The DC-1 can be lifted by forklift, or by using the lifting points on the base and column castings. For details on how to lift the DC-1 refer to the Pre-Installation Guide, or the machine lifting placard located on the machine.

Connect the Air Supply at the lube panel shown in the image as Input Air Supply.

Note: For air specifications refer to the decal located on the front of the lube cabinet door.

The required air pressure for the DC-1 machine is 85psi.

Connect the air supply and verify the pressure gauge [1] on the regulator shows the correct pressure.

If the pressure needs to be adjusted, pull the regulator cap [2] up, and then twist it to set the outgoing air to 85 psi.

Once the gauge reads 85 psi, push the regulator cap down to lock it in place.

Fasten the top bracket [1] and the bottom bracket [2] that secure the pendant to the enclosure panel [3].

Use 2 BHCS to secure the top bracket, and 3 BHCS to secure the bottom bracket. 

Feed the cables [4] coming from the top of the enclosure through the top bracket so that they can be connected to the pendant.

Note: Make sure the hose for the operator blow gun [5] is fed through the bottom bracket [3]. See next step for connecting blow gun fittings to the bracket

Note: Do not damage the cables when fastening the top bracket. Feed the cables through before fastening the bracket if needed.

Install the top bracket cover [1] using the 4 BHCS [2] to fasten the cover to the top bracket that is attached to the pendant.

Secure the bottom of the pendant to the mounting bracket by fastening it with a SHCS [3] from underneath the bracket.

Make sure the rubber spacer [4] is in between the pendant and the mounting bracket. Place the one washer on each side of the rubber spacer.

Note: Make sure the top bracket cover doesn't pinch any of the cables that go to the SKBIF PCB.

Install the fittings at the bottom mounting bracket for the operator blow gun.

Attach the air hose [2] coming from inside the enclosure (routed in step 1) to the check valve [3].

Fasten the elbow fitting [1] to the check valve with the mounting bracket in between to secure the fittings in place.

Install the cover to the lower bracket to protect the fittings.

Attach the operator blow gun to the elbow fitting [1].

Remove the rear panel of the pendant to gain access to the SKBIF PCB.

Make sure to connect all the cables that were routed through the top pendant mounting bracket that was installed in the previous step.

• Connect 33-4521 to the connector of 33-1300 which is connected to J20 [1] on the SKBIF PCB.
• Connect the USB cable to J9 [2] of the SKBIF PCB.
• Connect the ethernet cable to J28 [3] on the SKBIF PCB.
• Connect the USB from the touchscreen assembly to J11 [4] on the SKBIF PCB. 
• Connect the ground wire to the cable clamp fastener [5] as shown in the image.

Note: Make sure that the ferrite filters [6] are installed onto the USB cables to protect them from electrical noise.

Once the wiring has been verified, reinstall the rear panel of the pendant.

For machines with the auto window feature, the auto window needs to be assembled and installed on the right side window of the machine. 

Important: The machine will be in an alarm state until the auto window cable 33-1169 is connected to P13 on the IO board and the clamp sensors are properly installed. Continue with these steps and AD0652 for instructions on installing the auto window.

The auto window kit is contained in the 30-14126 package that is shipped with the machine.

Remove the right window enclosure panel [1] from the DC-1 by unfastening the 4 BHCS [2]. 

Remove the jumper wire (33-1388) [1] from the window close connector of the (33-1169) cable [2]. The 33-1169 cable is connected to P13 of the IO PCB. 

This jumper wire [1] gets replaced by the connector to the window closed sensor [3]. This sensor is on the bottom of the cylinder behind the enclosure cover.

Note: The purpose of this jumper is to prevent alarms related to the window being open prior to the auto window being installed.

Once this jumper is removed, the haas control will throw an alarm saying that the side window is not closed.

To clear this alarm, the clamp sensor [3] must be installed onto the auto window lift cylinder.

Refer to AD0652 for instructions on how to install the cylinder and sensors.

Slide the two window guides [1] onto the side window enclosure panel [2].

To secure the window guides in place, bend the tabs [3] extending from the top of the enclosure panel over the window guides to lock them in position.

Slide the window [4] from the top into the guides [1] and test that the window slides through the guides easily and can be aligned with the window lift bracket [5]. 

Important: Do not fix the lift bracket [5] to the window at this time. AD0652 provides details on how to complete the auto window installation.

Take the auto window mounting panels [1] and fasten them to the DC-1 enclosure [3] as shown in the left image.

Fasten the window panel [4] to the mounting panels [1] using the 6 FBHCS [5] fasteners included in the kit.

Note: The right image shows the window panel mounting from the viewpoint of inside the machine. Make sure the mounting panels [1] are facing the proper direction.

The lift cylinder assembly for the DC-1 auto window is the same as other auto windows for other machines. 

Remove the bolt keeping the door fastened to the enclosure [2].

Remove the X-axis and Y-axis shipping brackets. Power on the machine and jog the Z-axis up so that you can remove the spindle head bracket [3] from the table.

Note: If the Z-axis cannot be jogged up far enough, the Z-axis zero position isn't set correctly. Refer to Chapter 5 - Operation / Tool Changer for details on how to reset the Z-axis zero position. 

Once the X-axis and Y-axis shipping brackets have been removed, the waycovers need to be fastened in position.

Remove the front table cover [1] and make sure that all waycover fasteners [2] are removed from the front cover and back side of the table.

Note: Before jogging along any axis of the machine, make sure the fasteners for the waycovers are removed. 

Once the front cover is removed, use the fasteners removed and the bag of fasteners ziptied to the Y-axis waycover [3].

Slide the waycovers into position as shown in the image.

Install the Y-axis waycover [1] to the saddle using the fasteners [2]

Fasten the X-axis waycovers [3] in position using the fasteners [4].

Note: Some of the X-axis waycover fasteners cannot be installed until after the front cover [5] is installed

Apply RTV sealant to the seams where the waycovers join the table to prevent coolant intrusion under the waycovers.

Install the table front cover [5] that was removed in the previous step.

Note: Make sure that the the fasteners on the back side of the table are 

Set the machine height using the four corner leveling bolts [1 ,2, 3, 4] to 3" +/- .5" (75 mm +/- 10 mm) above the floor. Turn each screw so they have equal tension.

Jog the X-axis and Y-axis to the middle of their travel, centering the table.

Note: For more information, refer to this link for a more detailed process on how to level a VMC machine.

Clean the table surface and leveling tool (T-2181) and check the calibration of the leveling tool before proceeding.

Position the level at the center of the table, parallel to the X-axis. Use a t-slot for alignment.

Note the position of the bubble.

Reposition the level by turning it 180 degrees. The bubble should display the same reading as previously.

If the readings are different by more than one division, return the level to Haas for adjustment and do not use it to level the machine.

Adjust corner leveling bolts [1, 2] or [3, 4] until the bubble parallel with the Y-axis is centered.

This levels the machine front to back.

Always raise the lower side of the machine to maintain clearance for the coolant tank (if equipped) and adjust the two leveling bolts on that side an equal amount.

Adjust corner leveling bolts [1, 3] or [2, 4] until the bubble parallel to the X-axis is centered.

This levels the machine left to right.

Again, raise the lower side of the machine and adjust the two leveling bolts on that side an equal amount.

Keep the level in the same position and jog the Y-axis to bring the table to the front of the machine.

Note the position of the bubble.

Jog the Y-axis across its full travel, stopping at the column. Look to see which rear corner of the machine is lowest, as shown by the leveling tool.

Raise the lowest rear corner by adjusting corner leveling bolt [3] or [4] until the bubble is centered on the level.

Jog the Y-axis back across its full travel, bringing the table to the front of the machine. Look to see which front corner is lowest, as shown by the level.

Raise the lowest front corner by adjusting corner leveling bolt [1] or [2] until the bubble is centered on the level.

Repeat steps 6 and 7, moving the table back and forth across the full travel of the Y-axis, raising the lowest corner each time.

Continue this process until the level reads zero at both ends of the Y-axis travel.

Once the machine has been leveled along both the X and Y axes, raise up the non-corner leveling bolts [5, 6, and 7] so that they are making contact with the base to provide support.

Lock the leveling bolts in place by tightening the locking nut while holding the leveling bolt. Ensure that the leveling bolts do not move during this process.

For a more in-depth guide on how to perform this procedure, please see:

Make sure the spindle chiller is in position on the platform[1] located to the rear of the machine.

There is a power cable, a flow alarm cable, and a ground cable that are installed to the control cabinet at the factory.

Note: Refer to the DC-1 - Spindle Chiller chapter of this manual for more information.

Verify that the fluid tank is full by inspecting the fluid level gauge [1] on the back of the spindle chiller unit.

Add fluid if needed through the inlet port at the top of the unit. The fluid gauge should show the level is near the top of the M range [2]. 

Note: Use a mixture of 30% ethylene glycol and 70% dionized water to fill the spindle chiller.

Important: Never run the Spindle Chiller without fluid in the tank. This can cause serious damage to the pump.

Make sure that the switch located on the front of the chiller unit is on. The settings and parameters for the chiller are set in the factory and should not be altered.

Note: The display of the spindle chiller will be blank. The chiller powers itself on when the spindle is running or during tool changes. 

Verify that the oil reservoir [3] is filled with Mobil DTE 24 Ultra (93-2546).

The flow rate of the oil into the air system also needs to be set correctly. Adjust the set screw [4] so that the flow rate is 1 drop every 3 to 10 minutes. The oil drip will be visible through the sight glass below the set screw [4].

The flow rate of oil into the airlines can only be set when the spindle is running. Run the following MDI program when trying to set the flow rate:

• S50 M99; 

Loosening the set screw will increase the flow rate of oil, and tightening will decrease the flow rate.

Note: Having a flow rate higher than this range could flood the air supply which could damage the machine.

Run the spindle run-in program.

Examine the sight glass, make sure the correct number of drops fall through the sight glass. 

Examine the fittings [1,2] on top of the oil pump tank.

The oil collects on top of the oil pump tank [3] either behind or in front of the sight glass bracket, underneath the leaking fitting.

Tighten any leaking fittings.

Go to the Maintenance tab.

Press [F2] to cycle an axis lubrication test.

Inspect the gauge on the grease lubrication system. Make sure it holds pressure.

Machines with Single/Dual Prog Air Option Only: 

Route the Foot Pedal cable (32-1390) from the control along the enclosure panels to the foot pedal cable mounting bracket[1].

For more details, refer to the Programmable Air Installation procedure.

Power off the machine.

Place the strainer basket [1] into the coolant tank [2].

Move the coolant tank assembly [2] under the drain slots at the base of the mill, under the front-left corner of the trough.

 NOTE: Make sure that the strainer basket [1] is directly under the drain slots to ensure coolant flows into the tank. 

Insert the coolant pump assembly [3] into the back left corner of the coolant tank when facing the spindle. 

Connect the hose to the coolant pump [1] into the coolant filter [2].

Connect the coolant pump power cable into the plug located beneath the control cabinet[3]. 

If included as a machine option, route the TSC pump[4] to the lube panel and fill the coolant tank with the necessary gallons of coolant.

Install the coolant float sensor into the coolant tank. Refer to Coolant Float Sensor - NGC - Installation or Coolant Float Sensor - CHC - Installation for more information. 

Spindle Operation 

Run the Spindle Run-In program O09221. 

In the case of an unusual spindle noise, run a vibration test. For a guide on how to perform a spindle vibration test please see: 

Coolant and Air Blast-DC Operation

Fill the coolant tank with the necessary gallons of coolant in order to fill the tank.

Connect the coolant pump.

Run coolant by pressing  [COOLANT] on control pendant.

Verify that there is coolant coming out of the nozzles around the machine.

There are two nozzles for coolant located by the spindle head. Make sure coolant comes out of the two nozzles on the left.

Note: The third nozzle by the spindle head is for the Air Blast-DC option. Refer to the decal [1] for which nozzles are for coolant.

To verify that the Air Blast option is operational, run the following command in MDI mode and make sure air comes out of the nozzle labeled AIR BLAST:

1. M83 - starts the air blast
2. M84 - stops the air blast

Through Spindle Coolant (TSC) 

If machine comes equipped with TSC, insert a TSC toolholder into the tool carousel side pocket.

Then load the toolholder into the spindle by calling T[pocket_number] on the control and pressing ATC FWD.

Important: Tools cannot be loaded directly into the spindle on a DC machine. For more details on how to load tools into the spindle for the DC machine, refer to the Operation Chapter.

Press [AUX CLNT] to start the TSC.

Correct operation is as follows:

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

Press [RESET].

Through-Tool Air Blast (TAB)

If machine comes equipped with TAB, operate this code in MDI mode:

M73;

G04 P5.;

M74;

G04 P3.;

M99;

M73 starts the TAB. M74 stops the TAB.

Manually operate the TAB:

Press [AUX CLNT]. Press the [RIGHT] cursor arrow.

The tool air blast starts.

Press [AUX CLNT].

The tool air blast stops.

Door Interlock

Press [MDI]. Type in S500 M3; Press [ENTER].

Make sure the machine IS NOT in SETUP MODE by checking the KEY SWITCH on the side of the pendant

With the door open, press [CYCLE START]. The machine should say to close the door and press [CYCLE START].

With the door closed, press [CYCLE START]. The interlock pin should extend and the spindle starts rotating.

 IMPORTANT: With the spindle rotating, test the door locks by trying to open the door. The spindle should not stop rotating. 

Test Key Switches

Insert the Setup/Run Lock Key (#2007) to the lower key slot and turn to the unlocked position.

Verify that the key can only be removed from the locked position.

Insert the Memory Lock Key (#2341) to the upper key slot and turn to the locked position.

Verify that the key can be removed from either position.

With the Memory Lock Key in the locked position, verify that changes cannot be made to the settings or programs.

Auto Window Installation

If machine has the auto window option, refer to Auto Window Installation - AD0652 for information on how to install the auto window on the DC-1.

Assemble the window enclosure.

Bolt the bottom bracket [1] to the enclosure above the window. 

Loosen the sensor clamp [2] on the bottom of the air cylinder.  Insert sensor [3] in between clamp and piston rod. Before tightening the sensor clamp, refer to the Auto Window - Troubleshooting Guide for sensor location. 

Remove the fitting plugs on the top and bottom of the air cylinder.  Connect the yellow airline [4] to the bottom hose fitting and the grey airline [5] to the top hose fitting. 

Reinstall enclosure cover. 

To test the auto window, operate this code in MDI mode:

M59 P151;

G04 P5.;

M69 P151;

G04 P5.;

M99;

Rotary Installation

If your machine came with a HRT or TRT rotary table please see the following link for installation instructions:

WIPS Calibration 

If your machine includes the WIPS option, please see the following link for instructions on the calibration procedure:

Wifi Camera Operation 

If the machine came with the Wifi Camera option, please see the following link for installation instructions:

The DC-2 can be lifted by forklift, or by using the lifting points on the base and column castings. For details on how to lift the DC-2 refer to the Pre-Installation Guide, or the machine lifting placard [1] located on the machine.

The DC-2 machine weighs 8860 lbs (4020 kg). Check the specification of the lifting equipment before trying to lift.

Important: The DC-2 machine is required to be anchored. See section 4.3 Anchoring for the anchoring kit part number and instructions.

Connect the Air Supply at the lube panel shown in the image as Input Air Supply.

Note: For air specifications refer to the decal located on the front of the lube cabinet door.

The required air pressure for the DC-1 machine is 85psi.

Connect the air supply and verify the pressure gauge [1] on the regulator shows the correct pressure.

If the pressure needs to be adjusted, pull the regulator cap [2] up, and then twist it to set the outgoing air to 85 psi.

Once the gauge reads 85 psi, push the regulator cap down to lock it in place.

For the DC-2 machine, the regen assembly needs to be installed on top of the control cabinet [1].

Feed the 2 wires [2] connected to the regen assembly through the cutout in the control so that the wires can be routed to the vector drive.

Use the 4 BHCS [3] to install the regen assembly [4] in the correct position on the top of the control

Route the regen cable [1] to through the control cabinet to the vector drive [2].

Connect the cables to terminal 1 and 2 [3] on the bottom of the vector drive according to the label on each cable.

Fasten the top bracket [1] and the bottom bracket [2] that secure the pendant to the enclosure panel [3].

Use 2 BHCS to secure the top bracket, and 3 BHCS to secure the bottom bracket. 

Feed the cables [4] coming from the top of the enclosure through the top bracket so that they can be connected to the pendant.

Note: Do not damage the cables when fastening the top bracket. Feed the cables through before fastening the bracket if needed.

Install the top bracket cover [1] using the 4 BHCS [2] to fasten the cover to the top bracket that is attached to the pendant.

Secure the bottom of the pendant to the mounting bracket by fastening it with a SHCS [3] from underneath the bracket.

Make sure the rubber spacer [4] is in between the pendant and the mounting bracket. Place the one washer on each side of the rubber spacer.

Note: Make sure the top bracket cover doesn't pinch any of the cables that go to the SKBIF PCB.

Remove the rear panel of the pendant to gain access to the SKBIF PCB.

Make sure to connect all the cables that were routed through the top pendant mounting bracket that was installed in the previous step.

• Connect 33-4521 to the connector of 33-1300 which is connected to J20 [1] on the SKBIF PCB.
• Connect the USB cable to J9 [2] of the SKBIF PCB.
• Connect the ethernet cable to J28 [3] on the SKBIF PCB.
• Connect the USB from the touchscreen assembly to J11 [4] on the SKBIF PCB. 
• Connect the ground wire to the cable clamp fastener [5] as shown in the image.

Note: Make sure that the ferrite filters [6] are installed onto the USB cables to protect them from electrical noise.

Once the wiring has been verified, reinstall the rear panel of the pendant.

The Z-axis cable carrier needs to be mounted. It is removed on some machines for shipping purposes.

Important: Make sure to verify it is fully installed before you begin jogging the machine.

The Z-axis cable carrier needs to be mounted. It is removed on some machines for shipping purposes.

Install the cable carrier mount plate [1] to the top of the column using the mounting screws [2].

Then attach the Z-axis carrier [3] to the plate [1] with the 4 BHCS [4].

Install the rear cover [1] to the cable carrier mounting plate. 

Use the 4 BHCS [2] to mount the cover to the mounting bracket [3].

Note: Make sure that the cover plate is oriented correctly. The cutout side [4] needs to be on the bottom right side as shown in the image.

Warning: The cables and hoses need to be separated and pulled to the sides of the cable carrier [1]. Pull them to the left and right sides and don't leave cables or hoses routed in the middle of the cable carrier. The cables could be pinched by some of the mechanical components in the spindle head area.

Once the cables are pulled to the sides, install all the missing links [2] of the cable carrier.

For machines with the auto window feature, the auto window needs to be assembled and installed on the right side window of the machine. 

Important: The machine will be in an alarm state until the auto window and the clamp sensors are properly installed. Continue with these steps and AD0652 for instructions on installing the auto window.

The auto window kit is contained in the 30-14126 package that is shipped with the machine.

Remove the right window enclosure panel [1] from the DC-1 by unfastening the 4 BHCS [2]. 

Slide the two window guides [1] onto the side window enclosure panel [2].

To secure the window guides in place, bend the tabs [3] extending from the top of the enclosure panel over the window guides to lock them in position.

Slide the window [4] from the top into the guides [1] and test that the window slides through the guides easily and can be aligned with the window lift bracket [5]. 

Important: Do not fix the lift bracket [5] to the window at this time. AD0652 provides details on how to complete the auto window installation.

Take the auto window mounting panels [1] and fasten them to the DC-1 enclosure [3] as shown in the left image.

Fasten the window panel [4] to the mounting panels [1] using the 6 FBHCS [5] fasteners included in the kit.

Note: The right image shows the window panel mounting from the viewpoint of inside the machine. Make sure the mounting panels [1] are facing the proper direction.

The lift cylinder assembly for the DC-1 auto window is the same as other auto windows for other machines. 

Remove the jumper wire (33-1388) [1] from the window close connector of the (33-1169) cable [2]. The 33-1169 cable is connected to P13 of the IO PCB. 

This jumper wire [1] gets replaced by the connector to the window closed sensor [3]. This sensor is on the bottom of the cylinder behind the enclosure cover.

Note: The purpose of this jumper is to prevent alarms related to the window being open prior to the auto window being installed.

Once this jumper is removed, the haas control will throw an alarm saying that the side window is not closed.

To clear this alarm, the clamp sensor [3] must be installed onto the auto window lift cylinder.

Refer to AD0652 for instructions on how to install the cylinder and sensors.

Remove the SHCS keeping the door fastened to the bracket [1].

Note: There are two brackets securing each door in position. One bracket near the door handle [2] and the other bracket on the other end [1].

Remove the X-axis and Y-axis shipping brackets. Power on the machine and jog the Z-axis up so that you can remove the spindle head bracket [3] from the table.

Note: If the Z-axis cannot be jogged up far enough, the Z-axis zero position isn't set correctly. Refer to Chapter 5 - Operation / Tool Changer for details on how to reset the Z-axis zero position. 

Once the X-axis and Y-axis shipping brackets have been removed, the waycovers need to be fastened in position.

Remove the front table cover [1] and make sure that all waycover fasteners [2] are removed from the front cover and back side of the table.

Note: Before jogging along any axis of the machine, make sure the fasteners for the waycovers are removed. 

Once the front cover is removed, use the fasteners removed and the bag of fasteners ziptied to the Y-axis waycover [3].

Slide the waycovers into position as shown in the image.

Install the Y-axis waycover [1] to the saddle using the fasteners [2]

Fasten the X-axis waycovers [3] in position using the fasteners [4].

Note: Some of the X-axis waycover fasteners cannot be installed until after the front cover [5] is installed

Apply RTV sealant to the seams where the waycovers join the table to prevent coolant intrusion under the waycovers.

Install the table front cover [5] that was removed in the previous step.

Note: Make sure that the the fasteners on the back side of the table are 

Remove the skirt [1] located at the bottom of the machine.

This will give access to the front two leveling bolts [2]. 

The DC-2 machine has supporting feet [3] near the skirt of the enclosure. 

Important: Make sure these support feet are not touching the ground when doing the leveling process.

Set the machine height using the four corner leveling bolts [1 ,2, 3, 4] to 4" +/- .5" (101 mm +/- 10 mm) above the floor. Turn each screw so they have equal tension.

Jog the X-axis and Y-axis to the middle of their travel, centering the table.

Note: For more information, refer to this link for a more detailed process on how to level a VMC machine.

Clean the table surface and leveling tool (T-2181) and check the calibration of the leveling tool before proceeding.

Position the level at the center of the table, parallel to the X-axis. Use a t-slot for alignment.

Note the position of the bubble.

Reposition the level by turning it 180 degrees. The bubble should display the same reading as previously.

If the readings are different by more than one division, return the level to Haas for adjustment and do not use it to level the machine.

Adjust corner leveling bolts [1, 2] or [3, 4] until the bubble parallel with the Y-axis is centered.

This levels the machine front to back.

Always raise the lower side of the machine to maintain clearance for the coolant tank (if equipped) and adjust the two leveling bolts on that side an equal amount.

Adjust corner leveling bolts [1, 3] or [2, 4] until the bubble parallel to the X-axis is centered.

This levels the machine left to right.

Again, raise the lower side of the machine and adjust the two leveling bolts on that side an equal amount.

Keep the level in the same position and jog the Y-axis to bring the table to the front of the machine.

Note the position of the bubble.

Jog the Y-axis across its full travel, stopping at the column. Look to see which rear corner of the machine is lowest, as shown by the leveling tool.

Raise the lowest rear corner by adjusting corner leveling bolt [3] or [4] until the bubble is centered on the level.

Jog the Y-axis back across its full travel, bringing the table to the front of the machine. Look to see which front corner is lowest, as shown by the level.

Raise the lowest front corner by adjusting corner leveling bolt [1] or [2] until the bubble is centered on the level.

Repeat steps 6 and 7, moving the table back and forth across the full travel of the Y-axis, raising the lowest corner each time.

Continue this process until the level reads zero at both ends of the Y-axis travel.

Once the machine has been leveled along both the X and Y axes, raise up the non-corner leveling bolts [5, 6, and 7] so that they are making contact with the base to provide support.

After the machine is leveled, touch down the supporting feet [1] of the enclosure.

Reinstall the machine skirt [2] that was removed before leveling.

Lock the leveling bolts in place by tightening the locking nut while holding the leveling bolt. Ensure that the leveling bolts do not move during this process.

For a more in-depth guide on how to perform this procedure, please see:

Make sure the spindle chiller is in position [1] on the platform [2] located to the rear of the machine.

There is a power cable, a flow alarm cable, and a ground cable that are installed to the control cabinet at the factory.

Note: Refer to the DC-Series - Spindle Chiller chapter of this manual for more information.

Verify that the fluid tank is full by inspecting the fluid level gauge [1] on the back of the spindle chiller unit.

Add fluid if needed through the inlet port at the top of the unit. The fluid gauge should show the level is near the top of the M range [2]. 

Note: Use a mixture of 30% ethylene glycol and 70% dionized water to fill the spindle chiller.

Important: Never run the Spindle Chiller without fluid in the tank. This can cause serious damage to the pump.

Make sure that the switch located on the front of the chiller unit is on. The settings and parameters for the chiller are set in the factory and should not be altered.

Note: The display of the spindle chiller will be blank. The chiller powers itself on when the spindle is running or during tool changes. 

Verify that the oil reservoir [3] is filled with Mobil DTE 24 Ultra (93-2546).

The flow rate of the oil into the air system also needs to be set correctly. Adjust the set screw [4] so that the flow rate is 1 drop every 3 to 10 minutes. The oil drip will be visible through the sight glass below the set screw [4].

The flow rate of oil into the airlines can only be set when the spindle is running. Run the following MDI program when trying to set the flow rate:

• S50 M99; 

Loosening the set screw will increase the flow rate of oil, and tightening will decrease the flow rate.

Note: Having a flow rate higher than this range could flood the air supply which could damage the machine.

Run the spindle run-in program.

Examine the sight glass, make sure the correct number of drops fall through the sight glass. 

Examine the fittings [1,2] on top of the oil pump tank.

The oil collects on top of the oil pump tank [3] either behind or in front of the sight glass bracket, underneath the leaking fitting.

Tighten any leaking fittings.

Go to the Maintenance tab.

Press [F2] to cycle an axis lubrication test.

Inspect the gauge on the grease lubrication system. Make sure it holds pressure.

Machines with Single/Dual Prog Air Option Only: 

Route the Foot Pedal cable (32-1390) [1] from the control [2]along the enclosure panels to the front of the machine [3].

For more details, refer to the Programmable Air Installation procedure.

Power off the machine.

Place the 2 chip strainer baskets [1] into the coolant tank [2].

Move the coolant tank assembly under the drain slots [3] at the base of the machine.

 NOTE: Make sure that the strainer basket [1] is directly under the drain slots to ensure coolant flows into the tank. 

Place the TSC pump on the left [4] if included in machine. Place the flood coolant pump on the right [5].

Connect the hose coming from the coolant pump [1] to the end of the chip separator [2].

Connect the hose from the T-fitting [3] to the coolant washdown going to the left side of the machine (right side as shown in the image from the back of machine)

Connect the hose from the right side of the chip separator [4] to the other side coolant washdown. Route the hose through the column casting to the far side of the machine.

Connect the hose coming from the spindle head [5] to the front fitting on the chip separator [6].

Connect the hose [7] to the coolant gun port on the front of the machine. Route it through the enclosure with the hose for the coolant washdown.

Spindle Operation 

Run the Spindle Run-In program O09221. 

In the case of an unusual spindle noise, run a vibration test. For a guide on how to perform a spindle vibration test please see: 

Coolant and Air Blast-DC Operation

Fill the coolant tank with the necessary gallons of coolant in order to fill the tank.

Connect the coolant pump.

Run coolant by pressing  [COOLANT] on control pendant.

Verify that there is coolant coming out of the nozzles around the machine.

There are two nozzles for coolant located by the spindle head. Make sure coolant comes out of the two nozzles on the left.

Note: The third nozzle by the spindle head is for the Air Blast-DC option. Refer to the decal [1] for which nozzles are for coolant.

To verify that the Air Blast option is operational, run the following command in MDI mode and make sure air comes out of the nozzle labeled AIR BLAST:

1. M83 - starts the air blast
2. M84 - stops the air blast

Through Spindle Coolant (TSC) 

If machine comes equipped with TSC, insert a TSC toolholder into the tool carousel side pocket.

Then load the toolholder into the spindle by calling T[pocket_number] on the control and pressing ATC FWD.

Important: Tools cannot be loaded directly into the spindle on a DC machine. For more details on how to load tools into the spindle for the DC machine, refer to the Operation Chapter.

Press [AUX CLNT] to start the TSC.

Correct operation is as follows:

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

Press [RESET].

Through-Tool Air Blast (TAB)

If machine comes equipped with TAB, operate this code in MDI mode:

M73;

G04 P5.;

M74;

G04 P3.;

M99;

M73 starts the TAB. M74 stops the TAB.

Manually operate the TAB:

Press [AUX CLNT]. Press the [RIGHT] cursor arrow.

The tool air blast starts.

Press [AUX CLNT].

The tool air blast stops.

Door Interlock

Press [MDI]. Type in S500 M3; Press [ENTER].

Make sure the machine IS NOT in SETUP MODE by checking the KEY SWITCH on the side of the pendant

With the door open, press [CYCLE START]. The machine should say to close the door and press [CYCLE START].

With the door closed, press [CYCLE START]. The interlock pin should extend and the spindle starts rotating.

 IMPORTANT: With the spindle rotating, test the door locks by trying to open the door. The spindle should not stop rotating. 

Test Key Switches

Insert the Setup/Run Lock Key (#2007) to the lower key slot and turn to the unlocked position.

Verify that the key can only be removed from the locked position.

Insert the Memory Lock Key (#2341) to the upper key slot and turn to the locked position.

Verify that the key can be removed from either position.

With the Memory Lock Key in the locked position, verify that changes cannot be made to the settings or programs.

Auto Window Installation

If machine has the auto window option, refer to Auto Window Installation - AD0652 for information on how to install the auto window on the DC-1.

Assemble the window enclosure.

Bolt the bottom bracket [1] to the enclosure above the window. 

Loosen the sensor clamp [2] on the bottom of the air cylinder.  Insert sensor [3] in between clamp and piston rod. Before tightening the sensor clamp, refer to the Auto Window - Troubleshooting Guide for sensor location. 

Remove the fitting plugs on the top and bottom of the air cylinder.  Connect the yellow airline [4] to the bottom hose fitting and the grey airline [5] to the top hose fitting. 

Reinstall enclosure cover. 

To test the auto window, operate this code in MDI mode:

M59 P151;

G04 P5.;

M69 P151;

G04 P5.;

M99;

Rotary Installation

If your machine came with a HRT or TRT rotary table please see the following link for installation instructions:

WIPS Calibration 

If your machine includes the WIPS option, please see the following link for instructions on the calibration procedure:

Wifi Camera Operation 

If the machine came with the Wifi Camera option, please see the following link for installation instructions: