This procedure will explain how to inspect the plunger [1] and adjuster [2] on the double arm for a Side-Mount Tool Changer (SMTC). 

NOTE: This procedure applies to both case and assembled double arm. This procedure will also apply to all BT, CT, and HSK tool changers on HMC and VMC machines.

Tools Required:

• Feeler Gauge
• Lithium Tacky Grease (part number: 99-1686)
• Shim Stack (part number: 45-0075)

NOTE: If the assembly was assembled with Moly grease please clean the assembly and reapply the taky grease listed above for this assembly. 

Remove all tools from the carousel and the spindle.

Override the rapid to 5% RAPID and in MDI mode, push [ATC FWD].

When the arm moves down and starts to turn, immediately push [EMERGENCY STOP].

Remove these parts from the double-arm:

1. the bottom plunger cover screws [1]
2. the plunger cover [2]
3. the spring [3]
4. the plunger [4]

Examine the end of the plunger shaft for burrs [1]. Remove all burrs from the end of the plunger shaft.

Measure the length of the plunger shaft. If it is less than 1.75 in (44 mm) replace it.

Apply a light layer of Lithium Tacky Grease to the plunger, the plunger cover, and the spring before reassembling these components.

 Caution: The adjuster assembly is spring-loaded. The adjuster assembly can fly out when you remove the adjuster cover.

Slowly remove the adjuster cover.

Remove these parts:

• Nut [1]
• Shim Washers [2] part number 45-0075
• Slide [3]
• Adjuster Shaft Assembly [4]
• Spring [5]
• Washer [6]
  • NOTE: Orientation of this washer matters, make sure that when rebuilt the flat side is placed against the spring.    

Examine the end of the adjuster shaft for burrs. Remove all burrs from the end of the adjuster shaft.

Apply molybdenum grease to the slide and adjuster assembly.

IMPORTANT: Reassemble it without the spring, it will be very hard to gauge the gap in the next step when the spring is installed.

 IMPORTANT: Remember to reassemble the slide assembly without the spring, or else you will be unable to gauge the gap with the spring installed.

Push down on the plunger [1] to make sure it moves freely.

Push down on the plunger [1] and hold it down. Then push on the slide [2] to make sure it moves freely.

 NOTE: If the plunger won't move all the way down make sure that the spring cavity is not hydro locked with grease.  If it is, push down by hand repeatedly until the excess grease is pushed out of weep hole on the bottom of the arm.

Push down on the plunger [3] and hold it down.

Put a tool holder [2] into the arm. During correct operation, the slide [1] moves in.

Release the plunger [5].

Try to remove the tool holder [4]. During correct operation, the slide does not move in and the tool holder locks in position.

Measure the space between the slide and the tool holder. Use a feeler gauge [6]. The correct space is between 0.014 in (0.36 mm) and 0.020 in (0.51 mm). If the machine is a DM-1 or DT-1, the correct space is between 0.005 in (0.13 mm) and 0.015 in (0.38 mm).

Add or remove 0.01 in (0.25 mm) shim washers, part number 45-0075,  until the space is correct.

Once the gap is set reassemble the slider assembly with the spring and washer installed. Apply a layer of Lithium Tacky Grease to the finger, spring and washer. 

 NOTE: Refer to Step 5 for an illustration of the shim washers and image of the slider assembly for reference.

Push [RECOVER]. Follow the onscreen instructions to complete the TOOL CHANGER RECOVERY.

This procedure tells you how to replace the double arm on a HSK Side-Mount Tool Changer. This procedure applies to the following kits:

• 93-30-12375 SMTC ARM HSK63A 10.438 INCH SVC KIT

Tools Required:

• Haas Control Key
• HSK split tool
• PN: T-2108 SMTC Alignment Tool
• (2) 3/8-16x2 1/2" Socket Head Cap Screws

Verify the double arm length

Check that the replacement double arm [2] is the correct length, measure from the center to center of the tool holder flange between the original [1] and replacement double arm [2].

NOTE: The same verification steps will apply to machined [1] and casted [2] double arm replacements.Some machines may still received machined [1] double arm replacements.

Verify that the double arm is the correct taper size and type

To differentiate between the BT, CT, and HSK verify that the BT V-flange is as shown in image [1] and the CT V-flange is as shown in image [2], and the HSK V-flange is as shown in image [3].

Verify that the double arm has the correct key slot offset

Now the casted double arm will have the key slot machined in a 0 degree angle position [1] or at a 2.5 degree angled position [2], both double arms will use only a straight key instead of an offset key.

Make sure no tool is in the current pocket and the spindle.

Power on the machine with your Haas Control Key.

Push [ZERO RETURN] and then [ALL].

Go into RECOVERY mode. Go into MANUAL TOOL CHANGER OPERATION mode.

Push [ATC FWD] until the arm moves down near the bottom of travel.

Push [EMERGENCY STOP].

Find the (2) holes [1] adjacent to the covers for the plungers. Put the T-2108 [2] onto the double arm. Use your fingers to tighten the screws [3] to the shaft and the arm. 

Loosen the (6) screws [4] from the clamp about 1/4" from the double arm. Do not move the screws.

Remove (2) of the (4) screws [5] from the hub [6]. Do not remove two screws adjacent to each other.

Insert (2) 3/8-16 x 2 1/2" jack screws [5] from the hub [6]. do not remove two screws adjacent to each other.

Insert (2) 3/8-16 x 2 1/2" jack screws [7] into the hub. Lightly grease the screw threads. Turn the (2) jack screws a small amount at a time. Do this until the double arm can turn freely on the output shaft.

Remove the T-2108 tool and double arm. Install all of the screws you removed.

Press down on the plunger [3].

Put a tool holder [1] with no cutter into the new arm.

Push the slide [2] back into the arm as far as possible. Measure the space between the slide and the tool holder using a feeler gauge. Make sure the space is between 0.015" (0.381 mm) and 0.025" (0.635 mm).

If adjustment is necessary, use SIDE-MOUNT TOOL CHANGER - DOUBLE ARM - PLUNGER AND ADJUSTER ASSEMBLY - INSPECTION.

Remove the tool holder.

Do this step again on the opposite side of the arm.

Release the plunger [3]. The slide should return to its original position.

Install the (6) clamp screws [4] on the double arm [2]. Leave the screws loose. Make sure the clamp can move easily.

Find the (2) holes [3] adjacent to the covers for the plungers. Put the (2) screws through the T-2108 tool [1] and into the double arm [2]. make sure the notches in the tool fit over the covers for the plungers. Tighten the (2) screws.

Caution: Be sure to support the double arm during this step. If the arm is not tightly held it can fall and cause injury.

Clean all grease from the shaft. Then install the double arm [2]. Turn the screw into the shaft. You turn the center screw to lift the double arm [2] on the shaft.

Lightly tighten the clamp screws. Do this until the double arm [2] stays in position, but you can turn it with your hand.

Note: Do not tighten the clamp too much. this makes it difficult to adjust the double arm [2] height.

Release the [EMERGENCY STOP].

Make sure to insert the Haas Control Key. If necessary cycle power.

Go into RECOVERY mode. Go into MANUAL TOOL CHANGER OPERATION mode.

Push [ATC FWD] until DOUBLE ARM has a value of CLAMP/UNCLAMP. Manually rotate the double arm [3] to be parallel with the y-axis.

Move the tool pocket [1] to the down position.

Push [EMERGENCY STOP]. Clear alarms.

Put a tool holder [2] with no cutter into the pocket.

Manually turn the double arm [2] so the slide touches the tool holder [1]. Use a caliper [3] to measure the height between the bottom of the V Flange and the double arm.

Manually turn he double arm so the arm engages the tool holder. Use caliper to measure the height between the bottom of the V Flange and the double arm.

If the measurement is different, then adjust the height of the arm and repeat this step. Use the T-2108 tool to adjust the double arm eight. When the measurement is the same, record the measurement.

Manually turn the double arm until you can remove the tool holder. Remove the tool holder with no cutter.

Push the bottom part [1] of an alignment split tool into the arm [4] near the pocket. Install the top part [2] of an alignment split tool into the pocket [3]. Align the split tools.

Put the pin [5] for the alignment split tool into the top and bottom parts to do an alignment check. Remove the pin.

Lightly tighten the clamp screws 1/4 turn. Tighten the screws [1] in the star pattern. Do an alignment check [2] each times you tighten all the screws. Do this until the screws tightly hold the double arm.

Remove the T-2108 tool [3].

Note: You must do this action a number of times. Do this to make sure the screws are torqued to 20 ft-lbs.

Push [EMERGENCY STOP]. Clear alarms.

Put a tool holder with no cutter into the pocket.

Release the [EMERGENCY STOP].

Push [ATC FWD] until the slide slightly touches the tool holder [1].

Push [EMERGENCY STOP]. Clear alarms.

Use a caliper [3] to measure the height between the bottom of the V Flange and the double arm [2].

Record the measurement. Compare the measurement you recorded in step 1. There should be no more than a 0.01" (0.25mm) difference.

If there is a difference of more than 0.01" (0.25 mm), adjust the height of the arm. For assistance freeing the arm review the Removal section from above. Adjust the arm to the correct height and start this section over.

If the measurement is the same, continue to the next step.

Release the [EMERGENCY STOP].

Push [ATC REV] until you can safely move the tool pocket to the up position. Move the tool pocket to the up position.

Push [EMERGENCY STOP]. Clear alarms

Remove the tool holder with no cutter.

Put the bottom part [1] of the alignment split tool into the arm near the pocket.

Release the [EMERGENCY STOP].

Push [ATC FWD] until ARM at CL/UNCL has a value of 1.

Push [EMERGENCY STOP]. Clear alarms.

Install an indicator [2] below the alignment split tool. Put the indicator tip on the bottom of the alignment split tool. Set the indicator to 0.

Note: The pocket is up.

Move the indicator [2] away from the pocket. Do not change he indicator setting. Remove the bottom part [1] of the alignment split tool.

Release the [EMERGENCY STOP].

Rotate the arm 180 degrees using [ATC FWD]. Push [ATC FWD] until ARM at CL/UNCL has a value of 1.

Push [EMERGENCY STOP]. Clear alarms.

Put the bottom part of the alignment split tool into the arm near the pocket.

Release the [EMERGENCY STOP].

Jog the indicator below the split tool. The indicator should not move more than 0.01" (0.25 mm).

If the indicator shows more than 0.01" (0.25 mm), you must do step 8.

If the indicator shows less than 0.01" (0.25 mm), skip step 8.

Push [EMERGENCY STOP]. Clear alarms.

Put a soft material on the table and the waycovers to protect them if a tool holder falls.

Insert a tool holder [1] into the spindle.

Close the operator door.

Release the [EMERGENCY STOP].

If your machine has a servo tool changer pres [25% RAPID].

Enter MDI mode.

Press [ATC FWD].

Do this again multiple times. Switching between pressing [ATC FWD] and [ATC REV].

If there are no problems at 25% do this step again at 100%.

If there are no problems push [EMERGENCY STOP]. Clear alarms. Check the alignment and adjust it as needed.

The following service video shows you how to align a side mount tool changer.

Note: This service video is for reference only and does not replace the written procedure.

Verify the double arm length

Check that the replacement double arm [2] is the correct length, measure from the center to center of the tool holder flange between the original [1] and replacement double arm [2].

NOTE: The same verification steps will apply to machined [1] and casted [2] double arm replacements.Some machines may still received machined [1] double arm replacements.

Verify that the double arm is the correct taper size and type

To differentiate between the BT, CT, and HSK verify that the BT V-flange is as shown in image [1] and the CT V-flange is as shown in image [2], and the HSK V-flange is as shown in image [3].

Verify that the double arm has the correct key slot offset

Now the casted double arm will have the key slot machined in a 0 degree angle position [1] or at a 2.5 degree angled position [2], both double arms will use only a straight key instead of an offset key.

Make sure that the taper lock [4] is sufficiently tight to prevent the double arm from falling off the shaft, but loose enough to rotate the double arm on the shaft.

Classic Haas Control (CHC)

1. Go into DEBUG mode. Go into RECOVERY mode. Select the MANUAL TOOL CHANGER OPERATION mode.

Next Generation Control (NGC)

1. Insert the Haas Control Key. If necessary cycle power.
2. Go into RECOVERY mode. Select the MANUAL TOOL CHANGER OPERATION mode.

Push [ATC FWD] until ARM at CL/UNCL has a value of 1. Manually rotate the double arm [3] on the cambox output shaft to be parallel with the Y Axis.

Push [EMERGENCY STOP]. Clear alarms.

Put a tool holder [2] with no cutter into the pocket [1].

Manually turn the double arm [2] on the shaft so the slide [4] slightly touches the tool holder [1].

Use a caliper [3] to measure the height between the bottom of the V Flange and the double arm.

Manually turn the double arm on the shaft so the arm engages the tool holder.

Use a caliper to measure the height between the bottom of the V Flange and the double arm.

If the measurement is different, then adjust the height of the arm and repeat this step. Use the T-2108 tool to adjust the double arm height. When the measurement is the same, record the measurement.

Manually turn the double arm until you can remove the tool holder.

Put the bottom part [1] of an alignment split tool into the arm [4] near the pocket. Install the top part [2] of an alignment split tool into the pocket [3].

Align the split tools.

Put the pin [5] for the alignment split tool into the top and bottom parts to perform an alignment check.

Remove the pin.

Lightly tighten the clamp screws 1/4 turn. Tighten the screws [1] in a star pattern. Perform an alignment check [2] each time you tighten all the screws. Repeat this process until the screws tightly hold the double arm.

Remove the T-2108 tool [3].

Torque the screws in the star pattern to the correct ft-lbs below.

 Note: You must repeat this action a number of times to make sure the screws are torqued to the correct ft-lbs.

• 8-Screw Double-Arm - 15 ft-lb (20 Nm)
• 6-Screw Double-Arm - 20 ft-lb (28 Nm)

Push [ATC REV] until you can safely remove the tool from the pocket.

Push [EMERGENCY STOP]. Clear alarms.

Remove both parts of the alignment split tool.

After all of the screws are torqued verify the double arm height alignment in Step 2.

Release the [EMERGENCY STOP].

This procedure covers changing an inline-mounted (not belted) cambox servo motor.

Power OFF the machine

Remove necessary sheetmetal (in green). This will vary from machine to machine.

Unplug the cables [4]. Loosen coupling [2] and servo motor bolts [1]. Remove faulty servo motor. 

When installing the motor, the fasteners must be tightened in stages to verify it is not binding from misalignment. 

Install the motor and leave the motor mount [3], coupler [2], and servo motor [1] bolts finger tight. Slide the coupler up and down on the motor and worm drive shafts to verify there are no binds. 

Torque the motor mount [3] and servo motor bolts [1]. Verify again that the coupler slides freely on the motor and worm drive shafts. Only then should you torque the coupler bolts [2].

HAAS TORQUE CHART

When reconnecting the servo motor cables, check that there is dielectric grease on the contact points of the cables. 

IMPORTANT: Make sure to only place grease on on the contact points of the connectors. Do not apply excess grease to the entire face of the connector. This can cause damage to the servo motor.

Perform the Servo-Driven SMTC - Double Arm Grid Offset and Tool Changer Offset - NGC procedure.