VMCsi - Replace Carousel Disc

Remove the 11 hex socket screws securing the outer sheet metal cover.

Carefully lift and remove the cover.

Unscrew the seven hex socket screws securing the gearbox cover.

Carefully lift and remove the sheet metal cover with the viewing window.

Unscrew the four hex socket screws securing the carousel cover.

Remove the cover and set it aside, noting its orientation if the ATC is not marked with position 1 beneath it.

Remove the pods from the bottom of the carousel. Each pod is secured by one screw.

Unscrew the 6mm socket head cap screw on the pot.

Push the pods back toward the center of the ATC and swing them downward.

Pull each pod forward to remove it, noting the orientation of the threaded holes in the pins for reassembly.

Once all pods are removed, unscrew the center screw on the black metal plate holding the carousel in place.

The four outer screws on the center plate are set screws and do not secure the carousel itself.

Slide the carousel disc off carefully; it is lightweight but delicate.

Use a 17mm wrench and 4mm Allen key to loosen and remove the roller bearings, washers, and nuts from the old carousel disc.

Inspect bearings for wear and replace if necessary.

Install the roller bearings, washers, and nuts onto the new disc, ensuring the correct orientation.

Tighten the nuts to approximately 35 lb-ft of torque.

Reapply grease to the bearings.

Slide the replacement carousel plate onto the machine, ensuring the segmentation cam and bearings are properly aligned.

Secure the carousel plate with the center screw. This screw holds the carousel disc in place.

Tighten the four outer set screws to ensure the carousel plate is stable. These screws are used for fine adjustments and should not be over-tightened

Verify that the proximity sensor detecting the carousel position is correctly positioned to trigger properly. Look at next step for more details.

The Home Position Sensor is mounted at a fixed position on the base and triggers when aligned with the steel target on the back of the carousel.

Illustration shows a close up of the Home Position Sensor at the home position on the carousel.

Photo shows switch location with the carousel removed. The Home Position Sensor Is mounted on the base at about the 2:00 position.

Air gap should be .080 - .090" or 2 - 2.25 mm.

Slide each pod onto its bracket, ensuring the spacer and bracket align correctly.

Swing the pods upward and pull them forward until they are flush with neighboring pods and touching the carousel interior.

Adjust the threads on the pins using a small screwdriver if needed for easier reinstallation.

Secure each pod with its 6mm socket head cap screw and apply a small amount of blue Loctite (242) to the threads.

Replace the carousel cover, ensuring it matches the original orientation.

Reinstall the gearbox cover and secure it with its seven hex socket screws.

Reinstall the ATC outer cover and secure it with the 11 hex socket screws.

Rehome the ATC system.

Perform manual tests of carousel rotation and tool changes to verify smooth operation.

Conduct a full CNC-controlled tool change sequence to ensure the system is functioning correctly.