The following procedure describes how to replace the H-5AX spindle head on VR and GM Series machines.

Note:  To complete a H-5AX spindle head replacement requires the factory send the spindle head shipping bracket along with the replacement spindle head.

Tools Required:

• T-0143 SHP BRKT HSD 5AX HEAD VR/GM

WARNING: It is important to verify and to go through the proper troubleshooting found in the H-5AX Spindle Head Troubleshooting guide and to fill out the H-5AX Service Request Form linked below before ordering a replacement head. 

This document applies to the following service kits:

• 93-3586    HSD 5AX HEAD HSK A63 SIG 7 SVC
• 93-3587    HSD 5AX HEAD HSK F63 SIG 5 SVC    
• 93-3588    HSD 5AX HEAD HSK A63 SIG 5 SVC
• 93-3589    HSD 5AX HEAD HSK F63 SIG 7 SVC  
• 93-3590    HSD 5AX HEAD HSK F63 SIG 7 CLT SVC
• 93-3591    HSD 5AX HEAD HSK A63 SIG 7 CLT SVC

 Note: This procedure uses a VR for illustrative purposes. GM Machine will use this procedure as reference.

Return the B and C axis to its home position

Place a piece of cardboard on the machine table to avoid damaging the table during the removal/installation Process

Place the replacement spindle on one end of the table, on the other end leave space for the shipping bracket that will remove the current spindle.

Place the H-5ax head shipping bracket on the empty side of the table on the machine, lower the spindle head onto the bracket. You will lower the spindle head until the spindle head is fully supported, this is indicated when the Z-axis load reaches 0-1%. 

With the spindle fully supported use the hardware provided to mount the spindle head to the bracket.

With the spindle fully supported and mounted to the bracket remove the mounting bolts that attach the spindle to the spindle head casting.

Separate the spindle from the spindle head casting by raising the Z-axis, make sure the casting clears both servo motors on the replacement spindle and current spindle. Power off the machine. 

Remove the lines from the spindle head manifold located inside the spindle head enclosure. Take a picture and mark the lines so that when the new manifold is installed matching the lines to the correct port is easier. Disconnect the barrel connectors from the top of the machine as well.

With all the wires and hoses unplugged use a forklift to move the old spindle head out of the machine and place the new spindle head into position. 

Note: Approximate weight of H-5AX Head Assembly:

H-5AX HEAD HSK A63 20K = 180 kg / 397 lbs 

H-5AX HEAD HSK F63  20K = 160 kg /  353 lbs

Slide the replacement spindle head under the casting in the position described below.

VR:

Make sure the Haas logo [1] on the spindle casting is facing the front of the machine, and that the servo motor [2] is oriented towards the front of the spindle head casting (see next step) or else the homing sequence may pose a problem later down the line if it is not. 

NOTE: The servo motor and Haas logo are usually positioned the same, in the event they are not, make sure the servo motor is located in the front of the casting regardless of the Haas logo.

GM:

Make sure the Haas logo [3] on the spindle casting is facing the operator side of the machine, and that the servo motor [4] is oriented towards the operator side or else the homing sequence may pose a problem later down the line if it is not. 

 NOTE: The servo motor and Haas logo are usually positioned the same, in the event they are not, make sure the servo motor is located towards the operators side of the machine, regardless of the Haas logo.

The spindle servo motor should be facing the front of the casting and the home switches located in the rear as seen in this image.

Plug all the hoses back into the manifold and plug all the barrel connector cables back to the using the pictures taken by the tech as reference. Neatly organize the hose and wires. 

With all the wires connected turn the machine back on, the spindle head originally sent with the machine may have been a sigma 5 motor and new motors use a sigma 7 motor.

To verify which motor is in the machine check the motor on the top of the replacement spindle head.

Sigma 7 motors have a blue line across the top as shown in the image.

If the replacement motor and new motor are different, select the correct rotary configuration that reflects the motor in the replacement spindle head. 

With the correct configurations selected correct any alarms present and jog the spindle head casting down toward the new spindle. Setting 53 jog without zero return will need to be turned on to do so. DO NOT ZERO RETURN THE SPINDLE HEAD. Carefully jog the z axis down making sure the spindle is straight to avoid wedging the spindle into the spindle head bore. Bolt the plate to the casting. 

Reset the grid offset, by zeroing parameters 6.140 B-AXIS GRID OFFSET and 7.140 C-AXIS GRID OFFSET and then zero returning each axis and pressing the axis B/C and pressing [F4].

Set the Tool change offset for the B-Axis by sweeping the side of the test bar so it reads zero to zero over the entire length of the test bar [B].

Set the Tool change offset for the C-Axis by sweeping the front side of the test bar so it reads zero to zero over the entire length of the test bar [C].

NOTE: This is NTE 0.0005 in (0.0127 mm), but it is recommended to get this value as close to zero as possible. If the machine is experiencing issues getting it closer to zero, complete the backlash compensation section and return to set the tool change offset.

B-Axis Backlash

After resetting the tool change offset re-zero the B and C-Axis set up the test bar [1] as shown in the image and place an indicator at the high spot 20 inches away from the test bar [2]. 

NOTE: If the test bar is not larger than 20 inches place it approximately an inch away from the end of the test bar.

B-Axis Backlash

With the indicator set up and B at 0 degrees and C at zero degrees [1] press [POSITION] and navigate to the operators page and set the Y-Axis and B-Axis position to zero.

Move the Y-axis enough to clear the indicator [2]

Rotate the B-Axis -10 degrees and return back to B zero position [3].

Move the Y-Axis back to the zero position on the operators page. 

Record the error value on the indicator.

B-Axis Backlash

With the indicator set up in the same starting position verify that the  Y-Axis and B-Axis position are zero on the operators page.

Move the Y-axis enough to clear the indicator [2]

Rotate the B-Axis +10 degrees and return back to B zero position [3].

Move the Y-Axis back to the zero position on the operators page. 

Record the error value on the indicator.

Add both error values from this step and the previous and input double the amount of error into Parameter 6.042 B-AXIS BACKLASH COMPENSATION. (Example total backlash observed : 0.004 inches,  Parameter 6.042 value: 0.008 deg)

This value is NTE 0.0003 in (0.0076 mm).

If the backlash value switched direction then the compensation was set too high. 

For example before the compensation value was set the negative motion value read [A] red, and the positive motion the value read [B] blue.

After the compensation value was set the negative motion value read [A] blue, and the positive motion the value read [B] red.

The B & C-Axis backlash  is NTE 0.0003 in (0.0076 mm)

C-Axis Backlash

After resetting the tool change offset re-zero the B and C-Axis set up the test bar [1] as shown in the image and place an indicator at the high spot 20 inches away from the test bar [2]. 

NOTE: If the test bar is not larger than 20 inches place it approximately an inch away from the end of the test bar.

C-Axis Backlash

With the indicator set up and B at -90 degrees and C at zero degrees [1] press [POSITION] and navigate to the operators page and set the Z-Axis and C-Axis position to zero.

Raise the Z-axis enough to clear the indicator [2]

Rotate the C-Axis -10 degrees and return back to C zero position [3].

Lower the Z-Axis back to the zero position on the operators page. 

Record the error value on the indicator.

C-Axis Backlash

With the indicator set up in the same starting position verify that the  Z-Axis and C-Axis position are zero on the operators page.

Raise the Z-axis enough to clear the indicator [2]

Rotate the C-Axis +10 degrees and return back to C zero position [3].

Lower the Z-Axis back to the zero position on the operators page. 

Record the error value on the indicator.

Add both error values from this step and the previous and input double the amount of error into Parameter 7.042 C-AXIS BACKLASH COMPENSATION. (Example total backlash observed : 0.004 inches,  Parameter 7.042 value: 0.008 deg)

This value is NTE 0.0003 in (0.0076 mm).

If the backlash value switched direction then the compensation was set too high. 

For example before the compensation value was set the negative motion value read [A] red, and the positive motion the value read [B] blue.

After the compensation value was set the negative motion value read [A] blue, and the positive motion the value read [B] red.

The B & C-Axis backlash  is NTE 0.0003 in (0.0076 mm)

Complete the latest inspection report found in the Alignment Inspection Report and Checklists folder on HBC.

 Note: This site is available only to Haas Service Techs.

Please refer to the H-5AX Single Yoke Spindle Head - Geometry Guide or the GM-2-5AX Head Alignment Procedure for further details on how to perform the 5AX inspection report checks.