Assemble the bleeding tool as shown.

Use teflon thread sealing tape if necessary.

Note: Be sure the arrows on the check valve are pointing towards 58-3050

• Home the B-Axis
• Press MDI, program "M11", press cycle start.
• Press the Emergency Stop button
• Open the lube panel on the tool-changer side of the machine
• Rotate the air shut off valve to cut off air the the machine
  • The wings of the valve should be perpendicular to the pipe

Purge excess air pressure from the machine by pulling and holding the ring on the purge valve until you no longer hear air escaping.

Note: The initial pull of the ring will make a popping sound. This is normal.

• Remove access plug
• To do so, drill a pilot hole then, screw in a wood screw to use as a handle to pull the plug out

Use a T-handle allen wrench to remove the threaded brake bleed plug.

Note: Be careful to not drop this plug into the casting.

• Screw in and tighten the bleed tool. 
• Ready a catch -can to catch any oil bled from the brake system.
• Attach a clear 1/4" OD hose to the bleed tool and run it to the catch-can.

• Turn air back on. The wings of the the valve should run parallel to the pipe.

• Release Emergency Stop and clear alarms.
• Open MDI, program "M10", press Cycle Start.
• The booster will pulse 3 to 5 times in an attempt to build pressure and in doing so will pump out brake fluid.
• You should recieve alarm 6.4011 Rotary Brake Engagement Failure.
• Clear the alarm and repeat until all air bubbles are bled from the system.

• If you did not recieve this alarm, and no oil left the bleed tool, check to see that the check-valve of the bleed tool is properly oriented.

• When finished, press emergency stop then turn air off again.

• Purge excess air pressure from the machine by pulling and holding the ring on the purge valve until you no longer hear air escaping.

• Remove the bleed tool then, quickly reinstall the threaded plug being careful to not drop the plug in the casting.

• Release Emergency Stop
• Turn air back on
• Jog the B-Axis, then X-axis, then B-Axis again to ensure the B-Axis brake reliably engages and disengages.
• Be sure to refill the B-Axis brake fluid resevoir to the appropriate level

• Install a new B-Axis bleed port access plug (20-5715)

• Jog the C-axis platter such that the access hole is in the 3 O'clock position. 

• Press MDI, program "M13", press cycle start.
• Press the Emergency Stop button
• Open the lube panel on the tool-changer side of the machine
• Rotate the air shut off valve to cut off air the the machine
  • The wings of the valve should be perpendicular to the pipe

Purge excess air pressure from the machine by pulling and holding the ring on the purge valve until you no longer hear air escaping.

Note: The initial pull of the ring will make a popping sound. This is normal.

• Remove access plug
• To do so, drill a pilot hole then, screw in a wood screw to use as a handle to pull the plug out

Use a T-handle allen wrench to remove the threaded brake bleed plug.

Note: Be careful to not drop this plug into the casting.

• Screw in and tighten the bleed tool. 
• Ready a catch -can to catch any oil bled from the brake system.
• Attach a clear 1/4" OD hose to the bleed tool and run it to the catch-can.

• Turn air back on. The wings of the the valve should run parallel to the pipe.

• Release Emergency Stop and clear alarms.
• Open MDI, program "M12", press Cycle Start.
• The booster will pulse 3 to 4 times in an attempt to build pressure and in doing so will pump out brake fluid.
• You should recieve alarm 7.4011 Rotary Brake Engagement Failure.
• Clear the alarm and repeat until all air bubbles are bled from the system.

• If you do not recieve this alarm, and no oil leaves the bleed tool, check to see that the check-valve of the bleed tool is properly oriented.

• When finished, press emergency stop then turn air off again.

• Purge excess air pressure from the machine by pulling and holding the ring on the purge valve until you no longer hear air escaping.

• Remove the bleed tool then, quickly reinstall the threaded plug being careful to not drop the plug in the casting.

• Release Emergency Stop
• Turn air back on
• Jog the C-Axis, then X-axis, then C-Axis again to ensure the C-Axis break reliably engages and disengages.
• Be sure to refill the B-Axis brake fluid resevoir to the appropriate level

• Install a new C-Axis bleed port access plug (22-9087)

• STOP: Only certified service personnel should perform this procedure. Reorientation of Z-pulse or Trip-Flag will require laser calibration to populate rotary compensation tables with new, correct, values.

• First, home the B and C-Axis. The platter should be flat in the XY plane and the T-Slots running parallel to the X-Axis.    

• Now, rotate the B-Axis +90° and remove the C-Axis bottom cover.

• Note the Z-pulse orientation of the encoder ring in relation to the trip flag.

• Then, uninstall the encoder hub by removing the 4 screws mounting the encoder hub to the taper-lock. 

• Next, mount and loosely install the new single-piece encoder ring assembly so that the Z-Pulse is in the orientation you noted in Step 3.

•  Do not torque mounting screws yet.

• Check and document the runout on the OD of the scale encoder ring hub using the upper-most diameter, as shown.

• Adjust as necessary. TIR must be 0.0005" or less.

• Torque the 4 bolts of the encoder hub to 30 in-lbf.

• Loosen the 2 bolts mounting the encoder read-head and slide it away from the encoder ring.

•  Then, use an indicator to find the high spot on the OD of the encoder ring.  

• Mark this high spot with a marker.

• Then, rotate the C-Axis so the high spot is positioned as shown
  •  Note: Trip-flag and Z-Pulse position do not matter for this step.

• Set the gap between the scale ring and read head as shown [1]  using the apporpriate mylar shim (0.008"). Do not use a metal shim.

• Torque the two read head mounting bolts to 20 in-lbf.

• After torquing, double check the gap with the shim to verify the read head has not shifted.

• Reinstall the C-Axis bottom cover being sure no tools, shims, etc. have been left in the casting.

•  Note: You will have to set a new tool change offset and update compensation table values for the C-Axis. This will require laser calibration.

• Home the B and C-Axis.
• Press the Emergency Stop button.
• Open the lube panel on the tool-changer side of the machine.
• Rotate the ball valve shown to cut off air the the machine.
  • The wings of the valve should be perpendicular to the pipe.

Purge excess air pressure from the machine by pulling and holding the ring on the purge valve until you no longer hear air escaping.

Note: The initial pull of the ring will make a popping sound. This is normal.

• Remove the brake line from the the C-Axis booster

Important: Damage to brake ring will occur if air supply is not disconnected and purged from machine before beginning procedure.

• Install a Male 7/16"-20 O-Ring Boss fitting (dash number -04) into the booster where the brake line was removed.

• Open the lube panel on the tool-changer side of the machine.
• Rotate the ball valve shown to return air to the the machine.
  • The wings of the valve should be parallel to the pipe.

• Release Emergency Stop
• Clear alarms
• Rotate the B-Axis -90°
• Remove the brake line from the the C-Axis brake by removing the fitting shown. You will have to remove the casting cover plate to do so.

• Home the B and C-Axis.
• Remove the plastic bolt cover plugs to access the platter mounting bolts.
• To do so drill a pilot hole then, insert a wood screw or similar to use as a handle to remove each plug. These will need to be replaced at the end of this procedure.
• Once you have access to the mounting screws, remove them as well.

• The platter can now be safely lifted from the rotary assembly.
• To do so first install 2 T-nuts and 2 eyebolts in the configuration shown.
• Next, use a lifting strap and crane/fork-lift to slowly lift the platter straight up and off of the rotary assembly.
• Be mindful of any shims where the platter mates to the gearbox. Be mindful to keep these shims in the same position you found them. This will save you time during the platter alignment process when reinstalling this platter.

• If removing a No-Slot or Pallet-Pool platter, you will need to use tool 15-6462.
• Next, use a lifting strap and crane/fork-lift to slowly lift the platter straight up and off of the rotary assembly.
• Be mindful of any shims where the platter mates to the gearbox. Be mindful to keep these shims in the same position you found them. This will save you time during the alignment process when reinstalling this platter.

• Remove the brake ring assembly by removing the 10 bolts shown.

• Throroughly clean all mating surfaces and inspect new brake ring assembly for damage
• Loosely Install the new brake ring assembly in the orientation shown using the 10 bolts removed previously.
• Do not torque.

• Indicate the outer diameter of the brake assembly within 0.001" TIR by jogging the C-Axis with the indicator tip on the outer diameter of the brake ring assembly as shown.
• Once indicated, TORQUE MOUNTING BOLTS TO SPEC. and home the C-Axis.
• Rotate the B-Axis -90° to reinstall the C-Axis hydraulic brake line.
• Reinstall the casting cover
• Home the B-Axis

•  Apply 5% MOLY MOBIL GREASE (99-1792) to the brake friction surface that will be in contact with the platter. 
• Be sure that the amount of MOLY MOBIL GREASE applied is not excessive and is uniform in application around the entire diameter

• After applying grease to the brake, thoroughly clean all mating sufaces of the platter and follow the UMC PLATTER REPLACEMENT PROCEDURE to properly install the platter. Failure to follow this procedure will result in platter misalignment.
• Read through the entire platter replacement procedure before attempting. This will include bleeding the C-Axis brake.

Home the B and C-Axis.

Press [MDI], program "M13", press cycle start.

Press the Emergency Stop button.

Open the lube panel on the tool-changer side of the machine. The wings of the valve should be parallel to the pipe. Rotate the ball valve shown to cut off air the the machine.

Purge excess air pressure from the machine by pulling and holding the ring on the purge valve until you no longer hear air escaping.

 Note: The initial pull of the ring will make a popping sound. This is normal

 Note: If you followed a link from the UMC C-AXIS BRAKE REPLACEMENT procedure to reach this page, complete this step then, skip to the Platter Installation section below.

Remove the brake line from the the C-Axis booster.

Install a Male 7/16"-20 O-Ring Boss fitting (dash number -04) into the booster where the brake line was removed. 

Remove the plastic bolt cover plugs to access the platter mounting bolts.

To do so drill a pilot hole then, insert a wood screw or similar to use as a handle to remove the plug. These will need to be replaced at the end of this procedure.

Next, remove the platter mounting bolts.

The platter can now be safely lifted from the rotary assembly. To do so first install 2 T-nuts and 2 eyebolts in the configuration shown. Next, use a lifting strap and crane/fork-lift to slowly lift the platter straight up and off of the rotary assembly. 

If removing a No-Slot or Pallet-Pool platter, you will need to use two (2) eyebolts as shown. Next, use a lifting strap and crane/fork-lift to slowly lift the platter straight up and off of the rotary assembly.

If installing a UMC 500 platter, be sure the gearbox mounting hole pattern is oriented as shown. The holes highlited in blue show the bolt pattern position required to mount the platter. 

Note: The single hole highlited in red needs to be pointing to the 9 O'clock position.

If the gear box is not in the orientation shown, you will need to jog the C-Axis to the correct position. To jog the C-Axis you will need to return air to the machine, release Emergency Stop, and clear alarms.

Warning: Before jogging the C-Axis verify the C-Axis booster is still plugged (see step 3 of the Removal Process above)

If installing a UMC-750, 1000 or 1250 platter, be sure the gearbox mounting hole pattern is oriented as shown. 4The holes highlited in blue show the bolt pattern position required to mount the platter.  

Note: The single hole highlited in red needs to be pointing to the 12 O'clock position. To jog the C-Axis you will need to return air to the machine, release Emergency Stop, and clear alarms.

If the gear box is not in the orientation shown, you will need to jog the C-Axis to the correct position.

Warning: Before jogging the C-Axis you will need to verify the C-Axis booster is still plugged (see step 3 of the Removal Process above)

If installing a Pallet Pool platter, be sure the gearbox mounting hole pattern is oriented as shown. The holes highlited in blue show the bolt pattern position required to mount the platter.  

Note: The single hole highlited in red needs to be pointing to the 9 O'clock position. To jog the C-Axis you will need to return air to the machine, release Emergency Stop, and clear alarms.

If the gear box is not in the orientation shown, you will need to jog the C-Axis to the correct position.

Warning: Before jogging the C-Axis you will need to verify the C-Axis booster is still plugged (see step 3 of the Removal Process above)

Next lower the platter onto the rotary assembly using one of the lifting configurations shown in Steps 5 & 6 of the Platter Removal section (above).

If installing a UMC-500 platter, place the platter onto the rotary assembly in the orientation shown on the left [1].

If installing a UMC-750/1000/1250 platter, place the platter onto the rotary assembly in the orientation shown in the middle [2].

If installing a UMC Pallet Pool platter, place the platter onto the rotary assembly in the orientation shown on the right [3].

Lightly install the platter mounting bolts. Do not torque in place. The platter position will need to be adjusted in the following steps.

If you did not need to jog the C-Axis in steps 1-3, ignore this step. Go to next step.

Press [MDI], program "M13", press cycle start.

Press the Emergency Stop button.

Open the lube panel on the tool-changer side of the machine. The wings of the valve should be parallel to the pipe. Rotate the ball valve shown to cut off air the the machine.

Purge excess air pressure from the machine by pulling and holding the ring on the purge valve until you no longer hear air escaping.

 Note: The initial pull of the ring will make a popping sound. This is normal

Remove the male ORB fitting from the booster.

Reinstall the brake line to the the C-Axis booster.

Open the lube panel on the tool-changer side of the machine.

Rotate the ball valve shown to return air to the the machine.

You will now need complete the C-Axis Bleeding portion of the UMC ROTARY BRAKE BLEEDING PROCEDURE before continuing to the next section.

Warning:  Do not perform any steps in this section without reading all steps in all previous sections.

Jog the platter while indicating off of the center bore ID. Runout must be 0.001" or less.  Adjust as needed. 

TORQUE THE PLATTER MOUNTING BOLTS TO SPEC then, verify runout.

SET C - AXIS TOOL CHANGE OFFSET AND MAKE PLATTER PARALLEL TO X

Check the Table Parallel to X-Axis by running an indicator on  the T-Slot. Adjust C axis to set Table parallel to X. (NTE 0.0005/10"; NTE 0.0010" overall).

In Service mode :  Go to the Parameters > Factory Settings page.

Type in .078 press [F1]

Enter the axis letter and press [F2] to set the tool change offset.

Press [OFFSET] and go to the Work offsets page

Set the X and Y-axis values for G54 based on the center bore of your platter. This can be done using either a dial indicator on the spindle or using your WIPS.

Set the Z, B, and C-axis to zero.

Put the shell mill listed above into Tool 1 in the machine. Set the tool length geometry offset for the shell mill using a tool setter or by using your WIPS.

Refer to Tool Offsets and Manual Tool Setters - Haas Tip of the Day 

Using a 1-2" micrometer, measure the distance from the top of the platter to the bottom counter bore. The goal is to machine the platter to a height of 1.3250" ± .0010" [1]

For work-holding platters, use a depth micrometer to measure the distance from the top of the platter to the union. The goal is to machine the platter to a height of 0.7000 ± .0010" [2]

Press [SETTING] and search “245"

Turn Setting 245: Hazardous Vibration Safety to OFF.

Load the program into the control from your USB. Make sure to upload the code for the correct machine.

Note:Run the program in graphics mode to make sure no alarms or errors occur.

Once all the above has been checked, run the program using 5% rapid on the first run through and 0.0000" in the Tool Length Wear register on the tool offsets page.

Once proofed through once with no issues, the rapid speed can be brought up to your comfort level.

Use the Tool Length Wear register to adjust the depth at which the machine will cut. Each pass should be in -0.003” or smaller increments. Rerun the program once you have updated the wear register.

Note: We recommend using some paint-pen or some dykem on the platter to confirm the tool is cutting the entire platter and not missing any spots.  

Note: The machine may not cut on the first run through.

Repeat until you measure the platter to be within the 1.3250” +/- 0.0010” for standard platters or 0.7000” +/- 0.0010” for work-holding platters.

Measure the platter face runout.

Note: C-Axis brake is off for this step.

Place precision guage block at the edge of the platter in the 12 o'clock position. Zero the indicator tip on the gauge block in this position. Rotate the C-axis  90° but, keep the guage block at the 12 o'clock position. Take a measurement from the top of the gauge block

Repeat this 2 more times for a total of 4 positions, 90° apart, at the edge of the platter as shown. 

The total indicated runout. (NTE 0.001") 

Parallelism of Platter Surface to XY plane

Zero-Return the C-axis so the T-slots run parallel to the X-axis

Place indicator tip on the platter and jog in the X-axis along the platter to find the X-axis platter parallelism (NTE 0.001” / 10"; 0.0015" / 15")

Next jog in the Y-axis along the platter to find the Y-axis platter parallelism (NTE 0.001” / 10"; 0.0015" / 15")

This AD0233 procedure will show you how to replace the B and C - axis assembly on a UMC-750/SS. 

Before beginning, verify that the machine is level.

• Refer to UMC-750 Leveling

This procedure is used for replacement kits:

• 93-2216 UMC-750 4TH/5TH AXIS SERVICE ASSY
• 93-2329 UMC-750/SS 4TH/5TH AXIS SERVICE KIT
• 93-30-5993 UMC-750 4TH/5TH ROTARY SERVICE ASSY 

A forklift and lifting straps will be required to lift the kits.

Push [ZERO RETURN]. Push [ALL].

Jog the B Axis to get access to the bottom (2) center screws on the rotary shields 3 and 4.

Push [POWER OFF].

Set the main circuit breaker to the OFF position.

Lock the main circuit breaker. Use an approved lock with a safety tag.

Remove the tool probe and mounting arm [5].

Remove the rear panels of the enclosure.

Remove the rotary shields [1] thru [4] in the sequence shown.

Set the main circuit breaker to the ON position.

Push [POWER ON].

Push [ZERO RETURN]. Push [ALL].

Jog the B Axis to 90 degrees.

Push [EMERGENCY STOP].

Set Parameter 498:3, C Axis DISABLED, to 1.

Set Parameter 76, LOW AIR DELAY, to 9999999.

Push [POWER OFF].

Turn the main air valve to the OFF position.

Remove the bottom cover [1] for the C Axis .

Disconnect all of the C-Axis cables and air hoses [2].

Install the bottom cover for the C Axis.

Power on the machine.

Jog the B Axis to 0 degrees.

Jog the X Axis to the end of travel in the negative (-) direction.

Push [EMERGENCY STOP].

Set Parameter 151:3, B Axis Disabled, to 1.

Push [POWER OFF].

Set the main circuit breaker to the OFF position.

Lock the circuit breaker and use a safety tag.

Disconnect all of the B-Axis cables and air hoses .

If the machine has the (2) oil reservoirs [1] mounted on the bridge, temporarily put them onto the top of the trunnion (B Axis).

Remove the filler panel [2] and the front clean-out cover [3].

Remove the (4) trunnion support screws [4].

Remove the (2) shims [5] from under the support.

Cut a cable tie [1] in equal halves. Put the two cut ends into the circular channel on the C-Axis body support.

This lets the remaining air and grease out of the assembly.

Turn the trunnion support [4] to the right.

 Caution: To lift the trunnion support, get the aid of another person. The support weighs 85 lb (39 kg).

Remove these parts:

• trunnion support [4]
• retainer for the support bearings [3]
• support bearings [2]

Do not remove the oil seal.

Attach the lift fixture [5] for the B/C Axis to the C Axis.

Use the rear eye bolt to lift the fixture.

Continue lifting until the lift supports the weight of the B/C-Axis assembly.

Loosen the (2) set screws [1] on the left side of the plate that holds the B/C-Axis assembly.

Make sure the lift supports the B/C Axis [3].

Remove the (3) dowel pins.

Remove the (6) screws [2] from the plate that holds the trunnion (B-Axis).

Remove the B/C-Axis assembly from the machine

Put a 2" x 4" x 48" (51 mm x 103 mm x 122 cm) piece of wood [1] onto a pallet.

Put the B/C-Axis assembly onto the pallet.

Install the tooling bracket (P/N T-0057) [2] for the oil reservoirs onto the B/C-Axis assembly.

Attach the oil reservoirs to the tooling bracket.

Remove these parts:

• (6) plugs [1]
• (6) screws [2]
• the C-Axis body support [3]
• (8) set screws [4]

Install these parts onto the replacement B/C-Axis assembly:

• (8) set screws [3]
• the C-Axis body support [2]
• (6) screws [1]

Tighten the screws, but do not torque them yet.

Install the B/C-Axis assembly [1] into the machine.

Install the (6) screws [2] into the B-Axis mounting plate.

Install the (3) dowel pins.

Tighten the screws, leave snug but do not torque..

If the machine had the (2) oil reservoirs mounted on the bridge, install them.

If the machine had the (2) oil reservoirs attached to the enclosure, they must be mounted to the bridge.

Drill and tap (4) 1/4-20 holes at the location illustrated. Drill the holes 0.5" (13 mm) deep.

• A - 6.98" (17.7 cm)
• B - 1" (25.4 mm)
• C - 6.98" (17.7 cm)
• D - 0.75" (19 mm)
• E - 6.25" (15.9 cm)

Connect all of the B-Axis cables and hoses.

Set the main circuit breaker to the ON position.

Push [POWER ON].

Set Parameter 151:3, B Axis DISABLED, to 0.

Push [ZERO RETURN]. Push [ALL].

Installthe (4) trunnion support screws [1].

Install the (2) shims [2] from under the support. 

NOTE: Replace using the SHIMS provided in the kit. 

Jog the B Axis until you can get to the bottom cover [1] for the C Axis.

Push [POWER OFF].

Set the main circuit breaker to the OFF position.

Lock the main circuit breaker and use a safety tag.

Remove the C-Axis bottom cover [1].

Put the C-Axis cables and hoses into the B/C-Axis conduit.

Connect all of the C-Axis cables and hoses [2].

Do not install the bottom cover for the C Axis. It is installed at the end of the alignment procedure.

Set the main circuit breaker to the ON position.

Push [POWER ON].

Set Parameter 498:3, C Axis DISABLED, to 0.

Push ZERO RETURN. Push ALL.

1. Solenoid valve connector
2. Solenoid valve
3. Air tube
4. Pneumatic piston
5. Brake booster
6. Piston
7. Return springs
8. Hydraulic line
9. Hydraulic pressure switch
10. Hydraulic fluid reservoir
11. Switch for the reservoir fluid

Corrective Action:

If air gets into the brake system, the brake does not generate the correct pressure. You must bleed the brake system to remove the air. Use bleed tool T-0062A for EC1600, T-0062 for UMC.

Machines made before November, 2016 may need to reconfigure the reservoir feed hose. Refer to EC-1600, UMC-750 - Hydraulic Brake Booster - Replacement for more information.

Refer to:

• UMC series machine: UMC - B-Axis and C-Axis Rotary Brakes - Bleed Instructions
• EC-1600 machine: EC-1600 - Rotary Brake - Bleed Instructions

Inspect the B or C-axis ground cable that is attached to the encoder mount plate.  Make sure is fasten to the encoder mount plate.  Verify the other end of the cable is connected to chassis.

If the machine does not have a ground cable installed. Verify the encoder mount has [1] 8-32 UNC location for the ground screw. 

Install the following  :

33-8001  GND to SP Encoder 16FT (C axis)

33-6055 GND to SP Encoder 13FT (B axis)

If needed;

20-7278A - MNT NCE/HOME SW B AXIS UMC

20-7279A - MNT NCE/HOME SW C AXIS UMC

Note: Do not loosen the read head screws, doing this will require the machine to be lazer compensated. 

Corrective Action:

Tighten the lock nut with the spanner wrench until the marks lined up

Corrective Action:

The machine monitors a pressure switch to ensure the brake is holding pressure when activated. Do these steps to test the pressure switch.

• Zero return all axes. Push [EMERGENCY STOP].
• Disconnect the sensor cable from the B-Axis booster unit.
• Connect the leads from a digital multimeter to the sensor contacts [1].
• Release the [EMERGENCY STOP].
• Manually activate the solenoid to unclamp the brake.
• The multimeter shows OL (open) when the brake is clamped, and 0.1 to 0.4 Ohms when it is unclamped.
• If there is air in the brake system, the brake does not generate enough pressure to activate the switch. Properly bleed the brake before you replace the switch.

Corrective Action:

Use code M11 and M13 to clamp and unclamp the axis brake. Check for 120 VAC at the solenoid.

If the voltage is present refer to: Solenoid Troubleshooting Guide.

If the voltage is not present refer to:

• I/O PCB - NGC - Troubleshooting Guide
  

Corrective Action:

Use the brake bleed kit (Haas P/N T-0062A for EC-1600, T-0062 for UMC) to check the system pressure. If you cannot build pressure, 400-425 psi (27.6 - 29.3 bar), or, if the pressure drops, the booster may have damaged seals. If the oil level in the reservoir consistently drops, the brake is leaking internally. Refer to UMC-750 - B- and C-Axis Brake Booster - Replacement for more information.

Corrective Action:

Remove the air cylinder from the brake booster body.

Push the air cylinder piston shaft [1] into the retracted position. Remove the rear air fitting.

Use a small diameter rod (.375” (10 mm) or smaller) [2] to push the piston assembly to the extended position.

Use a stone to remove any burrs or high spots on the shaft.

Use your hand to move the shaft back and forth. It should move freely.

Sigma-5 servo motors, non-contact encoders output serial data signal to the control. If the serial data signal is missing or becomes unreliable the control will generate a serial data communication error. Electrical noise can cause the serial data signal from the encoder to become unreliable and cause false alarms. Follow the troubleshooting guide below to help eliminate the noise in the system.

1. Incorrect machine grounding. Make sure the ground wire size is correct. Also the ground wire should run all the way back to the electrical panel.
2. Noise from other equipment. Make sure the machine does not share it's electrical service with another machine.
3. Loose encoder data connectors at PCB or at the motor encoder, can cause the serial data to become unreliable. Refer to the Main Processor / Encoder Cable section.
4. Loose ground or high voltage power connectors will induce noise into the system.
   • electrical cabinet check for loose connection at all the ground and high voltage power terminals (vector drive, wye-delta contactors, transformer..etc).
   • pendant check for loose terminal connectors.
   • spindle head check for loose ground and motor power terminals.
5. The ferrite filters suppress high frequency noise produced by the amplifiers and vector drive, when servos are on. Make sure they are installed in:
   • Encoder data cables. Make sure there is a ferrite filter P/N 64 1252 installed in all the encoder data cables.
   • Axis motor power cables. Make sure there is a ferrite filter P/N 64-1252 installed in X, Y, Z axis motor power cables [1].
   • Spindle motor cables. Make sure there is a ferrite filter installed in the motor output of the vector drive.

     For a 40HP vector with 6 wire leads [1] use ferrite P/N 64-1254.

     For a 40HP vector with 3 wire leads [2] use ferrite P/N 64-1252.

     For a 20HP vector drive with 6 or 3 wire leads [3, 4] use ferrite P/N 64-1252.

6. Cable routing. Make sure that the encoder cable is separated from high power spindle/axis/pump cables.

Corrective Action:

Examine the connector [1] on the Maincon. Make sure it is not damaged.

Examine the cable. Look for signs of damage or stiffness. The connector [4] has two housings [2,3] for the cable pins.

If the pins have been pushed into the motor, you must replace the motor and cable together.

Make sure the cable is firmly connected at both ends. Reseat both connections. Make sure the cable is installed in the correct connector at the Maincon or MOCON PCB.

Disable the C-Axis by changing parameter 7.004 to 1.

Remove the bottom cover from the C-Axis. Then, unwire the C-Axis servo motor and the scale.

Remove the 4 bolts that attach the C-Axis body to the B-Axis platter. (See Image)

Remove these 4 bolts.

Install the T-2194A lifting aid.

Remove the A-Frame support bolts and shims. Then, remove the A-Frame support.

Use the eye bolt installed on T-2194A to hoist the C-Axis with a forklift or crane.

Remove the remaining bolts that attach the C-Axis body to the B-Axis platter. (See Image)

Remove the C-Axis assembly from the machine.

Now that the C-Axis is out of the way, check the runout of the B-Axis center bore. Record this reading.

Note: Record the value in Setting 254 5-Axis Rotary Center Distance. Depending on the indicator set up, Setting 254 may need to be set to Zero to prevent false readings.

• Home the B and C-Axis.
• Press the Emergency Stop button.
• Open the lube panel on the tool-changer side of the machine.
• Rotate the ball valve shown to cut off air the the machine.
  • The wings of the valve should be perpendicular to the pipe.

• Purge excess air pressure from the machine by pulling and holding the ring on the purge valve until you no longer hear air escaping.
• Note: The initial pull of the ring will make a popping sound. This is normal.

• Remove sheet metal panels at the back of the enclosure to access the B-Axis brake assembly. 
• Locate the hydraulic line [1] and B-Axis brake boosters [2]

• Remove the brake line from both B-axis boosters

Important: Damage to brake ring will occur if air supply is not disconnected and purged from machine before beginning procedure.

• Install a Male 7/16"-20 O-Ring Boss fitting (dash number -04) into the booster where the brake line was removed.

• Open the lube panel on the tool-changer side of the machine.
• Rotate the ball valve shown to return air to the the machine.
  • The wings of the valve should be parallel to the pipe.

• Remove the hydraulic line from the the B-Axis brake by removing the fitting shown. 

Make sure the brake booster is disconnected from the rotary before continuing. If the brake is pressurized with the platter removed, it will become damaged beyond recovery.

Remove the platter.

Inspect the brake surfaces.

Remove the 10 bolts shown. (See Image)

Then, remove and replace the B-Axis brake if needed.

Clean the new brake ring and brake ring mounting surface on the B axis body.

Feed the hose through the opening in the bottom of the casting. Do not connect the opposite end of the hose to the T fitting on the master cylinder at this tme.  Snug the 10 screws and back them out 1/4 turn.  

Using the T-0128 for UMC- 750/1000 or T-0129 for UMC-500, indicate the OD of the brake ring and adjust to NTE: 0.001” TIR. Torque the brake ring mounting bolts per Haas torque chart

Using the T-0128 for UMC- 750/1000 or T-0129 for UMC-500, indicate the OD of the brake ring and adjust to NTE: 0.001” TIR. Torque the brake ring mounting bolts per Haas torque chart

Coat the brake ring OD surface with the 5% MOBIL MOLY GREASE (99-1792)

Installing the B axis platter, leave the mounting bolts hand tight.

Connect all of the brake booster and hydraulic fittings and Refer to UMC-500/750/1000 Rotary Brake Bleed - AD0496 to bleed the B axis brake

Clamp the B axis brake (This will center the B axis platter over the brake ring) and gradually torque the B axis platter mounting bolts. Refer to Haas torque chart

Verify the runout of the ID of the B axis platter center bore once the bolts are torqued. 

Rotate the B axis over the full travel. Observe the servo load (spikes would indicate that the brake ring is dragging). Listen if there is any abnormal noises from the brake area as the B axis rotates.

Use the eye bolt installed on T-2194A to hoist the C-Axis with a forklift or crane.

Reinstall the C axis to the B axis and install the top 4 bolts 

Remove T-2194A and install the 4 bolts

Install remaining 4 bolts under the C AXIS BODY. Be sure to torque all bolts.

Refer to Haas torque chart

Install the brass center plug into the B axis platter.

Warning :  Verify B axis brake bleeding procedure is complete before installing plugs.

Install all plugs into the C axis body.

 Connect all the cables and hydraulic lines to the C axis. Re-install the Rotary Front Support. 

Refer to UMC-500/750/1000 Rotary Brake Bleed - AD0496 to bleed the C axis brake

Perform a complete geometry check:

EA0420 UMC 500 Inspection Report

EA0373 UMC 750 Inspection Report

EA0418 UMC 1000 Inspection Report