1. TSC Coolant Pump
2. TSC Check-Valve Assembly
3. Vacuum Generator
   

Put these parts through the cable channel covers:

• 20' (6096 mm) 1/4" gray tube [1]
• 20' (6096 mm) 1/4" purple tube [2]
• 3/8" hose [A]
• 14.5' (4420 mm) pressure sensor cable [B]

Connect the cable [B] to P15 [3] on the maincon PCB.

Disconnect the 5' (1524 mm) 1/4" black tube [1] from the push-lock fitting [2]. The push-lock fitting [2] is on the top of the TRP-spring retainer [3].

Remove and discard the push-lock fitting [2] from the TRP 90-degree fitting [4].

 Caution: While you turn the push-lock fitting, make sure you support the fitting [4] to make sure the fitting [4] does not turn. The fitting [4] could break if it turns.

Remove these parts from the TRP:

• 1/4" black tube [2]
• 1/4" fitting [1]
• 1/8" fitting [3]

Discard the fitting [1] and the tube [2].

Install these parts to the TRP fitting:

• 1/8" hex fitting [4]
• 1/8' check valve [5] (make sure the arrow is in the direction shown).
• 1/8" fitting [6] (this is the fitting that you removed from the TRP).

Attach the TSC check-valve assembly [9] to the bracket [10]. Use the (2) 1/4-20 x 1-1/2" socket-head cap screws (SHCS) [8].

Install the assembly [9] to the rear head-cover of the machine. Use the (2) 1/4-20 x 1/2" flanged button-head cap screws (FBHCS) [7].

Connect these components to the TSC check-valve assembly:

• 3/8" hose [A]
• 14.5' (4420 mm) pressure-sensor cable [B]
• 5' (1524 mm) 1/4" black tube [1]
• 20' (6096) 1/4" purple TSC-purge solenoid tube [2]
• high-pressure braided hose [3]

Connect the hose [3] to the TRP 90-degree fitting [4].

Connect the other end [5] of the tube [1] to the TRP fitting assembly [6].

Connect the 3/8" hose [8] to the coolant-drain port [7].

 Note: The next (3) steps will show you how to install the vacuum generator. Choose the correct configuration.

If you have the dome plugs [1] near the front of the spindle:

Remove the plugs [1].

Connect these parts to the vacuum generator [5]:

• 5' (1524 mm) 1/4" gray vacuum-generator tube [2]
• Use the clamp [3] to connect the 3/8" black hose [4].

Find the space near the front of the spindle. Move the vacuum generator [5] down into the space.

Install the vacuum generator [5]. Use a 1/4-20 x 1/2" flanged button-head cap screw (FBHCS) [6].

If the dome plugs [1] are near the rear of the spindle:

Remove the plugs [1] and the bottom spindle-head cover [2].

Install the vacuum generator [4] on the cover [2]. Use a 1/4-20 x 1/2" FBHCS.

Put theses through the opening behind the spindle:

• 3/8" black hose [6]
• 5' (1524 mm) 1/4" gray tube [3]

Connect these parts to the vacuum generator [4]:

• 5' (1524 mm) 1/4" gray tube [3]
• Use the clamp [5] to connect the hose [6].

Install the cover [2].

For machines that have a large opening [5] on the left side of spindle head casting:

Connect these parts to the vacuum generator [2]:

• 5' (1524 mm) 1/4" gray tube [1]
• Use the clamp [3] to connect the 3/8" black hose [4].

Install the vacuum generator [2] in the large opening [5]. Use a 1/4-20 x 1/2" FBHCS [6].

Open the door to the lubrication cabinet.

From the bottom of the manifold, remove and discard the third manifold plug [1].

 Note: Clean the manifold port threads.

Install the compression fitting [2] on the TSC-purge solenoid [3]. This solenoid [3] has (2) purple cable ties. Install the solenoid [3] in the third manifold port from the bottom.

 Note: For TSC-300 Psi, Install The Solenoid [3] With The 35 Psi Regulator. For TSC-1K Psi, Install The Solenoid [3] With The 85-Psi Air Regulator.

Remove the plug [5] for the pre-charge solenoid [6].

Install the elbow fitting [4] that has the gray cable tie to the pre-charge solenoid [6].

Cut the 20' (6096 mm) 1/4" purple tube [7] to the correct length. Connect the tube [7] to the check valve fitting [11] of the solenoid [3].

Connect the 20' (6096 mm) 1/4" gray tube [8] to the solenoid [6].

Connect the TSC-purge solenoid cable [10] to the TSC UNION section [9] on the connector panel.

Remove the cover [1] for the power supply (PSUP) PCB.

Remove the electrical jumper at position CB5 on the PSUP PCB.

Remove the (3) push-on connector covers from position CB5.

Install the 15A circuit breaker [2] at position CB5.

If you do not have a door panel installed in the control cabinet:

Open the control cabinet. Remove the cover for the I/O PCB.

Install these parts:

• Use (2) screws [2] to install the top hinge plate [1].
• Use (2) screws [3] to install the bottom hinge plate [4].
• Use (4) screws [5] to install the (2) door brackets [6].
• door panel [F]

Install these parts on the door panel:

• (2) spacers [2]
• motor-drive PCB [G]
• (2) socket-head cap screws (SHCS) [1]

Connect the 33-1944A cable [4] to these locations:

• P2 [3] on the motor-drive PCB (put the cable [4] through the left cable-carrier channel).
• P73 [5] on the I/O PCB.

Connect the 33-0987B cable [2] to these locations:

• P4 [1] on the motor-drive PCB (put the cable [3] through the top and right cable channels).
• Connections 77, 78, and 79 [3] on the transformer (each wire is has an identification label).

Connect the 12' TSC extension cable [C] to P1 [4] on the motor-drive PCB.

Put the cable [C] through the top and right cable channels.

Put the cable [C] behind the cover of the receptacle bracket.

Remove the AUX COOLANT plug [3] from the receptacle bracket.

Install the clamp [2] around the receptacle end [1] of the cable [C].

Use the (2) screws to attach the clamp [2] to the receptacle bracket.

Install the fan bracket [2]. Use the (2) 1 x 1/4" Phillips pan-head screws (PPHS) [1]. Make sure the arrows [3] on the fan assembly point in the correct direction.

Install the fan assembly [5] to HS6 [4] on the I/O PCB. Use the (2) 1/4" PPHS [6].

Connect the fan-assembly cable [7] to P37A [8] on the I/O PCB.

Remove the 33-0930G cable. This cable is connected to P9 and P4 on the PSUP PCB and P44 on the I/O PCB.

Install the 33-0930H cable to P9 and P4 on the PSUP PCB and P44 on the I/O PCB.

• Remove and discard the larger cover adjacent to the standard coolant pump.
• Install the smaller cover adjacent to the standard coolant pump.
• Install the TSC pump [E]. If necessary, remove the #8 fitting [1] and install the #6 fitting [2]. The #6 fitting [2] is for machines that have a 3/8" hose.

On the TSC-purge solenoid, find the fitting [4] that does not have a check valve. Connect the other 20' (6096 mm) 1/4" purple tube [3] to the fitting [4] and to the air cylinder on the pump.

Connect the 3/8" hose [A] to the pump.

If you did not install the 12' TSC extension cable [C]:

Discard the plug [5] for the receptacle bracket.

Install the 12' TSC extension cable [C].

Connect the 4-pin connector [1] of the cable [C] to P45 [2] on the I/O PCB.

Install the receptacle end [3] of the cable [C] to the receptacle bracket. Use the twist lock mount [4] and the screws.

Connect the power cable for the TSC pump to the receptacle end [3] of the cable [C].

Connect the 16.5' vacuum-sensor cable [D] to these locations:

• P26 [1] on the I/O PCB
• vacuum sensor [2] for the TSC pump.

Operate this code in MDI mode:

M59 P1148 ;

G04 P5.0 ;

M69 P1148 ;

G04 P2.0 ;

M99 ;

P1148 is for inline spindles.

For HS machines, use P1124 and not P1148.

For belt-drive spindles, use P1120 and not P1148.

If the machine has a bearingless TSC union, it moves up and down at 7-second intervals. The up and down movement is small.

The illustration shows the up and down movements for 40-taper [1], 40-taper (CALM) [2], and 50-taper [3] machines.

Put a TSC toolholder [1] in the spindle. Push [AUX CLNT] to start the TSC.

Correct operation is as follows:

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

Push [RESET].