BMT45 - Turret Indexer Assembly - Troubleshooting Guide

Introduction

Quad-Ring
Torque arm
Cluster Gear
Worm Shaft
Spur Gear
Turret Motor
Servo Motor

Home Switch
Clamp/Unclamp Switch

Symptom Table

Symptom	Possible Cause	Corrective Action
Alarm 114 TURRET FAILURE TO REACH CLAMP SWITCH	The incoming air flow is incorrect.	Check the incoming air supply.
	There is a problem with the voltage to the turret clamp/unclamp solenoid.	Check the voltage to the turret clamp or unclamp solenoid.
	The turret clamp/unclamp proximity sensor is faulty.	Check the turret clamp/unclamp proximity sensor.
	The turret did not pop out far enough.	Check the piston, internal gears and spring assembly for damage.
Alarm 8125 TOOL TURRET NOT SEATED	Obstruction between tool turret and housing.	Clear obstruction such as chips. If the turret is not virtually clamping correctly and the backlash is () then inspect the 2 wave washers located on the tool changer side of the worm shaft.
Alarm 2022 TURRET FAILED TO LEAVE CLAMP SWITCH Important : Do no disassemble the tool changer unless advised to do so by Haas Service	Tool turret attempted to unclamp but failed to leave the clamp switch because air is bypassing the turret piston quad-ring.	Refer to 06/13/2024 Service Notification - Alarm 2022 ST-10/15 Turret Replacement Service kit
	The Turret Tool Changer Alignment is not set correctly.
	The turret clamp/unclamp proximity sensor is faulty.
	The turret did not unclamp enough.
High torque loads during tool change	Interference between the housing and turret.	See High Loads during tool change section below.

Incoming Air Supply

Make sure that the air compressor supplies the correct air pressure and air flow. For Haas machine air pressure specifications, go to New Machine Pre-Installation for your machine model. Select your machine and scroll to the the section labeled "Air/Coolant Requirements."

Attempt a tool change on the machine. When the machine has the correct air pressure and flow, the needle on the air pressure gauge should not drop more than 10 PSI (0.70 bar) during a tool change. This test confirms that the air pressure and air flow into the machine are correct.

Clamp/Unclamp Proximity Sensor

Navigate to the Diagnostic screen on the pendant. Go to the I/O tab. Use an M43 (Unclamp) M44 (Clamp) code in MDI mode to troubleshoot the clamp/unclamp switch.

Check that Input 4 Tool Turret Locked changes states when the turret is commanded to unclamp/clamp.

Test the sensor by placing a screwdriver in front of the sensor. Make sure the inputs change states.

If the input does not change, jump the cable connector on the turret connector bracket. If the input changes, replace the sensor.

If the input does not change, refer to:

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.

Servo Motor

Corrective Action:

Disconnect the axis servo motor cables. Make sure they are not contaminated. Measure the resistance from the pins labeled A, B, and C at the motor power cable connector to chassis ground. The reading should show an open circuit. If there is resistance to ground, the cable is at fault.

Go to: Axis Servo Motor and Cables - Troubleshooting Guide to troubleshoot the SIGMA motor and SIGMA motor cables.

Turret Pop Out

If you commanded an M43 (Unclamp) and the turret moved, but did not move far enough to clear the coupler, measure the distance the turret traveled.

Set indicator to zero when turret unclamped M43. Command the turret to clamp M44. The indicator should measure 0.160" - 0.250".

Note : If the turret does not travel far enough, the piston shaft, gears, or spring assembly could be at fault. Contact Haas Service for more information.

Important : Do not remove the indexer turret (disk) to check the unclamp distance.

Clamp / Unclamp Solenoid Voltage

Measure the voltage of the clamp/unclamp solenoid. The solenoid is inside the Consolidated Air/Lubrication Manifold (CALM) Cabinet.

Run M43 (Unclamp) and M44 (Clamp) codes in MDI mode and measure the voltage of the solenoids. The voltage must measure 120 VAC.

If there is no voltage, refer to the Next Generation Control - I/O PCB - Troubleshooting Guide.

High Loads during tool changes

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.

2

Index the turret to tool number 1.

Turn off the main air supply to the machine.

Remove the TT-Axis motor [1] to check the torque required to rotate the turret when unclamped.

3

Use a inch-pounds torque screwdriver attached to the coupler.

It should read between 15-20 in-lbs. If the torque is high, use the following steps to check the main turret shaft.

4

Remove the Turret and live drive and check the torque required to rotate the shaft.

If the torque is low with the turret removed. Reinstall the live drive and turret. Refer to the BMT45 Turret - Live Tool Drive - Alignment procedure to reset the live drive alignment.

If the torque is high with the turret removed, contact Haas Service.