4.4 DT/DM Alignment

This procedure will show you how to align the tool changer on the DT/DM series.

 NOTE: There are 2 independent tool unclamp systems that need to be aligned: manual [5, 7] and automatic [2,3] unclamping. Manual unclamping is responsible for manually inserting and removing the tool whereas Automatic unclamping is responsible for inserting and removing the tool during an automatic tool change operation. 

Diagram

1.  Cam Box
2.  Tool Release Cam
3. Striker Block
4. Support Bearing
5. Tool Release Piston
6. Rocker Arm Return Spring
7. Manual Release Arm
8. Pushout Adjustment Clevis
9. Rocker Shaft Support Bearing (x2)
10. Rocker Arm
11. Rocker Arm Follower
12. Guide Release
13. Cam Follower Arm
14. Cam Follower
15. Double Arm
16. Taper Lock

Tools Required

• T-2108 Double Arm Alignment Tool
• (2) 3/8-16 x 2.5" Socket-Head Cap Screws (SHCS)
• DT:
  • T-1224 BT 30 Taper Split Tool
  • T-2173 BT 30 Taper Split Tool Pin
• DM:
  • T-2086 CT 40 Taper Split Tool
  • T-2087 BT 40 Taper Split Tool

 NOTE: This step applies for the old style rocker arm, the new style rocker arm does not need the striker block, skip this step if the new style rocker arm is not installed in the spindle head .

Set the Z-axis tool change offset

The correct gap between the striker block and the bearing is 0.0040" - 0.0020".

Put a 0.0040" shim [2] between the striker block [3] and the bearing [1]. If the shim does not fit, go to Step 2.

If the shim fits, do these steps:

• Loosen the (4) screws [4] that retain the striker block.
• Put a 0.0020" shim between the striker block and the bearing.
• Push the sticker block against the shim.

Torque the screws. Refer to Haas Fastener Torque Specifications.

Remove the shim.

Zero return the Z-axis. With the double arm at the home position, put a toolholder into the spindle using the manual release buttom. Position a drop indicator against the bottom face of the toolholder. Zero the indicator.

While pushing up on the toolholder, activate the tool release button.

 Caution: Do not allow the tool to drop.

The pushout should be 0.035”(+.010”, -0). If it is not, move to step 3.

If the indicator does not show 0.035" (+0.010"/ -0"), do these steps to adjust the pushout:

• Remove the clevis pin.
• Use a 1 1/8" wrench to loosen the 3/4" -16 jam nut [1] on the clevis.
• Adjust the clevis:
  • Turn the clevis clockwise to reduce pushout, counter clockwise to increase.
  • 1/2 turn of the clevis equals 0.010" of pushout.

Install the clevis pin and check the pushout again.

When the pushout is correct, tighten the jam nut.

In order to ensure the rocker arm pushout is adjusted correctly:

ZERO RETURN the Z Axis. Press HOME G28.

Display Toolchanger Arm axis to view the position while jogging:

• For NGC set parameter 11.019, TA INVIS AXIS to FALSE. This will require a service key in NGC.
• For Classic Haas Control set parameter: 462:18, V INVIS AXIS, to 0. 

Go to the Positions page and check the appropriate axis box. The axis is now displayed.

Jog the double arm until it is at the home position. Place a tool holder [1] into the spindle using the manual release.

Put the indicator tip [2] against the bottom of the toolholder. Zero the indicator.

Gently move the indicator base [3] away to allow for room to jog the toolchanger arm. Remove the toolholder.

Jog the toolchanger arm to tool change position (around 160) or until the drawbar is fully released.

With the draw bar released,  position a toolholder all the way in the spindle taper with your hand.

 Caution: The drawbar will not clamp the toolholder.

Gently position the indicator against the bottom of the toolholder while continuing to hold it with your hand.

If the rocker arm pushout is correctly adjusted, the indicator reads 0.035" (+ 0.005"/- 0").

Add or remove rocker arm shims [1] until the indicator readout is correct.

Make sure the rocker arm bearings are adjusted correctly.

Jog the double arm to the home position.

Put a 0.040" shim [2] between each of the rocker arm bearings [1]  and the spindle guide release [3].

The correct adjustment puts the bearings [1] 0.040" above the release [3].

If the bearings are not 0.040 " (+/- 0.01") above the guide release, but the pushout is correct, do these steps:

• Find the hard stop bolt [1] for the rocker arm.
• Use a 1/2" wrench to loosen the 3/8"-24 jam nut [2].
• Adjust the stop bolt until the bearings are 0.040" above the release.
• Re-check the rocker arm pushout

Remove the 0.040" shims you put between each of the rocker arm bearings and the spindle guide release

Put the alignment tool [2] onto the double arm. Use the (2) screws [6] for the alignment tool.

 Note: Make sure the legs of the alignment tool clear the covers [3] for the plungers.

Put the double arm [1] onto the output shaft.

Turn the center screw [4] to raise the double arm on the output shaft.

Lightly tighten the clamp screws [5]. Do this until the double arm stays in position, but you can move it with your hand.

 Note: Do not tighten the clamp screws too much. This makes it difficult to adjust the height for the double arm.

Release EMERGENCY STOP.

Jog the V-axis to 0 degrees. This rotates the carousel for the Side-Mount Tool Changer (SMTC).

Push EMERGENCY STOP.

Insert a tool holder into the active tool pocket. Make sure the tool holder has a flat face. The tool must have a minimum nose length of 2" (51 mm).

Put the indicator tip onto the bottom of the tool holder. Set the indicator to zero.

Go into DEBUG mode.

Release EMERGENCY STOP.

Jog the table to move the indicator away from the tool holder.

Remove the tool from the tool pocket.

Push ZERO RETURN. Push Z. Push HOME G28.

Jog the V Axis in the negative (-) direction to -8.0 degrees.

Jog the T Axis in the negative (-) direction to -243.0 degrees.

 Note: The arm should be near the bottom of the travel.

Push EMERGENCY STOP.

Put the tool holder [1] into the double arm on the carousel side.

Push the plunger on the double arm down. Put the lower half of the split-tool [3] in the double arm under the spindle. Put the upper half of the split-tool [2] on the lower half.

Align the split tool halves. Insert the split-tool alignment rod [4]. Hold the rod in the split-tool using your palm.

 Caution: Make sure your hand is not inbetween the arm and the spindle.

Release EMERGENCY STOP.

Push T. Push HAND JOG. Push .01.

Slowly jog the T Axis in the negative (-) direction to -284.0 degrees.

 Caution: Make sure the tool holder does not hit the carousel pocket.

 Caution: Make sure the spindle dog [1] and the upper half of the split-tool [2] are aligned to the lower half of the split-tool [4].

Push the upper half of the split-tool into the spindle using the rod. Make sure it is firmly seated into the spindle.

Slowly jog the T Axis in the negative (-) direction to -302.0 degrees.

To correct a misalignment, jog the T Axis in the positive (+) direction to -284.0 degrees and repeat this step.

The gap [3] between the upper half of the split-tool and the lower half of the split-tool should be no more than 0.06" (1.52mm).

Push EMERGENCY STOP.

Make sure the lower half of the split-tool [1] does not come out of the arm.

Remove the split-tool rod [2]. Use your hand to rotate the double arm. Align the split tool halves. Insert the split-tool alignment rod.

 Note: The split tool must go in smoothly. If the split-tool is off in the X-direction, the SMTC must be aligned.

Release EMERGENCY STOP.

Jog the indicator [1] under the tool holder with the flat face. Turn the center screw [2] until the indicator shows 0.

The gap between the upper half of the split-tool and the lower half of the split-tool should be no more than 0.06" (1.52mm).

Lightly tighten the (6) clamp screws [3]. Do these steps to torque the screws for the clamp:

• Tighten the screws in a star pattern.
• Torque the screws in increments of 5 ft-lb (6.8 N-m).
• Look at the indicator to make sure the arm is level. The indicator must not move more than 0.005" (0.13 mm). Change the tightening pattern if necessary to keep the arm level.
• Repeat the pattern until the screws are torqued to 25 ft-lb (33.9 N-M).
• Each time you complete the pattern insert the split-tool alignment rod. The split tool must go in smoothly. Correct the alignment if the split-tool is off.
• If the indicator moves too far, you must re-start the alignment procedure.

Set the indicator to 0. Move the indicator away from the tool. Do not change the indicator setting.

Slowly jog the T Axis in the posotive (+) direction to -243.0 degrees. Remove the split-tool halves.

With the indicator measure the height of the tool holder in the positions that follow:

 Caution: Make sure you jog the arm slowly to avoid crashing it into the tool changer pockets.

• The tool holder under the spindle [1] when the T axis is set to -302.0 degrees.
• The tool holder between the tool pockets [2] when the T axis is set to -100.0 degrees.

If the indicator measures more than 0.01" (0.25 mm) between Step 7 and Step 9 at -302.0 degrees, the double arm is not level. Do this procedure again.

If the indicator measures more than 0.01" (0.25 mm) at -302.0 degrees or -100.0 degrees, the SMTC must be adjusted.

If the indicator measures less than 0.01" (0.25 mm), the double arm is level.

Jog the T Axis in the positive (+) direction to -100.0 degrees.

Jog the V Axis in the positive (+) direction to 0 degrees.

Install the split-tool halves [1, 2] in the tool pocket and double arm.

Carefully put the alignment rod [3] through the top [1] and bottom [2] halves of the split-tool.

• If the tool pocket and the double arm do not align in the Y direction, jog the V axis no more than 0.3 degrees. Then change parameter415.
• If the double arm does not align in the X direction, the SMTC must be adjusted.

Remove the alignment tool and the indicator.

Release EMERGENCY STOP.

Push RESET to clear the alarms.

Jog the T Axis down until it reaches the bottom of travel.

Push EMERGENCY STOP.

Remove the tools.

Go out of DEBUG mode.

Change Parameter 462:18, INVIS AXIS, to 1.

Change Parameter 390:18, INVIS AXIS, to 1.

Do a tool changer recovery.