30/40 Taper - Tool Release Piston - Sensor Adjustment

Introduction

This procedure tells you how to adjust the Tool Release Piston clamp/unclamp switches of a 30 or 40-taper spindle.

The following service video shows how to set the TRP precharge.

NOTE: This service video is for reference only and does not replace the written procedure.

TRP Push Out Check

1

Note: You will need service kit 93-2621 to complete this procedure.

Put a tool holder with no tool into the spindle.

Put a piece of paper on the table to protect the table.

Put the aluminum block on the piece of paper.

Jog the Z Axis until the toolholder is approximately 0.30" (8 mm) from the top of the block.

Set the jog rate to .001/1.

Jog the Z Axis until the toolholder makes contact with the block and is tight.

Push [POSIT] then [ORIGIN] to zero the Z Axis position.

Set the jog rate to .01/10.

2

Jog the Z Axis 0.100" (2.54 mm) above the block.

Push and hold the [Tool-Release] button.

Try to move the aluminum block. If the push-out is correct, the block does not at 0.100".

Jog the Z Axis 0.110" above the block.

Push and hold the [Tool-Release] button.

Try to move the aluminum block. If the push-out is correct, the block should be loose at 0.110".

Caution: New tolerance for Single Sensor TRP (Tool Release Piston) on VF-1 - VF-5 machines: There's no need to make adjustments to the drawbar height if it's tight between 0.080" to 0.130".

Note: The number of jog increments in the negative direction is the number of shims to add. The number of jog increments in the positive direction is the number of shims to remove.

Add or Remove Shims

1

Inline Style Shim Adjustment:

Loosen the (4) screws [1] for the striker plate.

Use the openings in the spindle head casting.

Add or remove the correct number of shims [2].

Note: The correct number of shims is the number of increments you moved the spindle until the block did not move, in the steps before.

Make sure the inner corner [1] in the shims is fully against the striker plate.

Tighten the striker plate screws [2].

Check the TRP Push Out again.

2

Gearbox/Belted with No TSC Style Shim Adjustment:

Disconnect the proximity-switch and solenoid cables at the solenoid bracket.

Disconnect the pre-charge and tool-release air tubes from the solenoid.

Lift the TRP assembly from the spindle and move it forward to remove it.

Use an open-ended wrench to hold the TRP shaft. Use a closed-end wrench to turn the TRP bolt [1] clockwise to loosen.

Note: The threads for the tool-release bolt are reverse thread.

Add or remove shim washers [2] from the tool TRP bolt. Apply blue threadlocker to the TRP bolt.

Install the TRP repeat the push-out check.

3

Gearbox/Belted with TSC Style Shim Adjustment:

Disconnect the proximity-switch and solenoid cables at the solenoid bracket.

Disconnect the TSC hose. Disconnect the pre-charge and tool-release air tubes from the solenoid.

Lift the TRP assembly from the spindle and move it forward to remove it.

Remove the TSC seal housing [1] and the TSC seal [2]. If the seal housing has hoses attached to it, remove them.

Use an open-ended wrench [3] to hold the TRP shaft. Use a closed-end wrench [4] to turn the TRP bolt [5] clockwise to loosen.

Note: The threads for the tool-release bolt are reverse thread.

Add or remove shim washers [6] from the tool TRP bolt. Apply blue threadlocker to the TRP bolt.

Install the TSC seal and TSC seal housing. If you removed hoses from the housing, connect them. Repeat the push-out check.

Pre-charge Adjustment - No TSC Machine

1

Assemble the pressure gauge:

Attach the gauge [1] to the tee-fitting [3].
Attach the (2) quick-release fittings [2] to the T-fitting.
Put the 1/4" tubing [4] into one of the quick-release fittings [2].

2

Disconnect the tube [1] from the output-side of the pre-charge pressure regulator [4].

Put the tube into the top of the pressure-gauge assembly [2].

Connect the 1/4" tube [3] from the pressure-gauge assembly to the regulator.

3

On some machines, you cannot adjust the regulator.

Use the pressure-gauge assembly to make sure the regulator operates correctly:

Push and hold the button on the pre-charge solenoid valve [1] for 20 seconds.

Pull the regulator adjustment knob to unlock it.

Set the air pressure to:

Belt/Gearbox: 4 psi (0.28 bar)
Inline: 30 psi (2.1 bar).

Release the solenoid button.

Push and hold the button on the solenoid valve [1], again for 20 seconds.

Make sure the gauge is reading the values you set above. Release the solenoid button. Push the regulator adjustment knob to lock it.

If the regulator is not adjustable, check to see if it measures the same pressure values as above.

If the gauge does not shows the correct pressure, the regulator is defective. Replace the regulator.

Remove the service kit assembly from the regulator.

Dual Sensor TRP - Adjust Sensor

1

Set Parameter 76 LOW AIR PRESSURE to 99999.

Turn the main air regulator to decrease the air pressure to 75 psi (5.2 bar).

Adjust the Draw Bar Closed sensor as follows:

Put a piece of paper on the table to prevent damage to the table.

Put the aluminum block [2] on the piece of paper.

Slowly jog the Z Axis until the toolholder lightly touches the block.

Push [POSITION] [ORIGIN] to zero out the Z Axis.

Push .001/1.

Jog the Z Axis 0.060" (1.52 mm) above the block.

2

Go to the I/O Diagnostics page.

Push and hold the [Tool Release] while you monitor the status of Draw Bar Open.

Adjust the unclamp sensor until Draw Bar Open changes to 1 when you push the tool-release button.

Jog the Z Axis 0.050" (1.52 mm) above the block.

Push and hold the [Tool Release] while you monitor the status of Draw Bar Open.

Adjust the lower (unclamp) sensor until Draw Bar Open changes to 0 when you push the tool-release button.

The adjustment of the lower unclamp sensor is complete when:

At 0.060" (1.52 mm) above the block, (Draw Bar Open=1) . The sensor is on.
At 0.050" (1.27 mm) above the block, (Draw Bar Open=0) . The sensor is off.

3

Adjust the Draw Bar Closed sensor as follows:

Remove the toolholder from the spindle.

Go to [MDI/DNC] and delete everything.

Write M59 P1120.

Put a 0.020" (0.508 mm) feeler gauge (or shim stock) [1] between the tool-release bolt [2] for the TRP and the drawbar [3].

Push [Cycle Start] to activate the unclamp pre-charge solenoid.

4

Monitor the status of Draw Bar Closed.

Adjust the clamp sensor until the Draw Bar Closed = 0 when the unclamp pre-charge solenoid is activated.

5

Push [Reset].

Put a 0.020" (0.508 mm) feeler gauge (or shim stock) [2] between the tool-release bolt [1] for the TRP and the drawbar [3]. Then remove the 0.020" (0.508 mm) feeler gauge (or shim stock) and put a 0.040" (1.016 mm) feeler gauge (or shim stock) [2] between the tool-release bolt [1] for the TRP and the drawbar [3], do this to verify the gap is not smaller than 0.020" (0.508 mm) or bigger than 0.040" (1.016 mm).

Push [Cycle Start] to activate the unclamp solenoid.

Make sure Draw Bar Closed = 1 when the unclamp pre-charge solenoid is activated if not re-adjust if necessary.

Set Parameter 76, LOW AIR DELAY, to 1500.

Run some tool changes to make sure that the TRP is correctly adjusted.

Verify the TRP has no leaks.

Single Sensor TRP - Adjust Sensor

1

Clear all the alarms.

Push and hold the [TOOL RELEASE] button.

Find the nut to adjust the height of the proximity sensor.

Turn the nut until the light on the sensor goes off. Then add a 1/4 turn more.

Make sure the switch adjustment is set properly by actuating the button a few of times.