Haas Alarm 6 fires when the way lubrication pump motor thermal overload trips due to excessive current draw. This protection mechanism activates when the lube pump encounters mechanical resistance, insufficient oil supply, or motor failure during its timed lubrication cycle.
HaasProgram/G-codeBasic5-10 minutes
6
Haas Alarm 6 - Value Out of Range
Out of Range
This alarm appears when commanded or calculated axis position data exceeds the machine travel limits defined in parameters or when attempting to move beyond software or hardware over-travel limits. The MOCON board continuously compares commanded positions against parameter-stored travel limits and triggers this alarm to prevent mechanical damage. This can occur during MDI commands, program execution, homing operations, or when invalid G-code calculations produce unrealistic coordinate values.
Root Cause Summary
Haas Alarm 6 fires when the way lubrication pump motor thermal overload trips due to excessive current draw. This protection mechanism activates when the lube pump encounters mechanical resistance, insufficient oil supply, or motor failure during its timed lubrication cycle.
Safety
Command rejected
Causes and Fixes
1
Check Oil Level Visually
Open electrical cabinet door and visually inspect the clear lube oil tank mounted on the back panel. Oil level should be between MIN and MAX marks.
Ensure machine is powered off and locked out before opening electrical cabinet
2
Verify Oil Level via Display
Press CURRENT COMMANDS, then navigate to the lubrication status screen to check if low oil level indicator is active.
Some NGC controls display lube tank level as a percentage on the status screen
3
Refill with Proper Lubricant
If low, refill tank with Haas-approved way oil (typically ISO 68 viscosity). Fill to MAX line but do not overfill.
Use only Haas P/N 93-32-5051 way oil or equivalent ISO 68 slideway oil
4
Reset Thermal Overload
Locate the lube pump motor thermal overload relay in the electrical cabinet and press the reset button. Clear alarm and test lube cycle.
Allow 10-15 minutes cooling time before resetting thermal overload
1
Inspect Lube Line Connections
Check all lubrication line fittings at the pump outlet and way covers for loose connections, kinks, or visible blockages.
Look for oil residue around fittings which indicates leakage and potential air ingestion
2
Test Manual Lube Cycle
From CURRENT COMMANDS menu, select manual lubrication cycle and observe oil flow at each lubrication point during pump operation.
Keep hands clear of moving axes during manual lube cycle test
3
Check Oil Filter Condition
Locate the inline oil filter in the lube system and inspect for contamination. Replace filter if darkened or clogged with debris.
Filter should be changed every 6 months or when oil appears contaminated
4
Verify Metering Valve Operation
Check progressive metering valve operation by observing equal oil distribution to all lubrication points. Uneven flow indicates internal valve problems.
Metering valves can be disassembled and cleaned with mineral spirits if clogged
1
Test Motor Resistance
Disconnect motor leads and use multimeter to check winding resistance between motor terminals. Readings should be balanced and within manufacturer specifications.
Ensure power is off and locked out before disconnecting motor leads
2
Check Motor Rotation
With motor disconnected from pump, briefly energize motor to verify smooth rotation without binding or unusual noise.
Motor should spin freely by hand when disconnected from pump coupling
3
Measure Operating Current
Using clamp-on ammeter, measure motor current during normal pump operation. Compare to motor nameplate rating.
Current draw should be 60-80% of nameplate rating during normal operation
4
Replace Motor Assembly
If motor tests indicate failure, replace with Haas OEM motor assembly. Ensure proper coupling alignment and electrical connections.
Use only Haas-approved replacement motors to maintain proper torque and current characteristics
1
Disconnect Pump Coupling
Remove coupling between motor and pump to isolate pump mechanical condition. Check motor rotation separately from pump.
Mark coupling alignment before removal to ensure proper reassembly
2
Test Pump Manual Rotation
Attempt to rotate pump shaft by hand. Pump should turn smoothly with slight resistance. Binding indicates internal damage.
Slight pulsing resistance is normal for gear-type pumps, but should not bind completely
3
Check Oil Contamination
Drain small oil sample and inspect for metal particles, water contamination, or excessive thickness that could cause pump binding.
Oil should be clear amber color without metallic particles or milky appearance
4
Replace Pump Assembly
If pump shows signs of internal binding or damage, replace with Haas OEM pump assembly. Flush system with clean oil before installation.
Always replace pump coupling and alignment pins when installing new pump
1
Verify Overload Setting
Check thermal overload relay current setting matches pump motor nameplate amperage rating. Adjust if necessary using relay adjustment dial.
Set overload to 110-115% of motor nameplate current rating
2
Test Relay Reset Function
After cooling period, test thermal overload reset button operation. Button should click and stay in when pressed.
Do not force reset button if it will not stay engaged - indicates continued overload condition
3
Monitor Current During Operation
Use ammeter to verify actual motor current is within normal range when thermal overload trips, indicating relay malfunction.
Document current readings and trip frequency to establish pattern of relay failure
4
Replace Thermal Overload Relay
Install new thermal overload relay with identical current rating and characteristics. Verify proper wiring connections.
Use only Haas-approved overload relays to ensure proper coordination with machine protection systems
DIY Feasiblehigh confidence
Call a technician if:
·Motor replacement required
·Pump replacement needed
·Electrical system modifications
·Repeated failures after repairs
Prevention
Check lube oil level weekly
Replace oil filter every 6 months
Use only Haas-approved way oil
Monitor lube cycle operation during daily startup
Common Mistakes
Using incorrect oil viscosity
Overfilling lube tank
Forcing thermal overload reset without cooling
Ignoring early signs of pump noise or irregular operation
