TCsi Overview

34242_TCsi Service Manual pg. 97

Backlash compensation helps correct for lost motion in the drivetrain. Over time, wear in ball screws and couplings can increase backlash which will affect part accuracy.

• Each TC820si is calibrated by King Rich. X-axis (AX1) and Z-axis (AX2) backlash values are stored under Axis MD parameter 32450[0].
• You must be in Manufacturer Mode to change values. Use [Select axis] to choose the correct Axis to make adjustments to backlash.
• On the MCP, go to [Setup] → [Mach data] → [Axis MD], then press [Search] and enter 32450.
• Measure axis backlash with a dial indicator before making any changes.
• Adjust these values if measurement indicates a change in backlash due to mechanical wear.
• Recalibrate after ballscrew replacement, motor coupling maintenance, or persistent taper/shoulder mismatch.

The turret must be both electronically referenced and mechanically aligned to ensure proper indexing, station location, and axis parallelism.

Dozuki: TCsi - Reference Turret

Turret referencing ensures the turret servo, clamping system, and internal encoder are in sync with the control. This may be required after crashes or if the turret position is out-of-sync with the active tool station display.

🔹 Old PLC (01.xx.xx)

• Enter service mode: Press [Feed Start] three times quickly.
• Alarm 700062 confirms entry.
• Press [Jog], then [Ref Point], then [◀] to reveal [T Ref].
• Press [T Ref] to reference turret to station T1​

🔹 New PLC (05.xx.xx)

• Hold [Spindle Stop], then press [Feed Stop] three times.
• Manually press [Feed Start] if lights don't flash.
• Follow the same [Jog] → [Ref Point] → [T Ref] process.

34242_TCsi Service Manual pg. 108-112

1. X-Axis Parallelism

• Mount an indicator to a magnetic base on the tailstock way.
• Run the turret face (where a turning tool would mount) ±2” in X.
• Error must be ≤ 0.0004”/4” (0.010mm/100mm)​

2. Z-Axis Parallelism

• Indicator positioned against the turret perimeter (boring bar side).
• Jog ±2” in Z.
• Same tolerance: ≤ 0.0004”/4”.

3. Adjusting the Turret

• Loosen 8 SHCS at front and rear of the turret.
• Access rear screws by removing turret panel.
• Adjust 2 red-marked screws to correct tilt/inclination.
• Re-tighten screws and verify both axes​

• Load boring bar holder into turret pocket.
• Clamp a dial indicator in the spindle and sweep the holder pocket at X0.
• Max error allowed: 0.002” (0.05mm).
• Adjust turret position if error exceeds limit​

Dozuki: TCsi - Geometry Alignment & Inspection

Geometry checks verify the alignment between the spindle, turret, and tailstock to ensure the machine produces accurate parts and avoids taper or chatter. This process is required after crashes, machine installation, or when part accuracy issues arise.

All geometry inspections assume:

• The machine is leveled within 0.0006"/12" (0.015mm/300mm)
• Gibs are torqued to 1.2 Nm
• Spindle belt tension is between 40–47.5 Hz

Each geometry step confirms alignment between key machine elements. Here's what you’re verifying:

1. Spindle Runout

Checks: Roundness and surface trueness of the spindle taper and face.

Tool: Dial indicator mounted to turret.

Max error:

• Taper: ≤ 0.0004" (0.01mm)
• Face: ≤ 0.0006" (0.015mm)​

2. Spindle Axis Parallelism (X & Y)

Checks: Movement of the spindle relative to X and Y travel.

Tool: 1-2-3 block and dial indicator.

• Max error: ≤ 0.0003"/3" (0.0075mm/75mm)​

3. Z-Axis Parallelism to Spindle

Checks: Whether Z-axis motion is square to the spindle centerline.

Tool: Spindle Alignment Bar (SWI-TOOL-009)

Max error:

• At headstock: ≤ 0.0004"
• At free end: ≤ 0.0008"
• Along top/side: ≤ 0.0004"/10" (0.01mm/250mm)​

4. Headstock Alignment

Checks: Whether the spindle is pointing correctly within the machine.

Method: Light cut on bar stock, measure both ends.

• Max taper: ≤ 0.0008" over 6" (0.02mm)​

5. Tailstock to Z-Axis Parallelism

Checks: Whether the tailstock travels parallel to Z-axis.

Tool: MT4 Alignment Tool (SWI-TOOL-008), indicator mounted to turret.

• Max error: ≤ 0.001"/4" (0.025mm/100mm)​

6. Tailstock to Spindle Centerline

Checks: Whether tailstock quill pocket aligns with spindle center.

Tool: Indicator in chuck, sweeping quill.

• Max error: ≤ 0.002" (0.05mm)​

7. B-Axis to Z-Axis Parallelism

Checks: Whether B-axis tailstock slide moves square with Z.

Tool: Same as tailstock parallelism check, repeat at extended B travel.

• Max error: ≤ 0.001"/4" (0.025mm/100mm)​

8. Turret to X and Z Axis Parallelism

Checks: Face of the turret is square to machine movement.

Tool: Indicator mounted on tailstock ways.

• Max error: ≤ 0.0004"/4" (0.010mm/100mm) in both X and Z​

9. Spindle to Turret Centerline Concentricity

Checks: Whether boring bar holder pocket aligns with spindle center.

Tool: Indicator in chuck, measuring inside of boring bar pocket.

• Max error: ≤ 0.002" (0.05mm) total in X/Y​

Dozuki: TCsi - Absolute Zero Encoder Reset

Dozuki: Eliminating Radial Movement in the Turret During Clamping and Unclamping

TRAK TCsi machines use absolute encoders for the X, Z, and Q axes (and Y for LTY models). These encoders retain their position without homing, but if reference data is lost or encoder hardware is replaced, the machine must be re-zeroed.

• After encoder replacement (X, Z, Q, or Y on LTY).
• When the machine powers up with missing or incorrect reference points.
• If turret rotation (Q-axis) loses alignment with station positions. (Radial Movement)

Dozuki: TC820si Gib Adjustment

The linear axes on the TCsi use tapered gibs to ensure precise sliding motion and eliminate unwanted clearance between the carriage and guideways. Gibs must be correctly torqued to maintain machine geometry and prevent binding or drift.

Gib adjustments are most commonly required:

- After shipping or relocation

- During machine build or inspection

- If axis feels loose, drifts after movement, or binds at certain positions

- When X or Z axis geometry shifts during cutting

- Use a flathead torque screwdriver to adjust all gib screws.

- Torque setting: 1.2 Nm (11 in-lbs)

- After each adjustment, jog the axis multiple times to settle the gib.

- Never use shop air to blow off gibs or way surfaces — this can embed chips into the slideways.

- Do not shim gibs — any damage or wear requires replacement, not spacing.

- Single-Side:

- Adjust one gib screw while both nuts are loosened.

- Repeat jogging and re-torque steps until snug and smooth.

- Lock screw in place using the outer nuts.

- Double-Side:

- Loosen both gib screws on one side and adjust from the opposite side.

- Always adjust one side at a time, never both simultaneously.

Dozuki: TCsi Calibrate Tool Setter

- After a crash involving the turret or tool setter.

- When a new probe is installed or remounted.

- If the probe is visibly misaligned or produces inconsistent results.

Alignment ensures the stylus face is square to axis motion (X and Z).

A dial indicator is used to sweep across four points on the stylus:

• - X+ / X– edges
• - Z+ / Z– edges

The goal is to reach ≤ 0.0008" deviation across all sides.

Alignment adjustments are made by loosening the four mounting screws and gently rotating the probe body.

Dozuki: Turning Centers: Collision Detection

TRAK TCsi lathes include a collision detection system. This monitors axis torque and flags events when torque thresholds exceed preset limits. Typically due to mechanical obstruction or crash.

This system is used primarily as a diagnostic aid and post-incident log. It does not interrupt machining or trigger an interlock. Collisions are soft-logged only.

TCsi Service Manual (P/N 34242)

Section 5.2 – Pages 85–86

• Inspect tool setter probe and turret for chips or coolant buildup.
• Clean coolant nozzles and confirm they’re unobstructed.
• Check hydraulic pressure for both the chuck and quill.
• Empty the chip bin and check chip conveyor function.
• Wipe down the touchscreen and MCP (no harsh chemicals).
• Inspect visible cables and hoses for wear or damage.
• Check air line pressure and drain any water from the regulator.

• Check spindle taper and face for burrs or damage; clean with a fine stone.
• Verify spindle belt tension (target range: 40–47.5 Hz).
• Confirm tailstock movement and alignment (if equipped).
• Recheck axis gibs if axis movement feels loose or inconsistent.
• Clean or replace the coolant filter if restricted.
• Check hydraulic filters and monitor any warning messages.

• Re-level the machine to within 0.0006"/12" (0.015 mm/300 mm).
• Measure axis backlash and update compensation parameters if needed.
• Inspect ballscrews for lubrication and abnormal movement.
• Clean electrical cabinet air filters and verify airflow.
• Recalibrate the tool setter if deviation is suspected.

• Replace the hydraulic pump return filter.
• Inspect and refill way oil and hydraulic fluid reservoirs as needed.
• Perform a full geometry inspection and alignment verification.
• Recheck absolute zero reference points for all axes.
• Retension or replace spindle motor belts if worn.
• Review and clear any stored collision detection logs.