Serial Number 339746

Original Instructions

MAINTENANCE MANUAL

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QUICK TURN

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200MB, 200MY, 200MS, 200MSY

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250MB, 250MY, 250MS, 250MSY

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Manual No.: UB72MA0018E0

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NC: MAZATROL SmoothG

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Serial No.:
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39 rp
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Before using this machine and equipment, fully understand the contents of this
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manual to ensure proper operation. Should any questions arise, please ask the
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nearest Technical Center or Technology Center.

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IMPORTANT NOTICE
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1. Be sure to observe the safety precautions described in this manual and the contents
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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
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as possible.
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2. No modifications are to be performed that will affect operation safety.

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3. For the purpose of explaining the operation of the machine and equipment, some
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illustrations may not include safety features such as covers, doors, etc. Before
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operation, make sure all such items are in place.

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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.
7. The export of machining programs may be restricted to prevent them from being
used for military purposes. The machining programs you prepared are your property,
so you should manage them yourself in accordance with the law.
Issued by Manual Publishing Section, Yamazaki Mazak U.K. Limited
10. 2021-R0

Copyright (C) 2017 YAMAZAKI MAZAK CORPORATION. All Rights Reserved.

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Serial Number 339746

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 Serial Number 339746

CONTENTS

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

1-1 Machine Overview .............................................................................................. 1-1

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

1-1-2 Operating position................................................................................................... 1-2

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

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1-2 List of Manuals to Be Used ................................................................................. 1-5

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1-3 Numbering System for Pages ............................................................................. 1-5

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1-4 Numbering System for Figures and Tables ........................................................ 1-5

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1-5 Revision Code .................................................................................................... 1-6
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2 SAFETY PRECAUTIONS ..................................................................... 2-1

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2-1 Rules .................................................................................................................. 2-1

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2-2 Residual Risks .................................................................................................... 2-2

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2-3 Basic Safety Items .............................................................................................. 2-5

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2-4 Clothing and Personal Safety ............................................................................. 2-7

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2-5 Safety Items Related to Operation...................................................................... 2-7

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2-6 Safety Items Related to Gripping Workpiece and Tooling (in Turning) ............... 2-9
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2-7 Safety Items Related to Gripping Workpiece and Tooling (in Milling) ................. 2-9

2-8 Safety Items Related to Maintenance ............................................................... 2-10

2-9 Safety Items Related to Workplace .................................................................. 2-11

2-10 Safety Items Related to Chip Conveyor............................................................ 2-12

2-11 Safety Equipment ............................................................................................. 2-12

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

2-13 Safety Plates .................................................................................................... 2-13

2-14 Safety Devices ................................................................................................. 2-14

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

3-1 Major Components ............................................................................................. 3-1

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3-2 Maintenance Cover ............................................................................................ 3-5

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4 REGULAR INSPECTION AND MAINTENANCE .................................. 4-1

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4-1 General............................................................................................................... 4-1

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MAINTENANCE CHECK Display ....................................................................... 4-2
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4-3 Maintenance/Inspection Items ............................................................................ 4-4

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4-4 Checking the Coolant Temperature Control Unit (Option) ................................ 4-10
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4-5 Supplying Oil and Coolant ................................................................................ 4-11

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

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5-1 Headstock/Hydraulic Chuck ............................................................................... 5-1

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5-1-1 Construction and operation ..................................................................................... 5-1

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5-1-2 Greasing and lubrication ......................................................................................... 5-3

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5-1-3 Adjustment of the chuck clamp/unclamp proximity switches .................................. 5-5

5-1-4 Replacement of the chuck ...................................................................................... 5-6

5-1-5 Checking the headstock for disturbed accuracy in the event of collision ................ 5-8

5-1-6 Cleaning.................................................................................................................. 5-9

5-1-7 Chuck assembly interface ..................................................................................... 5-11

5-2 Turret ................................................................................................................ 5-13

5-2-1 Construction and operation (MB, MS, MY, MSY specifications) ........................... 5-13

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5-2-2 Adjustment ............................................................................................................ 5-18

5-2-3 Cleaning................................................................................................................ 5-20

5-2-4 Turret unit internal maintenance ........................................................................... 5-21

5-3 TOOL EYE ....................................................................................................... 5-22

5-3-1 Construction and operation ................................................................................... 5-22

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5-3-2 Checking and adjustment ..................................................................................... 5-23

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5-4 X-, Y- and Z-Axes ............................................................................................. 5-26

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5-4-1 Construction and operation ................................................................................... 5-26

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5-4-2 Zero-point setting method ..................................................................................... 5-28

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5-4-3 Adjustment ............................................................................................................ 5-39
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5-5 Secondary Headstock and W-Axis ................................................................... 5-40

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5-5-1 Checking and adjustment ..................................................................................... 5-40

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5-5-2 Cleaning................................................................................................................ 5-41

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5-6 Tailstock ........................................................................................................... 5-42

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5-6-1 Construction and operation ................................................................................... 5-42

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5-6-2 Disassembly ......................................................................................................... 5-42

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5-6-3 Adjustment ............................................................................................................ 5-43

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5-6-4 Cleaning................................................................................................................ 5-47

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5-7 Hydraulic Unit and Hydraulic Circuit ................................................................. 5-48

5-7-1 Construction and operation ................................................................................... 5-48

5-7-2 Checkups before starting hydraulic unit ................................................................ 5-54

5-7-3 Inspection when starting hydraulic unit ................................................................. 5-54

5-7-4 Inspection and maintenance of hydraulic unit ....................................................... 5-54

5-7-5 Line filter for the hydraulic cylinder ....................................................................... 5-56

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5-8 Lubrication Unit and Lubrication Circuit ............................................................ 5-58

5-8-1 Construction and operation (Grease lubrication) .................................................. 5-58

5-8-2 Inspecting the electric grease pump of the slideway section and
replenishing grease .............................................................................................. 5-58

5-8-3 Construction and operation (oil lubrication) .......................................................... 5-63

5-9 Coolant System ................................................................................................ 5-74

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5-9-1 Construction and operation ................................................................................... 5-74

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5-9-2 Checking and replenishment ................................................................................ 5-76

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5-9-3 Cleaning................................................................................................................ 5-77

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5-9-4 Replacement ......................................................................................................... 5-79

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5-9-5 Method of pulling out the coolant tank .................................................................. 5-80
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5-9-6 Maintenance of chip conveyor .............................................................................. 5-83

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5-10 Air Unit.............................................................................................................. 5-84

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5-10-1 Construction and operation ................................................................................... 5-84

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5-10-2 Maintenance of the air unit ................................................................................... 5-92

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5-10-3 Additional air unit for linear scale (option) ............................................................. 5-93
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5-11 Headstock Cooling Unit and Headstock Cooling System ................................. 5-95
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5-11-1 Cooling of the main headstock ............................................................................. 5-95

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5-11-2 Cooling of secondary spindles .............................................................................. 5-99

5-11-3 Control panel cooling .......................................................................................... 5-100

5-12 Steady Rest (Option) ...................................................................................... 5-101

5-12-1 Construction and operation ................................................................................. 5-101

5-12-2 Cleaning up chips on steady rest periphery ........................................................ 5-102

5-12-3 Replacing the limit sensor for checking the connecting position of the
steady rest .......................................................................................................... 5-103

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5-12-4 Replacing the bracket (supporter) for mounting the steady rest ......................... 5-105

5-13 Milling turret cooling unit and milling turret cooling system ............................. 5-110

5-13-1 Cooling of the milling turret ................................................................................. 5-110

5-14 Way Cover ...................................................................................................... 5-114

5-14-1 Procedure for removing the Z-axis way cover .................................................... 5-116

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5-14-2 Procedure for removing the W-axis way cover ................................................... 5-122

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5-15 Milling Holder .................................................................................................. 5-123

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5-15-1 Checking for secure mounting of cutting tools and holders ................................ 5-123

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5-15-2 Checking for the turret, milling holders, and cutting tools to scan for chips ........ 5-123

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5-15-3 Checking for the entry of coolant into milling through holder .............................. 5-123
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5-15-4 Checking for the looseness of eccentric pin mounting bolts ............................... 5-123
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5-15-5 Run adjustment of a tool ..................................................................................... 5-123

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5-16 Operator Door Automatic Open/Close Unit (Option)....................................... 5-125

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5-16-1 Automatic door maintenance menu (servomotor) ............................................... 5-125

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5-16-2 Zero-point return (electric actuator) .................................................................... 5-127

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5-16-3 Procedures for door controller error .................................................................... 5-127

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5-16-4 Replacing the safety switch (contact pressure sensor) ...................................... 5-135
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5-17 Others............................................................................................................. 5-137

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5-17-1 CNC unit ............................................................................................................. 5-137

5-17-2 Cleaning the NC screen ...................................................................................... 5-140

5-17-3 Electrical control cabinet ..................................................................................... 5-140

5-17-4 Replacing the batteries in the battery box .......................................................... 5-142

5-17-5 Replacing the battery of the NC unit ................................................................... 5-144

5-17-6 Procedure for replacing the proximity sensor ..................................................... 5-147

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5-17-7 Replacing the LED lamp ..................................................................................... 5-149

5-17-8 Wipers ................................................................................................................. 5-151

5-17-9 Front door glass .................................................................................................. 5-153

5-18 List of Consumption Goods ............................................................................ 5-154

6 INSTALLATION .................................................................................... 6-1

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6-1 Preparation for Installation.................................................................................. 6-1

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6-1-1 Environmental requirements ................................................................................... 6-1

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6-1-2 Power requirements ................................................................................................ 6-2

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6-1-3 Air source (Air consumption amount) ..................................................................... 6-4

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Foundation work ..................................................................................................... 6-4
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6-1-5 Foundation parts ..................................................................................................... 6-5

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6-1-6 Delivering the machine ........................................................................................... 6-6

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6-2 Machine Installation ............................................................................................ 6-8

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6-2-1 Precautions for machine installation ....................................................................... 6-8

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6-2-2 Unpacking, inspection and cleaning ..................................................................... 6-16

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6-2-3 Location of transit clamps ..................................................................................... 6-17

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6-2-4 Installation procedure ........................................................................................... 6-21

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6-3 Connecting the Power Supply Cable and Air Supply Hose .............................. 6-23
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6-3-1 Connecting the power supply cable ...................................................................... 6-23

6-3-2 Grounding ............................................................................................................. 6-25

6-3-3 Connecting the air hose ........................................................................................ 6-26

6-4 Coolant Tank Installation .................................................................................. 6-28

6-5 Trial Operation .................................................................................................. 6-32

7 TROUBLESHOOTING .......................................................................... 7-1

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7-1 Troubleshooting Procedures .............................................................................. 7-1

7-1-1 If the tool has come into contact with the workpiece, chucks or other
sections................................................................................................................... 7-1

7-1-2 If the source of the trouble cannot be located ......................................................... 7-1

7-1-3 Using the GRAPHIC MAINTENANCE display ........................................................ 7-2

7-2 Troubleshooting for Each Unit ............................................................................ 7-3

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7-2-1 Headstock ............................................................................................................... 7-3

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7-2-2 Chuck...................................................................................................................... 7-4

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7-2-3 Turret ...................................................................................................................... 7-5

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7-2-4 TOOL EYE .............................................................................................................. 7-5

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7-2-5 X-axis ...................................................................................................................... 7-5
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7-2-6 Z-axis ...................................................................................................................... 7-6

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7-2-7 Y-axis ...................................................................................................................... 7-6

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7-2-8 Tailstock .................................................................................................................. 7-6

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7-2-9 Secondary spindle .................................................................................................. 7-6

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7-2-10 W-axis ..................................................................................................................... 7-7

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7-2-11 Hydraulic unit .......................................................................................................... 7-7

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7-2-12 Grease lubrication unit ............................................................................................ 7-8

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7-2-13 Oil lubrication unit ................................................................................................... 7-8

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7-2-14 Coolant unit............................................................................................................. 7-8

7-2-15 Air unit..................................................................................................................... 7-9

7-2-16 Headstock cooling unit............................................................................................ 7-9

7-2-17 Milling headstock cooling unit ................................................................................. 7-9

7-2-18 Wiper for the door and wiper for the way cover ...................................................... 7-9

7-2-19 Milling holder ......................................................................................................... 7-10

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7-2-20 Coolant temperature control ................................................................................. 7-10

7-2-21 NC unit and controller ........................................................................................... 7-10

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 Serial Number 339746

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
QUICK TURN 200MB QT-200MB
QUICK TURN 250MB QT-250MB
QUICK TURN 200MY QT-200MY
QUICK TURN 250MY QT-250MY

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QUICK TURN 200MS QT-200MS

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QUICK TURN 250MS QT-250MS

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QUICK TURN 200MSY QT-200MSY

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QUICK TURN 250MSY QT-250MSY

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1-1 Machine Overview

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1-1-1 Intended use of the machine

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The QUICK TURN series are next-generation standard machines. They achieve a high
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progressivity and productivity which are required for CNC Turning Centers and have been
developed by Mazak.
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The machine is designed to carry out a variety of machining processes on a wide range of
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materials including metals, plastic and composites in industrial applications. Work pieces are
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held in the machine by means of a hydraulic chuck mechanism. Intended machining processes
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include facing, turning, drilling, boring, thread cutting and knurling. Depending on the model, the
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machine can also carry out milling processes. The machine is intended to operate within the
environmental conditions as specified in section 6-1-1 of the maintenance manual.
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The combination of these functions and MAZATROL Smooth, which has been evolved from
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MAZATROL, helps to ease operation and to improve the productivity significantly.

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In addition, with an emphasis on “ease of use for the operator”, operability and maintenance
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features have vastly improved.

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Moreover, this environment-friendly CNC Turning Center contributes to energy conservation,

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and aims at reducing energy consumption through the use of LED lights, auto-off function for
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the NC backlight, etc.

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1-1
 Serial Number 339746

1 INTRODUCTION

1-1-2 Operating position

The usual operating position of the machine is within the range as follows.

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Operator’s door
Operating panel

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Operating area
B72-0053

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Fig. 1-1 Top view of the machine 74 ora
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1-2
 Serial Number 339746

INTRODUCTION 1
1-1-3 Features

1. Achieving high performance

A substantial improvement in productivity is achieved with the following characteristics.

A. High speed, high torque, high precision built-in motor headstock

It has been made more powerful and a quick spindle rise with high torque and high revolution
has been achieved by using an upgraded built-in headstock with high spindle rigidity and
cooling effect.

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B. Non-lift high speed turret

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Since a 12-corner [16 (option)] drum turret with reduced friction is used, machining is possible

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with 12 tools [16 (option)] fully attached and a change in the type of a workpiece can also be

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easily handled.

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Since the turret takes short swings (random type), programming can be done without being

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concerned about the swing time of the tools and the Chip to Chip time is reduced substantially.

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C. MAZATROL SmoothG CNC system

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MAZATROL SmoothG is a high-speed, high-precision, high-reliability CNC system,
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strengthened with the ample know-how about the reputed CNC systems of the MAZATROL
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Series, which enable intuitive operations with touch panels, using the latest servo technology
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and the latest hardware.

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Moreover, this CNC system is user friendly with features like - refining of on-screen display
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according to the programs used (MAZATROL/EIA), giving a list type display of tools etc.
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D. High-speed high-precision positioning

Reduction of non-cutting time is aimed at with a fast feed speed of 30 m/min for the X-axis,
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21 m/min (only for the MY and MSY specifications) for the Y-axis, and 33 m/min for the Z-axis.
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The smooth high-gain servo-control technique attains high-precision machining with smooth
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acceleration and deceleration and a high tracking capacity.

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E. NC Tailstock
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Operability has been improved and initial setup has been made easier since the movement and
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thrust of the tailstock is controlled using the servo motor.

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The servo motor usually monitors the pressing thrust, and the thrust can be changed while a
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workpiece is pressed.
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Thrust setting value can be 0.1 kN force and the pressing thrust can be controlled according to
the material and shape of the workpiece.

F. Secondary spindle
In conventional machining without a face driver or robot, setup changes or other machines are
required for the process of chuck clamping. This affects productivity negatively, such as
prolonged machining lead time and other-machine requirement.
The secondary spindle of this machine was developed to solve the above mentioned problem.
Instead of a usual tailstock, a mechanism with which the secondary spindle can move, the
chuck can be opened or closed, or the spindle can be driven with a program is provided. Also,
bar materials can be machined to completed products.

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 Serial Number 339746

1 INTRODUCTION

2. Achieving high-precision machining

1. Improvement in continuous machining precision is aimed at by keeping the heat generation
in the main structure low using the following heat displacement countermeasures.
• Improving the cooling capacity of the headstock
• Determining an appropriate cooling method and casting form on the basis of the thermal
expansion analysis of the main structure
• Separating the coolant tank from the main body and preventing adverse effects due to
chips and coolant
• Installing the environment-responsive postural control “intelligent thermal shield” as
standard and automatically compensating the postural change of the main structure

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caused by temperature change in CNC.

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2. Since a built-in spindle is used, the vibrations generated by the motor, belt etc. disappear

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and a stable circularity and surface roughness is achieved in any rotary area.

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3. Lost motion

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Prevention of stick-slip at the time of low speed feeding and reduction in slide resistance is

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aimed at by using a linear guide. (Tracking capacity of 1 pulse 0.1 µm can be achieved.)

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 Serial Number 339746

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 (EIA/ISO)
Parameter list, alarm list, M-code list Detailed description of NC parameters, NC alarms, and M codes
Parts list Part procurement
Electrical wiring diagrams Electrical connections
Operating manual for optional specifications All aspects of operation

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1-3 Numbering System for Pages

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1. Normal case

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Page number in chapter

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Chapter number

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2. For additional pages to be inserted
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Additional page
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1-4 Numbering System for Figures and Tables

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1. Figure number
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Fig. 3-1 Main machine components (1/2)

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Number of figures with this title, as indicated

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by the denominator, and the serial number

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of the figure within the figures with this title,

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as indicated by the numerator.

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Title
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Number of figure in chapter

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Chapter number
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2. Table number
Table 2 - 1 Safety nameplate details

Title
Number of table in chapter
Chapter number

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 Serial Number 339746

1 INTRODUCTION

1-5 Revision Code

This manual is revised with each improvement of the product or each modification of its
specifications, and the document number of the manual is correspondingly updated.
Revised sections of the manual are denoted by the revision numbers beginning with R, on the
CONSTRUCTION page facing the back cover page.
Also, all revisions are coded at one of three levels and these revision codes are given between
the corresponding section titles and page numbers on the “Contents” page so that the readers
can readily identify which item has been added, changed, or deleted.
 

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Updating (modification) number

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Revision code: A = Addition

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C = Change

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D = Deletion

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Revision codes only denote the previous and/or current revisions, and the revision codes for

A
any revisions preceding the previous ones are crossed out from this manual.

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A revision record is given at the end of this manual to denote the history of the manual.
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1-6 E
 Serial Number 339746

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 Rules
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

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to its own working safety as well as to observe the precautions described below.

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2. The meanings of our safety precautions to DANGER, WARNING, and CAUTION are as

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follows:

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: Failure to follow these instructions could result in loss of life.

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DANGER

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

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machine damage.
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CAUTION
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2-1
 Serial Number 339746

2 SAFETY PRECAUTIONS

2-2 Residual Risks

1. Residual risk map

Residual Risk Map Showing the Residual Risks Requiring Customer’s Protective Measurers
Products: QT-200MB, 200MS, 200MY, 200MSY
QT-250MB, 250MS, 250MY, 250MSY
Created on December 15, 2015
Yamazaki Mazak Corporation

* Operate the machine only after reading the instruction manual carefully and understanding the contents thoroughly.
This material is a reference for the instruction manual and do not operate the machine after understanding the contents
only in this material.

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“Seriousness of Harm” is classified and described according to the definition indicated below.

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• DANGER: Failure to follow these instructions could result in loss of life.

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• WARNING: Failure to observe these instructions could result in serious harm to a human life or body.

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• CAUTION: Failure to observe these instructions could result in minor injuries or serious machine damage.

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The numbers shown in the figure below correspond to the No. in the “Residual Risk Table” of the machine.

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Refer to the “Residual Risk Table” for details of residual risks.

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Location DANGER Location DANGER Location DANGER

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E No.4, No.5, No.6, No.7, B I
(inside WARNING No.9, No.15, No.16 WARNING No.2 (floor) WARNING No.14
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the
machine) CAUTION No.8, No.12, No.20 CAUTION CAUTION
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Location DANGER
F
Location
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Location WARNING DANGER

DANGER C
D
WARNING No.2, No.9
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No.3, No.11, No.16 CAUTION No.13

WARNING
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No.20 CAUTION
CAUTION
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20
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B72-0055
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B72-0054

Location No.1 Location No.19 Location Location

DANGER DANGER DANGER DANGER
A G H J
No.9, No.11 No.14, No.18 WARNING No.14, No.18
WARNING WARNING No.10 WARNING

No.20 CAUTION No.12, No.13 CAUTION

CAUTION CAUTION

Residual risks for DANGER Received on Year/Month/Day:

which corresponding
WARNING Customer Name
machine location
cannot be specified CAUTION No.17, No.21 Department/Section
Person in Charge Signature

2-2
 Qualifications Reference in Reference in
Location in Seriousness Protective Measures to be Taken
No. Operation Step Work or Training Details of Harm Operating Maintenance
2.
Machine of Harm by the Customer
Needed Manual Manual
1 Installation Installation C
Second class A DANGER Physical contact with an energized Do not connect the power supply at the factory – 6-3-2
electric workop part side until the operation is finished. Make sure to
specialist yr ask an authorized electric worker for grounding.
ig Failure to do so may cause an accident leading to
ht a serious personal injury or death or damaging the
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2 Use Power ON B, C WARNING Serious personal injury
© Do not remove the maintenance covers while PART 2 3-3 –
the power is ON. Do not turn the power ON
when any of the maintenance covers and/or the
20
Residual risk table

23 electric control cabinet door is removed (or

opened). Check that the sheath of the cables is
Ya free of damages.
3 Use Machine D m
WARNING Erroneous operation Do not operate a switch while wearing gloves. PART 2 2-2 –
operation Se az Before operating the machine, thoroughly read
ria a the manual.
4 Use Machine E WARNING Personal injury by getting caught in Do not go inside the machine or operate the – 3-2
operation moving machine parts machine while a part of the body is put in the 5-2-5
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um az machine.
5 Use Machine E WARNING Serious personalbinjury caused
ak by a Do not go inside the machine or operate the – –

2-3
operation sharp cutter on moving
er machineCparts machine while a part of the body is put in the
Maintenance Maintenance E WARNING Personal injury by getting OFF the power and place a saying – 3-2
33caught inor machine.
6
and repair inside moving machine parts 97 poTurn “Working inside the machine. Do not turn ON
Serial Number 339746

the machine 46 therapower.”.

7 Maintenance Maintenance E WARNING Serious personal injury caused by a Turn iOFF – –
t o the power and place a saying
and repair inside sharp cutter on moving machine parts “Working ninside Do not turn ON
the machine
. Weartheamachine.
the power.”.A safety protector.
Maintenance Maintenance E CAUTION A person is trapped in the machine Put bolts into fixture – 5-14
8
ll installation holes on the
and repair inside with the front door closed completely front door not to close
rig the front door completely.
the machine and an interlock applied. ht
9 Maintenance Maintenance and A, C, E WARNING Electric shock or serious personal Set the main power disconnect
s switch in the – 4-1
repair inside the injury by getting caught in moving “OFF” position and lock it inrethat position with
electrical control machine parts the padlock. se
cabinet and the rv
machine e
10 Use Greasing the G WARNING The chuck jaw is not sufficiently Make sure to grease the chuck jaw withdthe . – 5-1-2
chuck jaw greased, and the gripping force of the specified grease once a day.
chuck is lowered, scattering
workpieces.
SAFETY PRECAUTIONS
2
 2
Qualifications Reference in Reference in
Location in Seriousness Protective Measures to be Taken
No. Operation Step Work or Training Details of Harm Operating Maintenance
Machine of Harm by the Customer
Needed Manual Manual
11 Daily Chip disposing C A, D WARNING Serious personal injury by being Turn the power OFF. – 5-5-2
inspection work op entangled in the machine 5-6-4
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12 Daily Chip disposing E, H ig CAUTION Hand laceration by removing chips Never touch chips directly with bare hands. – 5-9-3
inspection work ht with bare hands Always use a scoop or appropriate gears when
© handling chips.
SAFETY PRECAUTIONS

13 Daily Chip disposing F, H CAUTION Injury caused by chips dropping from

20 Do not put the body under the chip discharge – –
inspection work 23the chip conveyor port.

14 Use Machine H, I, J WARNING Serious personal injury by slipping If any coolant or fluid is spilled on the floor, wipe – 5-9-3
operation and falling due to coolant spills on the it off completely.
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15 Use Tool change E WARNING Serious personal injury from tool Use a tool and insert within the specification PART 2 5-1 –
failure due to the use of a tool or insert range. Replace the excessively worn tool.
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exceeding the specification
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16 Use Tool D, E WARNING The machine will
l “heavy tool”, “large tool”, and “long tool” PART 2 5-1 –
registration
N i Mbe damaged unless Enter
tool attribute information, such as attributes correctly after carefully checking the
u
“heavy tool”,
atool”
z and “long tool to be used.
tool”, is registered
m “largecorrectly.

2-4
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17 Use Coolant No C
CAUTION Machine damager due to deterioration the coolant manufacturer to check that – 5-9
selection specific of seals made of NBR 33(nitrile rubber) the coolant to be used does not deteriorate NBR
or Contact
location 97 po seals.
Use of J, H WARNING Serious accident such as ignition not approach the machine with fire. PART 1 2-3 2-3
Serial Number 339746

18 Use 4 andraDo
flammable fire by bringing fire close to a6 Do
tionot use any inflammable lubricant or coolant.
substances flammable substance
Machining G
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DANGER Workpiece coming off during rotation, Accept. the possibility that the workpiece or PART 1 2-3 2-3
19 Use A
breaking through the door and cutting tooll could fly out of the machine during PART 2 4-2
crashing into the operator’s body machining andl r do not enter areas where
dangerous situations
ig can be anticipated, such
as in front of the front
ht door.
Cleaning A, D, E CAUTION Personal injury by getting caught in
s – 5-5-2
20 Daily Check that the machiner is at a completely stop.
inspection moving machine parts 5-6-4
es
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21 Daily Cleaning No CAUTION Serious personal injury to the eye due Do not use compressed air forrremoving
ve chips. – 4-1
inspection specific to chips blown with compressed air
location
d.
 Serial Number 339746

SAFETY PRECAUTIONS 2
2-3 Basic Safety Items
 There are high voltage devices on the electrical control panel, transformer, motors,
junction boxes, and other equipment (with a battery warning 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 is to be removed, first set the main power breaker to OFF and lock it.
 Do not power on the machine, with door/protective cover removed.

 Memorize the position of the EMERGENCY STOP button so that you can press it
immediately from any position.

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 To prevent incorrect operation of the machine, carefully check the position of the

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WARNING

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switches before operation.

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 Take care not to touch any of the switches accidentally while the machine is in operation.

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 Under no circumstances touch a rotating workpiece or the tool with your bare hands or

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any other object.

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 Take care not to catch your fingers in the chuck.

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 Whenever you may work inside the machine, be cautious about chips and possible

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slippage due to coolant. 74 ora
 Do not enter the machine unless necessary for maintenance.
39 rp

 Always switch off the power switch on the operation panel and set the main power
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breaker to OFF if no machine operation is required.
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 Set the main power breaker to OFF before cleaning the machine or its peripheral
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equipment(s).
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 Set the main power breaker to OFF and lock it before performing maintenance work
inside the machine.
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 If more than one operator are using the machine, do not proceed to the next step without
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indicating to the other operator(s) that you are about to do so.

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 Do not modify the machine in any way that will affect its safety.
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 If in the slightest doubt about a procedure, ask the person in charge.

20

 Do not enter the machine. If you have to enter the machine, take measures such as
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turning off the main power disconnect switch. Always switch off the main power
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disconnect switch and lock it with a padlock before entering the machine. This will
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eliminate the possibility of the machinery being accidentally started by someone else.
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 All assembly and maintenance work must be carried out by qualified personnel only.
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2-5
 Serial Number 339746

2 SAFETY PRECAUTIONS

 Do not fail to conduct inspection periodically in accordance with the instruction manual.
 Check and make certain that there is nothing interfering in the home direction.

CAUTION  Do not open any doors or safety covers while the machine is in automatic operation.
 After a job has been completed, set up each part of the machine so that it is ready to be
used for the next series of operations.
 If there is a power failure, immediately set the main power breaker to OFF.
 Do not subject the CNC unit, the operation panel, or the electrical control panel to strong
shocks.
 Do not change the parameter values, volume values, or other electrical setting values

.
without good reason. If it becomes necessary to change a value, first check that it is safe

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to do so, then make a note of the original value so that it can be reset if necessary.

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 Do not paint, soil, damage, modify, or remove any of the safety nameplates. If the details

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become illegible or if the nameplate is lost, obtain a replacement by sending the part

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number stamped at the bottom right-hand corner of the nameplate to Mazak Technical

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Center or Technology Center and mount the replacement in the original position.

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2-6
 Serial Number 339746

SAFETY PRECAUTIONS 2
2-4 Clothing and Personal Safety
 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 dust-generating materials.
 Always use safety shoes with steel toecaps 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.

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 If you should wear a neck tie or necklace and the like, be careful not to let it roll into the

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machine drives.

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 Always use gloves when loading or unloading workpieces or tools and when removing

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chips from the work area to protect your hands from sharp edges and heat generated

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during machining.

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 Do not operate the machine while under the influence of drugs with powerful effects,

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unprescribed drugs, or alcohol.

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 Do not operate the machine if you suffer from dizziness or fainting spells.
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2-5 Safety Items Related to Operation
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Do not proceed to operating the machine before completely understanding the descriptions
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about the maintenance, PART 3 “OPERATING NC UNIT AND PREPARATION FOR

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AUTOMATIC OPERATION”, and PART 4 “AUTOMATIC OPERATION”.

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 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
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ensure a fire extinguisher is readily available as a safety measure. Additionally, if an

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WARNING inflammable lubricant is used, the machine should never perform unmanned operation.
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An operator must always be present to ensure safety. The same precautions must be
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23

taken when machining inflammable materials such as magnesium alloy.

20

 Close all doors and covers of the CNC unit, operation panel, electrical control panel, and
junction boxes to prevent damage from water, chips, and oil.
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 Check all electrical cables for damage to prevent accidents due to current leakage or
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electric shock.
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 Check the safety covers regularly to make sure that they are properly fitted and that they
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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 Mazak Technical Center or Technology Center,
refer to the Parts List and specify the part numbers.
 Do not operate the machine with any of the safety covers removed.
 Do not handle coolant with bare hands since it is liable to cause irritation. Operators with
allergies should take special precautions.
 Do not adjust the coolant nozzles while the machine is in operation.
 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.

2-7
 Serial Number 339746

2 SAFETY PRECAUTIONS

 When loading workpiece blanks onto or unloading products from machines which do not
have an automatic workpiece changer, make sure that the tool is as far away as possible
from the work area and that it has stopped rotating.
 Do not wipe the workpiece or clear away chips with your hand or with a rag while the tool
is rotating; always stop the machine and use a brush.
 Do not remove or otherwise interfere with safety devices such as stop dogs, limit
switches, or interlocks in order to increase axis travel.
 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.

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 When using fork lifts or cranes, make sure that there are no obstructions in the vicinity of

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these machines.

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 Always use wire rope or slings of a standard suitable for the load to be supported.

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 Check slings, chains, hoists, and other lifting gear for defects before use. Repair or

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replace defective gear immediately.

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 Do not operate the machine during violent thunderstorms.

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 A machine with MAZACARE has a mobile phone terminal in the electrical control cabinet.

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A person who utilizes a medical electric device like a pace maker or an automatic cardiac
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defibrillator (AICD) must manipulate the electrical control cabinet of a device at least
74 ora
22 cm away from the device mounting part. Even though no MAZACARE is equipped,
39 rp

electromagnetic waves are radiated from an NC machine tool. Although they are very low
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6
compared with those from a mobile phone terminal or the like, they do not ensure stable
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motions of the medical electric device; so consult with the medical electric device maker
and a medical doctor in charge before deciding participation of the job without fail.
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 Before operating the machine make sure that the appropriate spindle speed and feed
rate are selected.
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 Before extending or retracting the TOOL EYE, make sure that your hands are not trapped
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by the chuck or the tool.

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 Check that the belts have the correct tension before operating the machine.
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 Check jigs and others to make certain that their workpiece clamping bolts are not loose.
20

CAUTION  Do not operate the switches on the operation panel while wearing gloves as this could
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lead to incorrect operation or other mistakes.

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 Warm up the spindle and all of the axis feed mechanisms before operation.
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 Make certain that mounted tools match with the program-entered tool numbers.
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 Check the POSITION display (or SET UP display) for a program number.
 Initially, execute the program with decreased rapid travel in the single-block operation
mode to make certain that no interference takes place.
 Check and make certain that no abnormal noise is produced while cutting.
 Do not allow chips to accumulate during heavy-duty cutting since they become hot and
may take fire.
 When one series of operations has been completed, switch off the NC unit, set the main
power breaker to OFF, and switch off the factory power supply.
 When using a crane, make sure that the crane does not come in contact with the
machine.
 Do not fix the chuck so that the chuck jaws extend further than the outer diameter of the
chuck. Interference of TOOL EYE and jaws may result in machine failure.

2-8
 Serial Number 339746

SAFETY PRECAUTIONS 2
2-6 Safety Items Related to Gripping Workpiece and Tooling (in Turning)
 Always use tools suitable for the work and which conform to the machine specifications.
 Replace tools quickly, since badly worn tools are a cause of accidents or damage.

WARNING  Before starting the spindle, check that any parts which are bolted or clamped to the chuck
or the steady rest are properly secured.
 If the center hole on large bar workpieces is too small, the workpiece could come off
when a load is applied. Make sure that the hole is big enough and that it has the correct
angle.
 Do not operate a spindle on which accessories are mounted at above the rated speed.

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 If the chuck or the accessory being used is not a product recommended by MAZAK,

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check the maximum safe operating speed with the manufacturer.

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 Take care not to catch your fingers in the chuck, steady rest and hand.

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 Always use the correct lifting gear for heavy chucks, steady rests, hand and workpieces.

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 Workpieces heavier than the design data of the machine must not be machined. If an

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attempt is made to machine a workpiece heavier than the value obtained by subtracting

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the weights of the chucks and jaws from the maximum supporting capacity of the

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machine, the workpiece may abruptly fly out to cause a hazardous situation.

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 Do not turn power off the machine while the tailstock is holding the workpiece. If the
74 ora
machine is powered off and then left as it is for a long time, there is a danger of the
39 rp

workpiece falling since the tailstock will decrease in workpiece holding force.
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 Do not extend unsupported bar outside of spindle or actuator. If supported bar is
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extended or a bar feed is installed,

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1) Be aware of danger of exposed rotating parts.

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2) Identify hazardous area and hang danger sign.

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 Make sure that the tool length is such that the tool will not interfere with fixtures such as
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chucks or other objects.

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 Perform a test operation after mounting tools and a workpiece.

CAUTION
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 After machining soft jaws, check that they grip the workpiece correctly and that the chuck
20

pressure is correct.
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 Since the tool holders can be mounted from the left or the right, check that the tool holder
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is mounted facing the correct direction.

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 Do not use a tool measuring device (TOOL EYE or tool length measuring unit) before
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making certain that there is nothing interfering.

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2-7 Safety Items Related to Gripping Workpiece and Tooling (in Milling)
 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: 100 g)
WARNING
 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 tool in the machine, make sure that the insert blade is properly
secured.
 Do not rotate a tool or holder at speeds greater than the rated speed. For the rated
speed, check with the manufacturer.

2-9
 Serial Number 339746

2 SAFETY PRECAUTIONS

2-8 Safety Items Related to Maintenance

Do not proceed to a maintenance work before completely understanding what is referred to in
the maintenance manual.

 Always set the main power breaker to OFF and lock it before carrying out any
maintenance work. This will eliminate the possibility of the machinery being started
inadvertently 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.

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 Maintenance work for electrical parts must be carried out by qualified personnel.

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 Even if the door of the power control panel is open, the power is not cut off. When

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working inside the power control cabinet or repairing the machine, always set the main

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WARNING
power breaker to OFF and attach a padlock (provided by customers).

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 Do not proceed to cleaning the machine and/or its peripherals before locking the main

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power breaker at the OFF position, with the machine made to completely stop operating.

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 Do not proceed to a repair on the machine before shutting off the input air source.

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 When carrying out maintenance in high places, always use a suitable ladder or a service
platform and always wear a helmet.
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74 ora
 Keep your fingers clear of belts and pulleys as well as chains and sprockets.
39 rp

 Always set the main power breaker to OFF and lock it before replacing bulbs or other
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electrical equipment and use products with the same specifications as the original.
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 Do not remove or modify over travel limit switches, interlock limit switches, proximity
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switches, or other safety devices.

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 Do not start the machine until all of the covers removed for maintenance have been
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refitted.
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 Wipe up any water or oil spills immediately and keep the maintenance area and the
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workplace clean and tidy at all times.

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 Be absolutely certain to use the specified and standardized parts as replacement or

23

consumable parts so as to maintain the as-shipped machine specifications. We take no

20

responsibility for any personal accidents or machine trouble due to inobservance of this
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warning.
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 A machine with MAZACARE has a mobile phone terminal in the electrical control cabinet.
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A person who utilizes a medical electric device like a pace maker or an automatic cardiac
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defibrillator (AICD) must manipulate the electrical control cabinet of a device at least
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22 cm away from the device mounting part. Even though no MAZACARE is equipped,
electromagnetic waves are radiated from an NC machine tool. Although they are very low
compared with those from a mobile phone terminal or the like, they do not ensure stable
motions of the medical electric device; so consult with the medical electric device maker
and a medical doctor in charge before deciding participation of the job without fail.

2-10
 Serial Number 339746

SAFETY PRECAUTIONS 2
 Maintenance work should be carried out by qualified personnel in accordance with the
instructions of the person in charge.
 Read the maintenance manual thoroughly.
CAUTION
 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 indicated on the instruction plate concerning the brands of oil to be
used, lubrication points, amount to be used, and oil change intervals.
 If one of the belts in a set has stretched beyond the prescribed limit, change the entire

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set.

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 Do not use compressed air to clean the machine or to remove chips.

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 Always wear leather gloves when clearing away chips; and use a brush to clear them.

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 Check the results of the maintenance work in the presence of the person in charge.

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 Substances that have adverse effects on the environment if not disposed of appropriately

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are used in some of the equipment used in Mazak machine tools. In order to protect the

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environment, dispose of machine tools and accessory equipment in accordance with the

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laws of the country concerned. Entrust the processing to a contractor who deals with
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industrial waste. Note that any expenses associated with this processing are to be borne
74 ora
by the customer.
39 rp
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2-9 Safety Items Related to Workplace

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 Immediately remove all water and oil spills from the floor and dry the floor to prevent
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accidents.
 Keep combustible materials well away from the work area and any other place where
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WARNING
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there are hot chips.

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 Always provide sufficient working space and clear access to the machine and peripheral
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equipment and store tools and other potential obstacles in a prescribed place away from
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the machine.
20

 Always provide sufficient lighting in the work area.

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 Use strong service platforms only and make sure that nothing can slip off them.
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 Never place tools or other potentially dangerous objects on top of the headstock, turret,
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or covers.
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 Make sure that the nominal cross-sectional area of the power supply cable between the
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factory power supply switch and the machine main power breaker 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.

2-11
 Serial Number 339746

2 SAFETY PRECAUTIONS

2-10 Safety Items Related to Chip Conveyor

 Before carrying out maintenance work or other jobs on the chip conveyor, make sure that
the power supply is turned off and that the conveyor itself is placed in the completely
stopped status. Failure to observe this precaution causes serious personal injury.
WARNING
 During the operation of the chip conveyor, keep hands away from and do not insert any
region of your body into any sections of the conveyor. Failure to observe this precaution
causes serious bodily injury.

 Do not put your hands or any part of your body under the chip discharge part. Failure to
follow this caution could result in injuries caused by chips from the chip conveyor.

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 Never use compressed air to clear the machine/conveyor from swarf build-up.
CAUTION

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 Do not allow swarf to build-up excessively in the chip bucket as it may be picked up by

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the belt and recirculated causing conveyor blockages.

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 Always wear gloves and use a brush when cleaning swarf from the conveyor; never use

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bare hands.

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 In the event of a blockage causing the conveyor to jam:

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− Halt the machine at the first available safe opportunity; attempt to identify the

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location and nature of the blockage.
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Minor blockages can often be freed by briefly reversing the direction of conveyor
74 ora
travel.
39 rp

− Never attempt to free a blockage using hands or hand-held implements whilst the
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conveyor is running as the belt poses a serious risk of entanglement. The conveyor
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must be isolated with the power off, or press the emergency stop button beforehand
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so the machine cannot operate.

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− Major blockages may require intervention by maintenance personnel – always refer

to the manual supplied by the conveyor manufacturer for further instructions.
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 If any safety cover must be removed to clear the blockage, first set the main power
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breaker of the machine to OFF and lock it.

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23

2-11 Safety Equipment

20

 The machine is provided with various devices for the operator’s safety.
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Never cancel any of the devices.

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Failure to observe this instruction could result in serious harm to a human life or body.
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WARNING
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This machine is provided with various safety devices to protect the operator and the machines.
C

The safety devices include interlock devices and emergency stop switches as well as doors and
covers.

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

 Before using the following cutting conditions:
− Cutting conditions for tools that are suggested to be used by the Machining
Navigation Function
WARNING
− Confirm that every necessary precaution in regards to safe 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.

2-12
 Serial Number 339746

SAFETY PRECAUTIONS 2
2-13 Safety Plates
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.
These safety plates must not be defaced, damaged, modified or 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 name plate unit within the mechanical parts list.

.
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 Always observe the precautions and instructions on the plates. Some

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representative nameplates are explained in a separate manual.

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Note : Nameplates that are not shown in the manual are equally important.

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< MB, MS, MY and MSY specifications > 3

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74 ora
39 rp
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4
be ak
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2 6
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23
20

1
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3
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3 1

B72-0056

Fig. 2-1 Positions of safety plates

2-13
 Serial Number 339746

2 SAFETY PRECAUTIONS

Table 2-1 List of plates

No. Name Part No.

1 HAZARDOUS VOLTAGE WARNING DANGER

2 GENERAL SAFETY WARNING WARNING
3 CRUSH HAZARD WARNING WARNING Please refer to
4 CHUCK WARNING WARNING Mechanical Parts List
5 BAR FEEDER WARNING WARNING
6 TOOL SPEED WARNING WARNING

2-14 Safety Devices

.
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Table 2-2 Overview of Safety Devices

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No. Location Function

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1 Front door • This door cannot be opened during machining.
(operator door)

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• Unlock the door after machining and open the door.

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• While the door is unlocked, the spindle rotates and the axis is fed at the safety speed

rig
or slower.

ll
2 Control cabinet door If this door is opened, the main power is shut off and the machine action is stopped.

A
3 Oil pressure monitoring In the event of an unusual decrease in oil pressure of the hydraulic unit or hydraulic chuck,

n.
the abnormality is detected to stop the machine.
4 Air pressure monitoring
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In the event of an unusual decrease in air pressure, the abnormality is detected to stop the
74 ora
machine.
39 rp

5 Front door glass The front door is glazed with a laminated glass pane which has been proved to withstand
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an impact energy of 8000 J minimum, with respect to a reflector of class B drag as

6

specified in EN12415, Annex B.

be ak

6 Machine outer cover This cover secures a safety clearance to protect human bodies.
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7 Human body protection The front door (operator door) is automatically locked at power failure so that the machine
l N ki M

at power failure will not move abruptly even though power is supplied to the machine again.
8 Protection circuit at an To ensure safety, this circuit shuts off the power and door interlock circuit simultaneously
a

emergency stop at an emergency stop so that the door interlock will not be released.
az

This protection circuit has the error detection function.

m

9 Hydraulic chuck For the chucks originally provided, check valves work to prevent the oil pressure from
Ya

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abruptly decreasing. (Check valve)

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23

10 Automatic front door The automatic closing motion of the front door is immediately stopped and reversed to
20

opening/closing opening when there is a considerable contact pressure put upon the safety switch by a
hand.
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2-14
 Serial Number 339746

SAFETY PRECAUTIONS 2

7
5
6

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B72-0001 8

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1

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A
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74 ora 2
39 rp
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6
be ak
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4
l N ki M

B72-0004
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3
Ya

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20

10
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B72-0003

Fig. 2-2 Layout of the safety devices

2-15
 2

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SAFETY PRECAUTIONS

20
23
Ya
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Se az
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2-16 E
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39 rp
Serial Number 339746

74 ora
6 tio
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 Serial Number 339746

OUTLINE OF THE MACHINE 3

3 OUTLINE OF THE MACHINE

3-1 Major Components

The major components of the machine are described below.

1. Main headstock unit

The headstock unit consists of a spindle and a headstock.
The spindle is supported by the bearings of the headstock and directly driven by the motor
contained within the headstock unit. The milling machine can freely control the indexing of the

.
C-axis in the angle range of 360°. The headstock unit is cooled by air or coolant for suppression

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of thermal displacement.

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2. Chuck

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The chuck is connected with a rotary hydraulic cylinder at the rear of the spindle by a

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connecting rod. When the piston in the cylinder moves towards the chuck, the chuck jaws open;

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when it moves away from the chuck, the chuck jaws close. (However, the movement directions

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of the chuck jaws may be reversed depending on the chuck model.)

A
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3. X-axis 74 ora
The X-axis mechanism is a unit that moves the turret in the X-axial direction by rotating the ball
39 rp

screw via an AC servomotor. The ball screw and the AC servomotor are connected using a
r 3 Co

6
coupling. Both ends of the ball screw are fixed and supported by bearings. The X-axial slideway
is a linear guide.
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4. Z-axis
l N ki M

The Z-axis mechanism is a unit that moves the carriage or carriage base in the Z-axial direction
a

by rotating the ball screw via an AC servomotor. The ball screw and the AC servomotor are
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connected using a coupling.

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The Z-axial slideway is a linear guide.

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23

5. Y-axis (MY, MSY specifications)

20

The Y-axis is rotated by the AC servomotor via the ball screw to move the carriage in the Yt-axis
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direction, and is driven in conjunction with the X-axis. The ball screw and the AC servomotor are
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connected using a coupling.

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The Yt-axial slideway is a linear guide.

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6. Turret unit
The turret unit has 12 faces and can hold 12 tools.
A 16D turret that can hold 16 tools is available with the bolt fixing type or VDI type for the
MB,MY, MS, and MSY specifications.
You can attach a rotary tool at any position for the milling machine.
The following two types of tool holders are provided: bolt fixing type and clamp type which is
similar to a VDI type. When the clamp type is used, tools can be quickly and easily mounted
and removed. When the bolt fixing type is used, the 10000 min-1 specification can be optionally
selected. During automatic operation, the turret rotates via the shortest route to index the
selected tool.
In manual operation mode, clockwise or counterclockwise rotation can be selected as required.
Except during rotation, the turret remains hydraulically clamped to the turret base.

3-1
 Serial Number 339746

3 OUTLINE OF THE MACHINE

On receiving a rotation command, the index couplings are disengaged to unclamp the turret.
Subsequently, the AC servomotor rotates the turret and when the encoder checks that the turret
has reached the command-specified position, the motor will stop and the turret will be clamped
again.
The milling head is cooled by coolant and oil mist for suppression of thermal displacement.

7. Tailstock
The tailstock is NC tail. The tailstock is driven by an AC servomotor and moves on the bed.

8. Secondary spindle
The secondary spindle is a built-in motor type (motor built in the headstock) and the spindle is

.
ed
driven directly by the built-in motor. The secondary spindle enables the 360° indexing (C-axis)

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control. The spindle is cooled by air to prevent thermal deformation. The angle of the secondary

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spindle can be changed by 0.0001°.

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9. Hydraulic unit

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The hydraulic unit supplies oil pressure to the headstock unit and the turret unit. The oil pressure

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is controlled by the solenoid valves provided for each unit.

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10. Oil lubrication unit

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74 ora
The oil lubrication unit supplies lubricating oil to the gear coupling of the turret unit.
39 rp

11. Grease lubrication unit

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The grease lubrication unit supplies grease to the linear guides and ball screws of each axis.
be ak

An NC unit supplies the optimum amount of lubrication based on running distance and operating
um az

hours.
l N ki M

12. Air kit

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An external air source is connected to the air unit to supply pressure-regulated air.
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The air unit consists of a filter, regulator, solenoid valve, etc.

Ya

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23

13. TOOL EYE

20

The TOOL EYE is provided to measure the position of the tool tip for tool setting. Measurement
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and data registration can automatically be achieved by simply bringing the tip of a mounted tool
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into contact with a sensor at the end of the TOOL EYE arm.
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14. Headstock cooling unit

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The headstock cooling unit consists of a tank, a pump, and a radiator. This unit circulates cooling
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water through the headstock unit to suppress its thermal displacement.

15. Milling headstock cooling unit

The milling headstock cooling unit consists of the tank pump radiator. The unit returns coolant to
the headstock and turret unit for suppression of heat buildup and thermal displacement in the
milling headstock motor.

16. Steady rest (Option on models with center distance of 1000 and 1500)
The steady rest consists of the steady rest arm, base unit, and connection unit. It automatically
moves when connected to the turret unit with the connection pin. Using the steady rest for
deflection caused by the weight of a long workpiece or when the tailstock cannot be used
secures safe machining.

3-2
 Serial Number 339746

OUTLINE OF THE MACHINE 3

17. Automatic operator door opening/closing device (Option)
Automatic operator door opening/closing is a unit that automatically operated with the aid of an
electric motor.
This unit consists of a motor-driven actuator and an operator door.
By installing safety switch and enabling electric speed control, it allows you to use safely without
worrying about getting caught. Opening/closing door with one-push enables workers to require
dramatically less burden.
5 8
1

17

.
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11

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13

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2

A ll
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14

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74 ora
39 rp
r 3 Co

6
6
be ak

9
um az

4
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16 B72-0057
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Fig. 3-1 Machine major components (1/3)

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20
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23
20

19
10
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21
22
B72-0058

Fig. 3-2 Machine major components (2/3)

3-3
 Serial Number 339746

3 OUTLINE OF THE MACHINE

15
3

.
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18

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12

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rig
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A
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74 ora
23
39 rp

7
B72-0055
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Fig. 3-3 Machine major components (3/3)

be ak
um az

No. Name No. Name

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1 Turret 13 USB interface panel

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2 Main circuit breaker 14 Operating panel

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3 Lubrication unit 15 Air unit

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4 Main headstock unit 16 TOOL EYE

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23

5 Headstock cooling unit 17 Pressure gauge (Chuck pressure)

20

6 Chuck pressure setting knob (Chuck pressure) 18 Electrical control cabinet

7 19 Motor-driven actuator
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Hydraulic unit
(automatic operator door opening/closing) (Option)
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8 20 Safety switch (automatic operator door opening/closing)

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Chuck
(Option)
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9 21 Steady rest (Option for machines with center distance of

Coolant tank
1000 and 1500)
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10 Tailstock 22 Pressure gauge (Steady rest)

11 Secondary spindle 23 Pressure booster valve (Steady rest)
12 Coolant pump - -

3-4
 Serial Number 339746

OUTLINE OF THE MACHINE 3

3-2 Maintenance Cover

 Do not remove the maintenance cover except in the maintenance.
 Always set the main power to OFF and lock it before removing the maintenance cover.
WARNING  Do not switch on the main power supply before attaching the maintenance cover. Failing
to do so may lead to serious physical injuries through body parts getting caught or
trapped between the drive parts.

This machine has a front, side, and rear maintenance cover as shown in Fig. 3-4 The
maintenance work on the inside of machine can be performed by removing them.

.
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74 ora
39 rp
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6
be ak

B72-0059
um az
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Right side Back maintenance cover

maintenance cover
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23
20
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B72-0060

Left side maintenance cover

Front maintenance cover

Fig. 3-4 Positions of the maintenance covers of this machine

3-5
 3

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OUTLINE OF THE MACHINE

20
23
Ya
m
Se az
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be ak

3-6 E
r 3 Co
39 rp
Serial Number 339746

74 ora
6 tio
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A ll
rig
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ed
.
 Serial Number 339746

REGULAR INSPECTION AND MAINTENANCE 4

4 REGULAR INSPECTION AND MAINTENANCE

4-1 General
1. Inspection and maintenance of the machine at regular intervals is necessary to keep the
machine in optimum operating condition as well as to allow the machine to operate for a
prolonged period. Therefore, regular inspection and maintenance should be given highest
priority.
 During either inspection or repair inside the control cabinet, lock the main power breaker
in the “OFF” position using a padlock. If the electrical control cabinet door is opened in a

.
state where the power is on, the power is switched off by a breaker trip. (Refer to Fig.

ed
WARNING 4-1.)

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* The customer should supply the padlock.

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rig
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A
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74 ora
39 rp
r 3 Co

6
be ak
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l N ki M
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Pad lock
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B72-0001
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Fig. 4-1 Main power breaker

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 Keep the door to the electrical control cabinet closed during inspection and maintenance
Se
23

work, unless it is electrically related. Never use compressed air while cleaning the
20

machine since fine dust and other foreign matter will enter the bearings and slide ways.
CAUTION
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2. Preparing the machine operation record and inspection/maintenance record

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To operate the machine according to schedule, a machine operation record is necessary.

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To record inspection/maintenance work, use either a machine operation record or prepare

a special record for this purpose.
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3. By spending a little time for regular inspection and maintenance, unexpected problems will
be eliminated. In addition, regular maintenance ensures high productivity of the machine
over a prolonged period and maintains the designed machine performance.
4. Lubrication
 Use only the recommended brands of oil listed in this manual. Use of a lubricating oil
which is not recommended could cause machine failure or other problems.

CAUTION
There are number of locations where lubricating oil must be supplied. Never supply too
much lubricating oil. To supply the lubricating oil, follow the steps described in this manual.
5. During regular inspection, checking, oil refilling, machine cleaning and other preventive
maintenance items specified in “4-3 Maintenance/Inspection Items” should be carried out.

4-1
 Serial Number 339746

4 REGULAR INSPECTION AND MAINTENANCE

4-2 MAINTENANCE CHECK Display

A MAINTENANCE CHECK display is provided to aid in checking items 1. to 5. listed in “4-1
General”.
The MAINTENANCE CHECK display is intended to notify the operator of the time to replace
coolants, lubricating oils, and other fluids. Thus, the operator can correctly check the time of
fluid replacement before an alarm occurs.
• For details, refer to PART 3 “11 DISPLAYS RELATED TO DIAGNOSIS” of
the Operating Manual of this machine.

.
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MAINTENANCE Display

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No. MAINTENANCE CHECK DATA TIME (H)
750

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CLEAN DRAIN HOLE UNDER SPINDLE
1 [ 0]

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COVER
6000

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CHANGE LONG LIFE COOLANT FOR

A
2 [ 0]
SPINDLE

n.
6000

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CHANGE LONG LIFE COOLANT FOR MILL
3 [ 0]
SP.
74 ora
39 rp

Note : This item is for the milling machine.

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6
be ak

[1500-HRS CHECK ITEMS] [3000-HRS CHECK ITEMS]

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l N ki M

1500-HRS CHECK ITEMS 3000-HRS CHECK ITEMS

No. No.
1 FUNCTION CHECK OF SAFETY UNIT 1 CHECK MACHINE LEVEL
a

2 CHANGE HYDRAULIC OIL 2 CHECK MACH. X/Z-AXIS BACKLASH

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3 CLEAN HYDRAULIC STRAINER 3 CLEAN THE LUBE SYSTEM TANKS(OIL)

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4 CHANGE LINE FILTER ELEMENT 4 CHECK SYSTEM WIRING

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5 CHECK ALL HYD. SYSTEM HOSES 5 CHANGE FILTER OF MIST SEPARATOR

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6 CHECK/REPLACE WAY COVER WIPERS 6

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7 CLEAN ALL FANS 7

8 LUBRICATE THE LINEAR BLOCK 8
20

9 CLEAN/REMOVE DRAIN OF DRAIN 9

SEPARATOR 10
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10 OVERHAUL/CLEAN CHUCK
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11 CHECK HD2 COOLING BELLOWS

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4-2
 Serial Number 339746

REGULAR INSPECTION AND MAINTENANCE 4

[DAY CHECK ITEM] [WEEK CHECK ITEM]

DAY CHECK ITEM WEEK CHECK ITEM

No. No.
1 GREASE TURN HYD. CHUCK 1 CLEAN THROUGH CHUCK CYLINDER
2 CHECK HYD. OIL LEVEL 2 CLEAN CHIP CONVEYOR
3 CHECK CENTRAL [Link] OIL LEVEL 3 CHECK EMERGENCY STOP BUTTON
4 CHECK TOOL AND HOLDER ENGAGEMENTS FUNCTION
5 CHECK TURNING SPINDLES 4 CLEAN COOLANT TANK AND FILTER
6 CHECK NO LIQUID LEAKAGE 5 CHECK FILTER OF DRAIN
7 CHECK NO FLAWS ON WINDOW GLASSES 6 CHECK DEGREE OF DIRT (LINE FILTER)
8 CHECK HYD. UNIT PRESSURE 7
9 CHECK LUBE. CONDITION 8
10 CHECK THE AIR PRESSURE 9

.
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11 CHECK CHUCK MOTION 10
12 CLEAN THE CHUCK UNIT

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13 CHECK COOLANT LEVEL

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14 CLEAN COOLANT FILTER [MONTH CHECK ITEM]
15 REMOVE CHIPS FROM THE DOOR RAIL

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16 CLEAN OPERATOR DOOR WINDOW MONTH CHECK ITEM

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17 REMOVE CHIPS FROM THE WAY COVERS No.

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18 REMOVE CHIPS FROM DOOR RAILS 1 CLEAN INTAKE FILTER OF CONTROL

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19 CLEAN AND CHECK TOOL EYE BOX
20 CLEAN AND ORGANIZE AROUND MACHINE 2 CHECK OF LAMPS ON OPERATION PANEL

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21 REMOVAL TAILSTOCK CHIPS

A
3 CLEAN COOLING SYSTEM FILTER (Note)
22 REMOVAL WORKREST CHIPS 4

n.
23 REMOVAL HD2 COOLING BELLOWS CHIPS
5

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74 ora 6
7
8
39 rp

9
10
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6
be ak
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l N ki M

Note : This item includes items for the secondary spindle of the MS and MSY specifications.
a
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23
20
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4-3
 Serial Number 339746

4 REGULAR INSPECTION AND MAINTENANCE

4-3 Maintenance/Inspection Items

The following list explains the check items and intervals. Carry out the routine inspection on the
basis of this list.
Inspection positions and corresponding numbers are given further down the list in the illustration.
Refer to the list and the illustration together.

Table 4-1 List of maintenance/inspection items

Period of inspection
Reference
sections in Number of months of

.
No. Inspection point Inspection item Every

ed
this Daily Weekly operation
manual 2 weeks

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1 3 6 12 24

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Arranging the machine periphery in order,

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1 General cleaning the machine and its periphery - 
(especially, the floor)

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Checking the chuck unit and its periphery

rig

to scan for chips

ll
Checking for secure mounting of the top

A

jaws

n.
Checking for smooth chucking/unchucking 

tio
5-1, 7-2-1,
2 Headstock Greasing the chuck unit (before operation) 7-2-2, 
74 ora
Disassembling and Cleaning the chuck 5-11-1 
39 rp

Removing any chips from the coolant

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
collector
6

Cleaning the draining holes underneath the

be ak


spindle front-end cover
um az

Checking the tailstock spindle to scan for

l N ki M


chips
Checking the tailstock body and tailstock
a

spindle for smooth forward/backward 

az

3 Tailstock movement 5-6, 7-2-8

m

Applying grease to the rear guide block 

Ya

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Checking for leakage of lubricating oil and

Se


23

for damaged piping

20

Checking the chuck unit and its periphery


to scan for chips
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Checking for secure mounting of the top

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
jaws
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Checking for smooth chucking/unchucking 5-1, 5-5-2, 

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5-11-2,
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4 Secondary spindle Greasing the chuck unit (before operation) 

7-2-9,
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Disassembling and Cleaning the chuck 7-2-10 

Removing chips sticking to the sheet metal
sections on the periphery of the secondary 
spindle
Cleaning the cooling fan filter 
Checking for secure mounting of the cutting

tools and the holder
5 Turret 5-2, 7-2-3
Checking the turret and the cutting tools to

scan for chips
5-4, 7-2-5,
X-axis, Yt-axis, Z-
6 Checking the backlush of X-, Yt- and Z-axis 7-2-6, 
axis
7-2-7

4-4
 Serial Number 339746

REGULAR INSPECTION AND MAINTENANCE 4

Period of inspection
Reference
sections in Number of months of
No. Inspection point Inspection item Every
this Daily Weekly operation
manual 2 weeks
1 3 6 12 24
Cleaning the sensor section and removing

any chips
7 TOOL EYE 5-3, 7-2-4
Checking for sounds of reaction during

sensor contact
Checking the oil levels, and if necessary,

refilling
4-5, 5-8,
8 Oil lubrication unit Cleaning the oil supply filter 
7-2-13
Checking for oil leakage and for damaged

.
ed

piping

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Checking grease amount/provide spare

se

Grease lubrication cartridges as needed 4-5, 5-8,
9

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unit Checking for oil leakage and for damaged 7-2-12


s
piping

ht
Checking for appropriate pressure 

rig
Checking the oil levels, and if necessary,


ll
refilling

A
Cleaning the strainers

n.

4-5, 5-7,

tio
10 Hydraulic unit Replacing the hydraulic oil 
74 ora 7-2-11
Checking for oil leakage and for damaged

piping
39 rp

Checking the line filter element, and if

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
6
necessary, replacing
be ak

Checking the coolant levels, and if


necessary, refilling
um az

Cleaning the radiator 

l N ki M

4-5,
Headstock cooling
11 Cleaning the radiator fan 5-11-1, 
unit
7-2-16
a

Replacing the coolant 

az

Checking the degree of dirtiness of the

m


filters and cleaning
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ria

Checking the coolant levels, and if


Se

necessary, refilling
23

Cleaning the radiator 

20

Milling spindle,
12 Cleaning the radiator fan 4-5, 7-2-17 
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turret cooling unit

Replacing the coolant 
ht

Checking the degree of dirtiness of the

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
filters and cleaning
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Checking the coolant levels, and if


necessary, refilling
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Checking the degree of dirtiness of the


filters and cleaning
13 Coolant unit Checking the degree of dirtiness of the 5-9, 7-2-14

coolant and if necessary, replacing
Cleaning up the chips 
Checking the line filter element, and if

necessary, replacing
Checking the element and if necessary,
5-10, 
14 Air unit replacing
7-2-15
Checking the air pressure 

4-5
 Serial Number 339746

4 REGULAR INSPECTION AND MAINTENANCE

Period of inspection
Reference
sections in Number of months of
No. Inspection point Inspection item Every
this Daily Weekly operation
manual 2 weeks
1 3 6 12 24
Checking if the door is fully closed 
Checking the electrical components for dirt
and discoloration and checking for loose 
Electrical control terminal screws 5-11-3,
15
cabinet Cleaning inside and outside fans of the 5-17-3

electrical control cabinet
Checking the degree of dirtiness of the

filters and cleaning

.
ed
Checking for loose connector/terminals


rv
16 Connectors between units 6-2-4,6-3

se
Checking the electric cables 

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Checking and adjusting the bed level using
17 Foundation 6-2-4 

s
a level

ht
Grounding Checking for a grounding resistance of 10 6-1-2,

rig
18 
resistance ohms or less (use a 500 V megger) 6-3-2

ll
Checking the wipers for abnormalities such 5-14,

A

Slideway and as damage 5-17-6,

n.
19
covers Checking the front door safety glass for 5-17-7,

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7-2-18 
abnormalities such as damage
74 ora
Checking for the accumulation of chips,
39 rp

and if necessary, cleaning

r 3 Co

(Around the operator door, upper area of

6

Machine internal chuck, lower area of headstock, around the 4-3, 5-6-4,
20
be ak

covers TOOL EYE, around the turret, and around 5-14

the tailstock)
um az

(When GL installed) Operator door

l N ki M


circumference
a

Cleaning up chips on the roller part and the


az

connecting pin part of the steady rest

m

Checking for smooth operation of the


Ya

ria

steady rest arm

21 Steady rest 5-12
Se

Cleaning up chips around the steady rest

23


body
20

Checking for leakage of lubricating oil/air


and for damaged piping/wiring
©
ht

Checking for secure mounting of cutting

5-15-1 
tools and milling holders
ig
yr

Checking the turret, milling holders and the

5-15-2 
op

cutting tools to scan for chips

22 Milling holder
C

Checking for entry of coolant into milling

5-15-3 
holder
Checking for looseness of eccentric pin 5-15-4,

mounting bolts 5-15-5
Automatic operator
Checking the safety switch and if
23 door 5-16 
necessary, replacing
opening/closing
Checking the degree of dirtiness of the oil

Coolant pan filter and cleaning
24 7-2-20
temperature control Checking and cleaning the chiller unit air

filter

25 Battery unit Replacing the batteries in the battery unit 5-17-3 

4-6
 Serial Number 339746

REGULAR INSPECTION AND MAINTENANCE 4

Period of inspection
Reference
sections in Number of months of
No. Inspection point Inspection item Every
this Daily Weekly operation
manual 2 weeks
1 3 6 12 24

Checking the filters for dirt or clogging 

Coolant Checking for liquid spilling from the
26 Temperature 4-4 
coupling parts of pipes
Control Unit
Checking for any abnormal sound or noise

during operation

Note 1: Maintenance check intervals are determined on the basis of eight hours operation a
day.

.
ed
Note 2: Actual inspection intervals differ according to the particular operating conditions of the

rv
machine and frequency of use. Understand that the listed values are for reference

se
only.

re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

4-7
 Serial Number 339746

4 REGULAR INSPECTION AND MAINTENANCE

5
21
11

.
ed
rv
se
re
s
ht
rig
A ll
n.
tio
74 ora
13
39 rp
r 3 Co

B72-0058
6
7
be ak

2
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

15

14
12
8
9 B72-0055
10

Fig. 4-2 Routine inspection items

4-8
 Serial Number 339746

REGULAR INSPECTION AND MAINTENANCE 4

.
ed
rv
se
re
s
ht
When cleaning this part, close the door and

rig
brush off chips to the inner side of the machine.

All
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op

B72-0061
C

Clean this area because chips may

become lodged in the tool.

Fig. 4-3 Cleaning sections of the machine internal covers

4-9
 Serial Number 339746

4 REGULAR INSPECTION AND MAINTENANCE

4-4 Checking the Coolant Temperature Control Unit (Option)

This machine can be equipped with a coolant temperature control unit as an optional
specification.
Perform a visual inspection check on the unit and record the results every specified interval.
• Checking the filters for dirt or clogging (every 2 weeks)
• Checking for liquid spilling from the coupling parts of pipes (every 3 months)
• Checking for any abnormal sound or noise during operation (every 3 months)

1. Arrangement drawing and list of the device

.
ed
rv
se
re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M

B72-0116
a
az

Coolant temperature
m

control unit (option)

Ya

ria
Se
23

Fig. 4-4 Arrangement drawing of the device

20

Rating
©

output of Coolant fluid Coolant fluid

ht

Device name Manufacturer Device model

compressor filling amount name
ig

motor
yr
op

Coolant temperature HABOR PRECISE

HJ-400PSBM2-30 0.98 kW – R410A
control unit (option) INDUSTRIES
C

4-10
 Serial Number 339746

REGULAR INSPECTION AND MAINTENANCE 4

4-5 Supplying Oil and Coolant

1. Lubrication points
 When supplying or exchanging coolant, hydraulic oil and lubricating oil, use only oil
brands recommended by MAZAK. Use of another brand of oil will cause machine
malfunction and will damage the machine.
CAUTION

Use the appropriate amount of the recommended brand of oil when adding or changing oil.

A. Hydraulic unit

.
ed
rv
se
re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az

5
m

4
Ya

ria

3 2 1
CMN-7036
Se
23

Fig. 4-5 Lubrication points (1/2)

20
©
ht
ig
yr
op
C

CMN-7037

Fig. 4-6 Lubrication points (2/2)

4-11
 Serial Number 339746

4 REGULAR INSPECTION AND MAINTENANCE

B. Headstock cooling unit/Chuck

.
ed
rv
se
re
s
ht
rig
6
B72-0001

ll
A
n.
tio
74 ora
B72-0003
10
39 rp
r 3 Co

6
Fig. 4-7 Lubrication points
be ak

C. Milling motor / milling head coolant

um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

8
9 B72-0004

Fig. 4-8 Lubrication points

4-12
 Serial Number 339746

REGULAR INSPECTION AND MAINTENANCE 4

D. Grease lubrication unit / air kit

11

.
ed
rv
se
re
s
ht
rig
ll
A
n.
tio
74 ora CMN-7035

Fig. 4-9 Lubrication points

39 rp
r 3 Co

6
E. Oil lubrication unit
be ak
um az
l N ki M

12
a
az
m

13
Ya

ria
Se
23
20
©
ht
ig
yr

14
op
C

CMN-7034

Fig. 4-10 Lubrication points

4-13
 Serial Number 339746

4 REGULAR INSPECTION AND MAINTENANCE

F. Grease lubrication unit for the ball screw and slide way (tailstock)

.
ed
rv
se
re
s
ht
rig
A ll
n.
15 A B C D E

tio
74 ora
CMN-7038
39 rp

Fig. 4-11 Lubrication points

r 3 Co

< Area requiring lubrication >

be ak

Nipple position MB, MY specifications

um az
l N ki M

A Rear, left rear bearing

B Front, left rear bearing
a

C Rear, right rear bearing

az

D Front, right rear bearing

m
Ya

E Ball screw
ria
Se
23
20
©
ht
ig
yr
op
C

4-14
 Serial Number 339746

REGULAR INSPECTION AND MAINTENANCE 4

2. List of oil and water supply
Table 4-2 Oil and water supply

Lubrication Refer
No. Part name Q’ty Recommended oil Remarks
point to
1 Oil filler port Exchange oil every 6
2 Level gauge DTE 24 (MOBIL) months, then clean
the strainer.
3 Strainer Hydraulic unit 20 L TELLUS S2 M 32 (SHELL) 5-7
Replace the line filter
4 Drain plug HYSPIN AWS 32 (CASTROL) element every 6
5 Line filter months.

6 Tank

.
ed
Headstock

rv
cooling unit

se
7 Oil filler port Exchange coolant
every 2 years.

re
5-11-1,
5.0 L LONG LIFE COOLANT (MOBIL) Follow the procedure
5-13

s
outlined in the

ht
8 Tank Maintenance Manual.

rig
Milling motor
Milling head

ll
cooling unit

A
9 Oil filler port

n.
tio
Grease 1 to KLUEBERPASTE ME (KLUEBER
10 Chuck Every day 5-1-2
74 ora
supply nipple 2 mL 31-52 LUBRICATION)
39 rp

Ball screw & Automatic lubrication.

11 Cartridge 0.7 L LHL X100-7 (LUBE) 5-8
slideway Supply occasionally.
r 3 Co

12 Oil filler port Turret index

be ak

gear Automatic lubrication.

13 Level gauge VACTRA OIL No. 2 (MOBIL)
um az

Milling head Supply occasionally.

1.8 L TONNA S3 M 68 (SHELL) 5-8-2
l N ki M

(Oil Clean the filter every

MAGNAGLIDE D 68 (CASTROL) year.
14 Suction filter lubrication
unit)
a
az

Ball screw & Manual lubrication

Grease (KYODO
m

15 slideway 30 mL Citrax EP No.1 Lubricate every 6 5-6

supply nipple YUSHI)
Ya

ria

(Tailstock) months.
Se
23

Note 1: The replacement period is determined on the basis of eight hours operation a day.
Delayed replacement or use of any product other than recommended oil may damage
20

the machine.
©
ht
ig
yr
op
C

4-15
 4

C
op
yr
ig
ht
©
20
23
Ya
m
Se az
REGULAR INSPECTION AND MAINTENANCE

ria a
l N ki M
um az
be ak

4-16 E
r 3 Co
39 rp
Serial Number 339746

74 ora
6 tio
n.
A ll
rig
ht
s
re
se
rv
ed
.
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-1 Headstock/Hydraulic Chuck

5-1-1 Construction and operation

1. Main headstock
The spindle is directly driven by a built-in motor using a variable-speed AC inverter. The
generated power is converted into machining power without mechanical loss. During manual
operation, the required spindle speed (in units of 10 min-1 or 1 min-1) is input directly to the NC

.
ed
unit. During automatic operation, the spindle speed is controlled by the constant cutting speed

rv
(surface speed) control mode.

se
re
The spindle head is cooled by coolant circulation.

s
ht
Built-in motor Headstock

rig
Speed detector

A ll
Spindle

n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M

Chuck
Cylinder
a
az

B72-0062
m
Ya

ria

Fig. 5-1 Construction of headstock

Se
23

2. Chuck
20

The chuck is connected with a rotary hydraulic cylinder at the rear of the spindle by a
©

connecting rod.
ht
ig

In case of a power chuck, when the piston in the cylinder moves towards the chuck, the chuck
yr
op

jaws open; when it moves away from the chuck, the chuck jaws close.
C

When a collet chuck is used, chuck is clamped by forward movement of the piston or
unclamped by backward movement of the piston.
 For the sake of safety and to ensure accuracy and a long chuck life, read the chuck
operation manual supplied by the chuck maker thoroughly and follow the instructions
precisely.
CAUTION

Note 1: When machining a chuck workpiece, the blank sponge of the hollow chuck and the
rear blank cap of the hollow cylinder should be used.
Note 2: When carrying out machining for a workpiece latched into the spindle, the rear blank
cap of the hollow cylinder should be used.

5-1
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

Note 3: When machining the bar material, a guide bush and filler tube of the corresponding
diameter should be used. Use only the filler tube in case of the collet chuck.
If sufficient attention is not paid to the above-mentioned points of caution, an excessive amount
of coolant may flow into the rear of the cylinder from the ‘plated through hole’ of the spindle, and
the coolant may leak out of the coolant collector part.

Cylinder Chuck
Spindle

.
ed
Solid chuck

rv
se
Chuck
Cylinder

re
Spindle

s
ht
Blank cap

rig
ll
Coolant collector

A
Hollow chuck

n.
Blank sponge

tio Chuck
74 ora
Cylinder Spindle
39 rp
r 3 Co

6
Blank cap
be ak

Coolant collector
um az

Collet chuck
l N ki M
a
az

Chuck
Cylinder
m

Spindle
Ya

ria
Se
23
20
©

Coolant collector Filler tube

ht
ig

Hollow chuck Guide bush

yr

(Bar-materials machining)
op

B72-0063
C

Fig. 5-2 Chuck

5-2
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-1-2 Greasing and lubrication

1. Greasing for the main headstock

 Bearings should be packed with the specified amount of grease when reassembling.
Particular care should be taken when packing the main spindle bearings, since
overheating of the main spindle greatly reduces its life. When packing grease, contact
CAUTION Mazak Technical Center or Technology Center.

The sections of the main headstock that require greasing are listed in Table 5-1 below.
Table 5-1 Greasing for the headstock

.
ed
Series Greasing section Recommended grease Amount of grease per row

rv
Spindle front bearing ISO FLEX NBU-15
8.0 – 8.4 mL / line

se
HTA024AEX1DB/G07UP-2: (NTN) (NOK KLUBER)

re
Spindle front bearing ISO FLEX NBU-15
QT-200 series 11.2 – 11.7 mL / line
NN3024HSKC9NAUP-10: (NTN) (NOK KLUBER)

s
ht
STABURAGS
Spindle rear bearing

rig
NBU 8 EP 4.5 – 4.7 mL / line
N1019HSKC0NAPX3: (NTN)
(NOK KLUBER)

All
Spindle front bearing ISO FLEX NBU-15
17 - 19 mL / line

n.
NN3026MBKRCC9P4YU17: (NSK) (NOK KLUBER)

tio
Spindle front bearing ISO FLEX NBU-15
74 ora
QT-250 series 14 - 16 mL / line
130BAR10STYNDBCP15P4AYU17: (NSK) (NOK KLUBER)
39 rp

STABURAGS
Spindle rear bearing
r 3 Co

NBU 8 EP 6.5 - 8.5 mL / line

6
N1022BMR1KRCC9P5YU17: (NSK)
(NOK KLUBER)
be ak

2. Greasing for the secondary headstock

um az
l N ki M

 Bearings should be packed with the specified amount of grease when reassembling.
Particular care should be taken when packing the main spindle bearings, since
a
az

overheating of the main spindle greatly reduces its life. When packing grease, contact
CAUTION
m

Mazak Technical Center or Technology Center.

Ya

ria

Table 5-2 Greasing for the secondary spindle

Se
23

Greasing section Recommended grease Amount of grease per row

20

Spindle front bearing ISO FLEX NBU-15

©

3.1 - 4.6 mL / line

HAR016-5DBCY4/14A: (JTEKT) (NOK KLUBER)
ht

Spindle rear bearing STABURAGS NBU 8 EP

ig

2.3 - 3.5 mL / line

HAR014CA-5DBCY4: (JTEKT) (NOK KLUBER)
yr
op
C

5-3
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

3. Greasing for the chuck jaws

 The specified grease must be used.
 Insufficient greasing may deteriorate the gripping force of the chuck and thus cause the
WARNING workpiece to fly about during machining.
 The power must be turned off before greasing.

A. To operate the chuck in its best condition over a long time, it is important to grease the
chuck jaws at the appropriate time. Greasing must be provided correctly and sufficiently.
Otherwise, malfunctions at low oil pressure, insufficient gripping force, decreases in
gripping accuracy, unusual wear, and/or thermal damage may result.

.
ed
B. Grease the chuck jaws from the grease nipples provided on the outer periphery of each

rv
master jaw. Greasing must be executed at least once a day using a grease hand pump. In

se
cases where high-speed rotation and a large amount of coolant water are to be used,

re
increase the frequency of greasing according to the particular operating conditions.

s
ht
Supplying new grease pushes out the existing grease. Continue greasing until the entire

rig
grease is replaced.

ll
A
C. During machine installation or if the chuck unit has not been used for a long period of time,

n.
grease the chuck jaws before starting any machining operations.
Recommended grease: tio
74 ora
Klueberpaste ME 31-52 (manufactured by KLUEBER LUBRICATION)
39 rp
r 3 Co

Note 1: After working, the chuck body and the jaw sliding surfaces must be completely
6

cleaned.
be ak
um az

Note 2: Use corrosion-preventive coolant water. Otherwise, the inside of the chuck body may
l N ki M

corrode and thus result in deterioration of its gripping force.

a

Grease nipple
az
m
Ya

ria
Se
23
20
©
ht

Grease hand pump

ig
yr
op

CMN-7039
C

Fig. 5-3 Greasing the chuck jaws

5-4
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-1-3 Adjustment of the chuck clamp/unclamp proximity switches
The proximity switches in the chucking cylinder must be adjusted if the chuck clamp or unclamp
signal is not input although the chuck has been clamped or unclamped.
Two proximity switches are provided to detect clamping and unclamping of the chuck.
Tool to be used: Wrench
(1) Set the chucking cylinder in the unclamped status.
(2) Loosen the lock nut for the unclamp proximity switch, turn the proximity switch until its head
portion comes into contact with the circumference of the detection plate.
(3) Turn the proximity switch in the reverse direction by one turn and then tighten the lock nut.

.
ed
The clearance between the proximity switch and the detection plate is set to 0.5 to 1.0 mm.

rv
se
(4) Set the chucking cylinder in the clamped status.

re
(5) Repeat steps (2) and (3) above (for clamp proximity switch).

s
ht
(6) Make sure that the clamp or unclamp proximity switch lamp is lit when the chucking

rig
cylinder is set in the clamped or unclamped status, respectively.

A ll
• For more details, refer to the instruction manual supplied by the chuck

n.
maker.
tio
74 ora
39 rp

Clamp proximity Unclamp

r 3 Co

6
switch proximity switch
be ak
um az

Lock nut
l N ki M
a
az

0.5 to
m

1.0 mm
Ya

ria
Se
23
20
©
ht

Detection
ig

plate
yr
op

B72-0008
C

Fig. 5-4 Chuck clamp/unclamp proximity switches

5-5
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-1-4 Replacement of the chuck

 When replacing the chuck, sling the chuck with hoisting belts or eye bolts to prevent the
chuck from falling. Failure to do so may cause a serious bodily injury or death.

WARNING
<Procedure>
(1) To secure the working space, return each axis to the zero point.

• For zero point returning procedure, refer to chapter “4. Manual operation” of
Part 2 in the Operating Manual of the machine.

.
ed
rv
(2) Select external chucking for the chuck.

se
(3) Open the chuck and make sure that the unclamping lamp of the chuck status indicator in

re
the display window lights up green.

s
ht
Green

rig
A ll
n.
 The draw tube comes out the front end.

tio
74 ora
• For opening of the chuck, refer to “3-8 Opening/Closing of Chuck” of Part 2
in Operating Manual of the machine.
39 rp
r 3 Co

(4) Set the main power breaker to OFF and lock it.
be ak

 Always set the main power breaker to OFF and lock it before replacing the chuck. This
um az

will eliminate the possibility of the machine being started inadvertently by someone else.
l N ki M

WARNING
a
az

(5) If a chuck cover is attached, remove it.

m
Ya

ria

(6) Loosen the jaw mounting screws and remove the top jaws and the T-nuts.
Se
23

(7) Remove the cover and the plug.

20

Note : Do this if the chuck is of a hollow type.

©

(8) Loosen the chuck fixing screw.

ht

Note : Do not remove the screw to prevent the chuck from falling.
ig
yr

(9) Attach eye bolts and lift the chuck with a crane.
op

Note : Do not lift the chuck more than necessary. Doing so will cause the chuck fixing screw
C

to break.
(10) Turn the draw nut counterclockwise with the connecting handle to disconnect it from the
draw tube.
(11) Remove the chuck, the chuck fixing screw and the draw nut.
Note : If a chuck adapter is mounted, remove it by removing its fixing screw.
To reassemble the chuck section, apply a sufficient coat of recommended grease and then
carry out a reverse procedure to that of disassembly. Be careful at that time to ensure that the
identification numbers of the chuck body and the master jaws become correct.
(12) To mount a new chuck and reassemble the chuck section, apply a sufficient coat of
recommended grease and then carry out a reverse procedure to that of disassembly.
Note : Be careful at that time to assemble the chuck and the T-nuts in the correct order.

5-6
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

Note : This procedure applies to the replacement of a three-jaw chuck manufactured by
Kitagawa Corporation, installed as Mazak standard.

• For other chucks, refer to the manuals issued by their respective

manufacturers.

Note : To maintain a high machining accuracy, the chuck should be assembled with precision
so that the runout of the chuck outer periphery will fall within 10 µm.

1 2 3

.
ed
4

rv
se
5

re
6

s
ht
rig
7

A ll
8

n.
tio
74 ora
12
39 rp
r 3 Co

9
be ak

11 10
CMN-7040
um az
l N ki M

Fig. 5-5 Replacement of the chuck

a

No. Parts name No. Parts name

az
m

1 Chuck adapter 7 Draw nut

Ya

ria

2 Chuck cover 8 Chuck fixing screw

Se
23

3 Chuck 9 Jaw mounting screw

20

4 Top jaw and T-nut 10 Chuck adapter fixing screw

5 Draw nut 11 Draw tube
©
ht

6 Plug 12 Connecting handle

ig
yr
op
C

5-7
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-1-5 Checking the headstock for disturbed accuracy in the event of collision

1. Checking the headstock for misalignment after collision

(1) Prepare the following test workpiece.
Carry out OD turning of the portion from B to A.

A B

ø100 mm

.
ed
rv
se
re
L/3 or less L = 200 mm

s
ht
rig
All
Fig. 5-6 Test workpiece

n.
tio
(2) Measure the cylindricity of the cut test workpiece using a micrometer.
74 ora
Measure portions A and B in Fig. 5-6.
39 rp

At that time, if the cylindricity stays within its tolerance of ±0.01 mm, the headstock is free
r 3 Co

from misalignment. If the cylindricity oversteps the tolerance, please contact Mazak
6

Technical Center or Technology Center.

be ak
um az

2. Checking the headstock for abnormalities occurring after collision

l N ki M

During the misalignment check described above, also check for unusual operating sounds from
a

the headstock. If they are occurring, please contact Mazak Technical Center or Technology
az
m

Center.
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

5-8
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-1-6 Cleaning

1. Cleaning the cylinder of the hollow chuck

If coolant overflows from the coolant collector, it will enter the hydraulic unit reserve tank
through the drain port. Particular care should be taken to prevent clogging the coolant collector
with chips and it should be ensured that that the coolant does not overflow within the coolant
collector.
Tool to be used: Allen wrench
(1) Remove the three bolts [2] and take the plate [1].

.
ed
(2) Chips can now be removed easily. Also check filter clogging.

rv
(3) Remount the plate in the reverse order of the removing.

se
re
1

s
ht
2

rig
A ll
3

n.
tio
4 74 ora
39 rp

5
r 3 Co

6
be ak
um az
l N ki M

7
6
a
az
m
Ya

ria

B72-0064
Se
23

Fig. 5-7 Cleaning the cylinder of the hollow chuck

20

No. Parts name No. Parts name

©
ht

1 Plate 5 Filter
ig

2 Bolt 6 Coolant collector

yr

3 Coolant 7 Drain port

op

4 Accumulated chips
C

5-9
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

2. Cleaning the draining holes underneath the spindle front-end cover

Chuck

.
ed
rv
se
re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak

Drain hole
B72-0065
um az
l N ki M

Fig. 5-8 Cleaning the draining holes underneath the spindle front-end cover

Clean the draining holes located underneath the spindle front-end cover. If the draining holes
a
az

become clogged with foreign substances such as dirt, the resulting entry of the coolant into the
m

spindle could lead to spindle damage.

Ya

ria

(1) Turn off the main power before starting the cleaning operations.
Se
23

(2) Remove dirt and other foreign substances from the draining holes by cleaning with a
20

marking-off pin or the like.

©

Note 1: Remove the chuck and the spindle front-end cover if dirt or other foreign substances
ht
ig

cannot be removed from the draining holes.

yr

Note 2: Do not blow off air to clean. If air is blown off, foreign substances such as dirt could
op

enter the spindle.

C

Note 3: Do not remove the chuck cover located at the top of the chuck. The chuck cover
prevents the rotating section of the spindle from being directly exposed to splashing
coolant.

5-10
 5-1-7
SURFACE OF SURFACE OF
CYLINDER ADAPTER SPINDLE
C 12-M12 THROUGH LEFT SIDE
1118 (MB/MY/MS/MSY 500U)
COVER 1188 (MB/MY 1000U/1500U) SURFACE OF
FACE COVER
op
517 (MB/MY/MS/MSY 500U)
447 (MB/MY 1000U/1500U)
yr
ig
CHUCK COVER
ht

Fig. 5-9
©
20
CYLINDER
23
Ya SUPPORT

m
Chuck assembly interface

Se az
ria a
l N ki M
um az
CYLINDER SUPPORT
be ak

5-11
r 3 Co
39 rp
A VIEW
Serial Number 339746

74 ora
6 tio CHUCK COVER
n.
A ll
rig
ht
s

Chuck assembly interface (QT-200 series spindle motor output 26 kW A2-6)

re
OPTION SPECIFICATIONS
se
(SPINDLE MOTOR OUTPUT: 26 kW)
rv
ed
.
MAINTENANCE OF MAJOR MACHINE UNITS

Unit: mm
B VIEW
5
 5
SURFACE OF
SURFACE OF
CYLINDER ADAPTER SPINDLE
C LEFT SIDE
1139.5 (MB/MY/MS/MSY 500U)
COVER 1209.5 (MB/MY 1000U/1500U) SURFACE OF
FACE COVER
op
468.5 (MB/MY/MS/MSY 500U)
476 (MB/MY 1000U/1500U)
yr
ig
ht CHUCK COVER

Fig. 5-10
©
20
23
CYLINDER
SUPPORT
Ya
m
Se az
MAINTENANCE OF MAJOR MACHINE UNITS

ria a
l N ki M
um az
CYLINDER SUPPORT
be ak

5-12
r 3 Co
39 rp
A VIEW
Serial Number 339746

74 ora
6
CHUCK COVER
tio
n.
A ll
rig
ht
s

Chuck assembly interface (QT-250 series spindle motor output 26 kW A2-8)

re
STANDARD SPECIFICATIONS
(SPINDLE
se MOTOR OUTPUT: 26 kW)
rv
ed
.
C DETAIL

Unit: mm
B VIEW
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-2 Turret

5-2-1 Construction and operation (MB, MS, MY, MSY specifications)

For construction of the turret see Fig. 5-11.

1. Component parts of the turret

The turret unit consists of following components.

A. Turret base unit

.
The base unit of the turret is where the turret component parts are mounted. It is fixed to the X-

ed
axis linear motion guide.

rv
se
B. Turret head

re
s
The turret head has 12 or 16 faces and each face (position) may be mounted with a cutting tool.

ht
rig
C. Milling spindle drive motor

A ll
This built-in motor provides the drive when a milling tool is used.

n.
tio
D. AC servomotor
74 ora
The roller gear cam unit rotates the turret head and can index the head to any position.
39 rp
r 3 Co

6
2. Turret head clamping
be ak

The turret head is hydraulically clamped to the turret unit while it is not rotating. The index
um az

coupling with which the turret head is engaged ensures accurate indexing of the turret to the
l N ki M

required tool position.

a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

5-13
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

3. Operation of turret
When the turret rotation command becomes active, the turret head is disengaged from the
index coupling and becomes unclamped. The turret head is then rotated by the AC servomotor.
The turret head position is detected by the encoder at the end of the AC servomotor; when the
turret head is indexed to the commanded position, the motor stops and the turret head is
clamped to the turret base.
During automatic operation, the turret rotation direction is determined from the currently located
turret head position and the target index position so that it will rotate in the shortest way.
During manual operation, the turret rotation direction is selected with the tool select button [33]
on the machine operating panel.

.
ed
: Forward, clockwise viewed from the turret face

rv
se
: Reverse, counterclockwise viewed from the turret face

re
Turret head Turret unit

s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M

AC servomotor
(with built-in encoder)
a

Milling spindle drive motor B72-0066

az
m

Fig. 5-11 Construction of turret (MB, MS, MY, MSY specifications)

Ya

ria

4. Turret rotation
Se
23
20

A. Turret head rotation method

©

The AC servomotor makes a short-cut turn toward the next tool to rotate the turret head during
ht

automatic operation. The turret head conducts two-step gear reduction via an intermediate gear
ig
yr

shaft and is set to achieve a final gear ratio of 1/36 (MB, MY, MS and MSY specifications) with
op

respect to the motor.

C

Turret position is detected by the encoder at the end of the turret motor.

B. Turret rotation direction

Forward (FWD): The turret rotates clockwise when viewed from the turret face.

C. Milling tool driving method

When using a milling tool, it is driven by the 5.5 kW AC spindle motor, and its rotation speed is
controlled by the AC inverter.
Standard rotation specifications: 5000 min-1

D. Milling tool rotation direction

Forward (FWD): The tool rotates counterclockwise when viewed from the output axis (tool) side.

5-14
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

E. Relationship between the turret and milling tool rotation directions and the milling
spindle drive motor rotation direction
The relationship between the turret and milling tool rotation directions and the milling spindle
drive motor rotation direction is shown in Fig. 5-12.
(Rotation directions of motors when those of turret head and tool are forward)
V-type Tool: CCW Rotation: CCW
Milling spindle drive motor
H-type Tool: CCW Rotation: CW
Swivel motor Turret head: CW Rotation: CW

When the AC servomotor rotates CW, the turret head moves FWD.

.
ed
(H-type tool)

rv
se
re
s
ht
FWD

rig
AC

ll
Encoder

A
servomotor

n.
tio
74 ora
Turret head
39 rp

Milling spindle
r 3 Co

6
drive motor
be ak
um az

Rotation direction
l N ki M

(Tool side) (Motor side)

FWD
H-type FWD
a

CW
az

(CCW)
m

V-type FWD
CCW
Ya

(CCW)
ria

CMN-7041
Se
23

Fig. 5-12 Rotation direction of turret head

20
©
ht
ig
yr
op
C

5-15
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5. Turret indexing sequence

The turret indexing sequence is explained below. This shows how the command to select tool
No. 5 is executed while the turret is in the position of tool No. 1.

A. Flow chart

Tool No. 5 command Addresses

Milling spindle orientation

.
ed
YV-1: ON Valve for turret head unclamp ON (Y130D)

rv
se
Turret clamp confirmation signal OFF (X1303)

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SQ-4: OFF

s
ht
Timer T15 Turret unclamp confirmed (T15)

rig
A ll
Turret motor ON Turret rotation start

n.
tio
Turret rotation stop
74 ora
In-position signal: ON
39 rp
r 3 Co

Milling spindle orientation:

6
Cancel
be ak
um az

YV-2: ON Valve for clamp ON (Y130C)

l N ki M

SQ-4: ON Clamp confirmation signal ON (X1303)

a
az
m

Turret motor OFF

Ya

ria
Se
23

Turret rotation completed

20
©

• For details of signal and sensor designations refer to the electric circuit
ht

diagram.
ig
yr
op
C

5-16
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

B. Timing chart

Tool Tool Tool Tool Tool

Start No. 01 No. 02 No. 03 No. 04 No. 05 Complete

Tool No. 5 command ON

OFF
unclamp
Turret head
clamp

Turret head rotating

stop
Turret motor ON
OFF
YV-1 ON

.
ed
(Turret head unclamped) OFF

rv
SQ-4 ON
(Clamp confirmation) OFF

se
In-position signal ON

re
OFF

s
Milling spindle orientation ON

ht
OFF

rig
Fig. 5-13 Timing chart

A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
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C

5-17
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-2-2 Adjustment

1. Reference position of turret indexing

The turret head is driven and indexed by a servomotor on the basis of an absolute positioning
system. The controller has the factory-set reference position stored in its memory to perform
absolute positioning. If the stored data should be lost due to a drop of the battery voltage or if
the controller itself has been replaced, set and store the reference position anew by the
following procedure:

(1) Press the button in the upper right of the NC screen, and then press .

.
ed
(2) Tap [TURRET MAINTE].

rv
LUBE ECO

se
FORCE MODE MAINTE- TURRET

re
MENU INVALID NANCE MAINTE

s
ht
rig
ll
(3) For the milling specification, tap [TURRET MILL ORT] when in manual mode to orient the

A
milling spindle. Menu turns blue (enabled).

n.
tio
Note 1: When the operation door is open, for safety reasons, you are required to tap
74 ora
[TURRET MILL ORT] while pressing and holding the Enable button.
39 rp
r 3 Co

TURRET TURRET TURRET TURRET

6

MILL ORT UNCLAMP [Link] HOME SET

be ak
um az

When the operation door is open, press and hold the Enable button
l N ki M

(4) In manual mode while you tap [TURRET UNCLAMP] to unclamp the turret. Menu turns
a

blue (enabled).
az
m
Ya

ria

TURRET TURRET TURRET TURRET

MILL ORT UNCLAMP [Link] HOME SET
Se
23
20
©

(5) Press and hold the key [17] on the machine operating panel while you tap [TURRET
ht

[Link]] to change to turret initial setting mode. Menu turns blue (enabled).
ig
yr
op
C

LUBE ECO
FORCE MODE MAINTE- TURRET
MENU INVALID NANCE MAINTE

TURRET TURRET TURRET TURRET

MILL ORT UNCLAMP [Link] HOME SET

While pressing and holding key [17]

Fig. 5-14 Turret zero-point setting (1/2)

5-18
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

(6) Press tool selector button [33] to move the position of tool number 1 so that it faces in the
direction of the spindle centerline (zero-point position). (Roughly visually align the turret
and the top of the turret base.)
Unlike regular rotation movement, the turret rotates continuously if the tool selector button
[33] is pressed and held when [TURRET [Link]] is blue (enabled).

.
ed
TNo.1

rv
se
re
s
ht
rig
B72-0067

A ll
Fig. 5-15 Turret zero-point setting (2/2)

n.
(7) Tap [TURRET UNCLAMP] to change from blue (enabled) to white (disabled).
The turret is clamped.
tio
74 ora
When the turret is clamped properly, clamping-piston contact sounds or motor beating
39 rp

sounds will not occur. Determine the position of tool number 1 when the machine is in this
r 3 Co

state.
be ak

(8) Tap [TURRET UNCLAMP] again to unclamp the turret.

um az

Menu turns blue (enabled).

l N ki M

(9) Ensure that [TURRET [Link]] is blue (enabled).

a
az

Press and hold the key [17] when the menu is not blue (enabled) while you tap
m

[TURRET [Link]] to change it to blue (enabled).

Ya

ria

(10) Tap [TURRET HOME SET] when the machine is in this state to set the turret zero-point
Se
23

position.
20

(11) Press and hold the key [17] while you tap [TURRET [Link]] to change menu from
©

blue (enabled) to white (disabled).

ht
ig

(12) Tap [TURRET UNCLAMP] to change from blue (enabled) to white (disabled).
yr

The turret is clamped.

op

When the turret is clamped properly, clamping-piston contact sounds or motor beating
C

sounds will not occur.

5-19
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-2-3 Cleaning

1. Cleaning the coolant block

If the discharge rate of the coolant from the tool nose decreases, when the coolant level in the
coolant tank, the coolant pump (electromagnetic switch), and the filter are normal, inside of the
coolant block is likely to be clogged with chips. Clean the coolant block in such a case.
Tool to be used: Allen wrench
(1) Turn off the main power. If cleaning is started with the main power on, the hydraulic oil will
spout.

.
ed
(2) Remove the four mounting bolts from the coolant block.

rv
(3) Remove the coolant block.

se
At this time, be careful not to lose the three O-rings mounted on the face between the

re
coolant block and the turret base.

s
ht
(4) After cleaning the coolant discharge hole, remount the coolant block.

rig
Fit the coolant block to the surfaces A and B taking great care so as not to damage the O-

ll
rings.

A
n.
tio
74 ora
39 rp
r 3 Co

6
A
be ak

M8 bolt (4 locations) O-ring (3 locations)

um az
l N ki M
a

B
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op

Coolant discharge hole

C

Coolant block

B72-0068

Fig. 5-16 Cleaning the coolant block

5-20
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-2-4 Turret unit internal maintenance
For the turret unit, the maintenance work on the inside of the machine can be performed after
the following procedure. Remove the cover [1] on the rear side of the machine. Remove the
mounting bolts of [2] from the front and rear sides of the machine and pull out [2] to the rear side
of the machine.

.
ed
rv
se
re
s
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rig
A ll
n.
tio
74 ora
39 rp

[1]
r 3 Co

[2]
be ak
um az
l N ki M
a

B72-0069
az

Fig. 5-17 Maintenance of the turret

m
Ya

ria
Se
23
20
©
ht
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5-21
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-3 TOOL EYE

5-3-1 Construction and operation

The TOOL EYE is used to measure the tool tip position for the tool set measurement function
and automatic tool wear compensation function. The arm of the TOOL EYE swings into
(extending) the measuring position by a motor.
The sensor mounted in the arm tip measures the tool tip position by bringing it into contact with
the sensor. After completion of measurement, the arm retracts to the stand-by position
(retracting). Completion of arm motion is confirmed by proximity sensors (SQ-7 (for extension)
or SQ-8 (for retraction)).

.
ed
rv
se
re
s
ht
rig
A ll
n.
tio
1
74 ora
39 rp
r 3 Co

6
be ak

5
um az

2
l N ki M

4
A-view 1
a
az
m
Ya

ria

3
Se
23

7
20

A 2 CMN-7042
©

Fig. 5-18 Construction of TOOL EYE

ht
ig

No. Parts name No. Parts name

yr

1 Proximity sensor SQ-8 5 Tool

op

2 Proximity sensor SQ-7 6 Turret

C

3 Arm 7 Torque motor

4 Sensor

5-22
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-3-2 Checking and adjustment

1. Checking the TOOL EYE for extending/retracting

To check the TOOL EYE for extending/retracting, use the following addresses displayed on the
DIAGNOSIS MONITOR display.
TOOL EYE extending : Address X1706 (bit 6 of X1700)
TOOL EYE retracting : Address X1707 (bit 7 of X1700)

2. Replacement of the TOOL EYE sensor

.
Tools to be used: Allen wrench

ed
Dial indicator (Micro dial indicator)

rv
se
(1) Tap the [TOOL DATA], [TOOL MEASURE], and [MSR UNIT ON] menu items in this order

re
to extend the TOOL EYE arm to the measuring position.

s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr

CMN-7043
op

Fig. 5-19 Replacement of the TOOL EYE sensor (1/4)

C

5-23
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

(2) Remove the four bolts.

.
ed
rv
se
re
CMN-7044

s
Fig. 5-20 Replacement of the TOOL EYE sensor (2/4)

ht
rig
(3) Pull the joint section from the arm body, and pull that section away by slightly rotating it.

ll
A
n.
tio
74 ora
39 rp
r 3 Co

6
be ak

Joint section
um az
l N ki M
a
az
m

CMN-7045
Ya

ria

Fig. 5-21 Replacement of the TOOL EYE sensor (3/4)

Se
23

(4) Remove the bolts and then the TOOL EYE sensor.
20
©
ht
ig
yr
op
C

CMN-7046

Fig. 5-22 Replacement of the TOOL EYE sensor (4/4)

(5) Mount the new TOOL EYE sensor and fix it in place following the above steps in the
reverse order.

5-24
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

(6) Adjust the alignment after changing the sensor.
• Fix the dial indicator or micro dial indicator to the turret and adjust parallelism using
the reference block of the sensor. At that time, leave the four bolts loose.
• Allowable parallelism to the X-axis is within 0.002 mm.
(7) After adjustment of parallelism, retighten the four bolts.
After fastening the bolts, repeat measurement once again to ensure accurate parallelism.

.
ed
rv
se
re
s
ht
rig
Bolt Reference block

A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M

Dial indicator
a
az

CMN-7047
m
Ya

ria

Fig. 5-23 Adjustment of the sensor section

Se
23
20
©
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ig
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5-25
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-4 X-, Y- and Z-Axes

5-4-1 Construction and operation

1. X-, Y- and Z-Axes

The turret and the carriage are driven respectively by the X-axis or Z-axis AC servomotor via the
ball screw to move in the respective directions. The position encoder is located at the end of the
motor and the motor is directly connected to the ball screw by coupling ensuring high
positioning accuracy.
The carriage is driven by the Y-axis AC servomotor via the ball screw to move on the carriage

.
ed
base in the Yt-axis direction. The Y-axis is composed based on this Yt-axis and the X axis. The

rv
Y-axis AC servomotor and the ball screw are connected directly by a coupling, offering highly-

se
accurate positioning. (MY, MSY specifications)

re
s
ht
rig
A ll
n.
tio
74 ora
X axis motor
39 rp

X-axis
r 3 Co

6
Z-axis
be ak

Z axis motor
um az
l N ki M

Y-axis
a
az
m

Y axis motor
Ya

ria
Se

B72-0070
23
20

Fig. 5-24 Construction of the axis

©
ht

X-axis ball screw Coupling AC servomotor

ig
yr
op
C

Bearing Bearing
CMN-7048

Fig. 5-25 Construction of X-axis

5-26
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

AC servomotor Coupling Z-axis ball screw

Bearing Bearing

.
CMN-7049

ed
rv
Fig. 5-26 Construction of Z-axis

se
re
Y-axis ball screw Coupling AC servomotor

s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
Bearing Bearing
CMN-7050
be ak
um az

Fig. 5-27 Construction of Y-axis

l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
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op
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5-27
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-4-2 Zero-point setting method

In case of the zero-point return operation using the operating panel, since the machine zero-
point becomes the machining standard for the NC unit (MAZATROL), the zero-point return
position must be adjusted accurately.
Since this machine is shipped after setting the zero-point, there is almost no need for the
customer to make any adjustments. When the customer replaces the ball screw, removes the
coupling or removes the encoder, or in case of data loss due to insufficient servo amplifier
battery capacity, it becomes necessary to adjust the zero-point position.
In the following case, set the zero-point by following the steps in “1. A. Zero point setting in the
event of an absolute zero point data loss (due to a decrease in the battery voltage)”.

.
ed
• If the battery voltage of the servo amplifier dropped

rv
se
However, in case of loss of zero-point position due to battery insufficiency, carry out this

re
operation after replacing the battery with a new one.

s
ht
In the following cases, set the zero-point by following the steps in “1. C. Zero point setting in the

rig
event of the zero point position shifting (when replacing servo amplifier, servo motor, ball screw,

ll
etc.)”.

A
n.
• If the servo amplifier is replaced

tio
• If the servo motor is replaced
74 ora
• If the ball screw is replaced
39 rp

All zero-points must be adjusted for X-axis, Y-axis and Z-axis (MY, MSY specifications), or the
r 3 Co

X-axis, Y-axis, Z-axis or turret axis (MB or MS specifications) when the integrated servo
be ak

amplifier is replaced.
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

Z-axis zero-point
alignment mark

X-axis zero-point
alignment mark

CMN-7051

Fig. 5-28 Nameplates for zero-point alignment marks

5-28
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

1. Setting of the absolute zero point

A. Zero point setting in the event of an absolute zero point data loss (due to a decrease in
the battery voltage)
If the absolute zero point is lost due to a drop in the voltage of the absolute pulse recorder
battery, set it again following the steps below. If the battery needs to be replaced, see “5-17-3
Electrical control cabinet” for replacement directions.
(1) Press the / / / key [13] on the machine operating panel.

Moving side

.
ed
rv
se
re
Fixed side

s
ht
rig
A ll
n.
tio
a: Zero-point return start
74 ora
b a position
b: Zero point arrow
39 rp

CMN-7052
r 3 Co

6
Fig. 5-29 Panels for zero point position
be ak

(2) Arrow-shaped panels are attached on the moving side and fixed side of each axis. (Refer
um az

to Fig. 5-29.)
l N ki M

Perform the axis movement until the arrow of the moving-side panel reaches the position “a”
(shown in Fig. 5-29) of the fixed-side panel using the manual pulse handle [22], and match
a
az

the positions roughly.

m
Ya

(3) Press the key [12] to set the machine to zero-point return mode.
ria
Se

(4) Press the axis movement key [28] to move the axis that sets the zero-point in the plus
23

direction.
20

(5) When the zero point arrow on the moving side panel aligns with the zero point arrow (red)
©

on the fixed side panel, the zero point return indicator for the corresponding axis lights (see
ht

Fig. 5-30) and the zero point is established.

ig
yr

(6) The indicator corresponding to each axis on the monitor of the NC display lights up.
op
C

MACHINE

X ← Lights when the X-axis has returned

to the machine zero point.
Z ← Lights when the Z-axis has returned
to the machine zero point.

 B72-0071

Fig. 5-30 Example of the indication of zero point return

5-29
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

B. If the zero-point is set to an incorrect position

If the zero-point is set to an incorrect position, delete the zero-point and set a zero-point again.
< Procedure >
(1) Tap the [PARAM] menu item.
(2) Tap the [MACHINE PARAM.] menu item and then the [M] menu item.
(3) Make a note of the parameter M16 value of the axis whose zero-point is to be deleted and
rewrite the value with 0.
 The zero-point is lost.
(4) Return the parameter value from 0 to the value before the change. (Note)

.
ed
(5) Restart the zero-point return operations from the beginning of “A. Zero point setting in the

rv
event of an absolute zero point data loss (due to a decrease in the battery voltage)”.

se
Note : If the parameter value is not returned to the correct value, the zero-point will become

re
out of alignment. Make sure to follow this procedure.

s
ht
C. Zero point setting in the event of the zero point position shifting (when replacing servo

rig
amplifier, servo motor, ball screw, etc.)

ll
A
When the servo motor or ball screw is replaced, or when the coupling or the encoder is

n.
removed, the zero-point will become out of alignment. The amount of grid shift and the absolute
zero-point need to be reset. tio
74 ora
(1) Move the axis (X-axis, Z-axis, or W-axis (MS, MSY specifications)) on which a new zero-
39 rp

point is set to the current zero-point. (Refer to 3. Determining zero-point.)

r 3 Co

(2) The SERVO MONITOR display is displayed by selecting [DIAGNOS] - [VERSION] -

be ak

[SERVO MONITOR].
um az

(3) Read the grid position of the axis for setting the zero-point on the SERVO MONITOR
l N ki M

display, and set the position in M16. (Refer to Fig. 5-31.)

a

Example : When the value of “GRID” of the X-axis is “8.2870 mm”, set “82870” (unit:
az

0.0001 mm) in the parameter M16 (X).

m
Ya

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B72-0072
C

Fig. 5-31 Grid position display

(4) Use manual pulse feeds to move the axis to set the zero point by half grids (X-axis: 5 mm,
Z-axis: 6 mm, W-axis: 5 mm) in the minus direction from the machine zero-point.

(5) Press the key [12] on the machine operating panel to set the machine to zero-point
return mode.
(6) Press the axis movement key [28] to move the axis that sets the zero-point in the plus
direction and start zero-point return action that stops the axis at the zero-point location.
(The zero-point is established.)
(7) Check if the determined machine zero-point is correct.
If fine adjustments are required, repeat the procedures from (1). If fine adjustments are not
required, the zero-point adjustment is completed.
If the software limit value (parameter M8) has been changed, return the value to the original
value.

5-30
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

2. Setting the machine zero-point using the proximity sensor (Y-axis only)

A. Principle of the zero point using the proximity sensor

If the absolute zero point has been lost, the Y-axis must be operated using the proximity sensor
or zero-point watchdog. Immediately after power-on, always perform the zero-point return to
store the zero point in the NC operation before automatic operation.
By performing the zero return operation, a predetermined point is established as the machine
zero point in the following manner.

(1) When the key [12] on the machine operating panel is pressed, the zero-point return
mode signal turns on.

.
ed
(2) Move the axis in the direction of the axis zero point using the axis movement key [28].

rv
se
(3) When the zero point proximity sensor is tripped by the dog, the deceleration signal is

re
turned on, turret motion is decelerated, and the turret moves at the predetermined feedrate.

s
(4) After the zero point proximity sensor is released from the dog, the turret continuously

ht
rig
moves to the point far from the last grid signal by the amount preset in parameter N10.
(This is the electrical zero point.) The turret further moves from this point by the zero-point

A ll
shift amount set in parameter M16.

n.
Parameter settings are as follows:
tio
74 ora
Axis Parameter Setting Parameter Setting
39 rp

Shift amount from the electrical to

r 3 Co

6
Y-axis N10 10 (fixed) M16 the machine zero point (variable,
machine-specific)
be ak
um az

The grid signal is always turned on at the fixed position unless the relative position between the
l N ki M

encoder input shaft and the ball screw is not changed. The zero point shift amount is a fixed
amount set with a parameter in the NC.
a
az

Proximity sensor
m
Ya

ria

Zero point return direction

Se
23
20
©
ht

Dog
ig
yr

ON
op

OFF OFF
Zero point proximity sensor
C

Axis feedrate

Zero return feedrate

N10 M16
ON

OFF
Grid signal
Machine zero point

Electrical zero point

B72-0073

Fig. 5-32 Principle of Y-axis machine zero point

5-31
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

B. Adjusting the proximity sensor and setting the zero-point shift amount
Before the machine zero-point is reset at replacement of the proximity sensor, servomotor, ball
screws, and others, the proximity sensor needs to be adjusted and the zero-point shift amount
needs to be reset.
(1) Adjust the clearance between the proximity sensor and the watchdog to 0.5 to 1.0 mm.
(For the adjustment procedure, refer to 5-17-6 “Procedure for replacing the proximity
sensor”.)
(2) Set the zero-point shift amount set in the Y-axis of the parameter M16 to 0.
(3) Adjust the watchdog position so that the distance from the proximity sensor OFF to the grid
point equals to the half of the grid distance.

.
ed
• The grid distance for the Y-axis is 10 mm.

rv
se
• The ON/OFF status of the zero-point proximity sensor can be checked with the

re
diagnosis memory I/O check on the DIAGNOSIS MONITOR display.

s
Y-axis zero-point sensor: When X1304 is 0, the proximity sensor is on, and when X1304

ht
rig
is 1, the proximity sensor is off.
The distance from the proximity sensor OFF to the first grid can be checked with GRID

A ll
(Refer to Fig. 5-31.) on page 2/2 of the SERVO MONITOR display.

n.
(4) Perform the zero-point return, and record the counter value after the zero-point return.
tio
74 ora
(5) Move the Y-axis to the zero point in accordance with the following “3. Determining zero-
point”, and record the counter value.
39 rp
r 3 Co

(6) Set the difference between the counter values of (4) and (5) in the Y-axis of the parameter
6

M16 as the zero-point shift amount.

be ak
um az
l N ki M
a
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5-32
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

3. Determining zero-point

A. X-axis
Determining after cutting the test piece
Mount a test piece (round bar) in the chuck and turn outside diameter. Measure the diameter
accurately after cutting. Let the diameter be D.

Zero point

X2

.
ed
rv
X1
X3

se
re
X

s
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rig
øD

A ll
B72-0074

n.
tio
74 ora Unit: mm
X1 X2 X3
Bolt on 12D 500 205 105
39 rp

VDI 12D 500 160 150

r 3 Co

6
Bolton 16D 500 215 105
VDI 16D 500 193 125
be ak
um az

Fig. 5-33 X-axis zero-point return (1/2)

l N ki M

The X-axis zero-point is X1 mm distant from the spindle center. Therefore, move the X-axis by X
a

= [X1– (X2 + X3 + D/2)] mm while observing the counter reading. The point reached is the X-
az

axis zero-point position.

m
Ya

ria

Note : The X-axis counter reads the diameter value. A value double the above value should
be read on the counter.
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5-33
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

When determining by the center of the hole of the boring bar holder and the center of the
spindle
Mount a boring bar holder on the turret. Mount a pick tester mounting jig on the chuck. Match
the pick tester with the inner diameter of the hole of the boring bar holder, rotate the chuck and
measure the movement of the pick tester. Move the X-axis such that the movement is 0.02 mm
or less.

Zero point

.
ed
X2

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s
X1

ht
X5

rig
ll
X4

A
n.
tio
74 ora B72-0075
39 rp

Unit: mm
r 3 Co

6
X1 X2 X4 X5
be ak

Bolt on 12D 500 205 200 95

VDI 12D 500 160 200 140
um az

Bolt on 16D 500 215 195 90

l N ki M

VDI 16D 500 193 197 110

a

Fig. 5-34 X-axis zero-point return (2/2)

az
m

The X-axis zero-point is X1 mm distant from the spindle center. Therefore, move the X-axis by
Ya

ria

X4 = [X1– (X2 + X5)] mm while observing the counter reading. The point reached is the X-axis
Se

zero-point position.
23
20

Note : The X-axis counter reads the diameter value. A value double the above value should
be read on the counter.
©
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5-34
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

B. Z-axis
Determining after cutting the test piece
Mount a test piece in the chuck and perform face turning.
Measure the length from the spindle nose to the test piece edge. Let the measurement be L1.

Z2

.
ed
Z1

rv
se
L1

re
s
ht
rig
A ll
n.
tio
B72-0076
74 ora
Unit: mm
39 rp
r 3 Co

Z1 Z2
6

500U 1000U 1500U

Bolt on VDI
be ak

Bolt on VDI Bolt on VDI Bolt on VDI

QT-200MB, MY (A2-6) 694 680 1159 1186 - -
um az

QT-200MS, MSY (A2-6) 544 530 964 991 - -

l N ki M

7 25
QT-250MB, MY (A2-8) 674 660 1139 1166 1659 1670
QT-250MS, MSY (A2-8) 524 510 944 969.5 - -
a
az
m
Ya

ria

Fig. 5-35 Z-axis zero-point return (1/2)

Se
23

The Z-axis zero-point is Z1 mm distant from the spindle edge. Therefore, move the Z-axis by Z
20

= [Z1 – L1] mm while observing the counter reading. The point reached is the Z-axis zero-point
©

position.
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5-35
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

When determining by the distance between the chuck edge and the turret edge
Set a block gauge on the chuck edge. Move the Z-axis using manual pulse (x10) such that it
slightly hits the edge of the block gauge (L2).

.
ed
rv
se
re
s
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rig
L L2
Z2

A ll
B72-0077

n.
tio
74 ora
Unit: mm
39 rp
r 3 Co

6
L
be ak

Hollow chuck (B-208) 103

Hollow chuck (B-210) 113
um az

Hollow chuck (BB-208) 111

l N ki M

Hollow chuck (BB-210) 113

a
az

Z2
m

500U 1000U 1500U

Ya

ria

Bolt on VDI Bolt on VDI Bolt on VDI

QT-200MB, MY 701 705 1166 1211 - -
Se
23

QT-200MS, MSY (A2-6) 551 555 971 1016 - -

20

QT-250MB, MY 681 685 1146 1191 1666 1695

QT-250MS, MSY (A2-8) 531 535 951 994.5 - -
©
ht
ig

Fig. 5-36 Z-axis zero-point return (2/2)

yr

The Z-axis zero-point is Z2 mm distant from the spindle edge. Therefore, move the Z-axis by Z
op

= [Z2 - (L + L2)] mm while observing the counter reading. The point reached is the Z-axis zero-
C

point position.

5-36
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

C. Y-(Yt-) axis

Jig

.
ed
Boring bar holder

rv
se
Pick tester

re
s
B72-0078

ht
rig
Fig. 5-37 Y-axis zero-point return

A ll
Mount a boring bar holder on the turret head.

n.
Mount a pick tester mounting jig on the spindle taper (1/16) and set the pick tester.
tio
74 ora
The Y-axis zero point is a position where the center of the spindle matches with the center of
the boring bar hole. Move the turret base to a position where the center of the boring bar hole
39 rp

matches with the center of the spindle.

r 3 Co

(Position of the X-axis from the zero-point MB, MY, MS, MSY specifications: 200 mm)
be ak

Then, put the tip of the pick tester on the hole face, and rotate the spindle once slowly. The zero
um az

point of the Y-axis can be obtained by adjusting the X-axis and the Y-axis so that the pick tester
l N ki M

does not swing.

a
az
m
Ya

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Se
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5-37
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

D. W-axis (secondary spindle)

As shown in the figure below, the mm position of the distance W between the main and
secondary spindle gauge lines is the W-axis zero point.

Main spindle edge

Secondary spindle edge
Secondary spindle zero point
A B

.
ed
rv
se
re
Unit: mm

s
W

ht
QT-200MS, MSY 837

rig
QT-250MS, MSY 817 B72-0079

A ll
Fig. 5-38 W-axis zero-point return

n.
tio
First, manually move the secondary spindle to the main spindle side. At the position where the
74 ora
chuck jaw of the secondary spindle touches the chuck of the main spindle, reset the W-axis
counter to 0.
39 rp
r 3 Co

Measure or refer to the assembly drawings to check the height of the mounted chuck, and
6

check the distance from the gauge line to the jaw edge. Regard this distance as A or B.
be ak
um az

Move the secondary spindle toward the zero point by [W - (A + B)] watching the numerical value
l N ki M

on the counter. The W-axis zero point can be obtained with these operations. As shown in the
figure above, the value of W differs depending on the machine specifications.
a
az
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5-38
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-4-3 Adjustment

1. Backlash compensation
The following factors between the X- or Z-axis position encoder and the turret generate errors
between the axis motion command value and actual turret position.
• Backlash in bearings and ball screws
• Ball screw pitch deviation
Backlash in the mechanical power transmission system is an unavoidable factor.
A too small backlash imposes overload on bearings, gears and other mechanical parts causing

.
ed
noise and shortening their life.

rv
The NC has the ability to compensate electronically for errors generated in the mechanical

se
system. This is called the backlash compensation function.

re
The backlash compensation function is factory-set to the optimum condition and will not need

s
ht
further adjustment after installation of the machine. However, if this does not compensate for

rig
backlash-caused error during a long period of use, the backlash compensation data can be set

ll
again.

A
n.
The backlash compensation data can be set by changing the parameter data stored in the NC.
Tool to be used: Dial indicator tio
74 ora
(1) Feed the turret in the “plus” (+) direction by 50.000 mm in rapid feed.
39 rp
r 3 Co

6
(2) Set the dial indicator at the “minus” (–) side of the turret and set the reading to “0”.
Set the dial indicator at the turret as shown in Fig. 5-39 for measuring lost motion.
be ak
um az

(3) Feed the turret further in the “plus” (+) direction by 50.000 mm in rapid feed.
l N ki M

(4) Return the turret in the “minus” (–) direction by 50.000 mm.
a

(5) Read the dial indicator.

az

The value read by the dial indicator shows the amount of “lost motion” which is the total
m
Ya

mechanical system error including backlash.

ria
Se

(6) Change the parameter settings.

23

Parameter N12: Rapid feed backlash

20

Parameter N13: Cutting feed backlash

©
ht
ig

(1) (2) (3) (4)

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Lost motion

B72-0080

Fig. 5-39 Measuring lost motion in the Z-axis

5-39
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-5 Secondary Headstock and W-Axis

5-5-1 Checking and adjustment

1. Backlash compensation
The following factors between the position encoder of the W-axis and the secondary spindle
generate errors between the axis motion command value and the actual secondary spindle
position.
• Backlash in bearings and ball screws
• Failure in adjustment of the linear guide

.
ed
• Ball screw pitch deviation

rv
se
1. Backlash in the mechanical power transmission system is an unavoidable factor.

re
A too small backlash imposes overload on bearings, gears and other mechanical parts

s
causing noise and shortening their life.

ht
rig
2. The NC has the ability to compensate electronically for errors generated in the mechanical
system. This is called the backlash compensation function.

A ll
3. The backlash compensation function is factory-set to the optimum condition and will not

n.
need further adjustment after installation of the machine. However, if this does not
tio
compensate for backlash-caused error during a long period of use, the backlash
74 ora
compensation data may be set again.
39 rp

4. The backlash compensation data can be set by changing the parameter data stored in the
r 3 Co

NC.
be ak

Tool to be used: Dial indicator

um az

<Adjusting procedure>
l N ki M

(1) Select the MDI mode.

a
az

(2) Feed the secondary headstock in the “plus” (+) direction approximately 50.000 mm in
m

rapid feed.
Ya

ria

(3) Set the dial indicator in the “minus” (–) side of the secondary headstock and set the
Se
23

reading to “0”.
20

Set the dial indicator on the secondary headstock as shown in Fig. 5-40 for
©

measurement of lost motion.

ht

(4) Feed the secondary headstock in the “plus” (+) direction by 50.000 mm again in rapid
ig
yr

feed.
op

(5) Return the secondary headstock in the “minus” (–) direction by 50.000 mm. (MDI)
C

(6) Read the dial indicator.

The value read by the dial indicator shows the amount of “lost motion” which is the
total mechanical system error including backlash.

5-40
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

(7) Change the parameter settings.
Parameter N12: Backlash in rapid feed (G00)
Parameter N13: Backlash in cutting feed (G01)

Reading the
(2) (3) (4) (5) dial indicator

.
ed
rv
se
re
B72-0081

s
ht
Fig. 5-40 W-axis lost motion measurement

rig
ll
5-5-2 Cleaning

A
n.
Clean up chips on the periphery of the secondary spindle at the rate of about once a month.

tio
Remove the front and right side maintenance covers of the machine to clean up the way cover.
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
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Right side maintenance cover

C

Front maintenance cover

B72-0082

Fig. 5-41 Cleaning the way cover at the rear of the secondary spindle

5-41
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-6 Tailstock

5-6-1 Construction and operation

Tailstock motion is controlled numerically.
The tailstock consists of the tailstock body and the tailstock drive unit.

Tail spindle

.
ed
Tailstock body

rv
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s
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rig
Linear guide

A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M

Ball screw
Servomotor
a
az

B72-0083
m

Fig. 5-42 Construction of tailstock

Ya

ria

The movement of the tailstock body is accomplished by rotating the servomotor of the tailstock
Se
23

drive.
20
©

5-6-2 Disassembly
ht
ig

A. Removing the rotational center

yr
op

Rotational center
C

Set screw

* Used to remove the rotational

center

Tailstock body

B72-0084

Fig. 5-43 Removing the rotational center

Note: The rotational center can be inserted easily, if the set screw illustrated above is
temporarily removed.

5-42
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

B. Removing the built-in center
The center is of the screw type having a screw thread for removal. The center can be removed
by screwing a nut onto it and tightening the nut.

Center

.
ed
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se
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Nut

s
B72-0085

ht
rig
Fig. 5-44 Removing the built-in center

A ll
5-6-3 Adjustment

n.
1. Adjusting tailstock thrust
tio
74 ora
Adjust the tailstock thrust with the machine menu.
39 rp
r 3 Co

6
(1) Press the button in the upper right of the NC screen, and then press .
be ak

 The following menu will be displayed.

um az
l N ki M

LOW
TAIL THRUST
THRUST MODE
a
az

(2) Tap [TAIL THRUST].

m
Ya

ria

 The following menu will be displayed.

Se
23

TAIL TAIL TAIL TAIL

THRUST THRUST THRUST THRUST
20

-/<< -/< +/> +/>>

©
ht

1.0kN 2.0kN 3.0kN 4.0kN 5.0kN

ig

225 lbf 450 lbf 675 lbf 900 lbf 1125lbf

yr

(3) Tap the thrust display you want to set.

op

 The set tail thrust is displayed in TAIL THRUST of the machine menu window.
C

Tapping [TAIL THRUST –/<<] decreases the tailstock thrust in 1 kN steps.

Tapping [TAIL THRUST –/<] decreases the tailstock thrust in 0.1 kN steps.
Tapping [TAIL THRUST +/>>] increases the tailstock thrust in 1 kN steps.
Tapping [TAIL THRUST +/>] increases the tailstock thrust in 0.1 kN steps.
 You can also tap [1.0kN 225 lbf] – [5.0kN 1125lbf] to directly select thrust values.
Range of thrust adjustment: 1.0 kN – 5.0 kN

5-43
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

<Machine Menu window>

.
ed
Note : Items displayed in the Machine Menu window vary from model to model.

rv
se
2. Tailstock reference position

re
The tailstock is driven by a servomotor on the basis of an absolute positioning system. The

s
ht
controller has the factory-set reference position stored in its memory. If the stored data should

rig
be lost due to a drop of the battery voltage or if the controller itself has been replaced, set and

ll
store the reference position anew by the following procedure:

A
n.
(1) Press the button in the upper right of the NC screen, and then press .
tio
74 ora
(2) Tap [MAINTE- NANCE].
39 rp

LUBE ECO
r 3 Co

6
FORCE MODE MAINTE- TURRET
MENU INVALID NANCE MAINTE
be ak
um az
l N ki M

(3) Press and hold the key [17] on the machine operating panel while you tap [TAIL
a
az

[Link]]. Menu turns blue (enabled).

m
Ya

ria
Se
23
20
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ht

LUBE ECO
FORCE MODE MAINTE- TURRET
ig

MENU INVALID NANCE MAINTE

yr
op
C

HEAVY
Yt AXIS TOOL TAIL TAIL
ON LAYOUT [Link] HOME SET

While pressing the key [17]

Fig. 5-45 Setting the tailstock reference position

5-44
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

(4) Select the on the tail spindle switch [32a] to move the tailstock to the zero-point
position.
The reference position is preset at the following distance from the spindle edge to the
tailstock edge:

.
ed
Distance from the spindle edge

rv
to the tailstock edge

se
A

re
B72-0086

s
ht
Unit: mm

rig
A

ll
500U 1000U 1500U

A
QT-200 MB, MY (A2-6) 847 1372 -

n.
QT-250 MB, MY (A2-8) 825.5 1350.5 1845.5

tio
74 ora
Fig. 5-46
39 rp
r 3 Co

(5) When you tap [TAIL HOME SET], the menu turns blue (enabled) and a zero-point position
6

is set.
be ak

The POSITION display turns red in front of the machine position W axis.
um az
l N ki M

(6) Tap [TAIL [Link]] to release the blue display. (Press while pressing and holding the
key [17]).
a
az
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Ya

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5-45
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

3. Tail spindle alignment

If the straight turning of a shaft workpiece with the tailstock center should result in a taper
turning, adjust the alignment of the tail spindle by the following procedure:

M8 hex socket head bolt (3 positions)

For sleeve eccentricity
A B Sleeve adjustment

Tailstock body

.
ed
rv
se
15 to 20 mm

re
Rotational center specifications Dial gauge

s
B72-0087

ht
rig
Fig. 5-47 Tail spindle alignment (horizontal)

ll
(1) Chuck a round workpiece and hold its face with the tailstock center. The chucking length

A
n.
should be 15 to 20 mm.
(2) Finish-turn the workpiece.
tio
74 ora
(3) Measure the cylindricity at A and B in the above figure using a dial gauge.
39 rp
r 3 Co

(4) Apply a dial gauge to the workpiece on the side of the tailstock, and set the needle to zero.
6
be ak

(5) Loosen three hex socket head bolts on the sleeve.

um az

(6) Mount a wrench at the rear end of the sleeve, and rotate the wrench watching the
l N ki M

indication on the dial gauge.

The sleeve is of the eccentric type.
a
az

(7) Tighten hex socket head bolts.

m
Ya

(8) Carry out OD turning again and measure the cylindricity.

ria
Se

(9) If a taper is still generated, repeat the above indicated steps from (4) to (7).
23
20
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 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-6-4 Cleaning
Covers to protect the ball screws and the linear guides have been installed. If chips are
entrapped into these covers, the preset thrust of the tailstock may not be obtained. The
accumulation of chips could also apply large force to the covers, resulting in the covers being
damaged.
Clean up chips on the periphery of the tailstock at the rate of about once a month. Remove the
right side maintenance cover of the machine to clean up the way cover.

.
ed
rv
se
re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M

B72-0088
a
az

Fig. 5-48 Cleaning up chips on tailstock periphery

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Ya

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23

Behind the
tailstock body
20
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Multistage cover at the

rear of the tailstock body

Cover in front of the tailstock body

B72-0089

Fig. 5-49 Places where chips easily accumulate

5-47
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-7 Hydraulic Unit and Hydraulic Circuit

5-7-1 Construction and operation

The hydraulic unit consists of the tank, hydraulic pump, strainer, and radiator.
The following units are hydraulically operated.
• Chuck
• Turret
• C-axis (milling machine)
• Parts catcher (option)

.
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• Steady rest (option)

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Note : See the hydraulic circuit diagrams from the next page.

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< Hydraulic unit manufactured by FUJIKOSHI >

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MB, MY, MS, MSY specifications

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A
Oil lubrication port/air breather

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74 ora
39 rp
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6
be ak
um az
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Fluid level
a

gauge
az
m
Ya

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Drain port
Se
23

Suction strainer
CMN-7036
20

Fig. 5-50 Construction of hydraulic unit

©
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5-48
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23
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5-49
r 3 Co
39 rp
Serial Number 339746

74 ora
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MAINTENANCE OF MAJOR MACHINE UNITS
5
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

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74 ora
39 rp
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20
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DISCHARGE AMOUNT
C

HYDRAULIC PRESSURE
TANK CAPACITY
HAYDRAULIC OIL

PUMP PERFORMANCE CURVE

Fig. 5-51 Hydraulic circuit diagram (MB, MY specifications)

5-50
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

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74 ora
39 rp
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MATCH MARK

Drawing No. 0B72HC00020

5-51
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

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74 ora
39 rp
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be ak
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a
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20
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DISCHARGE AMOUNT

HYDRAULIC PRESSURE
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TANK CAPACITY
HAYDRAULIC OIL
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PUMP PERFORMANCE CURVE

Fig. 5-52 Hydraulic circuit diagram (MS, MSY specifications)

5-52
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

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74 ora
39 rp
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MATCH MARK

Drawing No. 0B72HC00030

5-53
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-7-2 Checkups before starting hydraulic unit

Before starting the hydraulic unit, check the hydraulic oil level. If the hydraulic oil level is below
the correct level, supply oil before turning the power on.
Note: Ensure that you confirm the hydraulic oil amount before starting an operation. The
amount appears to be less since the hydraulic oil is supplied through a piping route
during the operation. If it is replenished during the operation there might be an
overflow during the operation stop.

1. Specified level

.
The upper limit level line of the oil level gage indicates the specified level.

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2. Allowable lowest level

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The center level of the specified level indicates the allowable lowest level of the hydraulic oil in

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the tank. Never operate the hydraulic unit while the oil level is lower than that. If the unit is

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operated, the following troubles will result:

rig
• The air is apt to be mixed in the hydraulic oil causing various types of malfunctions of the

A ll
pump such as seizing of the pump, noises, faulty valve operation, and unstable pressure

n.
variance during operation.

tio
• Vibration of the piping runs, which in turn causes oil leakage.
74 ora
• The hydraulic oil will be deteriorated rapidly.
39 rp
r 3 Co

• Other troubles of the hydraulic unit.

6
be ak

5-7-3 Inspection when starting hydraulic unit

um az
l N ki M

1. Pump rotation direction

a

With the motor started, the pump starts rotation. Check to be sure that the pump rotation
az

direction is as indicated on the legend plates of the motor and pump. The pump rotation
m
Ya

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direction can be checked at the motor fan side opposite to the motor shaft side.
Se

Once the motor is stopped, never try to start it again immediately. At least one minute motor rest
23

is required in this case. If started again immediately, the motor is overloaded by the residual
20

pressure in the hydraulic circuit.

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2. Pressure
ig
yr

Use the pressure gauge to check that the pressure is set to standard pressure.
op
C

5-7-4 Inspection and maintenance of hydraulic unit

 When replenishing the hydraulic unit with oil, use only the recommended oil. If hydraulic
oil other than the recommended oil is used, it will cause malfunction of the machine.

CAUTION

1. Replenishment
Replenish the hydraulic oil when the oil level gauge float is below the center.
(1) Remove the cap on the supply port of the oil tank.
(2) Replenish the hydraulic oil through the supply port up to the yellow line of the oil level
gauge.
(3) Fasten the supply port cap securely.

5-54
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

2. Replacing the hydraulic oil and cleaning the strainer
Hydraulic oil replacing interval varies depending on machine operation conditions and ambient
conditions: At least, it must be replaced in three months after machine installation for the first
time, and in every six months after that.
 Hydraulic oil may be warmed up to high temperature after the continuous operation. Care
should be taken not to be get burnt.

CAUTION

(1) Place a container with a capacity of 30 L or so underneath the drain outlet.

.
(2) Remove the drain plug and discharge the hydraulic oil.

ed
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(3) When all hydraulic oil has been discharged, remove the sheet metal in the periphery of the

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hydraulic unit, and take the hydraulic unit off the machine in the way you remove a lid.

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(4) Remove the hexagon head bolts and take off the top cover of the tank.

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(5) Using a rag, carefully wipe away the dirt and other sediment which have accumulated

rig
inside the tank.

A ll
Note: Under no circumstances must any metal or other such articles be used to clean

n.
inside the tank since they will damage the paint.

tio
(6) Attach the suction strainer, and fit the tank top cover back into place. At this point, do not
74 ora
wrap sealing tape around the suction strainer.
39 rp
r 3 Co

(7) Clean the drain plug, wrap new sealing tape around it, and fit it back securely into the drain
6

outlet as far as it will go.

be ak

(8) Pour 20 L of fresh hydraulic oil through the supply port.

um az
l N ki M

(9) Inspect the oil level gauge and drain outlet, tighten the supply port cap, and finally attach
the machine’s cover.
a
az

Remove the bolts and

m

remove the cover

Ya

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20
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Remove the strainer

and clean it

To tighten up To loosen

Drain outlet

CMN-7053

Fig. 5-53 Cleaning the tank and strainer

5-55
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-7-5 Line filter for the hydraulic cylinder

This machine has a line filter as standard to prevent thermal damage to the hydraulic chuck
cylinder due to the entry of foreign substances into the hydraulic circuit.

1. Replacing the line filter element of the hydraulic cylinder

The replacement time of the line filter element differs according to the particular operating
conditions of the machine. It is suggested, however, that the element be replaced at least once
every six months. At the time of replacement, it is recommended to also replace the O-ring
mounted in the filter case.

.
Order replacement filter element and O-ring from Mazak Technical Center or Technology

ed
Center.

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Tools to be used: Oil receivers such as oil pans, Allen wrench (24 mm, 5 mm)

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rig
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Head

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74 ora
O-ring
39 rp

Filter element
r 3 Co

6
O-ring
be ak
um az

Case
l N ki M

CMN-7037
a
az

Fig. 5-54 Line filter for the hydraulic cylinder

m
Ya

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(1) Apply an Allen wrench to the hexagonal part at the bottom of the case, and loosen the case.
Se

Since the oil inside will drip, do not completely remove the case.
23
20

Note: Oil trickles down when the filter is tilted and this oil should be collected in some
container such as an oil pan.
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(2) Remove the case, and pull out the element from the boss in the head.
ig

Note: Since the oil will drip, receive the oil using an oil pan or equivalent.
yr
op

(3) Clean the case.

C

(4) Put a new element onto the boss in the head.

Name : Line filter element
Parts No. : G30ZZ00334C
Model : E247700
(5) Replace the O-ring of the case with a new one.
Name : O-ring
Parts No. : J25NV005790
Model : OJASO2053H90 <NOK>
(6) Screw the case into the head.
Note: Tightening torque of the filter case: 25 to 35 N·m [thread size: M60 × 2.0]

5-56
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

(7) Fix the line filter body in place on the machine cover using bolts.

2. Replacing the line filter of the hydraulic cylinder (hydraulic unit manufactured by ANY
POWER only)
For the hydraulic unit manufactured by ANY POWER only, a line filter is attached also on the
return side. The replacement time of the line filter differs according to the particular operating
conditions of the machine. It is suggested, however, that it be replaced at least once every six
months.
Order the replacement line filter from Mazak Technical Center or Technology Center.
Tools to be used: Oil receivers such as oil pans.

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Head

ll
Tighten Loosen

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74 ora
O-ring
39 rp
r 3 Co

Filter
be ak
um az

CMN-7054
l N ki M

Fig. 5-55 Line filter for the hydraulic cylinder

a

(1) Holding the filter with your hand, loosen and remove it by rotating it in the direction
az

illustrated above.
m

Note : Oil trickles down when the filter is tilted and this oil should be collected in some
Ya

ria

container such as an oil pan.

Se
23

(2) Screw in the new filter in the reverse direction from when you loosened it.
20

Name : Replacement filter (O-ring set)

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Parts No. : U49ZZ001620

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Model : FPE30-10N
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5-57
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-8 Lubrication Unit and Lubrication Circuit

5-8-1 Construction and operation (Grease lubrication)

The grease lubrication unit of the spindle linear guides and ball screws is centrally controlled by
the electric intermittent lubricating grease pump attached to the right side of the machine. This
unit monitors running distance and operating hours to supply the optimum amount of lubrication
for machine use.
If a malfunction occurs in the lubrication system, the pressure switch mounted inside the piping
is activated, and alarm message 260 GREASE LUBRICATION ALARM is displayed on the
screen.

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Operation light

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74 ora
39 rp
r 3 Co

6
be ak
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Air removal plug

Grease discharge port
Se

CMN-7035
23
20

Fig. 5-56 Grease lubrication unit composition

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5-8-2 Inspecting the electric grease pump of the slideway section and replenishing
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grease
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1. Inspecting the grease amount

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Before starting the machine every day, check the amount of grease cartridge of the electric
grease pump. If the remaining amount of grease in the grease cartridge is less, be sure to
replace it with a new grease cartridge. Never replenish grease in the cartridge container and
reuse the container. This could damage the cartridge container.

2. Replacing the grease cartridge

If the alarm 260 GREASE LUBRICATION ALARM or 1327 GREASE LEVEL LOW WARNING
is displayed perform the procedure described below.
Alarm 260 cannot be canceled until the replenishment of grease is complete. (If alarm 260
occurs during automatic operation, the machine performs a single block stop.)

5-58
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

< Procedure >
(1) Check if grease is remaining in the grease cartridge.
If no grease is left, replace the grease cartridge.
Follow the procedure described in (a) through (d) to replace the grease cartridge. After
replacing, perform the operation described in step (3) and thereafter.
(a) Remove the cover by turning it by hand in the counterclockwise direction.

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74 ora
39 rp
r 3 Co

6
be ak

CMN-0036
um az

Fig. 5-57 Grease cartridge replacing procedure (1/4)

l N ki M

(b) Remove the empty cartridge by turning it in the counterclockwise direction.

a
az
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CMN-0037

Fig. 5-58 Grease cartridge replacing procedure (2/4)

5-59
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

(c) Mount a new cartridge by turning it in the clockwise direction with the internal plug
attached to it. The internal plug breaks when the cartridge is mounted.
Note : Carefully mount the cartridge so that air and foreign matter will not enter.

.
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n.
CMN-0038

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Fig. 5-59 Grease cartridge replacing procedure (3/4)
39 rp

(d) Install the cover by turning it in the clockwise direction by hand until it stops.
r 3 Co

6
be ak
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l N ki M
a
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CMN-0039

Fig. 5-60 Grease cartridge replacing procedure (4/4)

If there is sufficient grease and the alarm is displayed, there may be air in the lubrication
circuit. In this case, bleed the air from the circuit according to the procedure explained in
paragraph 5-8-2.5 “Bleeding air” and then perform steps (3) and on.
(2) Press the key [12] on the machine operating panel.

 The Manual operation mode is selected.

5-60
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

(3) Tap the button on the top right of the NC screen and then tap .
(4) Tap [LUBE FORCE MENU].
 The following menu is displayed.
OIL GREASE
LUBE LUBE
FORCE FORCE

MIST
LIGHT CONVEYOR COLLECT.
OFF CAN. OFF CAN. OFF CAN.

(5) Tap [GREASE LUBE FORCE].

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The menu display on the screen starts flashing and grease supply is started. On

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completion of grease supply, the menu display changes to blue and then returns to

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white.

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(6) Make sure that alarm 260 GREASE LUBRICATION ALARM or 1327 GREASE LEVEL

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LOW WARNING is cancelled.

rig
If the alarm still remains active, there may be air in the lubrication circuit. In this case,

A ll
bleed the air from the circuit according to the procedure explained in paragraph 5-8-2.5

n.
“Bleeding air” and then perform steps (3) and on.

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74 ora
3. Prohibitions about the use of grease
39 rp

 Failure to observe these prohibitions might result in machine trouble, coagulation or

r 3 Co

performance degradation. (The term “coagulation” refers to a phenomenon in which

be ak

grease becomes hard.)

CAUTION
um az

•
l N ki M

Do not use any brand of grease other than those recommended by the manufacturer. For
the recommended brands of grease refer to Table 4-2.
a
az

• Never use grease containing molybdenum disulfide.

m

• Avoid using grease that has been stored for an extended period of time if oil has separated
Ya

ria

from other ingredients. Grease with a small amount of oil on the surface, however, may be
Se
23

used.
20

4. Cautions about the storage of grease

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• Keep the lid closed securely.

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• Store grease indoors, in a cool place where it will not be exposed to direct sunlight, rain or
op

dust.
C

• Since the grease container has no label to show product name and code, pay due attention
not to confuse the grease container with other containers.
• Always keep a spare grease cartridge.
• Replace the grease cartridge when it is emptied.
• Do not re-use the grease cartridge by replenishing grease. Replenishing grease can cause
entry of foreign matter and air into the grease in the cartridge that will cause machine
trouble.

5-61
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5. Bleeding air
Always bleed the air when connecting a grease cartridge or if the air is trapped in the pump.
Loosen the air bleeding plug in the pump (turn the valve counterclockwise by 1 turn) and start
the pump.
Stop the pump when only grease comes out of the air bleeding hole. After completing air
bleeding, tighten the air bleeding plug.

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Air bleeding plug

rig
Spanner

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A
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74 ora
39 rp

Loosen
r 3 Co

6
be ak
um az
l N ki M

CMN-0040
a
az

Fig. 5-61 Air bleeding

m
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5-62
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-8-3 Construction and operation (oil lubrication)
The oil lubrication unit for the linear guides, ball screws, turret index gear and milling spindle
gear is centrally controlled by the automatic lubricator. If the pressure drops below 0.7 MPa due
to a trouble in the lubrication system, the pressure switch is activated. In this cases 261 OIL
LUBRICATION ALARM message will be displayed on the screen. Single block stop of the
machine occurs. If lubricating oil runs short, the float switch is activated. In this cases 262 OIL
LUBRICATION LEVEL LOW alarm will be displayed. In such cases, the machine does not stop
if automatic operation is in progress.

Motor

.
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Discharge port

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Oiling port

A
Level gauge

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74 ora
Oiling port filter
39 rp
r 3 Co

Reserve tank
6

Suction filter
CMN-7034
be ak
um az

Fig. 5-62 Oil lubrication unit composition

l N ki M

1. Inspecting the lubrication unit and supplying oil

a
az

A. Inspecting the lubricating oil amount

m
Ya

ria

Before starting the machine every day, check that the lubricating oil reserve tank is filled with
Se

the specified lubricating oil to the specified level. If the oil level is lower than the center of the
23

upper and lower level lines of the level gauge at the tank side, supply the same brand of
20

lubricating oil from the oiling port on the upper part of the lubrication unit so that the oil level do
©

not exceed the upper limit level line.

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ig

B. Cleaning and changing the filter

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op

The suction filter in the automatic intermittent lubricating pump can be removed by taking off the
C

screws of the upper part of the pump.

The filter on the oil filler port can be removed in the same manner. Clean the filters once in a
year.

C. Checking lubricating status

Before starting the day’s operation, check every lubricating status of the lubricating parts.
Shortage of oil in the lubricating parts causes clogging of the flow unit and oil leakage from the
piping route. Entry of foreign particles like chips into the flow unit causes clogging and
malfunction of the flow unit. In such a case, replace the flow unit.

5-63
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
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Fig. 5-63 Lubrication circuit diagram (Grease, MB specifications)

5-64
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be ak

5-65
r 3 Co
39 rp
Serial Number 339746

74 ora
6 tio
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Drawing No.
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ed
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MAINTENANCE OF MAJOR MACHINE UNITS

0B72LC00020
5
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

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A ll
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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
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20
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Fig. 5-64 Lubrication circuit diagram (Grease, MY specifications)

5-66
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Se az
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l N ki M
um az
be ak

5-67
r 3 Co
39 rp
Serial Number 339746

74 ora
6 tio
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Drawing No.
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MAINTENANCE OF MAJOR MACHINE UNITS

0B72LC00030
5
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
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20
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Fig. 5-65 Lubrication circuit diagram (Grease, MS specifications)

5-68
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23
Ya
m
Se az
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l N ki M
um az
be ak

5-69
r 3 Co
39 rp
Serial Number 339746

74 ora
6 tio
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Drawing No.
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MAINTENANCE OF MAJOR MACHINE UNITS

0B72LC00040
5
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

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A ll
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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

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20
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Fig. 5-66 Lubrication circuit diagram (Grease, MSY specifications)

5-70
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23
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Se az
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l N ki M
um az
be ak

5-71
r 3 Co
39 rp
Serial Number 339746

74 ora
6 tio
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A ll
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Drawing No.
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.
MAINTENANCE OF MAJOR MACHINE UNITS

0B72LC00050
5
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

.
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A
n.
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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
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20
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Fig. 5-67 Lubrication circuit diagram (oil)

5-72
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

.
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A ll
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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
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20
©
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NYLON TUBE

Drawing No. 0B72LC00060

5-73
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-9 Coolant System

5-9-1 Construction and operation

The coolant system consists of the coolant pump and the coolant tank where coolant is stored.
A nozzle is mounted in the turret or tool holder for supplying coolant to cool the cutting tool at
the cutting point. It is used for cooling and cleaning tools or workpieces, and removing chips
while cutting workpieces.
The coolant inside the coolant tank is suctioned by the coolant pump mounted on the coolant
tank and ejected from the nozzle on the turret or tool holder. The injected coolant is passed

.
ed
through the chip receiving plate and then collected inside the coolant tank.

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If the through-coolant ready milling tool holder is selected, a line filter is added to the coolant

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circuit to prevent the bearings in the through-coolant ready holder from being damaged in a

re
short time by sludge.

s
ht
Note : Depending on the workpiece, it may not be possible to use the coolant. In addition,

rig
chip-draining coolant is not ejected for workpieces that primarily require dry machining.

ll
Periodically clean the coolant system and remove the chips.

A
n.
tio
74 ora
Chip receiving plat
39 rp
r 3 Co

6
be ak
um az
l N ki M

Coolant pump
a
az

Filter
m
Ya

ria
Se
23

Coolant tank
20
©
ht
ig
yr

Level gauge
op
C

CMN-7055

Fig. 5-68 Construction of coolant system (Specifications without chip conveyor) (Standard)

5-74
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

Chip receiving plat

Secondary filter
Primary filter

Coolant pump

.
ed
rv
Coolant tank

se
re
s
ht
rig
A ll
n.
tio
Level gauge 74 ora
Drain port
39 rp

Chip bucket
r 3 Co

6
CMN-7056
be ak

Fig. 5-69 Construction of coolant system (Horizontal chip conveyor specifications) (Option)
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

5-75
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-9-2 Checking and replenishment

 When replenishing coolant to the coolant tank, use a rust preventive coolant. Otherwise,
corrosion may occur and cause malfunction of the machine.

CAUTION

1. Checking the coolant level

Check if coolant is stored in the coolant tank to the specified level before starting the day’s
operation. If insufficient, replenish it in the next process.
Note: Ensure that you confirm the coolant amount before starting an operation. The amount

.
ed
appears to be less since the coolant is supplied through a piping route during the

rv
operation. If it is replenished during the operation there might be an overflow at the

se
time of operation stop.

re
s
2. Supplying coolant

ht
rig
(1) Pull out the coolant tank.

ll
A
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a

CMN-7057
az
m

Fig. 5-70 Supplying coolant (1/2)

Ya

ria

(2) Replenish the coolant that has been arranged to the appropriate density beforehand. The
Se
23

quantity of the coolant to be replenished should be as much as the line indicating the
20

uppermost level on the verification board of the level gauge.

©
ht
ig
yr
op
C

CMN-7058
Fig. 5-71 Supplying coolant (2/2)

5-76
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-9-3 Cleaning

1. Cleaning the filter

The filter should be cleaned daily after finishing the day’s operation.
Note: Clean the Secondary filter first to protect entering foreign particles in the coolant pump
side.
(1) Slowly pull out 1 sheet of the Secondary filter from the coolant tank.
(2) Clean the filter using a hand held air nozzle. Wear protective glasses to protect your eyes
from the flying particles.

.
ed
(3) Slowly place the filter back into the coolant tank.

rv
(4) Then, clean the Primary filter in a similar manner.

se
re
Secondary filter

s
ht
rig
Primary filter

A ll
n.
tio
74 ora
39 rp
r 3 Co

6
CMN-7059 CMN-7060
be ak

Fig. 5-72 Cleaning the filter (1/2) Fig. 5-73 Cleaning the filter (2/2)
um az

(5) Replace the filter if it is very much clogged with dirt.

l N ki M

(When ordering a replacement filter from Mazak Technical Center or Technology Center,
a
az

refer to the Parts List and specify the part number.)

m

(6) If the filter has an attached chip conveyor, remove the chip bucket from the coolant tank
Ya

ria

and dispose of any chips.s

Se
23

Filter Primary filter Secondary filter Chip bucket

20

Standard (MB, MY, MS, MSY) 3321924802* 3321924801* —

©

With an attached side discharge

ht

chip conveyor 4320442928* 3320442929* 0B72920017*

(MB, MY, MS, MSY option)
ig
yr
op
C

5-77
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

2. Cleaning the coolant tank

Carry out such cleaning at the time of coolant replacement.
(1) Remove the filters and chip receiver from the coolant tank.
(2) Position a collection pan at the drain opening, and loosen the drain to open and allow
coolant to discharge.

.
ed
rv
se
re
s
ht
CMN-7061

rig
Fig. 5-74 Coolant drainage

ll
A
(3) Remove the chip receiving plate and clean the inside of the coolant tank.

n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se

CMN-7062
23

Fig. 5-75 Cleaning the coolant tank (1/2)

20

(4) After the coolant is drained, use a rag to wipe chips and other debris from the coolant tank
©

interior.
ht
ig
yr
op
C

CMN-7063

Fig. 5-76 Cleaning the coolant tank (2/2)

(5) Finally clean the gaps in the inner part.

5-78
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-9-4 Replacement
Once in 6 months or when the coolant is heavily contaminated, change the coolant completely.
(1) Place the oil drain pan under the drain port.
(2) Pull out the two filters in the coolant tank and drain the coolant. Remove the drain plugs
after completing the discharge.
(3) Remove the chips and other left-overs from the coolant tank.
(4) Clean the screws of the drain outlet and the drain plug. Wrap new sealing tape around the
drain plug and fit it back securely into the drain outlet as far as it will go.

.
(5) Fill coolant up to a level above the drain outlet and check for coolant leakage from the drain

ed
outlet.

rv
se
(6) Fill coolant that has been arranged to the appropriate density beforehand up to the

re
uppermost level line of the level gauge check plate.

s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

5-79
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-9-5 Method of pulling out the coolant tank

1. Without a chip conveyor

(1) Tighten up the jack bolts at the front positions of the coolant tank using a wrench. There is
a need to fully tighten each bolt until the bolt head has moved away from the ground
surface.

.
ed
rv
se
re
s
ht
CMN-7064

rig
Fig. 5-77 Coolant tank jack bolt position

A ll
(2) Remove the rubber hose and the cable supplied to the coolant pump from the hose

n.
tio
receiver. 74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20

Wind a hose around the wiring

©

receiver when reassembling the

coolant tank.
ht

CMN-7065
ig

Fig. 5-78 Wiring process in case of pulling out the coolant tank (Without a chip conveyor)
yr
op

(3) Pull the coolant tank forward.

C

(4) Follow the same procedure in the reverse order when reassembling the coolant tank.

5-80
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

2. With an attached horizontal chip conveyor
(1) Tighten up the jack bolts at the front positions of the coolant tank using a wrench. There is
a need to fully tighten each bolt until the bolt head has moved away from the ground
surface.

.
ed
rv
se
CMN-7064

re
s
Fig. 5-79 Coolant tank jack bolt position

ht
rig
(2) Detach the rubber hose for supplying to the coolant pump.

ll
Note: Keep a container ready for collecting the coolant as it may overflow.

A
n.
(3) Separate the connector (No.X231) of the cable that supplies to the coolant pump.

tio
Separate the connectors (No.X271 and X50) of the cable that supplies to the chip conveyor.
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

Remove

CMN-7066 CMN-7067
Fig. 5-80 Cable connector Fig. 5-81 Wiring process in case of pulling out the coolant
tank (with chip conveyor)

5-81
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

(4) Remove the emergency stop box on the upper surface of the exhaust card of the chip
conveyor.
Provide an emergency stop box for this machine.

.
ed
rv
se
re
s
ht
Can be removed easily by

rig
loosening this bolt

A ll
n.
tio
74 ora CMN-7068

Fig. 5-82 Removing the emergency stop switch for the chip conveyor
39 rp
r 3 Co

(5) Pull the coolant tank forward.

6

(6) Follow the same procedure in the reverse order when reassembling the coolant tank.
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

5-82
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-9-6 Maintenance of chip conveyor
 Before carrying out the maintenance work, set the main power disconnect switch to the
“OFF” position and lock it in that position with a padlock. Failure to observe the instruction
could cause serious injury to operators.
WARNING
 To prevent entanglement in the conveyor, make sure to attach the emergency stop
switch to the chip conveyor after cleaning.

• For the maintenance of the chip conveyor, refer to the relevant manuals
issued by the manufacturer.

.
ed
rv
se
re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

5-83
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-10 Air Unit

5-10-1 Construction and operation

The air unit consists of a mist separator, regulator and a solenoid valve.
The mist separator removes moisture from the compressed air.

 Moisture in the compressed air causes deterioration and damage to the air actuators
used in the machine.

.
WARNING

ed
rv
se
re
s
ht
rig
ll
A
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23

B72-0090a
20
©

Fig. 5-83 Location of the air unit

ht
ig
yr

The following units are operated pneumatically

op
C

1. Standard specifications
The air is used for the following purposes in standard specification machines:
• Main spindle air curtain
• Turret milling gear oil and air lubrication
• Secondary spindle chuck air blow
• Milling motor air purge

5-84
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

2. Optional specifications
Air can also be used in the following applications in optional specifications.
• TOOL EYE air blow (option)
• Workpiece measurement (option)
• Main spindle chuck air blow (option)
• Turret air blower (option)
• Automatic parts catcher air purge (option)
• Steady rest base unclamp (option)

.
ed
• Steady rest air purge (option)

rv
• Auto window (option)

se
•

re
Turret mill joint (option)

s
• Scale feedback (option)

ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

5-85
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

3. Air circuit diagram

A. Air circuit diagram for MB/MY

.
ed
rv
se
re
s
ht
rig
ll
A
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

Fig. 5-84 Air circuit diagram

5-86
 C
op
yr
ig
ht
©
20
23
Ya
m
Se az
ria a
l N ki M
um az
be ak

5-87
r 3 Co
39 rp
Serial Number 339746

74 ora
6 tio
n.
A ll
rig
ht
s
re

Drawing No.
se
rv
ed
.
MAINTENANCE OF MAJOR MACHINE UNITS

0B72ACA01V0
5
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

B. Air circuit diagram for MS/MSY

.
ed
rv
se
re
s
ht
rig
ll
A
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

Fig. 5-85 Air circuit diagram

5-88
 C
op
yr
ig
ht
©
20
23
Ya
m
Se az
ria a
l N ki M
um az
be ak

5-89
r 3 Co
39 rp
Serial Number 339746

74 ora
6 tio
n.
A ll
rig
ht
s
re

Drawing No.
se
rv
ed
.
MAINTENANCE OF MAJOR MACHINE UNITS

0B72ACA02V0
5
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

4. Components of the Air circuit

Ref. Mazak Part No. Part Name Supplier Supplier Part No. Function
-001E G45FT003550 Regulator Festo MS4-LR-1/4-D7-AS-Z Regulator
-001R G48FT005840 Filter Festo MS6-LF-1/2-CRV-Z Filter - Air plate
-001J G63SV000170 Booster SMC VBA2100-03N-X Steady rest clamp
pin
(MB, MY only)
-002B GRLZ-1/8-RS-B Speed Controller Elbow (Rc1/8 - Festo GRLZ-1/8-RS-B Speed controller -
ø8mm Tube) (Meter Out) Main air kit
-002E G45SV003340 Regulator - Rc1/4 - Flow - Left > Right SMC AR2000-02BE-1-B Steady rest
(MB, MY only)

.
ed
-002R G48FT005850 Fine Filter Festo MS6-LFM-1/4-B-R-V-Z Fine filter - Air plate

rv
-004A G51SV000340 Silencer (R1/8) SMC AN110-01 Auto window

se
re
-004B G54SV001890 Speed Controller Elbow (Rc1/8 - SMC AS2211F-01-06S Spindle air curtain
ø6mm Tube) (Meter In)

s
ht
-004R G48SV005370 Oil Mist Separator SMC AFD20-F02C-A Scale feedback

rig
-004F G14JN003200 Check Valve (Rc3/8) Ihara KZU00-035E (Rc3/8) ̶

ll
Science

A
-005A G51SV000340 Silencer (R1/8) SMC AN110-01 Auto window

n.
tio
-005C G20SV021090 Cylinder 74 ora SMC RHCL32-660-C73 Auto window
-005E G45SV000820 Regulator - Rc1/4 - Flow - Left > Right SMC AR2000-02-G Scale feedback
-005R G48SV002181 Dryer SMC IDG5-02B-S Scale feedback
39 rp
r 3 Co

-007B G54SV002130 Speed Control - Slow Start Valve SMC ASS300-03 Auto window
6

-008B G54SV002130 Speed Control - Slow Start Valve SMC ASS300-03 Auto window
be ak

-009G G13SV001720 Pressure Gauge SMC GC3-P10AS Pneumatic pressure

um az

gauge
l N ki M

-013B G54SV001371 Straight Speed Controller SMC AS2002F-06 Milling motor air
(ø6mm Tube) purge
a
az

-021B G54SV001371 Straight Speed Controller (ø6mm SMC AS2002F-06 Milling motor -
m

Tube) Speed controller

Ya

ria

-023B G54SV001671 Straight Speed Controller SMC AS1002F-06 Spindle air curtain
(ø6mm Tube)
Se
23

-SP02 G55FT003260 N/O Pressure Switch Festo PEV-1/4-B Main air kit -
20

Pressure switch
©

-SP15 G23SV002860 N/O Pressure Switch SMC IS10-01-L ̶

ht

-VAL1 G50FT017020 3/2 Valve - Sol Op / Pneu Spring RTN Festo VUVS-LK25-M32C-AD- Main air kit
ig

/ NC G14-1B2-S
yr

-YV50 ̶ LH Solenoid 24VDC Coil Festo LH Solenoid ̶

op

-VAL2 G50FT017000 3/2 Valve - Sol Op / Spring RTN / NC Festo VUVS-L20-M32C-MZD- ̶

C

G18-F7-1C1
-YV51 ̶ LH Solenoid 24VDC Coil Festo LH Solenoid ̶
-VAL3 G50FT017010 3/2 Valve - Sol Op / Pneu Spring RTN Festo VUVS-LK20-M32C-AD- Main air kit -
/ NC G18-1C1-S-QM3 Tooleye air blast
-YV35 ̶ LH Solenoid 24VDC Coil Festo LH Solenoid ̶
-VAL4 G50FT017070 3/2 Valve - Sol Op / Pneu Spring RTN Festo VUVS-LK20-M32C-AD- Main air kit - Sub
/ NC G18-1C1-S-QM4 chuck air blast
(MS, MSY only)
-YV319 ̶ LH Solenoid 24VDC Coil Festo LH Solenoid

5-90
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

Ref. Mazak Part No. Part Name Supplier Supplier Part No. Function
-VAL5 G50FT017060 3/2 Valve - Sol Op / Pneu Spring RTN Festo VUVS-LK20-M32C-AD- Main air kit - Turret
/ NC G18-1C1-S-QM5 air blast/ Workpiece
measurement
-YV33 ̶ LH Solenoid 24VDC Coil Festo LH Solenoid ̶
-VAL6 G50FT017040 3/2 Valve - Sol Op / Pneu Spring RTN Festo VUVS-LK20-M32C-AD- Main air kit - Turret
/ NC G18-1C1-S-QM7 mill joint
-YV05 ̶ LH Solenoid 24VDC Coil Festo LH Solenoid ̶
-VAL7 G50FT017050 3/2 Valve - Sol Op / Pneu Spring RTN Festo VUVS-LK20-M32C-AD- Main air kit - Chuck
/ NC G18-1C1-S-QM6 air blast
-YV32 ̶ LH Solenoid 24VDC Coil Festo LH Solenoid ̶

.
ed
-VAL8 G50SV008760 5/3 Valve - Pilot OP / Manual SMC VFS2420-5D-02 Auto window

rv
Override / Spring RTN / NC

se
-YV30 ̶ LH Solenoid 24VDC Coil Festo LH Solenoid ̶

re
-YV31 ̶ RH Solenoid 24VDC Coil Festo RH Solenoid ̶

s
ht
-VAL9 G50SV010730 5/2 Valve - Sol OP / Spring RTN / NC SMC VFS2120-5D-02 Steady rest joint pin

rig
(MB, MY only)
-YV86 ̶ LH Solenoid 24VDC Coil Festo LH Solenoid

All
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

5-91
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-10-2 Maintenance of the air unit

1. Replacing the filter element

Replace the filter element at least once a year.
(When ordering a replacement filter from Mazak Technical Center or Technology Center,
specify the part number.)
Name : Air filter element
Parts No.: G48FT00584∗
Model : MS6-LF-1/2-CRV-Z

.
ed
< Procedure >

rv
se
(1) Exhaust the unit.

re
(2) Push the unlocking slide [1] in the direction of the arrow.

s
(3) Turn the filter bowl in an anti-clockwise direction [2].

ht
rig
(4) Pull the filter bowl away from the unit [2].

ll
(5) Turn the filter plate [3] in anti-clockwise direction.

A
n.
(6) Replace the filter cartridge [4]. Grasp the new filter cartridge only at the lower end. A

tio
support span is fitted in the new 5μm filter cartridge.
74 ora
(7) Tighten the new filter cartridge with the filter plate hand-tight [5].
39 rp

(8) Fit the individual parts back in the reverse sequence [7].
r 3 Co

The following checks must be made:

be ak

– the locking pin [6] of the filter bowl must face the large recess in the housing.
um az

– the unlocking slide must be heard to clip into place when the end stop is reached [10].
l N ki M

(9) Commission the system again.

a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

Fig. 5-86 Replacing the filter element

2. Cleaning the air unit

• Use only the following cleaning agents:
– water or soap suds (max. +60 °C);
– petroleum ether (free of aromatic compounds).

5-92
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-10-3 Additional air unit for linear scale (option)

1. Additional components
Additional air unit is provided for linear scale specification (option) besides the standard air unit.
The additional air unit consists of a mist separator, an air dryer and a regulator. The air cleaned
by the unit is circulated through the linear scale and protects it.
 Moisture in the compressed air causes deterioration and damage to the air actuators
used in the machine.

WARNING

.
ed
rv
se
re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a

Mist separator Air dryer Regulator

az
m
Ya

ria

B72-0118
Se
23
20

Fig. 5-87 Position of the additional air unit

©
ht
ig
yr
op
C

5-93
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

2. Replacing the filter element of the linear scale mist separator

Replace the filter element at least once a year.
Tool to be used: Allen wrench
(1) Remove the drain tube from the filter case.
(2) Remove the screws from the body of the mist separator and then take out the filter case.
(3) Replace the filter element with a new one.
(When ordering a replacement filter from Mazak Technical Center or Technology Center,
refer to the Parts List and specify the part number.)
(4) Remount it in the reverse order of the removing paying attention to the seal of the body and

.
ed
the filter case.

rv
se
re
s
ht
rig
ll
A
n.
tio
74 ora
39 rp

Filter
r 3 Co

element
6
be ak

Filter case
um az
l N ki M
a
az
m
Ya

ria
Se
23
20

B72-0119
©

Fig. 5-88 Replacing the filter element

ht
ig
yr
op
C

5-94
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-11 Headstock Cooling Unit and Headstock Cooling System

5-11-1 Cooling of the main headstock

1. Construction and operation

The headstock cooling unit is installed in the integrated form with the headstock.
The headstock is cooled in the following manner:
(1) Coolant is supplied to the headstock by the centrifugal pump from the headstock cooling
unit tank and the headstock is cooled.

.
ed
(2) The coolant warmed while circulating inside the headstock is cooled by the radiator and the
cooling fan and returned to the tank of the cooling unit.

rv
se
re
s
ht
rig
6

A ll
n.
tio
74 ora
5 1
39 rp

2
r 3 Co

6
4
be ak
um az
l N ki M

3
a
az
m
Ya

ria
Se
23

B72-0092
20

Fig. 5-89 Construction of headstock cooling unit

©
ht

No. Parts name No. Parts name

ig
yr

1 Replenishing port 4 Centrifugal pump motor

op

2 Level gauge 5 Pressure switch

C

3 Coolant tank 6 Radiator

5-95
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

Fan cooler

Tank

.
ed
rv
Headstock

se
re
s
ht
rig
A ll
Pressure switch

n.
tio
74 ora
39 rp

Centrifugal pump
r 3 Co

CMN-7069
be ak
um az

Fig. 5-90 Headstock cooling system

l N ki M

2. Replenishing and replacement of coolant

a

<Checking coolant level>

az
m

The coolant level can be checked at the level gauge located on the left side cover.
Ya

ria

Center to upper limit : Proper

Se
23

Lower than center level : Replenish coolant immediately.

20
©
ht
ig
yr
op
C

Tank
Level gauge

CMN-7070

Fig. 5-91 Location of the level sight gauge

5-96
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

 When replenishing coolant, use only the recommended coolant. If coolant other than the
recommended ones is used, it will cause malfunction of the machine. (Refer to Section 4-
5 “Supplying Oil and Coolant”.)
CAUTION
 If the coolant level is lower than the center mark of the level sight gauge, the headstock
cannot be cooled satisfactorily, causing overheating of the headstock and machine
malfunction. Replenish the coolant occasionally so that the coolant level is maintained
correctly.
<Replenishing coolant>
(1) Remove the left side rear cover of the machine.
(2) Remove the replenishing port cap and replenish the coolant.

.
ed
rv
se
re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

CMN-7071
be ak
um az

Fig. 5-92 Replenishing the coolant

l N ki M

• Recommended coolant
MACHINE TOOL LONG LIFE COOLANT (MOBIL)
a
az

Exchange coolant every 2 years. When exchanging the coolant, clean the inside of the
m

reserve tank at the same time.

Ya

ria

<Discharging coolant>
Se
23

Instrument to be used: Oil drain pan

20

(1) Remove the left side cover.

©
ht

(2) Place the oil drain pan under the coolant tank.
ig
yr

(3) Disconnect the lower hose from the coolant tank and discharge the coolant.
op
C

CMN-7072

Fig. 5-93 Discharging the coolant

5-97
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

<Changing the coolant>

Headstock coolant must be replaced quickly without interruption. If the headstock is left
drained of coolant or becomes filled with distilled water, corrosion may occur. Waste
coolant must be disposed of legally.
Replace headstock coolant in accordance with the following procedure, depending on
coolant consumption rate (discoloration).
1. When headstock coolant is not low or discolored
(1) After turning off the power, remove all remaining coolant by blowing air through the pipe
using an air compressor.

.
(2) Fill the tank with coolant.

ed
rv
(3) Run the machine for about 10 minutes to circulate coolant throughout the entire cooling

se
system. Confirm that the coolant has been spread throughout the system sufficiently as

re
indicated by the lowered level of coolant in the tank. Top up with coolant to the required

s
level.

ht
rig
2. When headstock coolant is low or discolored

ll
(1) After turning off the power, remove all remaining coolant by blowing air through the pipe

A
using an air compressor.

n.
tio
(2) Pour distilled water or ion exchanged water into tank and circulate to clean for about 15
74 ora
minutes.
39 rp

(3) Drain water for cleaning using the same procedure as in (1).
r 3 Co

(4) Immediately pour new coolant into the tank.

be ak

(5) Run the machine for about 10 minutes to circulate coolant throughout the entire cooling
um az

system. Confirm that the coolant has been spread throughout the system sufficiently as
l N ki M

indicated by the lowered level of coolant in the tank. Top up with coolant to the required
level.
a
az

3. When headstock coolant gets too low or too discolored

m

Check for the following:

Ya

ria
Se

• Check that recommended coolant was used.

23
20

• Check if oil or foreign matter was mixed into coolant in the headstock coolant tank.
©

Thorough cleaning is required in this case. After checking the above conditions, contact Mazak
ht

Technical Center or Technology Center.

ig
yr
op
C

5-98
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-11-2 Cooling of secondary spindles

1. Construction and operation

The secondary headstock is cooled by air from a fan. This fan, located underneath the
headstock, takes air in from the machine exterior through an intake duct, then cools the entire
headstock efficiently, and lets the air out to the machine exterior. A filter is attached to the end
of the intake duct to prevent foreign substances, such as dust and chips, from being taken into
the machine.

.
ed
5

rv
se
6

re
7

s
ht
rig
A ll
n.
1
tio
74 ora
39 rp

4
2
r 3 Co

6
be ak

3
um az

8
l N ki M

B72-0093
a

Fig. 5-94 Construction of the spindle cooling fan

az

No. Parts name No. Parts name

m
Ya

ria

1 Secondary headstock 5 Spindle cooling fan

Se

2 Slide base 6 Finger guard

23

3 Bellows duct 7 Filter

20

4 Intake duct 8 Duct cover

©
ht

2. Cleaning
ig
yr

 Before remounting the filter, be sure to allow it to dry well.

op

 Always operate the machine with the filter mounted in place. The frequency of filter
C

cleaning depends on the environment. However, clean the filter at least once a month.
CAUTION
Otherwise, damage to the internal components of the secondary spindle could result.

Cleaning the filter

When the filter is dirty, remove it and wash it lightly in clean water.
(1) Remove the filter.
(2) Wash the filter in water.
(3) Let the filter dry well and then remount it.
(4) Replace the filter if it is very much clogged with dirt.
(When ordering a replacement filter from Mazak Technical Center or Technology Center,
refer to the Parts List and specify the part number.)
Filter parts No.: 4310405762∗

5-99
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-11-3 Control panel cooling

1. Construction and operation

Air is taken in from the machine exterior to efficiently cool the amplifier installed in the back of
the electrical control cabinet. A filter is mounted at the air intake port to prevent mist from the
atmosphere from being entrained during air intake.

.
Electrical control cabinet

ed
rv
se
Air intake port

re
s
ht
rig
Filter

All
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M

B72-0094
a
az

Fig. 5-95 Control panel cooling

m
Ya

ria

2. Cleaning
Se
23

 Before remounting the filter, be sure to allow it to dry well.

20

 Always operate the machine with the filter mounted in place. The frequency of filter
cleaning depends on the environment. However, clean the filter at least once a month.
©

CAUTION
Otherwise, damage to the internal components of the electrical control cabinet could
ht
ig

result.
yr
op

Cleaning the filter

C

When the air filter is dirty, remove it and wash it lightly in clean water.
(1) Remove the filter.
(2) Wash the filter in water.
(3) Let the filter dry well and then remount it.
(4) Replace the filter if it is very much clogged with dirt.
(When ordering a replacement filter from Mazak Technical Center or Technology Center,
refer to the Parts List and specify the part number.)
Filter parts No.: 4B07460143∗

5-100
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-12 Steady Rest (Option)

5-12-1 Construction and operation

The steady rest is an automatic steady rest which can be moved by traction.
The steady rest comprises the body of the steady rest, the base and the connecting pins.

Main body

.
ed
rv
se
Base

re
s
ht
rig
A ll
n.
tio
Connecting pin 74 ora Linear guide

CMN-7073
39 rp
r 3 Co

Fig. 5-96 Steady rest configuration

6
be ak

* The body of the steady rest is moved by fastening it to the turret unit with connect pins and
um az

then pulling it.

l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

5-101
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-12-2 Cleaning up chips on steady rest periphery

The steady rest has covers to protect the linear guides. If chips are entrapped into these covers,
the connect pins may fall off due to increased friction and movement may not be possible.
The accumulation of chips could also apply large force to the covers, and in a worst case
scenario, this may result in the covers being damaged.
The accumulation of chips on the connect pins may result in malfunctioning of the limit switch
and there is also a possibility of a connection failure.
In order to prevent such problems, clean up chips on the periphery of the steady rest at the rate
of about once a month. The access necessary for cleaning the periphery of the steady rest can
be easily obtained by keeping the left and right doors wide open.

.
ed
(The rear side of the machine becomes more visible when the tailstock maintenance cover on

rv
the right side of the machine is removed).

se
re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m

Maintenance cover B72-0003

Ya

ria

Fig. 5-97 Cleaning up chips on steady rest periphery

Se
23
20
©
ht
ig
yr
op
C

Cover in front of the steady rest

Behind the steady rest,

Multistage cover between the around the connect pins
steady rest and the tailstock
Multistage cover of the back of the tailstock
B72-0095

Fig. 5-98 Places where chips easily accumulate

5-102
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-12-3 Replacing the limit sensor for checking the connecting position of the steady rest
Because this steady rest is a traction move type, the limit switch is provided for checking if the
turret is on a correct connecting position. This section describes how to replace the limit switch.
Note : Always power off the machine before replacing the limit switch.
(1) Remove the chip cover and maintenance cover shown in the figure.

.
ed
rv
se
re
s
ht
rig
ll
A
n.
tio
74 ora
39 rp
r 3 Co

CMN-7074
be ak

B72-0003
um az
l N ki M

Fig. 5-99 Position of the chip cover and maintenance cover

a

(2) Remove the cover of the Junction box.

az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

CMN-7075

Fig. 5-100 Position of the junction box

5-103
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

(3) Remove the connector of the limit switch near the pressure gauge for the steady rest and
the flexible hose fixed metal fittings. Remove the fixed metal fittings inside the box in the
same manner.

Connector

Fixed metal
fittings

.
ed
rv
se
re
s
ht
rig
Fixed metal
fittings

A ll
CMN-7076

n.
tio
Fig. 5-101 Position of the limit switch connector and fixed metal fittings
74 ora
(4) Replace the limit switch in a way that the length (mm) of the protruding switch part is the
39 rp

same as that of the previous limit switch. (Rough standard 24.5 mm)
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20

Limit switch CMN-7077

©
ht

Fig. 5-102 Checking of the installation position of the limit switch

ig
yr
op
C

5-104
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

(5) Confirm that the limit switch touches the dog at the connecting position of the turret
connect pins.

24.5 mm

.
ed
rv
se
re
s
ht
CMN-7078

rig
ll
Fig. 5-103 Adjustment procedure of the limit switch

A
n.
5-12-4 Replacing the bracket (supporter) for mounting the steady rest
tio
74 ora
1. Assembly procedure
39 rp
r 3 Co

Install the bracket for mounting the steady rest on the base part attached on the linear guide.
6

(1) Make sure that the machine power is off.

be ak
um az

(2) Set the bracket for mounting the steady rest on the steady rest base and temporarily
l N ki M

tighten bolts.
(3) Apply a dial gauge to the surface of the bracket for mounting the steady rest to which the
a
az

steady rest is mounted, as shown below. Adjust the parallelism against the X axis within
±0.01 mm. Tighten the bolts, and then tighten the taper pin.
m
Ya

ria

Note : Because the position of the taper pin has usually been determined at shipment,
Se

determine the position of the bracket using the taper pin and the positioning pin on the
23

surface of the bracket. Check the parallelism of the X axis after the installation.
20
©
ht
ig

Bracket for mounting the

yr

steady rest
op

X axis
C

Positioning pin

Base

Taper pin Mounting bolt

CMN-7079

Fig. 5-104 Mounting bracket used to attach steady rest

5-105
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

(4) Mount the steady rest to the bracket for mounting the steady rest. Temporarily tighten the
mounting bolts.

Mounting bolts

.
ed
rv
se
re
s
ht
rig
All
CMN-7080

n.
tio
Fig. 5-105 Positions of mounting bolts
74 ora
(5) Connect hoses to the steady rest.
39 rp

The following five hoses are connected.

r 3 Co

Lubrication (oil) 1 hose (Lubricant for the steady rest ø4)

be ak

Hydraulic pressure 2 hoses (Steady rest clamp/unclamp 1/4”)

um az

Coolant 1 hose (Steady rest coolant 3/8”)

l N ki M

Air 1 hose (Steady rest air purge ø4)

a
az

Air pipe
m
Ya

ria
Se
23

Oil pipe
20
©
ht
ig
yr
op
C

Coolant pipe

Hydraulic pressure pipe

CMN-7081

Fig. 5-106 Supply pipes for the steady rest

(6) Power on the machine, and install a test bar between the chuck and the tailstock.
Note : Use a test bar which has the same diameter as that of a workpiece to be machined.
When setting the test bar between the chuck and the tailstock, always adjust the
parallelism of the test bar.

5-106
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

(7) Set the dial gauges in the X and Y directions of the test bar.

Measure with the dial

gages.
Y direction

X direction

.
ed
rv
se
re
s
ht
rig
CMN-7082

ll
Fig. 5-107 Adjustment procedure of the steady rest main body

A
n.
(8) Apply pressure so that the three rollers can hold the test bar. The clamping operation

tio
pressure here must be the same as that applied in the practical operation.
74 ora
(9) Fix the adjusting bolts to adjust the dial gauge vibration of when the rollers hold the test bar
39 rp

to a value close to the following value.

r 3 Co

6
Allowable value: Within 0.01 mm (in both X and Y directions)
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23

Adjusting bolt
20
©
ht
ig
yr
op
C

CMN-7083

Fig. 5-108 Installation positions of adjusting bolts

Note : Perform the centering operation of the steady rest at the position where a workpiece is
actually held (at the Z Axis).
If the steady rest is moved from the adjusted position, the hold accuracy may be
lowered.
(10) After the adjustment, proceed to the final tightening of the steady rest mounting bolts.
Basic assembly and centering operations are completed with the above steps. However,
centering and adjusting operations must be performed in the following cases.
• The clamping operation pressure has been changed.
• The workpiece holding diameter has been changed.
• The workpiece holding position is changed.

5-107
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

2. Removal procedure
(1) Make sure that the machine power is off.
(2) Remove the hydraulic pressure hose and the coolant hose of the steady rest.
(3) Hang a chain block on the main body of the steady rest. Loosen the adjusting bolts and the
mounting bolts, and remove the steady rest from the bracket for mounting the steady rest.
(4) Remove the setscrew of the positioning pin.

.
ed
rv
se
re
CMN-7084

s
ht
Fig. 5-109 Method of removing the bracket for mounting the steady rest (1/4)

rig
(5) To remove the bracket for mounting the steady rest, remove the positioning pin and taper

ll
pin first.

A
n.
tio
74 ora
39 rp
r 3 Co

6
Positioning pin
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23

Taper pin
20
©

CMN-7085
ht

Fig. 5-110 Method of removing the bracket for mounting the steady rest (2/4)
ig
yr

(6) To remove the positioning pin, pull the pin using an M6 removal tap until the groove of the
op

pin can be seen. (The positioning pin can be easily pulled with a special tool such as a
C

sliding hammer.) (If the positioning pin is not pulled out completely, the pin can be easily
mounted next time.)

Front view of the

positioning pin

Groove of the pin CMN-7086

Fig. 5-111 Method of removing the bracket for mounting the steady rest (3/4)

5-108
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

(7) To remove the taper pin, pull out the pin using an M6 removal tap.

.
ed
CMN-7087

rv
se
Fig. 5-112 Method of removing the bracket for mounting the steady rest (4/4)

re
(8) Hang a chain block on the bracket for mounting the steady rest. Loosen the mounting bolts,

s
ht
and remove the bracket for mounting the steady rest from the base part.

rig
(9) Install the chip cover to the base part.

A ll
Remark : The step (3) can be skipped by removing the steady rest as it is mounted on the

n.
bracket for mounting the steady rest.

tio
74 ora
Chip cover for the
steady rest
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23

CMN-7088
20

Fig. 5-113 Chip cover for the steady rest

©
ht

 If the operation is performed while the machine power is on, be careful not to get your
ig

hands caught in the roller part.

yr
op

 After the operation, remove a workpiece before powering off the machine.
CAUTION
C

 Regularly perform the centering operation of the steady rest.

If the machine is used when the center of the steady rest is misaligned, a workpiece may
come out of the chuck.

5-109
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-13 Milling turret cooling unit and milling turret cooling system

5-13-1 Cooling of the milling turret

1. Construction and operation

The milling turret cooling unit is located on the rear panel of this machine.
The milling turret is cooled in the following manner:
(1) Coolant is supplied to the milling turret to cool the motor and milling head by the centrifugal
pump from the tank of the milling turret cooling unit.

.
(2) The coolant warmed while circulating inside the turret is cooled by the radiator and cooling

ed
fan and returned to the tank.

rv
se
re
s
ht
rig
A ll
n.
5

tio
74 ora
39 rp
r 3 Co

6
be ak
um az

1 4
l N ki M
a

2 3
az
m
Ya

ria
Se
23

B72-0096
20

Fig. 5-114 Structure of the milling turret cooling unit

©
ht

No. Parts name No. Parts name

ig
yr

1 Replenishing port 4 Centrifugal pump motor

op

2 Level gauge 5 Pressure switch

C

3 Coolant tank 6 Radiator

5-110
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

Fan cooler

.
ed
Tank

rv
se
re
s
ht
Milling turret

rig
A ll
n.
tio
74 ora
Pressure switch
39 rp
r 3 Co

6
Centrifugal pump
B72-0097
be ak

Fig. 5-115 Milling turret cooling system diagram

um az
l N ki M

2. Replenishing and replacement of coolant

a

<Checking coolant level>

az
m

The coolant level can be checked on the level gauge located on the rear cover.
Ya

ria

Center to upper limit : Proper

Se
23

Lower than center level : Replenish coolant immediately.

20
©
ht
ig
yr
op
C

Tank

Level gauge

B72-0098

Fig. 5-116 Location of the level sight gauge

5-111
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

 When replenishing coolant, use only the recommended coolant. If coolant other than the
recommended ones is used, it will cause malfunction of the machine. (Refer to Section 4-
5 “Supplying Oil and Coolant”.)
CAUTION
 If the coolant level is lower than the center mark of the level sight gauge, the headstock
cannot be cooled satisfactorily, causing overheating of the headstock and machine
malfunction. Replenish the coolant occasionally so that the coolant level is maintained
correctly.
<Replenishing coolant>
(1) Remove the tank maintenance cover at the bottom of the back of the machine.
(2) Remove the replenishing port cap and replenish the coolant.

.
ed
rv
se
re
s
ht
rig
ll
A
n.
tio
74 ora
39 rp

B72-0099
r 3 Co

Fig. 5-117 Replenishing the coolant

be ak

• Recommended coolant
um az

MACHINE TOOL LONG LIFE COOLANT (MOBIL)

l N ki M

Exchange coolant every 2 years. When exchanging the coolant, clean the inside of the
a
az

reserve tank at the same time.

m

<Discharging coolant>
Ya

ria

Instrument to be used: Oil drain pan

Se
23

(1) Remove the cover at the bottom of the back of the machine.
20

(2) Place the oil drain pan under the coolant tank.
©
ht

(3) Disconnect the lower hose from the coolant tank and discharge the coolant.
ig
yr
op
C

B72-0100

Fig. 5-118 Discharging the coolant

5-112
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

<Changing the coolant>
Milling turret coolant must be replaced quickly and without interruption of the process. If the
headstock is left drained of coolant or becomes filled with distilled water, corrosion may
occur. Waste coolant must be disposed of legally.
Replace milling turret coolant according to the following procedure, depending on coolant
consumption rate (discoloration).
1. When milling turret coolant is not low or discolored
(1) After turning off the power, remove all remaining coolant by blowing air through the pipe
using an air compressor.
(2) Fill the tank with coolant.

.
ed
(3) Run the machine for about 10 minutes to circulate coolant throughout the entire cooling

rv
system. Confirm that the coolant has been spread throughout the system sufficiently as

se
re
indicated by the lowered level of coolant in the tank. Top up with coolant to the required
level.

s
ht
2. When milling turret coolant is low or discolored

rig
(1) After turning off the power, remove all remaining coolant by blowing air through the pipe

A ll
using an air compressor.

n.
tio
(2) Pour distilled water or ion exchanged water into tank and circulate to clean for about 15
74 ora
minutes.
39 rp

(3) Drain water for cleaning using the same procedure as in (1).
r 3 Co

(4) Immediately pour new coolant into the tank.

be ak

(5) Run the machine for about 10 minutes to circulate coolant throughout the entire cooling
um az

system. Confirm that the coolant has been spread throughout the system sufficiently as
l N ki M

indicated by the lowered level of coolant in the tank. Top up with coolant to the required
level.
a
az

3. When milling turret coolant gets too low or too discolored

m

Check for the following:

Ya

ria
Se

• Check that recommended coolant was used.

23
20

• Check if oil or foreign matter was mixed into coolant in the milling turret coolant tank.
©

Thorough cleaning is required in this case. After checking the above conditions, contact Mazak
ht

Technical Center or Technology Center.

ig
yr
op
C

5-113
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-14 Way Cover

The way covers on each sliding surface prevent chips from entering the sliding surfaces and
maintain a uniform oil membrane. Therefore, always pay attention so as to prevent cover
damage due to falling of a workpiece or tool.
Replace worn-out or damaged way covers. (Please refer to the relevant Parts List and place an
order to Mazak Technical Center or Technology Center)
The W-axis way covers consist of multistage covers and wipers are attached to each covers.
These wipers protect the multistage covers from chips. Always watch out for unusual wear on
the lips of the wipers and for wiper damage due to chips. Replace worn-out or damaged wipers.
(Please refer to the relevant Parts List and place an order to Mazak Technical Center or

.
ed
Technology Center.)

rv
se
1

re
s
ht
rig
All
n.
tio
74 ora 2
39 rp
r 3 Co

6
be ak
um az
l N ki M

B72-0101
a
az

3
4
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

B72-0102
7

Fig. 5-119 Sliding surface covers

5-114
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

Parts No. (Unit No.)
No. Parts name
500U 1000U 1500U

BMT 0B72450073* -
MB specifications
VDI 0B72450074* -
0B72450017*
BMT 0B72450073* -
MS specifications
VDI 0B72450074* -
1 Z-axis way cover
BMT 0B72450077*
MY specifications 0B72450048*
VDI 0B72450075*
0B72450001*

.
ed
BMT 0B72450077* -
MSY specifications

rv
VDI 0B72450075* -

se
MB specifications -

re
s
MS specifications -

ht
2 Z-axis bellows cover Z33ZZ00914* Z33ZZ00915*

rig
MY specifications Z33BC01413*

ll
MSY specifications -

A
n.
MB specifications -
0B72450066* 0B72450066*

tio
MS specifications -
74 ora
3 X-axis way cover
MY specifications 0323450003*
39 rp

0323450003* 0323450003*
r 3 Co

MSY specifications -
6

W-axis tailstock front way MB specifications -

be ak

cover 0B72450002* 0B72450014*

um az

(Main spindle – tailstock) MY specifications 0B72450025*

l N ki M

4 W-axis secondary spindle

front way cover
a

MS, MSY specifications 2323542658* 0B72450083* -

az

(Main spindle – Sub

spindle)
m
Ya

-
ria

W-axis tailstock front way MB specifications -

5 cover 0B72860013*
Se

-
23

(Main spindle – steady rest) MY specifications 0B72450025*

20

W-axis tailstock front way MB specifications - -

6 cover 0B72860018*
©

(Steady rest – tailstock) MY specifications - 0B72450024*

ht

W-axis tailstock rear way MB specifications -

ig

cover
yr

0B72450003* 0B72450012*
(Tailstock - Machine Right
op

MY specifications 0B72450067*
cover)
C

7
W-axis secondary spindle
rear way cover
MS, MSY specifications 0322450003* 0B72450084* -
(Sub spindle - Machine
Right cover)

5-115
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-14-1 Procedure for removing the Z-axis way cover

The removal method requires equipment such as cranes and lifts which lift the cover.
Refer to the foundation drawing for details of the required space.
If you don’t have a crane, lift, or any lifting machine, please consult Mazak Technical Center or
Technology Center.

1. Removing covers from the left side of the machine

(1) Remove the left side maintenance cover, the upper side cover of the machine, and back
maintenance cover.

.
Upper side cover of

ed
the machine

rv
se
re
s
ht
rig
All
n.
tio
74 ora
39 rp
r 3 Co

Left side maintenance cover

6
Back maintenance cover
be ak

B72-0103
um az

Fig. 5-120 Maintenance cover removal

l N ki M

(2) Remove the Z-axis way cover wiper.

a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

Way cover wiper (front) Way cover wiper (rear) Way cover wiper (front)

B72-0104

Fig. 5-121 Removal of the Z-axis way cover wiper

5-116
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

(3) Remove the intermediate fixed cover on the main spindle side.

.
ed
rv
se
B72-0105

re
Fig. 5-122 Intermediate fixed cover

s
ht
(4) Move the Z-axis to the –Z edge.

rig
Remove the guide brackets from the roller on the top of the Z-axis way cover.

A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m

B72-0106
Ya

ria

Fig. 5-123 Z-axis way cover guide bracket

Se
23

(5) Hang a chain block on the upper part of the Z-axis way cover.
20

(There is a tap for hanging)

©
ht
ig
yr
op
C

M12

B72-0107

Fig. 5-124 Z-axis way cover hanging position

5-117
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

(6) Remove the bolt securing the Z-axis way cover upper section shown in the following
diagram.

.
ed
rv
se
re
s
ht
B72-0108

rig
Fig. 5-125 Fixed bolt points of the Z-axis way cover

ll
A
(7) Remove the Z-axis way cover upper section from the left side of the machine.

n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23

B72-0109
20

Fig. 5-126 Z-axis way cover removal

©
ht
ig
yr
op
C

5-118
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

2. Removal from the ceiling (when there is no space on the left side of the machine:
Maintenance)
(1) Remove the left side maintenance cover, the upper side cover of the machine, and back
maintenance cover.

Upper side cover of

the machine

.
ed
rv
se
re
s
ht
rig
All
Back maintenance cover Left side maintenance cove

n.
B72-0103

tio
74 ora
Fig. 5-127 Maintenance cover removal
39 rp

(2) Remove the Z-axis way cover wiper.

r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

Way cover wiper (front) Way cover wiper (rear) Way cover wiper (front)

B72-0104

Fig. 5-128 Removal of the Z-axis way cover wiper

5-119
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

(3) Remove the intermediate fixed cover on the main spindle side.

.
ed
rv
se
B72-0105

re
Fig. 5-129 Intermediate fixed cover

s
ht
(4) Move the Z-axis to the –Z edge.

rig
Remove the guide bracket and amplifier duct from the roller on the top of the Z-axis way

ll
A
cover.

n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m

B72-0106
Ya

ria
Se
23

Fig. 5-130 Z-axis way cover guide bracket and amplifier duct
20

(5) Hang a chain block on the upper part of the Z-axis way cover.
(There is a tap for hanging)
©
ht
ig
yr
op
C

M12

B72-0107

Fig. 5-131 Z-axis way cover hanging position

5-120
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

(6) Remove the bolt securing the Z-axis way cover upper section shown in the following
diagram.

.
ed
rv
se
re
B72-0108

s
ht
Fig. 5-132 Fixed bolt points of the Z-axis way cover

rig
(7) Remove the Z-axis way cover to a position on the left side of the machine where it will not

A ll
come into contact with the main spindle junction box.

n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a

Protrude the cover by

az

approximately 500 mm from

m

the edge of the machine

Ya

ria

B72-0110
Se
23

Fig. 5-133 Z-axis way cover removal (1/2)

20

(8) Remove the upper part of the Z-axis way cover upward from the machine.
©
ht
ig
yr
op
C

B72-0111

Fig. 5-134 Z-axis way cover removal (2/2)

5-121
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-14-2 Procedure for removing the W-axis way cover

(1) Remove the right side maintenance cover.
(2) Remove the bolts (8 nos.) fixing the W axis.

.
ed
rv
se
re
s
ht
rig
B72-0112

ll
A
Fig. 5-135 W-axis way cover removal

n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

5-122
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-15 Milling Holder

5-15-1 Checking for secure mounting of cutting tools and holders

Check whether fixing nuts of the tool or fixing bolts of the holder are loose. If so, tighten them.

5-15-2 Checking for the turret, milling holders, and cutting tools to scan for chips
Check visually whether chips accumulate on the milling holder or turret. If so, clean it to remove
chips.

5-15-3 Checking for the entry of coolant into milling through holder

.
ed
rv
H type

se
• Rotate the turret and move the milling through holder to the machining position, then check

re
whether the coolant is leaking from the draining holes.

s
ht
If coolant leakage occurs, contact Mazak Technical Center or Technology Center.

rig
ll
5-15-4 Checking for the looseness of eccentric pin mounting bolts

A
n.
Check whether fixing bolts are loose. If so, adjust the eccentric pin referring to “5-15-5 Run
adjustment of a tool”.
tio
74 ora
39 rp

5-15-5 Run adjustment of a tool

r 3 Co

An eccentric pin is mounted for turret and HD milling holder positioning. Adjusting the eccentric
be ak

pin allows the run and center height of the tool to be precisely adjusted for highly accurate
um az

machining.
l N ki M

<Procedure on run adjustment with the eccentric pin>

a

(1) Connect a test bar to the HD milling holder.

az
m

(2) After bringing the dial indicator into contact with the far end of the test bar, rotate the test
Ya

ria

bar several times by hand and confirm the median value of the readings on the dial
Se
23

indicator.
20

(3) Perform a Z-axis movement to bring the dial indicator into contact with the base end of the
©

test bar, then rotate the test bar several times by hand, and confirm the median value of
ht

the readings on the dial indicator.

ig

(4) Calculate the adjustment value as the difference between the readings from the far end
yr
op

and the base end of the test bar.

C

If there is no difference, no adjustment is required since the run is normal.

(5) If there is a difference, perform a Z-axis movement to move the dial indicator to the far end
of the test bar.
(6) Loosen the fixing bolts of the eccentric pin and the fixing bolt of the holder so that they can
be adjusted. Hook the spanner to the rear end of the eccentric pin, and rotate the pin while
checking the adjustment value on the dial indicator.
(7) Repeat the above steps (2) to (6) until an adjustment value becomes 0.

5-123
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

(8) After the adjustment, tighten the fixing bolts of the eccentric pin and the fixing bolt of the
holder.

Fixing bolt for

the holder

Dial indicator
Eccentric pin fixing
Z-axis bolt

.
ed
rv
se
re
s
ht
rig
ll
A
Test bar

n.
CMN-7089

tio
74 ora
Fig. 5-136 Adjustment by the eccentric pin
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
op
C

5-124
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-16 Operator Door Automatic Open/Close Unit (Option)
In the specifications of the operator door automatic open/close unit (option) of this machine, an
electric actuator or servomotor is used for door opening/closing drive.

5-16-1 Automatic door maintenance menu (servomotor)

Use the maintenance menu of the automatic door to adjust the closing end (zero-point) and
opening end positions of the operator door.
Note 1: The zero point of the servo axis is the closing end. When you change the closing end
(zero-point), set the opening end again.

.
Note 2: For the electric actuator, the closing end (zero-point) and opening end positions

ed
cannot be set with the following procedure. Refer to “5-16-2 Zero-point return (electric

rv
se
actuator)”.

re
1. Door closing end (zero-point) setting

s
ht
(1) Set the setup switch to “O”.

rig
ll
(2) Tap the button on the upper right of the NC screen, and then tap .

A
n.
 The following menu appears.

tio
74 ora
AUTO
DOOR
39 rp
r 3 Co

(3) Tap [AUTO DOOR]

6
be ak

AUTO
um az

DOOR
l N ki M
a
az

 The following menu appears.

m
Ya

ria

INI. SET HOME JOG OPEN

MODE SET MODE SET
Se
23
20

(4) Tap [INI. SET MODE] while pressing the key on the machine operating panel.
©

INI. SET HOME JOG OPEN

ht

MODE SET MODE SET

ig
yr
op
C

 [INI. SET MODE] and [JOG MODE] turn blue (enabled).

(5) Use the automatic door close button to operate the door to the closing end position.
(6) Tap [HOME SET].
INI. SET HOME JOG OPEN
MODE SET MODE SET

 The closing end (zero-point) of the door is established.

(7) Tap [INI. SET MODE] while pressing the key on the machine operating panel.

5-125
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

INI. SET HOME JOG OPEN

MODE SET MODE SET

 [INI. SET MODE] and [JOG MODE] turn white (disabled).

(8) Power off the NC unit, and then power on the main power breaker.
(9) Power on the NC unit.
Note : When the power is turned off before the operation of (7) is performed, the closing end
(zero-point) of the door is not established. In this case, perform (8) and (9) again.

.
ed
2. Door opening end setting

rv
se
(1) Tap the button on the upper right of the NC screen, and then tap .

re
 The following menu appears.

s
ht
rig
AUTO

ll
DOOR

A
(2) Tap [AUTO DOOR]

n.
tio
74 ora
AUTO
DOOR
39 rp
r 3 Co

6
be ak

 The following menu appears.

um az

INI. SET HOME JOG OPEN

l N ki M

MODE SET MODE SET

a

(3) Tap [JOG MODE] to set the door operation as jog feed.
az
m

INI. SET HOME JOG OPEN

Ya

ria

MODE SET MODE SET

Se
23
20

 [JOG MODE].turns blue (enabled).

©
ht

(4) Use the automatic door open button to operate the door to the opening end position.
ig
yr

(5) Tap [OPEN SET].

op

INI. SET HOME JOG OPEN

C

MODE SET MODE SET

 The door opening end position is set to parameter RL26.

(6) Tap [JOG MODE].
INI. SET HOME JOG OPEN
MODE SET MODE SET

 [JOG MODE].turns white (disabled).

Note : The door opening end position can be input directly to parameter RL26.

5-126
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-16-2 Zero-point return (electric actuator)
To activate the operator door automatic open/close function, supply the power to the machine
and perform the zero-point return operation only once before normal operations. The alarm
message 1308 AUTO DOOR NOT HOME RETURN is displayed on the NC screen.
Zero-point return is performed on the closing side.
When the automatic door open button or automatic door close button on the machine operating
panel is pressed, the door moves in the input direction at 50 mm/s and stops when it reaches
the end. The alarm stops automatically.

5-16-3 Procedures for door controller error

.
ed
 Press the emergency stop button first and confirm that the machine does not start

rv
operating. Failure to confirm safety may result in serious injury or death.

se
re
WARNING

s
ht
If the following 1318 DOOR CONTROLLER MALF. alarm appears on the NC display, an error

rig
has occurred in the electric actuator.

A ll
The details of the alarm are displayed on the controller of electric actuator. Press the

n.
emergency stop button to stop the machine operation, and then check the alarm status on the

tio
controller and take corrective measures. 74 ora
The alarm is cancelled with the key on the machine operating panel, but for some
39 rp
r 3 Co

alarms, the machine is required to be restarted.

6
be ak

1. Procedure for checking an alarm

um az

(1) Check the display part [3] of the controller of electric actuator.
l N ki M

The alarm number and details blink alternately on the display part. “Alarm 33 (Excessive
a

voltage: Details 1)” occurs as shown below.

az
m
Ya

ria
Se
23
20

Blink
©

[3]
ht
ig

2 s interval
yr
op
C

Blink

CMN-7098

Fig. 5-137 Procedure for accessing the controller

5-127
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

2. Alarm list
Cancel the alarm with the method in the “Alarm cancellation method” column after removing the
cause.
Alarm cancellation method

Reset key
Alarm on the
Name Explanation Power
No. machine
OFF  ON operating
panel
The voltage of the control circuit and main circuit has
A.10 Insufficient voltage dropped  

.
ed
An internal part (CPU) of the controller has broken
A.12 Memory error 1 (RAM) 

rv
down

se
An error has occurred in the printed board or CPU
A.13 Clock error clock 

re
Breakdown of an internal part (EEP-ROM) of the
A.15 Memory error 2 (EEP-ROM) 

s
controller

ht
Encoder initial communication A communication error has occurred between the
A.16 

rig
error 1 encoder and controller
An error has occurred in an internal part of the
A.17 Circuit board error 

ll
controller

A
An internal part (Flash-ROM) of the controller has

n.
A.19 Memory error 3 (Flash-ROM) broken down 

tio
The combination of controller and servomotor is
A.1A Motor combination error 
74 ora
different
A.1C Software combination error Software check sum error 
39 rp

Encoder initial communication An error has occurred in an internal part of the

r 3 Co

A.1E 
6
error 2 encoder
Encoder initial communication
be ak

A.1F error 3
The connected encoder is not supported 
um az

Encoder normal A communication error has occurred between the

A.20 communication error 1 encoder and controller 
l N ki M

Encoder normal
A.21 The encoder data has an error 
communication error 2
a

Ground fault of the controller servomotor power line

az

A.24 Main circuit error

and servomotor  
m

Breakdown of the regeneration transistor inside the

A.30 Regeneration error * *
Ya

controller
ria

The servomotor rotation speed has momentarily

Se

A.31 Overspeed  
23

exceeded the permissible range

A current value that is in excess of the permissible
20

A.32 Overcurrent
current of the controller is flowing 
©

A.33 Excessive voltage The bus voltage is in excess  

ht

A.35 Instructed frequency error The instructed frequency that is input is too high  
ig
yr

A.37 Parameter error The parameter setting value exceeds the limit 
op

A.39 Program error The program has an error 

C

Main circuit element The controller is abnormally overheated from the

A.45 overheating inside * *

A.46 Servomotor overheating The servomotor is abnormally overheated * *

The controller overload protection characteristic
A.50 Overload 1
feature is surpassed * *
The maximum output current flowed continuously for
A.51 Overload 2 * *
a few seconds
The accumulated pulse has exceeded the alarm
A.52 Excess errors  
level
A.61 Operation alarm The point table is erroneous  
A.8E USB communication error USB communication error  
888 Watchdog The CPU and components are faulty 

5-128
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

 If an alarm marked with the * sign occurs, do not restart the operation
repeatedly after cancelling the alarm as this could lead to breakdown of
the controller servomotor. Remove the cause of occurrence of the alarm,
and at the same time, provide a cooling period of at least 30 minutes
before restarting operation. The warning is cancelled automatically as
soon as the cause of occurrence is removed.

3. Warning list
The warning is cancelled automatically as soon as the cause of occurrence is removed.
Alarm Stopped/Not stopped
from the time of

.
Name Explanation

ed
No. servomotor rotation

rv
Zero-point return incomplete
A.90 Zero-point return is not performed properly Stopped

se
warning
The controller internal temperature has exceeded the

re
A.91 Controller overheating warning Not stopped
warning level

s
Zero-point setting mistake

ht
A.96 The operation did not finish normally after zero-point return Stopped
warning

rig
The program was operated in a state in which program
A.97 Program execution failure Not stopped
operation could not be performed

A ll
A.98 Software limit warning The current position has reached the software stroke limit Stopped

n.
A.99 Stroke limit warning The stroke limit in the movement direction has reached Stopped

tio
There is a possibility of the regeneration power being in
74 ora
A.E0 Over-regeneration warning Not stopped
excess of the permissible regeneration power
39 rp

A.E1 Overload warning 1 There is a possibility of occurrence of an overload alarm Not stopped
r 3 Co

6
A.E6 Servo forced stopping warning The forced stopping signal has been turned OFF Stopped
be ak

The servo was turned ON when the main circuit power

A.E9 Main circuit OFF warning Stopped
supply was OFF
um az

Operation involving the flow of current that is concentrated

l N ki M

[Link] Overload warning 2 in any one phase of the servomotor and exceeding the Not stopped
rated current is being repeated
A state in which the number of output watts of the
a

Output watt excess warning servomotor exceeds the rated output continues at a
az

[Link] Not stopped

regular pace
m

A.F0 Tough drive warning Tough drive has occurred Not stopped
Ya

ria
Se
23
20

 The details of the main alarms and warnings, as well as the action to be
taken is described on the next paragraph.
©
ht

If the alarm does not stop even after taking an action, or if an alarm that
ig

is not described in the details occurs, turn OFF the power supply, stop
yr

using the machine, and contact Mazak Technical Center or Technology

op

Center.
C

5-129
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

4. Details and actions for alarm and warning

Alarm number: A.10 Name: Insufficient voltage

Alarm explanation • The voltage of the control circuit power supply has dropped.

• The voltage of the main circuit power supply has dropped.

• The main circuit power supply has been cut off.

Details
Device name Cause of alarm Action
display
The connector of the control circuit power
1 supply has come off. Alternatively, the Connect the connector properly.
contact may be poor.
Drop in voltage of Check the control circuit power supply
The voltage of the control circuit power
control circuit power voltage, and if necessary, contact Mazak

.
10.1

ed
2 supply is low. The voltage is 19 VDC or
supply Technical Center or Technology Center.
below.

rv
(Note 1)

se
A momentary power failure of 1 ms or more
3 has occurred. Correct the power supply.

re
The connector of the main circuit power
1 Connect the connector properly.

s
supply has come off. Contact failure.

ht
Drop in voltage of Check the main circuit power supply

rig
the main circuit The voltage of the main circuit power supply voltage, and if necessary, contact Mazak
10.2 2
power supply is low. The voltage is 140 VAC or below. Technical Center or Technology Center.

ll
(Note 2)

A
3 The controller is faulty. Change the controller.

n.
tio
The connector or wire of the main circuit
1 power supply has come off.
74 ora Connect the connector properly.
Main circuit power Check the main circuit power supply
supply cutoff The voltage of the main circuit power supply voltage, and if necessary, contact Mazak
39 rp

10.3 (Momentary power 2 is low. The voltage is 140 VAC or below. Technical Center or Technology Center.
r 3 Co

6
failure) (Note 2)
A momentary power failure of the main
be ak

3 circuit power supply has occurred. Correct the main circuit power supply.
um az
l N ki M

Alarm number: A.16 Name: Encoder initial communication error 1

a

Alarm explanation An error occurred in the communication between the encoder and controller.
az

Details
m

Device name Cause of alarm Action

display
Ya

ria

The encoder cable is defective. The shield

Se

16.0 1 Replace the cable.

23

16.1 is faulty.
20

16.2 Encoder transmission Investigate the noise and ambient

2 The surrounding environment is faulty. temperature, and take action according to
©

16.5 data error

16.6 the cause of occurrence.
ht
ig

16.7 3 The controller is faulty. Change the controller.

yr

1 The encoder cable has come off. Connect the cable properly.
op

The encoder cable is faulty. The shield is

C

2 Replace the cable.

faulty.
Encoder transmission
3 Breakdown of the encoder. Replace the servomotor.
16.3 data error 3 (no
controller reception) 4 The controller is faulty. Change the controller.
Investigate the noise and ambient
5 The surrounding environment is faulty. temperature, and take action according to
the cause of occurrence.

5-130
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

Alarm number: A.20 Name: Encoder normal communication error 1

Alarm explanation An error occurred in the communication between the encoder and controller.
Details Device name Cause of alarm Action
display
1 The encoder cable has come off. Connect the connector properly.
The encoder cable is faulty. The shield is
2 faulty. Replace the cable.
Encoder transmission
data error 3 (controller 3 Breakdown of the encoder. Replace the servomotor.
20.1
reception error) 4 The controller is faulty. Change the controller.
Investigate the noise and ambient
5 The surrounding environment is faulty temperature, and take action according to

.
ed
the cause of occurrence.
The encoder cable is faulty. The shield is

rv
1 faulty. Replace the cable.

se
20.5 Encoder reception Investigate the noise and ambient

re
data error 2 The surrounding environment is faulty. temperature, and take action according to
20.7 the cause of occurrence.

s
ht
3 Breakdown of the encoder. Change the controller.

rig
A ll
Alarm number: A.24 Name: Main circuit error

n.
•
tio
Alarm explanation A ground fault has occurred in the controller servomotor power line.
74 ora
• A ground fault has occurred in the servomotor.
Details
39 rp

Device name Cause of alarm Action

r 3 Co

display
6

If the alarm occurs even after removing

1 The controller is faulty.
be ak

the power cable, change the controller.

Ground fault or short-circuit of the
um az

2 servomotor power cable. Replace the power cable.

Detection of ground
l N ki M

24.1 fault by 3 Ground fault of the servomotor. Replace the servomotor.

24.2 hardware/software
A ground fault has occurred in the power
a

detection circuit 4 Correct the wiring.

supply input line and servomotor power line.
az

Investigate the noise and ambient

m

5 The surrounding environment is faulty. temperature, and take action according to

Ya

ria

the cause of occurrence.

Se
23
20

Alarm number: A.32 Name: Overcurrent

©

Alarm explanation A current value that is more than the permissible current value of the controller is flowing.
ht

Details Device name Cause of alarm Action

ig

display
yr

If the alarm occurs even after removing

op

1 The controller is faulty. the power cable, change the controller.

Ground fault or short-circuit of the
C

32.1 2 servomotor power cable. Replace the power cable.

Detection of
32.2 overcurrent by
3 The servomotor is faulty. Replace the servomotor.
32.3 hardware/software
detection circuit Investigate the noise and ambient
32.4
4 The surrounding environment is faulty. temperature, and take action according to
the cause of occurrence.

Alarm number: A.33 Name: Excessive voltage

Alarm explanation The value of status display Pn (bus voltage) indicates excessive voltage (5).
Details Device name Cause of alarm Action
display
Check the main circuit power supply
Main circuit voltage The voltage of the main circuit power supply voltage, and if necessary, contact Mazak
33.1 error 1 is high. The voltage is higher than 253 VAC. Technical Center or Technology Center.
(Note 2).

5-131
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

Alarm number: A.45 Name: Main circuit element overheating

Alarm explanation The controller is abnormally overheated from the inside.

Details Device name Cause of alarm Action
display
The ambient temperature has exceeded
1 Lower the ambient temperature.
55°C.
The power supply was repeatedly turned
Circuit board 2 ON/OFF in an overload state. Correct the operation pattern.
45.1 temperature error
3 The radiator and aperture are clogged. Clean the radiator and aperture.

4 The controller is faulty. Change the controller.

.
ed
Alarm number: A.46 Name: Servomotor overheating

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se
Alarm explanation The servomotor is abnormally overheated.

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Details Device name Cause of alarm Action

s
display

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The ambient temperature of the servomotor Lower the ambient temperature of the
1

rig
has exceeded 40°C. servomotor.
The load is high. Either reduce the load or

ll
46.1 Servomotor error 2 The servomotor is overheated. take action to discharge heat from the

A
servomotor.

n.
Breakdown of the thermal sensor within the

tio
3 encoder. 74 ora Replace the servomotor.
39 rp

Alarm number: A.50 Name: Overload 1

r 3 Co

Alarm explanation The controller overload protection characteristic feature is surpassed.

be ak

Details Device name Cause of alarm Action

um az

display
l N ki M

The controller is used beyond the

1 The load is high. Reduce the load.
Overload thermal 1 continuous output current.
error during After the occurrence of the overload alarm, After the occurrence of the alarm, wait for
a

50.1
operation/termination
az

2 the operation was started again without at least 30 minutes before resetting the
50.4 (continuous operation providing sufficient cooling time. alarm.
m

protection)
3 The controller is faulty. Change the controller.
Ya

ria

There has been a collision with the Make sure no foreign object is interfering.
Se

1
23

machine. Correct the operation pattern.

20

2 Disconnection of the power cable. Replace the power cable.

Overload thermal 2
The servomotor is connected to the wrong
©

50.2 error during 3 Correct the wiring of the power cable.

operation/termination destination.
ht

50.5 (short-time operation The controller is used beyond the

4 The load is high. Reduce the load.
ig

protection) continuous output current.

yr

5 The controller is faulty. Change the controller.

op

6 The encoder is faulty. Replace the servomotor.

C

5-132
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

Alarm number: A.51 Name: Overload 2

Alarm explanation The maximum output current flowed continuously for a few seconds due to machine collision.
Details Device name Cause of alarm Action
display
1 Disconnection of the power cable. Replace the cable.
The servomotor is connected to the wrong
2 destination. Correct the wiring of the power cable.
Make sure that the correct connection is
3 Wrong connection of the encoder cable.
Overload thermal 3 established.
51.1 There has been a collision with the Make sure no foreign object is interfering.
error during 4
51.2 operation/termination machine. Correct the operation pattern.
5 The torque is saturated. Correct the operation pattern.

.
ed
6 The controller is faulty. Change the controller.

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7 The encoder is faulty. Replace the servomotor.

re
s
ht
Alarm number: A.52 Name: Excess errors

rig
The accumulated pulse between the instructed position and current position has exceeded the
Alarm explanation
alarm level.

A ll
Details Device name Cause of alarm Action

n.
display

tio
The servomotor power line is either not
1 Correct the wiring of the power cable.
connected or connected incorrectly.
74 ora
Make sure that the correct connection is
2 Wrong connection of the encoder cable.
established.
39 rp

There has been a collision with the Make sure that the correct connection is
r 3 Co

3
6

Maximum machine. established.

52.3 The machine cannot be started because
be ak

accumulated pulse
4 of insufficient torque due to a decline in Correct the power supply voltage.
um az

power supply voltage.

The addition subtraction speed time
l N ki M

5 constant is short. Correct the operation pattern.

6 The encoder is faulty. Replace the servomotor.

a
az

Exceeded errors The parameter of the torque limit value is “0”.

m

52.4 during zero torque 1 The torque limit value is “0”. Contact Mazak Technical Center or
Ya

ria

limit value Technology Center.

Se
23
20

Alarm number: A.90 Name: Zero-point return incomplete warning

©

Warning explanation Zero-point return is not performed properly.

ht

Details Device name Cause of alarm Action

ig

display
yr

Incomplete zero-point The positioning operation was executed

op

90.1 1 Perform zero-point return.

return without performing zero-point return.
C

Alarm number: A.96 Name: Zero-point setting mistake warning

Warning explanation The operation did not finish normally after zero-point return.
Details Device name Cause of alarm Action
display
In-position not Accumulated pulse is remaining in excess of Make sure no foreign object is interfering
96.1 reached 1 the setup value of the in-position range. near the closed end of the door.

5-133
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

Alarm number: A.E6 Name: Servo forced stopping warning

Warning explanation The forced stopping signal has been turned OFF.
Details Device name Cause of alarm Action
display
1 Forced stopping (EM1) is turned OFF. Release the Emergency Stop button.
Make sure the correct connection is
established. Check the control circuit
Servo forced stopping
E6.1 2 External 24 VDC power is not supplied. power supply voltage, and if necessary,
warning
contact Mazak Technical Center or
Technology Center. (Note 1).
3 The controller is faulty. Replace the controller.

.
ed
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Alarm number: A.E9 Name: Main circuit off warning

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Warning explanation Servo ON (SON) is turned ON when the main circuit power supply is OFF.

re
Details Device name Cause of alarm Action

s
ht
display

rig
1 The main circuit power supply is OFF. Turn ON the main circuit power supply.

ll
The connector of the main circuit power

A
Servo ON (SON) 2 Connect the connector properly.
supply has come off.
E9.1 turned ON when main

n.
Check the main circuit power supply
circuit is OFF

tio
The voltage of the main circuit power supply voltage, and if necessary, contact Mazak
3 is low. The voltage is 140 VAC or below.
74 ora Technical Center or Technology Center.
(Note 2)
39 rp
r 3 Co

 As for alarm and warning explanation (Note 1) and (Note 2), check the
be ak

voltage of the corresponding part of the below-described controller, and

um az

if the cause of occurrence is applicable, note down the explanation and

l N ki M

contact Mazak’s online support.

a
az
m
Ya

ria

(Note 2)
Se
23

Connector CNP1
Between L1-L2
20
©

(Note 1)
ht

Connector CNP2
ig

Between 24 V and 0 V
yr
op
C

CMN-7099

Fig. 5-138 Checking the control circuit power supply voltage and main circuit power supply voltage

5-134
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-16-4 Replacing the safety switch (contact pressure sensor)
If the safety switch (contact pressure sensor) is disconnected, an alarm is displayed.
Replace the switch following the procedure below.
Name Part No. Model
Switch R30PC00163∗ OT-10BP-B500
Switch R30PC00195∗ OT-10BP-B1100

1. Removal procedure
(1) Power off the machine.

.
ed
(2) With the operator door open, remove M6 bolts [1].

rv
(3) Remove the connector cover [2].

se
(4) Remove the M6 bolts [3].

re
s
(5) Remove the safety switch mounting brackets [4] and [5].

ht
rig
Note : Pay attention not to pull the electrical wiring of the safety switch forcibly.

ll
(6) Disconnect the electrical wiring of the safety switch to be replaced.

A
n.
tio
74 ora
[1]
[2]
39 rp

[4]
r 3 Co

6
be ak
um az
l N ki M
a
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20
©
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[3]

[5]

CMN-7090

Fig. 5-139 Removing the safety switch (contact pressure sensor) (1/3)

5-135
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

[7]
[6]

.
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CMN-7091

s
Fig. 5-140 Removing the safety switch (contact pressure sensor) (2/3)

ht
rig
(7) To replace the safety switch, leave the rubber cap [6] in the direction of the arrow.

A ll
(8) Slide the rubber [7] in the longitudinal direction to remove it.

n.
Note 1: At this time, disconnect the wiring on both ends one by one.

tio
74 ora
Note 2: If the rubber is caught and cannot be removed smoothly, soapy water will help
the removal.
39 rp
r 3 Co

[9]
be ak

[8]
um az
l N ki M
a
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Ya

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20
©
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CMN-7092

Fig. 5-141 Removing the safety switch (contact pressure sensor) (3/3)

(9) Remove the M4 countersunk-head screws [8], and remove the aluminum frame [9] of the
safety switch.

2. Mounting procedure
Mount the safety switch (contact pressure sensor) in the reverse procedure above.
Note : When mounting the aluminum frame, mount the rubber cap at the same time, and
then slide the rubber to mount it.

5-136
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-17 Others

5-17-1 CNC unit

The CNC control enables ultrahigh-speed controls (feed rate acceleration/deceleration, spindle
acceleration/deceleration, PLC operations, high-speed roughing cycle, optimum constant cutting
speed control, turret indexing, and others). Spindle and servomotor control is fully digitized.

.
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A ll
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74 ora
39 rp
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6
be ak
um az
l N ki M
a
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Ya

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CMN-7093
Se
23
20

Fig. 5-142 Lathe control (QT-200/250MB 26 kW)

©
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5-137
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

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A
n.
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74 ora
39 rp

CMN-7094
r 3 Co

6
be ak

Fig. 5-143 Lathe control (QT-200/250MY 26 kW)

um az
l N ki M
a
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20
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CMN-7095

Fig. 5-144 Lathe control (QT-200/250MS 26 kW)

5-138
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

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74 ora
39 rp
r 3 Co

CMN-7096
be ak
um az

Fig. 5-145 Lathe control (QT-200/250MSY 26 kW)

l N ki M

No. Name No. Name

a

1 NC operating panel 11 Milling spindle motor

az

2 NC unit 12 Turret indexing servo control unit

m

3 Spindle, X-axis, Z-axis, Y-axis servo control unit 13 Servomotor for turret rotation
Ya

ria

4 Primary spindle motor 14 W-axis or tail spindle servo control unit

Se
23

5 X-axis servomotor 15 W-axis or tail spindle servomotor

20

6 Z-axis servomotor 16 Servo control unit for the spindle, X-, Z-axes and
turret rotation
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7 Y-axis servomotor 17 X-axis, Z-axis servo control unit

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8 Secondary spindle control unit 18 Primary spindle control unit

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9 Secondary spindle motor 19 Y-axis servo control unit

op

10 Milling spindle control unit − −

C

5-139
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-17-2 Cleaning the NC screen

The NC screen is a touch screen that may respond poorly to touch commands when significant
dirt accumulates on the screen. Follow the procedure below to clean dirt accumulation from the
screen:
< Procedure >

(1) Turn the power off the machine, or press and hold the key [16] on the machine
operating panel to disable the touch screen.

• For more information about the key [16] on the machine operating
panel, see Section 2 “2 OPERATING PANELS” of the operating manual.

.
ed
rv
(2) Wipe the dirt from the screen with a soft, dry cloth.

se
When cleaning the screen with liquid, wipe the surface gently with a soft cloth moistened

re
with ethanol or diluted neutral detergent.

s
ht
Note 1: When cleaning the outer surface of the operating panel with liquid, do it in the same

rig
way as the above.

A ll
Note 2: If cleaning using liquid is performed repeatedly for an extended period of time, it may

n.
cause the operating panel to discolor (become cloudy) or crack, its coated surface to

tio
change in gloss or its coating to peel off.
74 ora
5-17-3 Electrical control cabinet
39 rp
r 3 Co

1. Checking the electrical control cabinet

be ak
um az

A. All terminal screws of electric parts are tightened securely.

l N ki M

B. Soldered portions have proper strength.

Lightly pull the solder parts by hand to check them.
a
az

C. The cap of the cartridge fuse is tightened securely.

m
Ya

ria

D. The spark extinguisher case is not discolored.

Se

If discolored, it is necessary to change the extinguisher.

23

 High voltages are applied to terminals inside the electrical control cabinet, transformer,
20

motor and relay box. Never touch these terminals.

©

 After the power supply has been turned off, the electric components inside the electric
ht

DANGER
ig

control cabinet are still alive with remaining voltage. Before touching these components,
yr

make sure that no voltage is applied using a multimeter or other proper instrument.
op

 Before attempting any repair or service work in the electrical control cabinet, confirm the
C

high voltage areas by referring to the electric circuit diagram.

 Only authorized personnel can carry out electric maintenance.

 Before carrying out inspection of the electrical control cabinet, turn off the power supply
WARNING at the factory power distribution board.
 The power is not cut off when the control cabinet door is opened. During either inspection
or repair inside the control cabinet, lock the main power breaker in the OFF position using
a padlock.
The customer supplies the padlock.

5-140
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

2. Resetting the thermal relays
If the alarm 200 THERMAL TRIP (EMERGENCY STOP) or 264 THERMAL TRIP (SINGLE
BLOCK) is displayed, this indicates that one or more of the thermal relays listed below have
tripped.
Overloading of the corresponding motor is the likely cause of tripping of the relays.
• Breaker with build-in thermal relay QF211 (for hydraulic pump motor use)
• Breaker with build-in thermal relay QF213 (for radiator fan motor use)
• Breaker with build-in thermal relay QF231 (for coolant pump motor use)
• Breaker with build-in thermal relay QF271 (for chip conveyor motor use)

.
ed
After removing the cause of overloading of the corresponding motor, reset the thermal relays as

rv
se
shown below.

re
s
ht
rig
A ll
n.
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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m

CMN-7097
Ya

ria

Fig. 5-146 Resetting the thermal relays

Se
23
20
©
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5-141
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-17-4 Replacing the batteries in the battery box

1. Battery box for the absolute position detection system

If the alarm 12 SERVO BATTERY WARNING occurs, this means the batteries for the absolute
position detection system are low. Follow the procedure “B Battery replacement procedure of
the battery box for the absolute position detection system” to replace the batteries in the battery
box shown in Fig. 5-147.
One battery unit uses four D alkaline batteries.
Note: Even if the alarm does not occur, replace the batteries every year.

.
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A
Battery unit

n.
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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
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m
Ya

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23
20
©

B72-0004
ht
ig

Fig. 5-147 Positioning of the battery unit in the machine

yr
op

A. Precautions
C

(1) Replace the batteries when the main circuit breaker is ON, or when the NC power is ON.
(2) Do not use manganese batteries.
(3) Use D alkaline batteries. Recommended products are listed below.
Name Recommended Manufacturer Model Yamazaki Mazak Product #
D Alkaline Battery LR20RS(2S)JEE D50FB002730

(4) Make sure to use all four D alkaline batteries that are new and of the same model.
(5) Do not use rechargeable batteries.

5-142
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

B. Battery replacement procedure of the battery box for the absolute position detection
system
<Procedure>

(1) Remove the battery unit cover.

.
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rig
The cover will come off by removing 4 screws.

ll
CMN-0054

A
n.
Fig. 5-148 Battery unit cover

tio
(2) Replace the 4 batteries. Do not reverse the polarity of the batteries.
74 ora
39 rp
r 3 Co

6
be ak

Facing out Facing out

um az
l N ki M
a

Facing out Facing out

az
m
Ya

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23

Alkaline battery
20

CMN-0055
©
ht

Fig. 5-149 Placement of batteries in the battery unit

ig

(3) Press down the cover and tighten the screws in diagonal order.
yr
op

C. Checking after replacing the batteries

C

Follow the procedure below to check if the batteries were replaced correctly.
To check this, the main circuit breaker must be turned OFF.
Note : If the main circuit breaker is turned off with the batteries not having been replaced
correctly, after 10 hours or longer, the axis home position will turn off.
(1) After replacing the batteries, turn OFF the NC power (if it is ON).
(2) Turn OFF the main circuit breaker.
(3) Turn ON the main circuit breaker.
(4) Turn ON the NC power.

5-143
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

(5) After the NC has turned ON, check that the alarm 12 SERVO BATTERY WARNING is not
displayed.
If the above procedure does not turn off the display of 12 SERVO BATTERY WARNING,
contact Mazak Technical Center or Technology Center.

2. Replacing the batteries in the battery box for the machine relocation detector (RD)
The battery box for the relocation detector (RD) is located inside the Electrical cabinet.
<Procedure>
• For battery replacement procedure of the machine relocation detector, refer
to the Maintenance Manual “Machine Relocation Detector Battery

.
ed
Replacement Procedure Manual.”

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5-17-5 Replacing the battery of the NC unit

ht
rig
 Do not disassemble the battery.

A ll
 Do not throw the battery into a fire or water.

n.
CAUTION  Do not apply a pressure to or deform the battery.
 Do not charge the battery. tio
74 ora
 Recycle or dispose of the removed battery in accordance with the local regulations.
39 rp
r 3 Co

6
be ak

1. Alarm display
um az

If the battery of the NC unit becomes low, the alarm 52 BATTERY ALARM will be raised. For
l N ki M

the action to be taken, which varies depending on the contents of the alarm, see Table 5-3.
a
az
m
Ya

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Se
23
20
©

Cause Applicable unit

ht
ig

CMN-7100
yr
op

Fig. 5-150 Detailed code of alarm message

C

Table 5-3 Causes of alarm

Cause Applicable unit Action

The battery voltage of the NC control unit is low. So, replace

1 1 the battery, following the instructions in “3. Procedure for
replacing the battery.”
The battery of the NC control unit is completely exhausted.
3 1 The data in the NC control unit is lost, so contact Mazak
Technical Center or Technology Center.

Note : Replace the battery every five years even if the alarm 52 BATTERY ALARM is not
raised.

5-144
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

2. Precautions
(1) If the alarm is raised, replace the battery within a week.
(2) After removing the battery, complete the replacement of the battery within 30 minutes.
(3) If the replacement of the battery is not completed within 30 minutes, the internal data will
be lost.
(4) If the internal data is lost, contact Mazak Technical Center of Technology Center.
(5) Use the battery specified below.
Name Manufacturer’s model Yamazaki Mazak parts No.
Manganese dioxide primary lithium battery Q6BAT D80MA01517*

.
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3. Procedure for replacing the battery

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The NC control unit is installed in the control cabinet.

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A ll
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74 ora
39 rp
r 3 Co

6
be ak

NC control unit
um az
l N ki M
a
az
m
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23
20

Control cabinet
CMN-7101
©

Fig. 5-151 Position of the NC control unit

ht
ig

Note : Back up the internal data, such as machining programs, tool data and parameters,
yr

before starting the replacement of the battery.

op
C

• For an explanation of the backup of the internal data, such as machining

programs, tool data and parameters, refer to Chapter 10 “DISPLAYS
RELATED TO DATA STORAGE” in Part 3 of the Operating Manual of the
machine.

5-145
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

<Replacement procedure>
(1) Turn off the machine power.
(2) Disconnect the battery connector from the NC control unit.
(3) Remove the battery.
(4) Mount a new battery in the reverse order of Steps (1) to (3).

.
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Battery connector

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A
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74 ora
Battery
39 rp
r 3 Co

6
be ak
um az

CMN-7102
l N ki M

Fig. 5-152 Replacing the battery of the NC control unit

a
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5-146
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-17-6 Procedure for replacing the proximity sensor

Washer Proximity sensor

Nut A
Bracket
Nut B

Washer

.
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rv
0.5 to 1.0 mm

se
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Watchdog CMN-0056

s
ht
Fig. 5-153 Replacing the proximity sensor

rig
(1) Remove nuts A and B and remove the sensor.

All
(2) Insert a new sensor into the hole of the bracket.

n.
tio
(3) Hand-tighten nuts A and B. 74 ora
• The permissible strength of the nut tightening torque differs according to the particular
39 rp

distance from the front end of the sensor head. The tightening torques at sections A and B
r 3 Co

in Fig. 5-154 are shown below. Tighten the nuts so that the permissible torques are not
6

exceeded. Overtightening causes damage.

be ak
um az

Tightening torque at section A: 11.8 Nm

l N ki M

Tightening torque at section B: 19.6 Nm

a
az
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20
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ht

A B
ig

CMN-0057
yr

Fig. 5-154 Proximity sensor

op
C

(4) Measure the clearance between the front end of the sensor and the watchdog. Use a feeler
gauge to measure the clearance.

5-147
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

(5) Perform adjustments for a clearance of 0.5 to 1.0 mm between the front end of the sensor
and the watchdog. Since the thread of the sensor is pitched at 1 mm, rotation of the nut
through one turn moves the sensor through 1 mm.
A. To move the sensor forward through 1 mm, loosen nut A by rotating it through one
counterclockwise turn, or tighten nut B by rotating it through one clockwise turn.
B. To move the sensor backward through 1 mm, loosen nut B by rotating it through one
counterclockwise turn, or tighten nut A by rotating it through one clockwise turn.
(6) Retighten the nuts.
(7) After adjustment, operate the machine and check that the LED of the sensor correctly turns

.
on and off.

ed
rv
Remark : Sensor on/off can also be checked on the DIAGNOSIS MONITOR display. The

se
DIAGNOSIS MONITOR display is displayed by selecting [DIAGNOS] - [VERSION] -

re
[DIAGNOS MONITOR].

s
For the input device of the sensor, refer to electrical drawings.

ht
rig
A ll
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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
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MAINTENANCE OF MAJOR MACHINE UNITS 5

5-17-7 Replacing the LED lamp
 Before replacing the LED lamp, be absolutely certain to set the main power breaker to
OFF and turn off the lamp.
 Ask an officially qualified “electrical technician” to replace the LED lamps.
WARNING
The LED lamp is located in the upper section of the main spindle as shown below.

LED lamp

.
ed
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A ll
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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M

B72-0113
a

Fig. 5-155 Replacing the LED lamp

az
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20
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5-149
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

1. LED lamp replacement procedure

Following is the method for replacing the LED lamp:
(1) Since the LED lamp is fixed, remove the 6 M5 bolts to remove the lamp.
(2) Remove the connectors (No.X1950 and No.X1951 at the tailstock side) inside the main
spindle junction box.
(3) Connect a new LED lamp to the connector.
(4) Use the 6 M5 bolts to secure the LED lamp again.

Main spindle junction box

.
ed
6–M5 bolts

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A
n.
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74 ora
39 rp

LED lamp
r 3 Co

B72-0114
be ak

Fig. 5-156 Replacing the LED lamp

um az
l N ki M

 The LED lamp is to be replaced under its machine-mounted status. Be extra careful not
to get injured during the replacement.
a
az
m

CAUTION
Ya

ria

Note: Use only the manufacturer-designated replacement parts.

Se
23

To clean the lamp glass, use a cloth dampened with a household detergent. Before
20

using a detergent, however, make sure that it does not damage the coated surface or
©

plastic sections of the lamp glass.

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ig
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5-150
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

5-17-8 Wipers
The wipers located on each sliding surface prevent chips from entering the sliding surfaces and
maintain a uniform oil membrane. Therefore, always watch out for unusual wear on the lips of
the wipers and for wiper damage due to chips.
Replace worn-out or damaged wipers. (Please refer to the relevant Parts List and place an
order to Mazak Technical Center or Technology Center.)

1 15 7
5
6

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2

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s
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rig
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3

A
4

n.
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74 ora
39 rp
r 3 Co

Front side
6
be ak

Back side
um az

10 16
l N ki M

9
a
az
m
Ya

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Se
23
20
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17

18
12

14

8
B72-0115

Fig. 5-157 Wipers for sliding surface cover

5-151
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

Table 5-4 MY, MSY specifications

Parts No.
No. Parts name MSY specifications MY specifications
500U 1000U 500U 1000U 1500U
1 Turret top wiper 0B72470070∗ 0B72470070∗ 0B72470070∗ 0B72470070∗ 0B72470070∗
2 Turret left rear wiper 1323553054∗ 1323553054∗ 1323553054∗ 1323553054∗ 0B72450030∗
3 Turret left front wiper 2323542661∗ 2323542661∗ 2323542661∗ 2323542661∗ 0B72450031∗
4 Turret right front wiper 0B72470046∗ 0B72470046∗ 0B72470046∗ 0B72470046∗ 0B72470046∗
5 Tailstock side top wiper — — 0323470033∗ 0B72470382∗ 0B72470892∗
6 Tailstock side top wiper — — — — —

.
ed
7 Turret right rear wiper 2323553055∗ 2323553055∗ 2323553055∗ 2323553055∗ 0B72470878∗

rv
Secondary spindle cover
8 3322558935∗ 3322558935∗ — — —
wiper

se
VDI:0B72470918∗ VDI:0B72470918∗

re
9 Z-axis way cover wiper 0B72470118∗ 0B72470118∗ Z33BC01443∗
BMT:0B72470922∗ BMT:0B72470922∗

s
10 Left door wiper (top) 0B72470236∗ 0B72470236 0B72470236∗ 0B72470236∗ 0B72470236∗

ht
rig
11 Right door wiper (top) — 0B72470395∗ — 0B72470395∗ 0B72470395∗
Left door wiper

ll
12 0B72470237∗ 0B72470237∗ 0B72470237∗ 0B72470237∗ 0B72470237∗

A
(door side panel)

n.
Right door wiper
13 — 0B72470396∗ — 0B72470396∗ 0B72470396∗
(door side panel)
Tailstock front cover
tio
74 ora
14 — — 3321506117∗ 3323592910∗ Z33BC01445∗
wiper
15 Turret top side wiper 4323558702∗ 4323558702∗ 4323558702∗ 4323558702∗ 4323558702∗
39 rp
r 3 Co

Carriage base front

6
16 1323357833∗ 1323357834 1323357833∗ 1323357834∗ 1323357834∗
wiper
be ak

17 Window glass Z52ZZ00111∗ Z52ZZ00111∗ Z52ZZ00111∗ Z52ZZ00111∗ Z52ZZ00111∗

um az

Packing of the gearing

18 0B72470012 0B72470452 0B72470012 0B72470452 0B72470452*
parts for the front door
l N ki M

Table 5-5 MB, MS specifications

a
az

Parts No.
m

No. Parts name MS specifications MB specifications

Ya

ria

500U 1000U 500U 1000U

Se

1 Turret top wiper

23

0B72470445∗ 0B72470445∗ 0B72470445∗ 0B72470445∗

2 Turret left rear wiper
20

3 Turret left front wiper — — — —

©

4 Turret right front wiper 0B72470046∗ 0B72470046∗ 0B72470046∗ 0B72470046∗

ht
ig

5 Tailstock side top wiper — — 0323470033∗ 0B72470382∗

yr

6 Tailstock side top wiper — — — —

op

7 Turret right rear wiper 0B72471159∗ 0B72471159∗ 0B72471159∗ 0B72471159∗

C

8 Secondary spindle cover wiper 3322558935∗ 3322558935 — —

VDI: 0B72470918∗ VDI: 0B72470918∗
9 Z-axis way cover wiper 0B72470118∗ 0B72470118∗
BMT: 0B72470922∗ BMT: 0B72470922∗
10 Left door wiper (top) 0B72470236∗ 0B72470236 0B72470236∗ 0B72470236∗
11 Right door wiper (top) — 0B72470395∗ — 0B72470395∗
12 Left door wiper (door side panel) 0B72470237∗ 0B72470237∗ 0B72470237∗ 0B72470237∗
Right door wiper (door side
13 — 0B72470396∗ — 0B72470396∗
panel)
14 Tailstock front cover wiper — — 3321506117∗ 3323592910∗
15 Turret top side wiper 4323558702∗ 4323558702∗ 4323558702∗ 4323558702∗
16 Carriage base front wiper 1323357833∗ 1323357834∗ 1323357833∗ 1323357834∗
17 Window glass Z52ZZ00111∗ Z52ZZ00111∗ Z52ZZ00111∗ Z52ZZ00111∗
Packing of the gearing parts for
18 0B72470012 0B72470452 0B72470012 0B72470452
the front door

5-152
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

< Procedure for replacing the Yt-axis wiper >
(1) Move the carriage base to a position (proximately –OT) where it will be easy to work on the
Z-axis.
(2) Remove the intermediate fixed cover on the main spindle side.
(3) Move the carriage to a position on the main spindle side at which all 4 Yt-axis wiper fixed
bolts are visible.
(4) Remove the cover in front of the carriage base and remove the Yt-axis wiper by sliding it
along the linear guide surface.
(5) Mount the wiper in the reverse procedure above.

.
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74 ora
39 rp
r 3 Co

Fig. 5-158 Removing the Yt-axis wiper

be ak
um az
l N ki M

5-17-9 Front door glass

a

Before operating the machine, be absolutely certain to check that the front door glass surface is
az

free from damage such as flaws. If even a slight flaw is found, stop the machine and replace the
m

glass. (When ordering a replacement glass from Mazak Technical Center or Technology Center,
Ya

ria

refer to the Parts List and specify the part number.)

Se
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20
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5-153
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

5-18 List of Consumption Goods

1
4
11

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12

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6 13
7

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A
10

n.
14 B72-0010

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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M

B72-0011 3 8
25 24
a
az
m

26
Ya

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Se

15
23
20
©

B72-0012
ht

19, 20,
18 16, 17
ig

21, 22
yr
op
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5
B72-0013
23

Fig. 5-159 List of consumption goods

5-154
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

Replacement
Parts No. Replacement
No. Name Manufacturer period (Rough Use Part
(Unit No.) time
standard)
Approximately
Illumination
50000 hours
1 LED lamp R61ZZ00188∗ HAKKOSONIC 10 minutes inside the
(About
machine
17 years)
MB, MS, MY,
Z33ZZ00914∗
MSY 500U
Approximately
MB, MS, MY, Turret right
2 Bellows cover Nippon Jabara 15000 hours 30 minutes
Z33ZZ00915∗ side
MSY 1000U (About 5 years)
MY 1500U Z33BC01413∗

.
ed
Wiper for the X- Mazak Approximately
MB, MS, MY, Front panel of

rv
3 axis way cover 0322450006∗ manufactured 6000 hours 60 minutes
MSY the turret

se
use products (About 2 years)

re
MB, MS, MY,
0B72470118∗
MSY 500U

s
Wiper for the Z- Mazak Approximately

ht
MB, MS, MY, VDI: 0B72470918∗ Z-axis way
4 axis way cover manufactured 6000 hours 60 minutes

rig
MSY 1000U BMT:0B72470922∗ cover
use products (About 2 years)

ll
MY 1500U Z33BC01443∗

A
n.
MB, MY 500U 0B72450004∗

tio
Wiper for the W- MB, MY 1000U 0B72450013∗ 74 ora Mazak Approximately
5 axis way cover MS, MSY 500U 0322450004∗ manufactured 6000 hours 60 minutes Tailstock rear
use products (About 2 years)
39 rp

MS, MSY 1000U Z33BC01523∗

r 3 Co

MY 1500U Z33BC01446∗
6

0B72470445∗
be ak

MB, MS
0B72470474∗
um az

0B72470070∗
l N ki M

1323553054∗
a

MY, MSY 2323542661∗

az

2323553055∗
m

Wiper for the 4323558702∗ Mazak Approximately

Turret
Ya

ria

6 turret manufactured 6000 hours 60 minutes

0B72470070∗ circumference
circumference products (About 2 years)
Se
23

0B72450030∗
20

MY 1500U 0B72450032∗
©

0B72470878∗
ht

4323558702∗
ig

MB, MS, MY,

yr

0B72470046∗
MSY
op

Secondary Mazak Approximately Secondary

C

7 spindle cover MS, MSY 3322558935∗ manufactured 6000 hours 30 minutes spindle
wiper products (About 2 years) circumference
MB, MS, MY,
1323357833∗ Mazak Approximately
Carriage base MSY 500U Front of the
8 manufactured 6000 hours 30 minutes
front wiper MB, MS, MSY, carriage
1323357834∗ products (About 2 years)
MY 1000U/1500U
MB, MY 500U 0323470033∗ Mazak Approximately
Wiper for the Turret right
9 MB, MY 1000U 0B72470382∗ manufactured 6000 hours 10 minutes
screen cover side
MY 1500U 0B72470892∗ products (About 2 years)

5-155
 Serial Number 339746

5 MAINTENANCE OF MAJOR MACHINE UNITS

Replacement
Parts No. Replacement
No. Name Manufacturer period (Rough Use Part
(Unit No.) time
standard)
MB, MS, MY,
3321506117∗
MSY 500U
Mazak Approximately
Wiper for the W- MB, MY 1000U 3323592910∗ W-axis way
10 manufactured 6000 hours 10 minutes
axis front cover cover
MS, MSY 1000U 0B72247155∗ products (About 2 years)
MY 1500U Z33BC01445∗
MB, MS, MY,
0B72470236∗
MSY 500U Mazak Approximately
Wiper for the front
11 MB, MS, MY, Left: 0B72470236∗ manufactured 9000 hours 30 minutes Front door
door use (Upper)
MSY 1000U Right: products (About 3 years)

.
ed
MY1500U 0B72470395∗

rv
MB, MS, MY,
0B72470237∗

se
MSY 500U Mazak Approximately
Wiper for the front

re
12 MB, MS, MY, Left: 0B72470237∗ manufactured 9000 hours 30 minutes Front door
door use (Side)
MSY 1000U products (About 3 years)

s
Right:

ht
MY1500U 0B72470396∗

rig
MB, MS, MY,
Packing of the 0B72470012∗ Mazak Approximately

ll
MSY 500U

A
13 gearing parts for manufactured 9000 hours 5 minutes Front door
MB, MY 1000U

n.
the front door 0B72470452∗ products (About 3 years)
MY 1500U

tio
74 ora
Mazak Approximately
Coolant air filter (Electrical control Machine left
14 4B07460143∗ manufactured 6000 hours 5 minutes
cabinet) side
39 rp

products (About 2 years)

r 3 Co

6
Approximately
15 Air filter element G48FT00584∗ FESTO 3000 hours 20 minutes Air unit
be ak

(About 1 year)
um az

Approximately
l N ki M

1500 hours
16 Line filter element G30ZZ00334∗ YAMASIN Line filter
(About
a

6 months)
az

30 minutes
Approximately
m

JIS standard 1500 hours

Ya

17 Line filter O-ring J25NV00579∗ Line filter

ria

product (About
6 months)
Se
23

Approximately
20

1500 hours
18 Line filter element *1 U49ZZ00162∗ F.P.C. 20 minutes Hydraulic unit
(About
©

6 months)
ht

Approximately
ig

Line filter for

Taisei Kogyo 1500 hours
yr

19 Line filter element (Option) G30TP00259A through

Co.,Ltd (About
op

coolant
6 months)
C

Approximately
Line filter for
JIS standard 1500 hours
20 Line filter O-ring (Option) J2600G1000∗ through
product (About
coolant
6 months)
30 minutes
Approximately
Line filter for
JIS standard 1500 hours
21 Line filter O-ring (Option) J2600G0550∗ through
product (About
coolant
6 months)
Approximately
Line filter for
JIS standard 1500 hours
22 Line filter O-ring (Option) J2600G0450∗ through
product (About
coolant
6 months)

5-156
 Serial Number 339746

MAINTENANCE OF MAJOR MACHINE UNITS 5

Replacement
Parts No. Replacement
No. Name Manufacturer period (Rough Use Part
(Unit No.) time
standard)
Wiper for the W-
MB, MY 1000U 0B72860019∗
axis way cover
use Mazak Approximately Between the
23 (Between the manufactured 6000 hours 60 minutes steady rest
steady rest and MY 1500U Z33BC01444∗ products (About 2 years) and TL
TL)
(Option)
Approximately
Four D alkaline batteries for battery Electrical
24 D50FB00273∗ FUJITSU 3000 hours 15 minutes
unit control cabinet
(About 1 year)

.
ed
Mazak

rv
25 Safety window glass Z52ZZ00111∗ manufactured As required 15 minutes Safety window

se
products

re
Approximately
Machine

s
26 Grease cartridge P52LA000111 LHL 3000 hours 15 minutes

ht
lubrication

rig
(About 1 year)

ll
*1 This item is only for the hydraulic unit manufactured by ANY POWER.

A
Note : Since the life of consumption goods changes according to the usage conditions,

n.
tio
replace after confirming the suitability.
74 ora
The recommended replacement intervals refer to the number of years or hours of
operation, whichever comes the earlier, and actual intervals differ according to the
39 rp

particular operating conditions of the machine and frequency of use. Understand that
r 3 Co

the listed values are for reference only.

be ak

The years and months of the replacement period (rough standard) are calculated
um az

considering machine operations of 3000 hours/year.

l N ki M

Order consumption goods from Mazak Technical Center or Technology Center.

Refer to the corresponding maintenance manual for the method of replacement of
a

consumption goods.
az
m
Ya

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Se
23
20
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5-157
 5

C
op
yr
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©
20
23
Ya
m
Se az
MAINTENANCE OF MAJOR MACHINE UNITS

ria a
l N ki M
um az
be ak

5-158 E
r 3 Co
39 rp
Serial Number 339746

74 ora
6 tio
n.
A ll
rig
ht
s
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ed
.
 Serial Number 339746

INSTALLATION 6
6 INSTALLATION

6-1 Preparation for Installation

6-1-1 Environmental requirements

1. Machine
Avoid the following places when choosing the installation site for the machine:
− Places subject to direct sunlight, near heat sources, or subject to excessive temperature

.
ed
change

rv
− Humid places

se
re
− Dusty places

s
− Places near vibration generating equipment

ht
rig
− Weak soil

ll
 If the machine is to be installed near vibration generating equipment, a vibration-proof

A
drain should be provided around the machine foundation.

n.
tio
 If the soil is weak, reinforce it by driving piles into the soil to avoid settlement and
CAUTION
74 ora
inclination of the soil after machine installation.
39 rp
r 3 Co

6
2. NC
be ak

A. Environmental temperature
um az
l N ki M

Allowable temperature range during machine operation: 0° to 40°C

a

B. Humidity
az
m

Allowable humidity: Less than 75%

Ya

ria

 As humidity increases, insulation deteriorates causing electrical component parts to

Se
23

deteriorate quickly. Although no special dehumidifying measures are required, the

20

machine should not be installed in humid places.

CAUTION
©
ht

C. Vibration
ig
yr

During operation : Less than 4.9 m/s2

op
C

During transportation : Less than 29.4 m/s2

D. Environment
If the machine must be installed in a dusty place or in an environment where organic, corrosive
gas concentration is high, consult Mazak Technical Center or Technology Center for proper
measures.

6-1
 Serial Number 339746

6 INSTALLATION

 MAZATROL uses a memory back up battery to maintain important data stored in memory
even after power supply is turned off. However, since the back-up data may be lost due to
expiration of battery life or misoperation or unexpected trouble, to ensure safety of
CAUTION important data, it is advisable to store the data such as machining programs, tool data,
and parameters with external device.
 If welding power supply and other such power supply is obtained from a source that
generates a powerful noise, it may cause NC malfunction. Hence, when giving power
supply, never use the same power supply.

6-1-2 Power requirements

.
ed
 To avoid electrical shock, provide electrical grounding in accordance with the appropriate

rv
grounding standards specified in your country.

se
In Japan, grounding with grounding resistance 10 Ω or less (Class C or higher) must be

re
WARNING performed.

s
Grounding with grounding resistance 100 Ω or less (Class D or higher) is also permissible,

ht
if an optional earth leakage breaker is installed in the main power breaker.

rig
ll
Note 1: When an earth leakage breaker is used, select one with a trip current of 200 mA. One

A
n.
with a trip current of 30 mA cannot be used for this machine equipped with inverters.

tio
When selecting an earth leakage breaker, select the one that is suitable for connecting
74 ora
an inverter driven equipment. (Only for Japanese specifications)
39 rp

Note 2: Use an AC inverter-use circuit breaker as the main power breaker of the factory. If an
r 3 Co

6
AC inverter-use circuit breaker is not used, the breaker may be tripped by the
be ak

characteristic high-frequency leakage current of the AC inverter. (Only for Japanese

um az

specifications)
l N ki M

If power capacity in your shop is insufficient for the machine, it will cause unexpected troubles on
machine functions and, further, result in shorter service life of electricals. In addition to those
a
az

problems, insufficient power capacity might result in hazardous conditions of machine operation.
m

Therefore, great care should be taken on power facilities in your shop so that the machine can be
Ya

ria

operated under rated power conditions.

Se
23

1. Power source
20
©

Voltage 200 to 220 V 200 to 480 V 380 to 415 V

ht
ig

Permissible voltage fluctuation ±10% ±10% ±10%

yr
op

Frequency 50/60 Hz ± 2 Hz 60 Hz ± 2 Hz 50 Hz ± 2 Hz
C

2. Primary incoming cable

Power supply cable: MLFC cable (110°C) of 38 mm2 or larger
Main ground cable: MLFC cable (110°C) of 38 mm2 or larger
• Environment temperature : Less than 30°C
• Power source : 200 VAC, 3 phases
• Metallic conduit : 3 pieces
• Continuous rating for spindle drive motor

6-2
 Serial Number 339746

INSTALLATION 6
3. Total power requirements
Table 6-1 Power requirement table

Model
QT-200/250MB QT-200/250MS QT-200/250MY QT-200/250MSY
Item

Spindle drive motor 26.0 kW

Axis servo Continuous rating 33.1 kVA 33.1 kVA 33.9 kVA 34.0 kVA
motor 30-min. rating 38.6 kVA 38.6 kVA 39.5 kVA 39.5 kVA
Hydraulic unit 0.98 kVA
Coolant supply pump 0.33 kVA
Radiator fan motor for headstock

.
0.16 kVA

ed
cooling

rv
NC unit 1.17 kVA

se
AC100 V Control source 0.43kVA 0.80 kVA 0.43 kVA 0.80 kVA

re
Continuous rating 36.1kVA 36.5 kVA 37.0 kVA 37.4 kVA
Total

s
30-min. rating 41.7kVA 42.1 kVA 42.6 kVA 43.0 kVA

ht
rig
Note 1: The spindle drive motor, and the servomotors are of the batch power supply scheme,

A ll
the ratios of the axes were calculated as follows:

n.
Spindle drive motor : 1.0
X-axis servomotor : 0.3
tio
74 ora
Z-axis servomotor : 0.3
39 rp

Y-axis servomotor : 0.3

r 3 Co

W-axis servomotor : 0.3

6
be ak

Note 2: The capacity of the hydraulic unit assumes the following load factor:
um az

Hydraulic unit : 0.5

l N ki M
a
az
m
Ya

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Se
23
20
©
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6-3
 Serial Number 339746

6 INSTALLATION

6-1-3 Air source (Air consumption amount)

1. Air source
If the discharge pressure of a compressor becomes less than 0.35 MPa, the malfunction of air
unit occurs. Use a compressor of sufficient capacity.
Pressure: 0.5 MPa or more
 If the air has high moisture content or if hot air is used, damage to the air actuators and
equipment could result. In such cases, use air dryer or similar equipment.

CAUTION

.
ed
rv
2. Air quality class ISO8573-1_Class 5.6.4 or higher

se
re
s
Solid particle Moisture Oil

ht
rig
Maximum number of particles Pressure dew
per 1m3 point Oil
Grade Grade Grade

ll
[air pressure at concentration

A
Particle size dµm 0.7 MPa]

n.
0.1 < d ≤ 0.5 0.5 < d ≤ 1.0 1.0 < d ≤ 5.0 °C mg/m3

tio
74 ora
1 ≤ 20000 ≤ 400 ≤ 10 1 ≤ -70 1 ≤ 0.01
2 ≤ 400000 ≤ 6000 ≤ 100 2 ≤ -40 2 ≤ 0.1
39 rp
r 3 Co

No
6
3 ≤ 90000 ≤ 1000 3 ≤ -20 3 ≤1
specification
be ak

No No
4 ≤ 10000 4 ≤ +3 4 ≤5
um az

specification specification
l N ki M

No No
5 ≤ 100000 5 ≤ +7
specification specification
a

6 ≤ +10
az
m

Note : Pressure dew point +10°C is equivalent to -17°C in atmospheric pressure dew point
Ya

ria

conversion.
Se
23

3. Selection of compressor
20

• The minimum required discharge pressure of a compressor is 0.5 MPa. When selecting a
©

compressor, allow approximately 0.2 MPa margin.

ht
ig

• There are three compressor operation types; manual unloader, automatic unloader, and
yr
op

pressure switch types.

C

The compressor should be a pressure switch type for this machine model.
• The compressor should be 0.75 kW in size. For details, contact a compressor maker.

6-1-4 Foundation work

 If the machine is to be installed near vibration generating equipment, a vibration-proof
drain must be provided around the machine foundation.
 If the soil is weak, reinforce it by driving piles into the soil to avoid subsidence and
CAUTION
inclination of the soil after machine installation.

For machine installation, select a flat place; avoid places subject to direct sunlight, humid places,
and places near heat or vibration generating equipment. Foundation work will vary according to
soil conditions. Compact the ground well or pour a concrete base to avoid subsidence or
inclination of the soil after machine installation.

6-4
 Serial Number 339746

INSTALLATION 6
6-1-5 Foundation parts
Foundation parts and their uses are listed in Table 6-2 and Fig. 6-1.
Table 6-2 List of foundation parts

For machine
No. Name Illustration
500U 1000U 1500U

Foundation

.
[1] 7 pcs 9 pcs 11 pcs

ed
plate

rv
se
re
s
ht
rig
ll
A
n.
[2] Foundation bolt
tio 7 pcs 9 pcs 11 pcs
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m

[3] Nut 7 pcs 9 pcs 11 pcs

Ya

ria
Se
23
20
©
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ig
yr
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Bolt
C

Nut

Plate

CMN-7103

Fig. 6-1 Foundation parts

6-5
 Serial Number 339746

6 INSTALLATION

6-1-6 Delivering the machine

To deliver the machine, the delivering entrances shown in Fig. 6-2 to Fig. 6-4 is required.

1. Center distance of 500

A. MB, MS, MY, MSY specifications

Unit: mm

MB, MY specifications: 2760 2260

.
ed
MS, MSY specifications: 2895
415 1845

rv
se
re
s
ht
rig
1857

A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak

B72-0034
um az

Fig. 6-2 Delivering the machine (MB, MS, MY, MSY specifications)
l N ki M

2. Center distance of 1000

a
az
m

A. MB, MS, MY, MSY specifications

Ya

ria
Se

Unit: mm
23
20

MB, MY specifications: 3705

2467
©

MS, MSY specifications: 3570

ht

472 1995
ig
yr
op
C

1857

B72-0035

Fig. 6-3 Delivering the machine (MB, MS, MY, MSY specifications)

6-6
 Serial Number 339746

INSTALLATION 6
3. Center distance of 1500

A. MY specifications

Unit: mm

4155 2467
472 1995

.
ed
rv
se
1862

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s
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rig
ll
A
n.
tio
74 ora
B72-0036
39 rp

Fig. 6-4 Delivering the machine (MY specification)

r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

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Se
23
20
©
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ig
yr
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C

6-7
 Serial Number 339746

6 INSTALLATION

6-2 Machine Installation

6-2-1 Precautions for machine installation

 Two or more workers are necessary to handle heavy objects.
 Only authorized workers should use a forklift or crane, or lift the machine using wire ropes.
WARNING  When operating a forklift or crane, care should be taken not to hit other objects.
 Use wire rope or a sling that can tolerate the weight to be lifted.
 Check the chain block, wire rope or sling, hoist, or other lifting equipment before using
them. Never use defective wire rope/slings or lifting equipment.

.
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 The machine must be lifted properly. Lift the machine slightly from the floor to check if it is

rv
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well balanced.

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CAUTION  The angle made by the wire rope or sling must be less than 60°.

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 When two or more workers are working together to lift the machine, they should cooperate

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carefully using signals.

A ll
 When lifting the machine, great care should be taken not to shock the machine, NC unit,

n.
or electrical control cabinet.

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 Before lifting the machine, check that each machine unit is fixed in position and that there
74 ora
are no tools or other objects on the machine.
39 rp

• The coolant unit will be delivered separately.

r 3 Co

6
be ak

1. Preparation for lifting

um az
l N ki M

(1) Secure the turret, carriage, carriage base and tailstock, or the secondary spindle and TOOL
EYE () while the power is ON.
a
az

• Fix the turret in the X-axis -100 mm position.

m

• Fix the carriage in the Z-axis -100 mm position.

Ya

ria

• Fix the carriage base in the Y-axis zero point position.

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23

• Fix the tailstock and secondary spindle in the W-axis zero point position.
20

• Fix the TOOL EYE in the retracted position.

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• Attach fixed metal fittings to secure the turret, carriage, tailstock and TOOL EYE. (Refer
ht
ig

to 6-2-3 “Location of transit clamps”.)

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(2) Turn off the machine power and the main power of the factory, and disconnect the factory
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power - machine power connection cable from the circuit breaker of the machine.
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(3) Disconnect the cable and hose of the coolant unit (pump) from the machine.
Remove the cable by removing the cannon connector from the control panel side.
Remove the hose from the pump side. The residual coolant within the hose flows out.
Receive this coolant using a waste oil can. The total amount of outflow is about 2 L.
Completely wipe away any coolant that may have spilled over the floor. Otherwise, workers
may overturn during lifting.
(4) Drain out the coolant from the coolant tank, then separate the tank from the machine, and
move the tank away to where the machine can be lifted smoothly.
(5) Remove the anchor bolt that secures the machine.

6-8
 Serial Number 339746

INSTALLATION 6
2. Procedure to lift the machine
The lifting should generally be left to our servicemen. If you undertake the job, take sufficient
safety measures and proceed with great care referring to the recommended lifting diagram
below.
(1) Place the wire ropes on the bed hook (1 place) and on the both ends of the pipe that passes
the bed.
Use wire ropes and a pipe with the dimensions shown in Fig. 6-6.
Use a crane supporting 6 t or heavier loads.
(2) Place the wire ropes on the crane hook.

.
Place wood blocks or pads between the machine and wire ropes so that the machine will

ed
not be damaged.

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Wire Z
Wire C

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A
Wire X Wire Y

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Frame74 ora
Wire B
39 rp
r 3 Co

Wire A
6
be ak
um az
l N ki M
a
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Ya

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Se
23
20
©

B72-0038
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ig

Fig. 6-5 Lifting the machine

yr
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(3) Raise the arm of the crane to such an extent that the wire ropes become taunt, and make
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sure that the ropes are firmly hooked on the machine body and at the chain block. If the
ropes are not correctly hooked, slacken and rehook them.
(4) After checking that the wire ropes are correctly hooked, operate the crane to lift the
machine.

6-9
 Serial Number 339746

6 INSTALLATION

Table 6-3 Machine weight of 500U Unit: kg

Items QT-200 QT-250

MB, MY MS, MSY MB, MY MS, MSY

Machine 5500 5600 5600 5700

Coolant tank 130
Parallel chip conveyor 260

Table 6-4 Machine weight of 1000U Unit: kg

Items QT-200 QT-250

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MB, MY MS, MSY MB, MY MS, MSY

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Machine 6200 6300 6300 6400

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Coolant tank 190

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Parallel chip conveyor 260

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rig
Table 6-5 Machine weight of 1500U Unit: kg

A ll
Items QT-250

n.
tio
74 ora MY

Machine 7200
Coolant tank 320
39 rp
r 3 Co

Parallel chip conveyor 320

6
be ak
um az

Note : The figures indicated on the machine plate shall be applied if different from the manual.
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
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C

6-10
 Serial Number 339746

INSTALLATION 6
Working load (static load): 2.59 t Unit: mm

A
2600 222

Working load (static load): 2.28 t

B
2956
MH-32
R90 ø32
Working load (static load): 0.53 t
111

.
1000 (Protected tube)

ed
C 3058

rv
4-M20 × P2.5

se
(complete thread permissible)
Wire C Wire B C2

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40
C2
C2 C2

s
10 (ø119.8) 10

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ø139.8

C2 C2

rig
200 280

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40

A
8-Hexagon nut M20 4-ø22 drilled holes C2
(through hole)C2 at both mouths C2
φ16

n.
(100) 482 725 453 (140)

tio
1900 74 ora
B72-0039
39 rp
r 3 Co

Fig. 6-6 Hoist (MB, MS, MY, MSY specifications for 500 center distance)
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
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C

6-11
 Serial Number 339746

6 INSTALLATION

ø18
WITH METAL SHIELD
WITH METAL SHIELD Working load: (Common to X, Y and Z)
(Common to X, Y and Z) 3.1 t (static load)
1338

Y Working load: 2.8 t

φ18
(static load)

1279

ø32
Z

.
Working load:

ed
φ18
MH-32
0.47 t (static load)

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1284

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s
Wire

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rig
WITH METAL SHIELD
(Common to A, B and C)
A

All
Working load: 3.1 t (static load)
ø18

n.
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2260
ra
po

Working load: 2.8 t

or

B (static load)
ø18

6
C
74
ak
39
az

2610
r3
iM
be
ak

C Working load: 0.47 t

um

(static load)
φ18
az
lN
m

1000 (Protected tube)

Ya

ria

2660
Se
23

Wire
20

Unit: mm
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B72-0040
ig
yr

Fig. 6-7 Hoist (MB, MS, MY, MSY specifications for 1000 center distance (wire area))
op
C

6-12
 Serial Number 339746

INSTALLATION 6
Thimbles
Wire rope dimensions (for X, Y and Z)
X

Thimbles
(for X, Y and Z) Safe working load:
1183 8000 kgf
or larger
(β: 0-45°)
Y β
vertical plane

1086

.
ed
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1131

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s
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rig
Thimbles
(for A, B and C)
A

ll
A
n.
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R70
2094
74 ora
39 rp

B
r 3 Co

6
be ak

R70
um az

2411
l N ki M

R90 C
a
az
m

R70
1000
Ya

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(Rubber protector) 2432

Se
23
20

NOTE: The wire ropes should have a safe working load (SWL) of 3700 kgf Unit: mm
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B72-0042
ig
yr
op

Fig. 6-8 Hoist (MY specifications for 1500 center distance (wire area))
C

6-13
 Serial Number 339746

6 INSTALLATION

C, Z
I-shaped steel 125 × 75 325
75
Z C

28
75 63.5

50 50
12.5

100
A, X 45 195 45

80 125 80

(345)
75
285

872
816

.
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I-shaped steel 125 × 75

rv
se
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(1157.9)

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rig
B, Y Y B
948.5 75 12.5
28

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I-shaped steel 125 × 75

A
1064

n.
100
Shackle SB22 (6 locations)

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50 50
X
74 ora
Y 3×2–φ27 Hole
39 rp
45

80
r 3 Co

6 195

125

285
be ak
um az

80
45

25963320330
l N ki M

Frame•SS400 3×4–C2
A B
a
az
m

6-φ22 drilled holes

Ya

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(through hole)C2 at both

100 402 725 453 (140) mouths
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23

43306623430: Bolt ∗40

20

Wire C Wire B
(10)

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(φ139.8)

(10) (φ119.8)

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ig
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Front
Rear
C

25963320340
Frame (pipe)•STKM13A
Unit: mm

B72-0041

Fig. 6-9 Hoist (frame and pipe areas of MB, MS, MY and MSY specifications for 1000 center distance)

6-14
 Serial Number 339746

INSTALLATION 6

RUD load ring VLBG 4t M24

6 places

.
ed
rv
Tap M24x48

se
both ends
3 places

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s
ht
rig
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6 places

A
grind flat

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74 ora
39 rp

032393U0010 Lifting frame Unit: mm (inch)

r 3 Co

6
B72-0043
be ak

Fig. 6-10 Hoist (frame area of MY specification for 1500 center distance)
um az
l N ki M
a

Wire rope B Wire rope C

az
m
Ya

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Se
23
20

Front 332393U0030 bolt

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332393U0020 lifting bar 332393U0040 collar

ig
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C

332393U0040 collar

Unit: mm (inch)

B72-0044

Fig. 6-11 Hoist (pipe area of MY specification for 1500 center distance)

6-15
 Serial Number 339746

6 INSTALLATION

6-2-2 Unpacking, inspection and cleaning

 When removing the rust preventive coating with cleaning oil, great care should be taken
so that the cleaning oil does not enter into the slideway surfaces passing the wiper.
 Used rags should be disposed of at a predetermined place.
CAUTION
• The machine is shipped with transit clamps so that the machine units will not move during
transportation. After installing the machine, remove all of the transit clamps. Store the clamps,
bolts, etc. in a suitable place to allow for reuse during movement or transport in the future.
• Install the covers and other parts, which are supplied in separate packages.
• Cleaning

.
ed
After having placed the machine on the base, remove the rust preventive coating from the

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slideway surfaces and machined surfaces using rags and cleaning oil. Never try to operate

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any section of the machine before cleaning since the rust preventive coating is apt to have

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been contaminated with dusts and other foreign particles during machine transportation.

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After having completely removed the rust preventive coating, apply the specified lubricant to

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rig
the slideway surfaces.

A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

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Se
23
20
©
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6-16
 Serial Number 339746

INSTALLATION 6
6-2-3 Location of transit clamps

TL-axis

.
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rv
X-axis

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Y-axis

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Z-axis

A
n.
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TOOL EYE 74 ora
39 rp
r 3 Co

6
be ak
um az

Left door
l N ki M
a
az
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Ya

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Se
23
20
©
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Right door
C

W-axis

B72-0120

Fig. 6-12 Location of transit clamps (MB, MS, MY, MSY specifications)

6-17
 Serial Number 339746

6 INSTALLATION

1. Details for each transit clamps location

A. MB, MS, MY, MSY specifications

.
ed
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rig
B72-0121

ll
A
Fig. 6-13 TOOL EYE

n.
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74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

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Se
23

B72-0122
20

Fig. 6-14 Z-axis

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ht
ig
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op
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B72-0123

Fig. 6-15 X-axis

6-18
 Serial Number 339746

INSTALLATION 6

.
ed
rv
se
B72-0124

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Fig. 6-16 Yt-axis

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ht
rig
ll
A
n.
tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az

B72-0125
m
Ya

ria

Fig. 6-17 TL-axis

Se
23
20
©
ht
ig
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B72-0126

Fig. 6-18 W-axis

6-19
 Serial Number 339746

6 INSTALLATION

Left door
fixture

.
ed
rv
se
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B72-0128

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rig
Right door

ll
A
fixture

n.
(1000U &
1500U)

tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se

B72-0129
23
20

Fig. 6-19 Front door

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ht
ig
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C

6-20
 Serial Number 339746

INSTALLATION 6
6-2-4 Installation procedure
The machining accuracy is greatly influenced by installation conditions. Install the machine
carefully to the utmost.

1. Temporary leveling adjustments

A. Using foundation bolts

(1) Arrange the jacks used to adjust the machine level around each foundation hole according
to the foundation plan.
(2) With the machine lifted, fit the foundation bolts, leveling bolt, nut and collars to the leveling

.
ed
bolt holes in the machine bed.

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(3) Lower the machine gently so that the foundation bolts are correctly inserted into the

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foundation holes prepared according to the foundation plan.

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* During this step, the leveling bolts cannot be used; pull them up from the machine

s
ht
bottom.

rig
(4) Adjust the machine level temporarily by adjusting the jack.

ll
A
(5) After leveling the machine temporarily, fix the foundation bolts with epoxy resin.

n.
tio
74 ora
39 rp

COLLAR
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria

EPOXY RESIN
NECESSARY VOLUME 1.8 L/LOCATION
Se

ANCHOR BOLT
23
20

Unit: mm
©

CMN-7104
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ig

Fig. 6-20 Foundation bolt

yr
op

2. Checking interconnections
C

After leveling is finished, check and confirm the following items before turning the power on.
• Grounding (grounding resistance 10 Ω maximum)
• Screws at terminals (must be tight)
• Connections of cannon connectors and other connectors (must be tight)
• Relays and timers (must be fitted and connected correctly)
• Timer and thermal relay settings (must be set correctly)

6-21
 Serial Number 339746

6 INSTALLATION

3. Machine height adjustment

After the epoxy resin has cured, remove the jack and adjust the machine height so that the
clearance between the front cover and the coolant tank will be 10 mm when the clearance
between the machine bottom surface and the floor is 10 mm.

.
ed
rv
se
Clearance:

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10

s
ht
rig
ll
Machine bottom surface: 10 Coolant tank: 10 Unit: mm

A
n.
B72-0129

Fig. 6-21 Machine height adjustment

tio
74 ora
39 rp

4. Final level adjustment

r 3 Co

Adjust the machine level again using leveling bolts. Place precision levels as illustrated in
be ak

Fig. 6-22.
um az

For details on the procedure to adjust the machine level and allowable leveling error, refer to the
l N ki M

attached accuracy table.

a
az

After tightening the leveling nuts and foundation bolts, check the machine level again. Use
m

precision levels having an accuracy of 0.02 mm division.

Ya

ria
Se
23
20
©
ht
ig
yr
op
C

Precision level

Leveling base (accessory)

CMN-7105

Fig. 6-22 Final level adjustment

6-22
 Serial Number 339746

INSTALLATION 6
6-3 Connecting the Power Supply Cable and Air Supply Hose

6-3-1 Connecting the power supply cable

 Do not connect the power supply cable to the factory power distribution board until all
installation work has been completed.

DANGER

Breaker Box Cover A

.
ed
rv
se
re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
Cable hole Power supply
cable entry
be ak
um az
l N ki M

Power supply cable path

CMN-7106
a
az

Fig. 6-23 Connecting the power supply cable (1/3)

m
Ya

ria

(1) Turn the breaker handle to the OFF position and remove the cover A.
Se
23

(2) Insert the power supply cable into the cable hole.
20

Note : After the power supply cable is connected to the breaker, fill the gap between the cable
and the cable hole and then carry out water proofing.
©
ht
ig
yr
op
C

6-23
 Serial Number 339746

6 INSTALLATION

(3) Connect the cable to the main power breaker.

Make sure connections to the R, S and T terminals and grounding terminal.

R S T

.
ed
rv
se
Grounding terminal

re
s
CMN-7107

ht
rig
Fig. 6-24 Connecting the power supply cable (2/3)

ll
A
(4) Check for correct connection using a phase tester.

n.
Otherwise, damage to the important sections of the machine may result.

tio
74 ora
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20

CMN-7108
©

Fig. 6-25 Connecting the power supply cable (3/3)

ht
ig

(5) Return the cover A to the original position, and tighten the bolts securely to fix it.
yr
op
C

6-24
 Serial Number 339746

INSTALLATION 6
6-3-2 Grounding
• 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.
• 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.
• 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 to be
done is basically class C grounding.

.
ed
Grounding resistance : 10 Ω max.

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Cross-sectional area of wires : 38 mm2 or larger

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Measuring equipment : Ground resistance meter

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ht
 To avoid electrical shock, provide electrical grounding in accordance with the appropriate

rig
grounding standards specified in your country.
In Japan, grounding with grounding resistance 10 Ω or less (Class C or higher) must be

All
WARNING performed.

n.
Grounding with grounding resistance 100 Ω or less (Class D or higher) is also permissible,

tio
if an optional earth leakage breaker is installed in the main power breaker.
74 ora
39 rp

Note 1: When an earth leakage breaker is used, select one with a trip current of 200 mA. One
r 3 Co

with a trip current of 30 mA cannot be used for this machine equipped with inverters.
6

When selecting an earth leakage breaker, select the one that is suitable for connecting
be ak

an inverter driven equipment.

um az
l N ki M

Note 2: Use an AC inverter-use circuit breaker as the main power breaker of the factory. If an
AC inverter-use circuit breaker is not used, the breaker may be tripped by the
a
az

characteristic high-frequency leakage current of the AC inverter.

m

 The grounding work must be entrusted to an electrical engineer with publicly recognized
Ya

ria

qualifications. If the work is done by an unqualified person, it could result in serious injury,
Se
23

death, or damage to the machine.

WARNING
20

• The connections between the machines and ground should be made as indicated below.
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 Never perform wiring as shown below.

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yr
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WARNING Machine Machine Machine

C

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.

6-25
 Serial Number 339746

6 INSTALLATION

• Independent connections

Machine Machine Machine

Each grounding resistance = 10 Ω max.

• Common connection

.
ed
rv
Machine Machine Machine

se
re
s
* The wires from the grounding terminal should be

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rig
directly connected to each of the machines.
10
Grounding resistance = Number of machines Ω

A ll
n.
tio
74 ora
6-3-3 Connecting the air hose
39 rp

Securely attach the external air supply to the connection port of the air unit located inside the
r 3 Co

6
right surface of the machine.
be ak

Note : The external air source pressure must be between 0.5 to 1.0 MPa. Do not adjust the air
um az

pressure on the machine side, the reducing valve on the machine side is set to 0.5
l N ki M

MPa at the factory before the shipment.

a
az
m
Ya

ria

Air unit
Se
23
20
©
ht
ig
yr
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C

Air hose

B72-0009a

Fig. 6-26 Connecting the air hose

6-26
 Serial Number 339746

INSTALLATION 6
<Interface Information>

.
ed
rv
se
Quick coupling plug

re
Male thread G1/4

s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

6
be ak

Fig. 6-27 Air connection port

um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig
yr
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C

6-27
 Serial Number 339746

6 INSTALLATION

6-4 Coolant Tank Installation

1. Without a chip conveyor

(1) Install the coolant tank on this machine.
(2) Fix by using the jack bolts in front of the coolant tank.
In such cases, ensure that its distance from the machine is 10 mm ± 5 mm. If not, adjust the
height of this machine using leveling bolts.

Clearance:

.
ed
10 mm

rv
se
re
s
ht
rig
ll
CMN-7064

A
n.
Fig. 6-28 Coolant tank jack bolts

tio
(3) Carry out plumbing of the rubber hose that supplies to the coolant pump.
74 ora
(4) Connect the connector (No.X231) of the cable that supplies to the coolant pump.
39 rp

(5) Tie up the rubber hose and the cable supplied to the coolant pump with the hose receiver.
r 3 Co

6
be ak

Connection of
the cable connector
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
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ig
yr
op
C

Hose connection
CMN-7065

Fig. 6-29 Installation of the chip conveyor

6-28
 Serial Number 339746

INSTALLATION 6
2. With an attached horizontal chip conveyor
(1) Install the chip conveyor on the coolant tank.
Note : The end of the conveyor should coincide with the left end of the tank.

.
ed
rv
se
re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
r 3 Co

Surface in contact with the chip conveyor

be ak
um az
l N ki M

CMN-7110
a

Fig. 6-30 Installation of the chip conveyor

az

(2) Install the shooter cover on the coolant tank.

m
Ya

ria

Note : The right end of the shooter cover should coincide with the chip conveyor.
Se
23
20
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ig
yr

Surface in contact with the shooter cover

op
C

CMN-7111

Fig. 6-31 Shooter cover installation

(3) Install the coolant tank on this machine.

6-29
 Serial Number 339746

6 INSTALLATION

(4) Fix by using the jack bolts in front of the coolant tank.
In such cases, ensure that its distance from the machine is 10 mm ± 5 mm. If not, adjust the
height of this machine using leveling bolts.

Clearance:
10 mm

.
ed
rv
se
CMN-7064

re
Fig. 6-32 Coolant tank jack bolts

s
ht
(5) Carry out plumbing of the rubber hose that supplies to the coolant pump.

rig
(6) Connect the connector (No.X231) of the cable that supplies to the coolant pump.

A ll
Connect the connectors (No.X271 and X50) of the cable that supplies to the chip conveyor.

n.
tio
74 ora
Connection of the cable
connector
39 rp
r 3 Co

6
be ak
um az
l N ki M
a
az
m
Ya

ria
Se
23
20
©
ht
ig

Hose connection
yr
op
C

CMN-7066 CMN-7067

Fig. 6-33 Cable connector Fig. 6-34 Wiring of the coolant tank, chip conveyor

6-30
 Serial Number 339746

INSTALLATION 6
(7) Install the emergency stop box on the upper surface of the exhaust guard of the chip
conveyor.

.
ed
rv
se
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In this case, bolts are used

s
for installation.

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rig
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CMN-7068

A
n.
Fig. 6-35 Emergency stop box of the side discharge chip conveyor

tio
(8) Place a cable connecting the chip conveyor into the cable receiver.
74 ora
39 rp
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6
be ak
um az
l N ki M
a
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m
Ya

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Se
23
20
©
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6-31
 Serial Number 339746

6 INSTALLATION

6-5 Trial Operation

After connecting the power supply cables and air supply hose to the machine, check the
following points before starting trial operation.
• The machine and machine parts are all free from damages.
• There are no missing parts and accessories.
• Each part of the machine is supplied with the specified lubricating oil and hydraulic oil.
• The chuck is lubricated with grease.
• The hydraulic pipes and hoses are securely connected.

.
ed
• The air supply hose is securely connected.

rv
• The coolant tank is mounted at the correct position.

se
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• The lifting jigs and the shipping brackets for each axis are removed.

s
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rig
A ll
n.
tio
74 ora
39 rp
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6
be ak
um az
l N ki M
a
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m
Ya

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Se
23
20
©
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6-32 E
 Serial Number 339746

TROUBLESHOOTING 7
7 TROUBLESHOOTING
7-1 Troubleshooting Procedures

7-1-1 If the tool has come into contact with the workpiece, chucks or other sections
(1) Immediately press the emergency stop button.
(2) Check the tool, the workpiece, the chuck, etc.
(3) Reset the emergency stop button.
(4) If the key [3] on the machine operating panel is lit in green or an alarm number is

.
ed
displayed, refer to the troubleshooting and alarm display.

rv
(5) If the states mentioned in step (4) above are not occurring, move the tool in the direction

se
that it does not interfere with the workpiece, chuck or other sections.

re
s
(6) Replace the tool, workpiece, chuck, etc. if they have been damaged or become defective.

ht
rig
(7) Before restarting the machine, perform visual and audible checks for damage and unusual

ll
operating sounds. If any trouble is found, please contact Mazak Technical Center or

A
Technology Center.

n.
tio
(8) If the machine is not damaged, machine a test piece(s) and check for normal machining
74 ora
and for sufficient accuracy.
39 rp

(9) If the accuracy and/or machining are/is abnormal, adjust the chuck/headstock/tailstock
r 3 Co

6
alignments.
be ak

7-1-2 If the source of the trouble cannot be located

um az
l N ki M

When the machine has any trouble, check the following things first and then inspect and
maintain the machine according to the instructions of this chapter.
a
az

Check of following things helps you when you inquire of Mazak Technical Center or Technology
m

Center about machine trouble.

Ya

ria
Se

(1) Check the location of the malfunction indicated on the GRAPHIC MAINTENANCE display.
23
20

(2) When an ALARM NAVIGATION message is displayed, follow the instructions listed.
©

(3) You can view all alarms, including past alarms, on the [DIAGNOS]−[ALARM] display.
ht

• For information about the [DIAGNOS]−[ALARM] display, refer to “11

ig

DISPLAYS RELATED TO DIAGNOSIS” in PART 3 of the operating manual

yr
op

for this machine.

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(4) Check to see whether the same trouble was recorded in the alarm history or not.
(5) Check to see whether the ambient temperature meets the specifications or not.
(6) Check to see if there was momentary power failure before the machine trouble or not.
(7) Check to see if the supply voltage is constantly normal or not. (Does supply voltage sharply
change by time?)
(8) Check to see if there is a difference between spindle normal rotation and reverse rotation
or not.
(9) Check to see if the trouble occurs in a certain operational condition or not.
(10) How frequently does the same trouble occur?
(11) How many years has the machine worked?
(12) Did you take any emergency measure against the trouble?

7-1
 Serial Number 339746

7 TROUBLESHOOTING

(13) In case of the alarm related to the spindle and servomotor, check the number displayed on
the LCD of each drive unit.

7-1-3 Using the GRAPHIC MAINTENANCE display

1. Overview
When a PC alarm sounds, the area of the malfunction is shown on the layout drawing.
Layout drawings encompass both complete layout drawings and partial layout drawings of
headstock or turret types with complex layouts of sensors, valves and other parts.
(Specifications differ based on the type of layout drawing.)

.
ed
Use of this screen assists the operator to swiftly recover machine operation following an alarm.

rv
PC: Devices that control operation of movable parts of the machine structure (excludes control

se
of spindle operation)

re
s
2. Using the screen

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rig
The GRAPHIC MAINTENANCE display is displayed automatically when a PC alarm sounds.

ll
The alarm area is further distinguished by the Change Page button you use to move from

A
screen to screen.

n.
tio
You can specify the device for which the malfunction alarm sounded in the reverse display area
74 ora
of the layout diagram for area in which the alarm sounded.
39 rp

3. Change page button and [ALL DATA DISPLAY] menu

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• When [ALL DATA DISPLAY] is enabled

be ak
um az

You can use the change page button to display all diagrams in order.
l N ki M

• When [ALL DATA DISPLAY] is disabled

a

Diagrams that can be displayed using the change page button are only shown when an
az

alarm occurs.
m
Ya

ria

4. Parameters
Se
23

The parameters for this screen are as follows:

20

• When F80 (Bit 4) = 1:

©

When a display request is ON, the GRAPHIC MAINTENANCE display is automatically

ht

displayed.
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yr

• When F80 (Bit 4) = 0:

op

Even if a display request is turned ON, the GRAPHIC MAINTENANCE display is not
C

displayed automatically.

7-2
 Serial Number 339746

TROUBLESHOOTING 7
7-2 Troubleshooting for Each Unit
This section mainly describes troubles and problems not covered by the self-diagnostic function,
that is, not indicated by an alarm message.

7-2-1 Headstock
Check the LED display of the integrated main spindle amplifier (26 kW) in the control panel and
contact Mazak Technical Center or Technology Center.

• See the electrical diagrams.

.
ed
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Tools/devices to be used: Tester and multimeter

se
Trouble Cause Remedy Refer to

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Motor does not rotate. • The power switch is off. • Turn ON the power.

s
ht
• If the power switch is not off, the no-fuse • Change the no-fuse breaker or —

rig
breaker or the magnet contactor is faulty. the magnet contactor.

ll
The 3-phase voltage is imbalanced. Balance the 3-phase voltage.

A
* If it is balanced, the motor is overloaded * Decrease the machine side

n.
or faulty, or the wiring is faulty. load, change the motor, or

tio
6-3
check the wiring.
74 ora
If the power lamp is not lit, the spindle Change the spindle amplifier.
39 rp

amplifier is faulty.
r 3 Co

6
The motor hums but Heavy load or short acceleration time Decrease the machine side load,
does not rotate. setting. or increase the acceleration time —
be ak

setting.
um az

If the voltage at the output terminals (U-V, V- Change the motor.

l N ki M

W, W-U) is imbalanced, the motor is faulty.

6-3
a

If the voltage at the output terminals (U-V, Change the spindle amplifier.
az

W-V, W-U) is balanced, the spindle amplifier

m

is faulty.
Ya

ria

The motor is Check if the motor is overloaded. Decrease the machine side load. —
Se

overheated.
23

If the voltage at the output terminals (U-V, Change the spindle amplifier.
W-V, W-U) is imbalanced, the spindle 6-3
20

amplifier is faulty.
©

Check if motor cooling is obstructed. Remove the obstacles.

ht

—
* If not obstructed, the motor is faulty. * Change the motor.
ig
yr

The motor does not Check if the motor is overloaded. Decrease the machine side load. —
op

rotate smoothly. Check if the output voltage changes during Change the spindle amplifier.
C

acceleration/deceleration. If it changes, the

spindle amplifier is faulty.
6-3
If the voltage at output terminals (U-V, W-V, Change the spindle amplifier.
W-U) is imbalanced, the spindle amplifier is
faulty.
The load varies. Reduce load variation. —

7-3
 Serial Number 339746

7 TROUBLESHOOTING

7-2-2 Chuck

• Refer to the instruction manual supplied by the chuck maker.

Trouble Cause Remedy Refer to

The chuck does not Chuck component part is damaged. Disassemble the chuck and
5-1-2
operate. replace the broken parts.
The rotary hydraulic cylinder does not Check the hydraulic system.
5-7-1
function.
The sliding portion is seized. Disassemble the chuck and

.
ed
remove or correct the seized 5-1-2

rv
portion. If necessary replace.

se
Master jaw stroke is Large volume of chips are accumulated Disassemble and clean the
5-1-4

re
not sufficient. inside the chuck. chuck.

s
Draw pipe is loosened. Remove and clean the draw

ht
—
pipe.

rig
Workpiece slips in the Master jaw stroke is insufficient. Recheck the master jaw stroke. —

A ll
chuck. Chuck clamping force is insufficient. Set the hydraulic pressure
—

n.
correctly.

tio
Soft jaws are not shaped correctly to the Shape the soft jaws correctly. Operating
74 ora
workpiece diameter. manual of the
machine
39 rp

PART 2 5-4
r 3 Co

Cutting force is too high. Calculate cutting force; change

—
be ak

cutting conditions.
um az

Master jaw and other sliding parts are not Grease them.
5-1-2
lubricated correctly.
l N ki M

Spindle speed is too high. Lower the spindle speed. —

a

Accuracy is not high. The chuck is shaking. If the chuck is shaking,

az

—
retighten the bolts.
m
Ya

Foreign matter on serration of master and Remove the soft jaws and clean
ria

—
soft jaws. the serration.
Se
23

Soft jaw clamping bolts are loose. Tighten the bolts to the
—
20

specified torque.
©

Soft jaws are not shaped correctly. Shape them correctly. Operating
manual of the
ht

machine
ig

PART 2 5-4
yr
op

Soft jaws are too high causing deformation, Lower the soft jaws.
—
or looseness of the soft jaw clamping bolts.
C

The workpiece is deformed due to Lower the gripping force.

—
excessively high gripping force.

7-4
 Serial Number 339746

TROUBLESHOOTING 7
7-2-3 Turret
Trouble Cause Remedy Refer to
The turret is not The clamp/unclamp control solenoid valves Check the solenoid valves (YV2/YV1) or
—
clamped/unclamped. (YV2/YV1) do not operate normally. replace them.
The turret does not rotate The [TURRET UNCLAMP] menu item is blue Turn the [TURRET UNCLAMP] menu
5-2-3
although it is unclamped. (set). item white (ineffective).
The index coupling teeth do not engage Contact Mazak Technical Center or
—
correctly. Technology Center.
The bolts fixing the turret are loose. Tighten the bolts. —
Hydraulic piping is incorrect. Check the hydraulic piping. 5-7-1
The turret keeps rotating The turret position detection encoder is Check the position detection encoder or
5-2-1, 5-2-2

.
ed
without positioning. faulty. change it.
The clamp control solenoid valve (YV2) does Check the solenoid valve (YV2) or

rv
—
not operate normally. replace it.

se
The valve is clogged. Clean the valve or change it. —

re
The turret rotates but stops The index coupling teeth do not engage Contact Mazak Technical Center or

s
—

ht
halfway. correctly. Technology Center.

rig
The clamp control solenoid valve (YV2) is Check the solenoid valve (YV2) or
—
faulty. replace it.

A ll
The turret position detection encoder is Check the position detection encoder or
5-2-1, 5-2-2

n.
faulty. change it.

tio
The turret rotates but does The index coupling teeth do not engage Contact Mazak Technical Center or
—
74 ora
not index correctly. properly. Technology Center.
The turret is not mounted correctly. —
39 rp
r 3 Co

The encoder is not mounted correctly. —

6

Tooling is not balanced. Balance the tooling. Operating

be ak

manual of the
um az

machine
PART 2 5-1-3
l N ki M

Play in drive mechanism is excessive. Contact Mazak Technical Center or

—
Technology Center.
a
az
m

7-2-4 TOOL EYE

Ya

ria

Trouble Cause Remedy Refer to

Se
23

The TOOL EYE does not operate. The proximity sensor (SQ7 or SQ8) is Adjust or replace the proximity
20

• The following alarm message is faulty. sensor (SQ7, SQ8).

displayed. Wiring is broken or socket is loose. Replace the wiring. 5-3
©

231 TOOL EYE POSITION

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SENSOR MALF.
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op

7-2-5 X-axis
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Trouble Cause Remedy Refer to

Positioning is not accurate. Bolts, taper pins and/or nuts are loose. Tighten them.
5-4
Coupling is loose. Retighten the coupling.
The X-axis zero-point The adjustment of the zero-point is Reset zero-point.
alignment mark is not inaccurate.
5-4-2
aligned after a zero-point
return.

7-5
 Serial Number 339746

7 TROUBLESHOOTING

7-2-6 Z-axis
Trouble Cause Remedy Refer to
Positioning is not accurate. Bolts, taper pins and/or nuts are loose. Tighten them.
5-4
Coupling is loose. Retighten the coupling.
The Z-axis zero-point The adjustment of the zero-point is Reset zero-point.
alignment mark is not inaccurate.
5-4-2
aligned after a zero-point
return.

7-2-7 Y-axis

.
ed
Trouble Cause Remedy Refer to

rv
Positioning is not accurate. Bolts, taper pins and/or nuts are loose. Tighten them.
5-4

se
Coupling is loose. Retighten the coupling.

re
The Y-axis zero-point The clamping bolts for the proximity sensor Retighten the clamping bolts for the
position is unstable. (The of the Y-axis zero-point are loose. proximity sensor of the Y-axis zero-point.

s
5-4-2

ht
variation is less than

rig
10 mm.)
The Y-axis zero-point The adjustment of the Y-axis zero-point Readjust the Y-axis zero-point watchdog.

A ll
position is unstable. (The watchdog is inaccurate. —

n.
variation is 10 mm or more.)

tio
74 ora
7-2-8 Tailstock
39 rp

Trouble Cause Remedy Refer to

r 3 Co

6
Noise from the rotary center The thrust power is excessively high. Adjust the thrust power. Operating
manual of the
be ak

machine
um az

PART 2 4-7-1
l N ki M

The tailstock does not move The selected thrust value is too small. Select the appropriate thrust value. —
forward and/or backward. The electromagnetic brake is not functioning Check or replace the electromagnetic
a

—
az

properly. brake.
m

The sliding surface is dry (too large in Provide manual lubrication.

—
Ya

ria

friction).
Se

The spindle is clogged with chips. • Select the maximum usable thrust
23

value. 5-6-4
20

• Remove chips.
©

The tailstock does not move The spindle has become caught at the Select the maximum usable thrust value.
—
ht

backward. workpiece.
ig

Stored reference position data is lost. Set the reference position of the spindle
yr

5-6-3
once again.
op
C

7-2-9 Secondary spindle

Trouble Cause Remedy Refer to
Motor does not rotate. The secondary spindle drive unit is faulty. Contact Mazak Technical Center or
Technology Center for the alarm display 5-5
for the secondary spindle drive unit.

7-6
 Serial Number 339746

TROUBLESHOOTING 7
7-2-10 W-axis
Trouble Cause Remedy Refer to
Positioning is not accurate. Bolts, taper pins and/or nuts are loose. Tighten them.
5-5-1
Coupling is loose. Retighten the coupling.
The W-axis zero-point The adjustment of the zero-point is Reset zero-point.
alignment mark is not inaccurate.
5-5-1
aligned after a zero-point
return.

7-2-11 Hydraulic unit

Trouble Cause Remedy Refer to

.
ed
Oil is not discharged. The pump does not rotate. Check the connection of the power cable
—

rv
(X211).

se
The pump is rotating in the reverse Check the polarity of the power supply.

re
5-7-3
direction.

s
—

ht
Suction pipe is clogged. Check the suction pipe.

rig
Strainer is clogged. Clean the strainer. 5-7-4

ll
Leak in suction pipe Check the suction pipe and its joint. —

A
Suction filter is not completely immersed in Replenish the hydraulic oil with the same

n.
oil. grade up to the reference line in the level 4-5

tio sight gauge.

74 ora
Discharge volume adjusting sleeve is Loose the sleeve.
—
39 rp

tightened excessively.
r 3 Co

6
Hydraulic oil viscosity is too high. Replace the oil entirely with oil of correct
viscosity.
be ak

4-5
* Warm the oil using a heater as
um az

temporary measures.
l N ki M

Although oil is discharged, The relief valve is not operating correctly. Disassemble and check the relief valve.
pressure is not built up.
a

Load is not applied in the hydraulic circuit. Check the circuit and apply the load. —
az

Leak in the hydraulic system. Check the piping and repair the leak.
m
Ya

Oil is not discharged or Seals inside the pump are broken. Contact Mazak Technical Center or
ria

volumetric efficiency lowers Technology Center. —

Se

Slide portions are worn abnormally due to

23

when pressure is built up. dust and foreign matter.

20

Noise is excessively large. Strainer is clogged. Clean the strainer. 5-7-4

©

Air is sucked from the suction pipe or other Check the point where air is sucked by
ht

portion. applying oil on the suspected portions.

ig

Bubbles inside the reserve tank. Check the return pipe and prevent
yr

—
generation of bubbles.
op

Bubbles trapped inside the piping. Repeat inching of the pump to discharge
C

the bubbles.
Low oil level Replenish the specified grade of the
hydraulic oil up to the reference line in 4-5
the level sight gauge.
Pump mount base is not rigid. Use rigid base; check loose bolts as well. —
Pump sliding portions exhibit wear. If the wear is abnormal, check for oil
contamination, water in the oil, oil
5-7-4
viscosity, and oil amount during pump
operation.
Pump generates heat. Heat generation due to improper volumetric If the pump surface temperature rises
efficiency. excessively, stop pump operation —
Seizure on sliding portions of the pump immediately.

7-7
 Serial Number 339746

7 TROUBLESHOOTING

7-2-12 Grease lubrication unit

Trouble Cause Remedy Refer to
Grease does not come out of the pump. Air is entrapped in the pump. Release the air.
5-8-1

The pump is not operating. • Check the connection and

reconnect the motor if the
connection is faulty. —
• If the service life of the motor
has expired, replace the motor.
The main piping pressure does not rise. Grease leak from a piping joint Either tighten with proper torque or
(due to a loose or overly tight relay the piping. —

.
connection)

ed
Ruptured pipe Replace the ruptured pipe.

rv
—

se
The pressure release device is not Check the connection and

re
functioning. reconnect the device if the —

s
connection is faulty.

ht
Cause not listed above Contact Mazak Technical Center or

rig
—
Technology Center.

ll
Grease does not come out of the valve. Clogged valve Replace the valve.

A
—

n.
The pressure release device is not Check the connection and
functioning.
tio reconnect the device if the —
74 ora
connection is faulty.
39 rp

The main piping pressure does not go The grease supply tip or valve is Dissemble, inspect and replace the
down. clogged. valve, or replace parts of the grease —
r 3 Co

supply tip.
be ak

The pipe has been crushed. Replace the pipe. —

um az
l N ki M

7-2-13 Oil lubrication unit

Trouble Cause Remedy Refer to
a
az

The 262 OIL LUBRICATION LEVEL Lubricating oil is insufficient. Refill the lubricating oil.
m

5-8-2
LOW alarm is displayed on the screen.
Ya

ria

The alarm message 261 OIL Leak from the lubrication pipe. Retighten the pipe.
Se

—
23

LUBRICATION ALARM is displayed on

20

the screen.
Lubrication pipe is clogged. Clean the pipe.
* Oil pressure has dropped below —
©

0.7 MPa.
ht
ig

7-2-14 Coolant unit

yr
op

Trouble Cause Remedy Refer to

C

Coolant is not supplied. Coolant is insufficient. Refill the coolant. 5-9-2

The thermal relay (QF231) is tripped. Reset the thermal relay (QF231).
* If the thermal relay is not tripped, * When the coolant pump fails, 5-17-3
the coolant pump is faulty. contact Mazak Technical Center
or Technology Center.
Filter of the coolnt tank is clogged. Clean the filter. 5-9-3
Coolant discharge hole inside the Clean the coolant discharge hole of
5-2-4
coolant block is clogged. the coolant block.

7-8
 Serial Number 339746

TROUBLESHOOTING 7
7-2-15 Air unit
Trouble Cause Remedy Refer to
Air flow volume decreases due to high Element is clogged. Change the element.
5-10-2
air flow resistance.
An excessive volume of water is found Water has accumulated. Discharge the water.
in the pipe down-stream from the —
element.

7-2-16 Headstock cooling unit

The alarm message 360 SPINDLE COOLING MALFUNCTION is displayed on the screen if an

.
ed
error occurs in the headstock cooling unit.

rv
• Refer to the separate Parameter List/Alarm List/M-Code List for details.

se
re
s
ht
Trouble Cause Remedy Refer to

rig
The alarm message 360 SPINDLE • Coolant is insufficient. • Replenish the coolant.

ll
COOLING MALFUNCTION is displayed • The pressure switch (SP4) is faulty. • Replace the pressure switch

A
on the screen. (SP4).

n.
• The spindle cooling fan (M114) is in 5-11
the overloaded state. • Confirm that it is not

tio disconnected.
74 ora
• Replace the fan (M114).
39 rp
r 3 Co

7-2-17 Milling headstock cooling unit

6
be ak

The alarm message 362 MILL SPINDLE COOLING MALFUNCTION or 363 MILL SPINDLE
um az

LUBRICATION ALARM is displayed on the display if a malfunction occurs in the milling

l N ki M

headstock cooling unit.

• Refer to the separate Parameter List/Alarm List/M-Code List for details.
a
az
m
Ya

ria

Trouble Cause Remedy Refer to

Se
23

The alarm message 362 MILL • Coolant is insufficient. • Replenish the coolant.
20

SPINDLE COOLING MALFUNCTION • The pressure switch (SP14/SP15) is • Replace the pressure switch
or 363 MILL SPINDLE LUBRICATION (SP14/SP15).
©

faulty. 5-13
ALARM is displayed on the display.
ht

• Confirm that it is not

ig

disconnected.
yr
op

7-2-18 Wiper for the door and wiper for the way cover
C

Trouble Cause Remedy Refer to

An unusual sound is emitted when an Chips in large quantities have Clear away the chips on the wiper
—
axis is moving. accumulated between wipers. part.
The wipers are damaged. Replace the wiper.
There are scratches on the surface of 5-17-6
the way cover.
Chips accumulate on the other side of A gap has developed between the wiper Readjust the wiper or replace it.
the machining area. and the way cover or between the wiper 5-17-6
and the door inner cover.

7-9
 Serial Number 339746

7 TROUBLESHOOTING

7-2-19 Milling holder

Trouble Cause Remedy Refer to
Machining of workpieces is not Milling holders are mounted incorrectly Remove the milling holders and
accurate. on the turret. clean the mounting surface of —
milling holders and turret.
The run of tool is not normal. Readjust the eccentric pin to restore
5-15-5
the run of tool to normal.
Unusual operating sounds are Bearing or gear is damaged. Contact Mazak Technical Center or
—
generated. Technology Center.
Cutting point does not last long. Cutting condition of tool is inappropriate. Change the cutting condition
—
appropriate for the tool.

.
ed
The run of tool is not normal. Readjust the eccentric pin to restore
5-15-5

rv
the run of tool to normal.

se
Decrease of discharge rate of the Seals are broken Contact Mazak Technical Center or

re
—
coolant from tool nose (only for through-coolant specifications). Technology Center.

s
Trouble occurs inside the machine. Refer to the troubleshooting of

ht
5-9
coolant.

rig
ll
7-2-20 Coolant temperature control

A
n.
Trouble Cause Remedy Refer to

tio
74 ora
The coolant chiller alarm appears on the Cooling device error. Check the description of the alarm
display. for the cooling device, and
39 rp

troubleshoot the problem according

r 3 Co

6
to the supplied operating manual. If
—
the cooling device still has a
be ak

malfunction, contact Mazak

um az

Technical Center or Technology

l N ki M

Center.
The air filter is clogged. Clean the air filter. 5-10-2
a
az

The pump and the cooling device are The air filter is clogged. Clean the air filter. 5-10-2
both operating; however, the oil is not
m

There is an obstacle near the intake or Remove the obstacle.

cooling. —
Ya

ria

discharge area.
Se

The ambient temperature is high. Use the device within the specified
23

temperature range.
20

If it is exposed to hot air, take —

©

appropriate measures to avoid

ht

exposure to hot air.

ig

Noise level gets higher. Filter of the coolant tank is clogged. Clean the filter. 5-9-3
yr

Abnormal noise is generated. Coolant is insufficient. Refill the coolant. 5-9-2

op

Cooling device malfunction. Contact Mazak Technical Center or

C

—
Technology Center.

7-2-21 NC unit and controller

Trouble Cause Remedy Refer to
The alarm message 12 SERVO The voltage of the batteries installed to Replace the batteries.
BATTERY WARNING is displayed on retain absolute position data is low. 5-17-4
the screen. (Battery life).
The alarm message 52 BATTERY The voltage of the batteries installed to Save the internal data Data backup method:
retain the data in the NC is low. (Battery immediately and replace Part 3, Chapter 10 of
ALARM is displayed on the screen.
life). the batteries as soon as the operating manual
possible. of the machine
Otherwise, the internal Battery Replacement
data will be lost. 5-17-5

7-10 E
 Serial Number 339746

Revision Record

Revision No. Revision date Manual No. Revision code (A#, C# or D#)
R0 10. 2021 UB72MA0018E0
R1
R2
R3

.
ed
R4

rv
se
R5

re
s
ht
rig
A ll
n.
tio
74 ora
39 rp
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All rights reserved.

No part of this manual shall be reproduced, stored in a retrieval system, or transmitted by
any means, electronically, mechanically, photocopying, recording, or otherwise, without
written permission of YAMAZAKI MAZAK CORPORATION.

YAMAZAKI MAZAK CORPORATION

 Serial Number 339746

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Statement about the Environment
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Yamazaki Mazak U.K. Limited operates an Environment Management System and is

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certified by BSI to BS EN ISO 14001:2015 under Certificate No. EMS 41381.

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A principal objective of such a system is to minimise, where technically possible and

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economically viable, the impacts of a company’s activities on the environment. This

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is particularly relevant to the recycling and safe disposal of metal cutting coolants,
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oils, swarf and faulty parts. As part of Yamazaki’s commitment to good environmental
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practice we would respectfully urge our customers to consider such matters in their
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use of Mazak Machine Tools. Further advice on recycling and safe disposal methods
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can be obtained from local Environment Agencies.

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The Health, Safety & Environmental Manager,

On Behalf of Yamazaki Mazak U.K. Limited