This procedure applies to the following kit:

• 93-3465 PALLET RECEIVER & CLAMP ASSY EC-400/500
• 93-3464 PALLET RECEIVER & CLAMP ASSY VC-400 

This procedure is meant to address leak issues seen on the 4th-Axis on the EC-400, EC-500, EC-500/50, and VC-400/SS. Please contact Haas Service for further information on this kit. 

NOTE: This procedure can be used for 93-3464 PALLET RECEIVER & CLAMP ASSY VC-400, there will be slight differences with the process but this procedure will serve as a guideline.

Minimum requirements:

• This kit is only available for reboot EC-400/500 and all VC-400's. Refer to the EC identification document for assistance on determining if the machine is a reboot machine.

 NOTE: For the reboot EC-400's 4th Axis assemblies that were built before 5/2022 or have not upgraded to the new design, refer to EC-400 4th Axis Receiver Rebuild.

NOTE: The kit is coated with anti-rust grease before shipping. If this grease is applied to the internal and external seals, please clean them and apply silicon grease to the seals.

Zero return the B-Axis before depressurizing the HPU

Set parameter 40.011 HPU 1 TYPE [1] to DISABLED [2]. 

 NOTE: Parameter 40.011 HPU 1 TYPE will need to be set to DISABLED in order for the depressurize page to work. If it is set to ALWAYS ON or ON DEMAND the HPU will not depressurize.

Depressurize the HPU using the HPU DEPRESSURE page.

Press [DIAGNOSTIC] then navigate to the MAINTENANCE tab [1] then navigate to the HPU DEPRESSURE tab [2]. Press [F3] to depressurize the HPU [3] and the HPU should no longer have pressure in the lines. The text on the screen will display a status that the HPU is safe to use [4]

 NOTE: Parameter 40.011 HPU 1 TYPE will need to be set to DISABLED in order for the depressurize page to work. If it is set to ALWAYS ON the HPU will not depressurize.

Release the brake, press E-stop and place lock-out on the machine.

Unbolt and lower the sensor/anti-rotation bracket [1]. Remove the snap ring [2] from the shaft. Lower the block [3] off the shaft.

NOTE: Mark the hydraulic lines, air lines, and fittings on the manifold with zip ties to ease reinstallation later during this procedure.

Install jack bolts [4] under the clamp plate to prevent damage to the piston quad-ring.

Remove the (8) bolts [5] from the receiver.

Install (2) eye bolts in the clamp plate. Use an appropriate lifting strap to raise the receiver from the rotary.

This assembly will weigh approximately 200 lbs.

NOTE: Hydraulic fluid will leak out when the receiver is lifted.

NOTE: Disassemble the receiver assembly and remove the springs as they will be reused later in the procedure. Hydraulic fluid will leak when disassembling the receiver.

Remove panel [1] to expose the HPU and its manifold block. It is important to cap the clamp, unclamp, and brake fittings [2] on the HPU manifold side in order to proceed with the installation section of this procedure. 

NOTE: Mark the hydraulic lines and fittings on the manifold with zip ties to ease reinstallation later during this procedure.

NOTE: The hydraulic lines will leak fluid when disconnecting them from the manifold, place a plastic bag or rags to maintain a clean machine.

Using 1/2-13 eye bolts safely lift and remove the platter.

This platter weights approximately 200 lbs use the proper lifting apparatus when removing. 

Release the brake and make sure the the HPU is depressurized before removing the line. Plug the brake like to prevent leakage. 

 WARNING: IF YOU DO NOT DISENGAGE THE BRAKE AND DISCONNECT THE LINES YOU CAN PERMANENTLY DAMAGE THE BRAKE BY REMOVING THE PLATTER.

The felt seal has already been installed to the bottom side of the platter denoted as [1], apply a thin layer of tacky grease on the felt seal as well as on the outer diameter of the brake. (5% Moly Grease 99-1792)

Before installing the platter to the brake install 57-0461 O-rings [2]  and 57-2144 [3] on the bottom side of the platter. Apply a thin layer of silicon grease to the internal seals [4] on the lower seal gland cap. 

 NOTE: The kit is coated with anti-rust grease before shipping. If this grease is applied to the internal and external seals, please clean them and apply silicon grease to the seals.

NOTE: Applying too much silicon grease may compromise sealing capabilities. 

Using 1/2-13 eye bolts [1] safely lower the platter [2] onto the brake assembly. Line up the brake bleed port on the brake with the access hole on the platter.

Loosely install the platter mounting bolts (SHCS M16 X 50 ) [3] these will be re-used from the previous platter assembly.

The platter weighs approximately 200 lbs, use the proper lifting apparatus to safely lift this component. 

Indicate the platter runout, this is NTE 0.0005 in (0.013mm).

The platter will have a line on the side of the platter, place your indicator on the lower surface [1]. 

Once indicated torque the mounting bolts in star pattern referencing the HAAS TORQUE SPECIFICATION document. 

NOTE: It is recommended to use a dead blow to adjust the runout, if the bake is used to self center the platter this will not allow the machine to use the depressurize page to drain the HPU.

Install 57-2975 O-ring [1] to the bottom side of the receiver, apply a thin layer of silicon grease to the O-ring.  

 NOTE: The kit is coated with anti-rust grease before shipping. If this grease is applied to the internal and external seals, please clean them and apply silicon grease to the seals.

 NOTE: Applying too much silicon grease may compromise sealing capabilities. 

Install the receiver [1] to the platter assembly using the provided 5/16-18 eye bolts [2] in the kit. Place the eye bolts in the inner bolt pattern. Line up the brake bleed access hole on the platter with the access hole on the receiver.

Use the SHCS 1/2-13 X 2 [3] provided to bolt down the receiver. 

The receiver weighs approximately 150 lbs, use the proper lifting apparatus to safely lift this component. 

IMPORTANT: It is recommended to indicate and adjust the receiver axial and radial runout before installing the piston and other internal components, otherwise with all the internal components this will be much harder to do. 

RECEIVER FACE RUNOUT:

With an indicator and mag base setup, locate the front right key and set the dial to zero. The front right key will have an arrow engraved on it [A].

Indicate the top face of the keys and measure face runout on the receiver rotate the receiver every 90 degrees this is NTE 0.0005 in (0.0127 mm) TIR. 

Once the runout has been adjusted torque the mounting bolts in star pattern referencing the HAAS TORQUE SPECIFICATION document. 

NOTE: The internal components (piston shaft, receiver cap and air blast manifold) are installed in the images, when they should not be. This step is to be used for reference.

RECEIVER RADIAL RUNOUT:

With an indicator and mag base setup, locate the front right key and set the dial to zero. The front right key will have an arrow engraved on it.

Indicate the side face of the keys and measure radial runout on the receiver, this is NTE 0.0005 in (0.0127 mm) TIR. 

NOTE: The internal components (piston shaft, receiver cap and air blast manifold) are installed in the images, when they should not be. This step is to be used for reference.

Install the external seal [1] on the piston and shaft assembly and add a layer of silicon grease.

This piston will have a 2 piece seal the first piece of the seal, the energizer rests behind the outer part of the seal.

There are two possible piston seal combinations, please see the next step for further instructions on how to install. 

 NOTE: The kit is coated with anti-rust grease before shipping. If this grease is applied to the internal and external seals, please clean them and apply silicon grease to the seals.

Kits built after 7/2022 may have two possible piston seal styles. 

The seal combination on the left is what the kits were originally built with, the seal combination on the right is what the kits are currently being built with. 

If the kit comes with the left seal combination apply a thin layer of grease to the energizer and install first. Apply a thin layer of grease to the outer seal and install. 

If the kit comes with the right seal combination apply a thin layer of grease to the energizer and apply a thin layer of grease to the outer seal and install it in one piece. 

 NOTE: Applying too much silicon grease may compromise sealing capabilities. 

Install the piston and shaft assembly [1] using the 1/2-13 eye bolts. 

The piston will need to get past the chamfer [2] on the receiver to do so we recommend using the receiver cap [3] to press the piston past the chamfer. 

Install 57-2155 the external O-ring [5] of the receiver cap [3] apply a thin layer of silicon grease to both the external and internal seals.

Make sure both external and internal seals [5] and [6] still have enough silicon grease for permanent installation. 

 NOTE: The kit is coated with anti-rust grease before shipping. If this grease is applied to the internal and external seals, please clean them and apply silicon grease to the seals.

 NOTE: Applying too much silicon grease may compromise sealing capabilities

 NOTE: Applying a coat of grease to the inner bore of the receiver will help with installation. 

 NOTE: The springs from the old receiver assembly will be reused on this assembly. Using the springs to install the piston shaft assembly will also allow the piston to reach its desired position against the top of the platter. 

Install the springs [1] in the grooves on the piston and install the cap [2] to the receiver casting using the 5-16-18 threaded rods provided in the kit, place them in 3 equally spaced bolt holes. Tighten the nuts in 1/2 turn increments to get the piston past the chamfer.

 IMPORTANT: Make sure to evenly lower the cap if it is not the piston can wedge against the receiver and cause metal to metal contact and damage the assembly. 

Use the provided nuts/studs to evenly drive down the cylinder cap enough to engage the SHCS 5/16-18 X 7/8 [3] and allow the piston to move past the chamfer. Tighten the bolts down until they are snug.

Verify the orientation of the receiver cap matches the image with the piston cap boss parallel to the keys with arrows. Torque the mounting hardware to the specified value.

HAAS TORQUE SPECIFICATION

Grease the internal seals using silicon grease in the air blast manifold.

Place the gasket [1] between the receiver cap and the air blast manifold assembly [2] and install using the provided hardware [3]. 

 NOTE: The kit is coated with anti-rust grease before shipping. If this grease is applied to the internal and external seals, please clean them and apply silicon grease to the seals.

Install the hydraulic manifold [1] on the under the gearbox and reconnect the lines. 

Grease the dowel pins using tacky grease. 

NOTE: It is recommended to use the retaining cap [2] to raise the manifold into position. Use a longer screw(s) or an appropriately sized 1/4-20 threaded rod with a 1/4-20 nut in place of the mounting bolt [8] to fully seat the hydraulic manifold

Using the longer screws or threaded rod with the retaining cap pull the manifold in place until all 4 internal seals have past over the first chamfer [3] and bottom out at the upper lip [4].

Once the manifold is fully installed remove the longer bolt/threaded rod and install the original 1/4-20 mounting hardware.

NOTE: The line denoted in RED [5] is unclamp, and the line denoted in GREEN [6] is clamp. The air line goes in the clear port [7]. Use the zip ties previously added to aid reinstallation.

Reinstall the sensor block in the correct orientation. The sensors may need to be readjusted if clamp/unclamp alarms appear.

IMPORTANT: Verify all hydraulic hoses keep clear from rotary encoder during clamp/unclamp positions.

Verify that the hydraulic pressure is zero on the gauges page before installing all the hoses back to the manifold block.

Install the hydraulic hoses to the clamp block and to the appropriate ports on the hydraulic manifold. Use the zip ties previously added to aid reinstallation.

With all the hydraulic hoses reinstalled the HPU can be repressurized, but will be done later in the procedure.

In the meanwhile download and apply the patches designated for this kit from HBC, if there is any difficulty applying the patch contact Haas Service for further assistance. 

AXIS OF ROTATION:

With an indicator and mag base setup, locate the front right key and set the dial to zero. The front right key will have an arrow engraved on it [A].

Rotate the rotary every 90 degrees and move your X and Z axis so that the indicator is marking the same point and record this value.

In this example the indicator is following the front right key with the arrow engraved. This value is NTE 0.0005 in (0.0127 mm)

Install the pallet clamp plate [1], if the dowel pins [2] do not line up with the holes [3] the clamp shaft will need to rotate into position. 

To rotate the shaft into position use the mounting bolts without the clamp plate installed, a screw driver can be wedged between and used to turn the shaft into the correct position. 

NOTE: Apply tacky grease to the dowel pins [2].

Set parameter 40.011 HPU 1 TYPE [1] from DISABLED [2] to its original state.

Repressurize the HPU using the HPU DEPRESSURE page.

Press [DIAGNOSTIC] then navigate to the MAINTENANCE tab [1] then navigate to the HPU DEPRESSURE tab [2]. Press [F4] to restart the HPU [3].

A prompt will show up that the pump could start any time.

Press YES [Y] and the pump will restart.

The HPU pressure gauge will rise to 550 PSI [1] and the page will display cautionary text that the pump is enabled [2].

NOTE: This image uses a simulator page for reference, the gauge SHOULD NOT read 0 PSI after restarting the pump. 

Verify no leaks are present after restarting the pump. 

Raise the HPU pressure to 600 PSI in order to get the same clamp force as the previous design. Loosen the jam nut denoted as [1] and tighten the set screw [2] to raise the HPU pressure, the HPU pressure value is shown on the diagnostics gauges page.

PALLET FACE RUNOUT:

With an indicator and mag base setup, place the indicator center of the side closest to the spindle and set the dial to zero. The pallet will have an arrow pointing towards the spindle, for reference place the indicator in front of the hole where the arrow is [A].

Without moving the indicator, rotate the pallet every 90 degrees and record the value on the indicator. This value is NTE 0.001 in (0.0254 mm).

PALLET CENTER BORE:

Place the tip of the indicator in the center of the bore on the pallet, jog in the Z-direction to the bottom half of the bore and jog to one side of the bore and set the dial to zero [1].

Rotate the pallet 360 degrees and record the value, this is NTE 0.003 in (0.0762 mm) TIR.

PALLET FLATNESS IN X DIRECTION:

Pick up a zero point on the top front right edge of the pallet, sweep the pallet in the X  direction and record the value. This value is NTE 0.0005 in/10 in (0.0127 mm/ 254 mm)

PALLET FLATNESS IN Z DIRECTION:

Pick up a zero point on the top front right edge of the pallet, sweep the pallet in the Z direction and record the value. This value is NTE 0.0005 in/10 in (0.0127 mm/ 254 mm)

PALLET AXIS OF ROTATION:

With an indicator and mag base setup, place the indicator center of the side closest to the spindle and set the dial to zero. The pallet will have an arrow pointing towards the spindle, for reference place the indicator in front of the hole where the arrow is [A].

Rotate the rotary every 90 degrees and move your X and Z axis so that the indicator is marking the same point and record this value.

In this example the indicator is following the front right key with the arrow engraved. This value is NTE 0.001 in (0.0254 mm)