1006

Common Causes

• Tool setter pneumatic air pressure is below required 80 PSI or air solenoid valve has failed preventing arm extension or retraction
• Proximity switch detecting arm position is misaligned, damaged, or has failed causing incorrect position reporting to MOCON board
• Wiring from proximity switches to IOCON board has broken conductors, loose terminal connections, or damaged shielding causing signal loss
• Mechanical obstruction such as chips, coolant buildup, or bent components preventing full travel of tool setter arm to home position
• Setting 78 Tool Probe Type or Parameter settings for tool setter inputs are incorrectly configured for the installed hardware model

Troubleshooting Steps

1. 1Step 1: Verify machine air pressure at regulator reads minimum 80 PSI and manually extend tool setter arm using M-code or manual solenoid override
2. 2Step 2: Access Diagnostics page and observe tool setter position inputs while manually cycling arm to confirm both extended and retracted signals change state
3. 3Step 3: Inspect tool setter arm for chips, coolant residue, or mechanical damage preventing full range of motion and clean thoroughly with compressed air
4. 4Step 4: Check proximity switch gap distance to target using feeler gauges, should be 0.5mm to 1.5mm depending on switch model, adjust mounting bracket if needed
5. 5Step 5: Trace wiring from each proximity switch to IOCON terminal blocks checking for continuity, proper shield grounding, and secure connections at both ends
6. 6Step 6: Replace failed proximity switch or pneumatic solenoid valve if diagnostics show no signal change or air flow when commanded, verify Setting 78 matches replacement hardware