7.1 Side-Mount Tool Changer - Double Arm - Plunger and Adjuster Assembly - Inspection - Mill

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.