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824 OneTouch Lite 5H
Operation Manual
17-00077 Rev. D.8.2024

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Summary of Contents for PennEngineering HAEGER 824 OneTouch Lite 5He

  • Page 1 824 OneTouch Lite 5H Operation Manual 17-00077 Rev. D.8.2024...
  • Page 2 © 2021 HAEGER, INC. All rights reserved. No part of this work may be reproduced, copied, adapted, or transmitted in any form or by any means without written permission from HAEGER, INC. HAEGER, INC makes no representation or warranties with respect to the contents here of and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose.
  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 - INTRODUCTION ..........................1 Congratulations!................................ 1 Haeger Locations Worldwide ............................ 1 Statement of Foreseen Use ............................2 Safety Information ..............................2 Customer Service ............................... 2 Responsibilities of the Operator ..........................2 Responsibilities of the Service Technician ......................... 2 Basic Maintenance ..............................
  • Page 4 Tooling Protection System ............................31 Lockout-Tagout ............................... 32 Fire Safety Equipment ............................. 33 Safety Awareness & Residual Risks ......................... 34 Operator Safety Awareness & Residual Risks ..................... 35 Maintenance Safety Awareness & Residual Risks ....................37 Safety System Tests ..............................38 Step 1: Safety Switch Test Procedure .........................
  • Page 5 Main Assembly ..............................105 Sheet Metal (Pt.1) ..............................107 Sheet Metal (pt.2) ..............................108 Electrical Cabinet ..............................110 MAS 350 Bowl Assembly ............................113 Dual Shuttle Assembly (15-41872) Pt.1 ......................... 115 Dual Shuttle Assembly (15-41872) Pt.2 ......................... 116 Dual Shuttle Assembly (15-41872) Pt.3 ......................... 118 Multi-Shuttle Assembly (15-40027) ........................
  • Page 6: Section 1 - Introduction

    SECTION 1 - INTRODUCTION Congratulations! You are using a genuine Haeger Hardware Insertion Machine - the industry standard for dependable fastener insertion. Haeger, Inc. is widely recognized as the industry leader in the development and implementation of innovative self-clinching fastener installation technologies. For over thirty years, Haeger engineers have been designing and building flexible systems for installing practically every kind of self-clinching fastener into practically every kind of work piece - creating new technologies to help Haeger owners get just about any job done productively and profitably.
  • Page 7: Statement Of Foreseen Use

    Statement of Foreseen Use The OneTouch Lite-5He insertion machines are intended for use in an indoor commercial or industrial environment. Factory-authorized training is made available for operators at the time of installation. The Insertion Logic technology and All Haeger machines are designed to operate at voltages ranging between 208-575V and at 50/60Hz with no additional power requirements.
  • Page 8: Basic Maintenance

    Basic Maintenance The customer is responsible for basic maintenance of the machine, including but not limited to:  Cleaning the machine regularly to prevent the buildup of dirt and debris.  • Inspecting the machine regularly for signs of wear and tear.  •...
  • Page 9: Basic Data Sheet

    Basic Data Sheet YOUR Machine Model 824 OneTouch Lite 5He Serial Number: Year Manufactured: Voltage: Amperes: Hertz (Machine): Hertz (MAS): Phase: 824 OneTouch Lite 4He Machine Matrix Voltage 208/240 380/480 Amperage Hertz 50 or 60 50 or 60 50 or 60 Phase Noise Measurement Summary LEX 8-hour...
  • Page 10: Illustrations Of Safety Notes

    Illustrations of Safety Notes Safety notes are identified by a pictogram and a signal word. The signal word describes the severity of the risk at hand. Warning possible dangerous situation that could cause minor physical injuries. Risk of electrical voltage possible dangerous situation that could cause serious physical injuries.
  • Page 11: Details Of Location In The Documentation

    Details of Location in the Documentation All information in these instructions concerning direction and location refer to the workplace of the operator. Rear Side of Machine Right Side Left Side Front side In this manual, the use of the terms left and right refers to the machine operator ’s left and right when they are standing in front of the machine and facing the work area Eye protection must be worn when operating this machine...
  • Page 12: Safety Precautions And Warnings

    Safety Precautions and Warnings Operate this Haeger Hardware Insertion Machine without proper Never instructions. Read and thoroughly understand this manual before attempting to operate this machine. Tamper with any part of this machine’s electrical system unless you Never are a trained electrician and thoroughly understand this machine’s electrical schematic.
  • Page 13: Section 2 - Installation

    SECTION 2 – INSTALLATION Handling The Haeger Hardware Insertion Machine is designed to provide the operator with a comfortable working height and to allow freedom of movement when positioning work pieces in the tooling area. Because of these features, the machine is top heavy when unloading. ...
  • Page 14: Recommended Safe Work Zone

    Recommended Safe Work Zone Prior to delivery, it is recommended that an area is laid out which allows operator and maintenance personnel ample space to work or service the machine. The distances shown below are general guidelines. It is the customer’s responsibility to adjust this “Safe Work Zone”...
  • Page 15: Skid Removal

    Skid Removal  The feet are already installed on the machine.  You will need to lift the machine to remove the skids.  You will need three different wrenches. Skid Bolt: 9/16 in./13mm socket 9/16”/13mm socket wrench Foot: 7/8 in./22 mm open end wrench 7/8 in./22 mm 15/16 in./24 mm open end wrench 15/16 in./24 mm...
  • Page 16: Machine Setup

    Machine Setup 1. Place the machine in the shop. The surface should be flat, level, and hard enough to support the machine's weight, which is detailed in the 'Basic Data' section of this manual. If you're unsure whether the surface can hold the machine's weight, consult a structural engineer. As of the time this manual was published, there are no known requirements to secure or anchor the machine to the surface.
  • Page 17 Machine Setup (Cont.) must be connected to the machine. Connect airline to the shut-off valve attached to the air regulator located at the back of the machine. Use only an airline that supplies clean, dry air. Air Flow Air Pressure 3 ft 3 /min - 85 l/min psi/6 Bar If the machine is not yet filled with hydraulic oil, remove the sides of the machine to access reservoir...
  • Page 18: Main Power Setup

    Main Power Setup The electrical connections required in this section must be made by a  qualified electrician. Check to make sure that the electrical power supply for this machine  has been disconnected at the supply source before doing any work on the machine’s electrical system.
  • Page 19: Machine Operator Basic Controls

    Machine Operator Basic Controls All the operator controls except the foot pedal are through the touch screen interface to the right of the machine. There are E-Stop buttons/Stop buttons are on both right and left sides of the machine. Touch Screen Control Panel This is the primary interface to the operation control system.
  • Page 20: Footswitch

    Footswitch Footswitch is shielded and connected to the Haeger Machine by a heavy-duty cable. It contains both the Down and Up Footswitches When the Down Footswitch is depressed, the cylinder ram moves down. Releasing the Down Footswitch will stop the ram. Depressing the Down Footswitch again will recommence downward ram movement.
  • Page 21: Testing Motor Phase (Direction Check)

    Testing Motor Phase (Direction Check) The Machine Setup must be completed before initiating this test. 1. Open Side Panels from machine base so that the Motor is in view. Turn the machine’s Main Disconnect Switch to the ON position. position 2.
  • Page 22 Testing Motor Phase (Continued)  NEVER tamper with any part of this machine’s electrical system unless you are a trained electrician and thoroughly understand this machine’s electrical schematic. Make sure that the electrical power supply for this machine  has been disconnected at the supply source before doing any work on the machine’s electrical system.
  • Page 23: The Upper Tool Holder

    The Upper Tool Holder The Upper Tool Holder is secured to the machine’s cylinder rod by the black serrated knob in the front. This Upper Tool Holder can usually be left on the machine. If it requires removal, do so with care. Continuity springs and guide pins inside the Upper Tool Holder may be easily knocked out during removal.
  • Page 24: Dual Shuttle

    Dual Shuttle The Dual Shuttle is a 1 piece shuttle platform module that contains two stations for shuttle tooling. Integrated electrical/air supply connections on the module allows quick mounting and removal from the machine. Step 1: Mount shuttle tooling to the bottom of multi-shuttle.
  • Page 25: The Turret Insertion System (T.i.s.)

    The Turret Insertion System (T.I.S.) Do not operate the machine without both the Upper and Lower Tools properly locked in place. The TIS-3 Lower Tool Holder is secured to the lower arm of the machine’s frame by a M16 X 50 SHCS (Socket Head Cap Screw) and aligned by pins on the bottom of the assembly.
  • Page 26: Univeral Lower Tool Holder H-166-8

    Univeral Lower Tool Holder H-166-8 The Universal Lower Tool Holder, H-166-8, is a single station lower tool holder that can be used for situations where the TIS’s turret arms are in the way of certain workpiece shapes. It is also used for Bottom Auto-Feed Tooling (ABFT).
  • Page 27: Quick Mount Auto Tooling

    Quick Mount Auto Tooling Installation and Changeover in Two Easy Steps Step 1: Place tooling onto the MAS adapter, align the module with to the locking and alignment pins. Step 2: Ensure the module is seated flush, and then push the lever towards the MAS bowl to lock.
  • Page 28: Modular Auto Feed System (Mas 350)

    Modular Auto Feed System (MAS 350) Modular Auto Feed System (MAS): This system allows the operator to run the MAS 350 bowl either at a continuous vibration or at intermittent vibration. Continuous vibration is commonly used when emptying the bowl out of hardware for a tool change or for small quantity hardware runs. Intermittent vibration is commonly used for normal high volume insertion applications.
  • Page 29: Quick Startup Procedure

    Quick Startup Procedure This procedure assumes that you are thoroughly familiar with this machine’s controls as described in the first part of this section. If you are not familiar with these controls, STOP. Return to the beginning of this section and review any controls you are not thoroughly familiar with before continuing.
  • Page 30: Positive Stop System Assembly

    Positive Stop System Assembly he Positive Stop System provides an easily adjustable method to precisely maintain a stopping point of the machine cylinder. This system is well suited for improving uniformity on delicate work pieces made of softer materials such as aluminum, fiberglass, or composite. It can also be used for inserting small hardware.
  • Page 31: Positive Stop System Setup Procedure

    Positive Stop System Setup Procedure This Setup Procedure can be used for production runs in both Conductive and Non-Conductive Modes. This setup procedure assumes that you are thoroughly familiar with this machine’s operating controls, safety systems, and conductive/non-conductive Modes. If you are not familiar with the above stated controls and systems, STOP! Go to those sections and become familiar with all of them before continuing.
  • Page 32 10. Remove the work piece from the machine. 11. Turn the Tube Assembly clockwise (right) approximately two revolutions. 12. Check your settings. Prepare hardware and workpiece for another insertion. 13. Bring the Punch down until it contacts the workpiece and stops. 14.
  • Page 33: Section 3 - Haeger Safety System

    SECTION 3 – HAEGER SAFETY SYSTEM Safety Precautions and Warnings Operate this Haeger Hardware Insertion Machine without proper Never instructions. Read and thoroughly understand this manual before attempting to operate this machine. Tamper with any part of this machine’s electrical system unless you Never are a trained electrician and thoroughly understand this machine’s electrical schematic.
  • Page 34: Safety System Description

    Safety System Description The Haeger Hardware Insertion Machine is equipped with a unique, reliable Safety System. Conductive Mode When the Safety System detects a non-conductive material between the Upper and Lower Tools, the Upper Tool’s downward motion reverses immediately and returns to its’ Up position. Non-Conductive mode The Upper Tool’s downward motion stops when any material is placed between the Upper and Lower Tools.
  • Page 35 In non-conductive mode:  Foot pedal must be released and pressed a second time.  Within safe position set by the TPS. Before each cycle, the state of the two sensors in the ram adapter are monitored by the dedicated Safety Controller.
  • Page 36: Tooling Protection System

    Tooling Protection System The Tooling Protection System (TPS) is intended for protecting the tooling and/or workpiece from damage in the event of wrong length fasteners or unintended obstructions that come in between the workspace. This system works in conjunction with the Safety System. The TPS is programmed during “Setup Stroke”...
  • Page 37: Lockout-Tagout

    Lockout-Tagout Lockout-Tagout is a safety procedure used to ensure that malfunctioning machines are properly shut off during maintenance or servicing. Before any repair work begins, the machine is isolated from hazardous power sources and rendered inoperative. The procedure involves locking the device or power source and attaching a tag to indicate that it should not be turned Lockout-Tagout procedure: Shut off machine and turn off computer from the touch screen if not already off.
  • Page 38: Fire Safety Equipment

    Fire Safety Equipment Haeger systems do not produce thermal, biological, fire or radiation hazards. However, having a Multi- Class rated fire extinguisher within reasonable distance from the machine and operator(s) is sound safety practice and is recommended. Your fire extinguisher(s) should be able to extinguish fires involving ordinary combustible materials, flammable/combustible liquids and energized electrical equipment.
  • Page 39: Safety Awareness & Residual Risks

    Safety Awareness & Residual Risks Introduction This section contains two sets of principles that must be followed to assure maximum safety when operating your Haeger Hardware Insertion Machine. The 1 explains situations and behaviors to avoid in order to prevent injury. The 2 principle describes residual risks that are inherent of the machine and cannot be removed.
  • Page 40: Operator Safety Awareness & Residual Risks

    Operator Safety Awareness & Residual Risks Risk of crushing: A high risk crushing hazard is created by the Punch and Anvil. Safety of the operator in non- conductive access operation must remain accessible only to trained and authorized personnel that are experienced in appropriate machinery operating conduct.
  • Page 41 Risk of pinching: A medium risk pinching hazard is created by the Multi-Shuttle moves back and forward exchanging lower tools. Risk of pinching: A medium risk pinching hazard is created by the TIS when rotating for the next station. 17-00077 Rev. D.8.2024...
  • Page 42: Maintenance Safety Awareness & Residual Risks

    Maintenance Safety Awareness & Residual Risks Risk of Electrical Shock: A high risk electrical shock while working on the RIGHT HALF of the electrical cabinet. See Section 7 Electrical Cabinet Assembly to identify components. High Voltage hazard is ALWAYS present in this location, until INCOMING (MAIN) power is shut OFF.
  • Page 43: Safety System Tests

    Safety System Tests There are three (3) Safety Tests in total. Do not skip or ignore any of them! Depending on the ambient shop temperature, you may need to warm up your Haeger Hardware Insertion Machine before beginning any operations. To do this, turn it on and let it run for about ten minutes.
  • Page 44: Step 2: Conductive Mode/Tps Test

    Step 2: Conductive Mode/TPS Test Never attempt to test or demonstrate this machine’s Safety System by placing any portion of your hand or body between the Upper and Lower tools. Always use the test procedure outlined in this manual. NEVER Operate this Machine without the proper tooling installed. The following instructions assumes the first Safety Sensor test has been performed and passed.
  • Page 45 Step 2: Conductive Mode Test (Cont.) 7. Place a non-conductive material (paper or cardboard recommended, harder materials may damage tooling if vacuum tip has a protruding pin) above the anvil, making sure the object completely covers the top surface of the Anvil. Keep your hands away from the tooling area. Depress and hold the Down Footswitch.
  • Page 46: Step 3: Safety Gap Test

    Step 3: Safety Gap Test Never attempt to test or demonstrate this machine’s Safety System by placing any portion of your hand or body between the Upper and Lower tools. Always use the test procedure outlined in this manual. NEVER Operate this Machine without the proper tooling installed. The following instructions assumes the first Safety Sensor test has been performed and passed.
  • Page 47 Step 3: Safety Gap Test (Cont.) This measurement must be at least .060” in. /1.52 mm or more for the safety systems to • function properly. If this measurement is less than .060” in. /1.52 mm, the gap is insufficient and must be •...
  • Page 48: Section 4 - Touch Screen Operation (Step By Step Demo)

    SECTION 4 – TOUCH SCREEN OPERATION (Step by Step Demo) OneTouch Lite -5He - Introduction This section provides you, the operator, with all the information that you need to operate the Haeger 824 OneTouchLite-4He safely and productively. Make sure that you read and understand all the descriptions, instructions and notes contained in this section.
  • Page 49: Touch Screen Hierarchy Overview

    Touch Screen Hierarchy Overview 17-00077 Rev. D.8.2024...
  • Page 50: User Level Security Access

    User Level Security Access User level security access, each login account is assigned a security level by the administrator. When the machine is first powered On or when operator change occurs, the user security level must be selected to access the Run or Start Production screen. Access & permissions are as follows: Haeger Administrator Adv.
  • Page 51: Quick Run Step By Step Demo

    Quick Run Step by Step Demo The 824 OneTouchLite-5He Insertion Machine is equipped with a computer running InsertionLogic software. This computer controls most of the machine’s settings and functions and is equipped with a touch screen. The touch screen is the main method of entering information into the software and controlling the computer.
  • Page 52 Touch on Quick Run Touch on Turn on Machine to start the motor. • Select Station • Touch on Station 1 Station: Stations high volume, Automatic insertion stations working in conjunction with the Modular Automated Feed System (MAS). Stations are Manual insertion stations.
  • Page 53 Tooling: This feature allows the operator to select the type of tooling to run in the • Tooling selected station. • Set to Shuttle Tooling Options are: Manual, Shuttle, Bottom Feed, and J-frame Touch on select fastener Material: Aluminum  Steel ...
  • Page 54: Tooling Control

    Unit & Size: Metric  Unified  • Select Fastener Unit of Measure • Touch on Metric • Select Fastener Size • Touch on M3 • Touch OK Force (lbs): Is the amount of force that will be applied during the hardware insertion cycle.
  • Page 55: Mas Values

    Dwell (Sec): Dwell is the length of time that the insertion force is applied. It can range from 0.0 seconds to 3.0 seconds. Setting the Dwell to 0.0 seconds will immediately return the ram upward after applying insertion force. A Dwell value greater than 0.0 seconds will keep the ram down, applying insertion force for that set amount of time.
  • Page 56: Quality Control

    Vibration (%): Vibration controls the MAS 350 bowl vibration speed. This determines how fast the hardware travels up the spiral track to reach the Multi Module. • Vibration (%) • Set to 25 The 25% value shown is a starting point only.
  • Page 57: Status

    Fastener Detection: This will instruct the machine to perform detection of a fastener at the fastener pickup point of the Shuttle Tooling Jaws. The Fastener Detection can be activated or deactivated by touching the Fastener Length ON/OFF button. • Fastener Detection •...
  • Page 58 Modular Auto Feed System (MAS): This feature allows the operator to either run the MAS 350 at a continuous vibration or • MAS an intermittent vibration. • Turn on continuous vibration to fill track and MAS 350 module. Continuous vibration is used for filling up the track and MAS 350 module or emptying the bowl out of hardware.
  • Page 59: Setup Stroke

    Setup Stroke : This feature sets up and records certain values for each station and project run. This must be completed at the beginning of each Quick Run. Setup Stroke records the fastener pickup point, fastener length, and insertion point. •...
  • Page 60 Setup Stroke is now complete for Station , and the system is ready for continuous insertions with current tooling. Repeat for Stations Stations 3-4 are manual tooling Touch on Next stations. Touch on Yes if the insertion is correct Touch on Close to exit Quick Run when project is completed.
  • Page 61: Programs Setup - Step By Step Demo

    Programs Setup - Step by Step Demo One of the most useful features of InsertionLogic is the ability to store and retrieve programs. When you save a program, you are saving all the setup values (for instance: Force, Dwell, Up Position, TPS, Fastener Detection, Fastener Length, and Teach sequences).
  • Page 62 The 824 OneTouchLite-5He Insertion Machine is equipped with a computer running InsertionLogic software. This computer controls most of the machine’s settings and functions and is equipped with a touch screen. The touch screen is the main method of entering information into the software and controlling the computer.
  • Page 63: Create New Program

    Touch on Programs Create New: Begins a new program. Programs are stored on the machine’s hard drive. • Create a new program • Touch on Create New Create New Program Program Name: Name to identify the program for later. For this example, use “Program Demo Plate 1 “...
  • Page 64: Library

    Touch on NEW New Customer: Adds a new Customer to the internal database. If a customer had been previously entered, choose “Existing” to see the list for selection. • Touch to bring up keyboard • Touch Type “Haeger, Inc.” • Touch Ok Program Notes: Space for any notes as necessary.
  • Page 65 Part Material: Material of the work piece/panel (Not the fastener). • Select Part Material • Touch on the Steel Fastener Type: Blind Standoff (ex. BSO)  Standoff (ex. SO)  Stud/Pin (ex. FH, HFH)  Nut (ex. CLS, S)  •...
  • Page 66: Insertion Values

    • Select Length • Touch on 10 Length: Fastener length Select Tooling Type: Shuttle tooling (automatic tooling) is typically setup on station 1 (automatic station). • Select Tooling Type • Touch on Shuttle When ready, use arrows to move to next setup. Tooling: Select tooling set for the job.
  • Page 67 Quality Control: Sensitivity Values: TPS Sensitivity Values: Minimum of 0.1, maximum of 1. Set Fastener Fastener Length Sensitivity: Detection Minimum of 0.1, maximum of 5. Fastener Detection Sensitivity: Minimum of 0, maximum of 1.813. Set Sensitivity Values Touch on Station 2 Repeat Wizard to program Station Touch on the * This time select a Nut: S-632-2.
  • Page 68 • Select Unit • Touch on Unified • Select Fastener Type • Touch on S • Select Size • Touch on 632 • Select Length • Touch on 2 • Select Tooling Type • Touch on Shuttle 17-00077 Rev. D.8.2024...
  • Page 69 When ready, use arrows to move to next setup. Set MAS Values Set Insertion Values Set Fastener Detection Quality Control: Sensitivity Values: TPS Sensitivity Values: Minimum of 0.1, maximum of 1. Fastener Length Sensitivity: Minimum of 0.1, maximum of 5. Fastener Detection Sensitivity: Set Sensitivity Values Minimum of 0, maximum of 1.813.
  • Page 70 Step through Wizard by touching on the selections shown below Select Tooling Type: Stations 3 and 4 are manually operated stations. Select Manual Tooling When ready, use arrows to move to next setup. Set Insertion Values Set Sensitivity Values 17-00077 Rev. D.8.2024...
  • Page 71 Touch on Station 4 Speed up the programming steps by using Search Fastener in lieu of the wizard to program Station Touch on the Search * This time select a Nut CLS-M10-1. Fastener Tab Touch on Global Touch on Fastener Name •...
  • Page 72 Touch select CLS-M10-1 Touch on Steel Touch on Manual Move to next step Set Insertion Values 17-00077 Rev. D.8.2024...
  • Page 73: Insertion Groups

    Move to next step Set Sensitivity Values Step: Add Insertion Groups For this example, create 4 insertion groups. Touch on Add to create an Insertion Group. Insertion Groups Station Number: Tapping the Station Column in each row (group) multiple times will toggle through the station numbers.
  • Page 74 Amount: This column sets the number of fasteners to be inserted for each insertion group. Touch here to enter # of fasteners for Station 1 Enter number of fasteners to be inserted. Touch on OK Picture: This icon associates a part image with the insertion group.
  • Page 75 Images can be selected from different locations. • Select image from Local USB: Typically used to pull  images from a camera or flash • Touch on Local HDD drive. Local HDD: Images that reside on  the machines local hard drive are selected from here.
  • Page 76 • Select a part picture for hardware insertion • Touch on Picture Icon for insertion group 2 Select Image Pre-Used: Saved images previously used. Select the same image Touch on Use from Pre Used Images • Touch the location for each insertion on the part. •...
  • Page 77 • Select a part picture for hardware insertion • Touch on Picture Icon for insertion group 3 Select Image Select Image: A different image with a different view of the part can be selected. Touch on Use • Select image from Local •...
  • Page 78 • Select a part picture for hardware insertion • Touch on Picture Icon for insertion group 4 Select Image Select the same image Touch on Use from Pre Used Images • Touch the location for each insertion on the part. Select Points: Add Insertion Points to the •...
  • Page 79: Editing Insertion Groups

    • System detected fastener amount discrepancy from step • Touch No to continue adding insertions Editing Insertion Groups • Touch to add a fastener insertion • Missing insertion is now corrected. Touch on OK A Tip or Lower Tool from a different station may be used if desired.
  • Page 80 Touch on Save to save the Insertion Program 17-00077 Rev. D.8.2024...
  • Page 81: Run Program - Step By Step Demo

    Run Program - Step by Step Demo This section provides you, the operator, with the information that you need to run a Program and operate the Haeger 824 OneTouch Lite-5He safely and productively. Machine Controls Touch Screen Emergency Stop Foot Switches ...
  • Page 82 Access Level Reminder: Advanced Haeger Administrator Administrator Operator Level Machine User Technician Programs Filter Select Programs Create New Program Edit Loaded Program Preview Program Start/Load Program Edit Selected Program Delete Program Administrator/Operator  Access Level Reminder: Login, Load Program, Close Program, Machine User does not have access to LOAD Logout a Program.
  • Page 83 Enter Password Touch on Programs Select desired program Touch on Start/Load 17-00077 Rev. D.8.2024...
  • Page 84 Production Run Overview Program Action • Batch Size: Is how many parts you must complete. Touch on the value itself, to touch type a new value. • MAS Vibration (%): This feature allows the operator to increase or decrease the vibration intensity of the MAS 350 bowl.
  • Page 85 Setup Stroke: This feature sets up and records the fastener pickup point, fastener length, and insertion point. This only needs to be setup the first time for each station when running a program. Upper tool in motion Depress the Down Footswitch.
  • Page 86 Yes: Insertion was completed successfully and ready to move on to next insertion point • Was hardware inserted No: Opens the Adjust Fastener Window. Change Insertion and/or correctly? MAS values as needed. • Touch on Yes or No ADJUSTING INSERTION VALUES Increase or decrease the value by touching the symbols on...
  • Page 87 TIS is now unlocked, allowing it to be turned to the next Station. When the correct position is reached, the TIS will automatically lock. Turn TIS to Station 2 Eject first fastener into the shuttle • Station tooling and fastener is in place &...
  • Page 88 Depress Footswitch again to apply force • Check Part • Touch on Next Confirm force and insert rest of fasteners according to program if any. 17-00077 Rev. D.8.2024...
  • Page 89 TIS is now unlocked, allowing it to be turned to the next Station. When the correct position is reached, the TIS will automatically lock. Turn TIS to Station 3 • Station tooling and fastener is in place & ready Manually place fastener into •...
  • Page 90 Confirm setup and insert rest of fasteners according to program if any. TIS is now unlocked, allowing it to be turned to the next Station. When the correct position is reached, the TIS will automatically lock. Turn TIS to Station 4 Manually place fastener into tooling •...
  • Page 91 Setup Stroke: This feature sets up and records the fastener pickup point, fastener length, and insertion point. This only needs to be setup the first time for each station when running a program. Follow Setup Upper tool in motion Stroke steps Confirm setup and finish inserting rest of fasteners if any...
  • Page 92 Program Ends and returns to Main Screen 17-00077 Rev. D.8.2024...
  • Page 93: Section 5 - Options

    SECTION 5 - OPTIONS Component Part # Description Picture Laser – Part 15-01801 Provides a highly visible, red- Locating Light laser indicator to aid in locating the lower tool under larger parts. Increases productivity and decreases operator fatigue. 17-00077 Rev. D.8.2024...
  • Page 94: Section 6 - Machine Maintenance

    SECTION 6 – MACHINE MAINTENANCE This maintenance schedule is applicable for standard machine shop operating conditions. When operating under severe conditions such as heavy dust and dirt, increase the schedule to reflect such conditions. DO NOT lubricate the Upper Tool Holder with any lubricant other than a small amount of lithium grease (white).
  • Page 95 Maintenance Schedule (Cont.) *Hydraulic Fluid The machine uses Exxon Humble Hydraulic H AW-32. Equivalent ISO 32 Viscosity Grade Hydraulic oils may used. ** Lithium Grease Each Haeger machine is shipped with a tube of Lubriplate 630-AA. This is the recommended grease to use for lubricating parts around the machine.
  • Page 96: Troubleshooting

    Troubleshooting Problem Source Solution Machine has no Disconnect Turn disconnect switch to the On position. power. switch is off. Open the cabinet and insure the disconnect switch attachment bar is still connected to the switch inside the cabinet. Inspect the condition of the disconnect switch handle for any damage and alignment to the attachment bar.
  • Page 97 Problem Source Solution Fastener will not MAS bowl is Check to ensure there is enough fasteners in the MAS Bowl. feed. empty. Check the MAS module(s) to ensure that there are no fasteners MAS module(s) or debris jammed in the fastener tracks. jammed.
  • Page 98 Problem Source Solution No pressure is Check the condition of the proportional amplifier. built. Ram comes Running non- Ensure that you are in the right mode for the material you are down, taps running. conductive workpiece, and material while in then returns up.
  • Page 99: Weekly Care & Maintenance

    Weekly Care & Maintenance This maintenance schedule is applicable for standard machine shop operating conditions. When operating in severe conditions such as heavy dust or dirt or running 24 hours, increase the schedule to reflect such conditions. (MAS 350): Care & Maintenance •...
  • Page 100: Flight Tube: Care & Maintenance

    Flight Tube: Care & Maintenance • Dirt, grease, debris builds up over time in the tubes. • It is recommended to blow out flight tube after each tool change. • 1 : Detach tube(s) from MAS 350 Module and upper tool changer.
  • Page 101: Dual-Shuttle: Care & Maintenance

    Dual-Shuttle: Care & Maintenance • It is recommended to dust out the dual shuttle changer weekly or more frequently based on usage. • Use dry compressed air to blow out debris. • Eye protection must • be worn DO NOT use rubbing alcohol, WD-40, diesel, gas, etc., to clean tool changer slides! DO NOT use Silicone Spray as a lubricant on this machine.
  • Page 102: Upper Tool Holder: Care & Maintenance

    Upper Tool Holder: Care & Maintenance • It is recommended to inspect the upper tool holder and its contacts DO NOT use rubbing alcohol, WD-40, diesel, weekly or more gas, etc., to clean contacts or any part of the holder! frequently based on usage.
  • Page 103 TIS-3: Care & Maintenance DO NOT use rubbing alcohol, WD-40, diesel, gas, etc., to clean contacts or any part of the TIS-3! • It is recommended to inspect the TIS-3 and its contacts weekly or more • : If it is necessary to frequently based on remove the TIS-3, unplug usage.
  • Page 104: Diagnostics: From Main Screen

    Diagnostics: From Main Screen Touch on Admin Touch on Diagnostics 17-00077 Rev. D.8.2024...
  • Page 105 Digital Inputs (DIxx): These are inputs for the PLC from various points on the electrical board. These Inputs determine what Outputs will be turned on at certain times. Digital Outputs (DOxx): These are Outputs from the PLC to various points on the board to control Relays, Air Cylinders, Modular Auto Feed (MAS), and other functions.
  • Page 106: Schematics & Diagrams

    Schematics & Diagrams Schematics and Diagrams are customized to accurately depict your machine and will not be bound in this operation manual. They will be delivered separately on large format paper in an effort make them legible and easy to read. Typical Drawing List: ...
  • Page 107: Customer Service

    Customer Service Haeger is proud of its reputation for providing you with first-class support. Our mission is to offer you cutting edge technology machines that will which provide your organization with world-class performance and value. Contact us today. A service tech will contact you within 24 hours To save time, please be prepared to give your area Haeger Representative the following information: 1.
  • Page 108: Limited Warranty

    Warranty Limited Warranty 1. EXCLUSIVE WARRANTY: This warranty is exclusive and in lieu of all other express or implied warranties including, without limitation, the implied warranties or merchantability and fitness for a particular purpose. 2. EFFECTIVE DATE: The warranty period starts from the date of installation by Distributor or Haeger Factory Technician, or from date of receipt if self-installed by the customer.
  • Page 109: Section 7 - Parts List

    SECTION 7 – PARTS LIST Description The Parts in this section of the manual are listed by Item Number, Part Number, Description and Quantity. ITEM NO. PART NUMBER DESCRIPTION QTY. XX-XXXXX XXXXXXXXXX Item Numbers : Are depicted with in a circle with an arrow pointing to the specific part or assembly. Part Number: Identifies a specific item in Haeger’s inventory.
  • Page 110: Main Assembly

    Main Assembly 17-00077 Rev. D.8.2024...
  • Page 111 Main Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-03969 LABEL, MACHINE LOGO, 6X6, 824WT5e 11-00515 MACHINE LABEL, "LIFT HERE" 11-00361 LABEL, HAEGER WARNING 16-00134 LABEL, ELECTRIC SHOCK WARNING 11-00233 LATCH KEY- 824 15-00220 DISCONNECT HANDLE 11-00232 DOOR LATCH 15-03955 HMI ARM 15-03538 LABEL, E-STOP LEGEND, YELLOW BLANK 15-03067...
  • Page 112: Sheet Metal (Pt.1)

    Sheet Metal (Pt.1) 17-00077 Rev. D.8.2024...
  • Page 113: Sheet Metal (Pt.2)

    Sheet Metal (pt.2) 17-00077 Rev. D.8.2024...
  • Page 114 Sheet Metal ITEM NO. PART NUMBER DESCRIPTION QTY. 15-03148 CYLINDER TOP COVER, (-5e) WT/OT 15-03574 COVER, POSITIVE STOP, WT/OT 15-03081 CYL. TOOL CABINET DOOR LINKAGE LATCH, WT/OT 15-02793 ANVIL STOR., TOOLING CABINET CYLINDER, WT (-5) 15-02795 DOOR, TOOLING CABINET CYLINDER, WT (-5) 15-02740 FRONT COVER, CYLINDER, WT (-5) 15-02794...
  • Page 115: Electrical Cabinet

    Electrical Cabinet 17-00077 Rev. D.8.2024...
  • Page 116 Electrical Cabinet ITEM NO. PART NUMBER DESCRIPTION QTY. 15-02734 CABINET, ELECTRICAL, WT (-5) 15-03961 ELECTRICAL PANEL A, LOW VOLTAGE 15-02745 ELECTRICAL PANEL B, HIGH VOLTAGE 15-03887 UNIVERSAL CONTROL BOARD, (-5) 15-03907-1 COMPUTER, BOX PC 15-03974 CONTROLLER MAS350 10-00019 PANDUIT WIRING DUCT 15-00220 DISCONNECT HANDLE (PISTOL GRIP) 15-03906...
  • Page 117 Electrical Cabinet (continued) MACHINE W/ SERIAL #’S OVERLOAD DESCRIPTION 8OTL50026 OR HIGHER 15-04008 7 TO 10 AMP OVERLOAD RELAY 15-04009 16 TO 24 AMP OVERLOAD RELAY MACHINE W/ SERIAL #’S OVERLOAD DESCRIPTION BELOW 8OTL50026 10-00670 6.0-8.5AMP OVERLOAD RELAY 15-00139 16-24AMP OVERLOAD RELAY 17-00077 Rev.
  • Page 118: Mas 350 Bowl Assembly

    MAS 350 Bowl Assembly 17-00077 Rev. D.8.2024...
  • Page 119 MAS 350 Bowl Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. SEE DRAWING DRIVE & BOWL , MAS 350 15-03685 BOWL ONLY, MAS 350 15-00858 DOWEL PIN, 4MM X 14MM, HARDENED STEEL 15-03739 BLOCK, MAS 350 MOUNTING 15-02924 LEVER, LOCKING, MAS 350 15-03957 1/4”...
  • Page 120: Dual Shuttle Assembly (15-41872) Pt.1

    Dual Shuttle Assembly (15-41872) Pt.1 ITEM NO. PART NUMBER DESCRIPTION QTY. BOTTOM HALF TOP HALF 15-02148 SHCS, M6 X 1.0 X 16MM, STAINLESS STEEL 15-01393 WASHER, LOCK, M6 STEEL, ZINC PLATED 15-01234 WASHER, FLAT, M6 X OD 12MM, STEEL, ZINC PLATED 17-00077 Rev.
  • Page 121: Dual Shuttle Assembly (15-41872) Pt.2

    Dual Shuttle Assembly (15-41872) Pt.2 17-00077 Rev. D.8.2024...
  • Page 122 Dual Shuttle Assembly (15-41872) Pt.2 ITEM NO. PART NUMBER DESCRIPTION QTY. 15-01754 DOWEL PIN, ¼” X ½”, HARDENED STEEL 15-01709 FHCS, M2 X 0.4 X 4, BLACK OXIDE 11-00238 SHSS, M5 X 6, BLACK OXIDE H-3915 SHCS, M3 X 16MM, BLACK OXIDE 15-02850 ASSY, ISOLATOR PLATE, UPPER TOOL CHANGER 15-01557...
  • Page 123: Dual Shuttle Assembly (15-41872) Pt.3

    Dual Shuttle Assembly (15-41872) Pt.3 17-00077 Rev. D.8.2024...
  • Page 124 Dual Shuttle Assembly (15-41872) Pt.3 ITEM NO. PART NUMBER DESCRIPTION QTY. 15-01754 DOWEL PIN, ¼” X ½”, HARDENED STEEL 11-00240 BHCS, M5 X 0.8 X 12MM 15-01804 M4 X 18 SHCS H-3871 SHCS, M3 X 8MM, BLACK OXIDE H-3891 SHCS, M3 X 10MM, BLACK OXIDE H-3915 SHCS, M3 X 16MM, BLACK OXIDE 11-00237...
  • Page 125: Multi-Shuttle Assembly (15-40027)

    Multi-Shuttle Assembly (15-40027) 17-00077 Rev. D.8.2024...
  • Page 126 Multi-Shuttle Assembly (15-40027) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-01870 SLIDE TABEL, MXS6, MULTI-SHUTTLE 15-02883 INSULATOR PLATE, MULTI-SHUTTLE 15-02881 ALIGNMENT PLATE, MULIT-SHUTTLE 15-02882 MOUNTING PLATE, MULTI-SHUTTLE 15-00305 FHCS, M4 X 0.7 X 16MM 15-01754 DOWEL PIN, ¼ “ X ½ “, HARDENED STEEL H-3871 SHSS, M5 X 0.4 X 12MM, BLACK OXIDE ALLOY STEEL H-3815...
  • Page 127: Quick Mount Assembly (15-40026)

    Quick Mount Assembly (15-40026) 17-00077 Rev. D.8.2024...
  • Page 128 Quick Mount Assembly (15-40026) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-02782 LOCKING AXLE, QUICK MOUNT, MULTI-SHUTTTLE 15-01674 SHCS, M3 X 0.5 X 25, STEEL, BLACK OXIDE 15-02784 LEG LOCKING SIDE, QUICK MOUNT UPPER 15-02785 LEG POSITION SIDE, QUICK MOUNT UPPER H-3738 SHCS, M5 X 0.8 X 12MM, BLACK OXIDE 15-01601...
  • Page 129: Dual Safety Sensor (15-42360) & Upper Tool Holder (15-40037)

    Dual Safety Sensor (15-42360) & Upper Tool Holder (15-40037) 17-00077 Rev. D.8.2024...
  • Page 130 Dual Safety Sensor (15-42360) & Upper Tool Holder (15-40037) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-03164 BODY, UPP. TOOL HOLDER, SAFETY SENSOR, OT 15-03650 SAFETY SENSOR, TURCK, NC 15-03649 SAFETY SENSOR, TURCK, NO 15-03206 CONTINUITY SPRING, 1 ¾ “, UNIVERSAL 11-00016 CONTINUITY GUIDE PIN H-3738...
  • Page 131 TIS-3 Assembly (15-41593) 17-00077 Rev. D.8.2024...
  • Page 132 TIS-3 Assembly (15-41593) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-00449 SHCS, M3 X 0.5 X 14MM, STAINLESS 15-01295 ROUND VINYL CAP BLUE 40 .320 X 1/16" 15-01296 ROUND VINYL CAP GREEN 23 .320 X 1/16" 15-01297 ROUND VINYL CAP RED .320 X 1/16" 15-01298 ROUND VINYL CAP YELLOW .320 X 1/16"...
  • Page 133 TIS-3 Assembly (15-41593) 15-02997 BASE TOOL HOLDER, TIS-2 QUICK DISCONNECT, WT 15-03031 CYLINDER, 5MM STR, 12MM BORE, MALE, SPR RET 15-00286 TUBING-TIUBO7B-20 0 0 1/4" 15-00285 TUBING-TUO425B-20 5/32" 15-01754 DOWEL PIN, ¼” X ½”, HARDENED STEEL 17-00077 Rev. D.8.2024...
  • Page 134: Dual Multi-Shuttle Vacuum Anvil (15-40030)

    Dual Multi-Shuttle Vacuum Anvil (15-40030) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-03349 VAC. ANVIL, 0.59 DIA X 4.3 LONG 15-02940 SLEEVE, VAC. ANVIL, 0.59 DIA 15-02968 SPRING, ID 0.603"XD 0.042" - 1.03" LONG, 4 COILS, ZINC PLATED 15-01983 O-RING, 11/16” X 3/32” 15-01763 ¾...
  • Page 135: Hydraulic Cylinder Main Assembly

    Hydraulic Cylinder Main Assembly 17-00077 Rev. D.8.2024...
  • Page 136 Hydraulic Cylinder Main Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-02889 HYDRAULIC CYLINDER, 8 TON, WT & OT (-5) 15-03072 7/16-20 x 1/4-18, 90 DEG ELBOW POSITIVE STOP SYSTEM ASSEMBLY 11-00271 824 CYL. INSULATION SHOE H-3804A 5/8 BOLT INSULATION H-3804B 5/8 BOLT INSULATION 15-03221 PRESSURE HOSE, .5”X 16 ¼”...
  • Page 137: Positive Stop System Assembly

    Positive Stop System Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-00116 POSITIVE STOP BASE PLATE 15-00115 POSITIVE STOP CLAMP PLATE 15-00117 POSITIVE STOP INNER TUBE 15-00683 ASSY, POSITIVE STOP SLOTTED TUBE 15-00119 POSITIVE STOP OUTER TUBE 15-00120 NUT, POSITIVE STOP, 824 WT & OT 15-00046 CET CONNECTING BAR 17-00077 Rev.
  • Page 138: Vacuum Generator Assembly (15-43004)

    Vacuum Generator Assembly (15-43004) 17-00077 Rev. D.8.2024...
  • Page 139 Vacuum Generator Assembly (15-43004) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-01325 FITTING: BUSHING BRASS 1/4 MALE NPT X 18 FEMALE NPT 15-03661 SHCS, M4 X 0.7 X 40MM H-5020 SWIVEL ELBOW, 90 DEG, 1/8 NPT X 1/4 TUBE 14-00638 AIR FITTINGS 11-00587 24V SOLENOID VALVE 11-00589...
  • Page 140: Air Manifold Assembly (15-03901)

    Air Manifold Assembly (15-03901) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-03901 AIR MANIFOLD (FULL ASSEMBLY) 15-03371 VALVE, DUAL 3/2, PNEUMATIC 15-02857 VALVE, 3-POSITION SINGLE, PNEUMATIC 15-00285 1/4” DIA. AIR LINE 15-00552 5/32” FITTING PLUG 15-00286 5/32” DIA. AIR LINE 17-00077 Rev. D.8.2024...
  • Page 141: Hydraulic Reservoir Assembly

    Hydraulic Reservoir Assembly 17-00077 Rev. D.8.2024...
  • Page 142 Hydraulic Reservoir Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-00782 H.S. RESERVOIR TOP 15-00784 RESERVOIR WELDMENT 15-02166 DRAIN PLUG, O-RING BOSS ½ “ 15-00226 LEVEL GAUGE W/O THERMOMETER 15-00758 RETURN FILTER ASSEMBLY 15-01183 FITTING, STRAIGHT, 3/4" MALE 3 824 HYDRAULIC COOLER ASSEMBLY HYDRAULIC SUCTION FILTER ASSEMBLY 15-01185 FITTING, MJ-MP 90 8-12...
  • Page 143: Motor Pump Assembly

    Motor Pump Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-00077 MOTOR, 5 HP, 1800 RPM, 50/60 HZ, 208/440 V 15-01124 COUPLER 8.5 "A" PUMP / 4.75 LONG 15-01123 PUMP 824 HS 15-01143 FITTING, 90 ELBOW, 16 MALE 37 JIC O-RING 15-01142 FITTING, 90 ELBOW, 12 MALE 37, JIC TO MAILE O-RING 15-00062...
  • Page 144: Hydraulic Cooler Assembly

    Hydraulic Cooler Assembly Item No. Part Number Description Qty. 15-00783 BRACKET, RESERVOIR COOLER MOUNT 15-01601 M6, WASHER, ZINC PLATED 15-01393 LOCK WASHER, M6, DIN127 ZINC 11-00319 SHCS, M6 X 1.0 X 20MM, STAINLESS 15-01132 COOLER, 824 H/S ECO 4 15-01147 MB-MJ 90 12-12 MALE BOSS TO MALE JIC 90 17-00077 Rev.
  • Page 145: Hydraulic Manifold Assembly (15-03913)

    Hydraulic Manifold Assembly (15-03913) 17-00077 Rev. D.8.2024...
  • Page 146 Hydraulic Manifold Assembly (15-03913) 17-00077 Rev. D.8.2024...
  • Page 147 Hydraulic Manifold Assembly (15-03913) ITEM NO. PART NUMBER DESCRIPTION QTY. MANIFOLD, HYDRAULICS, UNIVERSAL, HYDAC 15-04003 VALVE, 4/2, 4WE, 10 GA 4-WAY 2 POSITION 15-04004 VALVE, 4/3, 4WE 10 L 4-WAY 3 POSITION 15-01398 COUNTER BALACE VALVE 15-03778 CHECK VALVE, 5PSI, FC10-2 15-04002 PRESSURE TRANSDUCER, 0-5000PSI, 4-20MA 15-01197...
  • Page 148: Hydraulic Suction Filter Assembly

    Hydraulic Suction Filter Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-01180 FITTING JIC MB-MJ 16-12 15-01163 FITTING JIC MB-MJ 16-16 15-02720 SUCTION ACCESS PLATE 15-01131 SUCTION FILTER 1” NUT STYLE 15-00781-1 1” X 4” PIPE NIPPLE 17-00077 Rev. D.8.2024...
  • Page 149: Return Filter Assembly (15-00758)

    Return Filter Assembly (15-00758) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-02715 CAP, FILTER ASSEMBLY RETURN 15-02714 RING, FILTER ASSEMBLY RETURN CAP 15-00888 HYDRAULIC FILTER ELEMENT 15-01183 FITTING MB-MJ 16-12 15-02537 FLANGE GASKET, FILTER RETURN ASSEMBLY 15-02629 BREATHER ELEMENT, FILTER RETURN ASSEMBLY 15-00212 BREATHER CAP 17-00077 Rev.
  • Page 150: J-Frame, Abft Assembly Option (15-41870)

    J-Frame, ABFT Assembly Option (15-41870) ITEM NO. PART NUMBER DESCRIPTION QTY. 15-03255 J-FRAME, BOTTOM FEED TOOL, WT H-172-3 CLAMP PLATE, LEFT HAND H-172-4 CLAMP PLATE, RIGHT HAND 11-00319 SHCS, M6 X 1.0 X 20MM, STAINLESS 15-01393 LOCK WASHER, M6, DIN 127, ZINC 17-00077 Rev.
  • Page 151: Service Tray Assembly

    Service Tray Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 15-01294 PART BIN 7 X 4 YELLOW 15-01291 PART BIN 7 X 4 DARK BLUE 15-01299 PARTS TRAY HOLDER 15-01292 PART BIN 7 X 4 MEDIUM GREEN 15-01293 PART BIN 7 X 4 RED 11-00179 SERVICE TRAY ARM 11-00184...
  • Page 152: Section 8 - Decommissioning Your Machine

    SECTION 8 – DECOMMISSIONING YOUR MACHINE The decommissioning of a Haeger machine is a rare occurrence as older models themselves become relocated or sold to other facilities around the world. In the event a machine component requires replacement, we recommend recycling the old. Most countries have recycling programs for such components like computers, petroleum-based fluids, metals and so on.

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