This procedure tells you how to remove and install an integrated trunnion assembly.

A temporary shipping base is sent from the factory. The damaged trunnion is attached to the base and returned to the factory. The repaired trunnion is shipped attached to the base. After the trunnion assembly is installed, the base is shipped back to the factory.

Remove the counterbalance cylinder [1].

Remove the (2) inboard hex screws [2] from the trunnion base.

Release the [EMERGENCY STOP].

Jog the A Axis to 0 degrees.

Push [POWER OFF].

Remove the (2) outboard hex screws from the trunnion base.

Remove the (4) socket-head cap screws from under the left-hand rotary [1] and from under the right-hand rotary [2], as shown.

Disconnect the A-Axis and B-Axis power and encoder cables.

 Warning: Do not disconnect the air supply to the trunnion.

Install eye bolts [1] onto the top of the trunnion assembly.

Put the chains [2] from the lift through the eye bolts. Place a spreader bar [3] between the chains.

 Warning: Ensure the air supply is connected to the trunnion assembly. Do not move the trunnion assembly without air pressure.

 Warning: The trunnion assembly weighs over 2150 lb (975 kg). Make sure to use a lift of the correct capacity.

Lift the trunnion assembly clear of the receiver table.

Remove the permanent slide keys [4] that were installed with the trunnion from under the trunnion base.

Note: Do not lose the slide keys. You will need them to install the repaired trunnion assembly.

Install the temporary slide keys [2] that came with the Trunnion base [4] onto the bottom of the trunnion assembly. They will return to the factory with the trunnion.

Lower the trunnion onto the Trunnion base [4].

Install the (2) outboard hex screws [1].

Disconnect the air supply hose.

Connect the A-Axis and B-Axis power and encoder cables to the trunnion.

Push [POWER ON].

Jog the A Axis in the negative (-) direction to -90 degrees.

Install the (2) inboard hex screws [3].

Jog the A Axis to 0 degrees.

Push [EMERGENCY STOP].

Set Parameter 43:3, A axis DISABLED, to 1.

Set Parameter 151:3, B axis DISABLED, to 1.

Push [POWER OFF].

Disconnect the A-Axis and B-Axis power and encoder cables.

Install a ½-13 screw [1] through each of the spacers and into the receiver tables. Use your fingers to tighten the screws. These hold the spacers in position while you check for flatness.

Put an indicator [2] on the spindle head. Put the tip of the stylus adjacent to the left-hand ½-13 screw. Set the indicator to 0.

Release the [EMERGENCY STOP].

Jog the X Axis until the stylus is adjacent to the right-hand ½-13 screw.

If the spacers are level, the reading on the indicator is no more than 0.0002”. If the reading is more than 0.0002", speak to the Haas Automation Service Department.

Lightly stone the spacers to remove burrs.

Remove the (2) ½-13 screws.

Push [POWER OFF].

Jog the A Axis in the negative direction to -180 degrees.

Remove the counterbalance [1]. Remove the (2) inboard hex bolts [2].

Jog the A Axis to 0 degrees.

Push [POWER OFF].

Disconnect the A-Axis and B-Axis power and encoder cables to the repaired trunnion. Do not disconnect the air hoses.

Remove the (2) outboard hex bolts [3].

Attach eye bolts [5] to the top of the trunnion.

Warning: Ensure the air supply is connected to the trunnion assembly. Do not move the trunnion assembly without air pressure.

Lift the repaired trunnion from the shipping bracket.

Warning: The trunnion assembly weighs over 2150 lb (975 kg). Make sure to use a lift of the correct capacity.

Remove the temporary slide keys [4].

Stone the mating surfaces on the bottom of the trunnion assembly.

Install the permanent slide keys that were installed with the machine.

Lower the repaired trunnion onto the receiver table inside the machine.

Install the (4) left-hand [1] and (4) right-hand [2] socket-head cap screws through the underside of the receiver table. Do not torque the screws.

Install the (2) outboard hex screws [3]. Do not torque the screws.

Connect the A-Axis and B-Axis power and encoder cables.

Push [POWER ON].

Zero return all axes.

Ensure that Parameter 43:20, A axis ROT TRVL LIM is set to 0.

Jog the A Axis in the negative direction to -180 degrees.

Push [EMERGENCY STOP].

Install the (2) inboard hex screws [1]. Do not torque the screws.

Install the counterbalance [2].

Release the [EMERGENCY STOP].

Jog the A Axis to 0 degrees.

Do these steps to calculate the A-Axis grid offset:

• Zero return the A Axis.
• Push [POSIT].
• Subtract the A-Axis value in DIST TO GO from the Target Distance. EXAMPLE:
  • Target Distance = 0.833
  • A-Axis DIST TO GO = 0.700
  • 0.833 - 0.700 = 0.133
• Multiply the result times the value in Parameter 47, A RATIO (Steps/Unit). EXAMPLE:
  • Value in Parameter 47 = 98304
  • 0.133 x 98304 = 13074
• Divide the result by the Scale X Factor (from the table above). EXAMPLE:
  • Parameter 43:30, A axis SCALE/X HI = 0
  • Parameter 43:31, A axis SCALE/X LO = 0
  • Scale X factor = 3
  • 13074/3 = 4358
• Set the value in Parameter 128, A GRID OFFSET, to the result of the calculation. EXAMPLE:
  • Parameter 128 = 4358
• Zero return the A Axis.

If the calculation is completed correctly, the A-Axis DIST TO GO = 0.833.

Do these steps to calculate the A-Axis grid offset:

• Zero return the A Axis.
• Push [POSIT].
• Subtract the A-Axis value in DIST TO GO from the Target Distance. EXAMPLE:
  • Target Distance = 0.833
  • A-Axis DIST TO GO = 0.700
  • 0.833 - 0.700 = 0.133
• Multiply the result times the value in Parameter 47, A RATIO (Steps/Unit). EXAMPLE:
  • Value in Parameter 47 = 98304
  • 0.133 x 98304 = 13074
• Divide the result by the Scale X Factor (from the table above). EXAMPLE:
  • Parameter 43:30, A axis SCALE/X HI = 0
  • Parameter 43:31, A axis SCALE/X LO = 0
  • Scale X factor = 3
  • 13074/3 = 4358
• Set the value in Parameter 128, A GRID OFFSET, to the result of the calculation. EXAMPLE:
  • Parameter 128 = 4358
• Zero return the A Axis.

If the calculation is completed correctly, the A-Axis DIST TO GO = 0.833.

Put the base of the 0.0005" indicator onto the spindle.

Put the tip of the stylus onto the top of the table adjacent to the edge. Set the indicator to 0.

Release the [EMERGENCY STOP].

Jog the B Axis to -180 degrees.

If the indicator still shows 0, put a mark [1] on the table where the stylus touches it.

Jog the B Axis to 0 degrees, the original position.

If the indicator still shows 0, mark the table where the stylus touches it.

If the indicator does not show 0, jog the B Axis in small increments until you can find (2) locations on opposite sides of the table that are at the same height. Mark those locations.

Jog the A Axis in the positive direction to +90 degrees.

Put the tip of the indicator stylus onto one of the marks. Set the indicator to 0.

Jog the X Axis until the stylus is adjacent to the other mark [2].

If the A Axis is parallel to the X Axis, the total indicated runout between the (2) marks is not more than 0.0003". No adjustment is necessary. Go to Step 4.

If the runout is more than 0.0003", go to step 3.

Do this step if the total indicated runout between the (2) marks is more than 0.0003".

Determine which end the trunnion must move on the Y Axis to correct the runout.

Loosen the (4) hex screws [1]. Tighten the outboard hex screw on the end that is opposite from the end to be moved. Keep the screw tight enough to control the adjustment.

Strike the base of the trunnion with a dead-blow hammer [2] to move it in the Y Axis. The trunnion pivots around the outboard screw.

Torque the (4) hex screws.

Do Steps 2 and 3 again until the runout is less than 0.0003".

If the runout is still more than 0.0003", loosen the screws on the receiver table. Do steps 2 and 3 again until the runout is not more than 0.0003".

Note: If you loosen the screws on the receiver table, you must align the ballscrew.

SET THE A-AXIS BACKLASH.

Jog the A Axis to 0 degrees.

Jog the B Axis until the tee slots on the table are parallel to the X Axis.

Put an 0.0001" indicator onto the spindle.

Put the tip of the indicator onto a tee slot.

Push [.01/10.].

Jog the A Axis one increment. Watch the indicator.

If the needle on the indicator moved, subtract ten from the value in Parameter 55, A BACKLASH.

If the needle does not move, do these steps:

• Add 10 to the value in Parameter 55.
• Jog the A Axis one additional increment. Add 10 to the value in Parameter 55 for each increment you jog until the needle moves.
• When the needle moves, subtract ten from the value in Parameter 55.

SET THE B-AXIS BACKLASH.

Jog the B Axis until the tee-slots on the table are parallel to the Y Axis.

Put the tip of the indicator onto a tee-slot.

Push [.01/10.].

Watch the indicator.

Jog the B Axis one increment.

If the needle on the indicator moved, subtract 10 from the value in Parameter 163, B BACKLASH.

If the needle did not move, do these steps:

• Add 10 to the value in Parameter 163.
• Jog the B Axis one additional increment. Add 10 to the value in Parameter 153 for each increment you jog until the needle moves.
• When the needle moves, subtract 10 from the value in Parameter 163.

SET THE A-AXIS TOOL CHANGE OFFSET.

Zero return the A Axis.

Jog the B Axis until the marks created in Step 1 are parallel to the Y Axis.

In DEBUG mode, set the value of Parameter 212, A TOOL CHANGE OFFSET, to 0.

Push [EMERGENCY STOP].

Put an 0.0001" indicator onto the spindle.

Put the stylus onto one of the marks.

Release the [EMERGENCY STOP].

Push [.0001/.1].

Jog the Y Axis from one mark to the other. Make sure the difference between the (2) marks in the B Axis is not more than 0.0003".

Record the value of A in the COMMAND COLUMN on the POS RAW DATA screen.

Set the value of Parameter 212 to the recorded value of A. The number must be a whole, positive integer.

Zero return the A Axis.

DETERMINE THE CENTER BETWEEN THE A AXIS AND THE B AXIS.

Jog the A Axis in the positive (+) direction to +90 degrees.

Push [EMERGENCY STOP]

Put an 0.0005" indicator between the spindle dogs. Make sure the spindle can turn freely.

Put the tip of the stylus onto the edge of the table.

Release the [EMERGENCY STOP].

Jog the B Axis until you find the highest location on the table. Then, make a mark at that location.

Set the indicator to 0.

Jog the A Axis in the negative (-) direction to -90 degrees.

Jog the B Axis 180 degrees. The marked location is at the top.

Jog the Y Axis until the platter is under the indicator.

Push [EMERGENCY STOP].

Use your hands to turn the spindle until the stylus is against the mark.

If the A Axis and the B Axis are centered relative to each other, the indicator shows a runout of no more than 0.0003".