built after 02/2015 have the overflow hole on the back of the oil sump tank [4]. Gearbox built before 02/2015 have an overflow hole on the bottom of the oil sump tank [5].

There is either the 500ml reservoir [6] or the fill tube [7] on top of the gearbox. Fill the gearbox with Mobil SHC627 in 4 oz increments until oil starts to come out of the overflow hole on the oil sump tank.