Side Mount Tool Changer (SMTC) - Carousel and Pocket ... · The cam followers on the carousel need grease. The cam followers on the carousel are worn. Check and grease the cam followers

LAST UPDATED: 02/14/2020

Side Mount Tool Changer (SMTC) - Carousel and Pocket - Troubleshooting Guide


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EXPLODED VIEW:

1. FBHCS 1/4-20 X 1/22. CAROUSEL COVER3. BEARING LOCKNUT4. JAM NUT 5/8-185. CAROUSEL6. CAM FOLLOWER7. BEARING8. POCKET ASSEMBLY9. CAROUSEL WASHER

10. TOOL CHANGER FRAME11. CAROUSEL SHAFT12. SPACER13. CAM BOX14. SHCS 1/2-13 X 215. CAROUSEL CAM ASSEMBLY16. POCKET STOP17. SHCS 1/2-13 X 518. CAROUSEL MOTOR19. POCKET TIPPER ASSEMBLY20. DOUBLE ARM

Carousel1. Tool In Position Proximity Sensor: It

lets the control know that the toolpocket is in position.

2. Carousel Cam: A DC or Servo Motorturns this Cam that rotates the toolcarousel.

3. Tool One Proximity Sensor: It lets thecontrol know that the tool pocket is toolone position.


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Pocket1. Cam Follower: Keeps the pocket in the

up position as the carousel rotates. Thecam follower follows a groove on thecarousel housing.

2. Shaft: The axle upon which the pocketpivots up and down.

3. Spring: Puts tension on the fourplungers inside the tool pocket.

4. Tool Pocket: Holds the tool.5. Plungers: The four plungers grip the

tool pull stud. They are lubricated withgrease.


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Symptom Table


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SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

The carousel tool in position, tool onein position, pocket up or downproximity sensor is damaged orcontaminated.

Rotate the carousel in recovery mode and test the sensorsand cabling.

No power to the carousel motor orthe carousel motor is damaged.

Check that the carousel can be rotated in the manualrecovery mode.VMC, HMC - Side-Mount Tool Changer - ManualRecovery

Tool change was interrupted beforecompletion.

A tool change was attempted beforeadequate air pressure was present.

A tool change was attempted with thepocket already down.

Do a Tool Change Recovery.VMC, HMC - Side-Mount Tool Changer - ManualRecovery

Alarm 625CAROUSELPOSITIONINGERROR

Carousel rotation was prevented byan obstruction. Clear the carousel path.

A tool change was attempted with thepocket already down.

Do a Tool Change Recovery.VMC, HMC - Side-Mount Tool Changer - ManualRecovery

The incoming air flow or pressure isincorrect. Correct the incoming air supply.

There is contamination in the slideguides. Clean and lubricate the slide guides.

The air cylinder for the tool pocketdoes not move freely. Check the air cylinder for the tool pocket.

The pocket up or pocket downproximity sensors are contaminated,damaged or have loose connections.

Clean and inspect the proximity sensors.

There is a problem with the pocketup/down system. Troubleshoot the check valve, air cylinder, and solenoid.

Movement is blocked by debris. Clear debris.

Alarm 626 TOOL-POCKET SLIDEERROR

The tool pocket, air cylinder, pocketslide, or slide follower is loose ordamaged.

Diagnose and correct.

Alarm2066 TOOLCHANGER HOMEPOSITION FAULT

The pocket up and down proximityswitches are in the incorrect state. Clean and inspect the proximity sensors.


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There is a problem with the tool-pocket stop shock-absorber. Check the tool-pocket stop shock-absorber.

The tool pocketis noisy. The tool pocket, air cylinder, pocket

slide, or slide follower is loose ordamaged.


The toolholders or pull studs areincorrect. Check for correct tool specifications.

The spring or the plungers are worn. Check the spring and the plungers for wear.The tool fallsfrom the toolpocket.

The tool pocket moves up and downtoo fast for heavy tools. Install the Pocket Slow Down Service Kit (P/N 93-0254).

Carousel rotation was prevented byan obstruction. Clear the carousel path.

The pocket up or pocket downproximity sensors are contaminated,damaged or have loose connections.

Clean and inspect the proximity sensors.The tool pocketis broken.

The tool pocket, air cylinder, pocketslide, or slide follower is loose ordamaged.


The cam followers on the carouselneed grease.

The cam followers on the carouselare worn.

Check and grease the cam followers.

The tool pocket slider set screw isincorrectly adjusted.

Make sure the tool pocket slider set screw is correctlyadjusted. See VMC - Side-Mount Tool Changer - Pocket SliderSet Screw Adjustment procedure.

The carouselmakes unusualnoises duringoperation.

The carousel cam bearhug nuts areloose.

A loose cam bearhug nut will cause rotational backlash onthe carousel assembly, noise and carousel position alarms.Tighten the carousel cam bearhug nuts with a spannerwrench.

The SMTC ArmMotion Speed IsToo Fast.

The tool is not flagged as heavy (H) inthe tool pocket table.

Tools flagged as heavy [1] in the tool pocket table, will causethe SMTC arm to rotate at 25% the speed (VFSS only).


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Carousel Proximity Sensors

Test the tool one position sensor:

1. Find the proximity sensor [3].2. Press the left or right arrow to move the carousel. Monitor the TOOL ONE POS bit on a Classic Haas Control

(CHC), or SMTC_CAROUSEL_POCKET_ONE on a Next Generation Control (NGC). This bit should change stateonce per carousel revolution at pocket one.

3. Touch the end of the proximity sensor with a screwdriver. Watch for the light to change, and monitor theTOOL ONE POS (CHC) or SMTC_CAROUSEL_POCKET_ONE (NGC) bit value.

4. If the sensor does not change state, use the PROXIMITY SENSOR - TROUBLESHOOTING GUIDE totroubleshoot the proximity sensors.

Corrective Action:

Test the tool in position sensor:

1. Clear the alarms and go into toolchanger manual recovery. Refer to VMC,HMC - SIDE-MOUNT TOOL CHANGER -MANUAL RECOVERY.

2. Press the left or right arrow to move thecarousel. Monitor the TOOL IN POS biton a Classic Haas Control (CHC), orSMTC_CAROUSEL_POCKET_MARK on aNext Generation Control (NGC). This bitwill be 0 unless the pocket is in position.It will be 1 when the pocket is inposition.

3. If the carousel moves but the bit doesnot change state, remove the carouselcover. If the carousel does not move,see Section 2.

4. To make sure the proximity sensor isnot tripped, turn the carousel until theflat side of the cam [2] faces theproximity sensor [1].

5. Touch the end of the proximity sensorwith a screwdriver. Watch for the lightto change, and monitor the TOOL INPOS orSMTC_CAROUSEL_POCKET_MARK value.

6. If the light or the bit value does notchange state, use the PROXIMITYSENSOR - TROUBLESHOOTING GUIDE totroubleshoot the proximity sensors.


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Carousel MotorCorrective Action:

1. With the motor connected, check for voltage at the back of the motor power connector.2. Set your meter to DC voltage.3. Set the DC voltage range on your meter to at least 200 VDC.4. Select the Min/Max mode to capture the voltage.5. Reset all the alarms, and go into tool changer manual recovery VMC, HMC - SIDE-MOUNT TOOL CHANGER -

MANUAL RECOVERY.6. Press the left or right arrow to move the carousel.7. The meter should record voltage between +/- 150 and +/-170 VDC in brief pulses.8. If you get the correct voltage and motor does not turn, the motor is damaged. If the voltage is incorrect,

refer to:◦ NEXT GENERATION CONTROL - I/O PCB - TROUBLESHOOTING GUIDE◦ CLASSIC HAAS CONTROL - I/O PCB - TROUBLESHOOTING GUIDE

Incoming Air Flow or PressureCorrective Action:

• Make sure that the air hose to the machine is the correct diameter.• Make sure that the air compressor supplies the correct air pressure and air flow.• Command 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. Thistest confirms that the air pressure and air flow into the machine is correct.

Refer to the "Compressed Air" requirements for your machine on NEW MACHINE PRE-INSTALLATION.

Pocket Slide Guides

Corrective Action:

1. Visually examine the slide guides [1] forthe tool pocket. Remove allcontamination.

2. Lubricate the surfaces with red grease.3. Go into tool changer manual

recovery VMC, HMC - SIDE-MOUNTTOOL CHANGER - MANUAL RECOVERY.

4. Press up or down arrow to move thetool pocket. Make sure the pockedmoves smoothy into and out of the toolchange position.


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Pocket Air Cylinder

Corrective Action:

1. Power off the machine and disconnectthe air supply.

2. Find the tool pocket cylinder.3. If equipped, remove the pilot-operated

check valve [1] and the hose to thebottom of the cylinder. For machinesthat do not have a pilot-operated checkvalve, disconnect the top and bottomhoses on the air cylinder.

4. Move the cylinder [2] up and down.5. Make sure that the piston moves freely.

Spray a small quantity of siliconlubricant into the cylinder to lubricatethe piston seal.

6. If the piston does not move freely, thetool pocket air cylinder is damaged.

7. Make sure the air supply to the machineis clean and dry.


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Pocket Up / Down Proximity Sensors


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Corrective Action:

Make sure the pocket up and pocket downproximity sensors [1] are clean. Contaminationon the switches may cause the carousel to rotateand break a pocket before it is in the fully upposition.

The DIAGNOSTICS page shows the state of thesensors. If the POCKET DOWN or POCKET UP(CHC), or the SMTC_TOOL_POCKET_UP orSMTC_TOOL_POCKET_DOWN (NGC), bits do notchange state, the sensors may have chips orcontamination on them.

Make sure that the tool pocket is up. Press[PARAMETER/DIAGNOSTIC] and go to the I/O tab.

Touch the end of the proximity sensor with ascrewdriver [1]. This test can cause Alarm 626.Ignore the alarm. The proximity sensor operatescorrectly if the PocketDown (CHC), SMTC_Pocket_Down (NGC), valuechanges from a 1 to a 0. Continuetroubleshooting if the diagnostic value does notchange.

To troubleshoot the pocket up sensor, make surethat the tool pocket is down. Touch the end of theproximity sensor with a screwdriver and monitorPocket Up (CHC), SMTC_Pocket_Up (NGC). Thevalue must change from a 1 to a 0.


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Pocket SolenoidCorrective Action:

Be sure to troubleshoot the solenoid correctly. Refer to SOLENOID - TROUBLESHOOTING GUIDE to troubleshoot thesystem. Refer to "4 Port Solenoid Applications."

Tool Contamination

Do these steps on CHC machines only: Findwhere the 820 cable connects to the I/O PCB atP3. Use an electrical jumper (P/N 33-8521) at P3[1]. If the Pocket Down value changes from a 1 toa 0, the I/O PCB operates correctly. Replace theSMTC cable assembly. Refer to PROXIMITYSENSOR HOW IT WORKS ANDTROUBLESHOOTING - VIDEO. Use the PROXIMITYSENSOR - TROUBLESHOOTING GUIDE totroubleshoot the proximity sensors.

To troubleshoot the pocket up sensor,reconfigure the jumper at P3 as shown [2].Monitor the Pocket Up value. If the value changesfrom a 1 to a 0, the I/O PCB operates correctly.Replace the SMTC cable assembly.

If the Pocket Down or Pocket Up value does notchange to a 0 when tested, refer to:

• NEXT GENERATION CONTROL - I/O PCB- TROUBLESHOOTING GUIDE

• I/O PCB - TROUBLESHOOTING GUIDE(CLASSIC HAAS CONTROL)

Corrective Action:

Make sure the tool is not contaminated by debris.Look for and remove any "nests" of chips in themechanism.

Refer to TOTD EPISODE 33 - STRINGY CHIPSWRAPPED AROUND YOUR TOOLS? CHIP CLEARSOLUTION to troubleshoot the system.


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Pocket Shock Absorber

Tool Holders and Pull Studs

Symptom: The tool pocket is noisy.

Possible Cause: There is a problem with the tool-pocket stop shock-absorber.

Corrective Action:

1. Make sure that the tool pocket is in theup position [1].

2. Push the shock-absorber in with yourthumb [3].

3. Release the shock-absorber [2].

For CALM machines, replace the shock-absorberwith the correct orifice (P/N: 58-0093) [4] betweenthe solenoid and the muffler if:

• There is no resistance when you pushthe shock-absorber.

• The shock-absorber does not extendafter you push it.

Note: For all other machines, replace theshock-absorber with a new shock-absorber.

Symptom: The tool falls from the tool pocket. Thetool cannot be removed from the pocket.

Possible Cause: The toolholder or pull studs areincorrect.

Corrective Action:

If the tool cannot be removed, remove the garterspring [3]. Wiggle the tool to loosen the plungers[1]. Be careful not to lose any plungers. Removethe tool. Replace spring.

Refer to the TOOLHOLDER AND PULL STUDINFORMATION document for the correcttoolholder and pull stud [2] information.


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Pocket Spring and Plungers

Pocket Slow Down Kit

Corrective Action:

1. Make sure that the (4) plungers [1] areintact in each of the pockets.

2. Inspect the plungers for wear. Replacethe them if they are worn.

3. Make sure that the hook on the springis not on top of any of the plungers.

4. Clean all of the debris from the toolpockets and lubricate the plungers [1]with grease. Apply grease to the toolpull stud.

Refer to REPLACE A TOOL POCKET ON YOURHAAS SIDE MOUNT TOOL CHANGER (SMTC) -VIDEO for more information on how to removethe pocket.

Some pockets use leaf springs. Look for brokenleaf springs. They are stacked (2) per corner.Replace any broken leaf springs.

Corrective Action:

Install the Pocket Slow Down Service Kit (P/N93-0254). This kit restricts the air escaping fromthe pocket up/down cylinder to slow down thepocket.

Refer to the TOOLHOLDER AND PULL STUDINFORMATION document.


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Side Mount Tool Changer (SMTC) - Carousel and Pocket ... · The cam followers on the carousel need grease. The cam followers on the carousel are worn. Check and grease the cam followers