I have a 1996 TC-22 and it has been mostly trouble free since 2002. Today I started it up like I always do and proceeded to run parts. On the first tool change I heard a loud "BANG" and ran over to see that happened. A plastic tool holder finger had broken off and the tool holder went crashing. I thought maybe it was stressed over time like a 2 or 3 other fingers have done over the years. So I relocated that particular tool into another tool slot in the carousel, modified the part program to reflect its new location, and began another part cycle. Only this time it broke ANOTHER finger off during the part cycle.
I read the manual and followed instructions for resetting tool changer height and noticed that the Z axis tool change height was about 1/2" higher than it should be. No wonder it was breaking off the tool holder fingers.
I reset/saved the proper tool change height after adjusting the Z-axis into place - something I haven't had to do since I bought the machine in 2002.
Then I rechecked all TLO offsets and expected them to be off, but everything there was perfect. How can the tool change height suddenly be 1/2" off but not the tool offsets as well?
I then rebooted the machine and before DOS loaded, got an error message that says " CMOS battery problem, defaults loaded....press F1 to continue" (This is the first time I've ever seen a CMOS battery error message since I got the machine.)
So I pressed "F1" and everything loaded and came up normally. I even checked the tool change height again and it was correct. So even though the CMOS battery is dead, the control is recalling/moving to the correct tool change height.
On a weird side note: when in the settings page>tool change(6)>Password (9)>Start (1), the Z axis moved to tool change height and the spindle orients as usual, except the coolant turns on. I have not seen that happen before.
Could a bad CMOS battery cause the inconsistent tool change height problem?
The second time I ran a part program after resetting the height, it successfully did 2 tool changes before breaking the finger on the 3rd tool change. So, whatever the problem is, it is not consistent.
How can this machine function at all with a bad CMOS battery?
I looked at the 3V button cell on the motherboard and it did not appear to have been leaking. Can I replace the cell with the machine turned on and not lose CMOS settings?
Any help would be appreciated.
PS. Where can I buy replacement fingers?