Wasino LJ-103M Problems

[Andy Fritz]

Hi folks!

Does anyone out there have a maintenance / repair manual for this lathe?
I have the user manual, wiring diagram and ladder plus the maintenance manual for the Fanuc 10T control.

Problem #1; I had the machine up and running and while manually indexing the turret the control went down. After reboot I get E-stop but no error codes and no other indications like lit leds etc other than the red EMERGENCY STOP led on the control pendant and the high lighted ---EMG--- on the monitor.

I found that a 3,2A fuse on the DC power supply and another 3,2A fuse on the 3 DI/DO card had blown. After replacing both and rebooting the 3,2A fuse on the DC power supply is ok, but the one on the DI/DO is blown.
Checking PC Diagnostics R103 indicates that Z and X shear pins are broken. I checked the pins and both are ok. I manually moved the Z and X a few inches away from limit switches and tried to reset the KEEP RELAYS for the shear pins but this does not work. I dont think the selector switch for MDI mode is functioning as the fuse is blown on the DI/DO board. I checked the Fanuc maintenace manual which says that the blown 3,2A fuse is there to protect the control from the machine side so I really need a trouble shooting guide to find what is causing the fuse to pop. Is there a short? If so how do I find it?
Maybe there is a procedure to manually bypass the E stop circuit and put the turret in correct position? I tried to push the solenoids, and using a level try to find a position where it is sort of "fairly" aligned. No joy.

The only thing abnormal I have found is that the solenoid for the claming of the chuck is quite warm. I can touch it with out burning, but I really dont know why it is hotter than the other solenoids? I removed the ice cube relay connecting power to this solenoid in case there was a short in it, but this did not stop the 3,2A fuse from blowing on power up.

Problem #2; Providing I can solve problem #2, I would be able to engage the C axis for milling mode. However, as soon as the C axis is engaged I get this weird humming noise from the C motor and C axis shaft. The noise goes away while jogging the C and the position seems to have a bearing on the noise. For example after C zero return I get a louder noise than moving a few degrees to either side. In any case the motor gets hot at idle and eventually I get an overload alarm. The current draw is much higher than the other motors at idle. I have swapped motor and C axis drive, but no joy so I assume the C axis shaft is pushing the motor shaft radially which may create a semi short in the winding. If the motor is removed from the C axis it is silent and does not get hot. Again I would need a repair manual for the machine side to see how to best break down the c axis and maybe replace or just re-align the shaft.

Wasino says there is no particular repair manual for the machine other than the very thin user manual I already have. If there is any service tech around how knows how to help me trouble shoot this over phone I am happy to pay for it.

All the best,

Andy