Service Home How To Procedures VMC - 50-Taper - Gearbox - 16DP-C - Pre-CALM - Installation - AD0137
Last updated: 03/03/2021

VMC - 50-Taper - Gearbox - 16DP-C - Pre-CALM - Installation

AD0137

Introduction

This procedure tells you how to install a 50-Taper 16DP-C gearbox on Haas vertical mill machines without the Consolidated Air-Lubrication Manifold (CALM) system. This procedure does not apply to Haas vertical machines with a ZF gearbox.

This gearbox is equipped with a large 3-liter sump tank [1] and a 500 ml reservoir [2].

Prerequisites:

Note: The gearbox 3-liter sump tank is filled with the correct amount of Mobil SHC 627 at the factory.

When the mill operates correctly, the 500-ml reservoir is empty. DO NOT fill the sump tank or the reservoir as part of regular maintenance.

Parts Required:

  • Trans VF 7.5K 50T 16DP-C: P/N 93-30-9743A

OR

  • Trans VF 10K 50T 16DP-C: P/N 93-30-9744B

OR

  • Trans VF-5/50 30HP 7.5K 16DP-C: P/N 93-30-9982B
OR
  • GEARBOX ASSY 16DP-C 50T VMC: P/N 93-30-11806A

VMC - 50-Taper - Gearbox - Installation Aid - Parameter Setup

Use the tables that follow to verify the correct parameter values. Some parameters may not apply to the software version you have. If changing from optical to magnetic encoder only change the parameters in the second table

Parameter Name Value Parameter Name  Value 
57:02 DISABLE GEAR BOX 0 1305 GEAR SHIFT RETRY TYPE 3
57:26 TRANS OIL LOW PRESS 1 1310 ENABLE GEAR BOX OIL LEVEL SENSOR 1
75 GEAR CHANGE SPEED 30 1311 GEAR BOX OIL FLOW SENSOR TYPE Pressure Switch = 0
Flow Sensor = 1
Level Sensor = 2
129 GEAR CH SETTLE TIME 200 1312 GEAR BOX OIL LEVEL ALARM DELAY (DAYS) 10
130 GEAR STROKE DELAY 750 1316 SP MOTOR TEMP SENSOR TYPE 2
180 SP SLIP GAIN 240 1317 SP MOTOR SENSOR MAX TEMP (DEG F) 500000
181 SP MIN SLIP 40 1318 SP MOTOR SENSOR MIN TEMP (DEG F) 0
188 SP ORIENT GAIN 750 1319 SP MOTOR CAUTION TEMP (DEG F) 210
725 SP HIGH SPEED CURRENT PROFILING 1 1320 SP MOTOR ALARM TEMP (DEG F) 250
1304 GEAR SHIIFT RETRY SPEED (RPM) 10 1274 GEAR STROKE TIMEOUT 3300

 

The parameters in the table that follows change with the encoder type and the maximum spindle RPM. Choose the value that matches the encoder type and the maximum spindle RPM.

 Note: Use the same values for shafted and hubbed encoders except where noted.

Parameter Name 7,500 RPM - Magnetic Encoder 7,500 RPM Optical Encoder 10,000 RPM Magnetic Encoder 10,000 RPM - Optical Encoder
79 SPINDLE STEPS/REV 4096 4000 2048 2000
131 MAX SPINDLE RPM 7500 7500 10000 10000
142 HIGH/LOW GEAR CHANGE 1965 1965 2950 2950
150 MAX SP RPM LOW GEAR 2325 2325 3100 3100
183 SP MAX FREQ 25000 25000 16667 16667
186 SP DECELERATION 81920 81920 76800 76800
187 SP MOT HI GEAR STPS/REV 4096 4000

4096

(Hubbed Encoder 5120)

 4000
239 SPINDL ENC STEPS/REV

8192

(Hubbed Encoder 4096)

 8000

8192 

(Hubbed Encoder 4096)

 4000
1287 SPINDLE MAX BEARING RPM 7500 7500 10000 10000
1288 SPINDLE RPM MAX FREQUENCY 7500 7500 10000 10000

VMC - 50-Taper - Tool Release Piston (TRP) - Pre-CALM - Removal

1

Push [POWER ON]

Jog the Z Axis to the bottom position.

Jog the X Axis to the center of the travel.

Jog the Y Axis to the front of the machine.

Push [POWER ON]. Lock the main circuit breaker. Use an approved lock with an approved safety tag.

Close the primary air valve to stop the air supply to the machine. Remove the enclosure panels.

If necessary, disconnect the spindle fan and tool release cables when you remove the enclosure panels.

Tools Required: 

  • T-2080

2

Disconnect the (2) switch cables [1] from the connector bracket for the Tool Release Piston (TRP).

Note: Put a label on each of the TRP air hoses to help you install them in the correct position.

Disconnect the (3) TRP air hoses [2].

If the machine is equipped with TSC, remove the coolant union and extension tube. Use T-2080 to hold the spindle stationary. The coolant union and extension have left handed-threads.

3

Remove the (4) TRP screws, washers and springs.

Note: Record the number and position of the shims under the TRP. Tape the shims together with electrical tape. This is necessary to correctly align the TRP when you install it.

Remove the TRP assembly.

VMC - 50-Taper - Gearbox - Pre-CALM - Removal

1

Remove the mid belt shield.

2

Disconnect the air supply [1].

Disconnect the cables for all of the switches and solenoids from the connector bracket [2].

3

Attach a hoist to the gearbox assembly [1].

Caution: The gearbox/spindle motor assembly weighs at least 500 lb (227 kg). Make sure to use a hoist that is rated for the weight of the gearbox/spindle motor assembly.

Remove the (8) gearbox screws [2].

Pull the gearbox assembly forward to lower the tension in the drive belt.

Remove the drive belt from the spindle side.

4

Slowly lift the gearbox/spindle motor assembly.

Raise the assembly slowly and look for other cables that are connected.

Disconnect the encoder cable [1].

5

Remove the connector bracket [1], TRP solenoids [2], and encoder cable [4] from the old gearbox.

Note: If the pre-CALM machine has been retrofitted with the HAAS Bearingless TSC union, then replace the new gearshift solenoid (has 2 coils) with the original solenoid (has 3 coils) from the old gearbox.

VMC - 50-Taper - Gearbox - 16DP-C - Pre-CALM - Installation

1

Install the connector bracket [1], TRP solenoids [2], and encoder cable [4] you removed from the old gearbox onto the new gearbox.

Note: If the pre-CALM machine has been retrofitted with the HAAS Bearingless TSC union, then replace the new gearshift solenoid (has 2 coils) with the original solenoid (has 3 coils) from the old gearbox.

2

If necessary, install the new drive belt before installation of the gearbox.

Note: The foam insulation on the back head cover can prevent the installation of the gearbox in the correct location. If this occurs, you must cut the foam insulation.

Use a hoist to lift the replacement gearbox/spindle motor assembly and put it into place.

Caution: The gearbox/spindle motor assembly weighs at least 500 lb (227 kg). Make sure to use a hoist that is rated for the weight of the gearbox/spindle motor assembly.

Connect the encoder [1]. Route it below and behind the gearbox.

3

Tighten the (8) gearbox screws with your hand.

Follow the VMC - Spindle Drive Belt - Tension Adjustment - Gates Sonic Meter Instructions to set the correct belt tension before you torque the screws.

4

Find the male 4-pin connector [1] of the 300A adapter cable supplied with the kit. Connect it to the connector labeled SPINDLE FAN on the connector bracket.

5

Find the cable from the tank-venting solenoid on the 3-liter sump tank.

6

Connect the cable from the tank-venting solenoid to the 2-pin female connector on the 300A adapter cable.

7

Connect the cable labeled TRANS OIL FLOW [1] to the connector labeled 950 LOW GEARBOX OIL PRESS STATUS.

Note: The cable labeled VMC GEARBOX 2 LEVEL [2] on the 3-liter sump tank is not used.

8

Connect the remaining switches and solenoids to the connector bracket [1]. Connect the air supply hoses to the T-fitting [2].

VMC - 50-Taper - Tool Release Piston (TRP) - Pre-CALM - Installation

1

Install the TRP assembly.

Install the shims you taped together in the same position that you removed from the TRP.

2

Install the (4) TRP screws, washers, and springs.

Torque the screws to 50 ft-lbs (76 Nm).

3

Connect the (2) switch cables [1] to the connector bracket for the Tool Release Piston (TRP).

Connect the (3) TRP air hoses [2] to the same fittings from where they were removed.

Use the labels to help you install them to the correct fitting.

Open the primary air valve to supply air to the machine. Examine all of the air hoses for leaks.

Set the main circuit breaker to the ON position. Push [POWER ON].

Push the [TOOL RELEASE] button to make sure that the TRP operates correctly.

Solenoid/Orifice Upgrade

1

Remove the solenoid [1] and the 0.010" and 0.03." orifices [2] from the oil tank assembly, and replace them with a 0.020" orifice [3] P/N 58-0297.

Install a muffler [4] P/N 58-1861 on the gearbox housing as shown on the image. 

Note: If the gearbox was equipped with a antisiphon solenoid there was a hose going to this port on the housing. 

Follow the instuctions on the reservoir decal to refill the tank.

2

PRESSURIZED OIL TANK (5PSI) FILL/TOP-OFF INSTRUCTIONS

1. Remove the fill plug and set aside.

2. Run the oil pump for one minute in MDI M59 P1107; for CHC machines.

3. If necessary, fill tank to top of fill plug with Mobil SHC627 or Mobil 1 15W-50.

4. Replace the fill plug securely and clean off all oil residue.

5. Run the spindle for 10 minutes and check for oil leaks; repair as necessary.

 

VMC - 50-Taper - Gearbox 16DCP - Pre-CALM - Test

1

Do this step to make sure that the oil-flow sensor and the gearbox tank-venting solenoid operate correctly.

Operate this program:

M03 S1000;

G04 P60.;

M03;

This program ensures that the oil-flow sensor and the gearbox tank-venting solenoid operate correctly.

While the spindle turns, examine all of the hoses for leaks.

When the spindle fan and oil pump stop, you hear the pressure release and the oil "gurgle" into the gearbox housing. This is normal.

If alarms show, make sure all of the cables are tightly connected.

2

Adjust the height of the TRP sensors. Refer to 50-Taper - TRP - Height Adjustment - VMC.

Install the enclosure panels.

Note: Make sure to connect the spindle fan to the 4-pin female connector on the adapter cable.