1211

Check air pressure gauge

Verify shop air pressure at the machine is between 80-120 PSI. Check the pressure gauge on the main air supply and at the machine's air filter/regulator unit.

Ensure machine is in E-STOP before checking pneumatic connections.

Inspect air filter and regulator

Check the air filter bowl for excessive moisture or contamination. Verify the regulator is set to proper pressure (typically 80-90 PSI for tool setter operation).

Drain the filter bowl daily in humid environments to prevent moisture buildup.

Test air flow to tool setter

Locate the pneumatic line feeding the tool setter cylinder and check for adequate air flow. Listen for air leaks around fittings and connections.

Use soapy water to identify small air leaks that may not be audible.

Access I/O diagnostics

Press [CURRENT COMMANDS] then navigate to DIAGNOSTICS > I/O to view input status. Locate tool setter arm position inputs (typically labeled as TOOL SETTER EXTEND and TOOL SETTER RETRACT).

Note the current state of both inputs - only one should be active at a time.

Manually test sensor response

With machine in E-STOP, carefully move the tool setter arm by hand (if accessible) and observe the I/O status changes. Both sensors should toggle as the arm moves between positions.

Ensure spindle is clear of tool setter area before manual manipulation.

Check sensor wiring and connections

Inspect proximity sensor cables for damage, loose connections at the sensor and at the control cabinet. Verify proper sensor gap (typically 1-4mm) from target surface.

Use a multimeter to verify 24VDC supply voltage at the sensor connector.

Visual inspection for obstructions

Check the tool setter arm travel path for chips, coolant buildup, or foreign objects. Inspect the arm mounting bracket and pivot points for damage or wear.

Ensure machine is powered down and in E-STOP during inspection.

Test manual arm movement

With air pressure disconnected, manually move the tool setter arm through its full range of motion. Movement should be smooth without binding or excessive resistance.

Apply light machine oil to pivot points if movement feels stiff or jerky.

Check pneumatic cylinder operation

Reconnect air pressure and observe cylinder movement speed. The arm should move decisively between positions in under 2-3 seconds.

If movement is sluggish, check for internal cylinder wear or contaminated air supply.

Locate solenoid valve

Find the tool setter solenoid valve, typically mounted in the electrical cabinet or near the tool setter assembly. It should be labeled or identifiable by air lines leading to the tool setter cylinder.

Solenoid valves often have manual override buttons for testing purposes.

Test electrical signal to solenoid

Using DIAGNOSTICS > I/O menu, monitor the output status for tool setter extend/retract commands. Verify 24VDC reaches the solenoid coil when output is active.

You should hear an audible 'click' when the solenoid energizes if it's functioning properly.

Test manual solenoid override

If equipped with manual override, test solenoid valve operation manually to isolate electrical vs. mechanical valve problems. Replace valve if manual operation also fails.

Only qualified personnel should replace pneumatic components.