This procedure will show how to upgrade the DS-30Y sub spindle encoder.

This document applies the following service kit:

• 93-4817 DS-30Y SUBSPNDL NCE 5.6" UPGRD KIT

Machine Compatibility:

• DS-30Y built from 02/11/22 to present

Note : This service kit offers a higher resolution sub-spindle encoder for increased accuracy.

The following parts are different :

• Union adapters [1] and [4]
• Encoder rings [3] and [6]
• Encoder head brackets [2] and [5]

 Note: This procedure has the front panel removed for illustrative purposes.

If equipped, remove the Sub-Spindle parts ejector [1] from the draw bar. See the Lathe - Sub-Spindle Part Ejector procedure. 

Remove the Sub-Spindle chuck [2] and chuck thread adapter [3]. It is recommended to attempt to remove the chuck adapter using a strap wrench before resorting to other methods that might damage the threads.

Important : Sub-spindle brake may be actuated to stop the spindle from rotating. C-axis brake can be found in Current Commands > Devices > Mechanisms > Sub-spindle Brake.

[Optional] Remove both the chuck adapter and drawbar together.

Important : Chuck adapter and drawbar are thread locked together so there is a possibility of removing them both at once. If they are removed together, refer to step 7 to install new drawbar and chuck adapter then skip to vibration testing in step 10.

Jog the turret [1] as close to the main spindle as possible and the Sub-Spindle [2] as far from the main spindle as possible.

Press [EMERGENCY STOP] then [POWER OFF].

Set the main circuit breaker to the OFF position.

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

Move the conveyor [1] enough to gain access to the right enclosure panel [2].

Remove the right enclosure panel [2].

Note : The right side access panel [2] is shown in the image. Other enclosure panels may need to be removed for easier access.

Remove Sub-Spindle covers [4] and [2] to gain access to the hydraulic union.

Note : Access is very limited which might require the cover to be removed in sections to access the hydraulic union.

Remove the hydraulic union [1] from the adapter [2]. The drawbar [3] is attached to the hydraulic union. 

Loosen the bolts [2] then evenly heat the old union adapter [3] at the highlighted area [1] until it is loose.

Remove the union adapter [2] and hardware [1].

Important : Ensure that the union adapter is pulled out evenly.

Remove ground wire and disconnect the encoder head cable.

Remove the hardware for the encoder head [1] along with the bracket [2].

Optional : Heat the encoder ring [3] and use a pulley puller to removed it.  

Install the new spindle encoder head bracket [1] using the provided hardware [2].

Slide on the encoder ring assembly [1] onto the spindle and install the union adapter using the provided hardware [3]. Ensure that the bolts are snug but not tight.

Important : Ensure that the encoder ring is facing the back of the sub-spindle.

Using a plastic mallet lightly tap union adapter to set the axial runout NTE .0005" (12.7 µm) TIR and radial runout NTE .0015"(38.1 µm) TIR

Torque the union adapter bolts.

Leave the encoder ring [1] uninstalled on the union adapter [4]. 

Slide the hydraulic union bolts [2] through the union adapter then Reinstall the hydraulic union [3].

Note : The encoder ring is not installed to have access to the hydraulic union bolts.

Bolt on the encoder ring [2] to the back of the union adapter using the provided hardware [1].

Note : Leave the bolts snug and do not tighten / torque until the run out is dialed in.

Check radial runout on the encoder ring bracket [2] using a dial indicator [1].

• NTE 0.0005" (12.7 µm) TIR

Note : Ensure the high spot is indicated using a marker for encoder head installation.

Check axial runout on the back face of the encoder ring bracket [2] using a dial indicator [1].

• NTE 0.005" (127 µm) TIR

Install the encoder head [1] using the provided hardware [2].

Use the plastic shim provided with the NCE to set the gap between the read head and the NCE ring by pushing the read head evenly onto shim/ring at the marked high point. 

Torque read head screw to 25 inch-Lbs once correct spacing is achieved. the shim should slightly drag as it is removed from the gap.

Install ground wire and connect the encoder head cable.

Warning : Ensure that the encoder head does not contact the ring.

[POWER ON] the machine

Install the chuck adapter [1] by using the foot pedal in MDI mode to extend the sub-spindle draw bar the pressing [E-STOP] and applying thread lock all the way around the first 2 threads of the chuck adapter. Thread the chuck adapter onto the sub-spindle draw tube until the threads bottom out by hand. Apply CHUCK EEZ grease or any similar chuck grease to the outer threads of the chuck adapter before installing the chuck.

If equipped, install the Sub-Spindle parts ejector [1]. See the Lathe - Sub-Spindle Part Ejector procedure. 

Note : Balancing set screws are placed on the sub-spindle brake assembly [3] so its best to leave it uncovered while balancing. Make sure that the spindle is at the home position and that the access panel is closed for safety purposes.

Important : Prior to balancing the spindle secure the hydraulic and brake lines away from any moving components.

Remove the chuck jaws [1] then warm up the spindle at 25% max speed for a minimum of 10 minutes.

Place vibration sensor on highlighted area [2] then proceed to run vibration test. Refer to Vibration Analysis - Ethernet Interface or Vibration Analysis - RS-232 Interface depending on type of vibration analyzer used for vibration test procedure.

Important : Minimize time of spindle running at max speed prior to fully balancing. 

Torque balancing bolts [3] to 15 ft-Lbs after the spindle is balanced

Note : Displacement values should not exceed 0.08 mil 

Install Sub-Spindle covers  [4] and [2] using hardware [3] and [1]. 

Important : Make sure no cables get pinched or damaged during this process.

Install the right enclosure panel [1] along with any other panels that were removed. 

Move the conveyor [2] back into position.