Service Home How To Procedures 40-Taper - Belt Drive - TSC-Ready - TSC - 300 and 1K PSI - Installation - VMC - CHC - AD0272
Last updated: 05/08/2025

40-Taper - Belt Drive - TSC-Ready - TSC - 300 and 1K PSI - Installation - VMC - CHC

AD0272

Applies to machines built from: January, 2016

Introduction

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

Install Kit

To select the correct TSC install kit for your machine refer to: Through Spindle Coolant - Field Install Kits

Tools Required

  • Spindle Lock Tool (T-1635)
  • Red-I Grease
  • Dial Indicator (that can measure 0.0001") with Magnetic Base

40-Taper - Belt Drive - TSC-Ready - TSC - 300 and 1K PSI - Installation

1

Push [POWER OFF].

Set the main circuit breaker to the OFF position. Lock the main circuit breaker. Use an approved lock with an approved safety tag.

 Danger: If the vector drive voltage indicator light is on, do not touch the electrical components. The high voltage in the control cabinet can kill you. Wait for the voltage indicator LED on the vector drive to go off completely.

Close the primary air valve. Pull the ring on the bleed valve in the air manifold. Wait until all air pressure is released.

Look at the manifold pressure gauge. Make sure that the air pressure is 0 psi.

Remove the spindle head covers.

Install the spindle lock tool (T-1635) onto the spindle.

2

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.

3

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.

4

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].

5

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.

6

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].

7

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].

8

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].

9

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.

10

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.

TSC 1K PSI - Motor Drive PCB and Electrical Components - Installation

Perform this procedure on machines that have an I/O PCB before P/N 34-3283C.

 Caution: When you handle a PCB, you must wear an Electrostatic Discharge (ESD) strap.

1

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]

2

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.

3

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.

4

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.

5

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.

TSC - 300 and 1K PSI - Pump - Installation

1

  • 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.

2

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].

3

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.

4

After you install TSC, you must change some parameters. Use the Parameter Checker Program. Use menu option 7. Select the TSC option.

Change the values of these parameters:

  • Parameter 149 — Pre-Charge Delay
  • *Parameter 209 bit 24 — TSC Enable
  • Parameter 235 — TSC Piston Seat
  • Parameter 238 — TSC Max Spindle RPM
  • Parameter 278 bit 5 — TSC Purge Enable
  • Parameter 608 — TSC Pressure Switch Type
  • Parameter 1279 — Enable Bearingless TSC Union (Relay No.)
  • Parameter 1386 — Coolant Filter Sensor

*You must have an unlock code for this parameter. 

TSC- 300 and 1K PSI - Test

1

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.

2

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].