Service Home How To Procedures EC-400/500 - POP-UP PROBE CYLINDER - SEAL REPLACEMENT
Last updated: 06/07/2022

EC-400/500 - POP-UP PROBE CYLINDER - SEAL REPLACEMENT

Prerequisites

This procedure explains how to replace the seals in the EC-400/500 pop-up probe cylinder. 

The seals should be inspected and replaced if:

  • The probe pop-up cylinder fails to extend or retract.
  • There is a constant air leak out of the probe retract/extend solenoid exhaust port when the the probe is fully extended or fully retracted. 

Pop-up Probe Cylinder - Disassembly

1

On the CURRENT COMMANDS page navigate to the DEVICES - MECHANISMS tab and press F2 [1] to extend the tool probe. 

2

While the probe is in UP position:

  • Loosen the six set screws [1] at the base of the OTS [2] and remove the OTS.
  • Hold the probe piston rod [3] from rotating with an 1" open end wrench while removing the mounting bolt [4] with the washer [5] that secures the trap box linkage and the OTS base [6] to the piston rod.  

NOTE: The damage of the probe pop-up cylinder internal components may occur if the mounting bolt [4] removed without holding the piston rod with the 1" open end wrench.

3

  • Swing the trap box linkage [1] out of the way and remove two bolts that secure the trap box assembly to the top of the probe pop-up cylinder.
  • Remove the trap box assembly [3].
  • Go to CURRENT COMMANDS page and press F2 to retract the pop-up probe piston.
  • Using permanent marker place the line [4] to mark the orientation of the probe piston [5] and the upper cylinder end cap [6].   

4

WARNING: Disconnect the air supply from the machine and drain the air from the machine's pneumatic system before performing this step. The upper part of the probe pop-up cylinder is pressurized at all time when the probe is retracted.

 

  • Remove two screws [2] 
  • Remove the four mounting bolts [1] that secure the pop-up probe cylinder to the B axis casting. NOTE: you can leave the probe UP/DOWN air lines and sensor cables connected and work on the cylinder while it still in the machine to avoid further disassembly.
  • Remove the upper cylinder cap [3]. There is a 57-0715 lip seal [5] installed into the upper groove with the lip facing up that prevents the chips from entering the air cylinder and the 57-0568 o-ring [6] installed into lower groove that is the rod seal.
  • Pull out the probe piston [4]. There is a 57-0714 o-ring [7] installed into the groove at the bottom of the probe piston that is the piston seal.
  • There are also two static o-rings: 57-0551 [8] and 57-2249 [9] that provide the seal between the cylinder and the upper cylinder cap.   

Pop-up Probe Cylinder - Assembly

1

IMPORTANT: Thoroughly clean all components of the probe pop-up cylinder before beginning the assembly process. Any contaminants left inside the cylinder will decrease the life of the cylinder and will affect the repeatability of the tool probe. Lightly grease the sliding surfaces and the locating features [6] on the piston and the cylinder cap with the silicone grease. 

NOTE: It is important to lubricate the o-ring seals with the 99-1793 SILICONE GREASE. Use of any other grease may cause the probe pop-up cylinder failure. Use a liberal amount of grease to lubricate the dynamic seals and fill the groove with grease. Use a light amount of grease on the static seals. 

Replace all of the dynamic seals:

  1. 57-0715 S SEAL 1.25 X 1.522 X .187 SL WIPER [1]. NOTE: Install with the lip pointed upward. 
  2. 57-0568 O-RING 2-218 BUNA SHORE A 90 [2].
  3. 57-0714 O-RING 2-325 BUNA SHORE A 50 [3].

Inspect the static seals and replace if necessary:

  1. 57-0551 O-RING 2-008 VITON [4].
  2. 57-2249 O-RING 2-033 VITON [5].

Assemble the probe pop-up cylinder in the reverse order.

NOTE: Make sure to orient the air piston and the upper cylinder cap so the marks made in the step 3 of the disassembly lined up.

2

Install two screws [1] that fasten the cylinder cap to the cylinder body.

Install four mounting bolts [2] that secure the pop-up probe cylinder to the B axis casting.

Install the probe trap box assembly [3] using two BHCS [4].

Remove the two BHCS [5] that attach the trap box lid linkage to the lid.  

With the lid fully open, turn the air supply on and extend/retract  the cylinder a few times to verify operation.

Leave the cylinder extended for the next step.

3

NOTE: Wrap the shop towel around exposed portion of the pop-up cylinder rod to avoid any damage while aligning the linkage base. 

Attach the trap box lid linkage [3] to the top of the pop-up cylinder rod [4] with the bolt [1] and the flat washer [2].

Setup a dial indicator [5] magnetic base on the spindle to indicate the straight edge [6] of the linkage base in Z axis. 

Rotate the linkage base until the straight edge [6] is parallel to Z axis motion NTE 0.003" (0.075 mm). 

Hold the pop-up cylinder rod from rotating with 1" open wrench and tighten the mounting bolt [7].

Verify the alignment of the straight edge [6] after tightening the mounting bolt. Repeat the alignment steps if needed.   

4

With the pop-up probe extended attach the linkage assembly [2] to the trap box lid [3] with the two BHCS [1]. Leave the bolts [1] loose at this time.

Retract the pop-up probe.

With the probe retracted make sure that the linkage mounting bolts [1] have some free movement in the slots. If the bolts are bound-up against the perimeter of the slot check the alignment of the linkage base in step 3.

Tighten the linkage mounting bolts [1] in small increments until snug.

Extend the pop-up probe. 

Finish tightening the linkage mounting bolts [1] while observing the movement in the links [2]. The linkage mechanism should not have any bind or tension and you should be able to move the links and the lid a small amount by hand. Bound-up linkage will cause the probe repeatability problems.

NOTE: If binding occurs, the screws that fasten the box to the cylinder body [4] can also be used for adjustment. 

     

 

5

Install the OTS [1] onto the OTS base [2] and tighten the six setscrews around the OTS base.

Align the OTS stylus. Refer to the link below for more info.

WIPS - Installation

Pop-up Probe Cylinder - Test

1

On the CURRENT COMMANDS page navigate to the DEVICES - MECHANISMS tab and press F2 [1] to extend/retract the tool probe. 

Observe the operation of the pop-up probe cylinder and the trap box lid.

Refer to the link below to calibrate the probing system.

 

NGC - Probe Calibration