Section 5 - Troubleshooting

Troubleshooting
Machine: 32-9914 Arbomex Nagel Precision, Inc.
5.0 TROUBLESHOOTING
5.1 Objectives
After reading this section TECHNICIANS will be able to:
◆ Locate general troubleshooting information pertaining to mechanical,

pneumatic, coolant, and electrical areas.
◆ Identify probable causes for specific machine symptoms.
◆ Determine the root cause of a problem and derive a solution by using the
information included in this manual, as well as their knowledge and
experience.
5.2 Troubleshooting Description
Troubleshooting is a process of discovering and eliminating the root cause of a

problem. This can be accomplished by:
1. Identifying the fault/condition on control screens
2. Locating the cause
3. Applying the solution
Technicians are in a unique position to assist in the troubleshooting process. Their
knowledge and understanding of the system can provide critical information as to the
cause of trouble. In addition, the technician’s familiarity with the machine can often
allow them to identify problems in their early stages.
As always, follow all SAFETY procedures when troubleshooting problems. Refer
back to the SAFETY section of this manual if you are unsure of the proper safety
procedures. If you are still unclear about a safety issue, contact your company’s
safety department or your supervisor.
NOTE: It is necessary to mention, when stated that a sensor (proximity switch)
needs adjusting or has failed all sensors that affect the particular component should
be checked (starting with the most obvious and working down). Therefor, it is
important to become familiar how all elements of this machine work together.
9/1/2022 Nagel Precision, Inc. 5.1

Troubleshooting
5.3 Coolant Faults
Coolant Faults
Fault Cause Solution
Coolant Failed To Flow Feed pump failed to run. Start unit.
I28.01
Flow switch not adjusted Adjust flow switch to
Correctly. corresponding tag
pressure.
Faulty flow switch wiring. Check and repair flow

switch wiring.
Faulty flow switch. Replace flow switch.
24 volt output not reaching Check the voltage to the

the valve. valve.
Mechanical interference Remove/repair

and/or restrictions. mechanical
interference/restrictions.
Faulty feed pump. Check pump.
Valve not energized. Check valve operation.

Coolant Low Level Coolant level is low Level is actually low,
I30.06 add coolant
Troubleshooting
Bad or dirty level switch

Clean or replace level
switch
Coolant Filter Dirty Dirty or clogged filter. Replace the filter.
I28.00
Prox cable unplugged or Fix or replace prox
broken. cable.
Tape Arm Coolant Feed pump failed to run. Start unit.
Failed To Flow
I28.05 Flow switch not adjusted Adjust flow switch to
Correctly. corresponding tag
pressure.
Faulty flow switch wiring. Check and repair flow

switch wiring.
Faulty flow switch. Replace flow switch.

the valve. valve.
Mechanical interference Remove/repair

and/or restrictions. mechanical
interference/restrictions.
Faulty feed pump. Check pump.
Valve not energized. Check valve operation.

Troubleshooting
5.4 Lube Faults
Lube Faults
Lube level low Low lube level. Fill lube to correct level.
I28.09
Faulty level indicator. Repair/replace lube level
indicator.
Prox cable unplugged or Fix or replace prox cable.

broken.
Lube Filter Dirty Dirty or clogged filter. Replace the filter.
I28.13
broken.
Lube Motor Failed to Run Pump not running. Start unit.
I03.10
the motor starter. motor starter.
Motor overload tripped. Reset the overload.
Mechanical interference Remove/repair mechanical

and/or restrictions. interference/restrictions.
Motor starter tripped. Reset motor starter.
Faulty pump. Replace pump.
Fix or replace prox cable.

Prox cable unplugged or
Troubleshooting
broken.
Lube Motor Overload Blocked or restricted Check for mechanical

I03.11 mechanically bound. restrictions.
Pump flow restricted. Check pump for physical

restrictions (rags, dirt slurry).
Overload tripped. Reset the overload.
Incorrect motor settings. Refer to prints for correct

motor settings.
Actual FLA (full load Replace pump if all

amperage) is greater than mechanical causes have
specified amperage. been eliminated.
Lube Zone 1 Not at  Lube pump not running.  Is power being supplied
Pressure (Cycled) to the lube system?
I30.10  Faulty pressure switch
 Check the lube pump. Is
 Leak it working correctly?
 Check the motor.
 Check component wiring.
 Adjust/replace pressure
switch.
 Replace solenoid.
Lube Zone 1 Not Relieved  Relief valve set  Set the relief valve to the
I30.09 incorrectly. correct pressure. See tag
value.
 Faulty check valve.
 Replace faulty valve.
 Filter dirty, lube
contaminated.  Replace the dirty filter.
 Faulty pressure switch

 Adjust/replace pressure
 Faulty solenoid. switch.
 Replace solenoid.

Troubleshooting
5.5 Pneumatic Faults
Pneumatic Faults
Main Air Not Ok Supply Valve Closed. Check air supply valve.
I28.04
Main air regulator not set Set main air regulator
correctly. pressure to the correct
pressure. See tag value.
Relief ball valves open. Close the ball valves.
Incoming air pressure low. If the plant air supply

pressure is low contact your
supervisor.
Bad pressure switch Replace switch is necessary.
Line filled with water Contact supervisor

Troubleshooting
5.6 Mechanical & Electrical Faults
Mechanical & Electrical Faults

Part Lift Failed To Motion Fault See Section 5.8 – Motion
Advance Faults.
I30.12
Part Lift Failed To Return broken
I30.13
Tailstock Failed To Motion Fault See Section 5.8 – Motion

Advance Faults.
I30.14
Tailstock Failed To Return broken
I30.15
Tape Head Slide Failed To Motion Fault See Section 5.8 – Motion
Advance Faults.
I38.00
Tape Head Slide Failed To broken
Return
I38.01
Tape Arm 1 Failed To Motion Fault See Section 5.8 – Motion

Advance Faults.
I42.00
Tape Arm 1 Failed To broken
Return
I42.01

Advance Faults.
I42.04
Return
I42.05

Advance Faults.
I42.08
Troubleshooting

Return
I42.09

Advance Faults.
I42.12
Return
I42.13

Advance Faults.
I41.00
Return
I41.01

Advance Faults.
I41.04
Return
I41.05

Advance Faults.
I41.08
Return
I41.09

Advance Faults.
I41.12
Return
I41.13

Troubleshooting

Advance Faults.
I40.00
Return
I40.01

Advance Faults.
I40.04
Return
I40.05

Advance Faults.
I40.08
Return
I40.09

Advance Faults.
I40.12
Return
I40.13

Advance Faults.
I39.00
Return
I39.01

Advance Faults.
I39.04
Troubleshooting

Return
I39.05

Advance Faults.
I39.08
Return
I39.09

Advance Faults.
I39.12
Return
I39.13
Lower Tape Lock Failed Motion Fault See Section 5.8 – Motion
to Advance Faults.
I29.04
Lower Tape Lock Failed broken
to Return
I29.05
Tailstock Not Rotating Motion Fault See Section 5.7 – Motion

Faults.

broken
Broken Belt Replace belt

Tape Index Error Motion Fault. See Section 5.7 – Motion
Faults.
Bad motor Repair or replace motor
Prox cable unplugged, Fix, replace or adjust prox

broken or out of adjustment cable.
Lobe #1 Tape Broken Too much tape slack
Use strip tape or staple
I42.02
Fold in the tape
Replace tape reel
Lobe #2 Tape Broken
Troubleshooting

I42.06 Parameters are off
Lobe #3 Tape Broken Tape Broke

I42.10
Lobe #4 Tape Broken

I42.14
Lobe #5 Tape Broken

I41.02
Lobe #6 Tape Broken

I41.06
Lobe #7 Tape Broken

I41.10
Lobe #8 Tape Broken

I41.14
Lobe #9 Tape Broken

I40.02
Lobe #10 Tape Broken

I40.06

I40.10

I40.14

I39.02

I39.06

I39.10

I39.14

Troubleshooting

Input Power Not On 24 Power supply is off. Check 24 volt power supply.
I03.00
Control Power Not On Guard doors not shut Make sure all guard doors
I03.01 are shut.
E-Stop depressed Before restarting the

machine determine why the
E-Stop was activated. Is
maintenance being
performed on the machine?
Was it to prevent injury or
machine damage? Was it
accidentally pushed? See
Section 3 -Operations for the
Machine Startup Procedure.
Proper pushbutton not used See Section 3 – Operations

during startup procedure. for proper start-up button
Main disconnect off Turn on main disconnect and

perform the Machine Startup
procedure in Section 3 –
Operations.
HMI E-STOP Depressed The E-Stop has been Determine why the E-Stop
I35.00 activated. was used. Was it for an
emergency, locked out for
repairs or accidental?
After determining that it is

safe, perform machine
startup procedure.
Emergency Return Acive The “Emergency Return” Determine why the button
I35.09 pushbutton has been was used.
activated.
After determining that it is
safe, perform machine
startup procedure.
Operator Guarding Relay Relay circuit is down. Check circuit for failure.
Fault
I03.02 See Section 7 - Electrical
Maintenance for
troubleshooting tips

Troubleshooting

Light Curtain Blocked Relay circuit is down. Check circuit for failure.
Fault
I03.03 See Section 7 - Electrical
Maintenance for
troubleshooting tips
Reset faults (if any) and
HOME the machine from the
Machine not at Home
HMI pushbuttons.
Operator Guard Door #2 One or more of the guard Tightly close all doors.
Open doors are open.
I04.02 Test guard door switches
Faulty guard door safety and replace if necessary.
Operator Guard Door #3 switch.
Open
I04.04
Operator Guard Door #4

Open
04.06
Operator Door Failed To Motion Fault See Section 5.8 – Motion

Advance Faults.
Operator Door Failed To Prox cable unplugged or Fix or replace prox cable.
Return broken
WARNING: Lobe #1 Tape Warning the tape is almost Check tape media and
Level Low gone replace (if needed) with a
I42.03 new tape reel
WARNING: Lobe #2 Tape

Level Low
I42.07

Level Low
I42.11

Level Low
I42.15

Level Low
Troubleshooting

I41.03

Level Low
I41.07

Level Low
I41.11

Level Low
I41.15

Level Low
I40.03

Level Low
I40.07

Level Low
I40.11

Level Low
I40.15

Level Low
I39.03

Level Low
I39.07

Level Low
I39.11

Level Low
I39.15
Troubleshooting

Part Not Present The physical part in (or not Change part or machine
I30.05 in) the station doesn’t match setup so they are the same.
part tracking. Re-start auto cycle.
Part Not Present in Auto
I30.05 No part present Make part available.
Part Not Oscillating Motion Fault. See Section 5.7 – Motion

Faults.
Prox cable unplugged, Fix, replace or adjust prox

broken or out of adjustment cable.
Polish Over Cycle In coming part size. Polish time has taken to long
due to the amount of stock
needing to be removed:
check the size of the
incoming parts.
Incorrect parameters Make sure all entered

entered. parameters are correct.
Worn tooling. Check tooling - replace if

worn.
509 Breaker Group  The breaker was turned  Turn the breaker back on
Faulted off
550 Breaker Group  A problem caused the  Correct the cause and
Faulted breaker to trip turn the breaker back on
609 Breaker Group

Faulted

Troubleshooting
5.7 Axis / Servo Faults
FAULT POSSIBLE CAUSES POSSIBLE SOLUTIONS
Servo 01 Drive 3-Phase Fuse OL or tripped Replace blown fuses

Power Off
Check wiring
I03.16
Check incoming voltage
Headstock Axis Fault Servo Axis problem Check Profibus screen and wiring.
Cross Slide Axis Fault Use the HMI honing system diagnostic
page.
Headstock Axis
Forward OT Fault The axis has reached Jog reverse
the over travel position.
Cross Slide Axis Search HOME or set ZERO.
Forward OT Fault Axis needs to search
HOME or ZERO must be Check parameters to make sure the home
set. offset is what it should be.
Headstock Axis Motion Bad “servo move” Check A-B Servo system. Reload A-B
Error Fault request software.
Cross Slide Axis If program has been changed, remove

Motion Error Fault changes.
Check if A-B flash card is up-to-date.

Headstock Axis The axis has made the Jog forward
Reverse OT Fault minus over travel
position
Cross Slide Axis
Reverse OT Fault Axis needs to search Search HOME or set ZERO.
HOME or ZERO must be
Troubleshooting
set. Check parameters to make sure the home

offset is what it should be.
Headstock Not off The drive and the HOME Check parameters
Home Prox prox do not match
I30.00 Search HOME on the axis
Headstock Not on Check the HOME prox

Home Prox
I30.00
Headstock VFD Faulted Check wiring to the VFD.

The VFD is not
communicating correctly
Index VFD Faulted Also see the VFD manual for more
or at all.
information about faults.
Headstock VFD Not

Active
Spindle is not
Check wiring to the VFD. Also, see the
Communicating with the
Index VFD Not Active VFD manual for more details about faults.
VFD
Headstock VFD Not

Ready Spindle is not
Check wiring to the VFD. Also, see the
Communicating with the
VFD manual for more details about faults.
Index VFD Not Ready VFD
Headstock VFD Not Error with rack Check rack and re-start the machine
Running
Check fuse, and replace if necessary
Index VFD Not Running Drive fuse is broke
Check relay
Relay has been tripped. Check cables and settings.
VFD is not
communicating
with processor

Troubleshooting
5.8 Motion Faults
Definition
A motion fault is any fault that prevents movement in the machine. When a motion
fault occurs there are standard hydraulic components/areas that should be checked
for problems.
CAUSE SOLUTION
Failed Cylinder Replace or repair cylinder
Faulty or mis-adjusted prox switch Replace or adjust prox switch
Dirty or Failed Valve Clean, repair or replace valve
Failed Solenoid Repair or replace Solenoid
Flow Rate problems Adjust or clear flow problem
Clogged or broken line Clear blockage or repair / replace line
Is pressure set correctly? Use a gage to verify pressure and set to the
corresponding tag
Mechanical bind or interference Repair or remove bind / interference
5.9 Pump/Motors Failed to Run
CAUSE SOLUTION
Pump not running Start pump
Pressure switch not adjusted Adjust pressure switch to corresponding tag
properly
Faulty pressure switch wiring Check and repair wiring
Faulty pressure switch Replace pressure switch
24 volt output not reaching the Check voltage to the motor starter
motor starter
Motor overload tripped Reset the overload
Mechanical interference and/or Remove / repair mechanical interference or
restriction restriction

Troubleshooting
5.10 Motor Overloads
CAUSE SOLUTION
Blocked or restricted mechanically Check for mechanical restrictions and clear
Pump flow restrictions Check pump for restrictions (eg. dirt, rags)
and clear
Overload tripped Reset the overload
Circuit breaker tripped Check voltage at motor
Incorrect motor settings Refer to prints for correct motor settings
Actual FLA (full load amperage) is Replace pump if all mechanical causes have
greater than specified amperage been eliminated
Troubleshooting Notes:

Section 5 - Troubleshooting

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Section 5 - Troubleshooting

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Troubleshooting

Machine: 32-9914 Arbomex Nagel Precision, Inc.

After reading this section TECHNICIANS will be able to:

◆ Locate general troubleshooting information pertaining to mechanical,

5.2 Troubleshooting Description

Troubleshooting is a process of discovering and eliminating the root cause of a

9/1/2022 Nagel Precision, Inc. 5.1

5.3 Coolant Faults

Faulty flow switch wiring. Check and repair flow

Faulty flow switch. Replace flow switch.

24 volt output not reaching Check the voltage to the

Mechanical interference Remove/repair

Faulty feed pump. Check pump.

Valve not energized. Check valve operation.

Bad or dirty level switch

Faulty flow switch wiring. Check and repair flow

Faulty flow switch. Replace flow switch.

24 volt output not reaching Check the voltage to the

Mechanical interference Remove/repair

Faulty feed pump. Check pump.

Valve not energized. Check valve operation.

9/1/2022 Nagel Precision, Inc. 5.3

5.4 Lube Faults

Prox cable unplugged or Fix or replace prox cable.

Motor overload tripped. Reset the overload.

Mechanical interference Remove/repair mechanical

Motor starter tripped. Reset motor starter.

Faulty pump. Replace pump.

Fix or replace prox cable.

Lube Motor Overload Blocked or restricted Check for mechanical

Pump flow restricted. Check pump for physical

Overload tripped. Reset the overload.

Incorrect motor settings. Refer to prints for correct

Actual FLA (full load Replace pump if all

 Check the motor.

 Check component wiring.

 Faulty pressure switch

9/1/2022 Nagel Precision, Inc. 5.5

5.5 Pneumatic Faults

Relief ball valves open. Close the ball valves.

Incoming air pressure low. If the plant air supply

Bad pressure switch Replace switch is necessary.

Line filled with water Contact supervisor

9/1/2022 Nagel Precision, Inc. 5.6

5.6 Mechanical & Electrical Faults

Mechanical & Electrical Faults

Tailstock Failed To Motion Fault See Section 5.8 – Motion

Tape Arm 1 Failed To Motion Fault See Section 5.8 – Motion

Tape Arm 2 Failed To Motion Fault See Section 5.8 – Motion

Tape Arm 3 Failed To Motion Fault See Section 5.8 – Motion

Mechanical & Electrical Faults

Tape Arm 4 Failed To Motion Fault See Section 5.8 – Motion

Tape Arm 5 Failed To Motion Fault See Section 5.8 – Motion

Tape Arm 6 Failed To Motion Fault See Section 5.8 – Motion

Tape Arm 7 Failed To Motion Fault See Section 5.8 – Motion

Tape Arm 8 Failed To Motion Fault See Section 5.8 – Motion

9/1/2022 Nagel Precision, Inc. 5.8

Mechanical & Electrical Faults

Tape Arm 10 Failed To Motion Fault See Section 5.8 – Motion

Tape Arm 11 Failed To Motion Fault See Section 5.8 – Motion

Tape Arm 12 Failed To Motion Fault See Section 5.8 – Motion

Tape Arm 13 Failed To Motion Fault See Section 5.8 – Motion

Tape Arm 14 Failed To Motion Fault See Section 5.8 – Motion