Anybody ever ran into a "EX64 Turret postion verified too high" fault? So far I can not find anything out of the ordinary. :(

I guess you don't have the manuals that explain this problem? Does the turret have an encoder or a rotary limit switch of some kind to indicate turret position, If encoder, it may need calibrating for position, When does the error occur? When you select a tool position?
Al.

I actually do have the manuals for this machine and think I just found the problem. I found some residual oil on the feedback board. Looks like I have a small hydraulic leak. I'm in the process of replacing the ferrul and putting it back together now. As always, thanks for the feedback.

The problem turned out to be a hydraulic leak in the clamping cylinder dripping oil on the feedback board. I've got the fault to clear but will need to order a rebuild kit (if available) to resolve the leaking cyclinder.

If you need to clean the board of oil, there is products out there for this that do not harm the components, it would probabally be best to get the non-deposit type, some leave a light film used for cleaning switches etc.
Al.

Update:
I apologize for taking so long to respond back.
Hydraulic fluid shorted out the feedback board. I traced the leak to the Lamina Hydraulic motor and am expecting it in today. I had to purge and clean the entire hydraulic system because it was VERY contaminated. I suspect that is the reason the wiper seals failed in the Lamina Hydraulic Cylinder. This shop has never had a PM system established and I strongly suspect the oil has never been purged. I am the only maintenance guy in a 20 year old shop that has never had a PM program in place. We have 20-30 milling machines, 20-30 lathes and numerous other fabrication type equipment, half with little to no technical documentation to reference. I am always swamped and at any given time have multiple equipment issues thrown at me. Thanks to all for the feedback.
Also, I contacted Monarch about a replacemnt filter and their part number is 79736 and the price is $21.90 ea. Does anybody have any cross referencing information that would help me locate this filter from another vendor for I'm sure would be a much cheaper price.

We have 20-30 milling machines, 20-30 lathes and numerous other fabrication type equipment, half with little to no technical documentation to reference. I am always swamped and at any given time have multiple equipment issues thrown at me.
I contacted Monarch about a replacemnt filter and their part number is 79736 and the price is $21.90 ea.

First I would convince the powers above to obtain all service manuals, search on ebay if neccessary, they should be convinced that $100.00 for a set of manuals is cheap compared to loss of production without them.
For the filter, I would try the local Grainger or your local Hydraulics suppliers, With that many machines, you must have salesmen call on you from the local suppliers, throw it in their laps and see what they can do, I am sure it would be an off the shelf part cross.
Al.

I've pitched my case somewhat unsuccessfully about the manuals. They are getting more receptive in purchasing them but rarely allow me the time to research and order them.
As far as the filters, it's been years since most have been changed, the shop is in that kind of shape. They really don't have an established vendor yet but I'm hoping to change that soon. I figured I'd post incase somebody might know off of the top of their head or might have ordered some recently. Thanks

I am now getting a "EX71 Turret Failed To Unclamp" fault. When checking the diagnostic screen, X0005 bit zero stays at 1. It should cycle on and off when the turret clamps and unclamps. I thought that because of that, that this was a switch problem but I have verified that the micro switch is opening and closing when the turret cycles. Could this be a board issue? Any other ideas? Thanks :(

Alot of systems use X as a physical input designation so it looks like an input is permanentally on, disconnect the switch completely, if it stays on then it may be as you say, a board issue, or something is in the input card itself.
If it has an input card for the I/O, disconnect at the card and this should prove out the input and wiring etc.
What control system is on this by-the-way?
Al.

.

Fanuc system 10

Fanuc have many configurations for their I/O systems in the way of distributed I/O and different types of I/O module's etc, but the thing to do is identify the rack and module and disconnect at the module, wire numbers will help if you have them, the numbers at the switch end and the module end should jive, they use alot of Honda plugs in their sytems which make it difficult to trouble shoot when identifying the conductors.
Al.

I just got the problem now by reseating the interface board. My turret position is now one position off though. Would I just remove the encoder and back it up one position? Or can that be re-taught?

Is that an encoder or a rotary multi-position Sanyo sensor switch (looks like an encoder), if it is the multi-switch it has to be rotated back one position.
If it is a switch you can see the input bit pattern on the screen to set it when in position, it has a servo mount type that can be loosened and turned to position.
Al.

I got the problem to clear by reseating the interface board. I am now in the process of dialing in the tool position. I have got it close but not in yet. Is there a trick to doing this or some way to use the diagnostic screen?

If it is a rotary switch as I mentioned earlier you should be able to set it using the input screen, for this it is ideal to have the schematic showing the input module, this shows the individual tool numbers for a given switch, you then make sure the turret is located and seated at any tool position, and then it is usually just a matter of turning the switch and watching the screen until the appropriate switch is made. I am assuming you have a turret switch and not an encoder, which is possible, but rarer.
Al.

Does anybody know which line or input screen I could use to reference if tool #1 is in postion?
Fanuc System 10

FYI, I was able to manually align the turret one tooth at a time. Thanks to all for the feedback.