EXPLODED VIEW:

1. SHUTTLE MOTOR
2. V-TRACK COVER
3. WIPER
4. WIPER RETAINER
5. SHCS 10-32 X 3/8
6. SLIP CLUTCH ARM
7. MOUNTING BLOCK
8. PROXIMITY SENSOR
9. SHUTTLE ROLLER
10. NUT 3/4-10 NYLON LOCK
11. WASHER 3/4 FLAT
12. TOOL CARRIAGE
13. NUT 3/8-24 HEX
14. GASKET TOOL CARRIAGE
15. CONNECTOR BRACKET
16. TURRET MOTOR
17. TOOL CARRIAGE COVER
18. MOTOR MOUNTING PLATE
19. SHCS M3 X 5
20. DRIVER GENEVA 2 PIN
21. CAM FOLLOWER 3/4 HEX
22. SPACER RING
23. BHCS 10-32 X 1
24. TOOL #1 STANDOFF
25. GENEVA STAR
26. VERTICAL AXLE
27. BEARING
28. BEARING LOCKNUT
29. BEARING HOUSING
30. DOOR SPRING
31. NUMBER RING
32. TOOL CHANGER CAP
33. SHCS 5/16-18 X 1
34. FHCS 10-32 X 3/8
35. SLIDING PANEL COVER
36. SLIDING PANEL DOOR
37. RIVET 3/32 X .200 X .160 HEAD DIA
38. EXTRACTOR BUSHING
39. ROLL PIN 3/16 X 7/8
40. EXTRACTOR COMPRESSION SPRING
41. EXTRACTOR
42. ALIGNMENT KEY
43. SHCS 1/4-20 X 7/8
44. SHCS 5/16-18 X 3/4
45. TOOL CHANGER COVER
46. TRAP DOOR
47. SWITCH COVER
48. SHCS 8-32 X 7/8
49. HOLDING PLATE
50. LOCATING PIN
51. DOOR OPENER BRACKET LOWER
52. DOOR OPENER BRACKET UPPER

1. Shuttle motor: DC motor that drives the slip clutch arm assembly to move the shuttle in and out of the spindle.
2. Carousel motor: DC motor that rotates the carousel.
3. Tool Changer pocket assembly: Holds the tools in the carousel, it consists of two extractor fingers, spring, locating tool key.
4. Slip clutch arm: Mechanism that couples the shuttle motor to the carriage casting, it will slip if there is a crash to prevent damage to tool changer.
5. Carousel motor connector bracket: The motor and sensors will connect to this connector bracket.
6. Shuttle in and out sensors: These sensors let the control know the shuttle position.
7. Tool #1 and tool mark sensors: These sensors let the control know the carousel position.

1. Remove the brush caps [1] from both sides of the motor

2. Inspect the brushes for coolant intrusion and clean and reinstall the brushes and their brush caps.

3. Order two (2) vinyl caps [2] for the shuttle motor

• PN 59-2011 for 32-1875: MTR ASSY CAROUSEL/SHUTTLE/APC
• PN 59-0297 for CM-1 tool changers

4. Fill the vinyl caps about a 1/4 of the way with RTV Silicone [3]

5. Push the vinyl caps onto the brush caps and rotate them clockwise and counterclockwise for an even seal [4]

6. A good seal could be seen in [5]

7. Put a rubber band around both caps as shown in [6] and leave them on for at least 4 hours to allow the vinyl caps seal to cure.

Note: Shuttle motors on umbrella tool changers built February 2022 and later are dipped and sealed at the factory and will not require the vinyl caps.

Corrective Action:

Check the top [1] and bottom [2] V-rails, and the wheels for chips. Check for damaged or worn wipers [3]. Some machines do not have a wiper bracket [4].

Remove any chips that prevent correct sensor operation. Remove the carousel motor from the carriage assembly. Remove the sensors [5] on both sides of the carousel motor plate to clean them.

Remove the cam follower assembly [6] and lower the slip clutch arm [8] to move the carriage assembly and access the sensors [7] behind the carriage assembly.

Older machine models use roller switches [5] in place of the proximity sensors. The plunger and roller must operate smoothly without sticking. If the switches or sensors are clean, but do not operate correctly, go to Mechanical Limit Switch - Troubleshooting Guide or Proximity Sensor - Troubleshooting Guide to troubleshoot them.

Corrective Action:

How to access the shuttle motor to troubleshoot alarms 113, 114, 125, 856, 859, and 2066: Remove the support arm cover [1] and cable channel cover [2]. Measure the voltage to the power cable.

How to access the carousel motor to troubleshoot alarms 115, 127, and 854: Remove the cover [4] to the carriage. Measure the voltage to the power cable [5] on the connector bracket.

Measure the voltage:

Measure for DC voltage at the connector that goes to the motor from the I/O PCB. Adjust the range to 0.0 and set your multimeter for Min/Max. The power to the motor will only be on for one second before an alarm generates and the power is shut off to the motor. Command a tool change. The reading must be 135-165 VDC, or show a signal change when it is commanded to run. Some multimeters are not fast enough to read the voltage before the alarm occurs. It should still show a signal change or OL before the alarm is generated. If there is no voltage, refer to:

• Next Generation Control - I/O PCB - Troubleshooting Guide
  
• I/O PCB - Troubleshooting Guide (Classic Haas Control)

Inspect the brushes.

1. Normal wear on brush.
2. Bad wear on brush.

Disconnect the motor from the connector. Measure the resistance from pin to pin. The resistance must be between 5-20 Ohms. Measure the resistance from one of the pins to the motor chassis. The resistance must be greater than 100k Ohms.

If the measurements are low, there is not a good contact between the brushes and the commutator. Vacuum and clean any contamination between the brushes and the commutator. Check for damage or wear. Make sure there are no signs of oil or coolant in the motor. Inspect the area around the DC motor for causes of contamination.

 IMPORTANT: Incorrect installation of the motor brushes can cause malfunction of the motor or noise.

Corrective Action:

Inspect the slip clutch arm: Remove and inspect the cam follower assembly [1] for damage and chips. Push the carousel motor housing in the direction of the spindle to get access to the slip clutch arm [2]. Manually turn the slip clutch arm [2] through 180° of movement. It should rotate smoothly, but with heavy resistance. If the arm does not move smoothly, the shuttle motor [3] is faulty.

Corrective Action:

Find the cause of the spindle orientation error.

Make sure spindle drive and encoder belts have the correct tension. Make sure the spindle motor pulley and encoder pulley are not worn.

Refer to these procedures

• CHC - Umbrella Tool Changer - Set Parameter 257 - Spindle Orientation Offset
• NGC - Umbrella Tool Changer - Spindle Orientation Offset
  

Corrective Action:

Test the suspected relay: Exchange the relay with another relay. If the alarm changes to a different alarm, the relay is at fault.

For example: If the machine displays Alarm 113, change the K9 relay with the K10 relay. If the alarm changes to Alarm 114, the relay is faulty. If the alarm does not change, proceed to other troubleshooting sections.

Corrective Action:

The extractor fingers and spring hold the tool in the tool pocket. Worn or damaged fingers or springs can let the tool fall.

Refer to:

•  VMC - Umbrella Tool Changer - Pocket - Replacement
• Video - Umbrella/Carousel Tool Changer Maintenance

Corrective Action:

If the tool-release piston (TRP) sensors are not adjusted correctly, a tool can get stuck in the spindle taper, or the drawbar might not release a tool. Damage to the umbrella tool changer can occur. Adjust the tool release piston switches correctly. Refer to the TRP - Proximity Sensor - Adjustment procedure.

Go to Umbrella - Tool Changer – Carousel Plate - Replacement for carousel plate replacement instructions.

Corrective Action:

Check for damage to the guide pin [1], trap door [2], and the plastic riders [3].

Refer to the Umbrella Tool Changer - Guide Pin and Trap Door - Replacement procedure.

DOUBLE ARM EXPLODED VIEW:

1. ARM COVER
2. BHCS 1/4-20 X 1/2 ZINC PLATED
3. SHCS 3/8-16 X 3/4 ZINC PLATED
4. DOUBLE ARM HUB
5. ARM SLIDE
6. WASHER 5/16 STEEL
7. PLUNGER
8. RETURN SPRING
9. ADJUSTER ROD
10. SHCS 1/4-20 X 5/8 ZINC PLATED
11. FHCS 1/4-20 X 5/8 LOCTITE
12. ARM KEY
13. DOUBLE ARM
14. NUT 1/4-20 HEX BLK
15. SPRING CAP
16. DOUBLE ARM CLAMP
17. SHCS 5/16-18 X 2 1/4

CAMBOX EXPLODED VIEW:

1. OUTPUT SHAFT
2. HOUSING
3. HOUSING TOP
4. SERVO MOTOR
5. SERVO MOTOR MOUNT
6.  INPUT WORM SHAFT
7. WORM GEAR
8. OIL FILL CAP
9. STAR GEAR BEARING ASSEMBLY
10. STAR GEAR
11. GLOBOIDAL CAM
12. CHECK VALVE AND MUFFLER
13. DOUBLE ARM MOUNT

Note: The exploded diagram of the cambox is provided for reference purposes only. The internal components of the cambox are not field-replaceable

1. Double arm: Moves tools to the carousel and the spindle.
2. Slide: Pushes against the tool to hold it in place during double arm movement.
3. Return spring: Pushes the slide against the tool.
4. Shim washers: Shims adjust the slide for proper clearance. If the slide is adjusted too tightly against the tool, it may not lock during rotation. If adjusted too loosely, tools will rock or fall out during rotation.
5. Adjuster rod: Locks the slide in place during a tool change.
6. Jam nut: This nut tightens against the slide to prevent the adjuster rod from rotating loose.
7. Plunger: Locks the adjuster rod during arm motion. The adjuster rod and slide cannot release the tool when the plunger is in the extended position.

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.

Verify the check valve [1] arrow is facing away from the cambox as shown. 

The check valve (PN 58-2754) [1] should be install between the brass fitting (PN 58-1674) [2] and muffler fitting (PN 58-1865) [3]. 

Corrective Action:

Remove the carousel number plate to get access to the sensors [1]. Go into the manual tool recovery and push ATC FWD to move the arm through a complete cycle. Make sure the LED on the sensor and the diagnostic bit state change at the correct stage of the tool change cycle. See the chart below.

If the sensors fail to change state, refer to the Proximity Sensor - Troubleshooting Guide.

Corrective Action:

Find the cause of the spindle orientation error.

Make sure spindle drive and encoder belts have the correct tension. Make sure the spindle motor pulley [1] and encoder pulley [2] are not worn.

Refer to VMC - Side-Mount Tool Changer - Spindle Orientation Offset - Parameter 257.

1: The tool release piston (TRP) sensor(s) are not adjusted correctly.

If the TRP sensors are not adjusted correctly, a tool can get stuck in the spindle taper, or the drawbar might not release a tool. Damage to the double arm can occur. Adjust the tool release piston switches correctly. Refer to VMC - 20/30/40-Taper- TRP - Proximity Sensor - Adjustment.

2: The arm crashed into a rotary or a fixture during a tool change.

Refer to your operator's manual to set the tool change offset, or alias an M06 command, to move the spindle to a safe height. Move the obstacle on the table to a safe distance away before the tool change. If you install a rotary or trunnion unit, mount it as far to the right as your setup will allow. This gives you more room for safe tool changes.

Go to Episode 21 - How to Command a Safe Tool Change Position to Avoid Fixtures and Rotaries for more information.

3: A failed cambox position cable or sensor may cause the machine to think the arm is at the home position. The Z Axis comes down and bends the arm. Refer to Cambox Proximity Sensors section in this document.

Minor burrs or gouges on the double arm can visually be removed with a small file without needing replacement.

Go to parts.haascnc.com to find the correct double arm for your machine. Follow the replacement instructions that ship with the assembly.

If the double arm is not bent check the double arm alingment. Refer to Side Mount (SMTC) - VMC - Double Arm - Alignment for instructions on how to check the alignment.

Corrective Action:

Inspect the belt for damage and replace it if necessary. Refer to VMC - Side-Mount Tool Changer (SMTC) - Carousel Motor - Replacement for how to replace the cambox belt.

Corrective Action:

Inspect the plunger and adjuster assembly. Refer to Side-Mount Tool Changer - Double Arm - Plunger and Adjuster Assembly - Inspection

Refer to Video - Side Mount Tool Changer (SMTC) Double Arm Maintenance for more information on how to maintain the double arm.

Cambox Lost Motion Test

Go to Tool changer recovery.

Rotate the double arm to clamp/unclamp position.

1. Push and pull on the arm. Record the movement.
2. Pull down and push up on the arm.   Record the movement.

There should be less than 1/4" (6 mm) of lost motion in the rotation or lift of the arm.

Cambox Internal Mechanical Test

Remove the cambox motor and rotate the pulley or coupling [1] to cycle the cambox through a complete tool changer cycle. Listen for any abnormal internal noise when cycling the cambox. Run cambox forward or backwards looking for any particular section of binding. Check oil level while noting the viscosity and coloration of the oil.

Note: Be sure to rotate the cambox to the complete tool changer cycle as some components are only engaged every other tool changer. 

There should not be any binding in the cambox. You should be able to turn the pulley by hand. It will take more effort to turn the pulley when the output shaft is retracting.

Note:  On machine with a servo driven cambox it is necessary to re-set the double arm origin position after reinstalling the servo motor.  Refer to the SMTC - Double Arm - Grid and Tool Change Offset procedure.

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. 

EXPLODED VIEW:

1. FBHCS 1/4-20 X 1/2
2. CAROUSEL COVER
   
3. BEARING LOCKNUT
   
4. JAM NUT 5/8-18
   
5. CAROUSEL
   
6. CAM FOLLOWER
   
7. BEARING
8. POCKET ASSEMBLY
9. CAROUSEL WASHER
   
10. TOOL CHANGER FRAME
11. CAROUSEL SHAFT
    
12. SPACER
13. CAM BOX
14. SHCS 1/2-13 X 2
    
15. CAROUSEL CAM ASSEMBLY
    
16. POCKET STOP
    
17. SHCS 1/2-13 X 5
    
18. CAROUSEL MOTOR
    
19. POCKET TIPPER ASSEMBLY
20. DOUBLE ARM

Carousel

1. Tool In Position Proximity Sensor: It lets the control know that the tool pocket is in position.
2. Carousel Cam: A DC or Servo Motor turns this Cam that rotates the tool carousel.
3. Tool One Proximity Sensor: It lets the control know that the tool pocket is tool one position.

Pocket

1. Cam Follower: Keeps the pocket in the up position as the carousel rotates. The cam follower follows a groove on the carousel housing.
2. Shaft: The axle upon which the pocket pivots up and down.
3. Spring: Puts tension on the four plungers inside the tool pocket.
4. Tool Pocket: Holds the tool.
5. Plungers: The four plungers grip the tool pull stud. They are lubricated with grease.

Corrective Action:

Test the tool in position sensor:

1. Clear the alarms and go into tool changer manual recovery. Refer to VMC, HMC - Side-Mount Tool Changer - Manual Recovery.
2. Press the left or right arrow to move the carousel. Monitor the TOOL IN POS bit on a Classic Haas Control (CHC), or SMTC_CAROUSEL_POCKET_MARK on a Next Generation Control (NGC). This bit will be 0 unless the pocket is in position. It will be 1 when the pocket is in position.
3. If the carousel moves but the bit does not change state, remove the carousel cover. If the carousel does not move, see Section 2.
4. To make sure the proximity sensor is not tripped, turn the carousel until the flat side of the cam [2] faces the proximity sensor [1].
5. Touch the end of the proximity sensor with a screwdriver. Watch for the light to change, and monitor the TOOL IN POS or SMTC_CAROUSEL_POCKET_MARK value.
6. If the light or the bit value does not change state, use the Proximity Sensor - Troubleshooting Guide to troubleshoot the proximity sensors.

Corrective Action:

To replace the idler Sprockets [1] and the bushing [2], you must first wrap a chain or strap around the carousel and frame, this is to eliminate the carousel from freely spinning. 

WARNING: If the carousel is not tied it can cause serious injury. 

Corrective Action:

1. Visually examine the slide guides [1] for the tool pocket. Remove all contamination.
2. Lubricate the surfaces with red grease.
3. Go into tool changer manual recovery VMC, HMC - Side-Mount Tool Changer - Manual Recovery.
4. Press up or down arrow to move the tool pocket. Make sure the pocked moves smoothy into and out of the tool change position.

Corrective Action:

1. Power off the machine and disconnect the air supply.
2. Find the tool pocket cylinder.
3. If equipped, remove the pilot-operated check valve [1] and the hose to the bottom of the cylinder. For machines that do not have a pilot-operated check valve, disconnect the top and bottom hoses on the air cylinder.
4. Move the cylinder [2] up and down.
5. Make sure that the piston moves freely. Spray a small quantity of silicon lubricant into the cylinder to lubricate the piston seal.
6. If the piston does not move freely, the tool pocket air cylinder is damaged.
7. Make sure the air supply to the machine is clean and dry.

Corrective Action:

Make sure the pocket up and pocket down proximity sensors [1] are clean. Contamination on the switches may cause the carousel to rotate and break a pocket before it is in the fully up position.

The DIAGNOSTICS page shows the state of the sensors. If the POCKET DOWN or POCKET UP (CHC), or the SMTC_TOOL_POCKET_UP or SMTC_TOOL_POCKET_DOWN (NGC), bits do not change state, the sensors may have chips or contamination on them.

Make sure that the tool pocket is up. Press [PARAMETER/DIAGNOSTIC] and go to the I/O tab.

Touch the end of the proximity sensor with a screwdriver [1]. This test can cause Alarm 626. Ignore the alarm. The proximity sensor operates correctly if the Pocket Down (CHC), SMTC_Pocket_Down (NGC), value changes from a 1 to a 0. Continue troubleshooting if the diagnostic value does not change.

To troubleshoot the pocket up sensor, make sure that the tool pocket is down. Touch the end of the proximity sensor with a screwdriver and monitor Pocket Up (CHC), SMTC_Pocket_Up (NGC). The value must change from a 1 to a 0.

Do these steps on CHC machines only: Find where the 820 cable connects to the I/O PCB at P3. Use an electrical jumper (P/N 33-8521) at P3 [1]. If the Pocket Down value changes from a 1 to a 0, the I/O PCB operates correctly. Replace the SMTC cable assembly. Refer to Proximity Sensor How it Works and Troubleshooting - Video. Use the Proximity Sensor - Troubleshooting Guide to troubleshoot the proximity sensors.

To troubleshoot the pocket up sensor, reconfigure the jumper at P3 as shown [2]. Monitor the Pocket Up value. If the value changes from a 1 to a 0, the I/O PCB operates correctly. Replace the SMTC cable assembly.

If the Pocket Down or Pocket Up value does not change to a 0 when tested, refer to:

• Next Generation Control - I/O PCB - Troubleshooting Guide
  
•  I/O PCB - Troubleshooting Guide (Classic Haas Control)

Corrective Action:

Make sure the tool is not contaminated by debris. Look for and remove any "nests" of chips in the mechanism.

Refer to TOTD Episode 33 - Stringy Chips Wrapped Around Your Tools? Chip Clear Solution to troubleshoot the system.

Symptom: The tool pocket is noisy.

Possible Cause: There is a problem with the tool-pocket stop shock-absorber.

Corrective Action:

1. Make sure that the tool pocket is in the up position [1].
2. Push the shock-absorber in with your thumb [3].
3. Release the shock-absorber [2].

For CALM machines, replace the shock-absorber with the correct orifice (P/N: 58-0093) [4] between the solenoid and the muffler if:

• There is no resistance when you push the shock-absorber.
• The shock-absorber does not extend after you push it.

 Note: For all other machines, replace the shock-absorber with a new shock-absorber.

Symptom: The tool falls from the tool pocket. The tool cannot be removed from the pocket.

Possible Cause: The toolholder or pull studs are incorrect.

Corrective Action:

If the tool cannot be removed, remove the garter spring [3]. Wiggle the tool to loosen the plungers [1]. Be careful not to lose any plungers. Remove the tool. Replace spring.

Refer to the Toolholder and Pull Stud Information document for the correct toolholder and pull stud [2] information.

Corrective Action:

        BT/CT pocket

1. Make sure that the (4) plungers [1] are intact in each of the pockets.
2. Inspect the plungers for wear. Replace them if they are worn.
3. Make sure that the hook on the spring is not on top of any of the plungers.
4. Clean all of the debris from the tool pockets and lubricate the plungers [1] with grease. Apply grease to the tool pull stud.

Refer to Replace a Tool Pocket on Your Haas Side Mount Tool Changer (SMTC) - Video for more information on how to remove the pocket.

Some pockets use leaf springs. Look for broken leaf springs. They are stacked (2) per corner. Replace any broken leaf springs.

        HSK pocket

1. Make sure that the collet assembly is intact in each of the pockets.
2. Inspect the (3) plungers and center cap in the collet assembly for wear. Replace them if they are worn. 
3. Inspect the rest of pocket for any damage. Replace if it is needed.
4. Clean all of the debris from pocket and lubricate the collet assembly with grease to ensure smooth operation.

Refer to HSK Pocket and Plunger - Replacement  for more information on replacing the HSK pocket.

Corrective Action:

Install the Pocket Slow Down Service Kit (P/N 93-0254). This kit restricts the air escaping from the pocket up/down cylinder to slow down the pocket.

Refer to the Toolholder and Pull Stud Information document.