Service Home How To Procedures BMT45 - Cluster gear Replacement - AD0776
Last updated: 10/23/2024

BMT45 - Cluster Gear Replacement

AD0776

Introduction

This procedure shows how to replace a cluster gear in BMT45/BOT10/VDI turret gearboxes.

This Document Applies to the following Service Kits:

  • 93-2754 GEAR, CLUSTER LATHE TURRET TOOL CHANGER 

Required tools and parts :

  • T-0178 BMT45 MAIN SHAFT LOCK NUT TOOL
  • T-0159 BMT45 LT POCKET ALIGNMENT TOOL
  • T-0147 BMT45 LT OUTPUT SHAFT ALIGNMENT TOOL
  • Dial indicator
  • Service USB Key
  • 99-1686 MobilGrease XHP 222
  • 93-2365 SYNTHETIC GEAR/BEARING OIL 1QT/0.94L
  • 57-0888 GASKET TURRET REAR COVER BMT-45

Optional Parts :

  • 49-4115 WASHER 1 1/2 SS .075THKX2.062ODX1.510ID
  • 45-2001 WASHER 1 1/2 STEEL .002THK X 2 1/8
  • 51-0062 BEARING LOCKNUT BH-16
  • 57-0029 S SEAL 3.000 X 3.500 X 0.375 S1S

Machine Compatibility :

  •     ST-10/10Y/15/15Y after 04/26/2022

Note : It is recommended to use the Haas Fastener Torque Specifications

Replacement

1

Remove LT motor [2] by undoing motor hardware [1] then remove the motor adapter plate [4].

2

Remove torque arm [2] by removing the clamping bolt [1] and installing a 3/8-16 bolt into the jack screw hole above then pulling it straight back.

Remove key [3] from shaft using pliers then proceed to remove the snap ring [4] and torque arm springs.

 

3

Important : when removing the lower alignment dowel block [5] make sure to loosen the set screws [3] before removing the bolts [4].

Remove the torque arm alignment dowel blocks [2] and [5].

4

Important : Loosen the clamping screws on the coupler [4] before removing the motor.

Remove the TT-axis motor [2] and make sure to also remove the key [3].

Note : To save time during assembly the coupler [4] and motor [2] can be remove together by loosening the clamping screw on the opposite side of the coupler. This will also maintain the distance from the motor so reinstallation can be easier. 

5

Remove the coupler [1] from the worm gear shaft by loosening the clamping screw and sliding it off then remove the motor mount [3] to be a able to remove the worm gear.

 

6

Remove the clamp and home proximity switches [2].

Note : If the home switch has any spacer / washers under it they need to be re-installed during assembly.

7

Important : The BMT45 gearbox contains 1 quart of lubricant and we recommend to prepare the work area by having plastic bags taped under the rear cover or a bucket to contain the spillage so it can be disposed of appropriately.

Remove the Rear cover [1]. If removing the cover is difficult after all the hardware [2] is removed then set screws may be inserted into the set jacking holes [3] to pop the cover. Rotating the worm gear may also help with the cover removal.

Note : Make sure to remove and inspect the wave spring [4].

Note : Replace gasket!!!  If the cover gasket is damaged during disassembly we recommend replacing it. Use a plastic scrapper to remove the old gasket material then install a new gasket P/N 57-0888.

8

Remove the Worm gear [1] by rotating it off the cluster gear. After removal of the cover inspect the cluster gear spring [2] and prepare for re-installation by cleaning the old grease.

9

Use T-0178 [2] to remove the lock nut [1].

 

10

Once the locknut [2] is removed the bearing [3] can be slid off the shaft to provide access to the cluster gear.

11

Remove the cluster gear [3] and retrieve the thin spacer [1] and thick spacer [2] underneath it.

 

12

Grease all the highlighted surfaces using 99-1686 MobilGrease XHP 222 then re-assemble the dowel [1] into the cluster gear [3] with the thick spacer [4] and thin spacer [2].

13

Re-install the bearing [1] and thread the locknut [2] by hand using T-0178 [3] to check for binding in the threads. If the threads on the locknut are damaged during disassembly we recommend replacing it P/N 51-0062.

Important : The chamfered edge is always facing the bearing.

14

Use a torque wrench [1] to torque the locknut [3] to 100 ft-lbs.

15

Important : The wave springs have been removed as part of a reliability improvement. Motor mount bracket 20-9561 has been updated to 20-9561A to accommodate this change.

Apply grease to the highlighted area then install the worm shaft assembly [1] by threading it into the cluster gear clockwise until it stops.

16

Install the motor bracket [2] using the original hardware [1] and torque the bolts.

Note : Apply grease on the highlighted area and make sure that the o-ring [3] is fully coated.

17

Install the coupler P/N 52-0104  [1] onto the worm shaft [2] making sure that it is shimmed 0.325" from the mating surface [3] then torque the clamping screw to 15 ft-lbs.

Important : Torque the clamping screw to 5 ft-lbs, then 10 ft-lbs, until finally reaching 15 ft-lbs.

18

Re-install the rear cover [2] and torque the rear cover bolts to 25 ft-lbs in a star pattern to ensure even clamping. Ensure that the old gasket is removed and the surface is clean of any lubricants before installing the new gasket.

Important : Make sure that the cover seal [3] does not roll over itself and that the spring inside of it is still in place when installing one the shaft [4]. 

19

Fill the gearbox with 1 quart of lubricant through the fill plug [1] until it spills out. Refer to Haas Lubrication Table

Haas Lubrication Table

20

Install the TT-axis motor [2] using hardware [1] and make sure that the key [3] is slid on the motor shaft before tightening the clamping screw on the coupler [4].

21

Reinstall the live tooling alignment dowel blocks [2] and [5]. 

22

Re-install the torque arm springs [1] along with the snap ring [2] then tap the key [3] back into position. Apply grease on the dowels then proceed by installing a 3/8-16 bolt into the jacking screw hole [5] until the torque arm [4] slides onto the shaft easily. Push the torque arm [4] on the shaft until it is resting onto the snap ring then unbolt the jacking screw and install the clamping bolt [6]. Align the live drive assembly using the  BMT45 Turret - Live Tool Drive - Alignment procedure.

Note : It is recommended to torque the clamping bolt to 45 ft-lb then using a mallet to tap it evenly until it is sitting flush with the snap ring then the clamp bolt gets torqued to 90 ft-lb.

23

Install the LT-axis motor adapter plate [4] then install the LT-axis motor [2]

Reset Turret Tool Changer Alignment

1

Remove all tools from the turret.

Change parameter 9.019 to FALSE.

Set parameter 9.078 TT_AXIS TOOL CHANGE OFFSET to 0.

Set parameter 9.140 TT_AXIS GRID OFFSET to 0.

 Press [POSITION]  and make the TT-axis visible by pressing [ALTER] then select the TT-axis and press [ENTER].

[Zero Return] the TT-axis, ignore any alarms. Press [DIAGNOSTICS] to get to the FACTORY parameters tab. Type TT and press [F4] to set the grid offset. [Zero Return] the TT-axis.

In [MDI] command an M43 to unclamp the turret. Handle jog the TT-axis until pocket 1 is in position, visually align the coolant nozzle. Press [ESTOP] to clamp the turret and verify the turret is fully seated.

Press [POSITION] and rotate the TT-axis motor coupler by hand to one end of travel. Record the TT-axis position. Rotate the TT-axis coupler to the other end of travel. Record the TT-axis position. Rotate the TT-axis motor coupler to the middle of the two positions. 

Example: (174.780 - 174.610)/2 + 174.610 = 174.695

Press [DIAGNOSTICS] to get back to parameters. Type TT and press [F2] to set the tool change offset.

Change parameter 9.019 to TRUE.

If loads are still high continue with the following steps.

Operate this code in MDI mode:

T1;
T2;
T3;
T4;
T5;
T6;
T7;
T8;
T9;
T10;
T11;
T12;
M99;

 Note: For a 24 station turret command the turret to all 24 tools. 

2

Important: Once clamped at each tool #, verify that the load is always below 5%.

  • Throughout the execution of the program, verify proper clamping / unclamping of the turret, and tool # position as commanded by the program.
  • If it does not operate properly, ensure that the parameters were set correctly per the procedures above.

Change parameter 9.019 to TRUE.