1004

Visual Inspection

Open the pallet changer door and visually inspect both pallets for chips, debris, or workpiece interference.

Ensure machine is in EMERGENCY STOP before opening pallet changer area

Check Pallet Alignment

Verify pallets are properly seated on locating pins and not cocked or tilted on the shuttle.

Look for shiny wear marks on locating pins indicating misalignment

Clear Obstructions

Remove any chips, coolant buildup, or debris from pallet surfaces and locating mechanisms.

Use compressed air to blow out chips from hard-to-reach areas

Test Pallet Exchange

Press PALLET CHANGER button on control panel to test exchange cycle after clearing obstructions.

Access Diagnostics

Navigate to CURRENT COMMANDS > DIAGNOSTICS > INPUTS to view pallet changer sensor status.

Look for sensors labeled PC (Pallet Changer) in the input list

Test Sensor Response

Manually trigger each proximity sensor with a metal object while observing input status changes on screen.

Only perform with machine in EMERGENCY STOP and power off to changer motor

Clean Sensor Faces

Clean proximity sensor faces with isopropyl alcohol and lint-free cloth to remove coolant residue and metal particles.

Check Sensor Mounting

Verify sensors are securely mounted and positioned at correct sensing distance (typically 2-4mm from target).

Check Hydraulic Pressure

Navigate to CURRENT COMMANDS > DIAGNOSTICS > PARAMETERS and check hydraulic pressure reading (typically 800-1000 PSI).

Parameter 800-series typically contains hydraulic system settings

Inspect Hydraulic Fluid Level

Check hydraulic reservoir fluid level through sight gauge - should be between MIN and MAX marks.

Listen for Pump Operation

Listen for hydraulic pump cycling during pallet change attempt - pump should run when pressure drops.

Low fluid level can damage hydraulic pump

Check for External Leaks

Inspect hydraulic lines, fittings, and cylinders for visible fluid leaks around pallet changer mechanism.

Check Drive Status

Navigate to CURRENT COMMANDS > DIAGNOSTICS > ALARMS HISTORY to check for drive-related fault codes preceding the 1004 alarm.

Test Manual Movement

With power off, manually check if pallet shuttle moves freely without binding or excessive resistance.

Disconnect power and lock out electrical panel before manual manipulation

Inspect Drive Connections

Check motor power cables and encoder feedback connections for looseness or damage at motor junction box.

Reset Drive System

Power cycle the machine and attempt pallet change operation to reset any temporary drive faults.

Measure Workpiece Height

Verify total workpiece and fixture height does not exceed maximum clearance specification for your pallet changer model.

Check Fixture Mounting

Ensure all clamps, vises, and fixtures are properly positioned within pallet boundaries and below height limits.

Verify Clearances

Manually cycle pallet changer (if possible) to observe clearance between workpiece and changer mechanism.

Perform clearance check at slow speed or manually with power off

Relocate Interference

Reposition or replace fixtures/workpieces that exceed clearance limits or interfere with changer operation.