Service Home DC-Series - Tool Changer - Troubleshooting Guide - TG0057

DC-Series - Tool Changer - Troubleshooting Guide - TG0057

5.4 DC-Series - Tool Changer - Troubleshooting

Last updated: 10/10/2025

DC-Series - Tool Changer - Troubleshooting

TG0057

Revision A - 04/2025

Introduction

This section shows how to troubleshoot common issues found with the DC-Series Tool Carousel.

Symptom Table

Symptom Possible Cause(s) Corrective Action
When performing a tool change, there is a loud clunking sound when the Z-axis comes to engage the tool The Z-axis zero position is not set in the correct position Force the machine into a recovery state for the Z-Axis or TT-axis depending on what seems misaligned. Reference section 5.3 - Tool Changer Recovery for more detail on going through recovery.
Something has changed from its position when the tool change parameters were set. This could be the result of a crash, or a motor / spindle being replaced. Refer to section 5.5 - Tool Changer Alignment to reset the component that is not in alignment. Start by checking the spindle orientation, then the TT-axis, and then the Z-axis. 
After powering up the machine, there is a 2066 Tool Changer Home Position alarm. The Z-axis or TT-axis moved slightly while the machine was powering off. Press the Recovery button to start Tool Changer Recovery. Use the Zero Axes option [Z] to reset the zero position for the axis that has "No Zero" on the Tool Changer Status window. Follow the Zero Axes information in section 5.3 - DC-Series Tool Changer Recovery for more details. Verify that the machine has the latest parameter values in the configuration for the parameters referenced in the service news HBC-N-1/21/2025.
Alarm 9.9920 TT-axis Servo Error Too Large when running tool changes at 100% rapid TT-axis motor might be damaged Remove the TT-axis motor and then use a volt meter to check the motor. Refer to the Tool Carousel Motor section below for what to check.
Alarm 3.165 Zero Return Margin Too Small when setting the Z-axis zero position in the Tool Changer Recovery page The Z-axis zero position was too close to the z-pulse of the motor generating a 3.165 alarm. Follow the instructions in the section Force Recovery State below. Then enter Tool Changer Recovery so that you can reset the zero position. This time jog the Z-axis so that the left arrow is about 1/4" above the right arrow. Set the zero position there.
When Z-axis is at it's zero position, the arrow decals are not exactly lined up. The position of the arrows is not designed to indicate where the z-axis zero position should be. The arrows are used during the alignment process as a guide. Use MDI mode to run some tool changes without any tools at 50% rapid. If it sounds fine add some tools to the carousel and do some tool changes starting at 5% rapid. Increase the rapid and see if there are any issues with excess noise.
When doing successive tool changes the Low Air Warning icon displays on the control There are several air blasts that prevent chips from entering spindle. The air blast is acuated during a tool change cycle.  This is expected for DC-series machines. The DC-series consume a high volume of air especially during tool changes. If a Low Air Alarm is generated make sure that the air supply to the machine is sufficient according to the machine specification.

Force Recovery State

Forcing Recovery WITHOUT a Service Key

You can reset the zero position for the Z-axis and TT-axis directly through the recovery page. 

When you first enter the recovery page you see a screen as shown in the image.

Press [Z] [1] to start the Zero Axes option. This will allow you to start the process of changing the zero position for either axis. Follow the Zero Axes section in the Tool Changer Recovery - 5.3 section in the manual.

Forcing Recovery WITH a Service Key

You can force recovery on the DC-Series machines with a service key by doing the following:

  1. Press [Z]+[Zero Return]+[Single] and that will bring up the window shown in the image.
  2. Highlight the Z-axis [1] and press [Undo] [2] to unzero the Z-axis.
  3. Press [Recover] and try to reset the zero position again.

Note: The yellow caution icon [3] indicates that the axis does not have a zero position set. A green check mark indicates that the axis has a zero position.

When resetting the zero position this time, make sure to jog the Z-axis up so that the arrow on the spindle head is about 1/8-1/4" above the arrow on the enclosure as shown in the image.

Follow the steps in recovery for setting the Z-axis zero position.

Note: You can use either the Zero Axes option or Automatic recovery option. If you use Automatic recovery you do not need to change any alignment using [F4].