HSD ES 959L Electrospindles Repair

Bybmsserwis

ROVER center service – repair of three HSD ES 959L units with unusual failures

Our CNC service received as many as three HSD ES 959L electrospindles designated for operation in a machining center ROVER B. Two of them were sent as damaged units, while the third one was marked by another service as "beyond repair" and intended as a donor for spare parts.

We took a comprehensive approach. Thanks to our advanced technical facilities and experience in servicing HSD electrospindles, we restored all three spindles to full working condition, as confirmed by our service reports and test results on the customer's machine.

Electrospindle specification:

  • Model: HSD ES 959L

  • Tool holder taper: HSK 63F

  • Rotational speed: 24,000 rpm

  • Machine: ROVER B machining center

HSD electrospindles ready for testing after service

Unusual failures?
That's our specialty

Many services avoid repairing electrospindles with non-standard failures – such as communication module damage or missing original components. In the case of HSD ES 959L electrospindles that reached us, we identified issues including:

  • spindle communication with the machine's electronics,
  • sensor malfunctions,
  • tool taper deformation,
  • severe wear of rotating components.

After thorough technical analysis, cleaning, and inspection, we decided to carry out a full regeneration of all three units.

HSD spindle repair – component preparation HSD electrospindle regeneration – cleaning and inspection stage

Scope of work performed
HSD ES during electrospindle regeneration

1. Replacement of ceramic bearings
we used top-class bearings ensuring optimal performance up to 24,000 rpm.
2. HSK 63F taper restoration
performed with accuracy down to a few microns of runout.
3. Repair and calibration of communication systems
Full functionality of inductive systems and encoders was restored.
4. Precision spindle balancing
performed to 0.4G accuracy class with full service protocol.
5. Installation in ROVER B machining center
all spindles were installed on-site and tested under real production conditions.
HSD spindle clamping force testing
HSD spindle runout measurement after repair
6. Dynamic testing
Spindles were tested under load across various speed ranges. We also analyzed dynamic forces and operating temperatures.
7. Full technical documentation
Each repair stage was documented – including clamping force, runout, and bearing clearance measurements.
8. Process safety
Each spindle was carefully protected during transport and storage between service stages.
9. Comprehensive approach
Even the spindle labeled as “beyond repair” was restored thanks to in-depth diagnostics and donor component reuse.
10. Final testing with documentation
The service process concluded with a comprehensive quality check, including tightness testing, thermal analysis, concentricity control, and trial machining cycle tests.

CNC spindle service
at the highest level

Our CNC spindle service includes full documentation of each repair. In this case, all key measurements and data were logged in our service reports:

  • bearing clearance measurements,
  • spindle runout,
  • tool clamping force,
  • vibration and thermal tests,
  • and final compliance with HSD factory parameters.

Thanks to this approach, we provide electrospindle repair even for units rejected by other services.

HSD electrospindle repair process at our CNC service center Installation of HSD spindle in ROVER machining center after overhaul

Trust experience
choose professionals in spindle repair

Need urgent HSD spindle repair? – contact us now.

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