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Access HMI Services > Tool Management screen and verify the magazine status display showing all pocket occupancy states.

Physically inspect the tool magazine and compare actual tool locations with the control's magazine table to identify discrepancies.

Ensure machine is in a safe state and spindle is stopped before opening magazine guards.

Remove unused or duplicate tools from the magazine to create available pockets, then update tool management data accordingly.

Execute magazine initialization routine (typically INIMAG or similar cycle) to resynchronize magazine positions with control data, then reset alarm and retry operation.

Magazine initialization will move the magazine through all positions - ensure clear path and no obstructions.

Navigate to Commissioning > Machine Data and review magazine configuration parameters (MD18xxx series), specifically checking total number of pockets (e.g., MD18090) and pocket types.

Document existing machine data before making any changes.

Check magazine topology data to verify pocket assignment, pocket locking status, and any restricted pocket definitions that may limit available locations.

Review tool management settings (MD20xxx series) for maximum tools allowed and compare against physical magazine capacity to ensure consistency.

If incorrect data is found, correct the machine data parameters, perform a control reboot (Power Off/On cycle), and reinitialize the magazine management system.

Control reboot required - ensure all programs are saved and machine is at a safe stop position.

Access the tool list and magazine overview simultaneously to identify tools that the system believes are in the magazine but may not actually be present.

Perform a complete physical inventory of all magazine pockets and document actual tool numbers and locations on paper.

Manually correct tool location data in the tool management system by editing each tool's magazine location to match the physical inventory, or delete ghost tool entries for empty pockets.

Make changes carefully - incorrect tool location data can cause collisions during automatic tool changes.

After correcting all discrepancies, test with a single manual tool change operation to verify synchronization before returning to automatic operation.