Verify the Installation preparations are in accordance with the Pre-installation Guide prior to setting the machine in place.

 Note: The condition of the foundation may require different heights at some leveling screws to make the machine level.

Order Anchoring Kit 93-1000861 (Qty 1) and verify the anchoring preparations are in accordance with the anchoring instructions prior to setting the machine in place.

  Important: It is required that the machine be anchored. Refer to the following link: ANCHORING INSTRUCTIONS.

Tools Required:

• HDC Tooling Kit

• Precision bubble level, calibrated to show 0.0005 inch per 10" (x2)
• Test indicator (0.0005") with mag base
• Two ¾" hex wrenches (one open end or box and one ratchet)
• HSK-A100T X 8” PREC SPINDLE ALIGNMENT TOOL

Place the first column on the 4 corner pucks in the location marked by the anchoring template. The middle pucks will be added later.

 Note: Stone the top of the column to ensure the surface is free from burrs.

Set the Laser [1] at the coolant tank location with the laser line 7 in (177.8 mm) off the ground. 

 Note: The 7 in (177.8 mm) laser height should be measured at the coolant tank location.

Level the first column so that the laser line intersects the machined pads [2] for the connection plates.

Verify the column's level by placing two precision levels [3] on the top of the column, one parallel and one perpendicular to the X-Axis.

Use the leveling laser [1] to set a reference line [2] from the two back anchor holes [3] of the second column to the back anchor stud of the first column [4].

Verify the columns position in the X-direction by measuring the distance between the anchoring stud and the side of the leveling screw. This should be 3.625 inches (92.075 mm). 

The long pry bar can be used to make adjustments.

 Note: If a crane is available some of the weight of the column can be supported to make this step easier. 

Use the leveling laser [1] to set a reference line [2] from the center of the saddles anchor holes to the column.

 Note: Position the laser line so it passes through all nine of the saddle anchor holes.

Verify that the column sits between 12.25 - 12.5 inches (311.15 - 317.5 mm) [1] from the anchor line [2] by using the laser line [4] from the previous step and measuring off the side of both leveling screws [3] closest to the saddle anchor holes.

The long pry bar can be used to make adjustments.

 Note: If a crane is available some of the weight of the column can be supported to make this step easier. 

Re-check the level [1] and adjust as needed.

Install the remaining middle pucks [2] and install all 6 anchors [3]. Torque the anchors to 80 ft-lbs.

Verify the level and height again. 

Install second column. 

Stone the top of the column to ensure the surface is free from burrs.

Set height of columns to each other with laser tool.

The laser should catch the edge of the top surface of each column equally. Adjust the second column's height if needed.

Verify the column's level by placing two precision levels on the top of the column, one parallel and one perpendicular to the X-Axis.

Verify the dowel pins are installed on the columns and are in good condition. 

Stone the bottom machined surface of the Spacer Tools to ensure the surface is free from burrs.

Install the Spacer Tool over the dowel pins of the first column.

The Spacer Tool is used to set the correct location of the second column.

Use a pry bar to adjust the second column to align the dowel pins with the Spacer Tool.

 Note: If a crane is available some of the weight of the column can be supported to make this step easier. 

The Spacer Tool should sit flush with the machined surface on both columns.

 Note: Weight may need to be added to the top of the Spacer Tool to fully seat it.

With the Spacer Tool in place verify and adjust the level and height of the second column so that it matches the first column.

Install the remaining pucks and anchors to both columns. Torque down the anchors to 80 ft-lbs.

Verify the level and height again.

Clean top of columns where the bridge will sit.

Use an air hose to remove any debris in the threaded holes on the top of the columns. 

Install the Tapered Pins (T-0195) on the four outside corners of the column and verify adjustment blocks are installed and in good condition.

Install the Tool Changer lifting tool (T-0192) on the Tool Changer assembly. 

Use the Fork LIFT TOOL to lift the bridge above the columns.

Lower the bridge onto the columns using the tapered pins (T-0195) as guides.

Install the bolts and washers to connect the bridge to the columns.

Once most of the bolts are installed, replace the tapered pins (T-0195) with the remaining bolts and washers.

Remove the Fork Lift Tool.

Install the remaining bolts after the Fork Lift Tool is removed.

Leave all of the bolts loose.

Install alignment bolts on the front of the bridge. The longer bolt will be installed in the through hole and the shorter bolt will be installed in the threaded hole.

Use the four jacking bolts [1] to remove the Spacer Tool. Evenly apply pressure with the screws to avoid damaging the tool or the dowel pins. 

Move the saddle between the columns and set on the three level pads [1] with Anti-Friction base [2] and pads [3] (from T-0198) underneath.

Rough level the saddle on the three leveling feet.

• With the table in the center of travel, place two levels at right angles to each other as close as possible to the center of the table. One will show the level across the width of the table and the other will show the level along the length of the table.
• Focus on leveling the table only in this X-axis position to establish a primary datum for the machine. 
• Only the first three leveling feet [1] should be supporting the saddle, the rest of the leveling feet should not be touching the pads. Use the precision levels and the three leveling screws to adjust pitch and roll.  

Set the height of the laser line [1] to intersect the mark [2] on the front of the column. 

Raise/lower the saddle so the laser line intersects the underside of the table plates [3].

After adjusting the height of the saddle on the three leveling pads, recheck the rough level.

 Note: The augur troughs have been removed for illustrative purposes. 

Install T-0198 HDC SADDLE ALIGNMENT TOOL KIT in the anchor holes at the ends of the saddle. 

Make sure the side screws are in a position that will make contact with the saddle. 

Adjust the saddle with the Alignment Tool to allow the installation of the connection plates. 

 Note: It is helpful to first engage dowel pins on the saddle, then adjust the saddle to align the holes in the connector plates with the dowel pins in the columns.

 Note: The connector plates will not drop to fully engage the pins. When the alignment is close, back off all of the Alignment Tool's jack screws and use connection plate bolts to evenly install the plates over the pins until fully installed. 

Once the connection plates are installed, lower the three adjacent leveling pads [2] and back off the original three leveling screws [1].

Remove the saddle Alignment Tool Kit, including the Anti-Friction bases [3] and pads [4]. Lower the original three leveling screws [1] and raise the adjacent leveling screws [2]. 

Verify the saddle height. 

Note: Some components of the Carousel where removed for illustration purpose only.

Use the proper lifting equipment as shown to support the tool changer and mount (approx. 2100 lbs. / 952.54 kg).

 Note: The tool changer should be lifted from the hook located closest to the bridge if the mount is attached.

Unbolt [2] the tool changer from the shipping location.

Move the Tool Changer assembly to the tool changer side of the machine.

 Note: Be careful not to pinch or stretch cables/hoses.

Clean the mount and bridge surfaces before installing the assembly onto the bridge.

Install the Tool Changer assembly onto the bridge. 

Install the unused copper washers provided in the hardware kit.

Torque the mounting bolts per the Haas Torque Specification.

Remove the bolts holding the control bracket closed. 

Using the CONTROL LIFT TOOL T-0194 to support the control cabinet (approx. 500 lbs / 226.8 kg).

Unbolt the control cabinet [1] from the shipping location.

Remove the shipping brackets. 

Lift the control cabinet into position and attach to the control bracket while it is in the 90 degree position. 

Torque all bolts per the Haas Torque Specifications. 

Remove the lifting bracket.

Close the 90 degree bracket and secure it with the provided hardware.

Torque all bolts per the Haas Torque Specifications. 

Install the Lube panel bracket [1] onto the right side of the control cabinet.

Install 2 of the 6 screws onto the Lube Panel Bracket.

Install Lube Panel [1] onto bracket. 

Tighten the 2 screws and install the remaining 4 screws to secure the Lube Panel to the bracket.

Install 25-15589 CONTROL WIRE BOX BOTTOM HDC-3 underneath the control cabinet. 

Install the following:

1 - 25-17124 ENCL PANL CONTROL BRKT TOP HDC

2 - 25-17122 CABLE CHANNEL BRIDGE SIDE LOWER HDC

Route the cables and hoses bundled with the control cabinet into the bridge cable channel.

Use cable clamps to secure the cables and hoses to the sheet metal as shown.

Once the cables are routed and secured using cable clamps in the bridge cable channel, install the following:

1 - 25-17123 ENCL PANL CONTROL CVR TOP HDC

2 - 25-17118 COVER CABLE CHANNEL BRIDGE SIDE HDC

3 - 25-17116 COVER CABLE CHANNEL BRIDGE TOP HDC

4 - 25 -1304A COVER CABLE HOLES

5 - 25-15006 ENCL PANL CONTROL CVR TOP REAR VS-3

Install the supports [1] (x5) onto the back of the bridge.

• 25-16010A PLANK SUPPORT SERVICE PLATFORM HDC

Install the platform [1] onto the catwalk supports.

• 20-9971 PLANK SERVICE PLATFORM HDC

 Note: The notches in the plank face will be closest to the back of the bridge.

Install the two side rails [1].

• 20-9977 END RAIL SERVICE PLATFORM HDC

Install the back railing [1].

• 20-9970 MAIN RAIL SERVICE PLATFORM HDC

Install the ladder [1].

• 20-9978 LADDER SERVICE PLATFORM HDC

Wiring the Saddle

• On the saddle, locate the bundle of wires containing 
  • Auger motor power (Green Line)
  • X-Axis motor power (Orange Line)
  • X-Axis scale (Orange Line)
  • X-Axis encoder (Orange Line)
  • X-Axis Lube lines (x2) (Purple Line)
• Locate the Coolant & Conveyor Electrical Connection Bracket cables (Blue Line)
• Route cables through the cable channel along the base of the saddle. Secure the cables to the channel.
• Continue through the column on the operator side 
• Route the cables up through the base of the control cabinet.
• Connect the X axis motor cable the Amplifier.
• Route the X axis encoder cable up to the Main Processor and connect to P1.
• Connect auger motors to open location on QUAD CHIPC  PBC  (P4 - P7)
• Connect the X-Axis scale cable into the interpolation box underneath the control cabinet.
• Route the lube lines up through the base of the CALM cabinet.
• Connect the X-Axis lube lines into the oil reservoir ports.

• Remove the shipping bracket and hardware completely from underneath the cable carrier [1].
• Remove the shipping bracket and hardware completely from the spindle head [2]. The hardware will be used to install sheet metal later.

 Note: Save the hardware from the spindle head bracket [2]. It will be used to install sheet metal later.

Wiring the Top of the Spindle Head

Install the following: 

1 - 25-15580A CBL CARRIER MNT BRKT YZ RIGHT HDC

2 - 25-15579 CBL CARRIER BRKT YZ LEFT HDC-3

3 - 25-15581A CBL CARRIER MNT BRKT YZ REAR HDC

Attach the cable carrier [4] to the bottom sheet metal panel [3].

Route and secure the cables and hoses using the cable clamps [5] to the sheet metal.

Install the following:

6 - 25-15582 CBL CARRIER BRKT YZ FRONT HDC-3

7 - 25-15598 CBL CARRIER BRKT YZ TOP HDC-3

Wiring the Coolant & Conveyor Electrical Connection Bracket

• Route one of the coolant hoses along the saddle to the Operator side coolant port [1] located inside the support leg and connect it. (Green Line)
• Route another coolant hose under the saddle to the Tool Changer coolant port [1] located inside the front leg and connect it. (Blue Line)
• Route the last coolant hose through the bridge to the Operator side column and along the side of the saddle to the Coolant & Conveyor Electrical Connection Bracket. (Red Line)

 Note: Use cable clamps to secure the coolant hose to the underside of the Operator and Tool Changer sheet metal pans. 

Wiring the Coolant & Conveyor Electrical Connection Bracket

• Mount the coolant electrical connection bracket and Coolant Filter to the side of the rear trough and connect hoses and cables.
• Connect the Conveyor cable to P24 on the I/O PCB.
• Connect the High pressure coolant Aux to P29 on the I/O PCB.
• Connect the low pressure coolant cable to P29 on the I/O PCB.
• Connect the coolant level sensor cable to P43 on the I/O PCB.
• Connect the hoses to the Coolant Chip Separator by following the Chip Separator - Installation procedure.

 Important: Use the hose clamps and a Ratchet Clamp Cinch Tool to secure the hoses to the Chip Separator.

 Note: The cable channel for the coolant and conveyor connections will be installed later in the procedure.

• On the Operator Side of the bridge, locate the bundle of hoses containing
  • Spindle airline (clear hose)
  • TSC (purple hose)
  • SMTC Pocket Up (green hose)
  • SMTC Pocket Down (red hose)
  • 4th Axis Unclamp (blue hose)
  • 4th Axis Clamp (opaque hose)
  • 5th Axis Unclamp (orange hose)
  • 5th Axis Clamp (black hose)
  • Y-Axis Lube Lines
  • Z-Axis Lube Lines
• Route the hoses in the cable channel to the CALM Cabinet. 
• Connect the airlines and lube lines according to the schematics located on the CALM Cabinet door.

Remove the HPU cover.

Move the HPU from its shipping location [1] to its permanent location [2]. 

Connect the Hydraulic hose.

Verify the HPU pressure is between 650-725 PSI (45-50 bars).

Install the cover back on.

Route the pendant cables [1] into the pendant [2] and install the cable harness retainer.

Connect the cables to the SKBIF PCB. Refer to the step below for connections.

Install the back cover [3].

Attach the  pendant assembly to the pendant stand [4].

Install the dome plugs [5]

Remove the rear panel of the pendant. Connect these cables:

• Remote Jog handle cable [1] to P9
• Power cable [2] to J20
• USB cable [3] to J9
• Ethernet cable [4] to J28

Install a ferrite [5] onto the USB cable [3] connected to SKBIF J9 connection.

Install a ferrite [5] on the touchscreen cable [6] connected to SKBIF J11 connection.

 Note: Make sure to loop the USB cable within the ferrite [5] as shown. 

Attach the ground wire [7] from pendant to the control cabinet. 

  Note: Recommended to attach the ground wire to the cable clamp as not all screws in that area can be used for grounding. 

Unblocking the Bridge

• Remove the shipping bracket and hardware completely from both sides of the Y-Axis [1].
• Remove the shipping bracket and hardware completely from the Z-Axis [2].

Unblocking the Table Base

• Remove the shipping bracket and hardware completely from the X-Axis.
• Install the cover plate onto the trough after removing the X-Axis shipping bracket.
• Install the side table cover.

WARNING : Use appropriate PPE equipment (face shield, gloves, etc.) when filling the hydraulic tanks.

 Note: The counterbalance pressure cannot be checked with the Z-Axis at the top of travel. 

If the tank's gauge reads less than 1050psi, use the steps below to fill the tank to 1050psi.

Make sure all tank valves are closed before beginning. 

Attach nitrogen tank fill nozzle

Begin filling counterbalance tank by SLOWLY cracking open the valve

Fill tank until gauge reads 1050psi.

Leveling the Machine

At this point the machine is completely unblocked and all axes are enabled. The process of leveling can now begin. The following criteria should have already been met at this point:

• The machine correctly placed with respect to the anchoring points.
• The machine is fully wired.
• Machine Power up.

Level the Table 

• With the table in the center of travel, place two levels at right angles to each other as close as possible to the center of the table. One will show the level across the width of the table and the other will show the level along the length of the table.
• Focus on leveling the table only in this X-axis position to establish a primary datum for the machine. 
• Only the first three leveling feet [1] should be supporting the saddle, the rest of the leveling feet should not be touching the pads. Use the precision levels and the three leveling screws to adjust pitch and roll. Once level, anchor those three feet to the full 80 ft-lbs. 
• When the table level is close to zero in both directions, the three leveling screws [2] may be brought down to touch the leveling pads.
• Use the three leveling screws [2] to adjust the pitch and roll. Once level, anchor those three feet to the full 80 ft-lbs. 
  
• Lower the next four leveling feet [3]. Do not adjust the pitch and roll. Once the leveling feet are touching, anchor those four feet to 40 ft-lbs.
• Lower the next four leveling feet [4]. Do not adjust the pitch and roll. Once the leveling feet are touching, anchor those four feet to 40 ft-lbs.
• Lower the next four leveling feet [5]. Do not adjust the pitch and roll. Once the leveling feet are touching, anchor those four feet to 40 ft-lbs.

Sweeping the Table

• Mounting the indicator on the spindle, first verify that the table is flat to the Y-axis plane.
• Place a parallel granite (38") on the table surface. Sweep the granite in the Y-axis to determine, and correct column / table flatness in the Y-axis direction. This is a very sensitive measurement method and corrections to this flatness should be made in conservative steps.
• Raise or lower the side of the table to get the flatness within specification using all the leveling screws on one side.
• Move the levels to the table and place them as close to the center as possible.
• One level should be parallel to the X-axis and one level should be perpendicular to the X-axis.
• Once the Column to Table flatness has been established, check the table for twist using the step below.

Table Twist 

• Focus on leveling the table only in this X-axis plane to establish a primary datum from the granite. 
• Make note of the reading that is present. 
  
• While monitoring the level, jog the table all the way to left and check if there is a change in the level reading.
• While monitoring the level, jog the table all the way to right and check every 15 inches if there is a change in the level reading.
•  If there is no change of reading, then the table has no twist. If there is a twist in the table, this must be corrected.

Level of the Bridge

• With the Y-Axis and Z-Axis in their home positions, insert T-0157A SPINDLE LEVEL TOOL CT50/HSK100A VS/HDC into the spindle. 
• Place a precision level on T-0157A
• The level should be perpendicular to the X-axis of the machine to check the pitch [1]. It is very unlikely that this surface will read zero; do not expect it to. Make note of the reading that is present.
• While monitoring the level, jog the Y-Axis to the end of travel and back and check if there is a change in the level reading. If there is no change in reading, then the columns are level. If the pitch is out, this must be corrected by adjusting all the leveling feet on one column evenly to either raise or lower one side of the bridge.
• Place a single level on the spindle level tool (T-0157A), parallel to the X-axis of the machine to check the roll [2]. It is very unlikely that this surface will read zero; do not expect it to. Make note of the reading that is present.
• While monitoring the level, jog the Y-Axis to the end of travel and back and check if there is a change in the level reading. If there is no change in reading, then the bridge has no twist. If there is a twist in the bridge, this must be corrected by evenly adjusting the front column leveling feet on the affected column.

Once the machine is rough leveled, torque all anchors to 40 ft-lbs.

 Note: Remove the shipping bracket connected to the X-Axis waycover and saddle.

Install the panels in the following order:

1 - 25-15975 ENCL PANL RT FRONT INTERMEDIATE PAN HDC

2 - 25-15976 ENCL PANL RT REAR INTERMEDIATE PAN HDC-3

 Note: Install one  25-15439 ENCL AUGER SUPPORT BRKT LONG VS-3 on both sides of the saddle before installing panels 3 and 4.

3 - 25-15974 ENCL PANL RIGHT INTERMEDIATE PAN HDC-3

4 - 25-15974 ENCL PANL RIGHT INTERMEDIATE PAN HDC-3

5 - 25-15973 ENCL PANL RIGHT FRONT PAN HDC-3

6 - 25-16025 ENCL PANL RIGHT REAR PAN HDC-3

7 - 25-15969 ENCL PANL LEFT MIDDLE PAN HDC-3

 Note: Install the chip guards before installing 30-13074B WAYCVR TELESCOPE 21X 153 X-AX VS-3. See step below.

8 - 30-13074B WAYCVR TELESCOPE 21 X 153 X-AX VS-3

 Note: Apply gasket tape and sikaflex to all the troughs. 

Install 25-15980 ENCL CBL CHANNEL RIGHT HDC-3 [1] on to the RIGHT INTERMEDIATE PAN [2].

Route and secure the cables and hoses to the cable channel. 

Install the following:

1 - 25-16014 CHIP BLOCKER X-AXIS VS-3 (x2)

2 - 25-16221 INTRNL PANL CHIP BLOCKER X-AXIS HDC/VS-3 (x2)

Re-position both of the 25-14834 WAYCOVER RIDER GUIDE [3] from the shipping position to the operating position shown.

Install the coolant drain tube [1] into the fitting under [2] the saddle. 

Install the drain pan [3] under the rear augers.

Secure the drain tube [1] to the drain pan [3] with a zip tie.

Install the panels in the following order:

1 - 25-15641 SMTC 50 PCKT CVR CAMBOX LEFT HDC-3

2 - 25-15642 SMTC 50 PCKT CVR CAMBOX RIGHT HDC-3

3 - 25-15631 SMTC 50 PCKT CVR LOWER LEFT HDC-3

4 - 25-15637 SMTC 50 PCKT CVR CAROUSEL LEFT HDC-3

 Note: Route the work light power cable, USB cable, Front curtain air lines (blue and orange hoses), and sensor cables through the hole on the side of the sheet metal [4].

5 - 25-15634 SMTC 50 PCKT CVR LOWER RIGHT HDC-3

6 - 25-15636 SMTC 50 PCKT CVR MIDDLE RIGHT HDC-3

7 - 25-15639 SMTC 50 PCKT CVR CAROUSEL TOP HDC-3

8 - 25-15633 SMTC 50 PCKT CVR UPPER LEFT HDC-3

9 - 25-15635 SMTC 50 PCKT CVR UPPER RIGHT HDC-3

10 - 25-15643 SMTC 50 PCKT CVR CAMBOX UPPER HDC-3

11 - 25-15640 SMTC 50 PCKT CVR CAROUSEL REAR HDC-3

12 - 25-15638 SMTC 50 PCKT CVR CAROUSEL RIGHT HDC-3

Install the panels in the following order:

 Note: 25-16041 ENCL PANL FRONT SUPPORT LEG HDC-3 is installed onto the pan before it is installed onto the machine.

1 - 25-16041 ENCL PANL FRONT SUPPORT LEG HDC-3

2 - 25-15982 ENCL PANL FRONT PAN EXT HDC-3

3 - 25-15981 ENCL PANL REAR PAN EXT HDC-3

 Note: Only the Tool Changer side of the machine is shown for illustrative purposes. This step also applies to the Operators side.

Add gasket tape along the top edges [1] of the pans and middle augers on both the Operator and Tool Changer side of the machine. 

Overlap the tape in the corners [2]. 

Two fundamental geometry checks need to be made. The first is the perpendicularity of the X-axis to the Y-axis, and the second is to verify the sweep of the Z-axis.

• The sweep of the X-axis to the Y-axis is accomplished using a granite square. Set zero by sweeping the X-axis on one side of the square, and then verify that the motion of the Y-axis is perpendicular by sweeping the adjacent side of the square. If the X-axis and Y-axis are not found to be within tolerance use the adjusting screws on the front of the columns to correct the X-Y perpendicularity.
• NTE 0.0010/35"
• Torque the bridge-to-column bolts to 450 ft-lbs.

Verify the sweep of the X/Z and Y/Z-axis:

• Sweeping the Z-axis is accomplished using a triangle square. 
• The line of motion of the Z-axis will be checked by comparing it to the line of intersection of the two most convenient relative planes, that of the X-Z plane and the Y-Z plane.
•  By assuring that each of these planes are perpendicular to the X-Y plane within specification, the machine geometry will be preserved. 

 Note: Sheet metal has been removed in the model for illustrative purposes. 

X-Z plane:

• Place a parallel granite [1] in the middle of the table parallel to the X-Axis. 
• Place the granite triangle [2] on top of the parallel granite with a one side of the triangle granite hanging over the edge of the parallel granite. 
• Attach an indicator to the spindle nose with the B-Axis at 90 degrees. 
• Run the indicator along the bottom of the triangle that is hanging off the parallel granite [3]. Use mylar shims between the granites to adjust the triangles level. NTE 0.0001". 
• Once the triangle is level, jog the indicator along the long side [4] of the triangle in the X-Z plane. 
• The X-Z plane is NTE 0.0010/35"
• If the X-Z plane is out, evenly adjust the front column leveling feet on both columns to bring the reading into spec.

X-Z plane: 

• Use the T-0196 JACK BLOCKS YZ SQUARING HDC [1] on one side of the carriage to lift it off the Y-Axis truck that needs shimming.
• Loosen the bolts on all 6 trucks leaving one upper truck screw on the opposite side of the jack tight as a pivot point.
• Add shims on the top surface of the top corner Y-Axis truck [3] to adjust the Y-Z plane.

 Note: The Y-axis ball nut needs to be floated in after a change in the Y-Z square. 

Y-Z plane: 

• Place a parallel granite [1] in the middle of the table perpendicular to the X-Axis. 
• Place the granite triangle [2] on top of the parallel granite with one side of the triangle granite hanging over the edge of the parallel granite. 
• Attach an indicator to the spindle nose with the B-Axis at 90 degrees. 
• Run the indicator along the bottom of the triangle that is hanging off the parallel granite [3]. Use mylar shims between the granites to adjust the triangles level. NTE 0.0001". 
• Once the triangle is level, jog the indicator along the long side [4] of the triangle in the Y-Z plane. 
• The Y-Z plane is NTE 0.0010/35"

Install the panels in the following order:

1 - 25-16037 ENCL PANL REAR RIGHT HDC-3

2 - 25-16028 ENCL PANL FRONT RIGHT HDC-3

3 - 25-16038 ENCL PANL REAR RIGHT EXT HDC-3

4 - 25-16029 ENCL PANL FRONT RIGHT EXT HDC-3

 Note: 25-16029 ENCL PANL FRONT RIGHT EXT HDC-3 is not shown but is a mirror image of and should be installed after 25-16038 ENCL PANL REAR RIGHT EXT HDC-3.

5 - 25-16259A ENCL PANL BRIDGE CVR FRONT HDC-3

 Note: Install the back curtain, 25-16264 ENCL PANL REAR BRIDGE CVR SUPPORT HDC-3 and 25-16263A ENCL PANL BRIDGE CVR REAR HDC-3, not shown in image, after 25-16259A ENCL PANL BRIDGE CVR FRONT HDC-3.

6 - 25-16264 ENCL PANL REAR BRIDGE CVR SUPPORT HDC-3

7 - 25-16263A ENCL PANL BRIDGE CVR REAR HDC-3

 Note: Panels 8-10 may get in the way when making adjustments for the X and Y-Axis geometry. 

8 - 25-16260A ENCL PANL BRIDGE CVR LOWER LEFT HDC-3

9 - 25-16261A ENCL PANL BRIDGE CVR LOWER RIGHT HDC-3

10 - 25-16262A ENCL PANL BRIDGE CVR LOWER MID HDC-3

Install the panels in the following order:

 Note: Panels 25-16043 ENCL PANL REAR SUPPORT LEG RIGHT HDC-3  and 25-16042 ENCL PANL REAR SUPPORT LEG LEFT HDC-3  will be installed onto 25-16040 ENCL PANL REAR PAN TC HDC-3 before it gets installed onto the machine.

1 - 25-16040 ENCL PANL REAR PAN TC HDC-3

2 - 25-16042 ENCL PANL REAR SUPPORT LEG LEFT HDC-3

3 - 25-16043 ENCL PANL REAR SUPPORT LEG RIGHT HDC-3

 Note: Sikaflex may need to be added to the seams between panels 4 and 5, 5 and 6, and 6 and 7 to prevent coolant leaks.

4 - 25-16036 ENCL PANL REAR RIGHT TC HDC-3

5 - 25-16035 ENCL PANL REAR EXT HDC-3

6 - 25-16031 ENCL PANL REAR HDC-3

7 - 25-16032 ENCL PANL REAR LEFT HDC-3

8 - 25-16034A ENCL PANL REAR LEFT LOWER HDC-3

9 - 25-16536 ENCL PANL REAR LEFT EXT HDC-3

10 - 25-16033 ENCL PANL REAR LEFT UPPER HDC-3

11 - 25-16052 ENCL PANL REAR DOOR STIFFENER HDC-3

Attach a bubble level [1] vertically to 25-16536 ENCL PANL REAR LEFT EXT HDC-3 [2]. Use the leveling screws [3] to make the panel perpendicular to the floor.

Install the panels in the following order:

1 - 25-16026 ENCL PANL FRONT HDC-3

2 - 25-16027A ENCL PANL FRONT LEFT HDC-3

3 - 25-16533 ENCL PANL FRONT LEFT EXT HDC-3

4 - 25-16532 ENCL PANL FRONT UPPER HDC-3

5 - 25-16534 ENCL PANL FRONT LEFT EXT BRACE HDC-3

Attach a bubble level [1] vertically to 25-16533 ENCL PANL FRONT LEFT EXT HDC-3 [2]. Use the leveling screw [3] to make the panel perpendicular to the floor.

Install the parts in the following order:

1 - 59-2118 AIR CYL 1.25 X 32.0 W/MAGNET

2 - 25-15658 PP TOP AIR CYLINDER BRKT AW 

3 - 25-15659 PP BOTTOM CYLINDER MNT BRKT

 Note: 25-15659 PP BOTTOM CYLINDER MNT BRKT VF-2 and 25-15658 PP TOP AIR CYLINDER BRKT AW will be attached to 59-2118 AIR CYL 1.25 X 32.0 W/MAGNET

Connect the grey and yellow air hoses to the push connect ports at either end of the cylinder. Match the hose to the corresponding colored zip tie. 

Test the auto window opens correctly and the window sensor gets triggered in the correct location.  Make any needed adjustments before installing the cover.

4 - 25-16531 CYLINDER COVER OPERATOR WINDOW HDC-3

Install the panels in the following order:

1 - 25-16537 ENCL PANL REAR LEFT EXT BRACE HDC-3

2 - 25-16535 ENCL PANL DOOR CURTAIN HDC-3

3 - 59-2272 AIR CYL 32MM X 380MM W/FIXED CUSHIONS

 Note: Install 25-16538 after cylinder mount is adjusted for proper door closure.

4 - 25-16538 ENCL PANL DOOR CURTAIN CYL CVR HDC-3

Install the longer curtains onto the [1] 25-16535 ENCL PANL DOOR CURTAIN HDC-3

Install the shorter curtains onto the [2] 25-16263A ENCL PANL BRIDGE CVR REAR HDC-3.

• On the Tool Changer, locate the bundle of cable containing: 
  • Front curtain Open (blue hose) (Green Line)
  • Front curtain close (orange hose) (Green Line)
  • Front curtain switch cable (Green Line)
  • USB cable (Orange Line)
  • Work Light power cable (Purple Line)    

• Route the cables and hoses through the cable hole in the Tool Changer's sheet metal [1].
• Route the USB and Work light power cables through the cable channel located on the inside of the front sheet metal panel 
• Connect the USB to the Camera and the Work light power cable to the Work light.
• Route the air hoses and sensor cable up towards the Front curtain Air cylinder.
• Route and connect the Tool Changer Window closed sensor cable.
• Connect the air hoses to the Air Cylinder.
• Connect the Front Curtain Sensor to the sensor bracket next to the Front Curtain hinge.

• In the bridge, locate the bundle of cable containing: 
  • Operator Window Open (grey hose)
  • Operator Window Close (yellow hose)
  • Operator Window switch cable
  • WIPS cable
  • USB cable
  • Monitor Power cable
  • Work Light power cable

• In the CALM Cabinet, locate the bag with the black hose and opaque hose. 
• Connect the Operator Window Open (grey hose) and Operator Window Close (yellow hose) to the toggle valves.
• Connect the black and opaque hoses to the air manifold inside the CALM Cabinet.
• Route the cables inside the bridge through the cable hole on the front of the bridge and sheet metal. 
• Route the hoses (black and opaque) for the Door and Window toggle valves through the cable hole on the bridge casting and through the cable channel on the outside of the 25-16026 ENCL PANL FRONT HDC-3. Plug the hoses into the toggle valves per the lube panel diagram. (Green Line)
• Route the WIPS cable and work light power cable through the cable channel on the inside of the 25-16026 ENCL PANL FRONT HDC-3. (Purple Line)
• Route the Air Cylinder sensor cable through the cable channel on the outside of the 25-16026 ENCL PANL FRONT HDC-3 to the Air Cylinder. (Blue Line)
• Route the monitor power and USB cables through the cable channel on the outside of the 25-16026 ENCL PANL FRONT HDC-3. (Orange Line)

Attach the bracket to the spindle chiller.

Attach the spindle chiller to the column using the brackets. 

Plug the spindle power cable [1] into the chiller power and flow chiller power cable [2].

Plug the spindle flow cable [3] into the chiller power  and flow spindle flow cable[4].

Connect the hoses [5] to the spindle chillers inlet [6] and outlet [7]. 

Once the hoses are connected, close the Drain Valve [1]. 

 Note: The Drain Value is closed when the handle is parallel to the floor. 

Install the camera monitor system by following the steps in the Camera and Monitor - Installation - AD0793 procedure. 

Use T-0190 SMTC HSK100A SERVICE SPLIT TOOL and follow the steps in the SMTC - Double Arm - Alignment - VMC procedure. 

Use T-0190 SMTC HSK100A SERVICE SPLIT TOOL and follow the steps in the Side-Mount Tool Changer - HSK - Spindle Orientation Offset - NGC procedure. 

Complete the latest Inspection Report on HBC and attach it to the machines history.

 Note: This site is available only to Haas Service Techs.

 Note: MRZP will be completed after the probe is calibrated and the compensations are calculated later in the procedure. 

Calibrate the probe by following the steps in the WIPS - Probe Calibration - NGC procedure.

Verify the Tool Changer alignment has been set with the split tool before running the Tool Change Program.

Download the Tool Change Program below onto a USB and load onto the machine.

Run the Program.

Verify every pocket has a successful tool change and there are not alarms generated after 500 tool changes. 

Tool Change Program:

O00012.nc

Complete a Ballbar Analysis by following the Ballbar Analysis - Quick Check Mode procedure.

Complete the HDC-3-5AX Post-install Checklist ID-0038 and attach it to the machines history.