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This procedure tells you how to replace the HSK-A63 Spindle.

Note: If you install a new spindle, install new spindle shims when you do the VMC - SPINDLE - SPINDLE SWEEP procedure.

Note: If you install the same spindle that you remove, record the location of the spindle shims. Install the spindle shims in the same location and then do the VMC - SPINDLE - SPINDLE SWEEP procedure.

• White lithium grease

Applicable Kits:

• 93-30-12369: SPINDLE HSK-A63 INLN 15K PIN DRV VMC SVC

Remove the front air scraper [1].

Record the location of the spindle lubrication fitting.

Disconnect the spindle lubrication tube.

Remove the 90° spindle lubrication fitting [2].

Install a 1/8" NPT plug [3] into the lubrication port. Install the plug [3] flush or below flush with the surface of the spindle.

Loosen the (4) screws [1] that attach the motor to the mounting plate. Do not remove the screws.

Loosen the (6) spindle screws [2] approximately (2) turns.

Install the protective cap [3] over the spindle nose.

Caution: The protective cap is necessary. It prevents damage to the spindle when it touches the table in the next step.

Jog the z-axis in the negative (-) direction until the spindle touches the table. If the spindle does not touch the table, put a wooden or aluminium block under the spindle.

Remove the (6) spindle screws [2].

Jog the z-axis in the positive (+) direction until the spindle is fully out of the spindle head.

Remove the shims [4].

Jog the z-axis in the positive (+) direction to the top of travel.

Clean and stone the spindle flange [1] and the spindle head surface [2] where the spindle flange will touch.

Caution: The motor shaft may become misaligned if spindle installation is done incorrectly.

Before installing the spindle loosen the motor mounting bolts at least a half of an inch.

If the pins are misaligned with the coupler, the motor will visibly lift instead of transmitting all of the axis thrust force into the motor shaft.

Apply a thin layer of lithium grease to these parts:

• transfer tube [1]
• (2) transfer tube o-rings [2]
• pin-coupler bushings [3]
• spindle coupler pins [5]

Install the transfer tube [1].

Turn the spindle until the lubrication port [4] aligns approximately with the position recorded when you removed the spindle.

Visually align the bushings [6] to the pins [5] on the motor coupler.

Caution: An incorrectly aligned coupler can cause damage to the bearings.

Slowly jog the z-axis in the negative (-) direction over the spindle.

While you jog the z-axis, use your hand to turn the spindle. If you feel a change in tension, stop immediately. Align the coupler pins to the bushings again.

When the spindle is fully into the spindle housing, do these steps:

• Turn the spindle to align it with the tapped holes in the casting.
• Install the (6) spindle screws [7].
• Torque the crews. Refer to  HAAS FASTENER TORQUE SPECIFICATIONS. Use the value for iron.

Remove the 1/8" NPT plug [1] from the lubrication port.

Install the 90° spindle lubrication fitting [2].

Install the front air scraper [3].

Connect the spindle lubrication tube.

Perform the VMC - Spindle - Spindle Sweep procedure.

Operate the spindle at 500 RPM for 20 seconds. Stop the spindle. This aligns the motor to the spindle.

Torque the (4) screws tat attach the motor to the mounting plate. Refer to Haas Fastener Torque Specifications. The TRP can be iron or aluminium. Use the correct value for iron or aluminium.

Note: Do not add oil to the spindle casting.

• Set Push Out:
• Engage the TRP (Tool Release Piston) so that the drawbar is in the unclamped position
• With the TRP engaged, use a depth gauge to measure the distance between the face of the clamping cone and the face of the spindle [1]
  • NTE (not to exceed) [0.41 in +/- 0.004 in] OR [10.5 mm +/- 0.1mm]
  • NOTE: For H-5AX HSK A63 spindles the push out distance is NTE (not to exceed) [0.417 in +.003/- 0 in] OR [10.59 mm +/- 0 mm]
• If the push out is not within the above specification do the following:
• Loosen the locking screw only 1-2 turns   
  • Note: backing out the locking screw too much can damage the spindle 
• Unscrew or tighten the clamping cone to adjust the push out distance measured
• Once set snug the locking screw using a 24mm wrench on the flats of the clamping cone and a 5mm hex bit

• Torque Locking Screw:
• Insert a hollow HSK-A63 tool holder without a collet to the spindle - this will prevent the drawbar from rotating while you torque the locking screw
  •  Use a long 5mm hex bit that will reach through the tool holder and a collet spanner wrench on the tool holder to prevent it from rotating
• Torque the locking screw to 20 Ft-lbs  (27 N-m)
• Check clamp force 2,835 - 4,050 lbs
  
  • Note: A new unit should be near 4,050 lbs, but if you are simply replacing it after cleaning, slightly lower force is acceptable
    
  • Once the force drops below 70% of max (2,835 lbs) is when the unit needs to either be re-greased, cleaned, inspected for damage, or have the drawbar inspected for damage as well.
• To achieve clamp force the clamping unit must be thoroughly greased, the drawbar must not have broken springs, the gripper segments must not be broken, and the spacer unit and gripper segments must not be worn

Place a tool in the spindle and verify it is seated correctly. A correctly installed tool has no gap and is seated flush to the spindle [1].

Remove the spindle head cover to gain access to the clamp switch.

Loosen the (2) screws [1] that hold the Clamp switch block [2] to the TRP.

Slowly slide the block [2] and sensor towards the spindle until the sensor [3] turns ON (becomes red).

Then lightly tighten the (2) screws [1].