This procedure will guide you on how to replace the H-5AX Spindle.

This document applies to the following Service Kits:

• 93-3385  SPINDLE ASSY HSK F63 H-5AX SVC KIT  
• 93-3388  SPINDLE ASSY HSK A63 H-5AX SVC KIT
• 93-3920 HSD A63 B-AXIS MOUNT PLATE SVC KIT
• 93-5049 HSD F63 B-AXIS MOUNT PLATE SVC KIT
• 93-5902 COOLANT RING SPINDLE RESEAL SVC KIT HSD

Before starting the procedure, do the following steps:

• Clean up any chips
• Make sure all sharp tools are removed and/or oriented away from the work area

Important: Before replacing any parts, download and complete the Spindle Inspection Report Checklist provided below.

WARNING: When replacing a spindle under warranty, the old part must be returned in the replacement part packaging. Failure to do so may void the warranty.

Remove the cover plate from the B axis body.

Jog the axis to the center of the table or in an area clear to complete the work on the table surface.

With the X and Y-axis in place, jog the B axis 90° and C axis so the spindle is facing your work area.

Jog the Z-axis down until the spindle assembly lightly rests on a wooden block or a similar support, just enough to support the spindle housing.

Power off the machine and place a safety Lock Out tag on the power source.

Install the two M6 x 1.0 x 100 MM bolts [1] from the COOLANT RING SPINDLE RESEAL SVC KIT HSD into the spindle coolant ring.

Remove the bolts [1] securing the coolant ring to the spindle.

Use the two M6 bolts [1] to pull the coolant ring off of the spindle.

Set the coolant ring aside as this coolant ring will need to be installed on the replacement spindle cartridge.

If any o-rings were damaged during the removal process, they can be replaced with o-rings from the COOLANT RING SPINDLE RESEAL SVC KIT HSD. 

Remove the spindle chiller outlet line from the pump assembly and blow air through the line to clear any excess chiller fluid in the lines. This help prevent coolant leaking into the motor housing.

Chiller location:

VR series - located in the rear of machine on the side of the Column.

GM Series - located on the rear of the Bridge assembly.

 Note: For more information about the Spindle Chiller refer to the Haas Spindle Chiller Operator's/Service Manual.

Cut all wire ties holding the cable to the B axis cover panel.

Remove the four screws from the spindle motor junction connector. 

Remove the six screws B axis motor cover plate and pull away from the B axis housing. This exposes the spindle motor cable, ground, and Barrel connectors for encoders and switches.

Remove the four screws from the motor junction box to the motor plate cover.

Use the template to mark the wiring configuration of the motor / vector drive leads to refer to when installing the new spindle.

With the B axis motor cover plate removed exposing the cables.

Remove the screw for the ground cables and capacitor [1]. 

Remove the six nuts [2] from the motor lead terminals and remove the motor cable legs from the terminal block.

Note: Sensor cable may not have capacitor installed, leads are very fragile, push them through the center bore carefully.

With all cables and Barrel connectors disconnected, remove the six bolts from the spindle clamps. 

Carefully pull the spindle assembly away from the mount plate, watching no O-rings fall out of position. 

Pulling the spindle from the mount plate, feed the spindle wiring harness through the center bore of the B axis in the following order:

1. Motor leads / ground
2. Sensor connector / Capacitor
3. Encoder connector

Note: Sensor cable may not have a capacitor installed, leads are very fragile, push through center bore carefully.

Clean and inspect the replacement spindle for any damage.

Clean and inspect the spindle mount plate for damage, verify all O-rings (PN: 57-1048) [2] and dowel pins (PN: 48-0077) [1] are in place. 

  Note: The center O-ring (PN: 57-0974) [3] is split and does not need to be replaced, unless the O-ring is damaged.

Using a block of wood or something similar, to rest the spindle assembly on, carefully feed the encoder barrel connector, signal barrel connector and cables through the center bore of the Spindle mount plate.

Secure the spindle to the mount plate by installing the spindle clamps and hardware.

Note: Sensor cable may not have a capacitor installed, leads are very fragile push through center bore carefully.

Note: Cables may prevent the spindle from sitting flat against the mount plate. If this occurs:
• Separate the spindle from the casting
• Adjust the cables until the spindle sits flat
If the spindle still does not sit flat, contact Haas Service for assistance.

Using the wiring configuration recorded from step 5 of the removal process, reconnect the ground cables [1], motor cables [2], and barrel connectors [3].

IMPORTANT: Verify that the spindle encoder and spindle signal barrel connectors are correctly connected. Incorrect connections may short the spindle encoder, potentially causing damage.

Note: Pins illustrated in red are not used.

Reinstall the motor cable junction box on the motor cover plate and remount the motor cover plate to the B axis body. Using tie wraps, secure the cable to the motor cover plate.

 Note: Replacement spindle cartridges may come with set screws inside the coolant passages. Verify all passages are clear before installing the coolant ring. Remove any set screws if needed.

Use the o-rings from the COOLANT RING SPINDLE RESEAL SVC KIT HSD to replace any damaged o-rings on the coolant ring that was removed from the original spindle cartridge. 

Apply grease to the inside of the coolant ring on the o-rings [1] and on the spindle cartridge surface that contacts the coolant ring [2] to make the installation of the coolant ring easier. 

Verify all o-rings are in place before carefully installing the coolant ring onto the spindle. 

 Note: The o-rings on the inside of the coolant ring can easily be damaged on the edge of the spindle nose.

Install the bolts [1] that secure the coolant ring to the spindle cartridge.

Remove the two M6 bolts [2] from the coolant ring.

Before installing the B axis cover plate, power on and Zero Return the machine to test the function of the spindle.

Test the following:

1. Spindle will not run with NO TOOL in the taper
2. TRP switches function correctly
3. With tool in the taper run the spindle to verify correct orientation and RPM

 If any issue occurs with the following tests, Contact Haas Service.

With all tests complete, install the B axis cover plate.