Maintenance Manual: INTEGREX E-1060v/6 II

MAINTENANCE MANUAL
INTEGREX e-1060V/6 II
Manual No.: H575MA0050E
Serial No.:
Before using this machine and equipment, fully understand the contents of this manual to
ensure proper operation. Should any questions arise, please ask the nearest Technical
Center or Technology Center.
IMPORTANT NOTICE
1. Be sure to observe the safety precautions described in this manual and the contents of the
safety plates on the machine and equipment. Failure may cause serious personal injury or
material damage. Please replace any missing safety plates as soon as possible.
2. No modifications are to be performed that will affect operation safety. If such modifications
are required, please contact the nearest Technical Center or Technology Center.
3. For the purpose of explaining the operation of the machine and equipment, some
illustrations may not include safety features such as covers, doors, etc. Before operation,
make sure all such items are in place.
4. This manual was considered complete and accurate at the time of publication, however, due
to our desire to constantly improve the quality and specification of all our products, it is
subject to change or modification. If you have any questions, please contact the nearest
Technical Center or Technology Center.
5. Always keep this manual near the machinery for immediate use.
6. If a new manual is required, please order from the nearest Technical Center or Technology
Center with the manual No. or the machine name, serial No. and manual name.
Issued by Manual Publication Section, Yamazaki Mazak Corporation, Japan
05.2011
CONTENTS
Page
1 INTRODUCTION .................................................................................. 1-1
1-1 Outline of the Machine........................................................................................1-1
1-1-1 Intended use of the machine .................................................................................. 1-1
1-1-2 Operating positions................................................................................................. 1-1
1-1-3 Features.................................................................................................................. 1-2
1-2 List of Manuals to Be Used.................................................................................1-3
1-3 Numbering System for Pages.............................................................................1-3
1-4 Numbering System for Figures and Tables ........................................................1-3
2 SAFETY PRECAUTIONS..................................................................... 2-1
2-1 Rule ....................................................................................................................2-1
2-2 Basic Safety .......................................................................................................2-1
2-3 Safety Considerations Relating to Operators including Clothing ........................2-3
2-4 Safety Considerations Relating to Machine Operation .......................................2-3
2-5 Safety Considerations Relating to Holding Workpieces and Tooling ..................2-4
2-6 Safety Considerations Relating to Maintenance .................................................2-5
2-7 Safety Considerations Relating to Workplace ....................................................2-7
2-8 Safety Considerations Relating to Chip Conveyor..............................................2-7
2-9 Safety Considerations Relating to Pallets...........................................................2-7
2-10 Safety Considerations Relating to Faceplate Jaws.............................................2-8
2-11 Safety Considerations Relating to Safety Devices..............................................2-8
2-12 Remarks on the Cutting Conditions Recommended by the NC..........................2-8
C-1
2-13 Safety Nameplates .............................................................................................2-9
2-14 Safety Considerations Relating to Mounting or Changing the Chuck

(Pallet) by the User...........................................................................................2-14
2-15 Safety Considerations Relating to Gripping Force and Rotating Speed ...........2-16
2-16 Safety Devices .................................................................................................2-17
2-17 Safety Plate Locations......................................................................................2-19
3 OUTLINE OF THE MACHINE STRUCTURE ....................................... 3-1
3-1 Overview of Machine Units.................................................................................3-1
3-2 Definition of Coordinate Axes .............................................................................3-5
3-3 Maintenance Cover ............................................................................................3-6
4 REGULAR INSPECTION ..................................................................... 4-1
4-1 General...............................................................................................................4-1
4-2 Table of Inspection and Maintenance Items .......................................................4-2
4-3 Daily Inspection and Maintenance......................................................................4-5
4-3-1 Inside the machine.................................................................................................. 4-5
4-3-2 Outside the machine............................................................................................... 4-6
4-3-3 Checking oil levels .................................................................................................. 4-6
4-3-4 Checking pressures (hydraulic and air) .................................................................. 4-7
4-3-5 Changing or replenishing oils ................................................................................. 4-7
4-3-6 Around the machine................................................................................................ 4-8
4-3-7 Checking the Z-axis servo load .............................................................................. 4-8
4-4 Weekly Inspection and Maintenance ..................................................................4-9
4-4-1 Changing or replenishing oils ................................................................................. 4-9
C-2
4-4-2 Around the machine................................................................................................ 4-9
4-5 Monthly Inspection and Maintenance ...............................................................4-14
4-5-1 Around the machine.............................................................................................. 4-14
4-6 Every Six-Month Inspection and Maintenance .................................................4-14
4-6-1 Changing or replenishing oils ............................................................................... 4-14
4-6-2 Greasing ............................................................................................................... 4-16
4-7 Every One-Year Inspection and Maintenance ..................................................4-28
4-7-1 Changing or replenishing oils ............................................................................... 4-28
4-8 Inspection and Maintenance before Stopping the Machine for a Long
Time .................................................................................................................4-39
4-9 Inspection and Maintenance before Starting the Operation after Stopping
the Machine for a Long Time............................................................................4-40
5 MAINTENANCE OF MAJOR UNITS .................................................... 5-1
5-1 Mill Spindle and B-axis .......................................................................................5-1
5-1-1 Troubleshooting ...................................................................................................... 5-1
5-1-2 Construction of the spindlehead ............................................................................. 5-3
5-2 X-axis, Y-axis, Z-axis..........................................................................................5-4
5-2-1 Troubleshooting ...................................................................................................... 5-4
5-2-2 Construction of the axis drive systems ................................................................... 5-5
5-2-3 Replacing the sealing packing of the Z-axis counter balancer ............................... 5-8
5-2-4 Replacing the battery for the axis amplifiers ........................................................... 5-8
5-3 ATC Magazine..................................................................................................5-10
C-3
5-3-1 Troubleshooting .................................................................................................... 5-10
5-3-2 Construction of the ATC magazine....................................................................... 5-11
5-4 Table ................................................................................................................5-12
5-4-2 Construction of the table....................................................................................... 5-13
5-4-3 Turning spindle and C-axis connection/disconnection menu................................ 5-14
5-4-4 Restoring the operation if the C-axis zero point is lost in the turning mode.......... 5-16
5-4-5 C-axis connection mechanism.............................................................................. 5-17
5-5 Pallet Changer..................................................................................................5-18
5-5-2 Construction of the pallet changer ........................................................................ 5-19
5-6 Hydraulic System..............................................................................................5-20
5-6-2 Maintenance of the hydraulic unit ......................................................................... 5-20
5-6-3 Hydraulic circuit diagram ...................................................................................... 5-22
5-7 Pneumatic System............................................................................................5-25
5-7-2 Construction of the air unit.................................................................................... 5-25
5-7-3 Maintenance of the air unit ................................................................................... 5-26
5-7-4 Pneumatic circuit diagram .................................................................................... 5-28
5-8 Centralized Lubrication Unit .............................................................................5-32
5-8-2 Maintenance of the centralized lubrication unit..................................................... 5-32
5-8-3 Linear guide and ball screw lubrication................................................................. 5-32
C-4
5-8-4 Mill spindle bearing lubrication.............................................................................. 5-33
5-9 Spindle Cooling Unit .........................................................................................5-34
5-9-2 Construction of the spindle cooling unit ................................................................ 5-35
5-9-3 Cooling system circuit diagram............................................................................. 5-36
5-10 Coolant System ................................................................................................5-38
5-10-2 Construction of the coolant system....................................................................... 5-39
5-10-3 Coolant circuit diagram ......................................................................................... 5-40
5-11 Covers ..............................................................................................................5-41
5-11-2 Machine covers..................................................................................................... 5-41
5-11-3 Changing the proximity sensor ............................................................................. 5-42
5-11-4 Maintenance of the X-axis way cover ................................................................... 5-43
5-12 NC Unit and Electrical Control Cabinet.............................................................5-45
5-12-2 Resetting the thermal relay................................................................................... 5-46
6 INSTALLATION .................................................................................... 6-1
6-1 Precautions on Installing the Machine ................................................................6-1
6-2 Preparing for Installation.....................................................................................6-2
6-2-1 Environmental requirements ................................................................................... 6-2
6-2-2 External power source requirements ...................................................................... 6-4
6-2-3 Air source requirements.......................................................................................... 6-7
6-2-4 Items to be confirmed when carrying the machine ................................................. 6-8
C-5
6-2-5 Foundation work ..................................................................................................... 6-9
6-3 Installation ........................................................................................................6-10
6-3-1 Precautions on installation.................................................................................... 6-10
6-3-2 Lifting .................................................................................................................... 6-10
6-3-3 Masses of machine units ...................................................................................... 6-12
6-3-4 Unpacking, inspection and cleaning ..................................................................... 6-12
6-3-5 Location of the shipping brackets ......................................................................... 6-13
6-3-6 Installing the machine ........................................................................................... 6-14
6-4 Connecting to the Power and Air Sources........................................................6-15
6-4-1 Connecting to the power source ........................................................................... 6-15
6-4-2 Grounding ............................................................................................................. 6-17
6-4-3 Connecting to the air source................................................................................. 6-19
6-5 Test Run...........................................................................................................6-20
6-5-1 Checking the machine before starting test run ..................................................... 6-20
6-5-2 Electric inspection before switching the power ON............................................... 6-20
6-5-3 Checking the parameter settings .......................................................................... 6-21
6-5-4 Checking the machine in manual operation.......................................................... 6-21
6-5-5 Breaking in operation............................................................................................ 6-21
7 APPENDIX............................................................................................ 7-1
7-1 List of Sensors, Limit Switches, and Oiling Points ..............................................7-1
7-1-1 List of oiling points .................................................................................................. 7-1
7-1-2 List of sensors and limit switches ........................................................................... 7-2
7-2 List of Wearable Parts ........................................................................................7-6
C-6 E
INTRODUCTION 1
1 INTRODUCTION
This manual describes the machine(s) specified in the title of this manual.
In this manual, machine model names are expressed using the abbreviation specified in the table
below.
Model Name Abbreviation
INTEGREX e-1060V/6 II e-1060V/6 II
1-1 Outline of the Machine
1-1-1 Intended use of the machine

The e-1060V/6 II is high-performance multi-tasking machines that provide high speed, high
accuracy and high added value. They incorporate a table enabling turning operations on a 5-axis
control machining center capable of contour control machining and milling on multiple faces by
utilizing three linear axes and two rotational axes.
It can minimize production lead time by enabling machining on multiple faces in a single setup in
multi-tasking operations (turning and milling) on the O.D. and I.D. of a large-diameter workpiece.
1-1-2 Operating positions

The normal operating position of the machine is in the range shown in the figure below.
Magazine
operating panel
Pallet changer
operating panel
NC operating panel e-Tower
Fig. 1-1 Operating positions
1-1
1 INTRODUCTION
1-1-3 Features
1. High productivity
The multi-tasking (turning and milling) function enables process integration for large and heavy
workpieces, and minimizes the lead time.
The high-speed and high-power spindle with a maximum speed of 10000 min–1, a motor output of
37/30 kW (30 min./cont.) and a maximum torque of 505 N·m (372.47 ft·lbf), and the table with a
maximum speed of 500 min–1, a motor output of 37/30 kW (30 min./cont.) and a maximum torque
of 2954 N·m (2178.76 ft·lbf) allow heavy-duty operation in rough machining of steel, cast, and
aluminum workpieces, and high-speed and high-accuracy operation in finish machining.
Through-spindle coolant enables accurate hole machining at high speed.
Adoption of low-inertia servomotors and high-speed ball screws has achieved a rapid traverse
rate of 42 m/min (1653.54 IPM). Positioning time can be reduced even in positioning over a
short distance.
The newly developed CNC performs ultra-high-speed calculations and motions simultaneously,
drastically reducing idle times for higher productivity.
2. Machine construction that guarantees high-accuracy

The capability to cut multiple faces in a single setup enables high-accuracy machining without
requiring a special fixture. In addition, the wide travel ranges of the X- and Y-axes assure high-
accuracy pitch on the top surface.
The use of cone couplings at the joint between the pallet and the table provides high rigidity and
improved repeatability at pallet changes.
3. Abundant unmanned operational functions

The standard tool magazine accommodates 40 tools, and optional tool magazines that
accommodate 80, 120 or 160 tools, and optional tool hives that accommodate 180, 240, or
330 tools are also available.
A 2-pallet changer is provided as standard, and a single level FMS (PALLETECH
MANUFACTURING CELL) or MAZATROL FMS (PALLETECH HIGH RISE SYSTEM) is
available as an option.
The cut chips are forcibly expelled from the machine by the chip conveyors provided at the right
and left sides of the table and flushed by Niagara coolant (mandatory option for machines
shipped inside Japan and standard for machines shipped overseas) supplied from the ceiling.
These functions assure unmanned operation with many kinds of workpieces over long periods.
1-2
INTRODUCTION 1
1-2 List of Manuals to Be Used

For this machine, the following manuals are provided.
Manual name Coverage

Operating manual All aspects of operation
Maintenance manual All aspects of maintenance, including inspections and adjustment
Programming manual All aspects of CNC programming
Parameter list, alarm list and M code list Detailed description of NC parameters, NC alarms and M codes
Tooling manual Dimensional drawings of tool shank and stud bolt
Parts list Part procurement
Electrical wiring diagrams Electrical connections
Operating manual for optional specifications All aspects of operation
1-3 Numbering System for Pages
1. Normal case
2 - 15
Page number in chapter
Chapter number
2. For additional pages to be inserted

3 - 16 - 1
Additional page
1-4 Numbering System for Figures and Tables
1. Figure number
Fig. 3 - 1 Main machine components (1/2)
Chapter Number Title Number of figures with this title, as indicated by the
number of figure in denominator, and the serial number of the figure
chapter within the figures with this title, as indicated by the
numerator.
2. Table number
Table 2 - 1 Safety nameplate details
Chapter Number Title

number of table in
chapter
HGMCGA0101E 1-3
1 INTRODUCTION
- MEMO -
1-4 E
SAFETY PRECAUTIONS 2
2 SAFETY PRECAUTIONS
The precautions to be observed to ensure safe operation of the machine are described here.
The machine must not be operated until these precautions have been thoroughly understood.
2-1 Rule
1. This section contains the precautions to be observed as to the working methods and states
usually expected. Of course, however, unexpected operations and/or unexpected working
states may take place at the user site.
During daily operation of the machine, therefore, the user must pay extra careful attention to
its own working safety as well as to observe the precautions described below.
2. The meanings of our safety precautions to DANGER, WARNING, and CAUTION are as
follows:
: Failure to follow these instructions could result in loss of life.

DANGER
: Failure to observe these instructions could result in serious harm to a human

life or body.
WARNING
: Failure to observe these instructions could result in minor injuries or serious

machine damage.
CAUTION
2-2 Basic Safety

! There are high voltage terminals on the electrical control cabinet, transformer, motors,
junction boxes, and other equipment (with a high-voltage danger mark attached).
DANGER DO NOT touch any of them under any circumstances.

! Make sure that all doors and safety covers are fitted before switching on the power. If any
door or safety cover must be removed, first cut off and lock the main power disconnect
switch.
HGMCGA0074E
2-1
! Memorize the position of the EMERGENCY STOP button so that you can press it
immediately from any position.
WARNING ! Take care not to touch any of the switches accidentally while the machine is in operation.
! Take care not to catch your fingers in the chuck. (For lathes)
! Never touch a rotating workpiece or the tool with your bare hands or any other object.
! To prevent incorrect operation of the machine, carefully check the position of the switches
before operation.
! If in the slightest doubt about a procedure, ask the person in charge.
! Always switch off the main power switch on the operating panel and the main power
disconnect switch when you are taking a break from work and are going to leave the
machine.
! If more than one operator is using the machine, do not proceed to the next step without
indicating to the other operator(s) that you are about to do so.
! Do not modify the machine in any way that will affect its safety.
! Do not enter the machine. If you have to enter the machine, take measures such as
turning off the main power disconnect switch or pressing the EMERGENCY STOP button
that disable machine operation.
! If there is a power failure, switch off the main power disconnect switch immediately.
! Do not subject the NC unit, the operating panel, or the electrical control panel to strong
CAUTION shocks.
! Do not change the parameter values, volume values, or other electrical setting values
without good reason. If you need to change a value, first check that it is safe to do so,
then make a note of the original value so that it can be reset if necessary.
! Do not paint, soil, damage, modify, or remove any of the safety nameplates. If the details
become illegible or the nameplate is lost, obtain a replacement by sending the part number
stamped at the bottom right-hand corner of the nameplate to Mazak and mount the
replacement in the original position. (If a nameplate has been lost, obtain the part number
from the “Parts List” supplied separately.)
! Do not open any doors or safety covers while the machine is in automatic operation.
! Stop all machine operations before cleaning the machine or any of the peripheral
equipment.
! After a job has been completed, set up each part of the machine so that it is ready for the
next series of operations.
2-2
2-3 Safety Considerations Relating to Operators including Clothing

! Tie back long hair which could become entangled in drive mechanisms.
! Wear safety equipment (helmet, goggles, safety shoes, etc.) whenever possible.
CAUTION ! Always wear a helmet if there are any overhead obstacles in the work area.
! Always wear a protective mask when machining magnesium alloys.
! Always use safety shoes with steel toe caps and oil-resistant soles.
! Never wear loose or baggy clothing.
! Always completely fasten buttons and hooks on the arms of clothing to avoid the danger of
entanglement in drive mechanisms.
! Always use gloves when loading or unloading workpieces or tools and when removing
chips from the work area to protect your hands from sharp edges and heat generated
during machining.
! Do not operate the machine while under the influence of drugs with powerful effects,
unprescribed drugs, or alcohol.
! Do not operate the machine if you suffer from dizziness or fainting spells.
2-4 Safety Considerations Relating to Machine Operation

! The use of inflammable lubricant as coolant is not recommended as it is dangerous and
may cause a fire. If such use is unavoidable, it is the responsibility of management to
ensure a fire extinguisher is readily available as a safety measure. Additionally, if an
WARNING
inflammable lubricant is used, the machine should never perform unmanned operation.
An operator must always be present to ensure safety. The same precautions must be
taken when machining inflammable materials such as magnesium alloy.
! Close all doors and covers of the NC unit, operating panel, electrical control cabinet, and
junction boxes to prevent damage from water, chips, and oil.
! Check all electrical cables for damage to prevent accidents due to current leakage or
electric shock.
! Do not handle coolant with bare hands since it is liable to cause irritation. Operators with
allergies should take special precautions.
! Do not operate the machine during violent thunderstorms.
! Check the safety covers regularly to make sure that they are properly fitted and that they
are not damaged. Repair or replace any damaged covers immediately.
! If the machine door, the cover, or other glass sections are found to be damaged,
immediately stop the machine and replace the damaged sections. Failure to observe this
instruction may result in injury due to the possible flyaway of the chuck jaws or tool during
machining. When ordering replacement parts from your MAZAK product distributor, refer
to the Parts List and specify the part numbers.
! Always obtain assistance in handling loads beyond your capacity.
! Do not operate fork lifts or cranes or carry out slinging work unless you have undergone
officially approved training.
! When using fork lifts or cranes, make sure that there are no obstructions in the vicinity of
these machines.
! Always use wire rope or slings of a standard suitable for the load to be supported.
2-3
! Wait until the machine has come to a complete stop before adjusting the position of the
coolant nozzle.
WARNING ! Do not remove or otherwise interfere with safety devices such as stop dogs, limit switches,
or interlocks in order to increase axis travel.
! Do not operate the machine with any of the safety covers removed.
! Always wear gloves and use a brush to clean chips off the tool tip; never use bare hands.
! Stop all machine operations before mounting or removing a tool.
! Check slings, chains, hoists, and other lifting gear for defects before use. Repair or
replace defective gear immediately.
! Electromagnetic waves are radiated from the NC machine tool. Although the level of
radiation is quite low compared to that from a cell phone terminal, reliable operation of
medical electrical devices cannot be guaranteed, so be sure to determine in advance
whether or not you can engage in operations at the operating panel by consulting the
manufacturer of your medical electrical device and your physician.
! Do not allow chips to accumulate during heavy-duty cutting since they will be hot and could
start a fire.
CAUTION ! Warm up the spindle and all of the axis motion mechanisms before operation. (Operate
the machine in the automatic mode for 10 to 20 minutes at maximum spindle speed or at
1/3 to 1/2 maximum axis motion speed.)
! Write the program for the warming-up operation so as to execute the functions of the full
range of machine components. If operation is to be performed at spindle speeds in
excess of 4000 min–1, pay meticulous attention to the warming-up operation.
! Do not operate the operating panel switches while wearing gloves as this could lead to
incorrect operation or other mistakes.
! When one series of operations is completed, switch off the power switch on the NC
operating panel, the main power disconnect switch, and then the factory power supply.
2-5 Safety Considerations Relating to Holding Workpieces and Tooling

! Always use tools which are suitable for the work to be carried out and conform to the
machine specifications. Always observe the restrictions on mass of tool insert and tool
diameter stipulated in the specifications. [Max. insert mass: 20 g (0.04 lbs)]
WARNING
! Replace tools promptly, since badly worn tools can cause accidents and injuries.
! Before starting operation, check that the workpiece is securely mounted and cannot
become detached by the cutting forces applied to it during machining.
! Before mounting a cutting tool in the machine, make sure that the tool and its stud bolt are
properly secured.
! Do not rotate a cutting tool or holder at speeds greater than the rated speed.
! Check maximum safe operating speeds with the manufacturer.
! Be very careful not to catch your fingers in workpiece holding devices.
! Always use the correct lifting gear for heavy fixtures and workpieces.
2-4
! Do not forget to consider the limitation for chuck and retainer when setting the spindle
speed.
WARNING ! Do not operate a spindle on which accessories are mounted at above the rated speed. If
the chuck or the accessory being used is not a MAZAK product, check the maximum safe
operating speed with the manufacturer. (Lathe)
! Before starting the spindle, check that any parts which are bolted or clamped to the chuck
or the steady rest are properly secured. (Lathe)
! Never leave a workpiece chucked when switching off the power.
! Workpieces heavier than the design data of the machine must not be machined. If an
attempt is made to machine a workpiece heavier than the value obtained by subtracting the
masses of the chucks and jaws from the maximum supporting capacity of the machine, the
workpiece may abruptly fly out to cause a hazardous situation.
! Mount the tool holder in the correct orientation by aligning it with the drive key.
! Occasionally check for looseness after using a milling chuck.
CAUTION ! Make sure that the workpiece is correctly mounted on the pallet or table.
! Check that vices, fixtures, etc., have no overhang with respect to the table.
! Make sure that the tools are arranged in the tool magazine correctly in accordance with the
tool data set in the TOOL LAYOUT screen.
! Check that the lengths of all tools to be used have been measured.
! Move the tool nose to the initial point (X0, Y0) to check the basic coordinate system.
! Perform a test operation after mounting a cutting tool and workpiece.
! Make sure that the tool length is such that the tool will not interfere with fixtures such as
chucks or other objects.
! After machining soft jaws, check that they grip the workpiece correctly and that the chuck
pressure is correct. (Lathe)
! Since the tool holders can be mounted from the left or the right, check that the tool holder is
mounted facing the correct direction.
2-6 Safety Considerations Relating to Maintenance

! Always switch off the main power disconnect switch and lock it before carrying out any
maintenance work. This will eliminate the possibility of the machinery being accidentally
started by someone else.
DANGER
! After the power has been switched off for a short while, check the voltage with a multimeter
or similar instrument to make sure that there is no residual voltage. Also discharge the
capacitors.
2-5
! Maintenance of electrical equipment must be carried out by qualified licensed electrical

engineers only.
WARNING ! Do not remove or modify limit switches, proximity switches, or other safety devices.
! When carrying out maintenance in high places, always use a suitable ladder or a service
platform and always wear a helmet.
! Always switch off the main power disconnect switch and lock it before replacing bulbs or
other electrical equipment, and use products with the same specifications as the original.
! Do not start the machine until all of the covers removed for maintenance have been refitted.
! Wipe up any water or oil spills immediately, and keep the maintenance area and the
workplace clean and tidy at all times.
! Be absolutely certain to use the specified and standardized parts as replacement or
consumable parts so as to maintain the as-shipped machine specifications. We take no
responsibility for any personal accidents or machine trouble due to inobservance of this
warning.
! Electromagnetic waves are radiated from the NC machine tool. Although the level of
radiation is quite low compared to that from a cell phone terminal, reliable operation of
medical electrical devices cannot be guaranteed, so be sure to determine in advance
whether or not you can engage in operations at the operating panel by consulting the
manufacturer of your medical electrical device and your physician.
! Maintenance work should be carried out by qualified personnel in accordance with the
instructions of the person in charge.
CAUTION ! Make sure you fully understand how to maintain the machine.
! Do not use compressed air to clean the machine or to remove chips.
! Always use gloves when clearing away chips; never touch chips with bare hands.
! Use only the specified grades of hydraulic oil, lubricating oil, and grease or their
equivalents.
! When changing a fuse, check that the new fuse has the correct rating. (Using a fuse with
too high a rating could result in damage to the equipment.)
! Follow the instructions on the instruction plate concerning the brands of oil to be used,
lubrication points, amount to be used, and oil change intervals.
! Check the results of maintenance work in the presence of the person in charge.
! Stop all machine operation before cleaning the machine or the surrounding area.
! Substances that have adverse effects on the environment if not disposed of appropriately
are used in some of the equipment used in Mazak machine tools. In order to protect the
environment, dispose of machine tools and accessory equipment in accordance with the
laws of the country concerned. Entrust the processing to a contractor who deals with
industrial waste. Note that any expenses associated with this processing are to be borne
by the customer.
2-6
2-7 Safety Considerations Relating to Workplace

! Immediately remove all water and oil spills from the floor, and dry the floor to prevent
accidents.
WARNING ! Use strong service platforms only and make sure that nothing can slip off them.
! Keep combustible materials well away from the work area and any other place where there
are hot chips.
! Always provide sufficient lighting in the work area.
! Always provide sufficient working space and clear access to the machine and peripheral
equipment and store tools and other potential obstacles in a prescribed place away from
the machine.
! Never place tools or other potentially dangerous objects on top of the headstock, turret, or
covers.
! Make sure that the nominal cross-sectional area of the power supply cable between the
factory power supply switch and the machine main power disconnect switch is such as to
enable a stable supply for operation at the maximum output.
! Protect all cables which will run along the floor from being damaged by chips, since this
could cause short-circuiting.
2-8 Safety Considerations Relating to Chip Conveyor

! Before attempting any kind of work related to the chip conveyor, make sure that the chip
conveyor is in a complete stop state with power supply shut off. Ignoring this will cause
serious injury.
WARNING
! While the chip conveyor is operating, never touch or extend your hands into any part of the
chip conveyor. Ignoring this will cause your hands or fingers to be caught into the chip
conveyor and injured seriously.
2-9 Safety Considerations Relating to Pallets

! When mounting a pallet on the machine, mount the pallet correctly so that the pallet
changer hook can be engaged in the pallet.
WARNING Failure to observe the instruction above could result in serious harm to a human life or
body.
! When removing a pallet in the set-up side, confirm that the pallet is unclamped.
Failure to observe the instruction above could result in minor injuries or serious machine
CAUTION damage.
(Refer to PART 2, 3-13 “Pallet Changer Operation” in the Operating Manual for the
procedure for confirming if the pallet is unclamped.)
2-7
2-10 Safety Considerations Relating to Faceplate Jaws

! Set the faceplate jaw base following the instructions given on the related caution plates.
! Securely tighten the faceplate jaw base clamp bolts (4 places).
WARNING Torque specification: 421 N·m (310.5 ft·lbf)
! Always set the stopper bolt to prevent the safety key from sliding to the unclamp side.
! Before rotating the faceplate table, make sure that stopper bolt is set in the groove
(4 places) at the periphery side of the faceplate.
2-11 Safety Considerations Relating to Safety Devices

! The machine is provided with various devices for the operator’s safety.
Never cancel any of the devices.
WARNING Failure to observe this instruction could result in serious harm to a human life or body.
2-12 Remarks on the Cutting Conditions Recommended by the NC

! Before using the following cutting conditions:
• Cutting conditions that are the result of the Mazatrol Automatic Cutting Conditions
WARNING Determination Function
• Cutting conditions suggested by the Machining Navigation Function
• Cutting conditions for tools that are suggested to be used by the Machining Navigation
Function
Confirm that every necessary precaution in regards to safe machine setup has been taken -
especially for workpiece fixturing/clamping and tool setup.
! Confirm that the machine door is securely closed before starting machining.
Failure to confirm safe machine setup may result in serious injury or death.
2-8
2-13 Safety Nameplates

The functions of this machine mean that it can be dangerous. Therefore, in order to prevent
accidents, safety nameplates are affixed at hazardous locations and at parts whose misoperation
can be anticipated, both on the machine and peripheral devices.
Always observe the cautions on the safety nameplates, and take care to operate the equipment
safely.
Some representative nameplates are shown below (note that the nameplates that are not shown
are equally important).
1. General safety nameplates

The nameplates give basic and general safety precautions. Operators and related personnel
are required to fully memorize and understand these precautions so that they can be strictly
followed without reading or referring to the nameplates each time an operation is performed.
2. Danger
<Safety Nameplates> <Remark>

(a)
3. Warning
(a)
The machine is provided with various

devices for the operator's safety.
Failure to observe this instruction could
result in serious harm to a human life
or body.
ｴｲｺﾞ 32556308970
2-9

(b) A nameplate bearing the
same contents is available
Before using the following cutting conditions: for horizontal machining
Cutting conditions that are the result of the Mazatrol Automatic Cutting
Conditions Determination Function
centers.
Cutting conditions suggested by the Machining Navigation Function
Cutting conditions for tools that are suggested to be used by the
Machining Navigation Function
Confirm that every necessary precaution in regards to safe machine setup
has been taken - especially for workpiece fixturing/clamping and tool setup.
Comfirm that the machine door is securely closed before starting machining.
Failure to confirm safe machine setup may result in serious injury or death.
Keep off machine when

in automatic mode.
Can cause sever injury.
Set control in manual
mode before standing on
machine. Turn off and
lock out power at
electrical panel before
servicing.
Keep hands clear of tool

changer. Tool changer
rotates automatically.
Can cause severe injury.
Turn off and lock out
power at electrical panel
before servicing.
Keep hands, clothing and body

clear of rotating tool/spindle.
Machine starts and moves
automatically.
SAFETY INSTRUCTIONS
Before working near spindle;
1.Return all tools to magazine.
2.Set in manual mode and stop
the spindle.
3.Hang "Do not touch" sign on
operator panel.
4.Wear safety helmet.
22726344100 ENGLISH
(c)
1.Avoid accidentally touching controls

while the machine is running.
2.Know function of each switch before
operating.
3.Close chip guard before running part.
ENGLISH エイゴ 41416052111
(d)
2-10
(e)
BEFORE ENTERING MACHINING AREA,

CONFIRM THAT ALL MACHINE MOTIONS
ARE STOPPED. BE CAREFUL AROUND
MACHINED CHIPS AND SLIPPERY SURFACES
42346405651
(f)
Never put your hands on

the conveyor duringchi p
conveyor operation.
Failure t o c omply wit h
this WARNING may
cause your fingers or
hands to be entangled
resulting in se vere injury.
Several se als m ade of NBRsy nthetic ru bber

(acr ylonitrile-butad iene r ubber) ar e used i n this machine.
Some types of coolant inclu de ingredients
t hat m ay any weaken N BR.
Before y ou use any coo lant,please co mfirm f rom
t he coola nt m anufacturer that the coolant will not
weaken NBRsynthetic rubber.
22726344810 ENGLISH
(g)
Keep off. Keep hands
and feet clear during
pallet change.
Can cause severe injury.
SAFETY INSTRUCTIONS
1.Be alert for pallet movement
when loading parts.
2.Make sure workpiece is clamped
securely.
3.Do not lay tools on pallet or
workpiece.
4.Turn off and lock out power at
electrical panel before servicing.
32726344040 ENGLISH
(h)
Use the tool within the tool’s tolerable speed.

Neglecting the usage can cause severe lnjury.
MAX. SPINDLE SPEED min-1

42366298750 エイゴ
2-11

(i) Rotate the spindle in the
permissible operating speed
ranges of the workpiece
holders such as the chuck
and the work rest (if the
workpiece holders are used
in multiple places, at the
lowest of the maximum
permissible speeds or less).
The operating speed limit
value inscribed on the
nameplate does not denote
the maximum permissible
spindle speed.
(j)
(k) Provided only on machines

equipped with a magazine.
Keep hands and body Exercise due care about
away from the tool
operating area to prevent sudden operation of the
serious injury during auto
mode operating. magazine.
Safety instructions
1.Be sure to switch to manual
mode for tool replacement.
2.Be sure to turn off the power
to the machine for maintenance.
3. Check if pull-stud is securely tigh-
tened to tool holder at tool loading.
4. Load the tools in magazine
so as to achieve good balance.
Do not open door when machine is in automatic mode.

32726344080 ENGLISH
2-12
(l) Always observe the following
WARNING procedures when entering the
magazine.
Failure to observe these
instructions, may cause the
operator get caught in the
moving parts, which can lead to
a serious injury.
Rotate and pull out the key
at the top of the magazine door
handle with the door opened.
When entering the magazine,
the operator who has pulled out
the key must keep it on his
person to prevent the door from
being closed.
31286266710
(m)
WARNING
The grounding work must be entrusted to
an electrical engineer with publicly recognized qualifications.
If the work is done by an unqualified person,
it could result in serious injury, death, or damage to the machine.
Grounding resistance: 10Ω max.
33736260480 ＥＮＧＬＩＳＨ
4. Other
(a) Indicates a danger of
electric shock.
2-13
2-14 Safety Considerations Relating to Mounting or Changing the Chuck (Pallet) by

the User
When the chuck (pallet) is mounted by the user after the installation of the machine or the chuck
(pallet) is changed from the one mounted on the machine when it was installed, the information
below must be stamped on the nameplate. The parameters must also be set meeting the chuck
(pallet) to be used.
1. Information to be stamped on the chuck nameplate

The information to be stamped on the chuck nameplate is indicated below.
MANUFACTURE (Manufacturer of chuck (pallet) and cylinder)

Example: KAWATATEC
CHUCK (Chuck (pallet) type)

Example: 1302660011
CYLINDER (Cylinder type)

Example: －
MAX. PRESSURE (Maximum setting pressure)

Example: －
* For this item, stamp the value obtained from the allowable maximum thrust of the chuck
(pallet) and the allowable maximum pressure of the cylinder.
MAX. STATIC GRIPPING FORCE (Maximum static gripping force)
Example: －
MAX. SPEED (Allowable maximum chuck (pallet) speed)

Example: 500 min–1
* For this item, stamp the value specified in the chuck (pallet) catalog.
2-14
2. Information to be stamped on the maximum workpiece dimension nameplate
The information to be stamped on the maximum workpiece dimension nameplate is indicated
below.
MAX DIAMETER (Max. workpiece diameter): φD (mm)

Example: 1250
MAX HEIGHT (Max. workpiece height): H (mm)

Example: 1216
* The maximum workpiece height is 1416 mm (55.75 in) from the chuck (pallet) mounting
reference face.
When the chuck (pallet) height is 200 mm (7.87 in), stamp “1216” which is obtained by the
calculation of “1416 – 200”.
MAX MASS (Max. workpiece mass): W (kg)
Example: 2000
* Loading of up to 2700 kg (5952 lbs) (total of chuck (pallet) and workpiece) is possible.
When the chuck (pallet) weighing 700 kg (1543 lbs) is used, stamp “2000” which is obtained
by the calculation of “2700 – 700”.
Max. workpiece height: H

Chuck (pallet) mounting
reference face
Chuck (pallet) height
2-15
3. Setting the parameter determining the clamp speed of turning spindle

! At the spindle parameter screen, set the allowable maximum speed of the chuck (pallet) to
SA1 and SA2 of SPDL2 (turning spindle). If the maximum speed (machine specification)
of the turning spindle is lower than the allowable maximum speed of the chuck (pallet), input
the maximum speed of the turning spindle instead.
(Maximum speed of the turning spindle of machine specification: 500 min–1)
! Spindle parameter screen:
Name SPDL 2
No.
SA1
SA2
Maximum speed of turning spindle
Example: If the allowable maximum chuck (pallet) speed is 450 min–1, set “450” for this
parameter.
If the allowable maximum chuck (pallet) speed is 600 min–1, set “500” for this
parameter.
Note: To make the set value valid, it is necessary to turn the power off once and then turn it
back on.
! When the machine is shipped without a chuck (pallet) mounted in the machine, the
parameter is set as below to ensure safety.
Max. Speed of Turning Spindle
Mode Comment
(min–1)
Manual 10 In the automatic mode, if a spindle speed of 18 min–1 or faster is
specified for the turning spindle, the turning spindle speed is
clamped at 18 min–1.
Automatic 18
Therefore, if you try to rotate the turning spindle exceeding this
limit in automatic operation, the spindle rotates at 18 min–1.
Note that this does not indicate a failure of the machine.
! Do not set a value larger than the allowable maximum speed of the chuck (pallet).
WARNING
2-15 Safety Considerations Relating to Gripping Force and Rotating Speed

! All operators must read the instruction manual of the chuck (pallet) to be used, which is
provided by the chuck (pallet) manufacturer, before attempting machine operation and
ensure that the information described in the instruction manual is thoroughly understood.
WARNING
! Do not operate the chuck (pallet) at a speed higher than the rotating speed that is indicated
in the “gripping force - rotating speed” diagram supplied by the chuck (pallet) manufacturer.
2-16
2-16 Safety Devices

1. This machine is provided with various safety devices to protect the operator and the
machines.
2. The safety devices include interlock devices and emergency stop switches, as well as doors
and covers.
! The machine is provided with various devices for the operator’s safety.
WARNING Failure to observe this instruction could result in serious harm to a human life or body.
The functions of the safety device are indicated below.
Arrangement of Safety Devices
No. Name Function

1 Operator’s door interlock 1. The operator’s door cannot be opened during automatic operation.
2. The operator’s door can be opened by pressing the door unlock button while the machine is
stopped.
3. While the operator’s door is open with the machine set up switch set at the “I” position, axis
feedrates (X-, Y-, and Z-axis) are restricted at the safety speed.
2 Magazine door interlock 1. If the magazine door is opened while the magazine is operating, the magazine stops operating.
2. While the magazine door is open, the magazine cannot be operated.
3 Pallet changer safety 1. If the pallet changer safety cover is opened while the pallet changer is operating, the pallet
cover and door interlock changer stops operating.
2. Pallet change operation is disabled while the door is open.
4 Emergency stop buttons 1. The emergency stop button is provided on each operating panel.
(5 places) 2. When the emergency stop button is pressed, the machine stops in the emergency stop state
independent of the selected operation mode (automatic, manual).
5 Safety plate A safety plate is fixed to the machine with screws to give operators and persons nearby warning
information that standing near the movable area of equipment and devices is dangerous.
6 Safety measures on 1. Connections where voltage is higher than 24 volts are protected by a cover or other similar part.
wiring between the 2. When the door of the electrical control cabinet is opened, main power supply is shut off and the
electrical control cabinet machine stops.
and machine (Option)
7 Operator’s door safety 1. The front door is glazed with a laminated glass pane which has been proved to withstand an
window glass impact energy of 6558 J minimum, with respect to a reflector of class C drag as specified in
EN12415, Annex B.
2. The laminated glass pane which has been proved to withstand an impact energy of 2236 J
minimum as specified in EN12417 is used.
8 Machine outer cover 1. The outer cover which has been proved to withstand an impact energy of 8000 J minimum,
with respect to a reflector of class C drag as specified in EN12415, Annex B is used.
2. The outer cover which has been proved to withstand an impact energy of 1192 J minimum as
specified in EN12417 is used.
9 ATC maintenance door The ATC maintenance door can be opened by pressing the door unlock button while the machine
interlock is in an emergency stop state.
2-17
Safety device locations
4 1
10 4 2
Fig. 2-1 Safety device locations
No. Name No. Name

1 Operator’s door interlock 6 Safety measures on wiring between the
electrical control cabinet and machine
2 Magazine door interlock 7 Operator’s door safety window glass
3 Pallet changer safety cover and door 8 Machine outer cover
interlock
4 Emergency stop buttons (5 places) 9 ATC maintenance door interlock
5 Safety plate 10 Air pressure relief valve (USA only)
2-18
2-17 Safety Plate Locations

The machine has safety plates at appropriate positions to give the information to be strictly
followed to ensure safety of operators during operation.
These safety plates must not be colored, stained, damaged, modified, nor detached.
If the letters on the safety plates get blurred or if any of the plates is lost, immediately order the
plate and replace the existing one with new one or affix the new one at the correct position. For
ordering the safety plate, use the part number stamped at the lower right area of the plate. The
part number is also found in the safety plate table.
15 14 5
16 8
17 3
10 13
Enlarged view
11 2
12
18 1 4
20
21
19
20
21
22 18
Fig. 2-2 Safety plate locations
2-19
No. Description Parts No.

1 General Safety Instruction – 25626328233
2 Danger at Electric Control Cabinet and Relay Box DANGER 33116228032
3 Warning on Canceling Safety Equipment WARNING 32556308970
4 Warning on Machining Navigation, Table, ATC and Spindle WARNING 22726344100
5 Warning on Operation at Operating Panel WARNING 41416052111
6 Warning on Flying Out of Workpiece WARNING 35766329180
7 Caution on Direct Mounting of Tool CAUTION 35626328371
8 Warning on Entry to Machine WARNING 42346405651
9 Prohibition on Standing on Way Covers – 44136243000
10 Warning on Chip Conveyor Operation and Caution on WARNING/ 22726344810
Coolant Supply CAUTION
11 Warning on Pallet Changer Operation WARNING 32726344040
12 Caution on Pallet Mounting CAUTION 35766426340
13 Warning on Max. Mill Spindle Speed WARNING 42366298750
14 Warning on Chuck Operation WARNING 33306205220
15 Warning on Faceplate Jaw Chuck WARNING 25756426290
16 Square Pallet Rotating Speed – 45766426320
17 Circular Pallet Rotating Speed – 45766443170
18 Max. Workpiece Dimensions – 35756451240
19 Max. Tool Dimensions – 35216237911
Max. Tool Dimensions CAPTO C8 – 35756449430
20 Warning on Magazine Operation WARNING 32726344080
21 Warning on Magazine Door Opening WARNING 31286266710
22 Air Pressure Indication [0.5 - 1.0 MPa (70 - 150 psi)] – 45776365110
23 Warning about Grounding WARNING 33736260480
24 High-voltage Danger Mark 42346292790
2-20 E
OUTLINE OF THE MACHINE STRUCTURE 3
3 OUTLINE OF THE MACHINE STRUCTURE
3-1 Overview of Machine Units

The machine consists of the following major units. (Refer to Fig. 3-1.)
1. Mill spindle head and B-axis

When a milling tool is used, the spindle is driven by an AC inverter motor and the spindle is
clamped by the coupling when a turning operation tool is used. A tool is clamped in the spindle
by spring force and a hydraulic cylinder is used to unclamp a tool.
Cooling fluid is circulated around the mill spindle outer casing to minimize temperature rise of the
spindle due to generation of heat from the bearings.
An AC servomotor is used to turn the B-axis (mill spindle head) via the roller gear cam.
2. X-axis
The table travels longitudinally, driven by an AC servomotor and a ball screw. A position
encoder used for position detection is built in the servomotor. Linear guides are used as the
guide for the table to move on the base.
3. Y-axis
The mill spindle head travels in the crosswise direction, driven by an AC servomotor and a ball
screw. A position encoder used for position detection is built in the servomotor. Linear guides
are used as the guide for the mill spindle head to move on the saddle.
4. Z-axis
The saddle travels vertically, driven by an AC servomotor and a ball screw. A position encoder
used for position detection is built in the servomotor. Linear guides are used as the guide for
the saddle to move along the column.
5. ATC arm
The roller-cam type ATC mounts/removes a tool to/from the spindle.
6. Tool shifter
The tool shifter carries a tool between the magazine and the ATC.
The tool shifter consists of the carrier pocket and the magazine shifter.
The carrier pocket turns from the horizontal position to the vertical position, actuated by a
hydraulic cylinder, while it is moving from the magazine standby position to the ATC standby
position. A ball screw is used for moving the carrier pocket.
Magazine shifter is the roller-cam type tool shifter that carries a tool between the magazine and
the standby position at the magazine side.
7. Magazine
The magazine stores tools. The magazine is driven by an AC inverter motor to index the
specified tool to the tool change position.
3-1
8. Table
An AC servomotor rotates (indexes) the pallet as the C-axis.
For turning operation, the pallet functioning as the spindle is driven by an AC inverter motor.
Switchover between the C-axis and the turning spindle is made mechanically in the following
manner:
In the C-axis mode, the worm and the worm wheel engage with each other (drop-worm method)
and the gear for turning operation is disengaged by the shifter.
In the turning spindle mode, the worm and the worm wheel are disengaged (drop-worm method)
while the gear for turning operation is engaged by the shifter.
9. Pallet changer
By the rotation of the arm, a pallet on the table is changed with a pallet at the setup station. For
the rotation of the arm, an AC inverter motor is used. At the setup station, a pallet can be turned
manually to facilitate set up.
10. Hydraulic unit

A hydraulic pump generates hydraulic pressure by pumping working oil reserved in the tank to
operate hydraulic actuators.
Refer to 5-6-3 “Hydraulic circuit diagram”.
11. Air unit

An external air source is connected to the air unit to supply the pressure-regulated air to operate
pneumatic actuators.
Refer to 5-7-4 “Pneumatic circuit diagram”.
The air unit consists of a filter (with automatic drain system), regulator (reducing valve), shut-off
valve, etc.
12. Centralized lubrication unit

Two lubrication systems are provided to supply lubricating oil to the lubrication points: one
system supplies lubricating oil to the mill spindle bearings and the ball screws, and the other
system supplies lubricating oil to the linear guides.
Refer to 5-8 “Centralized Lubrication Unit”.
By the intermittent operation of the pumps, lubricating oil is automatically supplied to the
lubrication points in the preset intervals as below: in intervals of 4 minutes for the spindle
bearings and in intervals of 5 minutes for the ball screws and the linear guides.
13. Cooling unit

A trochoid pump is used to draw cooling fluid from the tank and feeds it to the oil chiller where
cooling fluid is cooled. Then, the cooling fluid is fed to the outer case of the mill spindle and the
turning spindle, and also to the cooling piping for the table bearings, and the turning operation
gear and the worm. Cooling fluid absorbs heat from the spindle and other mechanical parts and
is cooled by the radiator and the fan; cooled oil is then circulated to the tank.
Refer to 5-9-3 “Cooling system circuit diagram”.
3-2
14. Coolant system
A coolant pump is used to feed coolant, pumped from the coolant tank, to coolant nozzles.
Refer to 5-10-3 “Coolant circuit diagram”.
Coolant has two functions; to cool cutting tools and to wash away chips.
15. Electrical control cabinet

Control units (spindle driver unit, servo control unit, NC unit, etc.) and control circuits are housed
in the electrical control cabinet.
16. NC unit
Machine operation is controlled by the NC unit. It also has the function to diagnose the machine
status.
Refer to 5-12 “NC Unit and Electrical Control Cabinet”.
17. Covers
Covers are provide to prevent chips generated during machining from scattering outside the
machine or entering the slideway surfaces as well as to protect operators from hazards.
As the covers, the machine has the ATC cover which automatically opens and closes for the
execution of automatic tool change operation and the pallet door which rotates along with the
pallet change operation during automatic. At the setup station, the safety cover is provided.
18. Machine light

Fluorescent tubes and LED lighting are used to light the inside of the machine.
19. Safety devices

Refer to the safety considerations relating to safety devices.
3-3
Pallet changer
Pallet changer safety cover
Spindle cooling tank

Main power disconnect switch
Hydraulic unit
Centralized lubrication unit
Table lubricating Operator’s door

oil cooling tank NC operating panel
Centering jig
Pulse handle operating panel Magazine
Pallet changer operating panel
ATC arm
Air unit
Magazine shifter
Electrical control cabinet
ATC maintenance door
Coolant tank ATC maintenance door operating panel
Magazine door
Saddle
Magazine operating panel
Spindle
Z-axis
Y-axis
X-axis
Pallet
Table
Column
Base
Fig. 3-1 Machine construction - major units
3-4
3-2 Definition of Coordinate Axes

In the manuals supplied with the machine, the coordinate axes are defined as indicated below.
Note: The coordinate axes are defined assuming that an operator is standing in front of the
machine.
X-axis Table movements in the longitudinal (forward/backward) direction
Positive direction (+): Table movement to the machine front side
Negative direction (–): Table movement to the machine rear side
Y-axis Mill spindle head movement in the crosswise (right/left) direction
Positive direction (+): Mill spindle head movement to the left
Negative direction (–): Mill spindle head movement to the right
Z-axis Mill spindle head movement in the vertical (up/down) direction
Positive direction (+): Mill spindle head upward movement
Negative direction (–): Mill spindle head downward movement
B-axis Mill spindle turning
Positive direction (+): Clockwise direction viewed from the operator’s door side
Negative direction (–): Counterclockwise direction viewed from the operator’s door side
C-axis Table rotation
Positive direction (+): Clockwise direction viewed from the top
Negative direction (–): Counterclockwise direction viewed from the top
+
B-axis
– Z-axis
–
Y-axis
+ – C-axis
+ (CW) – (CCW)
+ –
X-axis
Fig. 3-2 Definition of coordinate axes
3-5
3-3 Maintenance Cover

! Do not remove the maintenance cover except for maintenance.
! Always set the main power disconnect switch to the “OFF” position and lock it before
WARNING removing the maintenance cover.
! Do not switch on the main power supply before fitting the maintenance cover. If you fail to
observe this instruction you could be entangled in or crushed by moving parts, resulting in
serious injury.
This machine has a maintenance cover as shown in Fig. 3-3.
The maintenance work inside the machine can be performed by removing the maintenance
cover.
Maintenance cover
Fig. 3-3 Position of the maintenance cover
3-6 E
REGULAR INSPECTION 4
4 REGULAR INSPECTION
4-1 General
Regular inspection and maintenance is essential to maintain high accuracy for a long period.
Therefore, regular inspection and maintenance must be given the top priority for operating the
production facility.
! When carrying out inspection and maintenance, keep the doors of the electric control
cabinet closed unless the intended inspection or maintenance requires the door to be open.
CAUTION ! Never use compressed air when cleaning inside the machine since it will cause sand grit,
dust and other foreign matter to enter the bearings and slideways, causing the failure of the
machine.
! Before carrying out maintenance or repair work on the machine, lock the main power
disconnect switch in the “OFF” position with a padlock so that other workers cannot operate
the machine.
WARNING
* The padlock should be prepared by the user.
Fig. 4-1 Locking main switch in the “OFF” position (example)
Oiling:
The machine has many places which require lubrication. For appropriate lubrication, the most
important point is “not to supply oil excessively”. When supplying oil, follow the instructions
given in this manual.
Note: If lubricating oil is consumed faster than usual or if the machine generates abnormal
noise, check the machine since such phenomena could be signs of machine failure.
4-1
4-2 Table of Inspection and Maintenance Items

Symbol “ ” indicates the inspection interval.
Approximate Operating Hours Inspection/Maintenance Intervals
Every 6 Refer to
Weekly Monthly Every year
Items Daily months
60 H 250 H 3000 H
1500 H
Inside the machine
1. Removing chips around the mill spindle 4-3-1
2. Removing chips from on top of the X- 4-3-1
axis way cover
3. Removing chips on the pallet changer 4-3-1
hook
4. Cleaning the window in the operator’s 4-3-1
door
5. Removing chips on the TOOL EYE and 4-3-1
laser tool length measuring unit (option)
6. Removing chips from inside the 4-3-1
machine
7. Adjusting the in-machine chip conveyor Refer to the
hinge belt tension (1 month instruction
after the manual
installation; supplied by
only at this the
time) manufacturer.
Outside the machine
1. Cleaning the 2-pallet changer hook -
coolant line filter by the manual handle
2. Removing chips from the conveyor 4-3-2
3. Cleaning the chip bucket 4-3-2
4. Cleaning the air filters of the table -
cooling fluid control unit
5. Cleaning the chip conveyor -
Checking oil levels
1. Checking the hydraulic oil level 4-3-3
2. Checking the spindle cooling fluid level 4-3-3
3. Checking the table lubricating oil level 4-3-3
4. Checking the mill spindle lubricating oil 4-3-3
level
5. Checking the slideway lubricating oil 4-3-3
level
6. Checking the coolant level 4-3-3
Checking pressures (hydraulic and air)
1. Checking the hydraulic unit oil pressure 4-3-4
2. Checking the air pressure 4-3-4
Changing or replenishing oils
1. Replenishing coolant (as needed) 4-3-5
2. Replenishing lubricating oil of the -
centralized lubrication unit (as needed)
3. Cleaning the strainers of the mill spindle 4-6-1
cooling fluid chiller unit and the table
lubricating oil chiller unit
4-2
Every 6 Refer to
Items Daily months
60 H 250 H 3000 H
1500 H
4. Changing the hydraulic oil of ATC unit 4-7-1
5. Changing the hydraulic oil of magazine 4-7-1
shifter unit
6. Changing the table lubricating oil and 4-7-1
cleaning the suction filter
7. Changing the oil in compound oil control 4-7-1
unit and cleaning the filter
8. Changing the oil in table cooling fluid oil 4-7-1
control unit and cleaning the filter
9. Changing the B-axis lubricating oil 4-7-1
Greasing
1. Greasing the carrier linear guide 4-6-2
2. Greasing the carrier ball screw 4-6-2
3. Greasing the ATC door linear guide 4-6-2
4. Greasing the counter balance 4-6-2
5. Greasing the NC operating panel linear 4-6-2
guide
Around the machine
1. Cleaning the exterior of the machine 4-3-6
2. Checking the machine and hydraulic 4-3-6
unit for oil leaks
3. Collecting coolant from the oil pan below 4-3-6
the magazine cover
4. Checking the Z-axis servo load 4-3-7
5. Cleaning the mill spindle taper hole 4-4-2
6. Tightening the retention knob 4-4-2
7. Checking the tools (inserts) for chipping, -
cracks, and other damage
8. Cleaning the tool shank 4-4-2
9. Cleaning the line filter of the through- 4-4-2
spindle cooling system
10. Cleaning the air filters of the compound 4-4-2
oil control unit
11. Cleaning the sensor detecting the 4-4-2
presence of a tool in a tool pot in the
magazine unit
12. Checking the indicator lamps on the 4-4-2
operating panels
13. Checking the emergency stop buttons 4-5-1
for correct operation
14. Checking the magazine chain tension ( ) 4-6-3
First one
month
15. Checking the safety devices for correct 4-6-3
operation
16. Checking the air unit drain function 4-6-3
17. Checking the wipers at the axis way 4-6-3
cover for damage
4-3

Every 6 Refer to
Items Daily months
60 H 250 H 3000 H
1500 H
18. Clearing chips from inside the X-axis 4-6-3
way cover
19. Cleaning the coolant tank and changing 4-6-3
coolant
20. Checking hoses on moving units for 4-6-3
damage
21. Cleaning the table filter -
22. Cleaning the spindle lubricating unit 4-7-2
filters
23. Cleaning the fans in the electrical control 4-7-2
cabinet
24. Checking the in-machine lighting 4-7-2
25. Inspecting the machine for noise, 4-9
vibration, and abnormal temperature
rise
26. Changing the machine light (fluorescent -
lamp) and cleaning the window
27. Visually inspecting all electric parts and -
relay panel
28. Checking the foundation bolts -
4-4
4-3 Daily Inspection and Maintenance
4-3-1 Inside the machine

! Switch off the power before cleaning inside the machine.
WARNING
Perform the following work.
1. Removing chips around the mill spindle
2. Removing chips from on top of the X-axis In-machine conveyor

way cover
(spindle side and pallet changer side)
Table
If chips accumulate on the X-axis way cover
during machining, discharge Niagara coolant 5. Removing chips on the
to the X-axis way cover by adjusting its TOOL EYE and laser tool
nozzle angle to wash away chips. If the length measuring unit
machine is kept operated with chips (option)
accumulated on the X-axis way cover, the X-
axis way cover may be damaged. If chips accumulate on
the TOOL EYE and laser
3. Removing chips on the pallet changer hook tool length measuring
(Inside the machine/setup station) unit, remove chips
manually.
If chips accumulate on the pallet changer If a measurement is
hook during machining, discharge cover carried out with chips
coolant to the pallet changer hook by accumulated on the
adjusting its nozzle angle to wash away chips. TOOL EYE and laser tool
If a pallet change operation is carried out with length measuring unit,
chips accumulated on the pallet changer the machine may be
hook, the machine may be damaged. damaged.
4. Operator’s door
Pallet changer
Pallet changer door
Setup station
Fig. 4-2 Inspection and maintenance inside the machine
4-5
4-3-2 Outside the machine
1. Removing chips from the conveyor

Check if chips are accumulated on the external chip conveyor belt through the window at the
back of the coolant tank.
When chips are accumulated on the belt, run the external chip conveyor for about five minutes.
Check for the accumulation of chips on

the external chip conveyor belt.
When chips are accumulated on the

external chip conveyor belt, run the
chip conveyor to dispose chips.
Fig. 4-3
2. Cleaning the chip bucket

! If coolant, oil or other fluid gets spilled on the floor, wipe it off with a cloth and dry the floor
immediately. If the floor remains wet with spilled fluid, personnel could slip over and be
injured.
WARNING
! Do not touch chips with bare hands, otherwise you could be injured.
CAUTION
Dispose of chips accumulated in the chip bucket several times a day according to the machine
operating conditions.
4-3-3 Checking oil levels

Check the oil level at each of the tanks by the oil level gauge. If the oil level is lower than the
allowable lower limit, replenish the specified oil.
1. Checking the hydraulic oil level
2. Checking the spindle cooling fluid level
3. Checking the table lubricating oil level
4. Checking the oil level (mill spindle lubricating oil and slideway lubricating oil)
5. Checking the coolant level
! Check to be sure that coolant level is higher than the lower limit line of the level gauge. If
the machine is operated although coolant amount is insufficient, the way covers and other
machine parts may be damaged due to chips accumulated in the machine caused by
CAUTION
insufficient coolant discharge amount or the coolant pump itself may be damaged. Note
that coolant could be consumed unexpectedly depending on conditions such as
temperature and humidity.
4-6
4-3-4 Checking pressures (hydraulic and air)
1. Checking the hydraulic unit oil pressure

0 MPa (0 psi): With power OFF
7.0 MPa (1000 psi): With power ON
2. Checking the air pressure

0.5 MPa (70 psi)
4-3-5 Changing or replenishing oils
1. Replenishing coolant (as needed)

injured.
WARNING
< Procedure >
(1) Check the coolant level at the oil level gauge.
Coolant tank capacity: 900 L (31.78 ft3)
! Since some kinds of coolant are injurious to health, you must be exercise due care when
handling coolant. Do not handle coolant with bare hands.
CAUTION
(2) If the coolant level is low, replenish with the stipulated coolant to the upper limit level of the
oil level gauge. If the coolant goes over the upper limit level, coolant returned to the
coolant tank could overflow the tank when the coolant pump is stopped.
Remark: For the selection of coolant, see PART 2, 4-3 “Preparing Coolant” in the Operating
Manual.
4-7
4-3-6 Around the machine
1. Cleaning the exterior of the machine

Wipe off oil, coolant, chips, and other foreign matter from the surface of the machine.
Use soft cloth soaked with neutral detergent to clean the screen and operating panels.
2. Checking the machine and hydraulic unit for oil leaks

Visually check the machine, hydraulic unit, hydraulic piping/hose, and blocks and cylinders for oil
leaks.
If oil leak is found, appropriate measures must be taken.
3. Collecting coolant from the oil pan below the magazine cover
< Procedure >

(1) Check the amount of coolant in the oil pan by observing the gauge.
(2) If coolant is viewed through the gauge, loosen the knurled knobs and pull out the oil pan.
Return the coolant reserved in the oil pan to the coolant tank.
(3) Set the oil pan as before and tighten the knurled knobs.
! Make sure to check the amount of coolant in the oil pan and also to secure the oil pan.
Otherwise, coolant leaks will occur.
CAUTION
4-3-7 Checking the Z-axis servo load

After the installation of the machine, measure and record the Z-axis servo load (operator side
and magazine side) and check the Z-axis servo load every day after that.
If the read servo load exceeds the recorded load by more than 20%, refer to 5-2-1
“Troubleshooting”.
4-8
4-4 Weekly Inspection and Maintenance
1. Replenishing mill spindle lubricating oil

When replenishing the spindle lubricating oil, pay attention so that the oil level does not exceed
the upper limit line of the oil level gauge of the lubrication unit.
• Tank capacity: 3 L (0.11 ft3)
• Lubricating oil consumption amount: 1.95 cm3 (0.12 in3) per hour
* Recommended oil: Refer to 7-1-1 “List of oiling points”.
Note: When replenishing oil, use only the oil specified by Yamazaki Mazak. Otherwise,
machine trouble and other problems will occur.
2. Replenishing slideway lubricating oil

When replenishing the slideway lubricating oil, pay attention so that the oil level does not exceed
the upper limit line of the oil level gauge of the lubrication unit.
• Tank capacity: 3 L (0.11 ft3)
• Lubricating oil consumption amount: 36 cm3 (2.20 in3) per hour
* Recommended oil: Refer to 7-1-1 “List of oiling points”.
Note: When replenishing oil, use only the oil specified by Yamazaki Mazak. Otherwise,
machine trouble and other problems will occur.

Perform the following to maintain tool holding accuracy, etc.
1. Cleaning the mill spindle taper hole

Clean the taper hole of the mill spindle with clean cloth.
2. Tightening the retention knob

Check the retention knob for looseness and tighten it if loose.
3. Cleaning the tool shank

Clean the tool shank with clean cloth.
4-9
4. Cleaning the line filter of the through-spindle cooling system (option)

Through-spindle coolant pressure: 0.8 MPa/1.5 MPa (120/220 psi)
Check the indicator and if a half of the indicator is red, remove the bolts and clean the element of
the line filter.
For the position of the line filter, refer to Fig. 5-23.
Indicator
Bolt
MC111-01327
Fig. 4-4 Cleaning the line filter
5. Cleaning the air filters of the compound oil control unit

The air filters at the oil filling port side of the compound oil control unit can be removed by pulling
the air filter upward while holding the knobs on the filter. After removing, clean the air filter
using a brush, a hand held air nozzle or a vacuum cleaner.
For details, refer to the LIQUID TUNER Instruction Manual, provided by KOUWAKOUGYO CO.,
LTD.
Note: Do not use a hand held air nozzle near the machine since this could cause machine
trouble.
Air filter of the spindle Air filter of the table

cooling fluid chiller unit lubricating oil chiller unit
Fig. 4-5 Locations of the air filters
4-10
6. Cleaning the sensor detecting the presence of a tool in a tool pot in the magazine unit
Lightly swab the lens of the sensor (photoelectric sensor) detecting the presence of a tool in a
tool pot with dry and clean cloth or a clean cloth soaked in water or neutral detergent. Note that
use of organic solvents such as benzene, acetone, and thinner can cause malfunctioning of the
sensor.
Sensor detecting the presence

of a tool in a tool pot
Fig. 4-6 Location of the sensor detecting the presence of a tool in a tool pot in the magazine unit
4-11
7. Checking the indicator lamps on the operating panels
FMS-ready specification Standard specification
NC operating panel
Pulse handle
operating panel
EMERGENCY STOP
EMERGENCY STOP
EMERGENCY STOP
1 CYCLE
PALLET CHANGE HOLD
PALLET CHANGE HOLD

LOCK UNLOCK
PALLET LOCK PIN
LOCK UNLOCK
PALLET LOCK PIN

1 CYCLE 1 CYCLE
PALLET CHANGE HOLD
Manual pallet rotation Powered pallet rotation Powered pallet

specification specification rotation specification
TOOL SELECT EMERGENCY STOP

AUTO MANUAL
FORWARD REVERSE
Magazine operating panel
Fig. 4-7 Checking the indicator lamps on the operating panels
4-12
Confirm that all of the indicator lamps on the operating panels turn on correctly. If there is an
indicator lamp that fails to turn on, contact the Mazak Technical Center or Technology Center.
• NC operating panel
• Pulse handle operating panel
• Pallet changer operating panel
• Mill spindle tool magazine operating panel
4-13
4-5 Monthly Inspection and Maintenance
1. Checking the emergency stop buttons for correct operation

Check that the emergency stop button arranged on the NC operating panel and pallet changer
operating panel functions correctly.
If an emergency stop button fails to function correctly, the button must be changed.
4-6 Every Six-Month Inspection and Maintenance
1. Cleaning the strainers of the mill spindle cooling fluid chiller unit and the table lubricating
oil chiller unit
If the strainer is not properly inspected and cleaned, the pump and valves will be rapidly worn
and further causing noises. Inspect, clean and replace the strainer regularly. Inspect, clean
and/or replace the oil filing port filter/air breather and the strainer every six months.
< Procedure >
(For details, refer to the LIQUID TUNER Instruction Manual, provided by KOUWAKOUGYO CO.,
LTD.)
(1) Shut off the power and place the main power disconnect switch to the “OFF” position.
(2) Remove the maintenance covers, remove the strainer cap and take out the screen.
For the spindle cooling fluid chiller unit, four strainers are provided, and for the hydraulic unit
and the table lubricating oil chiller unit, one strainer is provided respectively.
(3) Clean the screen with cleaning oil and check external appearance. If abnormality is found,
replace the screen.
(4) Clean and check the air breather and the oil filling port filter in the same manner. Replace
the air breather or the oil filling port filter if abnormality is found.
(5) Return the screen as before, i.e., the state before step (2).
No. Parts name

1 Body
2 Cap
3 Screen
4 Gasket
5 Plug
Fig. 4-8 Construction of the strainer
4-14
Strainer of the
spindle cooling
fluid chiller unit
Strainer of the
spindle cooling
fluid chiller unit Strainer of the hydraulic unit
Fig. 4-9 Locations of the strainers (for mill spindle)
Strainer of the
table lubricating
oil chiller unit
Fig. 4-10 Locations of the strainers (for table)
4-15
4-6-2 Greasing
! Shut off the power before changing the hydraulic oil.
! When supplying grease, use only the grease specified by Yamazaki Mazak. Otherwise,
WARNING machine trouble and other problems will occur.
1. Greasing the carrier linear guide
Carrier unit
A
ATC arm
Grease nipples
View A
Fig. 4-11 Greasing the carrier linear guide
< Procedure >

(1) Place the main power disconnect switch to the “OFF” position.
(2) Supply grease through the grease nipples. (Amount of grease: 2.4 cm3 (0.15 in3) × 2 places)
Note: When supplying grease, do not remove parts attached to the carrier unit.
(If a part is removed, it can cause faulty tool change operations to result in alarm stop.)
4-16
2. Greasing the carrier ball screw
Carrier unit
ATC arm
B
Grease nipple
View B
Fig. 4-12 Greasing the carrier ball screw
< Procedure >

(2) Supply grease through the grease nipples. (Amount of grease: 2.4 cm3 (0.15 in3))
Note: When supplying grease, do not remove parts attached to the carrier unit.
(If a part is removed, it can cause faulty tool change operations to result in alarm stop.)
4-17
3. Greasing the ATC door linear guide
A
Greasing port of
ATC door linear guide (upper)
A DETAIL
Greasing port of
ATC door linear guide (lower)
Detach the cover. B DETAIL
Fig. 4-13 Greasing the ATC door linear guide
< Procedure >

(2) Detach the cover. (2 locations on section B)
(3) Supply grease through the grease nipple in section A. (Amount of grease: 2.2 cm3 (0.13 in3))
(4) Move the ATC door 560 mm (22.05 in).
(5) Supply grease through the grease nipples in section B. (Amount of grease: 1.1 cm3
(0.07 in3) × 2 places)
4-18
4. Greasing the counter balance
< Procedure >
(1) Position the Z-axis at “–1300 mm” position and place the main power disconnect switch to
the “OFF” position.
(2) Remove the maintenance cover.
The greasing panel is now visible.
Maintenance cover
Fig. 4-14
(3) Remove the front nozzle from the grease hand pump.
Screw 1/8
Nozzle
Reference part number: P21LA000210 Type: LG-400 Lube
Fig. 4-15
(4) Fill the grease hand pump with grease (Toray Dow Corning SH33M).
Amount of grease: 100 cm3 (6.1 in3) × 2 places
4-19
(5) Remove the hexagon socket head plug on the greasing panel.
IN OUT
side side
Hexagon socket head
Fig. 4-16
(6) Fit the grease hand pump to the bushing (IN side: upper left side), feeding grease to for the
magazine side, on the greasing panel and supply grease. Confirm that grease oozes
through the OUT port.
Greasing port 1/8
Front end of the grease

hand pump
Fig. 4-17
Note 1: The greasing port size is PT1/8. If the type of the available grease hand pump differs
from the specified type, use a bushing so that the grease hand pump is connectable to
the greasing port.
Note 2: If grease is supplied with the grease nipple fitted to the greasing port, the grease nipple
is deformed and grease cannot be supplied correctly. Therefore, supply grease after
connecting the front end of the grease hand pump to the greasing port.
(7) Supply grease to the operator side (lower side on the greasing panel) in the same manner.
(8) After finishing greasing, fit the hexagon socket head plug to the IN and OUT side ports.
4-20
5. Greasing the NC operating panel linear guide
Turn the NC operating panel 120°.

Detach the cover.
Greasing port of NC
operating panel linear guide
A DETAIL
(2 places)
Fig. 4-18 Greasing the NC operating panel linear guide
< Procedure >

(2) Turn the NC operating panel 120° and remove the covers (2 section A locations).
(3) Supply grease through the grease nipples.
4-21
1. Checking the safety devices for correct operation

! Since the machine may move unexpectedly, leading to a hazardous situation if a safety
device is faulty, do not rest your body, or leave any unnecessary objects, on the moving
units or within the range of movement of the units when performing inspections.
WARNING
If an abnormality is found in the inspection, contact Mazak Technical Center or Technology
Center.
A. Operator’s door interlock

Check that the operator’s door interlock operates correctly by referring to PART 2, 2-9
“Operator’s Door Interlock” in the Operating Manual.
B. Pallet changer safety cover interlock

Check that the execution of pallet change operation is controlled according to the state of the
pallet changer safety cover as indicated below.
Safety Cover Pallet Change Operation
Closed → Executed
Open → Not executed
2. Checking the magazine chain tension

! Set the main power disconnect switch to the “OFF” position before checking the chain,
otherwise you could sustain serious injury.
WARNING
Although the magazine chain tension is adjusted after initial elongation of the chain before
shipping, the magazine chain will be elongated during use of the magazine over a long time.
Indexing of tools is carried out by the rotation of sprockets and slight slackness of the magazine
chain causes no problems with indexing accuracy. However, if the slackness of the magazine
chain is apparent to the touch , it will cause overloading of the drive motor. Therefore, the chain
tension must be adjusted using the tension adjusting bolts.
4-22
40-tool magazine
Magazine chain tension

adjusting section
Fig. 4-19 Tool magazine (40 tools)
80-tool magazine

adjusting section
4-23
120-tool magazine

adjusting section
160-tool magazine

adjusting section
4-24
3. Checking the air unit drain function
Mist separator
Drain port
Phillips-head
screwdriver
Fig. 4-23 Checking the air unit drain function
The automatic drain function of the mist separator is faulty in the following cases.
A. Air is always leaking through the drain port.
Corrective action: Poke the drain port several times with the Phillips-head screwdriver.
If the air still leaks, refer to 5-7 “Pneumatic System” for the corrective
action to be taken.
B. Large amount of water is discharged from the drain port when the Phillips-head screwdriver
is inserted into the drain port.
Corrective action: The mist separator must be changed.
4-25
4. Checking the wipers at the axis way cover for damage

! Set the main power disconnect switch to the “OFF” position before entering the machine.
Otherwise, you may sustain serious or fatal injury.
WARNING
Visually check the wipers at the X- and Y-axis way covers for damage. If damage is found in a
wiper, change it with new one as soon as possible.
Y-axis way cover
Wiper A Wiper A
X-axis way cover
Wiper B Wiper B
Fig. 4-24 Checking the wipers at the axis way cover for damage
5. Clearing chips from inside the X-axis way cover

See 5-11-4 “Maintenance of the X-axis way cover” for the procedure to remove the X-axis way
covers.
4-26
6. Cleaning the coolant tank and changing coolant
injured.
WARNING
< Procedure >
(1) Pull out the tank to the machine front side.
(2) Remove the filters, bucket, coolant pump, and top cover from the coolant tank. If the
machine is equipped with the chip conveyor, remove the chip conveyor too.
(3) Pump the coolant from the coolant tank.
(4) If coolant level becomes low and pumping becomes impossible, loosen the drain plug of the
coolant tank to completely discharge coolant from the coolant tank.
(5) When the coolant is completely discharged from the coolant tank, remove chips and sludge
deposited at the bottom of the tank.
(6) Clean the inside of the coolant tank with rag.
(7) After cleaning the coolant tank, refit the drain plug and other parts removed.
(8) Supply new coolant to the coolant tank.
For the procedure to supply new coolant, refer to 4-3-5 “Changing or replenishing oils”.
7. Checking hoses on moving units for damage

! Switch off the power before checking hoses on moving units for damage. Otherwise, you
may sustain serious or fatal injury.
WARNING
< Procedure >
(2) Move the e-Tower aside and check the hoses to the rear of the machine for damage.
Check the hoses for damage such as cracks, abnormal bulge, and deterioration.
If any damage is found, contact Mazak Technical Center or Technology Center.
4-27
4-7 Every One-Year Inspection and Maintenance

! Shut off the power before changing the hydraulic oil.
! When replenishing oil, use only the oil specified by Yamazaki Mazak. Otherwise, machine
WARNING trouble and other problems will occur.
1. Changing the hydraulic oil of ATC unit
ATC arm
Oil filler port
Oil level gauge ATC unit
Drain hole
Fig. 4-25 Changing the hydraulic oil of ATC unit
< Procedure >

(2) Loosen the drain plug to discharge the oil.
(3) Tighten the drain plug.
(4) Supply the fresh oil while observing the amount oil by the oil level gauge.
(Amount: 6 L (0.21 ft3))
Note: When supplying the hydraulic oil, do not remove brackets and other parts attached to
the ATC unit.
4-28
2. Changing the hydraulic oil of magazine shifter unit
Oil filler port
Magazine shifter
(Magazine shifter unit)
Oil level gauge
Drain port (at the bottom)
Fig. 4-26 Changing the hydraulic oil of ATC unit
< Procedure >

(2) Loosen the drain plug to discharge the oil.
(3) Tighten the drain plug.
(4) Supply the fresh oil while observing the amount oil by the oil level gauge.
(Amount: 3.6 L (0.13 ft3))
For the specified oil, refer to 7-1-1 “List of oiling points”.
4-29
3. Changing the table lubricating oil and cleaning the suction filter
Lever Cover
IN
OUT
T-joint Suction filter

Pull out the coolant tank 770 mm (30.31 in).
Fig. 4-27 Changing the table lubricating oil
Since the cooling fluid of the table unit circulates through the chiller unit, change the lubricating
oil at the same time as changing the oil in the chiller unit. Clean the suction filter at the same
time as changing the table cooling fluid.
< Procedure >
(2) Drain the oil from the chiller unit. (Refer to 5. “Changing the oil in table cooling fluid oil
control unit and cleaning the filter”.)
The filter becomes visible when the coolant tank is pulled about 770 mm (30.31 in).
The cooling fluid inside the table is drained by removing the plug fitted in the T-joint in the
piping from the filter to the tank.
(The cooling fluid starts draining when the plug is removed, so receive it with an oil pan until
it stops.)
(3) Turn the lever 90°.
→ The cover is released, allowing its removal.
! Before this step, place an oil collecting thing such as an oil pan under the suction filter unit
since the lubricating oil in the suction filter unit will flow out when the cover is released.
CAUTION
4-30
(4) Remove the suction filter.
Since the suction filter is set in place using the spring, remove the suction filter while holding
the spring.
(5) Remove the suction filter with a spanner and clean it with a hand held air nozzle.
(6) Fit the suction filter.
Make sure to fit the suction filter correctly. Set it in the manner the open port faces the
OUT side.
(7) Attach the cover and return the lever to the horizontal position.
Make sure that the cover is correctly clamped in place. Otherwise, lubricating oil can leak
through the cover.
(8) Fit the plug to the T-joint.
(9) Return the coolant tank to the previous position.
(10) Supply the oil to the chiller unit. [35 L (1.24 ft3)].
(11) Turn on the NC power and the oil starts circulating from the chiller unit to the table and then
to the chiller unit.
(12) Replenish the oil while observing lowering of the oil level.
* Maximum oil amount in the table unit is 35 L. Do not supply the oil exceeding this limit.
65 L (2.30 ft3) in total [Chiller unit: 35 L (1.24 ft3), Table unit: 30 L (1.06 ft3)]
4. Changing the oil in compound oil control unit and cleaning the filter
! Make sure to shut off the power before maintaining the machine.
! When replenishing spindle cooling fluid, use only the cooling fluid specified by Yamazaki
WARNING Mazak. Otherwise, machine trouble and other problems will occur.
Oil changing intervals for the spindle cooling fluid and working oil depend on machine operating
conditions. In general, however, the oil should be changed in the first six months of machine
installed and every year thereafter.
For the specified spindle cooling fluid, refer to 7-1-1 “List of oiling points”.
< Procedure >
LTD.)
(2) Remove the cap at the oil filler port.
(3) Place a drain collecting pan under the drain port and loosen the drain plug with a wrench.
→ Oil (cooling fluid, working oil) will be discharged. (Spindle cooling fluid: 108 L (3.81 ft3),
Working oil: 60 L (2.12 ft3))
(4) After making sure that the tank is completely emptied, set the drain plug on which new seal
tape is wound to the drain port and tighten it securely.
(5) Fill the tank with fresh oil through the air breather (oiling port filter) while observing the oil
level with the level gauge.
Be sure to fill the oil to the correct tank.
(Spindle cooling fluid: 108 L (3.81 ft3), Working oil: 60 L (2.12 ft3))
4-31
(6) Fit and tighten the cap at the oil filler port.
Note: When changing the oil, check and clean the strainers. If a strainer is clogged, it will
cause malfunctioning of the circulation pump. Furthermore, if the oil is not circulated
through the cooling circuit, refrigerating cycle load increases unduly to lead to failure of
the machine.
Oil filler port Oil filler port
Oil level gauge Oil level gauge

(spindle cooling fluid) (working oil)
Drain (spindle cooling fluid) Drain (working oil)
Fig. 4-28 Changing spindle cooling fluid and working oil
A. Processing of refrigerant
HFCs (hydrochlorofluorocarbons: alternatives to chlorofluorocarbons) are used as refrigerants in
compound oil control units. HFCs must be collected and disposed of in accordance with the
applicable national regulations. Therefore, when disposing of a compound oil control unit,
contact a waste collection and disposal service company and ask for appropriate processing of
the HFCs.
Note: If you have no contact with an appropriate waste collection and disposal service
company, please contact us. We will respond to your request at your expense.
4-32
5. Changing the oil in table cooling fluid oil control unit and cleaning the filter
! Make sure to shut off the power before maintaining the machine.
! When replenishing spindle cooling fluid, use only the cooling fluid specified by Yamazaki
WARNING Mazak. Otherwise, machine trouble and other problems will occur.
Oil changing intervals for the table cooling fluid depend on machine operating conditions. In
general, however, the oil should be changed in the first six months of machine installed and
every year thereafter.
For the specified table cooling fluid, refer to 7-1-1 “List of oiling points”.
< Procedure >
LTD.)
(2) Remove the cap at the oil filler port.
(3) Place a drain collecting pan under the drain port and loosen the drain plug with a wrench.
→ Oil (cooling fluid) will be discharged. (Table cooling fluid: 35 L (1.24 ft3))
(4) After making sure that the tank is completely emptied, set the drain plug on which new seal
tape is wound to the drain port and tighten it securely.
(5) Fill the tank with fresh oil (cooling fluid) while observing the oil level. (Table cooling fluid:
35 L (1.24 ft3))
(6) Fit and tighten the cap at the oil filler port.
Note: When changing the oil, check and clean the strainers. If a strainer is clogged, it will
cause malfunctioning of the circulation pump. Furthermore, if the oil is not circulated
through the cooling circuit, refrigerating cycle load increases unduly to lead to failure of
the machine.
Oil filler port
Oil level gauge
Drain
Fig. 4-29 Changing table cooling fluid
4-33
A. Processing of refrigerant
HFCs (hydrochlorofluorocarbons: alternatives to chlorofluorocarbons) are used as refrigerants in
the table cooling oil controller unit. HFCs must be collected and disposed of in accordance with
the applicable national regulations. Therefore, when disposing of a table cooling oil controller
unit, contact a waste collection and disposal service company and ask for appropriate
processing of the HFCs.
Note: If you have no contact with an appropriate waste collection and disposal service
company, please contact us. We will respond to your request at your expense.
6. Changing the B-axis lubricating oil
< Procedure >

(1) Move the Z-axis down to the position where operation steps below will be facilitated. Shut
off the power and place the main power disconnect switch to the “OFF” position.
(2) Remove the plug from the oil filler tap and the level tap.
(3) Remove the drain plug to drain the lubricating oil.
(4) After completely draining the lubricating oil, fit the drain plug.
(5) Supply the lubricating oil. When the oil begins flowing through the level tap, fit the plug to
the filler tap and the level tap.
Lubricating oil amount: 12 L (0.42 ft3)
Oil filler tap
Level tap
Drain plug
Fig. 4-30
4-34
1. Cleaning the spindle lubricating unit filters

< Procedure >
(1) Take out the filter from the oil filler port and clean it by supplying compressed air from the
inside of the filter using the hand held air nozzle.
Note: Do not use a hand held air nozzle near the machine since this could cause machine
trouble.
Oil filler port

filter
Fig. 4-31 Cleaning the oil filler port filter
2. Cleaning the spindle lubricating unit filters (suction port)
< Procedure >

(1) Switch off the power to the machine.
(2) Take out the lubrication unit.
Lubrication unit
Pipe
Take out
Tank Bolt
Suction filter
MC111-01190
Fig. 4-32 Cleaning the suction filter (1/2)
4-35
Note: Do not disconnect the pipes. Otherwise, air will enter the pipe and cause spindle
trouble.
(3) Remove the drain plug to discharge lubricating oil.
(4) Fit and tighten the drain plug after discharging the lubricating oil.
(5) Remove the screws clamping the pump unit to the tank and separate the pump unit from the
tank.
(6) Remove the filter clamp and take out the suction filter.
(6 places)
Pump
Suction filter
Tank
Filter clamp
Fig. 4-33 Cleaning the suction filter (2/2)
(7) Clean the suction filter.

Use washing oil (kerosene, etc.) to clean the suction filter.
At the same time, clean the inside of the tank with rag.
4-36
3. Cleaning the fans in the electrical control cabinet
Electrical control
cabinet door
Fasteners Fasteners
Fan guard
Fan
Fig. 4-34 Cleaning the fans in the electrical control cabinet
< Procedure >

(2) Turn the fasteners, fitted at the top and bottom of the electrical control cabinet doors, to
unlock them.
(3) Open the electrical control cabinet doors.
(4) Loosen the fan guard mounting bolts.
(5) Remove the fan guard and clean the fan and fan guard with cloth.
(6) Attach the fan guard and fix it by tightening the bolts.
(7) Close the electrical control cabinet doors.
(8) Turn the fasteners, fitted at the top and bottom of the electrical control cabinet doors, to lock
them.
! Place the main power disconnect switch to the “OFF” position before cleaning the fans in
the electrical control cabinet.
WARNING
4-37
4. Checking the in-machine lighting
In-machine lighting
Fig. 4-35 Checking the in-machine lighting
< Procedure >

(1) With the power to the machine turned ON, check the in-machine lighting on the ceiling (2
locations) and the LED lights on the sides (4 locations) from inside the machine.
If the lighting is dim, blown, or flickering, it must be replaced.
When replacement of the lighting is necessary, contact the Mazak Technical Center or
Technology Center.
4-38
4-8 Inspection and Maintenance before Stopping the Machine for a Long Time
When stopping the machine for longer than two weeks, carry out the following inspection and
maintenance.
• Applying rust preventive oil
• Discharging coolant
• Saving the NC data
1. Applying rust preventive oil

! Switch off the power before applying rust preventive oil.
WARNING
If the machine is not operated for a long time, unpainted surface of the following parts will be
rusted and the function of them will be deteriorated. Therefore, apply rust preventive oil to
these parts if the machine will not be operated for a long time.
• Linear guide rails (X-, Y-, Z-axis)
• Ball screws (X-, Y-, Z-axis)
• Way covers (X-, Y-, Z-axis)
• Pallet
• Table
• Pallet changer
• ATC magazine
• Spindle
2. Discharging coolant
Completely discharge coolant from the coolant tank and clean both the inside and outside of the
coolant tank.
For details, refer to 4-6-3 “Around the machine”.
3. Saving the NC data

Save all NC related data to external recording media (memory card, etc.).
For details of operation procedure to save the NC data using external recording media, refer to
the instruction manual of the NC.
4-39
4-9 Inspection and Maintenance before Starting the Operation after Stopping the
Machine for a Long Time
Before restarting the machine which has been stopped for longer than two weeks, carry out the
following inspection and maintenance.
• Wiping off rust preventive oil
• Replenishing coolant
• Usual inspection before starting the operation
• Inspecting the machine for oil leaks
• Warm-up operation
• Inspecting the machine for noise, vibration, and abnormal temperature rise
• Uploading the NC data
1. Wiping off rust preventive oil

! Switch off the power before wiping off rust preventive oil.
WARNING
Remove rust preventive oil, applied as explained in 4-8 “Inspection and Maintenance before
Stopping the Machine for a Long Time”, using the rag soaked with washing oil.
2. Replenishing coolant
Replenish coolant to the coolant tank.
For details, refer to 4-6-3 “Around the machine”.
3. Usual inspection before starting the operation

Perform the inspection which are required before starting daily operation.
For details, refer to PART 2, 3-1 “Inspection before Starting Operation” in the Operating Manual.
4. Inspecting the machine for oil leaks

After switching on the power, visually check the machine, piping and hoses of the hydraulic unit,
blocks, and cylinders for oil leaks.
5. Warm-up operation
Run the machine for approximately three hours using the warm-up program (PNO. 6000) which
is stored in the NC memory.
Refer to the instruction manual of the NC.
6. Inspecting the machine for noise, vibration, and abnormal temperature rise
Check the machine for generation of abnormal noise and vibration, and also for abnormal
temperature rise at the motors and bearings.
If any abnormality is found, take appropriate corrective action by referring to Chapter 5
“MAINTENANCE OF MAJOR UNITS”.
4-40
7. Uploading the NC data
Before starting the operation, upload the NC data having been saved to the micro disk before
stopping the machine.
4-41
- MEMO -
4-42 E
MAINTENANCE OF MAJOR UNITS 5
5 MAINTENANCE OF MAJOR UNITS
If a machine trouble occurred, first check the following items and carry out inspection and
maintenance according to the information described in this Chapter.
If you contact Mazak Technical Center or Technology Center, the results of your check will very
helpful to locate the cause of the trouble.
1. Call the diagnosis (alarm) screen and confirm the past alarms in addition to the latest alarm.
(For details of the diagnosis (alarm) screen, refer to the Operating Manual of NC provided
separately.)
2. Check the trouble and alarm if it recurs.
3. Check the ambient temperature if it is within the specified range.
4. Check if momentary power failure has occurred.
5. Check the source voltage for fluctuation.
6. Check if conditions differ depending on motion direction - forward and reverse rotation,
retract and advance motion, etc.
7. Check if the trouble or alarm occurs only at specific operation or command.
8. Check the trouble or alarm occurrence frequency.
9. Check how long the machine has been operated.
10. Confirm if corrective action has been taken.
5-1 Mill Spindle and B-axis
5-1-1 Troubleshooting
Symptom Check Points and Probable Causes Corrective Action Refer to
• Mill spindle does not start. 1. Insufficient capacity or a trouble Prepare the power supply which 6-2-2
• Mill spindle stops due to alarm. of external power supply meets the requirements indicated in
6-2-2 “External power source
requirements”.
2. Ambient temperature of the Lower the ambient temperature. -
spindle drive unit is higher than
40°C (104°F).
3. Load is excessively large. Reduce load applied to the spindle. -
4. The spindle drive unit is Contact Mazak Technical Center or -
defective. Technology Center.
The spindle drive motor is
defective.
There is a trouble in the spindle.
• Mill spindle orientation does not The spindle drive unit is defective. Contact Mazak Technical Center or -
complete. The spindle drive motor is defective. Technology Center.
• Mill spindle orientation status There is a trouble in the spindle.
cannot be canceled.
• There is abnormal noise or 1. The spindle is rotating at a high Replace the tool with a balanced tool. -
abnormal vibration during mill speed with an unbalanced tool
spindle rotation. mounted in it.
2. The spindle drive unit is Contact Mazak Technical Center or -
The spindle drive motor is
defective.
Loose bolts
5-1

• Tool clamp operation is not 1. The sensor is defective. Replace the sensor. 5-11-3
completed. (Although the clamp/unclamp
• Tool unclamp operation is not cylinder operates correctly, the
completed. sensor is not turned on.)
2. The sensor is not mounted Mount the sensor correctly.
securely.
(Gap between the sensor and the
dog is larger than 0.5 mm
(0.020 in).)
3. The hydraulic valve is defective Contact Mazak Technical Center or -
or blocked. Technology Center.
(The clamp/unclamp cylinder fails
to operate).
4. The clamp/unclamp cylinder is
defective.
(The clamp/unclamp cylinder
does not operate although the
hydraulic valve has no problems.)
5. The hydraulic unit is defective.
(Hydraulic pressure is always
lower than 7.0 MPa (1000 psi).)
6. Loose bolts
• Oil leak 1. The seal in the clamp/unclamp Contact Mazak Technical Center or -
cylinder has been worn. Technology Center.
2. The seal in the mill coupling
cylinder has been worn.
• ATC air blast is not supplied. 1. An external air source is not Connect the external air source. 6-4-3
• ATC air blast does not stop. connected.
2. The solenoid valve is defective. Contact Mazak Technical Center or -
Technology Center.
• B-axis does not rotate. 1. There is an interfering object. Remove the interfering object. -
• B-axis cannot be indexed correctly. 2. The B-axis drive servomotor is Contact Mazak Technical Center or -
3. The B-axis drive mechanism is
defective.
• B-axis and mill spindle coupling 1. The sensor is defective or it is not Replace the sensor or adjust its -
clamp/unclamp operation is not mounted correctly. (Although the position. Contact Mazak Technical
completed. clamp/unclamp operation is Center or Technology Center.
performed, the sensor fails to turn
on.)
2. The solenoid valve is defective or Contact Mazak Technical Center or -
clogged. (Clamp/unclamp Technology Center.
operation is not performed).
3. The hydraulic cylinder is
defective. (Clamp/unclamp
operation is not performed
although the solenoid valve is
normal).
• Abnormal noise is generated There will be a trouble in the B-axis Contact Mazak Technical Center or -
during B-axis rotation. drive system, such as damaged Technology Center.
bearing.
• B-axis positioning is inaccurate. 1. Loose bolts Tighten the loose bolts. -
2. Position encoder in the Contact Mazak Technical Center or -
servomotor is defective. Technology Center.
5-2
5-1-2 Construction of the spindlehead
Flood coolant valve

Through-spindle air valve
Through-spindle coolant valve B-axis coupling valve
Mill spindle coupling valve

Spindle bearing
oil-air lubrication air Tool clamp/unclamp valve
pressure switch
Oil-air lubrication air valve
B-axis coupling clamp sensor
B-axis coupling unclamp sensor

Tool unclamp sensor
Tool clamp sensor
Fig. 5-1 Construction of the spindlehead
• A tool is clamped in the spindle by spring force.

Tool unclamp operation is performed by the hydraulic cylinder.
• The mill spindle bearings are lubricated by oil-air. The pressure switch is provided to
prevent lubrication failure problem even if air pressure is lowered.
5-3
5-2 X-axis, Y-axis, Z-axis
• Positioning cannot be made 1. Bolts of axis drive parts (ball Contact Mazak Technical Center or -
accurately. screw, coupling, linear guide, Technology Center.
etc.) are loose.
2. The encoder in the servomotor is
defective.
• Zero-point position is not fixed or 1. The bolts fixing the zero-point Contact Mazak Technical Center or -
the limit switch does not function return limit switch are loose. Technology Center.
correctly. 2. The bolts fixing the zero-point
dog are loose.
• An axis stops due to alarm. 1. Load is excessively large. Reduce load applied to the spindle. -
2. Ambient temperature of the servo Lower the ambient temperature. 6-2-1
control unit is higher than 40°C
(104°F).
3. The servo control unit in the Contact Mazak Technical Center or -
electrical control cabinet is Technology Center.
defective.
4. The servomotor is defective.
5. N2 pressure in the counter 1. Replenish the N2 gas. 5-2-2
balancer is low. 2. Contact Mazak Technical Center
or Technology Center.
• Abnormal noise is generated 1. The wiper at the way cover is Replace the wiper. 4-6-3
during axis movement. damaged.
2. The way cover is defective. Contact Mazak Technical Center or -
Technology Center.
3. A trouble in the axis drive system
such as damaged ball screw
support bearing.
• Z-axis servo load has increased N2 pressure in the counter balancer is 1. Replenish the N2 gas. 5-2-2
more than 20%. low. 2. Contact Mazak Technical Center
or Technology Center.
5-4
5-2-2 Construction of the axis drive systems
1. Construction
Y-axis linear guide

Z-axis drive AC servomotor
Encoder
Encoder
Y-axis drive AC servomotor
Y-axis ball screw
Spindle
Saddle
Column
X-axis ball screw
Z-axis ball screw X-axis drive AC

servomotor
Z-axis linear guide Encoder
Table
X-axis linear guide Base
Fig. 5-2 Construction of the axis drive systems
5-5
2. Replenishing the gas for the counter balancer
Gas filler ports

Counter balancers
Counter balancing rods
Fig. 5-3
If the Z-axis servo load checked in 6-month inspection is larger than the Z-axis servo load
checked and recorded after machine installation by 20% or more, replenish the N2 gas following
the procedure below. Note it is necessary to remove the right and left ceiling covers before
replenishing the gas. Refer to Fig. 5-4.
< Procedure >
(1) Position the Z-axis at the zero point and the Y-axis at –530 mm (–20.87 in) position, then
place the machine in an emergency stop state.
(2) Fit plug A to the gas filler port, provided at the top end of the counter balancer. Then, after
fitting the male and female plugs, connect the gas replenishing kit to them.
Make sure that the lever cocks of the gas cylinder and regulator are closed.
(3) Attach the regulator to the gas cylinder and after setting the lever in the exhaust position
return it to the neutral position.
(4) Open the lever cock of the gas cylinder to check that the pressure in the gas cylinder is
higher than 7.0 MPa (1000 psi). If the pressure is lower than this, replace the gas cylinder
since replenishing of the gas is impossible.
(5) Set the pressure gauge at the counter balancer side to 7.0 MPa (1000 psi).
5-6
(6) Turn the lever to the replenish side to replenish the gas to the counter balancer.
Watch the pressure gauge at the gas cylinder side and if the pressure gauge does not show
pressure decrease any more, it indicates replenishing has completed.
(7) Perform the steps above for counter balancer at the operator side and the magazine side.
N2 gas cylinder specification (for filling the two counter balancers)

Gas kind: N2 (Nitrogen)
Gas pressure: 14.7 MPa (2130 psi) or more
Gas cylinder capacity: 0.047 m3 (1.66 ft3) or more
(N2 gas volume of 7 m3 (247.24 ft3) or more is required at atmospheric
pressure)
Gas purity: 99% or more
Connection port: W22 female thread or W23 male thread adapter (fixture side)
Silencer Ball valve Pressure gauge Pressure gauge

9A3754-020 9A3405-020 (Gas spring side) (Gas cylinder Lever cock of gas cylinder
side)
N2 gas cylinder
Exhaust Lever Pressure:
position Replenish Approx. 14.7 MPa
position High-pressure hose (2130 psi)
(Standard length: 2 m (6.56 ft))
8FH20320000
Regulator Adapter
9A3127-040 4ZJG63661A
High-pressure hose (Standard length: 0.5 m (1.64 ft))
8FH2030500
Set of gas replenishing fixture

Not supplied with the machine.
Plug (female)
8FQC02HS00 Supplied with the machine
as the standard tool.
Bolt
DNJ-C-5 (To be
purchased separately)
Plug A Plug (male)
DNJ-P-5 DNJ-C-CM (To be
purchased separately)
Gas spring
Fig. 5-4
5-7
5-2-3 Replacing the sealing packing of the Z-axis counter balancer

The gas pressure may fall due to loss of the sealing performance of the packing caused by
deterioration of or damage on the packing in the counter balancer. If the Z-axis servo load
increases soon even after replenishing gas, contact Mazak Technical Center or Technology
Center.
As a rule, replace the sealing packing in the counter balancer every two years or 1500 km
(932 miles) of Z-axis sliding.
5-2-4 Replacing the battery for the axis amplifiers

When alarm 12 ABSOLUTE POSITION WARNING is displayed, it indicates that the voltage of
the battery used in the absolute position detection system is low. If this alarm message is
displayed, replace the battery for all axis amplifiers by following the procedure below.
Note: Keep the power to the machine on for at least 30 minutes before replacing the battery.
Battery replacement must be completed within an hour.
1. Battery type
Manufacturer: Mitsubishi Electric Corporation
Manufacturer’s type: ER6V-C119B
Mazak part No.: D80MA016250
2. Battery replacement procedure

(1) Turn off the input power breaker and confirm that the power to the drive unit for which the
battery is to be replaced is turned off.
(2) Open the cover of the battery holder on the upper part of the front of the drive unit.
(3) Disconnect the battery cable connector from the drive unit and take out the battery.
Disconnect the battery connector.
Open the cover toward you

while pushing the battery
holder tab downward.
Fig. 5-5
(4) Connect the cable connector of the new battery to the same connector position where the
battery cable connector was disconnected in step (3).
5-8
(5) Put the battery in the battery holder and close the cover.
Connect the cable connector of the new

battery to the connector where the
battery connector was disconnected.
Put the battery into the battery holder.
Fig. 5-6
5-9
5-3 ATC Magazine
• ATC cover open/close operation Refer to 5-11 “Covers”. Refer to 5-11 “Covers”. 5-11
does not complete.
• The magazine does not rotate. 1. A tool exceeding the tool size Store the tools in the magazine. PART 2, 4-1 in
• The magazine stop position is specifications is stored in the the Operating
shifted from the correct index magazine. Manual
position. 2. The magazine drive unit is Contact Mazak Technical Center or -
3. The magazine rotation motor is
defective.
• The magazine shifter does not 1. The magazine shifter motor with Replace the sensor or adjust its -
operate. the reducer is defective. position.
2. The magazine shifter unit is Contact Mazak Technical Center or -
3. The sensors and/or limit switches
are defective, or they are not
mounted correctly.
• The carrier does not operate. 1. The sensor is defective or not Replace the sensor or adjust its 5-11-3
mounted correctly. position. 7-1-2, 7-1-3
(Although the ATC standby
pocket operates, the sensor is
not turned on.)
2. The carrier is defective. Contact Mazak Technical Center or -
3. The hydraulic valve is defective. Technology Center.
(The carrier does not operate.)
4. The hydraulic cylinder section is
defective. (Although the hydraulic
valve is free of troubles, the
carrier does not operate.)
5. Oil is not supplied to the hydraulic
valve.
• The ATC arm does not operate. 1. The drive motor is faulty. Contact Mazak Technical Center or -
2. The ATC unit is defective. Technology Center.
• A tool cannot be returned to the The tool existence detection sensor is -

magazine. defective.
5-10
5-3-2 Construction of the ATC magazine
Shift
Magazine
Carrier
Spindle
Tool UP/DOWN
Magazine shifter
Tool rotation
ATC unit
Fig. 5-7 Construction of the ATC magazine
5-11
5-4 Table
• Pallet clamp operation is not 1. The pressure switch is defective. Contact Mazak Technical Center or -
completed. (Although clamp/unclamp Technology Center.
• Pallet unclamp operation is not operation is executed, the
completed. pressure switch is not turned on.)
2. The solenoid valve is defective or
blocked.
(Pallet clamp/unclamp operation
is not executed.)
3. The hydraulic cylinder is
defective.
(Although the hydraulic valve is
free of problems, clamp/unclamp
operation is not executed.)
5. The seal in the center shaft has
worn.
(Turning operation) 1. The table cooling fluid chiller is Restore the chiller, referring to the -
• Table temperature is abnormally not operating. LIQUID TUNER Instruction Manual,
high. provided by KOUWAKOUGYO CO.,
LTD.
• The table does not rotate but roars.
2. The table drive motor is loaded Contact Mazak Technical Center or -
• The motor does not rotate
excessively or acceleration/ Technology Center.
smoothly.
deceleration time is too short.
3. The table drive motor is Reduce the load. -
overloaded.
(C-axis operation) 1. An interfering object. Remove the object hindering table -
• The table does not rotate. rotation.
• The table is not indexed correctly. 2. The table rotation motor is Contact Mazak Technical Center or -
• Pallet clamp operation is not
completed. 3. A trouble in the table.
• Abnormal noise is generated from 4. Loose bolts
the C-axis servomotor. 5. The worm is overloaded.
• Pallet correct clamp detection air 1. The solenoid valve is defective. Contact Mazak Technical Center or -
blast is not supplied. 2. The air discharge port is blocked. Technology Center.
• Pallet correct clamp detection air
blast does not stop.
• Oil leak 1. The seal in the pallet Contact Mazak Technical Center or -
clamp/unclamp cylinder has been Technology Center.
worn.
2. The seal in the rotary joint has
been worn.
• Pallet positioning accuracy 1. Loose bolts Contact Mazak Technical Center or -
deviates. 2. The encoder in the servomotor is Technology Center.
defective.
• Zero-point return operation is not The encoder in the servomotor is Contact Mazak Technical Center or -
executed correctly. defective. Technology Center.
5-12
5-4-2 Construction of the table
Turning operation drive gear engage/disengage

confirmation sensors PLG sensor
C-axis servomotor
Table drive motor for

turning operation
Table orientation encoder

Drain port
Worm engage/disengage
confirmation sensors
Fig. 5-8 Construction of the NC rotary table (1)
Pressure switch for

table clamp detection Gear engage/disengage
Pressure switch for pallet solenoid valve
clamp/unclamp detection
Worm engage/disengage
solenoid valve
Pallet unclamp
solenoid valve
Solenoid valve for air
blow (pallet seating)
Solenoid valve for

table unclamp
Lubrication switchover valve

(turning operation gear/worm)
Fig. 5-9 Construction of the NC rotary table (2)
5-13
5-4-3 Turning spindle and C-axis connection/disconnection menu

The turning spindle and C-axis connection/disconnection menu should be used only when the
mode cannot be switched between the turning mode and milling correctly. The functions in this
menu are valid only when the specified conditions are satisfied.
< Procedure >
(1) In the manual mode, press the (machine menu) key, and the following menu is
displayed.
ATC MAGAZINE PALLET B AXIS SPINDLE ATC #4 ZERO #2 ZERO
MAINT. SHT.CARI MAINT. C AXIS MENU RETURN RETURN
MAINT.
(2) Press the display selector key at the left end, and the second page of the menu is displayed.
OPTION TOOL MAINTE- TOOL EYE TOOL EYE
BREAKAGE NANCE COVER COVER
DETECT OPEN CLOSE
(3) Press the [MAINTENANCE] menu key, and the following menu is displayed.
MENU TURNING. TURNING. C AXIS C AXIS WK LIGHT CONVEYOR
ENABLE SPINDLE SPINDLE CONNECT CANCEL OFF OFF
CONNECT CANCEL CANCEL CANCEL
(4) Press the [MENU ENABLE] menu key together with the + (MF1 and MF2) keys.
The [MENU ENABLE] menu item is highlighted and the turning spindle and C-axis
connection/disconnection menu becomes valid.
Turning spindle and C-axis connection/disconnection menu
Pressing the [MENU ENABLE] menu key or selecting other menu item while the [MENU
ENABLE] menu item is selected returns the display of the [MENU ENABLE] menu item to
normal display.
Note that, however, it is not possible to return the display to normal while the turning spindle
and the C-axis are connected at the same time.
Interlocks while the [MENU ENABLE] menu item is highlighted
- Switching the operation mode to automatic is prohibited.
- Rotation of the spindle/turning spindle is prohibited.
- [−C] axis movement button is invalid.
- Rapid feed override is fixed at R1 (3%).
5-14
1. [TURNING.SPINDLE CONNECT] menu item
Conditions for operation:
The C-axis is at the second zero point with the C-axis connected, and all axes/all servo are
in stop.
Pressing the [TURNING.SPINDLE CONNECT] menu key together with the + (MF1
and MF2) keys while the conditions for operation are satisfied turns off the turning spindle
disconnection SOL (Y332) and then turns on the turning spindle connection SOL (Y331).
The menu item is highlighted when
- The turning spindle connection confirmation sensor (X2B5) turned on, and
- The turning spindle disconnection confirmation sensor (X2B6) turned off.
2. [TURNING.SPINDLE CANCEL] menu item

The C-axis is at the second zero point with the C-axis connected, the turning spindle is in
the orient stop position, and all axes/all servo are in stop.
Pressing the [TURNING.SPINDLE CANCEL] menu key together with the + (MF1
and MF2) keys while the conditions for operation are satisfied turns off the turning spindle
connection SOL (Y331) and then turns on the turning spindle disconnection SOL (Y332).
- The turning spindle connection confirmation sensor (X2B5) turned off, and
- The turning spindle disconnection confirmation sensor (X2B6) turned on.
3. [C AXIS CONNECT] menu item

The turning spindle is at the orient stop position with the turning spindle connected, the C-
axis is at the second zero point, and all axes/all servo are in stop.
Pressing the [C AXIS CONNECT] menu key together with the + (MF1 and MF2)
keys while the conditions for operation are satisfied cancels the turning spindle orientation state,
turns off the C-axis disconnection SOL (Y334) and then turns on the C-axis connection SOL
(Y333).
- The C-axis connection confirmation sensor (X2B3) turned on, and
- The C-axis disconnection confirmation sensor (X2B4) turned off.
4. [C AXIS CANCEL] menu item

The C-axis is at the second zero point with the turning spindle connected, and all axes/all
servo are in stop.
Pressing the [C AXIS CANCEL] menu key together with the + (MF1 and MF2) keys
while the conditions for operation are satisfied turns off the C-axis connection SOL (Y333) and
then turns on the C-axis disconnection SOL (Y334).
- The C-axis connection confirmation sensor (X2B3) turned off, and
- The C-axis disconnection confirmation sensor (X2B4) turned on.
5-15
5-4-4 Restoring the operation if the C-axis zero point is lost in the turning mode
The following explains the procedure for restoring the operation when the C-axis zero point is
lost in the turning mode.
Usually, it is not possible to move the C-axis in the turning mode. Therefore, if the C-axis zero
point is lost, the menu functions that allow C-axis movement in the turning mode only when the
specified conditions are satisfied are used to return the C-axis to the zero point.
< Procedure >
(1) In the turning mode, C-axis zero point lost alarm 9 ABSOLUTE POSITION MALFUNCTION
occurred.
(2) Press the (HOME) key to select the zero point return mode.
(3) In the manual mode, press the (machine menu) key, and the following menu is
displayed.
ATC MAGAZINE PALLET B AXIS SPINDLE ATC #4 ZERO #2 ZERO
MAINT. SHT.CARI MAINT. C AXIS MENU RETURN RETURN
MAINT.
(4) Press the display selector key at the left end, and the second page of the menu is displayed.
OPTION TOOL MAINTE- TOOL EYE TOOL EYE
BREAKAGE NANCE COVER COVER
DETECT OPEN CLOSE
(5) Press the [MAINTENANCE] menu key, and the following menu is displayed.
(6) Press the [MENU ENABLE] menu key together with the + (MF1 and MF2) keys.
The [MENU ENABLE] menu item is highlighted and C-axis movement is enabled.
Do not use these four menu functions.
Pressing the [MENU ENABLE] menu key or selecting other menu item while the [MENU
ENABLE] menu item is selected returns the display of the [MENU ENABLE] menu item to
normal display.
Interlocks while the [MENU ENABLE] menu item is highlighted
- Switching the operation mode to automatic is prohibited.
- Rotation of the spindle/turning spindle is prohibited.
- [−C] axis movement button is invalid.
- Rapid feed override is fixed at R1 (3%).
(7) Return the C-axis to the zero point by pressing the +C (axis movement) button.
(8) Turn off the power supply to the NC and then turn off the main power supply.
5-16
(9) Turn on the main power supply and then the power supply to the NC.
(10) Press the (HOME) key to select the zero point return mode.
(11) Press the C-axis link button to connect the C-axis.

This completes the restoration of operation if the C-axis zero point is lost in the turning mode.
5-4-5 C-axis connection mechanism
Gear ratio Wheel Worm

C-axis position encoder C-axis drive motor
Worm : Wheel C-axis Disconnected State
Worm
1 ： 122
Wheel
C-axis disconnection
C-axis zero point sensor C-axis connection confirmation sensor ON
(SQ6/X2B7) confirmation sensor (SQ221/X2B4)
(SQ220/X2B3)
C-axis Connected State
C-axis disconnection C-axis connection cylinder
confirmation sensor Connection (YV510/Y333)
(SQ221/X2B4) Worm Disconnection (YV511/Y334)
C-axis connection
confirmation sensor ON
(SQ220/X2B3)
Fig. 5-10 C-axis connection mechanism
5-17
5-5 Pallet Changer
• Vibration is excessively large Pallet load exceeds the allowable Mount workpieces according to the PART 5, 1-1 in
during pallet change cycle. limit. instructions in the OPERATING the Operating
MANUAL. Manual
• Pallet change operation does not 1. There is an interfering object. Remove the interfering object. -
start even when a pallet change 2. The home position return sensor Replace the sensor or adjust its 5-11-3
command is specified. is defective or it is not mounted position. 7-1-2, 7-1-3
• Pallet change operation stops correctly.
halfway.
3. The hydraulic valve is defective Contact Mazak Technical Center or -
or blocked. Technology Center.
4. The pallet changer rotating motor
or its drive unit is defective.
6. Loose bolts
• Pallet change operation does not 1. Insufficient capacity of external Prepare and connect the air source 6-2-3, 6-4-3
start even when a pallet change air source meeting the specifications given in
command is specified. 6-2-3 “Air source requirements”.
• The setup pin extend operation 2. The home position return sensor Replace the sensor or adjust its 5-11-3
does not complete although the is defective or it is not mounted position. 7-1-2, 7-1-3
pallet in the setup station is correctly.
indexed to the 0° position. (Although the setup pin operates,
the sensor is not turned on.)
(The setup pin does not operate.) Technology Center.
4. The air cylinder is defective.
(The solenoid valve is free of
troubles and pipes are correctly
connected.)
5. Loose bolts
• The setup pin cannot be retracted. 1. Insufficient capacity of external Prepare and connect the air source 6-2-3, 6-4-3
air source meeting the specifications given in
6-2-3 “Air source requirements”.
Technology Center.
3. The air cylinder is defective.
4. Loose bolts
• Oil leak The seal in the hydraulic cylinder has Contact Mazak Technical Center or -
been worn. Technology Center.
5-18
5-5-2 Construction of the pallet changer
Pallet changer drive motor
Pallet changer rotating unit
Pallet change hook
Loading station section
Hydraulic valve (Pallet unclamp)
Hydraulic valve (Pallet change hook UP/DOWN) Pallet changer hook clamp detection gap sensor
Fig. 5-11 Construction of the pallet changer
5-19
5-6 Hydraulic System
• Pressure is always lower than 1. Insufficient oil amount in the Replenish the specified oil. 4-6-2
7.0 MPa (1000 psi). hydraulic unit tank.
• Hydraulic oil is not discharged. 2. The hydraulic unit filter is Clean the filter. 4-6-2
• Heat generation from the pump or clogged.
motor is excessive. 3. Oil viscosity is too high. Change the oil to the specified oil. 7-1-1
4. Hydraulic unit pump or motor is Contact Mazak Technical Center or -
(There is no problems with the
wiring.)
5. The relief valve of the hydraulic
unit is defective.
6. Oil leak in the hydraulic circuit.
• Noise level gets higher. 1. The hydraulic unit filter is Clean the filter. 4-6-2
• Abnormal noise is generated. clogged.
2. Insufficient oil amount in the Replenish the specified oil. 4-6-2
hydraulic unit tank.
3. Bolts used in the hydraulic unit Tighten the bolts. -
get loose.
5. The external suction filter is Replace the filter cartridge. 5-6-2
clogged.
• Oil amount in the hydraulic unit There is oil leak in the hydraulic unit Contact Mazak Technical Center or -
tank reduces. circuit. Technology Center.
5-6-2 Maintenance of the hydraulic unit

! Shut off the power to the machine before maintaining the hydraulic unit. Failure to
observing this could cause operator's injuries or severe machine troubles.
CAUTION
1. Changing the hydraulic pressure gauge

LTD.)
< Procedure >
(1) Loosen and detach the pressure gauge.
(2) Mount the new pressure gauge after winding the threads with sealing tape.
5-20
2. Replacing the external suction filter cartridge
Replace the external suction filter cartridge by following the procedure below. Note that the
replacement interval for the external suction filter cartridge varies depending on the operating
status of the machine. The guide replacement interval is 500 to 1000 hours.
< Procedure >
(1) Fit a commercially available filter wrench or pipe wrench onto the polygonal part at the
bottom of the cartridge and loosen the cartridge to remove it.
Note : Oil will drip out at this time, so receive it with an oil pan.
(2) Apply a sufficient amount of grease or sealing agent to the gasket.
(3) Screw the new cartridge into the head.
Tighten until the gasket is crushed and the top face of the cartridge comes into contact with
the head with a tightening torque of 40 N·m (29.5 ft·lbf).
Head
Gasket
Cartridge
Compound oil control unit rear
Tightening direction
Fig. 5-12 Replacing the external suction filter cartridge
Consumable parts
Q’ty
Part Name Part No. Type Maker Remark
(pcs./machine)
Cartridge - CS08B00A001A Yamashin Filter 1
5-21
5-6-3 Hydraulic circuit diagram
Fig. 5-13 Hydraulic circuit diagram
5-22
Drawing No. 0575HCD0100
5-23
Hydraulic circuit diagram parts list

No. Parts No. Parts Name Type Maker Q’ty Remarks
1 G34WA003441 Oil control unit KMV-150-M37-001 KOUWA 1
KOUGYO
2 25754167600 Manifold 2 Dense bar
3 G27FH000220 Block MOB-01X-B5-10 FUJIKOSHI 1
4 G27FH001450 Plate MOB-G01-10 FUJIKOSHI 2
5 G16FH004412 Solenoid valve SA-G01-A3X-C1-30 FUJIKOSHI 1
6 G11FH001201 Reducing valve OG-G01-P1-21 FUJIKOSHI 1
7 G16FH004431 Solenoid valve SA-G01-E3X-C1-30 FUJIKOSHI 2

9 G27FH001980 Manifold MOB-01Y-W4-10 FUJIKOSHI 1
10 G14FH001400 Check valve OC-G01-T1-20 FUJIKOSHI 3
11 G16FH000350 Solenoid valve SA-G01-E3X-C1-11 FUJIKOSHI 3
13 G14FH001541 Pilot check valve OCP-G01-A1-21 FUJIKOSHI 1
14 G11FH001340 Reducing valve OG-G01-PC-K-20 FUJIKOSHI 1
15 G17FH000230 Flow regulator OCY-G01-A-X-20 FUJIKOSHI 1
16 G14FH001371 Pilot check valve OCP-G01-W1-21 FUJIKOSHI 1
17 G23NS001001 Switch CP-20-514 Nagano 2
18 G23NS002040 Switch CE10-373 Nagano 1 5.0 MPa (70 psi)
19 15750868813 Manifold 1 S45C
21 G17FH001900 Free flow plate MOB-G01-A-10 FUJIKOSHI 1
22 G27FH000200 Sub plate MSA-01Y-T FUJIKOSHI 1
24 G17FH000160 Flow regulator OCY-G01-W-Y-20 FUJIKOSHI 1
25 G16FH004460 Solenoid valve SA-G01-C6-C1-20 FUJIKOSHI 1
26 G27FH000170 Manifold MOB-01X-B2-10 FUJIKOSHI 1
28 G27FH001450 Plate MOB-G01-10 FUJIKOSHI 1
29 G27FH000060 Sub plate MSA-01Y-T-10 FUJIKOSHI 1
30 G14FH001371 Pilot check valve OCP-G01-W1-21 FUJIKOSHI 1
31 G17FH001160 Flow regulator OCY-G01-W-Y-20 FUJIKOSHI 1
32 G11FH001201 Reducing valve OG-G01-P1-20 FUJIKOSHI 1
33 G16FH002850 Solenoid valve SLD-G01-E3X-C1-10 FUJIKOSHI 1
34
35
36 G11FH001831 Reducing valve OG-G01-A1-21 FUJIKOSHI 1
37 G20SV022990 Cylinder CHDFFA40B-135ST SMC 1
38 G14FH001420 Check valve OC-G01-P1-20 FUJIKOSHI 1
5-24
5-7 Pneumatic System
• The pressure is lower than 1. Insufficient capacity of external air Prepare and connect the air source 6-2-3
0.5 MPa (70 psi). source meeting the specifications given in
2. Reducing valve in the air unit is Replace the reducing valve. -
defective.
3. Mist separator in the air unit is clogged. Replace the filter element. 5-7-3
4. Leak in the pneumatic circuit. Contact Mazak Technical Center or -
5. Air pressure switch, mounted in the Technology Center.
spindle unit, is defective.
• Air is constantly leaking through Automatic drain of the mist separator is Replace the mist separator. 4-6-3, 5-7-3
the drain port of the air unit. defective.
• Oil is accumulated in the mist Oil-mist concentration is high in the used air. Prepare and connect the air source 5-7-3, 6-2-3
separator for the scale. meeting the specifications given in
Replace the filter element.
Replace the dryer.
5-7-2 Construction of the air unit
Air unit for the scale air purge circuit
Air unit for the main air circuit
Mist separator Dryer Reducing valve
Reducing Mist separator Pressure release valve

valve
Fig. 5-14 Construction of the air unit
5-25
5-7-3 Maintenance of the air unit
1. Changing the filter element of mist separator

! Shut off the power to the machine by turning the main power disconnect switch to the
“OFF” position and disconnect the external air source before changing the filter element.
Attempting to replace the filter element without taking these precautions could cause
WARNING
machine damage or severe injuries.
The filter element is a consumable part and should be changed every two years.
In the list given in 7-2 “List of Wearable Parts”, “element ass’y” indicates a set of filter element, O
ring, and gasket. When changing the filter element, order the “element ass’y”.
Bolt
(1)
Body
Hole
O ring Gasket
(4)
(3)
(2) Filter
element
Upside down view of body
Housing
MC111-01143
Fig. 5-15 Changing the filter element
< Procedure >

(1) Loose the four bolts and detach the body from the housing.
(2) Fit a new O ring to the body.
(3) Fit a new gasket to the body.
(4) Insert a new filter element into the housing with the hole in the filter element facing up.
(5) Fix the body to the housing with the bolts.
5-26
2. Changing the filter element of the mist separator
[only for the scale feedback system (option)]
! Shut off the power to the machine by turning the main power disconnect switch to the
“OFF” position and disconnect the external air source before changing the filter element.
Attempting to change the filter element without taking these precautions could cause
WARNING
machine damage or severe injuries.
! When disconnecting the joint of the external air source, do so only after closing the ATC
door. If the external air source joint is disconnected while the ATC door is open, the
shutter will close by its own mass to cause machine damage or severe injuries.
The filter element is a consumable part and should be changed every two years.
In the list given in 7-2 “List of Wearable Parts”, “element ass’y” indicates a set of filter element
and O ring. When changing the filter element, order the “element ass’y”.
Body assembly
Tension bolt
Filter element assembly
Case O ring (2) Spanner hooking flats
(1) Case assembly
Fig. 5-16 Changing the filter element
< Procedure >

(1) Hold the case assembly by your hand. Remove the case assembly by turning it in the
counterclockwise direction.
(2) Set the spanner on the spanner hooking flats on the filter element. Remove the filter
element by turning it in the counterclockwise direction.
(3) Replace the filter element with a new one. Set the spanner on the spanner hooking flats
on the filter element and fix the element by turning it in the clockwise direction.
Tightening torque: 0.35 ± 0.05 N·m (0.26 ± 0.04 ft·lbf)
(4) Hold the case assembly by your hand. Hand tighten the case assembly to the body
assembly by turning the case assembly in the clockwise direction.
Tightening torque: Approx. 2.2 N·m (1.62 ft·lbf)
5-27
5-7-4 Pneumatic circuit diagram
Fig. 5-17 Pneumatic circuit diagram
5-28
Drawing No. 0575ACD0073
5-29
Pneumatic circuit diagram parts list

1 G48SV001330 Mist separator AM350-03BD-JR SMC 1
2 G45SV001010 Regulator AR3000-03G-R SMC 1
3 G54SV000340 Solenoid valve VXD02130-03-1D SMC 1
4 G50SV006070 Solenoid valve VFS2420-1D-02 SMC 1
5 G51SV000340 Silencer AN110-01 SMC 2
6 G45SV001730 Speed controller AS2051F SMC 2
7 G50SV004790 Solenoid valve VX2130-02-1D-B SMC 1
8 G20KT006070 Cylinder DA25X25-3-CS5B1 Koganei 1

9 G50SV007090 Solenoid valve VFS-1120-1D-01-F-R SMC 1
10 G50SV010190 Solenoid valve VX2120-01-1D-B SMC (1)
11 G50SV006070 Solenoid valve VFS2420-1D-02 SMC (2)
12 G51SV000340 Silencer AN110-01 SMC (4)
13 G47SV000190 Mist spray unit LMU200-10 SMC (1)
14 35764184780 Bracket 1 SPHC
16 H14SV001860 Mixing valve LMV210-20 SMC (1)
17 G54SV000590 Speed controller AS2200-02-08 SMC 1
18 G50SV008200 Solenoid valve VNC214B-10A-1D SMC 2
20 G50SV005950 Solenoid valve VX2130-02-1D-B SMC 3
21
22 G77LA000450 Mixing valve MIX-1A4B SMC 1
23 G23SV001220 Switch IS1000-01-X201 2
25 35750869620 Manifold 1 FC250
26 G50SV004890 Solenoid valve VXD2130-03-1D SMC 1
29 G54SV001040 Speed controller AS2000F-02-08 SMC 1
31 G50SV005950 Solenoid valve VX2130-02-1D-B SMC (3)
32 G50SV010130 Solenoid valve VT325-031D SMC 2
33 G45CB001380 Regulator R1000-8-L-b3 CKD 1
34 R67CB000920 Gap sensor GPS2-05-PGF-BL- CKD 2
FL280004
35 G48SV002170 Separator AFD2000-02D SMC 1
36 G48SV002180 Dryer IDG5-02B-S SMC 1
37 G45SV000820 Regulator AR2000-02G SMC 2
38 G23AM000680 Switch 176-110-100-N1 Asia 1
39 35764184770 Bracket 1 SPHC
40 G54SV001530 Speed controller AS3001F-10 SMC 1
41 G54SV000480 Speed controller AS2200F-01-06 SMC (2)
42 G54SV001720 Speed controller AS2051F-06 SMC (2)
43 G54SV001770 Speed controller AS2311F-02-08S SMC (1)
44 G73ZZ000080 Vacuum generator VUH05-016A PISCO (1)
5-30
45 G54SV001480 Speed controller AS3001F-08 SMC (1)
46
47 G14JN002540 Check valve KZU00-005E Ihara 1
48 G52SV000310 Hand valve VHS40-03-X1 SMC 1
50 G45SV000670 Regulator AR2000-02BG CKD 1
51 R67CB001140 Gap sensor GPS2-07-PGF-BL- CKD 1
FL353356
52 G54SV000270 Speed controller AS2051F-08 SMC 2
53 G14JN003200 Check valve KZU00-035E Ihara 3
54 G50SV010130 Solenoid valve VXD02130-03-1D-B SMC 1
5-31
5-8 Centralized Lubrication Unit
• Lubricating oil is not consumed. 1. Piping is blocked. Contact Mazak Technical Center or -
2. The centralized lubrication unit Technology Center.
pump is defective.
• Lubricating oil is consumed Piping is loose. Contact Mazak Technical Center or -
abnormally quickly. Technology Center.
5-8-2 Maintenance of the centralized lubrication unit

For the information on centralized lubrication unit maintenance, refer to the following sections.
4-5 “Monthly Inspection and Maintenance”
4-7 “Every One-Year Inspection and Maintenance”
5-8-3 Linear guide and ball screw lubrication

Circuit diagram and lubricating oil discharge amount (per cycle)
0.10 cm (0.0061 in ) × 4
3 3
Linear guide bearings (4 places)
X-axis 3 3
0.05 cm (0.0031 in ) Ball screw nut
0.10 cm (0.0061 in ) × 2
3 3
TAC bearings (2 places)
0.10 cm (0.0061 in ) × 4
3 3
Y-axis 3 3
0.05 cm (0.0031 in ) Ball screw nut
0.10 cm (0.0061 in ) × 2
3 3
0.10 cm (0.0061 in ) × 4
3 3
Z-axis
0.05 cm (0.0031 in ) × 2
3 3
Ball screw nut (2 places)
0.10 cm (0.0061 in ) × 4
3 3
Magazine
0.05 cm (0.0031 in ) × 4
3 3
Chain pockets (4 places)
Fig. 5-18 Centralized lubrication circuit diagram
5-32
5-8-4 Mill spindle bearing lubrication
Circuit diagram and lubricating oil discharge amount (per cycle)
Operation interval 4-minute cycle (OFF for 3 min. and ON for 1 min.)
Oil supply interval (approx.) Approx. 5 months
(assuming operations of 10 hours/day and 31 days/month)
3 3
0.03 cm (0.0018 in ) Angular bearing
3 3
3 3
3 3
3 3
0.01 cm (0.0006 in ) Roller bearing
Fig. 5-19 Mill spindle bearing lubrication circuit diagram
5-33
5-9 Spindle Cooling Unit
• The following alarm message is 1. Insufficient amount of spindle Replenish the specified spindle 4-7-1
displayed. cooling fluid cooling fluid.
203 SPINDLE OIL PRESSURE 2. Oil viscosity is too high. Change the oil to the specified oil. 7-1-1
DOWN
3. Leak in the spindle cooling circuit. Contact Mazak Technical Center or -
(Spindle cooling chiller unit) Technology Center.
4. The chiller is defective.
5. Air filter is blocked. Wash the air filter. After washing 4-7-1
the air filter, press the reset button in
the relay box of the chiller unit.
6. There is an obstacle near the Remove the obstacle and press the -
suction and/or the exhaust port. reset button in the relay box of the
chiller unit.
7. Ambient temperature is high. Use the chiller unit in the environment -
where temperature is within the
specified operating temperature
range.
If the chiller unit is directly subject to
hot air, take measures so that the
chiller unit will not be subjected to the
hot air. After that press the reset
button in the relay box of the chiller
unit.
• Spindle cooling fluid is consumed Leak in the spindle cooling circuit. Contact Mazak Technical Center or -
abnormally quickly. Technology Center.
• Noise level gets higher. 1. The filter is clogged. Clean the filter. 4-7-1
• Abnormal noise is generated. 2. Insufficient amount of spindle Replenish the specified spindle 4-7-1
cooling fluid cooling fluid.
3. Loose bolts Tighten the bolts. -
5. The chiller is defective.
• The following alarm message is Insufficient flowrate of table Clean the filter in the chiller unit. 4-7-1
displayed. lubricating oil
206 SPINDLE LUB. CHILLER
MALF.
(Table lubrication chiller unit)
5-34
5-9-2 Construction of the spindle cooling unit
Lever Cover
T-joint Suction filtert
Spindle cooling unit

[2 mm2/s (0.0031 in2/s)]
Table cooling unit
Trochoid pump
[68 mm2/s (0.11 in2/s)]
Z-axis ball screw

Y-axis ball screw
[2 mm2/s
[2 mm2/s (0.0031 in2/s)]
(0.0031 in2/s)]
Mill motor Table motor stator

stator [2 mm2/s (0.0031 in2/s)]
[2 mm2/s
(0.0031 in2/s)]
Mill spindle bearing

[2 mm2/s (0.0031 in2/s)]
X-axis ball screw
[2 mm2/s (0.0031 in2/s)]
Cross roller bearing
68 mm2/s (0.11 in2/s) Turning operation gear
Worm
Fig. 5-20 Construction of the spindle cooling unit
• Cooling fluid, cooled by the spindle cooling fluid cooling unit is fed to the axis feed ball
screws, the mill spindle motor outer case, the table drive motor (turning operation) outer
case, and the mill spindle bearings.
• Cooling fluid, cooled by the spindle cooling fluid cooling unit is fed to the turning operation
gears, cross roller bearings and worm shaft in the table.
• 68 mm2/s (0.11 in2/s) cooling fluid, heated by parts being cooled, is returned from the tank in
the table to the chiller by the trochoid pump.
5-35
5-9-3 Cooling system circuit diagram

Circuit diagram of the cooling system for the spindle and the ball screw core
Cooling the mill spindle

Cooling the Z-axis
ball screw core
Cooling the Y-axis

ball screw core
Table cooling
Oil pump
Cooling the X-axis Cooling unit

ball screw core
Compound oil control unit

Filters
Fig. 5-21 Spindle cooling circuit diagram
5-36
Circuit diagram of the table cooling system
Intermediate shaft (gear shift)

Cross roller bearing lubrication
Intermediate shaft (fixed gear)
Motor shaft
C-axis worm shaft
and bearing lubrication
6 3/4 Solenoid valve

3/8 3/8 VNC214B-10A-1D
Hose relay section 25754168390 Silencer Silencer

AN110-01 AN110-01
Fluid sensor
SI1000-8E0511-E10907
AIR IN AIR IN
Throttle valve
3/8
3.5 L/min
[0.12 ft3/min]
Solenoid valve 3/8 3/8
VNC-214B-
15A-1D
Throttle valve 3/4 1/2 1/2
Solenoid valve
2 L/min VNC214B-10A-1D
1/2
1
[0.07 ft3/min] 3/4 1/2 1/2
AIR IN 3/4 3/4 1/2 1/2

3/4 1
3/4 1/2 1/2 1

Manifold
25750869610
Trochoid pump Filter Manifold

TOP-2MY750-206HBMVB0.5 SQ-06Z-037 25750426402
Discharge: 11 L/min
[0.39 ft3/min]
Fig. 5-22 Circuit diagram of the table cooling system
5-37
5-10 Coolant System
• Coolant is not discharged. 1. The filter is clogged. Clean the filter. -
• Coolant discharge volume is 2. Coolant amount is insufficient. Replenish the specified coolant. 4-3-5
reduced.
3. Discharge nozzle is blocked. Clean the nozzle. -
• Coolant is not discharged. 1. Due to interlock Remove the cause of interlock. -
• Tool unclamp
• Pallet unclamp
• ATC cover open
• Operator’s door open
• Coolant stop menu-key ON
• Special tool selected
2. The coolant pump is defective. Contact Mazak Technical Center or -
(There is no problems with the Technology Center.
wiring.)
3. The solenoid valve is defective.
• Coolant discharge does not stop. The solenoid valve is defective. Contact Mazak Technical Center or -
Technology Center.
5-38
5-10-2 Construction of the coolant system
Through-spindle coolant
Coolant pump for flood

Flood coolant
and spindle-through coolant
Niagara coolant
Line filter for

through-spindle
coolant
Coolant pump for

Niagara coolant
Pallet changer cover coolant

Cover coolant
Coolant pump for cover coolant
and pallet changer hook coolant X-axis cover coolant
Fig. 5-23 Coolant system
5-39
5-10-3 Coolant circuit diagram
Fig. 5-24 Coolant circuit diagram
5-40
5-11 Covers
• Door interlock alarm occurred Limit switch is defective. Replace the limit switch. -
although the door is not open.
• When moving an axis, abnormal 1. The wiper of the way cover is Replace the wiper. -
noise is generated from the way damaged.
cover. 2. Way cover is defective. Contact Mazak Technical Center or -
Technology Center.
• ATC cover open operation does 1. Insufficient capacity of external Prepare and connect the air source 6-2-3
not complete. air source meeting the specifications given in
• ATC cover close operation does 6-2-3 “Air source requirements”.
not complete. 2. Proximity switch is defective. Replace the proximity switch. 5-11-3
(Although air cylinder has
operated correctly, the proximity
switch is not turned ON.)
Technology Center.
4. Air cylinder is defective.
(Solenoid valve is free of
problems and the piping is free of
disconnection.)
5. Loose bolts
5-11-2 Machine covers
Z-axis way cover
Y-axis way cover
Pallet changer safety cover
X-axis way cover
Fig. 5-25 Arrangement of cover
5-41
5-11-3 Changing the proximity sensor
Proximity sensor
Washer
Nut A
Bracket
Washer
Nut B Gap: 1.0 - 1.3 mm

(0.04 - 0.05 in)
Dog
MC111-01217
Fig. 5-26 Changing the proximity sensor
< Procedure >

(1) Remove nuts A and B by using the wrenches and then remove the sensor from the bracket.
(2) Set a new sensor in the bracket.
(3) Tighten nuts A and B temporarily.
(4) Measure the gap between the sensor front edge and the dog using the thickness gauge.
(5) Adjust the gap by turning the nuts.
Gap: 1.0 to 1.3 mm (0.04 to 0.05 in)
Since the thread pitch of the sensor is 1 mm (0.04 in), one turn of the nut moves the sensor
1 mm (0.04 in)
(6) Tighten nuts A and B at the same torque.
(7) After adjusting the sensor, operate the related machine unit and make sure that the sensor
operates ON/OFF correctly by observing the LED in the sensor.
Note: The tightening torque varies according to the distance from the front end of the sensor
head to the position of nut B. Tighten nuts A and B to the same torque within the
allowable torque ranges for them.
LED Allowable tightening torque of the nut
Dimension A ≤ 10 mm (0.39 in)

11.8 N·m (8.7 ft·lbf)
Dimension A > 10 mm (0.39 in)
19.6 N·m (14.5 ft·lbf)
A
Fig. 5-27 Proximity sensor
5-42
5-11-4 Maintenance of the X-axis way cover
! Shut off the power to the machine by setting the main power disconnect switch to the “OFF”
position before entering the machine. Otherwise, you may sustain serious or fatal injury.
WARNING
< Procedure >
(1) Move the X-axis (table) to the first zero-return point and switch off the power to the machine.
(2) Unscrews all bolts A that hold the way cover (right) to the table and slide the No. 1 cover to
the mill spindle side.
No. 3
No. 2
No. 1
Mill spindle side
(–)
X-axis
(+)
X-axis way cover (right)
Bolt A
X-axis way cover (left)
Fig. 5-28 Maintenance of the X-axis way cover (1/2)
Carry out table maintenance or clean the area inside the X-axis way cover.
(When cleaning the area inside the X-axis way cover, the left cover must also be removed.
In this case, follow the steps indicated below. If only table maintenance should be carried
out, follow the steps (12) and on after completing the maintenance.)
(3) Switch on the power to the machine.
(4) Move the X-axis (table) by turning the pulse handle near the stroke end at the mill spindle
side.
When moving the X-axis pay sufficient care so that the way cover and joint bars will not be
subject to excessive force.
5-43
(6) Unscrew all bolts C that hold the X-axis way cover (left) to the table and side the cover to the
Z-axis first zero point side.
(–)
X-axis
(+)
Bolt C
X-axis way cover (left) Z-axis first zero point side
Fig. 5-29 Maintenance of the X-axis way cover (2/2)
(7) Clean the area inside the X-axis way cover.

(8) After completing the cleaning, close the X-axis way cover (left) and tighten bolts C.
(9) Switch on the power to the machine.
(10) Move the X-axis near the first zero-point by turning the pulse handle.
(12) Pull the X-axis way cover (right) to the table side and fix the X-axis way cover (right)
removed in step (2) to the table using bolts.
(13) After recovering the X-axis way cover completely, move the X-axis (table) slowly in the
entire stroke range by turning the pulse handle to check if the X-axis way cover is correctly
fixed to the table.
If abnormal noise is generated or irregular movements of the X-axis way cover are observed,
stop the machine and review the operation step by step.
5-44
5-12 NC Unit and Electrical Control Cabinet
• Alarm message <052> blinks on Voltage of the battery used to retain Replace the battery. Instruction
the screen. the NC data is low. The data will be lost if the battery is manual of the NC
(Battery has been used to the life.) not changed.
• Error with the LCD screen Power supply to the display is faulty, Contact Mazak Technical Center or -
or the display itself is faulty. Technology Center.
• Alarm message <053> is displayed 1. Ambient temperature of the NC Lower the ambient temperature of -
on the screen. unit is higher than 40°C (104°F). the machine.
2. Cooling fan of the NC unit is Replace the NC unit cooling fan. -
defective.
• Alarm message <217, 218> is 1. Any of the motors is overloaded. Eliminate the cause of overload and 5-12-2
displayed on the screen. reset the thermal relay.
2. The unit which uses the motor for Follow the maintenance instructions 5-1 to 5-11
which the terminal relay has been for the individual units.
tripped is defective. If the cause is unknown, contact -
(The same alarm occurs again Mazak Technical Center or
soon even when the thermal Technology Center.
relay is reset after cooling the
motor.)
5-45
5-12-2 Resetting the thermal relay

If alarm message 217 THERMAL TRIP or 218 CONVEYOR THERMAL TRIP is displayed, any
of the following thermal relays is tripped. This could be caused by the overload of the related
motor.
FR11 (thermal relay under magnetic contactor KM11)･･･ For flood coolant/through-spindle
coolant pump motor
FR33 (thermal relay under magnetic contactor KM33)･･･ For cover coolant/pallet hook
coolant pump motor
FR13 (thermal relay under magnetic contactor KM13)･･･ For chip conveyor motor (option)
FR15 (thermal relay under magnetic contactor KM15)････For in-machine chip conveyor
motor 1
FR16 (thermal relay under magnetic contactor KM16)････For in-machine chip conveyor
motor 2
FR12 (thermal relay under magnetic contactor KM12)･･･ For Niagara coolant pump motor
(option)
FR1 (in the compound oil control unit) ･･･････････････････ For hydraulic oil pump
If a thermal relay is tripped, eliminate the cause and reset the thermal relay by pushing the
corresponding reset button as shown below (Fig. 5-30). Thermal relay (other than FR10) are
provided in the control panel.
FR10 to FR16
Reset button
Fig. 5-30 Thermal relay
5-46 E
INSTALLATION 6
6 INSTALLATION
6-1 Precautions on Installing the Machine

! Before starting the installation work, read Chapter 2 “SAFETY PRECAUTIONS” and make
sure you thoroughly understand the information in this Chapter.
WARNING ! The floor must be completely dry and free of oil so that operators will not slip and fall during
carrying and installation of the machine, electrical work, machine adjustments, or other
work.
! Safety equipment (helmet, goggles, safety shoes, etc.) and clothing appropriate for the
work to be undertaken must be worn.
! Use wire rope or slings whose specifications state that they can support the weight to be
lifted, and inspect them for any abnormality before use.
! Lifting aids such as wire rope and slings must be secured at the specified locations, and the
lifting angle must be correct.
! During piping and wiring work, check the matchmarks between the hose and fitting location
when fitting hoses.
! Prepare an air source that meets the external air source requirements.
! Prepare a power source that meets the external power source requirements.
! When connecting the main power disconnect switch to the power source, carry out piping
work such that the main power disconnect switch box is protected to IP54 standards.
! When carrying out machine adjustments, refer to the safety considerations relating to
safety devices and make sure that all safety devices function correctly.
6-1
6 INSTALLATION
6-2 Preparing for Installation
6-2-1 Environmental requirements
1. Machine
A. Ambient temperature
+5 to +40°C (+41 to +104°F)
Note: This indicates the temperature range for permitting normal machine operation but it
does not indicate the range that allows machining accuracy to be maintained.
B. Atmosphere
Avoid the following places for installing the machine.
• Places where the machine is exposed to direct sunlight, near a heat source, or temperature
varies excessively.
• Places near the exit where external air will flow in.
• Take into consideration environment so that machine generating heat will be easily
dissipated.
• Do not apply wind blown from the air conditioner directly to the machine.
• Places where the floor is not strong enough to support the machine.
• Places near vibration generation equipment.
• Humid and dusty places.
Note 1: If the machine has to be installed near vibration-generating equipment, make
foundation according to the specification of Mazak and take appropriate measures
against vibration.
Note 2: If the soil is weak, reinforce it by driving piles to avoid settling and subsidence of the
soil after the installation of a machine.
6-2
INSTALLATION 6
2. NC
A. Ambient temperature
Allowable temperature range during machine operation: +5 to +40°C (+41 to +104°F)
B. Relative humidity
Allowable relative humidity during operation: 30 to 75% (no condensation)
Note: As humidity increases, it impairs insulation and also accelerates deterioration of
electric component parts. Although it is not necessary to take special dehumidifying
measures, installation of a machine in humid places should be avoided.
C. Atmosphere
Although installation of the machine should be avoided in a dusty area or area where there is
high concentration of organic or corrosive gas, if the machine must be operated under such
environment, consult Mazak for appropriate measures.
D. Vibration
Allowable maximum vibration during operation: 4.9 m/s2 (16.08 ft/s2) or lower
Allowable maximum vibration during transportation: 34.3 m/s2 (112.53 ft/s2) or lower
3. Requirements for maintaining the guaranteed accuracy
A. Basic requirements
The machine should be installed at a site with tightly-packed soil no vibration-generating
equipment nearby.
B. Environmental requirements (air conditioned)

Ambient temperature: 20 ± 2°C (68 ± 3.6°F)
Temperature variation: 1°C (1.8°F)/30 min or lower
Relative humidity: 75% or lower
Dust and other foreign matter: 0.3 mg/m3 or lower
6-3
6 INSTALLATION
6-2-2 External power source requirements

! To prevent electric shock, ground the machine to earth in compliance with the applicable
local regulations. In Japan, grounding of class C or higher (grounding resistance 10 Ω or
lower) is required.
WARNING
If the specified class of grounding work is impossible due to restrictions such as machine
installation place environment, class D grounding (grounding resistance is 100 Ω or lower)
can be applied by mounting a earth leakage breaker (option) to the main power disconnect
switch.
! Use cable conductors that meet the following requirements
(200 VAC power source)
Primary power cable: 150 mm2 (0.233 in2) or larger ([MLFC equivalent] Max. allowable
temperature of insulator: 110°C (230°F))
Grounding cable: 80 mm2 (0.124 in2) or larger
For details of the power source connection cable specifications corresponding to the
available source voltage, refer to Table 6-2 “List of total power requirements”.
Cable specifications are given in three groups of input voltages, [1] 200/220/230/240 VAC,
[2] 380/400/415 VAC, and [3] 440/460/480 VAC.
Note 1: When an earth leakage breaker is used, select one with a trip current of 200 mA. One
with a trip current of 30 mA cannot be used for this machine equipped with inverters.
If an earth leakage breaker is to be used, select the type that is appropriate for the use
in the circuit where inverter driven equipment is connected.
(This Note applies to the machine for Japanese market.)
Note 2: Use an AC inverter-use circuit breaker as the main power disconnect switch of the
factory. If an AC inverter-use circuit breaker is not used, the breaker may be tripped by
the characteristic high-frequency leakage current of the AC inverter.
1. Power source voltage

Allowable input voltage of the machines is determined from the following three groups according
to the machine specifications. Make sure to check the allowable input voltage of your machine
before connecting it to the power source.
[1] Voltage: 200/220/230/240 VAC, 3 phase
[2] Voltage: 380/400/415 VAC, 3 phase
[3] Voltage: 440/460/480 VAC, 3 phase
Permissible voltage fluctuation: ±10%
2. Frequency
50/60 Hz ±1%
6-4
INSTALLATION 6
3. Total power requirements
When installing the machine, the machine may malfunction if the power capacity is insufficient
and the service life of the electric parts will be shortened.
In some cases, this may incur serious problems from the standpoint of safety. Therefore,
always pay sufficient attention to the power facility so that sufficient power can be supplied to the
machine.
Table 6-1 Power source
Frequency 50/60 Hz ±1%

Voltage 3 phases (3 lines) 200/220/230/240 V
3 phases (3 lines) 380/400/415 V
3 phases (3 lines) 440/460/480 V
Permissible voltage ±10%
fluctuation
Grand total of power See the separate table.
requirement * Install the transformer having the capacity (kVA) larger than
the grand total of the continuous rating.
Power source See the separate table.
connection cable * Provide the earth (metallic conduit wiring) having grounding
resistance of 10 Ω or less.
6-5
6 INSTALLATION
Table 6-2 List of total power requirements
Machine
10000 min–1
specifications
Item
40/80 tools 120/160 tools
Motor output
Spindle drive Continuous rating 30 kW/37 kW 42
motor Short-period rating 52 (30 min)
Servomotors X-axis 7.0 kW 79.94
Y-axis 7.0 kW 89.74 (30 min)
Z-axis (master) 11.0 kW
Z-axis (slave) 11.0 kW
B-axis 7.0 kW
C-axis 4.5 kW
Power requirement MATRIX 0.2
of NC
Other motors Hydraulic unit motor 2.2 kW 2.01
Chiller unit 1 3.91 kW 6.32
Chiller unit 2 1.5 kW 2.50
Flood coolant pump 1.21 kW 1.57
motor
Cover coolant pump 0.88 kW 1.15
motor
Spiral conveyor 0.4 kW 0.52
Magazine drive 1.5 kW 1.96 4.58
motor
Total power requirement 16.25
ATC arm drive motor 1.5 kW (2.5 kW) Not added
Tool shifter drive motor 1.5 kW (2.5 kW) Not added
Tool carrier drive motor 0.2 kW (0.26 kW) Not added
Pallet changer 1.5 kW (2.5 kW) Not added
Control circuit 1.1
(including slideway lubrication motors
and cooling fans)
Grand total of power requirement (kVA) Continuous rating 100.4 103.1
Short-period rating 110.3 112.9
Power source connection cable size: [MLFC equivalent]
Selection on the specifications of “Max. allowable temperature of insulator: 110°C (230°F)”
Input voltage [1] 200/220/230/240 V [2] 380/400/415 V [3] 440/460/480 V
2
Power source connection cables Power cable 150 mm 80 mm2 80 mm2
(Ambient temperature: (0.23 in2) (0.12 in2) (0.12 in2)
30°C (86°F) or lower) Grounding cable 80 mm2 38 mm2 38 mm2
(0.12 in2) (0.06 in2) (0.06 in2)
6-6
INSTALLATION 6
6-2-3 Air source requirements
Pressure 0.5 to 0.9 MPa (70 to 130 psi)
Minimum discharge Standard 700 L/min (ANR) [24.72 ft3/min (ANR)]:
Equivalent to 7.5 kW compressor
With air blast option 950 L/min (ANR) [33.55 ft3/min (ANR)]:
Equivalent to 7.5 kW compressor
Dew point −17°C (1.4°F) or lower (at atmospheric pressure)
Oil mist concentration 30 mg/m3 (0.0000018 lbs/ft3) or lower
Note: Supply clean air containing a minimum of water and moisture.
Do not supply the air directly from the air compressor by connection through a short
pipe. If the air is supplied directly from the compressor, hot air will be cooled in the
machine and water and oil contained in the air will condense, blocking the valves and
piping, corroding the related parts, and, in the worst case, resulting in the seizure of the
spindle bearings.
If the air to be supplied contains a large amount of water or it is hot, use auxiliary
equipment like an air drier.
6-7
6 INSTALLATION
6-2-4 Items to be confirmed when carrying the machine
1. Machine dimensions
In order to carry the machine into the plant, an entrance that will allow the machine to pass
through must be available (dimensions indicated in Fig. 6-1).
Fig. 6-1 Machine dimensions when carrying into the plant
Machine W H D
Standard 3500 (137.80) 3316 (130.55) 6135 (241.54)
High-torque table 3500 (137.80) 3316 (130.55) 6480 (255.12)
Unit: mm (in)
6-8
INSTALLATION 6
6-2-5 Foundation work
! If the machine has to be installed near vibration-generating equipment, make foundation
according to the specification of Mazak and take appropriate measures against vibration.
CAUTION ! If the soil is weak, reinforce it by driving piles to avoid settling and subsidence of the soil
after the installation of a machine.
For machine installation, select a flat place; avoid places subject to direct sunlight, humid places,
and places near vibration generation equipment. Although required foundation work will vary
according to soil conditions, it is necessary to compact the ground well or pour concrete to avoid
settlement or inclination of the soil after machine installation.
• Foundation parts
Quantity
Part Name Part No.
40/80-Tool 120-Tool 160-Tool
Plate 31276624280 3 3 3
Collar 44716100040 22 22 22
Anchor bolt 34716100030 22 22 22
Bushing 44716100301 22 22 22
Plate 34716100010 22 22 22
Collar 44716100020 22 22 22
Block 14746100580 22 22 22
Block 34746100590 22 22 22
Block 34746100600 22 22 22
Bolt 44746100610 22 22 22
Plate 31276624270 5 6 8
Bolt 34710400020 5 6 8
Nut 34710400030 5 6 8
Washer 42456104710 2 2 3
Anchor bolt A05UJ001080 2 2 3
Hexagonal socket head screw A06CB161200 2 2 3
M16 × 120
Hex. Nut M24 A40JJ00M240 22 22 22
Washer, M24 A41JJ00M240 22 22 22
Set screw M6 × 16 A15B06X0160 44 44 44
6-9
6 INSTALLATION
6-3 Installation
6-3-1 Precautions on installation

! Two or more workers must handle heavy objects.
! Use wire rope or a sling that can bear the weight to be lifted.
WARNING ! The machine must be lifted properly. Lift the machine slightly off the floor to check if it is
well balanced.
! The angle made by the wire rope or sling must be less than 60°.
! Before lifting the machine, check that each machine unit is fixed in position and that there
are no tools or anything else on the machine.
CAUTION
6-3-2 Lifting
Lift the machine in the manner as shown in Fig. 6-2.
Before lifting the machine, remove the X-axis way cover (left) and the cosmetic cover on the
upper part opposite the operator’s door. (The machine is shipped with these covers removed.)
Refer to 5-11 “Covers” and 6-3-4 “Unpacking, inspection and cleaning”.
1. At the machine front side: Fix the lifting blocks on the upper face at the base front
(2 places) and hook the wire ropes on them [1].
At the machine rear side: Hook the wire rope on the lifting hooks (2 places) at the top of
the column [2].
2. Fix the machine units at the following positions using shipping brackets.
Spindle head (Y-axis)･･･････At the center of Y-axis stroke [3]
Table (X-axis) ･･････････････–1155 [4]
Saddle (Z-axis) ･････････････–1040 [5]
3. The wire rope and the crane must have the capacity indicated below.
Wire rope ･･････････At least 32 mm (1.26 in) diameter [6]
Crane ･･････････････At least 30 t (66000 lbs)
4. Place wood blocks or pads between the machine and wire ropes so that the machine will
not be damaged by direct contact of the wire ropes.
5. When lifting the machine, pay attention so that the wire ropes will not touch the piping,
hydraulic equipment, wiring, control equipment, and covers.
6. Make sure that the drain ports of hydraulic oil tank, coolant tank, and lubricating oil tank are
all securely tightened so that oil will not leak.
7. When carrying the machine using rollers, pay attention so that impact will not be applied to
the machine.
6-10
INSTALLATION 6
Machine body
4 5
Fig. 6-2 Lifting the machine
6-11
6 INSTALLATION
6-3-3 Masses of machine units

Unit: kg (lbs)
e-1060V/6 II
Machine body (standard specifications) 34620 (76324.10)
Coolant tank 590 (1300.73)
Chip conveyor (front discharge type) 720 (1587.33)
Note: The figures indicated in the machine plates shall be applied if ones in the manual may
differ.
6-3-4 Unpacking, inspection and cleaning
1. Removing the shipping brackets

The machine is shipped with its units fixed in place with shipping brackets so that they will not
move during transportation. After installing the machine, remove all of shipping brackets.
Store the removed shipping brackets and bolts in a suitable place to allow for reuse during
movement or transport of the machine in the future.
2. Installing the cover and other part

Install the cover and other part which are supplied in separate packages.
Installing the X-axis way cover
Install the X-axis way cover by referring to the explanation given in 5-11 “Covers”.
3. Cleaning
Slideways and other machine parts are coated with rust preventive oil to protect the metallic
surfaces from rusting.
Since sand grits, dust and other foreign matter tend to stick to this rust preventive coating during
the transportation of the machine, do not operate the machine before cleaning the machine.
Remove rust preventive oil with rag soaked with washing oil.
Note: Take care to avoid entry of cleaning oil into the slideway surfaces passing the wiper.
6-12
INSTALLATION 6
6-3-5 Location of the shipping brackets
Tool to be used: Allen wrench (10 mm, 17 mm)
Shipping bracket fixing the saddle (red)
Shipping bracket fixing the spindlehead

- Magazine side (red)
Shipping bracket fixing the table

- Column side (red)
Block for lifting the

machine (red) Shipping bracket fixing the table Shipping bracket fixing
- Pallet changer side (red) the spindlehead
- Operator side (red)
Fig. 6-3 Location of the shipping brackets
6-13
6 INSTALLATION
6-3-6 Installing the machine

Machining accuracy is greatly influenced by installation conditions. No matter how precisely the
slideway surfaces have been finished, machining accuracy will still be poor if the machine is not
correctly installed.
Tools to be used: Allen wrench (3 mm)
Wrench (24 mm, 32 mm, 46 mm )
1. Temporary leveling adjustments
< Procedure >

(1) With the machine lifted, fit the foundation bolts and foundation plates to the leveling bolt
holes in the machine.
(2) Lower the machine gently so that the foundation bolts are correctly inserted into the
foundation holes prepared according to the foundation plan.
Note: During this step, the leveling bolts cannot be used; pull them up from the bottom of the
machine.
(3) Adjust the machine level temporarily by driving wedges under the machine.
(4) After leveling the machine temporarily, fix the foundation bolts with mortar.
When fixing the foundation bolts with mortar, the steel foundation plate bottom surface may
be coated with grease to cut off the air.
(4.25)
108
(3.94)
100
φ24
(0.94)
(15.75)
400
230
(9.06)
180 (7.09) 140 (5.51)

Unit: mm (in)
320 (12.60)
Fig. 6-4 Foundation bolts
6-14
INSTALLATION 6
2. Checking interconnections
After temporary leveling is finished, check and confirm the following items before switching the
power on.
• Grounding (class C grounding work)
• Screws at terminals (must be tight)
• Connection of cannon connectors and other connectors
• Relays (must be fitted and connected correctly)
3. Final level adjustment

After the mortar has cured, adjust the machine level using the leveling bolts. Place precision
levels on the bed and pallet upper surface.
Precision level accuracy: 0.02 mm (0.00079 in)/division
For details on the procedure used to adjust the machine level and allowable leveling error, refer
to the accuracy table supplied with the machine.
After tightening the leveling nuts and foundation bolts, check the machine level again.
6-4 Connecting to the Power and Air Sources
6-4-1 Connecting to the power source

! Do not connect the power cable to the shop power distribution board until all installation
work has been completed.
DANGER
< Procedure >
(1) Unscrew the bolts holding the main switch box cover in place, turn the switch to the “OPEN
RESET” position and remove the cover.
Fig. 6-5 Connecting the power supply cable (1/2)
(2) Pass the power supply cable into the main switch box through the hole at the back of the
electric control cabinet.
6-15
6 INSTALLATION
(3) Connect the wires to the R, S, and T terminals and the ground terminal of the NFB (no-fuse
breaker).
MC111-01337
Fig. 6-6 Connecting the power supply cable (2/2)
6-16
INSTALLATION 6
6-4-2 Grounding
1. All electrical devices must be grounded in order to protect personnel and machines from
electrical hazards. Grounding must be performed after the machine has been installed in
accordance with the standards for electrical equipment.
2. Ideally, the grounding point should be as close as possible to the machine, but depending
on the machine installation site this may not always be possible.
3. The work must be performed by personnel with publicly recognized qualifications. This will
depend on the size of the company, but generally there will be a chief engineer or someone
licensed to perform electrical work who should be asked to carry out the work. The work
must be done in compliance with the applicable regulation (class C grounding in Japan).
Grounding resistance: 10 Ω max.
Cross-sectional area of wires: Refer to Table 6-2 “List of total power requirements”
Measuring equipment: Earth resistance tester
! To prevent electric shock, ground the machine to earth in compliance with the applicable
local regulations. In Japan, grounding of class C or higher (grounding resistance 10 Ω or
lower) is required.
WARNING
If the specified class of grounding work is impossible due to restrictions such as machine
installation place environment, class D grounding (grounding resistance is 100 Ω or lower)
can be applied by mounting a earth leakage breaker (option) to the main power disconnect
switch.
Note 1: When an earth leakage breaker is used, select one with a trip current of 200 mA. One
with a trip current of 30 mA cannot be used for this machine equipped with inverters.
If an earth leakage breaker is to be used, select the type that is appropriate for the use
in the circuit where inverter driven equipment is connected.
Note 2: Use an AC inverter-use circuit breaker as the main power disconnect switch of the
factory. If an AC inverter-use circuit breaker is not used, the breaker may be tripped by
the characteristic high-frequency leakage current of the AC inverter.
! The grounding work must be entrusted to an electrical engineer with publicly recognized
qualifications. If the work is done by an unqualified person, it could result in serious injury,
death, or damage to the machine.
WARNING
6-17
6 INSTALLATION
4. The connections between the machines and ground should be made as indicated below.
! Never perform wiring as shown below.
WARNING
Machine Machine Machine
Fig. 6-7
When the grounding work is performed, no more than one wire should be connected to any
terminal. The reason for this is to prevent a serious accident. For example, if a wiring plan
like the one shown above is used, a faulty connection at one of the terminals could cause
short-circuited current from another terminal to be fed back to the machine, resulting in
serious damage.
- Independent connections
Each grounding resistance = 10 Ω max.
Fig. 6-8
- Common connection
The wires from the grounding terminal should be directly connected to each of the
machines.
10
Grounding resistance = Ω
Number of machine
Fig. 6-9
6-18
INSTALLATION 6
6-4-3 Connecting to the air source
Connect the air hose to the connection port of the air unit.
Mist separator
Reducing valve
External air source

connection port
Fig. 6-10 Air unit
6-19
6 INSTALLATION
6-5 Test Run
6-5-1 Checking the machine before starting test run

1. Make sure that the lifting fixture and the shipping brackets are all removed.
If the machine is operated while they are still attached, the machine will be damaged.
2. Make sure that there are no missing parts or accessories.
3. Make sure that the centralized lubrication unit tank is filled with the specified lubricating oil to
the specified level.
4. Make sure that the hydraulic unit tank is filled with the specified oil to the specified level.
5. Make sure that the spindle cooling fluid tank and the turning spindle lubricating oil tank are
filled with the specified oil to the specified level.
6. Make sure that the hoses and cables of the circuits for hydraulic, pneumatic, and coolant
circuits are correctly connected.
7. Make sure that the coolant tank is correctly placed.
Make sure that the coolant receiving opening in the tank is correctly placed under the chip
disposal duct.
8. Make sure that the connection to the air source is correct.
6-5-2 Electric inspection before switching the power ON
1. Check the phase sequence of power supply

If the NC power is switched on while the phase sequence of power supply is incorrect, trouble
such as runaway of the machine and blowing of fuses will occur. Therefore, under no
circumstances switch on the NC power until the phase sequence is confirmed to be correct.
A. Checking the phase sequence with the phase tester

Connect the phase tester to the transformer as shown in the illustration below (U ↔ R, V ↔ S,
W ↔ T). The phase tester must show clockwise rotation.
Transformer Phase tester
Fig. 6-11 Checking the phase sequence
6-20
INSTALLATION 6
2. Receiving power
If the phase sequence is correct, the main switch may be turned on.
For the machine using the mill spindle drive motor:
Turn on the main switch and check the indication of the LED lamps at the front panel of the
spindle controller. Make sure that the LED lamps do not show an alarm indication.
Correct
Alarm
If any of the following letters is displayed in this position,

it indicates that alarm has occurred.
1, 2, 3, 4, 5, 6, and E
Fig. 6-12
6-5-3 Checking the parameter settings

Check the present parameter settings by referring to the parameter table in the electrical control
cabinet.
6-5-4 Checking the machine in manual operation

Operate the machine manually to make sure that the following operations are executed correctly.
• Spindle rotation (mill spindle and turning spindle)
• Axis movement (X-, Y-, and Z-axis)
• ATC cycle
• Zero-point return
6-5-5 Breaking in operation

When operating the machine for the first time after the installation, pay special attention so that
the machine can operate without abnormalities.
Breaking in operation should be carried out for approximately 8 hours. During breaking in, do
not apply a large load to the machine.
The machine is shipped with the program for breaking in operation (Pno. 6000) already input;
use this program for breaking in operation (approx. 8 min/cycle).
6-21
6 INSTALLATION
- MEMO -
6-22 E
APPENDIX 7
7 APPENDIX
7-1 List of Sensors, Limit Switches, and Oiling Points
7-1-1 List of oiling points

The lubrication period is decided on the basis of eight hours operation a day.
In case of the failure to change cooling fluid and use of other oil, some problems may be
produced in the machine.
Fig. 7-1 Lubricating point
No. Lubrication Point Q’ty Recommended Oil Remarks Refer to

1 Mill spindle 3 L (0.11 ft3) MOBIL DTE 24 Proper amount of 4-4-1
SHELL TELLUS OIL 32 lubricant is
3
automatically supplied.
2 Slide way 3 L (0.11 ft ) MOBIL VACTRA OIL No. 2
Clean the filter every
Ball screw SHELL TONNA OIL S68
year.
3 Table 30 L (1.06 ft3) MOBIL SHC626 Change oil and clean 4-7-1
4 35 L (1.24 ft3) the filter every year.
5 B-axis 12 L (0.42 ft3) MOBIL SHC629

3
6 Spindle cooling unit 108 L (3.81 ft ) MOBIL VELOCITE OIL No. 3
3
7 Hydraulic power unit 60 L (2.12 ft ) MOBIL DTE 24
SHELL TELLUS OIL 32
3
8 Shifter 3.6 L (0.13 ft ) MOBIL VACTRA OIL No. 2 Change oil every year. 4-7-1
9 ATC 6 L (0.21 ft3) SHELL TONNA OIL S68
10 Carrier linear guide 2.4 cm3 × 2 <Grease> Supply grease every 6 4-6-2
(0.15 in3 × 2) MOBIL MOBILUX EP2 months in manual
operation.
11 Carrier ball screw 2.4 cm3 SHELL ALVANIA GREASE RL2
(0.15 in3)
12 ATC door linear guide 1.1 cm3 × 4
(0.07 in3 × 4)
13 NC control panel 1.1 cm3 × 4
linear guide (0.07 in3 × 4)
14 Counter balance 100 cm3 × 2 <Grease>
(6.10 in3 × 2) SH33M (PASCAL)
7-1
7 APPENDIX
7-1-2 List of sensors and limit switches
Fig. 7-2 List of sensors and limit switches
7-2
APPENDIX 7
7-3
7 APPENDIX
Fig. 7-3 Table specifications
Fig. 7-4 Mill spindle specifications
7-4
APPENDIX 7
Fig. 7-5 Tool measurement specifications
7-5
7 APPENDIX
7-2 List of Wearable Parts

Service life of wearable parts below will vary according to the conditions under which they are
used.
Location Name Part No. Type Manufacturer To be Changed in Refer to

Air unit Element ass’y G48SV00130A AM-EL350 SMC 2 years 5-7-3
Element ass’y G48SV00217B AFD20P-060AS SMC 2 years 5-7-3
Centralized Filter set G06LAP00140 489011 Lube 3 years -
lubrication unit
Way cover X-axis 55755101200 - MAZAK 3 years -
(R: Column side)
wiper set
X-axis 55755100900 - MAZAK 3 years -
(L: Pallet changer side)
wiper set
Y-axis wiper 55765200200 - MAZAK 3 years -
(left/right set) (Remark 1)
X-axis pantograph 25755139410 - MAZAK As needed -
(R: Column side)
(Note 1)
X-axis pantograph 25755139140 - MAZAK As needed -
(Note 1)
Y-axis pantograph 25765217840 - MAZAK As needed -
(Note 2)
Z-axis pantograph Z33HV00744H - HAUSUNG As needed -
(upper right) (Note 3)
Z-axis pantograph Z33HV00745H - HAUSUNG As needed -
(upper left) (Note 3)
Z-axis pantograph Z33HV00679G - HAUSUNG As needed -
(lower right) (Note 4)
Z-axis pantograph Z33HV00680G - HAUSUNG As needed -
(lower left) (Note 4)
Machine light Fluorescent tube R61MB000281 FA21021P111 Matsushita 1 year -
Table Lubrication section filter G30TP000800 SFN-06-100K Taisei 1 year -
Remark 1: The term Y-axis wiper refers to the set of parts indicated as [1] in the figure below.
[1]
[1]
Note 1: Order two pantographs for one X-axis way cover.

Note 2: Order four pantographs for one Y-axis way cover.
Note 3: Order three pantographs for one upper Z-axis way cover.
Note 4: Order four pantographs for one lower Z-axis way cover.
7-6
APPENDIX 7
Y-axis way cover
Z-axis way cover
(upper/lower right)
Z-axis way cover

(upper/lower left)
X-axis way cover
(R: Column side)
X-axis way cover

Fig. 7-6 Location of the way covers
7-7
7 APPENDIX
- MEMO -
7-8 E

Maintenance Manual: INTEGREX E-1060v/6 II

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Maintenance Manual: INTEGREX E-1060v/6 II

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MAINTENANCE MANUAL

Manual No.: H575MA0050E

1 INTRODUCTION .................................................................................. 1-1

1-1 Outline of the Machine........................................................................................1-1

1-1-1 Intended use of the machine .................................................................................. 1-1

1-1-2 Operating positions................................................................................................. 1-1

1-1-3 Features.................................................................................................................. 1-2

1-2 List of Manuals to Be Used.................................................................................1-3

1-3 Numbering System for Pages.............................................................................1-3

1-4 Numbering System for Figures and Tables ........................................................1-3

2 SAFETY PRECAUTIONS..................................................................... 2-1

2-1 Rule ....................................................................................................................2-1

2-2 Basic Safety .......................................................................................................2-1

2-3 Safety Considerations Relating to Operators including Clothing ........................2-3

2-4 Safety Considerations Relating to Machine Operation .......................................2-3

2-5 Safety Considerations Relating to Holding Workpieces and Tooling ..................2-4

2-6 Safety Considerations Relating to Maintenance .................................................2-5

2-7 Safety Considerations Relating to Workplace ....................................................2-7

2-8 Safety Considerations Relating to Chip Conveyor..............................................2-7

2-9 Safety Considerations Relating to Pallets...........................................................2-7

2-10 Safety Considerations Relating to Faceplate Jaws.............................................2-8

2-11 Safety Considerations Relating to Safety Devices..............................................2-8

2-12 Remarks on the Cutting Conditions Recommended by the NC..........................2-8

2-14 Safety Considerations Relating to Mounting or Changing the Chuck

2-16 Safety Devices .................................................................................................2-17

2-17 Safety Plate Locations......................................................................................2-19

3 OUTLINE OF THE MACHINE STRUCTURE ....................................... 3-1

3-1 Overview of Machine Units.................................................................................3-1

3-2 Definition of Coordinate Axes .............................................................................3-5

3-3 Maintenance Cover ............................................................................................3-6

4 REGULAR INSPECTION ..................................................................... 4-1

4-2 Table of Inspection and Maintenance Items .......................................................4-2

4-3 Daily Inspection and Maintenance......................................................................4-5

4-3-1 Inside the machine.................................................................................................. 4-5

4-3-2 Outside the machine............................................................................................... 4-6

4-3-3 Checking oil levels .................................................................................................. 4-6

4-3-4 Checking pressures (hydraulic and air) .................................................................. 4-7

4-3-5 Changing or replenishing oils ................................................................................. 4-7

4-3-6 Around the machine................................................................................................ 4-8

4-3-7 Checking the Z-axis servo load .............................................................................. 4-8

4-4 Weekly Inspection and Maintenance ..................................................................4-9

4-4-1 Changing or replenishing oils ................................................................................. 4-9

4-5 Monthly Inspection and Maintenance ...............................................................4-14

4-5-1 Around the machine.............................................................................................. 4-14

4-6 Every Six-Month Inspection and Maintenance .................................................4-14

4-6-1 Changing or replenishing oils ............................................................................... 4-14

4-6-2 Greasing ............................................................................................................... 4-16

4-6-3 Around the machine.............................................................................................. 4-22

4-7 Every One-Year Inspection and Maintenance ..................................................4-28

4-7-1 Changing or replenishing oils ............................................................................... 4-28

4-7-2 Around the machine.............................................................................................. 4-35

5 MAINTENANCE OF MAJOR UNITS .................................................... 5-1

5-1 Mill Spindle and B-axis .......................................................................................5-1

5-1-1 Troubleshooting ...................................................................................................... 5-1

5-1-2 Construction of the spindlehead ............................................................................. 5-3

5-2 X-axis, Y-axis, Z-axis..........................................................................................5-4

5-2-1 Troubleshooting ...................................................................................................... 5-4

5-2-2 Construction of the axis drive systems ................................................................... 5-5

5-3 ATC Magazine..................................................................................................5-10

5-3-2 Construction of the ATC magazine....................................................................... 5-11

5-4 Table ................................................................................................................5-12

5-4-1 Troubleshooting .................................................................................................... 5-12

5-4-2 Construction of the table....................................................................................... 5-13