DT/DM - Spindle Motor - Replacement

Introduction

Use this procedure for replacing the spindle motor on a DT/DM machine.

This Document Applies to the Following Service Kits:

93-30-12159A SPINDLE MOTOR ASSY SERVICE DM NCE PIN
93-30-13543 SPINDLE MOTOR ASSY 40T DM HIGEN SVC
93-30-11678 SPINDLE MOTOR ASSY SERVICE DM BELTED KT
93-30-12159 SPINDLE MOTOR ASSY SERVICE DM BELTED PIN
93-30-12159A SPINDLE MOTOR ASSY SERVICE DM NCE PIN
93-30-12401 SPINDLE MOTOR ASSY 30T 15K DT
93-30-12606 SPINDLE MOTOR ASSY 30T 8.1K/10K DT
93-30-13543 SPINDLE MOTOR ASSY 40T DM HIGEN SVC
93-30-4462B SPINDLE MOTOR ASSY SERVICE DT NCE
93-30-4470 SPINDLE MOTOR ASSY SERVICE DT BELTED

Tools Required:

T-0058 Encoder Ring Removal Tool 2"
T-0059 Encoder Plate Removal Tool 2"

NOTE: Tools are only required for non-contant encoders.

IMPORTANT: If replacing a Baldor motor with a Higen, make sure to download and update to latest Configuration file from the HBC site.

Spindle Motor Removal

1

CAUTION: Push [EMERGENCY STOP] to remove the head cover.

Push [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.

2

DT/DM with Belted Encoder:

Remove the TSC union if equipped. Refer to COMPENSATING TSC UNION - REPLACEMENT - VMC for more information. Note position of plate, then disconnect the encoder/spindle motor wires and remove the motor.

Remove the encoder assembly [1], top plate [2] with standoffs [3], and the J-box [4] from the used motor.

3

DT/DM with Non-Contact Encoder:

Remove the TSC union if equipped. Refer to COMPENSATING TSC UNION - REPLACEMENT - VMC for more information. Note the position of plate, then disconnect the encoder/spindle motor wires and remove the motor.

Remove the J-box [1] from the used motor.

Remove encoder mounting plate [2] with encoder read head [3] on top. Encoder ring [4] stays on the shaft.

Non-Contact Encoder Replacement

1

To remove encoder ring [1], put plate removal tool T-0059 [2] on top of the spindle-motor hub.

Use the (2) 1/4 x 20" socket-head cap screws (SHCS) [3] to loosely install the (2) parts of the encoder-ring removal tool T-0058 [4].

Apply the anti-seize compound to the (4) 1/4 x 20" stud-set screws [5]. Put the (4) screws into the threaded holes on the encoder-ring removal tool assembly.

Make sure the encoder-plate removal tool fits correctly on the spindle-motor hub.

2

In 1 turn increments, tighten the (4) screws [1] in a star pattern until the encoder ring [3] is removed from the spindle-motor hub.

Remove the encoder-ring removal tool assembly [2].

Note: Do not damage the spindle-motor hub when you remove the assembly [2].

Remove the encoder-plate removal tool [4].

Remove these parts from the assembly [2]:

(4) 1/4 - 20 x 1" SSS [5]
(2) 1/4 x 20" SHCS [6]
NCE ring [3].

3

To install the encoder ring on the new motor, turn the encoder-ring removal tool assembly [2] upside down.

Put the NCE ring [3] on the spindle-motor hub.

Use the (2) 1/4 x 20" SHCS [1] to install the (2) parts of the assembly [2].

Apply the anti-seize compound [4] to the (4) 1/4 - 20 x 1 1/4" SHCS [5]. Install the SHCS [5]. Tighten the SHCS [5] in a star pattern.

Note: Make sure you gradually tighten the screws until the lip inside the NCE ring [3] touches the top of the spindle-motor hub.

4

Remove the (4) 1/4 x 20" SHCS [1] and the encoder-ring removal tool assembly [2].

Inspect the NCE ring [3] for any damage.

Note: When you are working on a machine with the spindle encoder disconnected it is necessary to jump the encoder cable to move the spindle. Refer to the SPINDLE ENCODER JUMPER - INSTALLATION procedure.

Check the runout of the outer diameter of the encoder ring NTE 0.002" TIR.

Spindle Motor Installation

1

Make sure all the following are installed on the replacement motor:

Install the top plate [1] with the included hardware, without the standoffs, rotated 90 degrees to prevent interferrence with the J-box.

Install the encoder assembly [2] on top of plate [1].

Install the motor J-box [3] on the side of the replacement motor.

Note: The air purge has been removed from current motor assemblies. Do not install it on the replacement motor.

2

For non-contact encoders perform the steps that follow:

Put a 0.3 mm plastic shim [2] between the encoder read-head [1] and the high spot marked on the encoder ring [3].

Push the encoder read-head [1] toward the encoder ring [2].

Tighten the (2) screws [4] for the encoder read-head. Remove the shim [2].

3

Install spindle motor using grease on the spider coupler or drive pins. Slowly bring down the spindle motor into the center of the mount. Make sure couplers engage smoothly.

To set alignment, run the spindle motor at 1000 RPM with mounting bolts loose. Tighten the 2 front mounting bolts while the motor is running. Push [EMERGENCY STOP] and tighten 2 back bolts.

Place the indicator on the marked high spot of the coupling [1] facing the front of the machine.

Jog spindle head down to measure the Y-axis offset between the two couplings NTE 0.0020".

Then, rotate spindle shaft CCW 90 degrees until the coupling's high spots faces the side of the machine.

Jog spindle head down to measure the X-axis offset between the two couplings NTE 0.0020".

Torque the screws. Refer to HAAS FASTENER TORQUE SPECIFICATIONS.

NOTE: If coupling offsets exceed tolerance, break all 4 upper motor mount screws loose and tap the motor into place until offset is within tolerance.

4

If equipped with TSC, install the union of the air purge system with the supplied hardware [1] and standoffs [2]. Refer to COMPENSATING TSC UNION - REPLACEMENT - VMC for more information.

NOTE: The depth of the air purge into the motor shaft might be shallower on the replacement motor due to shortening of the motor shaft. This is normal.

5

If equipped with the spindle motor air purge, it must be disconnected.

Remove the air purge fittings [1] from the spindle air solenoid. Use a plug to close the port, then remove the T-fitting [2] and extension tube [3]. Plug the spindle air orifice and quick connect directly into the solenoid fitting [4].

NOTE: Make sure the spindle fan is blowing out the top of the enclosure and not down on the motor.

Testing

1

Operate the spindle at 25% [1], 50% [2], and 100% [3] of the maximum speed.

NOTE: In this example the maximum speed is 7500 RPM.

2

To make sure the encoder operates correctly, check the Spindle Orientation. Refer to SIDE-MOUNT TOOL CHANGER - SPINDLE ORIENTATION OFFSET - NGC for more information.

3

Push [COOLANT] to start the TSC.

Correct operation is as follows:

Coolant flows correctly from the TSC tool holder [1].
A few drops flow from the vacuum-generator hose [2].

Push [RESET].

Make sure there are no leaks in the air hoses and coolant hoses.