SECTION SEVEN

TOOL CHANGER

TABLE OF CONTENTS
TITLE PAGE
INTRODUCTION........................................................................................................................................... 1

HYDRAULIC OPERATIONS ........................................................................................................................ 4

HYDRAULIC CONTROL ELEMENTS ......................................................................................................... 6

TOOL CHANGER ACTION FLOW ILLUSTRATION ................................................................................... 7

MANUAL TOOL LOAD/UNLOAD................................................................................................................ 8

LIFTING THE TOOL CHANGER.................................................................................................................. 8

MECHANICAL INSTALLATION AND SETUP............................................................................................. 9

INSTALLATION............................................................................................................................... 9
TOOL CHANGER SETUP .............................................................................................................10
INTRODUCTION
Automatic tool changers (ATC) provide a means of storing and retrieving tools used in part machining
programs. An ATC consists of three basic components: the tool magazine, the tool changing mechanism
and the tool arm (Figure 7-1). The tool changing mechanism retrieves a pre-selected tool from the
magazine and moves to the spindle transfer position. The tool arm extracts the tool from the machine
spindle and then rotates to exchange this tool with the tool that had been pre-selected from the magazine.
The tool changing mechanism proceeds to the magazine transfer position, returning the tool to its proper
storage location and in position to retrieve the next required tool.
The standard tool magazine for the 480 series machines has 60 tool pots (storage locations). Optional
tool changers can have 90 or 120 tool pots. There are limits to the weight, length and diameter of the
tools as listed in the specification below. The tool changers used on HBM 480-series machines are
purchased from Gifu Enterprise Co., LTD. The unit is purchased complete, except for the tool magazine
drive motor and related parts (Figure 7-2), the tool changing mechanism rail support bracket which
mounts on the machine column (Figure 7-1), the tool changer base, the profibus block assembly (Figure
7-2), and the guarding.
Tool changer specifications are as follows (standard tool changer shaded):

GIFU Model No. CT5060H6 IS5060H6 CT5090H6 IS5090H6 C50120H6

Quantity of Tools 60 60 90 90 120
ISO-50 ISO-50
Spindle Taper CAT-50 CAT-50 CAT-50
(SK50) (SK50)
ANSI B5.50 ANSI B5.50 ANSI B5.50
Type of Tool DIN 69871-1 DIN 69871-1
CAT-50 CAT-50 CAT-50
Type of Pull Stud ANSI B5.50 DIN 69872-A ANSI B5.50 DIN 69872-A ANSI B5.50
Drive Ratio Tool Magazine 1/100 1/96
Power Supply of Magazine Electric (Servo)
Power Supply of ATC Hydraulic
Magazine Index Time 0.4 Sec./Pot
Tool Change Time 15 Sec.
Max. Tool Weight 50 kg (110 lbs.)
Max. Tool Length 750 mm (29.5”)
Max. Tool Moment 110 Nm (1120 kg-cm) (81 lb-ft)
Max. Tool Diameter.
130 mm (5.1”)
(All Pockets Full)
Max. Tool Diameter.
280 mm (11”)
(Alternate Pockets Empty)

7-1
 Tool Changing Mechanism

Tool Changer - 60 Tool

(From GIFU Catalog)

Tool Magazine Tool Arm

Machine Column

Tool Changing Mechanism

Transfer Chain

Tool Changer Rail Bracket

Transfer Chain Shown in Position for Shipment

Tool Arm at Magazine

Figure 7-1
Tool Changer, Magazine Base
& Rail Mounting Bracket
(60 Tool Pot Changer Shown)

7-2
 Front of Tool Magazine
(Shown without Motor Cover)
Electric Servo Motor Drive Sprocket
(See Cross Section Below)

Tool Pot Chain Drive Shaft Sprocket

(Shown without Cover)

Bushing
Belt Sprocket
Motor Mount Plate

Profibus Block
Assembly
Belt
Tensioner Rear of (60) Tool Magazine
Electric Servo Motor

Figure 7-2
Tool Magazine Drive Components
(For Rotation of Tool Pots CW/CCW and Tool Pot Positioning

Tool Pot Chain

Tension Adjustment

Test Tool
Figure 7-3
(Made to max. weight ,
length, diameter, & tool Front of (60 pot) Tool Magazine
moment ) (With Covers Removed)

7-3
HYDRAULIC OPERATIONS
Hydraulic pressure from the secondary circuit of the machine’s main hydraulic unit supplies the tool
changer. The normal hydraulic pressure is 70 bar (1000psi) or 76 bar (1100 psi) during a spindle tool
unclamp. Hydraulic pressure is used to operate a hydraulic motor that provides the tool changing
mechanism’s movement from the tool magazine load/unload position to the spindle load/unload position.
(This is referred to as parallel shifting mechanism of the tool changing mechanism, in the vendor
documentation). There are two speeds used during the tool changing mechanism’s movement to/from
spindle and tool magazine.
The tool changing mechanism uses a hydraulic cylinder to provide the in/out movement for
removing/inserting a tool in the spindle or tool pot of magazine. A hydraulic cylinder is used to provide
the 180° rotation of the tool arm for exchange of tools at the spindle.
For 90 & 120 tool pot magazines only, a hydraulic cylinder (Figure 7-4) is used to actuate a “chain
positioning” device. This device holds the chain and accurately locates the required tool pot, during either
a manual or automatic tool exchange. The solenoid actuates during the clamp cycle, releasing to the
normally unclamped position.

Cylinder Clamped Cylinder Unclamped

Figure 7-4
Tool Magazine Positioning Cylinder & Mechanism
(For 90 &120 Tool Pot Changers)
Shown with Cover Removed

Two cylinders are used during the manual tool unload operation. One cylinder releases the tool (held by
the retention knob) from the tool pot. The second cylinder pushes the tool out of the tool pot (releasing
the tool from the taper). A pad mounted to the release cylinder makes contact with the shot pin
mechanism on the rear of the tool pot. Figure 7-6 shows a cross section of the tool pot and a view of the
rear of the tool pot.
The tool magazine uses a hydraulic cylinder (Figure 7-5) to release the tool from the tool pot during the
automatic tool change cycle. The tool eject cylinder is not required during automatic cycle, rather the tool
arm is used to pull the tool from the tool pot.

7-4
 Tool Arm in Extended Position

Auto Tool Release

Cylinder

Tool Arm Manual Tool

CW/CCW Unload Cylinder
Rotation Cylinder
Tool Arm In/Out Manual Tool
Piston Rod Release Cylinder

Figure 7-5
Hydraulic Cylinder Locations

Cross Section of Tool Pot

Manual Release
Tool Pad

Manual Eject
Tool Pin
Rear of
Tool Pot

Figure 7-6
Manual Load/Unload and Tool Pot Cross Section

7-5
HYDRAULIC CONTROL ELEMENTS
The control elements for hydraulic piping are shown in figure 7-7.
Figure 7-5 Control Element
Position
1 Single Head Solenoid
2 Single Head Solenoid
3 Single Head Solenoid
Only used with 90 & 120 Tool Magazines Engage cylinder to position & Positioning & Backwarding
4 Single Head Solenoid DP-Y15
5 Right Twin Head Solenoid
and Throttling Valve
5 Left
6 Right Twin Head Solenoid
and Throttling Valve
6 Left
7 Right Twin Head Solenoid
7 Left
8 Twin Head Solenoid
and Throttling Valve
Electrical Function GIFU Description
Label
DP-Y12 Eject tool from tool pot after Tool Unloading
release. Manual operation
DP-Y13 Manual release tool from tool Tool Unloading Release
pot or allow tool to be loaded
DP-Y14 Auto release tool from tool pot Tool Changing Release
hold tool magazine chain
during tool change.
DP-Y7 Tool arm extend and adjust Tool Pulling & Forwarding
speed arm extends
DP-Y8 Tool arm retract and adjust Tool Pulling & Backwarding
speed arm retracts
DP-Y9 Tool arm rotate 180° CW and Tool Changing &
adjust rotation speed Backwarding (Turn Right)
DP-Y10 Tool arm rotate 180° CCW Tool Changing & Forwarding
and adjust rotation speed (Turn Left)
DP-Y4 Tool changing mechanism Tool Magazine in Parallel
slow movement at tool Shifting
magazine
DP-Y5 Tool changing mechanism Spindle in Parallel Shifting
slow movement at spindle
DP-Y6 Tool changing mechanism Parallel Shifting at High
fast movement and adjust Speed
slow speed (right) and adjust
fast speed (left)

For 90 or 120 Tool Magazine For 60 Tool Magazine

8 8
7
7
6 6
5
5
Hydraulic Pressure 3
4
from Main 2
3 Hydraulic Unit 1
2
1 Hydraulic Return to
Main Hydraulic Unit

Figure 7-7
Hydraulic Piping Control Elements
(Mounted on Rear of Tool Magazine)

7-6
TOOL CHANGER ACTION FLOW ILLUSTRATION

Means Fast Travel Means Slow Travel

Figure 7-8
Action Flow Illustration
(From GIFU Documentation)

7-7
MANUAL TOOL LOAD/UNLOAD
A manual tool load/unload station is provided at the far end of the tool magazine. There is an operator
control panel with an emergency stop, tool magazine chain jog clockwise and counter clockwise
pushbuttons, and manual/automatic tool change mode lighted pushbutton. (Button is illuminated during
automatic mode). In order to manual jog the tool pot chain, the tool magazine guard door must be closed
and the manual/auto button pushed to manual mode (light off).
The “unload” foot pedal switch is used to release the tool from the tool pot. This pedal actuates a
hydraulic cylinder with a pad connected to the cylinder. The pad contacts and drives a spring loaded rod,
setting the tool holder retention knob free (see tool pot cross section figure 7-6). After a short delay a
second hydraulic cylinder makes contact with the retention knob, pushing the tool out of the tool pot. The
“load” foot pedal switch only actuates the cylinder to release the balls and accept the tool retention knob.
The foot pedals only work with the tool magazine guard door open. The cables from the foot pedals
connect directly into the profibus (Figure 7-2) on rear of tool magazine. See Figure 7-9 for manual
controls.

Tool Magazine Chain Tool Magazine Chain

CW CCW

Manual/Auto Tool
Changer Mode
(Illuminated during Auto
Mode)
Emergency
Stop

Manual Tool Load/Unload Station Unload Load

(Shown without tool magazine guarding) Tool Tool

Figure 7-9
Manual Tool Load/Unload Controls

LIFTING THE TOOL CHANGER

The tool changer should be empty of all tools before lifting. The weight of an empty 60 pot tool changer
with base is 3200 kg (7040 lbs.). The weight of an empty 90 pot tool changer with base is 4300 kg (9460
lbs.). The weight of an empty 120 pot tool changer with base is 5300 kg (11660 lbs.). Make certain the
crane, lifting chains and other lifting hardware are rated to handle the weight.
When lifting the tool changer it should be level. Use a carpenter’s level to check for a level condition.

7-8
MECHANICAL INSTALLATION AND SETUP
The tool changer has been completely assembled, mounted to the machine and tested at the factory. It is
disassembled and shipped in a number of pieces. The tool magazine base is normally shipped separated
from the tool magazine. The tool magazine, tool changing mechanism with tool arm and one section of
the transfer rail is shipped as a unit. The remaining two sections of the transfer rail, the tool changing
mechanism rail support bracket, and the tool magazine guarding are shipped separately. For 90 & 120
tool changers there is a bracket that supports the tool magazine to the column (Figure 7-10), which is also
shipped separately.

Bracket

Jack Screw

Rear of Tool
Rear of Column Magazine Base Tool Changer Magazine

Figure 7-10 Figure 7-11

Magazine Support Bracket Jack Screws on Bottom of Tool Magazine
(90 & 120 Tool Only)

INSTALLATION
Begin the installation by attaching the rail support bracket to the column and attach the two sections of
transfer rail to the bracket. For 90 & 120 tool changers, assemble the tool magazine bracket to the
column, the six bolts should be finger tight at this time. Assuming that the proper lifting equipment is
available, the tool magazine with tool changing mechanism should to be mounted onto the base. To
make the alignment process easier, make sure the jack screws (Figure 7-11) are below the bottom of tool
magazine by approximately 25 mm (1”) before putting tool magazine on base. Move the base and tool
changer as a unit, mounting the base per the Line and Foundation Drawing.

Tool Changing
Rail Section Splice
Mechanism
Transfer Chain

Locating Pin and Bracket

for Rail Section Splice

Tool Changer on Base with Figure 7-12

Guarding Removed Aligning Tool Changer to Column Attached Rail
(60 tool pot shown)

7-9
Using jack screws (Figure 7-11), adjust the position of the tool magazine on the base so that the transfer
rail on the tool changer aligns with the transfer rail section mounted to the column. The locating pin
shown in figure 7-13 should be removed before connecting the rail sections and reinserted after the splice
has been made.
For 90 & 120 tool changers, assemble support bracket (Figure 7-10) to rear of tool magazine with six
bolts. Bolts should only be finger tight at this time. The column must be aligned before these bolts and
those holding the bracket to the column are permanently fastened.
Once the transfer rail sections
are spliced together, extend and
fasten the tool changing
mechanism transfer chain
(Figure 7-13). There are eight
cap screws which hold the chain
to the rail. On the opposite end,
near tool magazine is the chain
adjusting block (Figure 7-13).
Connect all electrical wires and Transfer Chain
hydraulic hoses from the utility Adjusting Block Spindle
carriers to the manifolds or
junction boxes. This will vary Figure 7-13
with the type of equipment Tool Changing Mechanism Transfer Chain
shipped with the machine.
Always use the machine specific electrical and hydraulic schematics that were shipped with your machine
For 90 & 120 tool changers, after column alignments have been completed the tool magazine support
bracket should be permanently fastened. Apply “Loctite” to each of the bolts holding the bracket to the
column and back of tool magazine. Bolts should be threaded “finger tight”, so that column alignment is
not altered.

TOOL CHANGER SETUP

The following procedures have been completed at the factory and should not need to be repeated.
However, in the case of a repair or part replacement, the procedures may have to be initiated again. The
following steps are for informational purposes only. If the tool changer requires set-up, it should be
performed only by qualified personnel such as a Giddings and Lewis service representative.
1. Using the exchange arm setup page (see tool changer section in electrical manual) verify tool
exchange I/O and motion of the tool changing mechanism.
A. Exchange arm extend and retract
B. Exchange arm CW and CCW. (CW/CCW looking from behind tool arm towards table)
C. Exchange arm back/forth motion – motion to magazine or to spindle.
2. Using the exchange arm setup page (see tool changer section in electrical manual) verify limit
switch I/O locations by moving the exchange arm to proper locations. Figure 7-14 shows location
of limit switches and the associated rail mounted detecting bars.
A. Exchange arm at magazine stop
B. Exchange arm at magazine slowdown
C. Exchange arm at park position
D. Exchange arm at spindle slowdown
E. Exchange arm at spindle stop
F. Exchange arm in machine area

7-10
 Exchange arm at magazine stop

Exchange arm at park position

Exchange arm slowdown

Exchange arm in machine area

Limit Switches
Exchange arm at spindle stop

Limit Switch Detecting Bars

Figure 7-14
Tool Changing Mechanism Rail Position Limit Switches and Detecting Bars

3. Establish tool magazine zero location setting. Use the tool magazine setup page and exchange
arm setup page (see tool changer section in electrical manual). The tool arm and #1 tool pot must
be aligned. After alignment, the #1 tool pot will be set at 0.000 degree rotation.
A. Tool Magazine CW & CCW motion. The tool pot numbers should count up on setup page as
moved CW looking through the magazine towards the column. Move magazine so tool pot
#1 is in the automatic tool load/unload position.
B. Use the tool changer
alignment tools (Figure Retention Knob #50,A Ring Bushing
7-15) and the exchange (M.1006.6560) (M.1006.7104)
arm setup page to
lineup tool pot #1 with
arm. The taper bushing
is loaded into tool pot.
Ring bushing is loaded
into gripper of tool arm.
(The gripper operates
mechanically to push in Taper Bushing Guide Bar
plunger and release (M.1006.7105) (M.1006.7103)
clamp as the arm moves
to the tool.) Guide bar is Figure 7-15
inserted through ring Tool Changer Alignment Tools
bushing into taper (M.1007.0364)
bushing. When guide
bar can be rotated 360°, arm will be aligned with tool pot (Figure 7-18)
C. Adjustments to horizontal arm position are made by modifying the hard stop and making sure
the slowdown plunger is not fully compressed (Figure 7-16).

7-11
 D. Vertical adjustments are made to the tool pot location. Use the incremental mode to move
the tool pot into position. Moves are made in units of degrees.
E. When the tool pot is aligned with the arm, see electrical manual for “setting the chain encoder
offset”.

Spindle
Adjustment
Magazine
Adjustment

“Arm into Magazine” “Arm into Spindle” (90 &120

Adjustment Bolt & Slowdown Plunger Adjustment Bolt & Slowdown Plunger Tool Pot Changer)
(60 Tool Pot Changer) (60 Tool Pot Changer)

Figure 7-16
Adjustment Bolt & Slowdown Plunger Locations

4. The following miscellaneous functions should be verified:

A. Tool changer Emergency Stop is functional (Figure 7-9).
B. The Auto/Manual button (Figure 7-9) is illuminated during automatic mode.
C. The tool load and tool unload foot pedals are operational. Door must be open. Manual mode
button depressed. Controls must be off manual page. Unload releases tool and ejects.
D. Magazine door closed registers on tool magazine setup page.
E. Manual magazine movement CW & CCW using buttons (Figure 7-9). Door must be closed.
Manual mode button depressed. Controls must be off manual page.
F. The tool in pocket registers on tool magazine setup page.
5. Set speeds of transfer motion. Use Figure 7-17, which is a representation of the solenoid and flow
controllers mounted on back of tool magazine.
A. The transfer arm traverse speed between slowdowns (at spindle, park and magazine) is set
with flow controller labeled “Transfer Arm Speed (Fast)”. In the slowdown areas, speed is set
by flow controller labeled “Transfer Arm Speed (Slow)”. The flows are adjusted to meet a 15
second tool change.
B. For the exchange motion (arm rotation CW & CCW), flow controllers labeled “Adjust Speed
Arm CCW” and “Adjust Speed Arm CW” are opened fully CCW and then knob closed one full
turn CW. Adjust for balance if required.
C. For the arm extend/retract (removing or inserting a tool), flow controllers labeled “Adjust
Speed Arm Extend” and “Adjust Speed Arm Retract” are opened fully CCW and then knob
closed half (0.5) turn CW.

7-12
 Transfer Arm Arm High Speed Transfer Arm
Speed (Fast) (Solenoid) Speed (Slow)
DP-Y6

Arm Low Speed

(Solenoid)
DP-Y5 DP-Y4

Arm CW/CCW
Adjust Speed (Solenoid) Adjust Speed
Arm CCW DP-Y10 Arm CW
DP-Y9

Arm Extend/Retract
Adjust Speed (Solenoid) Adjust Speed
Arm Retract DP-Y8 DP-Y7 Arm Extend

Tool Magazine
NOT USED ON
Position & Clamp
60 TOOL POT
DP-Y15 CHANGERS
Auto Tool
Release
DP-Y14
Manual Tool
Release
DP-Y13
Manual Tool
Unload
DP-Y12

Figure 7-17
Solenoid and Flow Controller Information

6. Establish Y-axis tool change position. Use the exchange arm setup page (see tool changer section
in electrical manual). The tool arm and spindle must be aligned.
A. The spindle must be oriented at 0.0 degrees to properly align arm with spindle.
B. Use the tool changer alignment tools (Figure 7-15) and the exchange arm setup page to
lineup spindle with arm. The taper bushing is manually loaded into spindle. Ring bushing is
loaded into gripper of tool arm.
C. Adjustments to horizontal arm position are made by modifying the hard stop and making sure
the slowdown plunger is not fully compressed (Figure 7-16).
D. Jog Y-axis to align center of gripper arm. You must move arm towards tool magazine in
order to use Y-axis jog.
E. When guide bar, inserted into ring bushing and taper bushing, can be rotated 360° the arm is
aligned to spindle (Figure 7-18). Rotate arm 180° and repeat alignment. Equalize any
difference between the two grippers.
F. Record the final Y-axis position and edit per electrical manual instructions.

7-13
 Figure 7-18
Using Exchange Arm Alignment Tool

7. Establish Z-axis (spindle in/out) tool change position.

A. Remove alignment equipment and insert a dummy tool into spindle.
B. Engage the exchange arm into the V-Flange
of the dummy tool. The Z-axis must be
adjusted until no deflection is apparent in the
exchange arm.
C. See tool changer section in electrical manual
for complete procedure.

Gripper into V
of Tool

Figure 7-19
Tool Exchange Arm Gripper

7-14