Service Home BMT45 - Live Tooling - Troubleshooting Guide - TG0034
Last updated: 10/29/2025

BMT45 - Live Tooling - Troubleshooting Guide

TG0034

Revision A - 10/2025

Introduction

Download and fill out the BMT45 Live Drive Inspection Report Checklist below before replacing any parts.

BMT45 Live Drive Inspection Checklist

100% duty cycle at 4500 RPM.

15% duty cycle at 6000 RPM.

Symptom Table

Symptom Possible Cause Corrective Action
Live Tooling Alarms 10.993, 10.103, and 10.9959 The servo motor has a fault Refer to the Sigma 5 Servo Motor Troubleshooting Guide.
The amplifier has a fault.

Refer to the Amplifier Troubleshooting Guide.

Note: If a short-circuit is found, inspect the cable and motor for a short circuit before installing a new amplifier.
Alarms 10.9918 and 10.217 Grease level is too high in gearbox. Drain the grease and refill to the correct level. Replace damaged components. Refer to the Lubricant Table for the latest information.
Alarm 10.116 LT (Live Tool) Spindle Orientation Fault

A tool change from a half station with an adjacent pocket that has a live tool to any other tool generates alarm 10.116 LT (Live Tool) Spindle Orientation Fault after updating software.		 Due to a stall or time out orient.  Check for obstruction of the live drive.
Noise/Vibration The drive is out of alignment. Re-align the live tooling drive.
Improper tool tightening / Installation. Refer to Alignment Cap section below.
A drive bearing has failed. Perform a Vibe Test.
The Live Tooling temperature exceeds 160°F (71°C). The RPM is over 4500 and exceeds the duty cycle.

The Live Tooling duty cycle is 15% at 6000 RPM.

Example: If the tool runs for 9 mins, it will need to rest for 51 minutes.

The Live Tooling duty cycle is 100% at 4500 RPM

Example: The tool can run continuously at 4500 RPM and lower.

Amplifier Short Circuit Inspection

Check the amplifier for a short. Power off the machine. Disconnect the cables for the axis servo motor at the amplifier that generates the alarm.

Place MultiMeter Leads Here Instructions

Set the meter to ohms, and take the following readings:

Ground screw to RED, WHT, and BLK terminals

If the meter does not show open (o.l) the amplifier is damaged.

Set the meter to Ohms, and take the following readings:

Black lead on HV (+) and Red lead to HV (-), RED, WHT, and BLK terminals

If the meter does not show mega ohms or higher the amplifier is damaged.

Set the meter to diode test mode, and take the following readings:

Red lead on HV (-) and black lead to HV (+), RED, WHT, and BLK terminals

If the meter does not show a voltage drop ranging from 0.2 to 0.8 volts the amplifier is damaged.

Set the meter to diode test mode, and take the following readings:

Black lead on HV (-) and red lead to HV (+), RED, WHT, and BLK terminals

If the meter does not show an open circuit (O.L) the amplifier is damaged.

Servo Motor Short Circuit Inspection

Corrective Action:

Check the cables for a short: Make sure the axis servo motor cables are not contaminated or pinched. Contaminated or pinched cables can cause a short. Replace the cables if necessary.

Inspect the servo motor. Disconnect and inspect the power cable connector at the motor. Make sure that there is no coolant contamination. Coolant contamination can cause this alarm and damage the amplifier. Measure the resistance from the pins labeled A, B and C at the motor connector to chassis ground.

  • The reading should show an open circuit.
  • If there is not open resistance, the servo motor is at fault.

Drive Alignment

1

Change parameter 9.019 to FALSE.

Set parameter 9.078 TT_AXIS TOOL CHANGE OFFSET to 0.

Set parameter 9.140 TT_AXIS GRID OFFSET to 0.

Press [POSITION]  and make the TT-axis visible by pressing [ALTER] then select the TT-axis and press [ENTER].

Remove all tooling from turret. [Zero Return] the TT axis, ignore any alarms. Press [DIAGNOSTICS] to get to the FACTORY parameters tab. Type TT and press [F4] to set the grid offset. [Zero Return] the TT axis.

In [MDI] command an M43 to unclamp the turret. Handle jog the TT axis until pocket 1 is in position, visually align the coolant nozzle. Press [ESTOP] to clamp the turret and verify the turret is fully seated.

Press [POSITION] and rotate the TT-axis motor coupler by hand to one end of travel. Record the TT-axis position. Rotate the TT-axis coupler to the other end of travel. Record the TT-axis position. Rotate the TT-axis motor coupler to the middle of the two positions. 

Example: (174.780 - 174.610)/2 + 174.610 = 174.695

Press [DIAGNOSTICS] to get back to parameters. Type TT and press [F2] to set the tool change offset.

Change parameter 9.019 to TRUE.

2

Run the live tooling without a driven tool in place. If the noise is gone or reduced check the live tooling drive alignment. 

Follow the BMT45 Turret - Live Tool Drive - Alignment procedure.  

Vibration Analyzer

For a detailed procedure see BMT45 Live Drive Turret Vibration Test

Install an empty live tool holder in tool #1. Install the accelerometer on the driven tool with the unit centered over axis of rotation to see maximum results.

Set the Averages to 8.

Right click on the plot and highlight X-Axis, click on CPM.

Right click on the plot and highlight Y-Axis, click on Vibration Displacement.

Right click on the plot and highlight Y-Axis, Scaling, click on .1 mil.

Run the live tooling at the maximum live tooling speed of the option purchased and start the vibe test. NTE 0.01 MIL at 4000 CPM (RPM) or NTE 0.01 MIL at 6000 CPM (RPM).

If the plot is out of tolerance, re-align the drive and test again.

Use another driven tool to verify that it is not causing the issue.

Verify alignment with the correct tooling before any parts are replaced.

Possible parts that cause vibration are the bearing and live drive shaft or the servo motor and coupler.  Another cause could be a coolant leak in the turret.  Verify that no coolant is found in the turret if replacing parts.  Coolants leaks happen if there is porosity in the turret.

Alignment Cap

Remove the live drive Alignment Cap [1] and inspect the highlighted surface. If live tools are being tightened incorrectly using the cap over time they will damage it and create groves at every station [2].

When pressure is applied to the inner face of the cap it will misalign and damage the live drive assembly.