Manual Servicio TMP4100

Service Manual
TMP4100-Series
®
PINSTAMP Marking Head
This manual contains troubleshooting, test, verification, service,
and reference data information for the Telesis TMP4100-Series
markers: the TMP4100 hand-held pneumatic-pin marker, the
TMP4100E hand-held electric-pin marker, and the TMP4150
and TMP4155 fixture-mounted pneumatic-pin markers.
This manual may be supplemented and kept current by Change

Notices and Revisions.
Manual No. 33474 Rev. C
Telesis Technologies, Inc. March 2004

28181 River Drive
P.O. Box 1000
Circleville, Ohio 43113
TMP4100-Series Service
Foreword
Telesis Technologies, Inc. (hereinafter referred to as Telesis) reserves the right to change the information
and specifications contained in this manual without prior notice. The reader should consult Telesis to
determine whether such changes have been made.
In no event shall Telesis be liable for any incidental, indirect, special, or consequential damages
whatsoever, including but not limited to lost profits, arising out of, or relating to this manual or the
information it contains, even if Telesis has been advised, has knowledge, or should have knowledge of the
possibility of such damages.
Telesis expressly warrants the equipment it manufactures as set forth in the Standard Terms and Conditions
of Sale. Telesis makes no other warranties, expressed or implied, including and without limitation,
warranties as to merchantability or fitness for a particular purpose.
The information contained in this manual is confidential and is proprietary to Telesis or its licensors.
All rights reserved. Printed in the U.S.A.
Copyright © 2000 - 2004 Telesis Technologies, Incorporated
Telesis and Pinstamp are registered trademarks of Telesis Technologies, Incorporated.
33474C.DOC i
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ii 33474C.DOC
Table of Contents
PARAGRAPH PAGE
Foreword ............................................................................................................................................ i
List of Illustrations............................................................................................................................. v
List of Tables ..................................................................................................................................... v
Safety Summary ................................................................................................................................. vi
Chapter 1
General Information
1.1 Service Overview.................................................................................................................. 1-1
1.2 Intended Use ......................................................................................................................... 1-1
1.3 Service Precautions............................................................................................................... 1-1
Thread Sealant................................................................................................................ 1-1
Gaskets ........................................................................................................................... 1-1
System Weight................................................................................................................ 1-1
Air Hoses ........................................................................................................................ 1-2
1.4 Telesis Customer Support ..................................................................................................... 1-2
1.5 Additional Publications......................................................................................................... 1-2
Chapter 2
Troubleshooting
Cartridge Base Won’t Move in X-Axis ............................................................................................. 2-1
Cartridge Base Won’t Move in Y-Axis ............................................................................................. 2-2
Solenoid Won’t Actuate..................................................................................................................... 2-2
Solenoid Stays Actuated .................................................................................................................... 2-3
Push-button Switch Malfunction ....................................................................................................... 2-3
Chapter 3
Test and Verification
3.1 Air Supply Requirements...................................................................................................... 3-1
3.2 Resistance Checks................................................................................................................. 3-2
3.3 Test Procedures..................................................................................................................... 3-3
Marking Head Run In ..................................................................................................... 3-3
Marking Head Test Print ................................................................................................ 3-4
Test Completion ............................................................................................................. 3-5
33474C.DOC iii
Table of Contents
PARAGRAPH PAGE
Chapter 4
Service
4.1 Disassembly.......................................................................................................................... 4-1
4.1.1 Cover, TMP4100 and TMP4100E ................................................................................. 4-1
4.1.2 Cover, TMP4150 and TMP4155.................................................................................... 4-2
4.2 Repair ................................................................................................................................... 4-3
4.2.1 Standoff.......................................................................................................................... 4-3
4.2.2 Front Dirt Cover (optional)............................................................................................ 4-3
4.2.3 Timing Belt .................................................................................................................... 4-4
4.2.4 Air Solenoid Valve Assembly ....................................................................................... 4-5
4.2.5 Electric Solenoid Assembly........................................................................................... 4-6
4.2.6 Limit Connector Board Assembly ................................................................................. 4-8
4.2.7 Tubing (1/8 in) ............................................................................................................... 4-9
4.2.8 Tubing (4mm) ................................................................................................................ 4-10
4.2.9 Tubing (6mm) ................................................................................................................ 4-11
4.2.10 Pulley, Idler.................................................................................................................... 4-12
4.2.11 Pulley, Motor ................................................................................................................. 4-12
4.2.12 Opto Assembly, X-Axis ................................................................................................. 4-13
4.2.13 Opto Assembly, Y-Axis ................................................................................................. 4-14
4.2.14 Flag, X-Axis Opto, TMP4155 ....................................................................................... 4-15
4.2.15 Motor Assembly, X-Axis............................................................................................... 4-16
4.2.16 Motor Assembly, Y-Axis ............................................................................................... 4-17
4.2.17 Cam ................................................................................................................................ 4-18
4.2.18 Bulkhead Elbow Fitting ................................................................................................. 4-18
4.2.19 Barb Fitting, 4MM ......................................................................................................... 4-19
4.2.20 Barb Fitting, M5............................................................................................................. 4-19
4.2.21 Marker Cable Assembly................................................................................................. 4-20
4.2.22 Push-button Switch Assembly ....................................................................................... 4-20
4.2.23 Handle ............................................................................................................................ 4-20
4.2.24 Handle Mount ................................................................................................................ 4-20
4.2.25 Right Cover .................................................................................................................... 4-21
4.2.26 Left Cover ...................................................................................................................... 4-22
4.3 Assembly .............................................................................................................................. 4-22
4.3.1 Cover, TMP4100 and TMP4100E ................................................................................. 4-22
4.3.2 Cover, TMP4150 and TMP4155.................................................................................... 4-24
iv 33474C.DOC
Table of Contents
PARAGRAPH PAGE
Chapter 5
Reference Data
5.1 Parts Ordering ....................................................................................................................... 5-1
5.2 Tooling.................................................................................................................................. 5-1
5.3 Test Equipment ..................................................................................................................... 5-1
5.4 Consumables ......................................................................................................................... 5-1
5.5 Wiring Diagrams and Schematics......................................................................................... 5-2
5.6 Part List................................................................................................................................. 5-4
5.6.1 TMP4100........................................................................................................................ 5-4
5.6.2 TMP4100E ..................................................................................................................... 5-5
5.6.3 TMP4150........................................................................................................................ 5-6
5.6.4 TMP4155........................................................................................................................ 5-7
List of Illustrations
FIGURE PAGE
5-1 TMP4100, TMP4150, and TMP4155 Wiring............................................................................... 5-3

5-2 TMP4100E Wiring........................................................................................................................ 5-4
List of Tables
TABLE PAGE
2-1 Troubleshooting ............................................................................................................................ 2-1
3-1 Air Supply Requirements.............................................................................................................. 3-1

3-2 Resistance Checks......................................................................................................................... 3-2
33474C.DOC v
Safety Summary
The TMP4100-Series markers use high voltage power supplies and high pressure pneumatic supplies.
Accordingly, there is some danger when working with, and near, Pinstamp® marking machines. The
following safety precautions should be observed at all times.
♦ Eye protection may be required when working in close proximity of an operating marker.
♦ Ear protection may be required when working with or near an operating marker.
♦ Keep all body parts, jewelry, and clothing clear of the marker while it is operating.
♦ On pneumatic markers, do not disconnect the tubing while air pressure is applied to the lines.
♦ Do not remove or defeat the marking system’s safety features or protective guards.
♦ Never use the marker in any manner or for any purpose other than that for which it was designed.
Warnings, Cautions, and Notes are placed throughout this manual to alert you to important information.
These messages have the following significance.
WARNING
Warnings contain information that is essential to the personal safety of the user.
CAUTION
Cautions contain information that is essential to avoid damage to the equipment.
NOTE
Notes call attention to information of special importance at specific points within the text.
vi 33474C.DOC
Chapter 1
General Information
1.1 SERVICE OVERVIEW

This manual provides general information, troubleshooting, test and verification, and service procedures for
the TMP4100-series markers. This manual also provides reference data such as parts lists and schematics.
*** NOTICE ***
This manual documents the TMP4100, TMP4100E, TMP4150, and TMP4155 marking heads.
The TMP4100, TMP4150, and TMP4155 heads contain a pneumatic pin that uses air pressure to
drive the pin from and return the pin to the pin cartridge. The TMP4100E uses no air pressure.
The TMP4100E uses an electric solenoid to drive and an internal spring to assist pin return.
Servicing of the marking heads is almost identical. Where variation do exist, they will be
clearly identified within the text to inform you of the differences.
TMP4100, TMP4100E: The TMP4100 and TMP4100E markers are hand-held markers. They
may be used in any orientation except inverted (that is, with the handle pointing upward).
TMP4150, TMP4155: The TMP4150 and TMP4155 markers are fixture-mounted markers for
in-line use. They may be mounted in any orientation except inverted (that is, with the
mounting holes pointing upward). Typically, they should be mounted on a tooling fixture
with the pin pointing downward. These marking heads employ a protective boot to help
prevent contaminants from entering the marking head cavity. The TMP4150 uses a neoprene
boot; the TMP4155 uses a nitrile (synthetic rubber) boot.
The marking system design and specifications are subject to change without prior notice.
1.2 INTENDED USE

The procedures and information within this manual are provided for agencies authorized by Telesis
Technologies, Inc., to service the TMP4100–series markers.
1.3 SERVICE PRECAUTIONS

Thread Sealant
Thread sealant is used on the marker. Use of sealant on threads will be noted in the service procedures.
Gaskets
The solenoid valves include gaskets. During the removal or replacement of solenoid valves ensure the gaskets
are not broken or crushed during assembly.
System Weight
The TMP4100 and TMP4100E markers each weigh approximately 5.5 lb. (2.5 kg). The TMP4150 and
TMP4155 markers each weigh approximately 8.7 lb. (3.9 kg). Personnel performing service should use care
when positioning, moving, and lifting the marker.
33474C.DOC 1-1
General Information
Air Hoses
TMP4100, TMP4150, TMP4155: Prior to performing any service action associated with the removal or
replacement of an air hose, first verify the routing and connections. Notice the routing of the hose and the
location of components related to the hose. When installing a new air hose, use caution not to introduce kinks.
Ensure during the operation of the marker, that air hoses will remain properly secured. Ensure that hoses will
not be damaged by physical contact with other parts or assemblies during operation.
1.4 TELESIS CUSTOMER SUPPORT

Telesis Customer Support offers the following assistance:
Phone Support - Telesis Customer Support offers free phone support to answer questions during normal
business hours.
On-Site Service - Telesis can send Customer Support professionals to your facility to perform equipment
start-up, repair, maintenance, and training.
Service Contracts - As part of your Service Contract, you receive periodic maintenance and quick on-site
customer support if a problem should occur.
Factory Service - Telesis Customer Support can repair defective parts in our factory to save you money.
For more information on any of these services, contact Telesis at one of the following locations:
Telesis Technologies, Inc. Telesis Europe B.V. Telesis MarkierSysteme GmbH

P.O. Box 1000 Innsruckweg 104 Wülfingstrasse 6
Circleville, Ohio 43113 3047 AH Rotterdam D-42477 Radevormwald
USA The Netherlands Germany
Tel: ++1 (740) 477 5000 Tel: ++31 (0)10-462 21 36 Tel: ++49 (0) 2191-60 90 8 0
Fax: ++1 (740) 477 5001 Fax: ++31 (0)10-462 38 63 Fax: ++49 (0) 2191-60 90 8 88
E-mail: support@telesistech.com E-mail: telesis.europe@wxs.nl E-mail: info@telesistech.com
Telesis Systèmes de Marquage TelesisEagle

BP 438 Colyton
77 481 Provins Cedex Devon, UK EX24 6LU
France Tel: ++44 (0) 1297 551313
Tel: ++33 (0)1 60 67 12 96 Fax: ++44 (0) 1297 551319
Fax: ++33 (0)1 60 58 07 45 E-mail: support@telesiseagle.co.uk
E-mail: gerbad@telesistech.com E-mail: sales@telesiseagle.co.uk
1.5 ADDITIONAL PUBLICATIONS

Additional information on the TMP4100-series markers can be located in the following publications:
TMP4100-Series Installation/Maintenance Manual
TMP4100 Operation Supplement
TMP4100E Operation Supplement
1-2 33474C.DOC
Chapter 2
Troubleshooting
This chapter provides troubleshooting information for the TMP4100-series marker. In the table that follows,
common problems are listed in the left column. The probable cause for the problem is listed in the center
column. The corrective action is in the right column. When a defective part or assembly is located, refer to
Chapter 4 for procedures on replacement. If the problem can not be resolved using this information, contact
Telesis Customer Support.
Table 2-1. Troubleshooting

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION
A. Cartridge Base Won’t Move A1. Belt broken Remove the right cover and examine the drive
in the X-axis belt.
If the belt is broken or defective, replace the
belt.
If the belt is okay, check for a loose motor
pulley.
A2. Motor pulley loose Examine the pulley on the X-axis motor shaft.
If the pulley is loose, secure the pulley to the
motor shaft; if not serviceable, replace.
If the motor pulley is okay, check for a
defective idler pulley.
A3. Idler pulley defective Examine the idler pulleys.
If a pulley is defective, replace.
If the pulley is okay, check for a restriction.
A4. Restriction Examine the area around the pulleys and the
belt for anything that would restrict the
motion of the belt. Examine the area around
the carriage base, frame, and retractable
hose for foreign objects or other
restrictions.
If no restrictions are located, check the limit
connection board.
A5. Limit connection board defective Use a volt-ohm meter to check the wiring
through the limit board.
Refer to Table 3-2 and Figure 5-1.
If the wiring is defective, correct as required.
If the wiring is okay, test the limit board.
If the limit board is defective, replace the
board.
If the limit board is okay, replace the X-axis
motor.
A6. Marker cable defective Use a volt-ohm meter to check the wiring
If the wiring is defective, replace the marker
cable.
A7. Carriage on rail is bound. Remove the belt from the motor and check the
cartridge base for freedom of movement in
the X- Axis.
continued on next page
33474C.DOC 2-1
Troubleshooting
Table 2-1. Troubleshooting (continued)

B. Cartridge Base Won’t Move B1. Cam slipping TMP4100, TMP4100E: Remove right cover.
in the Y-axis TMP4150, TMP4155: Remove the cover.
Examine the cam on the Y-axis motor.
If the cam is loose, replace the cam.
If the cam is okay check for a restriction.
B2. Restriction Examine the area around the cam for anything
that would restrict the motion. Examine the
area around the carriage base, frame, and
cam for objects or other restrictions.
If no restrictions are located, check the limit
connection board.
B3. Broken spring Check both springs mounted between motor
and frame. Replace spring(s) if defective.
B4. Limit connection board defective Use a volt-ohm meter to check the wiring
If the wiring is okay, test the limit board.
If the limit board is defective, replace the
board.
If the limit board is okay, replace the Y-axis
motor.
B5. Marker cable defective Use a volt-ohm meter to check the wiring
cable.
C. Solenoid Won’t Actuate C1. Solenoid wiring defective Use a volt-ohm meter to check the wiring to the
solenoid.
If any indication is not correct, visually examine
the wiring between to the solenoid.
If the wiring is okay, test the solenoid.
C2. TMP4100, TMP4150, TMP4155: TMP4100, TMP4150, TMP4155:
Solenoid defective Apply 10 psi of air to the marker.
TMP4100, TMP4150, TMP4155:
Apply +12VDC ("5%) between pins 9(+)
and 12(-) of the marker cable. The solenoid
should actuate and pass air to the carriage
base.
TMP4100, TMP4150, TMP4155:
If the solenoid does not actuate, replace the
solenoid.
C3. Marker cable defective Use a volt-ohm meter to check the wiring
cable.
continued on next page
2-2 33474C.DOC
Table 2-1. Troubleshooting (continued)

D. TMP4100, TMP4150, D1. TMP4100, TMP4150, TMP4155: TMP4100, TMP4150, TMP4155:
TMP4155: Solenoid Stays Solenoid defective Apply 10 psi of air to the marker.
Actuated TMP4100, TMP4150, TMP4155:
If the solenoid passes air with no power
applied, replace the solenoid.
E. TMP4100, TMP4100E: E1. TMP4100, TMP4100E: TMP4100, TMP4100E:
Push-button switch Switch assembly defective Use a volt-ohm meter to check the wiring to
Malfunction the push-button switch assembly.
TMP4100, TMP4100E:
If any indication is not correct, visually
examine the wiring to the switch.
TMP4100, TMP4100E:
If the wiring is defective, correct as
required.
TMP4100, TMP4100E:
If the wiring is okay, replace the push-
button switch assembly.
E2. Marker cable defective Use a volt-ohm meter to check the wiring
cable.
33474C.DOC 2-3
Troubleshooting
2-4 33474C.DOC
Chapter 3
This chapter provides the information to operationally check the TMP4100-series marker after service is
completed. The data that follow are also included as a supplement to the troubleshooting procedures in
Chapter 2 and the reference information in Chapter 5.
3.1 AIR SUPPLY REQUIREMENTS

TMP4100E: The TMP4100E does not use air pressure to drive the marking pin. The following section does
not apply to the TMP4100E marker.
TMP4100, TMP4150, TMP4155: The following table lists the typical air supply requirements necessary for
the proper operation of the TMP4100, TMP4150, or TMP4155 marking head. Actual air pressure and volume
needs will vary in accordance with the material being marked and the depth of impression. Supply air
pressure to the marker shall not exceed 120 psi.
Table 3-1. Air Supply Requirements
APPLICATION TYPICAL VALUE UNITS
Input Air Pressure 120 psi

Marking Air Consumption (150S pin) 1.5 scfm
Drive Air Pressure 90 psi
33474C.DOC 3-1
3.2 RESISTANCE CHECKS

Table 3-2 lists resistance checks for the TMP4100-Series marker. Resistance checks are provided as a guide
to aid troubleshooting and fault isolation. The following values are for indication only and will vary among
units. Some differences in readings are expected and are not intended to be used as a sole source of error
indication. Measurements were obtained with a digital volt-ohm meter. Values are in ohms.
Table 3-2. Resistance Checks
LOCATION FROM PIN TO PIN VALUE (Ω) FUNCTION

(negative lead) (positive lead)
Marker Cable 1 2 2.2 X-Axis A

3 4 2.2 X-Axis B
5 6 2.2 Y-Axis A
7 8 2.2 Y-Axis B
9 10 <1 Solenoid Common
9 or 10 12, 13 or 14 12 Solenoid Coil [TMP4100, TMP4150, TMP4155]
9 or 10 12, 13 or 14 .01 Solenoid Coil [TMP4100E]
21 20 >1 M +5 VDC
22 20 >1 M A Home Signal
22 21 >1 M A Home Signal
25 20 >1 M B Home Signal
25 21 >1 M B Home Signal
26 any >1 M Push-button 2
27 any >1 M Push-button 3
29 20 >1 M Push-button 1(not pushed)
29 20 <1 Push-button 1(pushed)
37 any >1 M Safety Ground
3-2 33474C.DOC
3.3 TEST PROCEDURES

Test the TMP4100-series marking heads in accordance with the following procedures. Refer to the TMC420
Operation Manual (or TMP4100E/400 Operation Manual) for complete operating instructions.
Marking Head Run In

1. Remove the marking head cover.
2. Attach the marking head to a mechanical test stand.
3 Disconnect plug from J6 and J7 on the Home Limit board.
4 TMP4100, TMP4150, TMP4155: Attach Drive Air to the marker. Set Drive Air pressure to 80 psi.
5 TMP4150, TMP4155: Attach Return Air to the marker. Set Return Air pressure to 20 psi.
6 TMP4100: Unhook air line from push connector on regulator assembly (30404). Attach a calibrated air
pressure gauge to the regulator. Turn on air supply. Loosen lock nut on regulator and turn the adjusting
screw clockwise until a reading or 20 psi (+1, -0 psi) is obtained. Apply VIBRA-TITE® to the lock nut.
While holding the adjusting screw, tighten the lock nut to lock adjusting screw in place. Ensure
pressure remains at 20 psi (+1, -0 psi). Attach return air line.
7 TMP4100, TMP4150, TMP4155: Attach a test cartridge assembly with carbide pin.
8. Attach the marking head to a TMC420 Controller (configured for the TMP4100, TMP4150, or
TMP4155) or to a TMC400 Controller (configured for the TMP4100E). Turn the controller ON.
9. Create two text fields as follows:
• Field #1: EEE SN%6V EEE (Top/Left Justified at X=0.0, Y=0.0)
• Field #2: EEEE %6S EEEE (Bottom/Left Justified at X=0.0, Y=0.3)
There should be a total of 28 characters and 4 spaces.
• Verify the characters appear on the display.
• Set the character height to 0.125 in., width to 0.083 in., and pitch to 0.125 in.
• In the first line of text, type the marker’s serial number.
• For the second line of text, reset the serial number parameter to 1.
10. TMP4100, TMP4100E, TMP4150: Use the jog function to test the 0.3 by 2.0 inch window.
TMP4155: Use the jog function to test the 0.3 by 1.5 inch window.
• Adjust the X and Y limit flags so the cartridge base moves freely, does not contact the frame, and
does not hit at either end.
• Verify that the flags pass through the optos without contacting them.
(continued on next page)
33474C.DOC 3-3
11. Verify the marker seeks, and finds, the Home limit.
• Home the marker, then manually push the cartridge to the right as viewed from the front until the
stanchion hits the pulley flange.
• Place the marker online (F2) verify the cartridge moves to the left and back to the home position.
• There should be a gap of .30mm to .50mm between the stanchion and the pulley flange.
Try to place a .30 mm feeler gauge between the stanchion and the pulley flange.
If the feeler gauge passes through, try a .50mm feeler gauge. This should not pass through.
• If neither condition is met, adjust the X-axis opto by loosening the screw, moving the opto, and
re-tightening. There is a slot in the underside of the frame to allow a 2.5mm hex key to
loosen/tighten the M3-.5 socket head cap screw.
• After adjusting, push the cartridge to the right (until the stanchion comes into contact with the
pulley flange). Home the marker. Verify the marker moves away and back home, and does not
continually seek home.
12 Place the system on line.
13 Connect a continuous print adapter (25029) to the TTL I/O connector on the back of the controller. The
head will continuously cycle without the pin firing.
14 Allow a minimum of one (1) hour run-in time.
15 When the run-in test is complete,
a. Turn the controller OFF
b. Remove the continuous print adapter from the TTL I/O connector on back panel of the controller.
16 Proceed with Marking Head Print Test.
Marking Head Test Print

1. Connect the solenoid wire to J6 or J7 (whichever was removed earlier) on the Home Limit board.
2. Turn the controller ON.
3. In text field #1, type: EEEEEE (six E’s).
• Set the speed rate at 70%.
• Set the character height to 0.3 in.
• Set the character width to 0.2 in.
• Set the character pitch to 0.3 in.
• Print, then print again.
4. Remove the test sample from the vise and visually inspect it for perpendicularly and alignment of
printed characters using a precision straight edge. Check the following:
• The bottom and top lines of the characters to be straight lines within ½ pixel
• The centerlines of the characters to be straight lines within 1 pixel
• The vertical lines of the characters to be perpendicular to the bottom within ½ pixel
• The dots, when printed in the same direction, are not off more the ¼ pixel.
5. Make adjustments, as necessary, to produce characters that meet the guidelines (above).
3-4 33474C.DOC
6. TMP4100 ONLY:
a. Attach Drive Air to the marking head. Set Drive Air pressure to 80 psi.
b. Attach marking head to controller. Turn the controller ON.
c. Using the text fields from the run-in test, mark a sample of the final test print:
• Mark sample on Tracking Form in area titled “TEST PRINT AREA – HAND-HELD MARK”
• Note the duration of marking head test on RUN TIME line of form (1 hr)
d. Return the head to Home position.
e. Turn the controller OFF and disconnect marking head from controller.
f. Relieve all air pressure. Remove the air tubing.
g. Remove the pin cartridge assembly.
h. Install the cover.
i. Proceed to Test Completion.
7. TMP4100E ONLY:
a. Attach marking head to controller. Turn the controller ON.
b. Using the text fields from the run-in test, mark a sample of the final test print:
• Mark sample on Tracking Form in area titled “TEST PRINT AREA – HAND-HELD MARK”
c. Return the head to Home position.
d. Turn the controller OFF and disconnect marking head from controller.
e. Install the cover.
f. Proceed to Test Completion.
8. TMP4150, TMP4155 ONLY:
a. Using the text fields from the run-in tests, mark a sample of the final test print:
• Mark sample on Tracking Form in area titled “TEST PRINT AREA – FIXTURED MARK”
b. Return the head to Home position.
c. Turn the controller OFF and disconnect marking head from controller.
d. Relieve all air pressure. Remove the air tubing.
e. Remove the marking head from the mechanical test stand.
f. Remove the pin cartridge assembly.
g. Install the cover.
h. Proceed to Test Completion.
Test Completion
1. Inspect all items listed in the System Analysis Table on the Tracking Form.
Check the appropriate box after each item is inspected.
2. Complete the bottom portion of the Tracking Form (serial number, job number, your name, date).
3. If additional comments are required, check the OVER box at the bottom of the page and write clear,
concise comments on the reverse side of the Tracking Form.
4. File the completed Test and Tracking Form as applicable for your recordkeeping.
33474C.DOC 3-5
3-6 33474C.DOC
TMP4100-Series Marking Head Test & Tracking Form
Copy this form. Complete form for each marking head tested. Retain completed form for record.
TEST PRINT AREA – FIXTURED MARK RUN TIME: ___________
TEST PRINT AREA – HAND-HELD MARK
SYSTEM ANALYSIS CHECKED (!)

TMP4100,TMP4150, TMP4155: No Air Leaks
Character Height OK (both lines of text)
All Labels Correctly Attached
No Scratches on Cover
TMP4100: Internal Regulator Set to 20 psi
No Movement of Pivot Point Dowel When 10 Lb. Pressure Is Applied to End of Dowel
TMP4100, TMP4100E: Pushbutton operates properly
SERIAL NUMBER:___________________________ JOB NUMBER: ______________________
TECHNICIAN:______________________________ DATE: ______________________
! OVER
33474C.DOC 3-7
3-8 33474C.DOC
Chapter 4
Service
This chapter provides the information necessary to service the TMP4100-series markers. Procedures in this
chapter include initial disassembly, mechanical repair, electrical repair, and final assembly. Assemblies and
components for replacement are identified by part name.
NOTE
Some procedures do not require initial disassembly. If initial disassembly is

required, perform only the steps necessary in Section 4.1 to gain access for service.
Final assembly procedures following service are provided in Section 4.3.
CAUTION
TMP4100, TMP4150, TMP4155: Prior to assembly of the solenoid valve, ensure proper
placement of the solenoid valve gasket to prevent air leaks or damage to the gasket.
It may be necessary to remove cable-ties during portions of this procedure. Caution

should be used to ensure insulation and wires are not damaged. Note routing of
cables and placement of cable-ties to facilitate re-assembly.
4.1 DISASSEMBLY
4.1.1 Cover, TMP4100 and TMP4100E

1. Place marker on work surface with cartridge assembly to right, cable to left and handle down.
2. Remove cover.
• If optional slide plates are attached, use a 2mm hex key to remove two screws from both top and
bottom retainer plates securing slide plates on front of marker.
• Remove four screws securing right stand-off to foot mount and marker.
• Using a 2.5mm hex key, remove four screws securing right cover to left cover.
• Separate covers and place right cover aside.
3. Remove marker cable assembly.
• Using a 2.5mm hex key, remove one screw securing wire-lug on marker cable to manifold base.
• Remove connector J2 of marker cable from J1 of limit connector board.
• Locate and remove 1/4-inch nylon finishing plug.
33474C.DOC 4-1
Service
4. Remove push-button switch.

• Locate and detach switch assembly connector from J2 of limit connector board.
• Locate set screw in handle under push-button switch.
• Using a 1.5mm hex key, loosen set screw five turns.
5. While carefully routing connector through hole in handle mount, remove push-button switch assembly
from handle.
6. Using a 2.5mm hex key, loosen set screw securing handle to handle mount.
• Remove handle from handle mount.
7. Using a 3mm hex key, remove two screws from bottom of handle mount securing handle mount to
manifold base.
8. TMP4100: Disconnect air line from removable elbow fitting on left cover.
• Locate air hose between manifold base and left cover.
• On elbow fitting, push-in retaining ring and pull-out air line.
9. Using a 2.5mm hex key, remove three screws securing left cover to manifold base and remove left
cover.
4.1.2 Cover, TMP4150 and TMP4155

1. Place marker on work surface with cartridge assembly to right, cable to left, and base down.
2. Remove cover.
• Lift up on the tabs of the latches located on the sides of the marker.
• Rotate the tabs counter-clockwise to loosen and disengage the latches.
• Slide the protective boot over the end of the cartridge.
• Slide the cover off the marker.
3. Remove marker cable assembly.
• Using a 2.5mm hex key, remove one screw securing wire-lug on marker cable to manifold base.
• Remove connector J2 of marker cable from J1 of limit connector board.
• If necessary, unscrew the water-tight fitting from the back plate, then thread the wires through
the back plate.
4. Disconnect air lines from removable bulkhead fittings.
• Locate air hose between manifold base and cover.
• On bulkhead fitting, push in retaining ring and pull out air line.
• On remaining fitting, push in retaining ring and pull out air line.
4-2 33474C.DOC
4.2 REPAIR
The procedures for repair of the TMP4100-series markers are provided in the following paragraphs. Repair
includes the removal and replacement of major subassemblies and individual component parts.
4.2.1 Standoff
TMP4100, TMP4100E: The following section applies to only TMP4100 and TMP4100E markers.
Removal
1. Using a 2.5mm hex key, remove four screws securing foot mount to standoff.
NOTE
Note the position of the foot mount in the slot of the standoff. Mark it if necessary.
2. Using a 2mm hex key, remove two screws securing standoff to cover.
3. If required, obtain standoff, foot mount/foot pad for replacement.
Installation
1. Secure standoff to cover with two M3-.50 x 10mm flathead cap screws using a torque screw driver and a
2mm hex bit. Torque screws to 12 in-lb.
2. Apply LOCTITE®222 to threads of four M3-.50 x 10mm phillips cap screws. Using a 2.5mm hex key,
secure foot mount/foot pad to standoff with four screws. Set the tip of the pin .125" below the surface
of the standoff.
4.2.2 Front Dirt Cover (optional)

Removal
1. Using a 2.5mm hex key, remove two screws securing cartridge to cartridge base.
NOTE
Remove standoff with retainer plates attached.
2. Using a 2mm hex key, remove four screws securing standoff mounts to covers.
3. Remove slide plates from front of marker.
Installation
1. Insert slide plates into marker, large plate first.
2. Secure standoff to cover with two M3-.50 x 10mm flathead cap screws using a torque wrench and a
3. Secure cartridge to cartridge base using a 2.5mm hex key.
33474C.DOC 4-3
Service
4.2.3 Timing Belt
Removal
1. Perform disassembly as described in Section 4.1.
2. Locate two extension springs attached to the forward portion of the frame; one between the frame and
the motor mount; one between the frame and the limit board mount.
• Using long-nose pliers, lift springs from frame.
3. TMP4100, TMP4150, TMP4155: Adjust or reposition the tubing to allow frame to be rotated.
• Rotate frame on motor mount 90° and slip timing belt from around motor pulley.
4. Using a 2.5mm hex key, remove one screw securing stanchion to rear of cartridge base.
• Remove stanchion and timing belt clamp piece (1/2-inch section of a timing belt) from rear of
cartridge base.
• Remove timing belt.
5. If required, obtain appropriate belt, timing belt clamping section and stanchion for replacement.
Installation
1. Rotate frame up to 90° on motor mount and slip appropriate timing belt around motor pulley and both
idler pulleys.
• Rotate frame back down.
• Move the frame and inspect for any TEFLON® tape that may have been dislodged between the
frame and motor mount. Replace as necessary with 7-mil TEFLON® tape.
2. Attach extension springs to forward portion of frame using long-nose pliers so loop is coming from
“back” side of tab.
3. Position cartridge base to center of travel.
4. Place timing belt clamp section on timing belt and interlock teeth.
5. Apply VIBRA-TITE® to threads of one M3-.5 x 6mm socket head cap screw. Allow to dry.
6. Place stanchion (centered) into slot of cartridge base behind timing belt and timing belt clamp section.
Push belt so edge is in contact with manifold base.
7. Secure stanchion to cartridge base with screw using a 2.5mm hex key.
8. TMP4100, TMP4150, TMP4155: Reposition the tubing.
TMP4100, TMP4150, TMP4155: Ensure tubing will not drag against motor or bind between motor and
frame.
Ensure wiring will not drag against motor or bind between motor and frame.
9. Measure / adjust the belt tension.
• Using a 2.5mm hex driver, loosen four cap screws securing X-axis motor.
• Hold assembly vertically with cartridge pointing downward
• Using 6 lbs. of force, pull the frame forward.
• Position X-axis motor squarely on motor mount.
• Using a 2 mm hex driver, tighten the button head cap screws to secure motor to motor mount.
10. Perform assembly as described in Section 4.3.
4-4 33474C.DOC
4.2.4 Air Solenoid Valve Assembly

TMP4100, TMP4150, TMP4155: The following section applies to only TMP4100, TMP4150, and TMP4155
markers.
Removal
2. Disconnect solenoid valve wires attached to limit connector board.
3. Using a 1.5mm hex key, remove two screws securing solenoid valve assembly to manifold base.
4. If required, obtain solenoid valve assembly for replacement.
Installation
CAUTION
Improper placement of the formed gasket used with the solenoid valve will
damage the gasket and could cause air leaks. Prior to assembly of the
solenoid, verify the formed gasket is properly placed in the solenoid.
1. Position solenoid valve on manifold base and secure with two M2-.4 x 20 mm socket head cap screws
and a 1.5mm hex key.
2. Route wires around rear of X-axis motor and attach to limit connector board at connectors J6 and J7.
Ensure wires do not interfere with any movement.
33474C.DOC 4-5
Service
4.2.5 Electric Solenoid Assembly

TMP4100E: The following section applies to only TMP4100E markers.
Removal
2. Remove the pin cartridge.
3. Disconnect connectors on J6 and J7.
4. Remove two M3-.05 x 6mm flat head cap screws from the electric pin. Remove the armature and
shim(s).
5. Rotate the solenoid over the end leg.
6. Remove two M3-.05 x 6mm flat head cap screws that secure the solenoid frame to the cartridge base.
7. Remove two nuts securing solenoid to the electric pin base.
8. Note wire routing and location of wire ties. Remove wire ties, as applicable, and remove solenoid.
Installation
1. Mount the solenoid with flex leads to the electric pin base using the two nuts provided on the solenoid,
flat side of base mating with the solenoid and hex nuts on “lower” flats.
2. Thread the wires from the solenoid through the hole in the face of the cartridge base leaving about 1½ to
2" protruding from the face.
3. Place the solenoid frame on the face of the cartridge base with wires through the notches and on top.
Align the screw holes and attach with two M3-.05 x 6mm flat head cap screws.
4. Rotate the solenoid over the end leg so that wires are on either side of the top leg.
5. Push the assembly down between the legs, solenoid first. Verify the armature and leg shims are in place
prior to inserting. Align the holes and attach with two M3-.05 x 6mm flat head cap screws.
4-6 33474C.DOC
CAUTION
Do not pull the wires through from the backside of the cartridge base. Doing
so might strip insulation from the wires and short the solenoid drivers.
6. Push the wires from the front through the notches while taking up the slack from the back of the
cartridge base until all slack is removed from the wires.
7. Place a tapered compression spring, wide end first, into bore on cartridge.
8. Place a pin, point first, into the cartridge and through the small end of the spring.
9. Place the cartridge over the solenoid armature shaft and secure in place with two M4-.7 x 12mm cheese
head screws.
CAUTION
Do not crush the wires when you tighten the wire ties.
10. Snug the wire down with wire ties.

a. Place a wire tie near the end of the 1/8" dowel pin in the back of the cartridge base, and around the
solenoid wires.
b. Route the wires down the side of the frame, opposite the cam, allowing enough wire with slight
slack when the cartridge is at the cam side of the frame.
c. As viewed from the top, place a wire tie around the frame and wires on the cross member, close to
the right side pulley .
d. Place a second wire tie around wires and through the frame’s large rear hole. Connect the wires
onto spade lugs J6 and J7.
11. Install the pin cartridge.
33474C.DOC 4-7
Service
4.2.6 Limit Connector Board Assembly
Removal
2. Disconnect wiring attached to limit connector board:
X-axis opto assembly (J4)
Y-axis opto assembly (J5)
X-axis motor assembly (J8)
Y-axis motor assembly (J9)
Solenoid valve assembly (J6 and J7)
3. Using a 2.5mm hex key, remove three screws securing limit connector board to manifold base.
4. If required, obtain limit/connector board assembly for replacement.
Installation
1. Apply LOCTITE®222 to threads of three M3-.50 x 10mm socket head cap screws.
2. Position limit connector board on motor mount (J6 and J7 near X-axis motor) and secure with screws
and a 2.5mm hex key.
3. Connect wiring to limit connector board:
Y-axis motor assembly (J9)
X-axis opto assembly (J4)
Y-axis opto assembly (J5)
X-axis motor assembly (J8)
Solenoid valve assembly (J6 and J7)
4-8 33474C.DOC
4.2.7 Tubing (1/8 in)

markers.
Removal
2. Disconnect (pull) tubing from barb fitting on the cartridge base and forward portion of manifold base.
3. Remove any wire ties securing tubing.
4. Obtain for replacement one 8-in. length of 1/16" ID x 1/8" OD tubing.
Installation
CAUTION
During the installation of the tubing, ensure it does not become crimped or
crushed between the frame and the motor mount.
Do not tighten wire ties too tightly. Excessively tight wire ties may crush
the tubing and render the marker inoperable.
1. Push tubing onto barb fitting on manifold base.

• Route tubing between limit connector board and manifold base.
• Route tubing and secure with wire ties. Do not crush tubing when tightening wire ties.
• Push tubing onto barb fitting installed on the cartridge base.
2. Ensure tubing does not drag against motor or bind between motor and frame.
33474C.DOC 4-9
Service
4.2.8 Tubing (4mm)

markers.
Removal
2. Using a razor knife, carefully cut tubing from barb fitting on the cartridge base.
3. Remove any wire ties securing tubing.
4. TMP4100: Remove the other end of the tubing from the regulator by pushing inward on the retaining
ring and pulling outward on the tubing.
TMP4150, TMP4155: Remove the other end of the tubing from the bulkhead fitting. Push in retaining
ring and pull out air line.
5. Obtain for replacement an 8-in. length of black, high flex tubing.
Installation
1. Push one end of the 8" tubing onto the barb fitting on the manifold base.
CAUTION
Do not tighten wire ties too tightly. Excessively tight wire ties may crush
the tubing and render the marker inoperable.
2. Route tubing and secure with wire ties. Do not crush tubing when tightening wire ties.
3. TMP4100: Connect the other end of the tubing to the regulator.
TMP4150, TMP4155: Connect the other end of the tubing to the bulkhead connector.
4-10 33474C.DOC
4.2.9 Tubing (6mm)

markers.
Removal
2. TMP4100: Remove the 1" piece of 6mm tubing between the other end of the plastic elbow and the
bulkhead fitting. Remove the 3" piece of 6mm tubing from the plastic elbow.
TMP4150, TMP4155: Remove the 3" piece of 6mm tubing between the manifold base and the bulkhead
fitting marked “D” (drive).
3. Obtain for replacement an appropriate length of 6mm tubing.
Installation
1. TMP4100: Attach a 3" piece of 6mm tubing to the plastic elbow. Attach a 1" piece of 6mm tubing
between the other end of the plastic elbow and the bulkhead fitting.
TMP4150, TMP4155: Install a 3" piece of 6mm tubing between the manifold base and the bulkhead
fitting marked “D” (drive).
33474C.DOC 4-11
Service
4.2.10 Pulley, Idler
Removal
2. Perform removal of timing belt. (Steps 1 through 3, only. See procedure).
3. Using a 3/16-inch flat blade screw driver, remove screw securing pulley to frame.
4. Obtain a .187, 18 teeth, .80 pitch, plastic pulley for replacement.
Installation
1. Apply LOCTITE®222 to threads in mounting hole (not bolt threads).
2. Ensure LOCTITE® does not contact pulley.
3. Position pulley on frame and secure with one .187 x .5 shoulder bolt using a 3/16-inch flat blade screw
driver.
4. Perform installation of timing belt. (See procedure.)
4.2.11 Pulley, Motor
Removal
2. Perform removal of timing belt. (Steps 1 through 3, only. See procedure).
3. Using a .050-inch hex key, loosen set screw securing pulley to motor shaft.
• Remove pulley.
4. Obtain a 5mm ID, 15-tooth, 2.03 pitch pulley for replacement.
Installation
1. Using a .050-inch hex key, remove set screw from pulley.
2. Apply LOCTITE®222 to threads of set screw.
3. Place pulley on motor shaft.
• Using a steel rule, position pulley vertically, in-line with idler pulleys.
• Verify belt is centered on pulley.
• Insert set screw and tighten using a .050-inch hex key.
4. Perform installation of timing belt. (Steps 1 through 9, only. See procedure).
4-12 33474C.DOC
4.2.12 Opto Assembly, X-Axis
Removal
2. Using a 2mm hex key, remove two screws securing Y-axis motor to motor mount.
Rotate cam as required to gain access to screws.
3. Disconnect X-axis opto assembly wiring from J4 of limit connector board assembly.
4. Using side cutters, locate and remove two wire-ties from opto assembly wiring.
5. Using a 2.5mm hex key, remove screw securing X-axis opto assembly to frame.
6. Obtain an X-axis opto assembly for replacement.
Installation
1. Apply VIBRA-TITE® to threads of two M3-.50 x 6mm socket head cap screws. Allow to dry before
assembling.
2. Position X-axis opto assembly on frame. Insert, but do not tighten both screws.
3. Position cartridge base to left until it contacts frame.
• Using a steel rule, reposition cartridge base .020 to .040-inches (.5 to 1mm) from frame.
• Position X-axis opto assembly to center X-axis flag (spring pin) in opto assembly.
• Using a 2.5mm hex key, tighten screw.
4. Move cartridge base along X-axis to ensure flag does not contact opto assembly and is centered in opto
assembly at extreme left position.
5. Route X-axis opto assembly wiring along path of Y-axis opto assembly wiring toward limit connector
board.
6. Connect wiring to J4 of limit connector board assembly.
7. Apply two wire-ties to wiring in same position where removed.
8. Position Y-axis motor assembly onto motor mount.
Wiring toward X-axis motor M3-.5 x 50mm screw with extension spring forward.
• Secure motor to motor mount with two M3-.50 x 10mm flat head cap screws using a
2mm hex key.
• Ensure wiring is clear of cartridge base and cam travel.
33474C.DOC 4-13
Service
4.2.13 Opto Assembly, Y-Axis
Removal
3. Disconnect Y-axis opto assembly wiring from J5 of limit connector board assembly.
4. Using side cutters, locate and remove two wire-ties from opto assembly wiring.
5. Using a 2.5mm hex key, remove one screw securing Y-axis opto assembly to frame.
6. Obtain a Y-axis opto assembly for replacement.
Installation
1. Connect Y-axis opto assembly wiring to J5 of limit connector board assembly.
2. Route Y-axis opto assembly wiring along path of X-axis opto assembly wiring from limit connector
board.
3. Position Y-axis motor assembly onto motor mount.
Wiring toward X-axis motor M3-.5 x 50mm screw with extension springs forward.
2mm hex key.
• Position Y-axis flag (spring pin) on cam to lowest position, away from frame.
4. Apply VIBRA-TITE® to threads of one M3-.50 x 6mm socket head cap screw.
• Allow 15 minutes drying time.
5. Position Y-axis opto assembly on frame.
• Insert, but do not tighten screw.
• Ensure center-line on long axis of opto assembly is on a line drawn between mounting screw and
center of motor shaft.
• Position frame to contact cam on Y-axis motor.
• Using a 2mm hex key, tighten screw.
6. Rotate cam to ensure flag does not contact opto assembly.
7. Apply two wire-ties to wiring in same position where removed.
8. Ensure wiring is clear of cartridge base and cam travel.
4-14 33474C.DOC
4.2.14 Flag, X-Axis Opto, TMP4155

TMP4155: The following section applies to only TMP4155 markers.
Removal
CAUTION
There are four small flat washers located under the X-axis opto flag. Be
careful when removing the flag. Do not allow the washers to fall into the
marking head cavity.
2. Locate the two M3 socket head cap screws in the two forward holes in the cartridge base assembly.
3. Remove the two cap screws and two M3 lock washers that secure the flag to the cartridge base.
4. Carefully lift the flag off the cartridge base assembly.
5. Remove two M3 flat washers from each of the two counter-bored holes in the cartridge base assembly.
6. Obtain a replacement flag for installation.
Installation
1. Drop two M3 flat washers into each of the two front counter-bored holes in the cartridge base assembly.
2. Place the opto flag over these two holes with the tab toward the center and the arm to the left.
3. Apply LOCTITE®242 to two M3-0.50 x 8mm socket head cap screws.
4. Use the two caps screws with two M3 lock washers to attach the flag to the cartridge base assembly.
5. Tighten the cap screws securely.
6. Move the cartridge base toward the X-axis opto. Ensure the spring pin and the flag clear the opto.
33474C.DOC 4-15
Service
4.2.15 Motor Assembly, X-Axis
Removal
2. Remove four screws and lock washers securing X-axis motor to motor mount.
3. Disconnect motor wiring from J8 of limit connector board.
4. Perform removal of pulley, motor. (See procedure.)
5. Obtain a stepper motor for replacement.
Installation
1. Perform installation of pulley, motor. (See procedure.)
2. Position X-axis motor in motor mount with wires facing forward.
Loosely attach motor to motor mount with four M3-.50 x 12mm button head cap screws, flat washers,
and lock washers using back set of holes (as viewed from top). See Figure 4-1.
Ensure belt is stretched around pulley but do not tighten screws.
3. Hold assembly vertically with cartridge pointing downward.
• Position X-axis motor squarely on motor mount. Pull down on motor mount with 6lbs. of force.
• Tighten screws securing X-axis motor to motor mount using a 2mm hex key.
4. Ensure no wiring is pinched or crimped and is clear of frame and cartridge base travel.
TMP4100, TMP4150, TMP4155: Ensure the tubing is not crushed or pinched.
4-16 33474C.DOC
4.2.16 Motor Assembly, Y-Axis
Removal
3. Disconnect Y-axis motor assembly wiring from J9 of limit connector board assembly.
4. Using an arbor press, separate cam from motor shaft.
5. Obtain a stepper motor for replacement.
Installation
1. Connect Y-axis motor assembly wiring to J9 of limit connector board assembly.
2. Position Y-axis motor assembly onto motor mount. Wiring toward X-axis motor.
2mm hex key.
3. Apply LOCTITE®222 to one M3-.50 x 6mm socket head cap screw.
• Install the screw into the shaft side of the motor at the 9 o’clock position
(as viewed from the shaft side).
• Leave approximately 1/8" of exposed threads when installing the screw.
4. Place an extension spring on the exposed threads of the M3-.5 x 6mm socket head cap screw.
5. Place an extension spring on end of screw and thread screw through hole in frame.
6. Using a 2.5mm hex key, remove screw securing Y-axis opto assembly to frame.
7. Apply LOCTITE®680 to Y-axis motor shaft as follows:
• Start application 1/4-inch above body of motor.
• Apply completely around shaft.
• Make application 3/8-inch wide.
8. Place cam on motor shaft, flag (spring pin) outward.
• Using a steel rule, position cam .050-inches above motor mount surface.
• Allow a minimum of 15 minutes drying time.
9. Apply VIBRA-TITE® to threads of one M3-.50 x 6mm socket head cap screw. Allow to dry.
10. Position Y-axis opto assembly on frame. Insert, but do not tighten screw.
• Position frame to contact cam on Y-axis motor.
• Align opto assembly on a center-line between motor shaft and mounting screw.
• Using a 2.5mm hex key, tighten screw.
11. Rotate cam to ensure flag does not contact opto assembly.
12. Ensure wiring is clear of cartridge base and cam travel.
33474C.DOC 4-17
Service
4.2.17 Cam
1. Obtain an insert bushing, cam and a 1/16 x 1/2 spring pin for replacement.
2. Position cam on a clean, dry, flat work surface and orient as follows:
• Center Hole (hole with bushing). Offset to right (3 o’clock position).
• Through Hole. Offset to left (9 o’clock position).
• Small Hole. Up and left of center (11 o’clock position).
Note: If the small hole is down and left, turn cam over (opposite side).
3. Press insert bushing into cam, until knurled surface is completely engaged.
Ensure full engagement of knurled section of bushing.
4. Position cam with offset to right and pinhole down and to left.
If not, turn cam over to other side.
• Press spring pin into cam until it contacts work surface.
5. Perform removal and installation of Y-axis motor assembly. (See procedure.)

• Replace cam during procedure.
4.2.18 Bulkhead Elbow Fitting

markers.
Removal
2. Using a 5/8-inch open-end wrench, loosen hex nut on inside of left cover.
3. Remove jam nut and washer on outside of cover, and remove elbow fitting.
4. Obtain a 6mm x 6mm bulkhead union elbow fitting for replacement.
Installation
1. Insert elbow fitting into hole in cover, elbow inside, threads outside.
2. Install washer and jam nut on fitting and hand tighten.
3. Tighten hex nut on inside of cover using a 5/8-inch open-end wrench.
4-18 33474C.DOC
4.2.19 Barb Fitting, 4MM

markers.
Removal
2. Unscrew fitting.
3. Remove tubing from fitting.
4. Obtain an M5-.70, 2.5mm ID tube, barb fitting for replacement.
Installation
1. Locate and secure fitting on manifold base.
2. Attach tubing to fitting.
4.2.20 Barb Fitting, M5

markers.
Removal
2. Remove tubing from fitting.
3. Using a thin open-end wrench, remove barb fitting from cartridge base.
4. Obtain a subminiature, M5-.70x2.5mm OD barb fitting for replacement.
Installation
1. Apply VIBRA-TITE® to threads of fitting.
2. Locate and secure fitting on cartridge base using a thin open-end wrench.
3. Attach tubing to fitting.
4. Ensure loops of tubing do not drag against motor or bind between motor and frame.
33474C.DOC 4-19
Service
4.2.21 Marker Cable Assembly

1. Obtain a marker cable assembly for replacement.
2. Perform disassembly (Section 4.1) and assembly (Section 4.3).
• Replace cable during procedure.
4.2.22 Push-button Switch Assembly

1. Obtain a push-button switch assembly for replacement.
• Replace switch during procedure.
4.2.23 Handle
1. Obtain a handle for replacement.
• Replace handle during procedure.
4.2.24 Handle Mount

1. Obtain a handle mount for replacement.
• Replace handle mount during procedure. Torque screws to 32 in-lb.
4-20 33474C.DOC
4.2.25 Right Cover

Removal
1. Place marker on work surface with cartridge assembly to right, cable to left and handle down.
2. Remove right cover.
• Using a 2.5mm hex key, remove four screws securing right cover to left cover.
• Using a 2mm hex key, remove two screws securing right stand-off to foot mount.
• Separate covers.
4. Obtain a right cover and a TMP4100-series label for replacement.
Installation
1. Apply label to outside of cover.
3. Attach right cover.
• Position marker cable strain relief into cut-out of left cover.
• Place right cover on top of left cover.
• Observe position of wires to push-button switch.
Ensure wires are placed in cut-out of right cover being installed.
• Secure right cover to left cover with four M3-.5 x 25mm socket head cap screws using a 2.5mm
hex key.
4. Secure right standoff to foot mount with two M3-.5 x 10mm flat head cap screws using a 2mm hex key.
33474C.DOC 4-21
Service
4.2.26 Left Cover

Removal
3. TMP4100: Perform removal of elbow fitting. (See procedure).
4. Obtain a left cover and a TMP4100-series label for replacement.
Installation
1. Apply label to outside of cover.
3. TMP4100: Perform installation of elbow fitting. (See procedure.)
4.3 ASSEMBLY
4.3.1 Cover, TMP4100 and TMP4100E

1. TMP4100: Connect air line to elbow fitting.
• Locate air hose on manifold base.
• Insert air line into inside portion of elbow fitting mounted on rear of left cover.
2. Rotate assembled components into left cover and attach left cover to manifold base using a 2.5mm hex
key and three M4-.70 x 10mm flathead cap screws.
3. Secure handle mount to manifold base with two M4-.70 x 25mm socket head cap screws using a torque
driver and a 3mm hex bit. Torque screws to 32 in-lb.
4. Position handle on handle mount.
• Using a 2.5mm hex key, tighten set screw.
4-22 33474C.DOC
5. Install push-button switch.

• Insert push-button switch into handle.
• Route four-wire connector through push-button hole and first hole in handle mount.
• Locate set screw in handle under push-button switch.
• Using a 1mm hex key, tighten set screw.
• Locate and attach switch assembly connector to J2 of limit connector board.
6. Install marker cable assembly.
• Connect marker cable connector J2 of to limit board connector J1.
NOTE
Do not use thread locker on the marker cable grounding screw.
• Using a 2.5mm hex key, secure wire-lug of marker cable to manifold base with one
M3-.50 x 4mm socket head cap screw and one #4 star washer.
7. Attach right cover.
• Position marker cable strain relief into cut-out of left cover.
• Place right cover on top of left cover.
• Observe position of wires to push-button switch.
• Ensure wires are placed in cut-out of right cover being installed.
• Secure right cover to left cover with four M3-.5 x 25mm socket head cap screws using a 2.5mm
hex key.
• Secure right standoff to foot mount with two M3-.50 x 10mm socket head cap screws using a
2.5mm hex key.
8. Install dirt cover. (optional)
• Place slide plates over cartridge base with short tab inward. Largest on first, progressively to
smallest.
• Longer side of smallest plate is 90° to larger plates.
• Place standoff with retainer plates over cover, with bent plate towards mounting surface of
marker (on handle).
• Secure standoff to cover with four M3-.50 x 10mm flat head cap screws and a 2mm hex key.
33474C.DOC 4-23
Service
4.3.2 Cover, TMP4150 and TMP4155

1. Connect air line to removable elbow fitting.
• Locate air hose (larger air line) from manifold base.
• Connect air hose to elbow fitting marked “D” (drive). Push in retaining ring and push in air line.
• Locate smaller air line (from cartridge base). Push in retaining ring and push in air line.
2. Install marker cable assembly.
• Thread the wires through the back plate, then screw the water-tight fitting onto the back plate.
• Connect marker cable connector J2 of to limit board connector J1.
NOTE
Do not use thread locker on the marker cable grounding screw.
• Using a 2.5mm hex key, secure wire-lug of marker cable to manifold base with one
M3-.50 x 4mm socket head cap screw and one #4 star washer.
3. Install cover.
• Slide the cover over the marker.
• Engage the latches and rotate the tabs clockwise to tighten.
• Push down on the tabs (so they lay flat against the sides of the marker.
• Slide the protective boot up, onto the cartridge.
4-24 33474C.DOC
Chapter 5
Reference Data
5.1 PARTS ORDERING

If you need parts for the marker, be sure to specify the marking head model number when ordering.
Contact Telesis Customer Support for more information. Refer to Chapter 1 for details.
5.2 TOOLING
The following tools may be required to service the TMP4100-series marker.
Cutter, wire Hex key, 3 mm
Hex bit, 2 mm Knife, razor
Hex bit, 3 mm Pliers, long-nose
Hex driver 2.5mm Press, Arbor
Hex key, .050-inch Screw driver, FB, 3/16-inch
Hex key, 1 mm Screw driver, PH, #1
Hex key, 1.5 mm Steel rule, 6 inch
Hex key, 2 mm Stripper, wire
Hex key, 2.5 mm Wrench, torque, >32 in/lb
5.3 TEST EQUIPMENT

The following test equipment is required to service the TMP4100-series marker.
Meter, Volt/Ohm Meter, Digital, Volt
5.4 CONSUMABLES
The following consumables may be required to service the TMP4100-series marker.
Alcohol, isopropyl Tape, TEFLON®, 7-mil
Cloth, lint-free Threadlocker, LOCTITE®222
Oil, Pneumatic Air Tool Threadlocker, LOCTITE® RC/680
Primer, LOCTITE®7471 (PRIMER-T) Tie, cable, nylon, 3 7/8 x 1/8-inch
Tape, TEFLON®, 3-mil VIBRA-TITE®
33474C.DOC 5-1
Reference Data
5.5 WIRING DIAGRAMS AND SCHEMATICS
Figure 5-1. TMP4100, TMP4150, and TMP4155 Wiring
5-2 33474C.DOC
Figure 5-2. TMP4100E Wiring
33474C.DOC 5-3
Reference Data
5.6 PART LIST

The following is sections list the component parts and assemblies for the TMP4100-series markers.
Parts are listed in alphabetical order.
5.6.1 TMP4100
The following parts list pertains to the hand-held TMP4100 marking head (PN 30306) which uses externally
controlled drive air and internally controlled return air.
26942 BELT, 118 TEETH, 2.03 PITCH, NEOPRENE, TMP4100

26978 BELT, TIMING, CLAMPING SECTION
28497 BOARD, ASSEMBLY, LIMIT/CONN, TMP4100/1700
35011 BOLT, SHOULDER, .187 x .312, 8-32THDS
26937 BOLT, SHOULDER, 3/16 x 1/2, SLOTTED
28938 BUSHING, OILITE, .188 ID, .314 OD, .375
26788 CABLE ASSEMBLY, TMP4100, STD
26954 CAM, TMP4100
30317 CARTRIDGE, BASE, TMP4100, RAIL, PNEUMATIC
18433 CLAMP, CABLE.1/4" DIA, 8-32 MOUNT
26957 COVER, LEFT, TMP4100
26956 COVER, RIGHT, TMP4100
37073 ELBOW, PLASTIC, BARBED, FOR 1/8" I.D. TUBE
30334 FITTING, BARB, ELBOW, SWIVEL, SMC, M-5ALU-4
30333 FITTING, BARB, SMC, M-5AU-4
26964 FITTING, ELBOW, 6MM x 6MM, BULKHEAD, UNION
30314 FRAME, RAIL, TMP4100
30422 GASKET, SMC, M-5G1
27478 LABEL, TMP4100, 1 3/8" x 3"
38051 MANIFOLD BASE, MAC 34 VALVE, TMP4100
26969 MOTOR, ASSEMBLY, LIN 4218M-01, 3" LEADS
38052 MOUNT, MOTOR, TMP4100, FREE STANDING
27502 MOUNT, TMP4100
26971 OPTO, ASSEMBLY, TMP4100, Y-AXIS
15543 PIN, SPRING, 1/16"D x 1/2"L
27649 PLUG, FINISHING, NYLON, 1/4
26938 PULLEY, 5MM ID, 15 TEETH, 2.03MM PITCH, TMP4100
28937 PULLEY, TIMING, .08, 18 TOOTH, SINGLE FLANGE
31318 RAIL/SADDLE, ASSEMBLY, THK NSK, 90MM
30335 REGULATOR, AIR, MINI, SMC, ARJ1020F-M5-04
43239 SCREW, BUTTON HEAD, M3-.5 x 12MM
26965 SCREW, FLATHEAD, CAP, M3-0.50 x 6MM
24731 SCREW, FLATHEAD, SOCKET, M3-0.50 x 10
14635 SCREW, ROUND HEAD, PHILLIPS, 4-40 x 3/8
15636 SCREW, SOCKET HEAD, CAP, M3-0.50 x 4MM
26936 SPRING, EXTENSION, 4 LB
26955 STANCHION, TMP4100
26948 STANDOFF, M3-.50 x 18MM, MALE/FEMALE
35009 TAPE, TEFLON, 6MIL, ADHESIVE, 1WIDE
30433 TUBING, 1/8 OD 1/16 ID, POLYURETHANE, BLUE
30420 TUBING, LEGRIS, 2.5MM ID x 4MM OD
26506 TUBING, POLY, 6MM, BLACK, LEGRIS
35014 VALVE, SOLENOID, ASSEMBLY, MAC34B, TMP4100
35012 WASHER, BELLEVILLE, .190 ID x .375 OD
15635 WASHER, FLAT, M3
27517 WASHER, LOCK, INTERNAL TOOTH(STAR), #4
15639 WASHER, LOCK, M3
5-4 33474C.DOC
5.6.2 TMP4100E
The following parts list pertains to the hand-held TMP4100E marking head (PN 38297) which uses and
electric solenoid to drive the pin and an internal spring to assist pin return.
30607 BASE, CARTRIDGE, ASSEMBLY, ELECTRIC, TMP4100

38299 BASE, MANIFOLD, ASSEMBLY, HUNG MTR, TMP4100E
26942 BELT, 118TEETH, 2.03PITCH, NEOPRENE, TMP4100
28497-1 BOARD, ASSEMBLY, LIMIT/CONN, TMP4100/1700
35011 BOLT, SHOULDER, 3/16 x .312, 8-32 THDS
26961 BUSHING, INSERT, TMP4100
28938 BUSHING, OILITE, .188ID, .314OD, .375
26788 CABLE, ASSEMBLY, TMP4100
26954 CAM, TMP4100
30600 CARTRIDGE, BASE, ELECTRIC, TMP4100
26830 CARTRIDGE, TMP1500, BOLT-ON, FOR 25XLE PINS
26957 COVER, LEFT, TMP4100
26956 COVER, RIGHT, TMP4100
30618 FRAME, ELECTRIC PIN, BASE, TMP4100E
27417 FRAME, ELECTRIC, PIN, TMP4100
26906 KIT, HANDLE, ASSEMBLY, TMP4100
30942 KIT, STANDOFF, TMP4100E, ELECTRIC
30226 LABEL, TMP4100E, 13/8 x 3 INCH
27411 MOUNT, FOOT, 4100
26959 MOUNT, HANDLE, TMP4100
38052 MOUNT, MOTOR, TMP4100, FREE STANDING {I}
27413 PAD, FOOT, TMP4100
15543 PIN, SPRING, 1/16"D x 1/2"L
26938 PULLEY, 5MMID, 15T, 2.03MMPTCH, 4100
28937 PULLEY, TIMING, .08, 18TOOTH, SINGLEFLANGE
31318 RAIL/SADDLE, ASSEMBLY, NSK, 90MM
43239 SCREW, BUTTONHEAD, M3-.5 x 12MM
27465 SCREW, CHEESE HEAD, SLOTTED, M4-0.70 x 12MM
14620 SCREW, SET, CONE POINT, M3-0.50 x 03MM
14627 SCREW, SET, M5-0.80 x 06MM
30949 SOLENOID, ASSEMBLY, TMP4100E
26822 SPRING, COMPRESSION, TAPERED, .156 x .281 x .38
31482 SPRING, EXTENSION, 5.6LB, .75"
27418 STANDOFF, ELECTRIC, TMP4100
35009 TAPE, TEFLON, 6MIL, ADHESIVE, 1 WIDE
19294 TIE, CABLE, NYLON, 37/8 x 1/8, BLACK
35012 WASHER, BELLEVILLE, .190ID x .375OD
27517 WASHER, LOCK, INTERNAL TOOTH (STAR), #4
33474C.DOC 5-5
Reference Data
5.6.3 TMP4150
The following parts list pertains to the fixture-mounted TMP4150 marking head (PN 38451) which uses
externally controlled drive air and externally controlled return air.

38419 BOOT, NEOPRENE, TMP4150
26954 CAM, TMP4100
38078 COVER, TMP4150
31972 LABEL, TMP4150, 1.6" x 3.5"
35035 LATCH, DRAW, LIFT AND TURN
15543 PIN, SPRING, 1/16"D x 1/2"L
38076 PLATE, MOUNT, TMP4150
38077 PLATE, MOUNTING, COVER, TMP4150
38433 REDUCER, 6MM_4MM, PUSH_ON, PISCO
35034 RIVET, SOLID, BRAZIER-HEAD .125 x .250
14627 SCREW, SET, M5-0.80 x 6MM
38456 SLEEVE, 5IN, NEOPRENE TMP4150
26936 SPRING, EXTENSION, 4LB
15210 TAPE, 2-SIDED, ACRYLIC, .005 x 1/2" x 180'
23964 TRIM, RUBBER EDGE, TMP3100
5-6 33474C.DOC
5.6.4 TMP4155
The following parts list pertains to the fixture-mounted TMP4155 marking head (PN 44320) which uses
externally controlled drive air and externally controlled return air.

44324 BOOT, NITRILE, SYNTHETIC RUBBER, TMP4155
26954 CAM, TMP4100
38078 COVER, TMP4150
44325 FLAG, TMP4155, 1.5" TRAVEL
44326 LABEL, TMP4155, 1.6" x 3.5"
35035 LATCH, DRAW, LIFT AND TURN
15543 PIN, SPRING, 1/16"D x 1/2"L
38076 PLATE, MOUNT, TMP4150
38077 PLATE, MOUNTING, COVER, TMP4150
38433 REDUCER, 6MM_4MM, PUSH_ON, PISCO
35034 RIVET, SOLID, BRAZIER-HEAD .125 x .250
14627 SCREW, SET, M5-0.80 x 6MM
38456 SLEEVE, 5IN, NEOPRENE TMP4150
26936 SPRING, EXTENSION, 4LB
15210 TAPE, 2-SIDED, ACRYLIC, .005 x 1/2" x 180'
23964 TRIM, RUBBER EDGE, TMP3100
33474C.DOC 5-7
Reference Data
5-8 33474C.DOC

Manual Servicio TMP4100

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Service Manual

This manual may be supplemented and kept current by Change

Manual No. 33474 Rev. C

Telesis Technologies, Inc. March 2004

Copyright © 2000 - 2004 Telesis Technologies, Incorporated

Telesis and Pinstamp are registered trademarks of Telesis Technologies, Incorporated.

This page intentionally left blank.

5-1 TMP4100, TMP4150, and TMP4155 Wiring............................................................................... 5-3

2-1 Troubleshooting ............................................................................................................................ 2-1

3-1 Air Supply Requirements.............................................................................................................. 3-1

1.1 SERVICE OVERVIEW

*** NOTICE ***

1.2 INTENDED USE

1.3 SERVICE PRECAUTIONS

1.4 TELESIS CUSTOMER SUPPORT

Telesis Technologies, Inc. Telesis Europe B.V. Telesis MarkierSysteme GmbH

Telesis Systèmes de Marquage TelesisEagle

1.5 ADDITIONAL PUBLICATIONS

Table 2-1. Troubleshooting

Table 2-1. Troubleshooting (continued)

Table 2-1. Troubleshooting (continued)

This page intentionally left blank.

3.1 AIR SUPPLY REQUIREMENTS

Table 3-1. Air Supply Requirements

APPLICATION TYPICAL VALUE UNITS

Input Air Pressure 120 psi

3.2 RESISTANCE CHECKS

Table 3-2. Resistance Checks

LOCATION FROM PIN TO PIN VALUE (Ω) FUNCTION

Marker Cable 1 2 2.2 X-Axis A

3.3 TEST PROCEDURES

Marking Head Run In

(continued on next page)

Marking Head Test Print

This page intentionally left blank.

TMP4100-Series Marking Head Test & Tracking Form

TEST PRINT AREA – FIXTURED MARK RUN TIME: ___________

TEST PRINT AREA – HAND-HELD MARK

SYSTEM ANALYSIS CHECKED (!)

SERIAL NUMBER:___________________________ JOB NUMBER: ______________________

TECHNICIAN:______________________________ DATE: ______________________

Some procedures do not require initial disassembly. If initial disassembly is

It may be necessary to remove cable-ties during portions of this procedure. Caution

4.1.1 Cover, TMP4100 and TMP4100E

4. Remove push-button switch.

4.1.2 Cover, TMP4150 and TMP4155

4.2.2 Front Dirt Cover (optional)

4.2.3 Timing Belt

4.2.4 Air Solenoid Valve Assembly

4.2.5 Electric Solenoid Assembly

10. Snug the wire down with wire ties.

4.2.6 Limit Connector Board Assembly

4.2.7 Tubing (1/8 in)

1. Push tubing onto barb fitting on manifold base.

4.2.8 Tubing (4mm)

4.2.9 Tubing (6mm)

4.2.10 Pulley, Idler

4.2.11 Pulley, Motor

4.2.12 Opto Assembly, X-Axis

4.2.13 Opto Assembly, Y-Axis

4.2.14 Flag, X-Axis Opto, TMP4155

4.2.15 Motor Assembly, X-Axis

5. Perform assembly as described in Section 4.3.

4.2.16 Motor Assembly, Y-Axis

* NOTICE *

SERIAL NUMBER:_____ JOB NUMBER:

TECHNICIAN:________ DATE: