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Check air pressure supply to ATC system. Verify minimum 5-6 bar (70-85 PSI) at the machine. Inspect pressure gauges and listen for air leaks at solenoid valves and cylinders.

Navigate to DIAGNOSIS > PMC > PMC-A to monitor ATC signals. Verify input signals for tool unclamped (TUCL), tool clamped (TCLP), arm advanced/retracted, and magazine position. Cross-reference with ladder diagram I/O addresses.

Manually jog the ATC through one cycle using MPG or manual ATC functions if available. Observe for mechanical resistance, unusual noise, or slow cylinder movement indicating binding or worn components.

Ensure spindle is stopped and machine is in safe position before manual ATC operation.

Inspect tool grippers, pull studs, and retention knobs for damage or debris. Check carousel bearings and alignment. Lubricate ATC components per maintenance manual specifications.

Access PMC ladder via DIAGNOSIS > PMC > PMC-MEN (ladder monitor) or use LADDER-III software. Locate the TMR (timer) instruction associated with tool change monitoring, typically labeled ATC_TIMER or similar in the ladder program.

Check the timer preset value in the ladder. Typical ATC timers range from 5-15 seconds (50-150 in 100ms increments). Compare with OEM machine specifications and actual measured cycle time using a stopwatch during manual operation.

If timer value is insufficient, increase by 20-30% margin. Modify via PMC ladder editing (requires proper backup and password). After modification, write to PMC and perform test tool changes to verify alarm clears.

Always backup PMC ladder and parameters before making modifications. Incorrect timer settings may cause safety issues.

Review PMC parameters via DIAGNOSIS > PMC > PMC-PRMS for any K-registers or D-registers used as dynamic timer values. Verify these are not corrupted or set to zero.

Navigate to DIAGNOSIS > PMC > PMC-A (I/O status display). Monitor all ATC-related input signals (typically X addresses) during a manual tool change cycle. Identify which signal fails to transition on/off at the expected point in the sequence.

Physically inspect the sensor identified in Step 1. Check mounting distance (typically 2-4mm for inductive proximity switches), cleanliness, and wiring continuity. Test sensor output with multimeter while manually triggering the target.

Use proper lockout/tagout procedures when working near moving ATC components.

Check I/O module LED indicators on the I/O Link or I/O device. Verify the input module corresponding to the faulty sensor shows LED activity when sensor is triggered. If no LED, suspect wiring or I/O module failure.

If sensor and wiring are confirmed good, verify PMC ladder logic is correctly reading the input address. Use DIAGNOSIS > PMC > PMC-MEN to trace the signal through ladder coils and verify it reaches the TFIN (tool change finished) output to CNC.