Manual de mantenimiento f3 f5 v1431 i-e1e-xc

/ MACHINE
MAINTENANCE MANUAL
(V1431I-E1E-XC)

Maintenance Manual
V1431I-E1E-XC
Usage of This Manual
This manual describes machine maintenance for vertical machining center. All
information required by the user prior to machine maintenance work is summarised.
This manual has been prepared and complied based on the standard specifications
available at the time of preparation. Parts numbers and other contents may differ due
to changes in specifications and designs following publication. Contact your Makino
service representatives for updated information. Note that the figures in this manual
may not apply to all the parts of the given product due to specification changes.
IMPORTANT NOTICE
• Read and understand Chapter 1 Safety prior to machine operation to ensure
safe working conditions.
• Designate specific operation and maintenance personnel for this machine to
ensure optimum machine performance and safety standards are maintained at
all times.
• Keep this manual in a clearly marked location for easy access whenever
necessary.
• Contact your Makino service representatives or local distributor if this manual
is lost or damaged.
• All right reserved. No part of this document maybe reproduced, copied, or
modified in any form or any means without direct permission of Makino.
• Ensure this manual is included when moving or reselling this machine.
• All specifications and designs are subject to change without prior to
notification.
- Read this manual thoroughly prior to adjusting or replacing the
machine parts.
- Heed the safety precautions provided in this manual at all times to
ensure the safety of operation and maintenance of the machine.
- Disregarding specific instructions or precautions included in this
manual may lead to serious injury or death.

Maintenance Manual
V1431I-E1E-XC
CONTENTS
Chapter 1 Safety................................................................................................. 1-0
1.1 Introduction.............................................................................. 1-1
1.2 Safety Precautions .................................................................. 1-1
1.2.1 Designated Personnel Only......................................... 1-1
1.2.2 Do Proper Maintenance............................................... 1-1
1.2.3 Be Careful.................................................................... 1-3
1.2.4 Wear Proper Attire....................................................... 1-4
1.2.5 Work Holding Device and Work Piece......................... 1-4
1.2.6 Compress Air Cleaning Restrictions ............................ 1-4
1.2.7 Foot Step..................................................................... 1-5
1.2.8 Check and Maintain Lubrication Oils ........................... 1-5
1.2.9 Use of Water-Soluble (Water-Based) Cutting Fluid ..... 1-5
1.2.10 Make Good Housekeeping A Way of Life.................... 1-5
1.2.11 Lifting Devices ............................................................. 1-6
1.2.12 Emergency Stop Button & Switches............................ 1-6
1.2.13 Switches, Limits & Interlocks ....................................... 1-7
1.2.14 Electrical Safety Precautions....................................... 1-7
1.2.15 Power Failure .............................................................. 1-9
1.2.16 Returning The Machine To Operation ......................... 1-9
1.3 Lock-Out & Tag-Out Confirmation ......................................... 1-10
1.4 Warning Labels...................................................................... 1-13
Chapter 2 Introduction ........................................................................................ 2-0
2.1 Introduction.............................................................................. 2-1
Chapter 3 Mechanical & Electrical Specifications............................................... 3-0
3.1 Introduction to Mechanical Structure ....................................... 3-1

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3.2 Out Line of Different Parts ....................................................... 3-2
3.2.1 Spindle Head............................................................... 3-3
3.2.2 Column ........................................................................ 3-3
3.2.3 Saddle ......................................................................... 3-3
3.2.4 Table............................................................................ 3-4
3.2.5 Bed .............................................................................. 3-4
3.2.6 Coolant Tank ............................................................... 3-4
3.2.7 Spindle Cooling Oil Temperature Controller ................ 3-4
3.2.8 Machine Tool Control................................................... 3-4
3.2.9 Automatic Tool Changer.............................................. 3-4
3.3 Mechanical Specifications ....................................................... 3-5
3.3.1 F3 Table ...................................................................... 3-5
3.3.2 F5 Table ...................................................................... 3-6
3.3.3 Spindle Head 12,000 rpm............................................ 3-7
3.3.4 Spindle Head 20,000 rpm............................................ 3-7
3.3.5 Spindle Head 30,000 rpm............................................ 3-8
3.3.6 Machine Accuracy ....................................................... 3-8
3.3.7 F3 Machine Size.......................................................... 3-8
3.3.8 F5 Machine Size.......................................................... 3-8
3.3.9 Automatic Tool Changer.............................................. 3-9
3.3.10 Coolant Flow Rate & Pressure .................................... 3-9
3.3.11 Tank Capacity............................................................ 3-10
3.3.12 Pneumatic Supply...................................................... 3-10
3.3.13 Spindle Cooling Oil Temperature Controller .............. 3-10
3.4 Introduction to Electrical Control Functions ........................... 3-11
3.4.1 CNC unit.................................................................... 3-11

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3.4.2 Motors........................................................................ 3-11
3.4.3 Peripherals ................................................................ 3-11
3.4.4 Limit switches and solenoid valves............................ 3-12
3.5 CNC UNIT ............................................................................. 3-13
3.5.1 DI/DO Boards ............................................................ 3-13
3.5.2 Main CPU Board........................................................ 3-13
3.5.3 LCD Display Unit ....................................................... 3-14
3.5.4 Manual Data Input (MDI) Unit.................................... 3-14
3.5.5 Function Keys & Rotary Switches.............................. 3-14
3.5.6 Operator I/O Board .................................................... 3-14
3.6 Electrical Specifications......................................................... 3-15
3.7 CNC Control Specifications ................................................... 3-18
Chapter 4 Periodic Maintenance......................................................................... 4-0
4.1 Periodic Maintenance of Mechanical Items ............................. 4-1
4.1.1 Outline/Precautions ..................................................... 4-1
4.2 Periodic Maintenance List........................................................ 4-3
4.2.1 Daily/Pre-Operation Inspection/Maintenance .............. 4-3
4.2.2 Post-Operation Maintenance....................................... 4-5
4.2.3 Monthly Maintenance................................................... 4-7
4.2.4 Biannual Maintenance ................................................. 4-7
4.2.5 Annual Maintenance.................................................... 4-7
4.2.6 160-Hour Maintenance ................................................ 4-7
4.2.7 500-Hour Maintenance ................................................ 4-8
4.2.8 2000-Hour Maintenance .............................................. 4-8

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4.2.11 12000-Hour Maintenance ............................................ 4-9
4.2.12 Alarm-Related Maintenance ........................................ 4-9
4.3 Spindle................................................................................... 4-11
4.3.1 Cleaning of Spindle Taper ......................................... 4-11
4.3.2 Sealing Rod (12K – BT (TSC)) .................................. 4-11
4.3.3 Sealing Rod Rubber Seal Replacement (12K – BT
(TSC)) ....................................................................... 4-13
4.3.4 O-Ring in Sleeve (20K/30K – HSK)........................... 4-15
4.3.5 Collet Lubrication (20K/30K – HSK) .......................... 4-18
4.4 Feed Axis............................................................................... 4-20
4.4.1 Feed Axis Ball-Screw/Linear Guide Grease Supply .. 4-20
4.5 ATC Unit................................................................................ 4-21
4.5.1 Cam Box Lubricant Level Check ............................... 4-21
4.5.2 Cam box Lubricant Replenishment............................ 4-23
4.5.3 Cam box Lubricant Replacement .............................. 4-25
4.6 ATC Tool Magazine............................................................... 4-27
4.6.1 Tool Shank Check/Cleaning & Tool Pot Key Check .. 4-27
4.6.2 Replacement of ATC Arm Finger Spring ................... 4-30
4.7 Spindle Cooling Oil Temperature Controller .......................... 4-32
4.7.1 Checking/Replacing of Cooling Oil ............................ 4-32
4.7.2 Cleaning of Air Filter and Condenser Coil.................. 4-34
4.7.3 Line Filter & Exhaust Cleaner Element Replacement 4-36
4.8 Hydraulic Unit ........................................................................ 4-40
4.8.1 Hydraulic Oil Check/Replacement (12K/20K Spindle)4-40
4.8.2 Line Filter Element Replacement (12K/20K Spindle). 4-41
4.8.3 Hydraulic Oil Check/Replenishment (30K Spindle).... 4-43

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4.9 Pneumatic Unit ...................................................................... 4-44
4.9.1 Air Panel Configuration.............................................. 4-44
4.9.2 Air Quality Control ..................................................... 4-45
4.9.3 Main Air Unit Pressure Check/Adjustment................. 4-45
4.9.4 Main Air Unit Filter Replacement............................... 4-46
4.10 Chip Disposal/Cutting Fluid Supply Unit ................................ 4-48
4.10.1 Cutting Fluid Level Check/Replenishment................. 4-50
4.10.2 Coolant Tank Cleaning .............................................. 4-52
4.10.3 Filter Cleaning ........................................................... 4-54
4.10.4 Pump Mechanical Seal Replacement........................ 4-56
4.11 Machine Controller ................................................................ 4-58
4.11.1 Absolute Pulse Coder Battery Replacement.............. 4-58
4.11.2 Battery Replacement for Data Memory Back-up ....... 4-60
4.12 Axes Telescopic Cover.......................................................... 4-62
4.13 Splash Guard Front Door Glass ............................................ 4-63
4.14 Optional Specification/Equipment.......................................... 4-64
4.14.1 Automatic Grease Cartridge Replacement ................ 4-64
4.14.2 Automatic Tool Length Measurement Unit (Touch Probe)
.................................................................................. 4-66
4.14.3 Automatic Workpiece Measuring Unit........................ 4-67
4.15 Recommended Lubricants..................................................... 4-73
4.15.1 Recommended Grease.............................................. 4-73
4.15.2 Recommended Cooling Oil/Hydraulic Oil/Lubricant... 4-73
4.16 Fuse Replacement ................................................................ 4-74
4.16.1 CPU Unit Fuse Replacement..................................... 4-74
4.16.2 Replacing Fuse in Power Supply Module .................. 4-75
4.16.3 Replacing Fuse in the Servo Amplifier Module.......... 4-76

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4.16.4 Replacing Fuse in Spindle Amplifier Module ............. 4-77
4.17 Replacing Fan Motor in CNC Unit ......................................... 4-78
4.18 Replacing Touch Screen Protection Sheet............................ 4-79
4.19 Replacing the Touch Panel Pen ............................................ 4-80
Chapter 5 Troubleshooting on Machine.............................................................. 5-0
5.1 Introduction.............................................................................. 5-1
5.1.1 Alarm Displayed on PMC............................................. 5-1
5.1.2 No Alarm Displayed on Machine Fault ........................ 5-1
5.1.3 Troubleshooting Section Based on Function ............... 5-2
5.2 Troubleshooting On Spindle .................................................... 5-4
5.2.1 Spindle Motor .............................................................. 5-4
5.2.2 Spindle Tool Clamp/Unclamp ...................................... 5-5
5.2.3 Clamp/Unclamp Limit Switches ................................... 5-5
5.2.4 Clamp/Unclamp Limit Mechanism ............................... 5-7
5.2.5 Limit Switch Adjustment............................................... 5-8
5.2.6 Draw Bar Setting For Repairs...................................... 5-9
5.2.7 Spindle Cooling System............................................. 5-11
5.2.8 Spindle Bearing Lubrication....................................... 5-12
5.2.9 Spindle Orientation .................................................... 5-13
5.2.10 Emergency Stop Button (Spindle Rotation) ............... 5-14
5.2.11 Spindle Start/Stop Malfunction .................................. 5-15
5.2.12 Spindle Speed Range Switching ............................... 5-15
5.3 Spindle Cooling Oil Temperature Controller .......................... 5-16
5.3.1 Trouble ...................................................................... 5-16
5.4 Circuit Breakers & Circuit Protectors ..................................... 5-20
5.5 Feed Axis............................................................................... 5-21

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5.5.1 Feed Axis Fails to Move in Manual Mode.................. 5-21
5.5.2 Servo Alarm Is Trigger During Operation................... 5-21
5.5.3 Feed Axis Runs until Hitting Mechanical Stop ........... 5-22
5.5.4 Positioning Accuracy Not Achieved........................... 5-22
5.5.5 Abnormal Noise & Vibration Generated..................... 5-23
5.6 Thermal Overload Relays...................................................... 5-24
5.6.1 Cause & Remedy ...................................................... 5-24
5.7 Main Air Pressure Switch....................................................... 5-25
5.7.1 Cause & Remedy ...................................................... 5-25
5.8 Emergency & Overtravel Limits ............................................. 5-25
5.8.1 Cause & Remedy ...................................................... 5-25
5.9 Lift Up Chip Conveyor (LUCC) .............................................. 5-26
5.9.1 Cause & Remedy ...................................................... 5-26
5.10 Automatic Tool Changer (ATC) ............................................. 5-26
5.10.1 Emergency Stop Button Pressed During ATC........... 5-26
5.10.2 Tool Exchange Operation Does Not Start.................. 5-27
5.10.3 Tool Dropped During Tool Exchange ........................ 5-28
5.10.4 ATC Standby Condition ............................................. 5-29
5.10.5 Moving ATC to Standby Condition............................. 5-29
5.10.6 ATC Flow Chart......................................................... 5-31
Chapter 6 Alarms................................................................................................ 6-0
6.1 Introduction.............................................................................. 6-1
6.2 Alarm Screen Display .............................................................. 6-2
6.3 Alarm Detail References.......................................................... 6-3

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Chapter 7 Tooling ............................................................................................... 7-0
7.1 Tooling Information.................................................................. 7-1
7.2 Pull stud................................................................................... 7-2
7.3 Tool Shank with Pull Stud........................................................ 7-3
7.4 Tool Size Specification ............................................................ 7-5
Chapter 8 Appendix ............................................................................................ 8-0
8.1 Limit Switches.......................................................................... 8-1
8.2 Solenoid Valves....................................................................... 8-2
8.3 Machine I/O List....................................................................... 8-4
8.4 Operator Panel I/O List.......................................................... 8-14
8.5 Connector Location & Application in FS18I Controller........... 8-18
8.6 Connector & Relay Locations on RELAY PCB ...................... 8-19
8.7 Connector & Relay Locations on Option PCB ....................... 8-20
8.8 Connector & Relay Locations for Operator PCB’s. ................ 8-21

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1-0 V1431I-E1E-XC
Chapter 1 Safety

Maintenance Manual
V1431I-E1E-XC 1-1
1.1 Introduction
This manual is design for use by experience personnel only. It does not
include precautions and warnings for potentially dangerous operating
conditions for personnel lacking required mechanical or technical knowledge
(operation, programming and maintenance).
There are many precautions that must be observed depending upon each
situation when operating and maintaining the machine. It is impossible to
cover all of these precautions in this manual.
The operator and maintenance personnel must understand the machine
thoroughly and always take care to ensure safety and be aware of possible
dangerous situations.
The following safety precautions are to re-enforce the fact that safety is a full
time concern and an important part of everybody’s job description.
1.2 Safety Precautions
All safety precautions discuss herein maybe supplemented with company
safety policies and procedures.
For the safety of the operator and maintenance personnel, please observe
the following safety precautions:
1.2.1 Designated Personnel Only
• DO NOT allow unauthorised or improperly trained personnel to
operate and maintain the machine tool.
• Only qualified electrical engineers may perform electrical work.
• Only qualified personnel may use a crane or forklift.
1.2.2 Do Proper Maintenance
• Assign specific personnel to perform the maintenance and
repair of the machine tools.
• Allow time for maintenance personnel to become familiar with
the machine and its components.

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1-2 V1431I-E1E-XC
• Before doing any maintenance or repair, study the sections
related to the repair in the parts and/or Maintenance manual
thoroughly and carefully.
• Disconnect all power sources, relays, and all stored energies
before attempting repairs or maintenance.
• Never perform maintenance and repair of machinery while
under the influence of alcohol or drugs.
• The maintenance personnel should be in proper physical
condition. If he / she suffer from a condition that impairs
judgment, it may result in serious injury or death.
• Inspection or maintenance engineers maybe out of sight from
other personnel when working. Hang or affix an "INSPECTION
IN PROGRESS" warning sign on the Main Power switch and
any other appropriate location to notify personnel of work in
progress.
• Some devices (motors, lighting devices, valves etc.) become
very hot when the machine is operating and remain hot soon
after the power is turn OFF. Be careful not to touch them soon
after stopping machine operation since this may result in a
burn.
• When 2 or more people are required to perform maintenance,
make sure to maintain clear communication at all times and be
ready to press the [EMERGENCY] stop button, in case of
accidents.
• When working with the cover removed in order to perform
maintenance or approaching the moving parts, take adequate
safety precautions. In adequate attention to safety may result in
serious injury or death.
• Never modify the machine or components. This may result in
the machine moving unexpectedly and/or a decrease in the
level of operational safety.
• Check for loose, damage, or worn parts on the machine. These
are the causes of abnormal noise or machine damage during
operation.

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V1431I-E1E-XC 1-3
• Check for loose or damage piping or electrical wiring. These
are the causes of oil leakage or electrical shocks during
machining.
• Back up the parameters set prior to shipping and the program
and offset data input by the customer periodically. If the
program and offset data are damage or lost, Makino cannot
accept any responsibility for this data.
• Contact your Makino service representative prior to replacing
parts. If the machine is operating with improper parts, it may
result in degrading the performance of the machine. It may also
make the machine less safe; result in machine damage or
injury.
1.2.3 Be Careful
• Exercise extreme care with the following items while the
protective covers are remove:
o Do not touch rotating or moving parts.
o Do not touch the axis when in motion.
o Exercise extreme care with parts that maybe about to
move.
• Never cross over or reach through guards when the machine is
running.
• Never alter, remove, or disable any safety device, warning, or
instruction plate.
• Beware of the movement range of the machine and auxiliary
components (each axis stroke, rotation range) and always keep
all body parts clear of moving components.
• When removing loaded springs, understand the forces involved.
Loaded springs can be very dangerous.

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1-4 V1431I-E1E-XC
1.2.4 Wear Proper Attire
• Operate and maintain the machine with the suitable clothes.
• DO NOT operate the machine while wearing a necktie, scarf,
accessories or any other clothes that may become entangle
with the machine moving parts of the machine.
• Persons with long hair should tie it back or contain it under a
cap (helmet), to prevent any entanglement with the machine.
• Wear protective glasses, safety shoes, safety cap (helmet) and
safety groves as the occasion demands.
• Protective gear should be worn to protect hearing when
excessive noise maybe generated during operation or
maintenance.
1.2.5 Work Holding Device and Work Piece
• Work holding device and workpiece should only be load and
unload after the spindle and the machine has completely
stopped.
• Always check for tightness of fixture mounting, the rigidity of
workpiece mounting and all adjustments, before starting the
machine and after a prolong shutdown period.
• Workpiece materials such as magnesium and titanium can
cause fire if mishandle. Take extra care when machining
workpieces make from materials with potential danger and
handling the cutting chips.
• Use the most appropriate cutting tool, tool holder, retention
knob and workpiece, and make sure that they are all tighten
securely. If not, the workpiece may fall or tool may fly out,
resulting in machine damage, serious injury or death.
1.2.6 Compress Air Cleaning Restrictions
• Never use compress air to clean the machine, the table or the
vicinity around the machine. Guards and cover on the machine
are designed to protect component assemblies from normal
chip flow. The movement of chips and coolants by compress air
does not constitute "NORMAL" chip flow.

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V1431I-E1E-XC 1-5
1.2.7 Foot Step
• The top of the machine covers are very slippery. Do not use
them as steps! Use only the factory installed footboards as a
footstep.
1.2.8 Check and Maintain Lubrication Oils
• Check the oil level in each reservoir on the machine everyday.
• Always add oil to keep the reservoir at their proper level.
• Take extreme care not to contaminate the oil system with dirt or
improper oil.
1.2.9 Use of Water-Soluble (Water-Based) Cutting Fluid
• Use a water-soluble (water-based) coolant other than chemical
solution type CLASS W3, or equivalent.
• Use of oil-based cutting fluid may result in fire.
• The chemical (cutting fluid, lubricant, etc.) use with the machine
should be secured and manage by supervising personnel.
1.2.10 Make Good Housekeeping A Way of Life
• Remember to keep the environment, near and around the
machine tools clean, organise and well lighted.
• Clean up oil or coolant spills immediately.
• Keep the machine tool clean and free of large amounts of chips,
oil and cutting fluids.
• Keep all flammable liquids away from the work area.
• Maintain adequate working space.

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1-6 V1431I-E1E-XC
1.2.11 Lifting Devices
• Lifting devices should be of sufficient capacity to handle the
weight of the machine.
• Refer to machine specifications for correct machine weight and
recommended lift points for proper balance.
• During lifting, please confirm that no one is close to the
machine, make sure the parts are well balance, and be careful
not to hit onto the other machine.
• Do not attempt to go under the lifted machine. Exercise extreme
caution for the lifted machine when it is being transfer.
1.2.12 Emergency Stop Button & Switches
• Make sure the operator and maintenance personnel knows the
location of the [EMERGENCY] stop buttons prior to operating
and maintaining the machine to enable immediate use in an
abnormal or dangerous situation following an accident.
• Check the controls; know the location and function of all controls
and switches on the machine control panels, before starting
operation.
• Periodically check that all switches work properly, especially
Feed Hold, Emergency Stop, Single Block, and Machine Lock.
• Know the status of the electrical power, ON or OFF. If the
power must be left ON use the [MACHINE LOCK] button to
prevent machine movement, while performing maintenance
task.
• The keys (release key for door lock switch, machine control
panel key, etc.) which are not necessary for regular operation
and maintenance must be removed from the machine and kept
by supervising personnel.

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V1431I-E1E-XC 1-7
1.2.13 Switches, Limits & Interlocks
• Never move or bypass the stroke limiting dogs, interlock limit
switches, interlocking circuits, etc. as this could result in damage
to the machine tool and possible personal injury.
• Do not move the switches or change the circuits except for
adjustment purposes. This may result in serious injury, death or
damage to the machine. In particular, operating the machine
with the interlock(s) or other safety devices/ functions disable is
especially dangerous and may result in serious injury, death or
damage to the machine. If you have to operate or maintain the
machine with the interlock(s) release, enable the [MACHINE
LOCK] function and pay extra attention to safety during
operation or maintenance.
1.2.14 Electrical Safety Precautions
• Ensure that current electrical drawings are use when performing
electrical maintenance.
• If working on live electrical equipment, avoid any position where
a slip would bring you into contact with exposed live electrical
connections.
• Ensure that all solid state devices are properly ground after
repairs.
• Remove power to the CNC and the PMC before arc welding on
the machine to prevent CPU damage.
• Ensure that a good earth ground exists to the ground bar in the
main electrical cabinet.
• Never attempt to modify or rework the machine electrical
system.
• Never touch electrical equipment when hands are wet. Never
activate electrical circuits while standing on a wet surface.
• Never use metal ladders when working on or near electrical
circuits.
• Replace fuses only with the same size fuse originally furnish.
Never use larger fuses, jumper fuses or circuit breakers.

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1-8 V1431I-E1E-XC
• While performing maintenance, make certain that no one can
turn on power without your knowledge. Use warning tags like
the one shown in Figure 1-1, or a company equivalent, and
appropriate locks to prevent any unauthorised use or
unintentional start.
DANGER
DO NOT
OPERATE
This tag must not be removed, except by
the person who signed and attached it.
Photograph
Name
Department
Date
Signature
Figure 1-1

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V1431I-E1E-XC 1-9
1.2.15 Power Failure
• When the machine is stop by a power failure, turn OFF the
machine power immediately. If the power is not turn OFF, the
machine will start operating unexpectedly when the power is
restore, and this may result in serious injury, death or damage to
the machine.
• When the machine is stop by a power failure, check the
parameter, program and offset data, to ensure that they have
not been damaged. If the machine operates using damage data,
it may damage the machine.
1.2.16 Returning The Machine To Operation
• Upon completing maintenance, replace all guards that were
removed and ensure all machine access enclosures are close
and lock.
• Make sure to return the parameter to its original setting,
whenever a parameter is change for maintenance or adjustment
purposes. If the setting is incorrect, the machine may operate in
an unexpected manner and this may result in serious injury,
death or damage to the machine.
• If a circuit needs to be changed for adjustment purposes, make
sure to return it to the original setting, after adjustment has been
completed.
• Remove all tools from machine.
• Ensure all hydraulic and pneumatic lines were connected and
secured.
• Jog the machine components through a complete cycle, check
for proper operation.
• Observe machine operation for a period of time to ensure proper
operation before releasing the machine to production.
• Clean up around the machine. Ensure all oils and cutting fluids
were wiped up.
• Do not use the machine in excess of its specifications or
performance range. This may cause unforeseen machine
motion that may result in injury or damage to the machine.

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1.3 Lock-Out & Tag-Out Confirmation
• Use established and approved Lock-Out and Tag-Out procedures.
• Lock-Out consists of shutting down the power source to the machine or
devices and locks it.
• Example:
Set the main power switch to the OFF position and secure it using a
padlock or cover such as a lock out device (Figure 1-3).
• Tag-Out consists of placing the signs to prevent anyone from switching
ON the power source.
• Example:
Place “Do Not Operate” or “Under Maintenance” signs (Figure 1-2) with
the operator’s name and department on the main power switch and main
operation panel.
• Lock-Out and Tag-Out can prevent accidental operation; however this
does not guarantee the safety of the operation and maintenance
personnel. It is their responsibility to read and understand the
precautions thoroughly in this chapter and each unit chapter, and be
aware of possible dangerous situations.
• The operator and maintenance personnel should perform Lock-Out and
Tag-Out by themselves. Perform this procedure prior to work and release
the lock and remove the signs yourself after work. Never release the lock
and remove the signs without confirming with or in the presence of the
operator.
• Use the Lock-Out and Tag-Out policy and procedures define by your
company.

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• Figure 1-2 shows the location where you should place the warning signs,
during the Lock-Out and Tag-Out procedures.
Figure 1-2
DANGER
DO NOT
OPERATE
This tag must not be removed, except by
the person who signed and attached it.
Photograph
Name
Department
Date
Signature
E.g. Hook
the warning
sign onto
the
Emergency
Button
Place the warning sign
at the Main Operation
Panel

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1-12 V1431I-E1E-XC
• Figure 1-3 shows the location of the main power switch, where you
switch off the power and secure it with a padlock, during the Lock-Out
and Tag-Out procedures.
• Location and type of switch differs depending on the machine model and
specifications.
Figure 1-3
Padlock
Main Power
Switch
Hook the Warning Tag
onto the padlock
The Main Power Switch is turn off and lock it
with a padlock.

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V1431I-E1E-XC 1-13
1.4 Warning Labels
Warning labels were attached to the machine to ensure safe operation of the
machine and provide important instructions. Confirm that the operator and
maintenance personnel are familiar with the language on the labels. If not,
contact your Makino service representative to get proper labels.
Operator and maintenance personnel need to be able to read and
understand all warning labels. Always keep the labels clean so that they can
be easily read.
Replace the labels when the labels peel off or become illegible. If the parts
on which the warning labels were attached were replaced, new labels must
be attached to the new parts. Contact your Makino service representative.
Table 1.1 DANGER / WARNING / CAUTION Statements
Possibility of Injury or Machine Damage
Major (Urgent) Medium (Possible) Minor (Hypothetical)
Death
* Serious
Injury
DANGER indicates
an imminently
hazardous condition,
which if not avoided,
will result in death or
serious injury.
WARNING indicates
an imminently
hazardous
condition, which if
not avoided, could
result in death or
serious injury.
** Minor
Injury &
Material
Loss
CAUTION indicates a
Potentially hazardous
condition, which if not
avoided, may result in
moderate or minor
injury. This is also
used to alert the
operator of unsafe
operating procedures.
* Serious Injury refers to an injury or condition which has a residual effect or
requires hospital treatment or long-term treatment as an outpatient. Examples are
loss of eyesight, burn, electrical shock, bone fracture or poisoning, etc.
** Minor Injury refers to an Injury, burn or electrical shock which does not require
hospital treatment or long-term treatment as an outpatient.

Maintenance Manual
2-0 V1431I-E1E-XC
Chapter 2 Introduction

Maintenance Manual
V1431I-E1E-XC 2-1
2.1 Introduction
The intent and purpose of this maintenance manual was to provide the
critical and necessary information for troubleshooting and maintenance of
your Vertical-Machining Center.
This manual was meant for the service and maintenance personnel with
fundamental electrical knowledge, and knowledge of the operation of the
machine tools including CNC operation, ATC operation and the operation of
other machine peripherals. This manual was not meant for electronic board
level or component level servicing.
For more information on the maintenance and troubleshooting of the AC
servo drives for axes motor and ATC magazine motor, and servo motors,
please refer to latest version of the following publications from Fanuc:
Description Part No.
Fanuc Control Motor Servo Amplifier α-i Series
Description Manual
B-65282EN/01
Fanuc Control Motor α Series Maintenance Manual B-65165E
For more information on the maintenance and troubleshooting of the AC
spindle drive unit and the spindle motor; please refer to the following
publication from Fanuc:
Fanuc Control Motor Amplifier α -i Series Description
Manual
(This manual covers the power supply modules, servo
amplifiers and spindle amplifiers)
B-65282EN/01
Fanuc AC Spindle Motor α Series Description Manual
The above manuals do not come with the machine but are available from
Makino or Fanuc. The Fanuc manuals, which will be included in your
machine, are as show below:
Fanuc FS310i User’s Manual B-63944EN
Fanuc FS310i Parameter Manual B-63950EN

Maintenance Manual
2-2 V1431I-E1E-XC
In case the preliminary checks on the machine could not solve the problem,
you can always contact our service department. Please provide the following
information to our service personnel.
1. Your name
2. The company name
3. The machine type and model
4. The machine serial number
5. The machine control type
If you leave a message in the PHONE MAIL system be sure to leave your
phone number (area code first) and a brief description of your problem, in
addition to the above information.

Maintenance Manual
3-0 V1431I-E1E-XC
Chapter 3 Mechanical & Electrical Specifications

Maintenance Manual
V1431I-E1E-XC 3-1
3.1 Introduction to Mechanical Structure
Your new Makino vertical CNC milling centre combines the speed, and the
precision of the Computer Numerical Control, with the world famous reliability
of the Makino machines. The F3/F5 vertical machining centre is particularly
well match for precision machining of small to medium batches of a wide
spectrum of different work piece. It can accommodate various cutting needs
ranging from high-speed processing of plastics and aluminium, to heavy
cutting of mild steel and stainless steel.
Short set up and high-speed automatic change system keep non-productive
time to a minimum. Short set up time is achieve due to the simple, clear
basic construction and the ergonomic design of the working area, the control
panel and other operating elements. The cam-driven tool change mechanism
enables a very short tool change time. It is one of the fastest of its kind (tool
to tool: 1.3 sec). F3/F5 has a fast rapid transverse of 40 m/min for X, Y & Z-
axis. The high-speed ATC & positioning system keeps non-cutting time to a
minimum and improves productivity. The standard package comes with 20
tool pots. The optional capacity of 30 tool pots is available for wide range of
engineering workshop requirement.
A powerful built-in spindle with speed range switching control system
ensures that the F3/F5 can perform high-speed cutting and low speed, high-
torque cutting with negligible vibration. Direct drive of the spindle by the built-
in motor gives high power efficiency.
The head design is solid, robust & capable of withstanding heavy cutting
load. The Z axis slide fully supports the entire stroke length to provide
rigidity. To accommodate high speed machining, high speed positioning and
maintaining machining accuracy, the linear motion guide ways and the
spindle cooling system are implement.
The spindle bearing is oil lubricate, which allows maintenance free operation,
high operating speed factor and a constant operating temperature. This will
prevents the bearings from wearing out or degrading at high speed
operation. A thermally symmetrical structure and a large oil cooling system
reduce thermal displacement at the spindle head.
The floor space for the F3/F5 is small. It covers only 5.8 m2
. Hence, F3/F5 is
design to optimise space and energy.
The machine will give a long life of precision and productive service, if the
fundamentals of the machine operations are properly follow. No matter how
sophisticated a control system maybe, or how ruggedly designed, or how
carefully crafted, the results will be disappointing, if the system is not
properly maintain, or does not operate according to good basic machining
practices.

Maintenance Manual
3-2 V1431I-E1E-XC
This manual provides the necessary instructions for the operation, and
maintenance of your new Vertical Machining Centre, to achieve its optimum
life and performance. Time invested in the study of this manual will yield
substantial returns.
3.2 Out Line of Different Parts
Figure 3-1
Spindle
Head
MTC/NC
Cabinet
Spindle
Cooling Oil
Temperature
Controller
Control Panel
Automatic
Tool Changer
(ATC)
Splash Guard
Coolant
Tank
Lift Up Chip
Conveyor
(LUCC Option)

Maintenance Manual
V1431I-E1E-XC 3-3
3.2.1 Spindle Head
The spindle head is support by linear guide ways throughout its
stroke at the front of the saddle. The spindle motor in the spindle
head produces high speed, steady spindle rotation by directly
driving the spindle. In order to raise torque at low speeds, Makino
employ a built-in speed range switching control motor. This
combination realises both high-speed spindle rotation and high
torque. The tool is positively clamp by disc springs inside the
spindle. During automatic operation, the tool shank and the spindle
taper are clean by compress air. Spindle orientation is electrically
performed to reduce the orientation time.
3.2.2 Column
The column is a box type one-piece close construction that solidly
supports the spindle and saddle for high accurate cutting. The
effectively position ribs inside the column enhance rigidity and
stability. The Machine Tool Controller unit (MTC) was mounted to
the side of the column.
3.2.3 Saddle
The effectively position ribs inside the saddle give rigidity and
stability for saddle .The guideways for the spindle (z-axis) were
mounted on top of the saddle longitudinally.
Spindle Housing
Table
Column
Bed
Saddle
X-Axis
Z-Axis
Y-Axis
Figure 3-2

Maintenance Manual
3-4 V1431I-E1E-XC
3.2.4 Table
The table moves longitudinally on the bed. The table comes with 5
T-grooves on the top face to facilitate clamping of material.
3.2.5 Bed
The bed, which serves as the base for the entire machine, has
strategically distributed ribs in the X and Y directions symmetrically
arranged for reinforcement that assures rigidity against torsion or
bending in any direction. The bed contacts the foundation at 6
points via the leveling screws. The Y axis guide way was mounted
securely to the bed.
3.2.6 Coolant Tank
The coolant tank has a capacity of 160 litres, which slide under the
front of the bed. The coolant was supplied to the ring type coolant
nozzles by a pump, with a flow rate of 25 l/min. The nozzles were
installed at the right side of the spindle.
3.2.7 Spindle Cooling Oil Temperature Controller
The spindle cooling oil system for the spindle head on your vertical
machining center is a close system, which incorporates an oil
temperature controller. This system minimises differential thermal
growth between the spindle head and the rest of the machine,
allowing greater control and producing better results and more
consistent performance.
3.2.8 Machine Tool Control
This unit houses the relay required for controlling the various
machine function (pump motor, lubrication pump motor, automatic
temperature controller, etc.).
3.2.9 Automatic Tool Changer
The system comprises arm, tool pots and tool magazine, which
were installed on the same base, and arranged neatly on the left
side of the bed, resulting in no wasted floor space. The system
employed a cam-driven tool change mechanism that enables a fast
tool change. It also has the following features:
• Random tool selection
• Fast tool change
• Compact

Maintenance Manual
V1431I-E1E-XC 3-5
3.3 Mechanical Specifications
3.3.1 F3 Table
Specifications Measurement Unit Measurement Unit
Table Working Surface 850x500 mm 33.465x19.685 In
Axes Travel (X, Y, Z) 650x500x450 mm 25.591x19.685x17.717 In
T-Slot 18 H8 x 5 mm x qty 0.709 H8 x 5 In x qty
T-Slot Pitch 100 mm 3.937 In
Maximum Pay-Load 800 kg 1763.698 lbs
Cutting Feed Rate 1~20,000 mm/min 0.039~787.402 In/min
Rapid Transverse (X, Y, Z) 0~20,000 mm/min 0~787.402 In/min
Figure 3-3
Top View (mm)
Side View
Top View (Inch)
(mm)
(Inch)

Maintenance Manual
3-6 V1431I-E1E-XC
3.3.2 F5 Table
Table Working Surface 1000 x 500 mm 39.370 x 19.685 In
Axes Travel (X, Y, Z) 900x500x450 mm 35.433x19.685x17.717 In
T-Slot 18 H8 x 5 mm x qty 0.709 H8 x 5 In x qty
T-Slot Pitch 100 mm 3.937 In
Maximum Pay-Load 1000 kg 2204.623 lbs
Cutting Feed Rate 1~20,000 mm/min 0.039~787.402 In/min
Rapid Transverse (X, Y, Z) 0~20,000 mm/min 0~787.402 In/min
Top View (mm)
Side View
Top View (Inch)
(mm)
(Inch)
Figure 3-4

Maintenance Manual
V1431I-E1E-XC 3-7
3.3.3 Spindle Head 12,000 rpm
Power (15min/cont) 22/18 kW 29.5/24.14 hp
Max. Torque (15min/cont.) 117/95 Nm 1035.5/840.8 lbf-in
Tool Clamping Force 8,826 +15/-5% N 1984.2 lbf
Specifications Measurement Unit
Speed Range 120~12,000 rpm
Specifications Description
Tool Shank & Retention Knob MAS403-BT40/DIN69871-A40/V-CAT/JIS B6339-40T
Cooling Method Jacket cooling
Max. Torque (5min/cont.) 32/19 Nm 283.2/168.2 lbf-In
Tool Clamping Force
BT40:
8,826 +15/-5%
HSK-A63:
17,652 +15/-5%
N
BT40: 1984.2
HSK-A63: 3968.3
lbf
Tool Shank & Retention Knob MAS403-BT40/DIN69871-A40/V-CAT/HSK-A63
Cooling Method Jacket cooling + Core cooling

Maintenance Manual
3-8 V1431I-E1E-XC
3.3.6 Machine Accuracy
3.3.7 F3 Machine Size
3.3.8 F5 Machine Size
Max. Torque (30min/cont.) 20.4/14.6 Nm 180.6/129.2 lbf-In
Tool Clamping Force 10,787 N 2,425 lbf
Tool Shank HSK-F63
Cooling Method Jacket cooling + Core cooling
Positioning +/- 0.0025 mm +/-0.0000984 In
Positioning With Optical Scale +/- 0.0015 mm +/- 0.0000591 In
Repeatability +/- 0.0014 mm +/- 0.0000551 In
Repeatability With Optical Scale +/- 0.0010 mm +/- 0.0000394 In
Height 3,065 mm 120.669 In
Width 2,440 mm 96.063 In
Depth (With Front Coolant Tank) 2,625 mm 103.346 In
Depth (With Rear Coolant Tank) 4,295 mm 169.094 In
Weight 7,300 kg 16,093.745 lbs
Height 3,065 mm 120.669 In
Width 2,565 mm 100.984 In
Depth (With Front Coolant Tank) 2,625 mm 103.346 In
Depth (With Rear Coolant Tank) 4,295 mm 169.094 In
Weight 7,500 kg 16,534.670 lbs

Maintenance Manual
V1431I-E1E-XC 3-9
3.3.9 Automatic Tool Changer
3.3.10 Coolant Flow Rate & Pressure
Specifications Description & Measurement
Tool Change Type Double Grip Single Arm
Tool Storage Capacity Standard: 20 Optional: 30
Maximum Tool Diameter With
Adjacent Pots Occupied
ATC20: 114 mm
ATC30: 76.2 mm
ATC20: 4.488 In
ATC30: 3 In
Maximum Tool Diameter With
Adjacent Pots Empty
120 mm 4.724 In
Maximum Tool Length 300 mm 11.811 In
Maximum Tool Weight 8 Kg 17.637 Lbs
Maximum Tool Moment 9.8 Nm 86.737 lbf-In
Magazine Rotating Speed 18 rpm
Tool Selection Random system
Tool Shank MAS 403, BT40 MF2450, No.40 (CAT40)
Pull Stud Type MAS 403, BT40 I type T4M-0070E
Tool Change Time (Tool-to-Tool) 1.6 sec. (12K), 1.8 sec. (20K), 4.5 sec. (30K)
Tool Change Time (Chip-to-Chip)
6 sec. (12K at 6,000rpm), 6 sec. (20K at 10,000rpm),
9 sec. (30K at 15,000rpm)
Specifications
Flow Rate
(l/min)
Flow Rate
(gal/min)
Pressure
(MPa)
Nozzle Coolant 30 7.925 0.2
Coolant Flush 80 21.134 0.2
Through Spindle Coolant - 1.5 Mpa, 12K 18 4.755 1.5 (At pump outlet)
Through Spindle Air - 12K - - 0.5
Through Spindle Air - 20K - - 0.5

Maintenance Manual
3-10 V1431I-E1E-XC
3.3.11 Tank Capacity
3.3.12 Pneumatic Supply
3.3.13 Spindle Cooling Oil Temperature Controller
Specifications
Measurement
(Litres)
Measurement
(Gallons)
Front coolant tank capacity (Total volume available for filling) 160 42.268
Rear coolant tank capacity (Total volume available for filling) 420 111
Front coolant tank effective capacity available for pump
suction
140 36.984
Rear coolant tank effective capacity available for pump
suction
335 88.5
Spindle cooling oil temperature controller tank capacity
(12K)
50 13.209
Spindle cooling oil temperature controller tank capacity
(20K/30K)
40 10.567
Hydraulic power pack oil capacity 8 2.113
Grease cartridge capacity for manual greasing 0.4 0.106
Grease cartridge capacity for auto greasing 1 0.264
ATC cam oil capacity 5 1.321
Air Pressure 0.5 MPa 72.519 lbf/in2
Air Consumption (For 20K spindle, air
quality equivalent to grade ISO1.5.1
specified by ISO 8573-1 (equivalent to
JIS B 8392-1))
400 l/min 105.669 gal/min
Delivery (50/60Hz) 25/30 l/min 6.604/7.925 gal/min
Cooling Capacity (50/60Hz) 2,600/3,000 kcal/h 10,319/11,907 BTU/hr
Temperature Detection Thermistor
Detecting Accuracy Machine temperature ±1oC

Maintenance Manual
V1431I-E1E-XC 3-11
3.4 Introduction to Electrical Control Functions
The components were functionally grouped into the following categories:
3.4.1 CNC unit
The term CNC unit mention in this manual means the integrated
type Fanuc Controller FS310i.
Servo Amplifier Module (SVM) and Power Supply Module (PSM)
The power amplifiers to drive the axis AC servo motors were the
state of art Fanuc Alpha Series Servo Amplifier Module (or SVM). A
single or dual amplifier was used to drive the axis motors. The built-
in type spindle motor was driven by a Spindle Amplifier Module (or
SPM) with a serial interface to the CPU. A central Power Supply
Module (PSM) supplies the power to the SVM and SPM.
3.4.2 Motors
These include axis AC servo motors, spindle motor, ATC magazine
motor, ATC arm motor, coolant pump motors, etc.
3.4.3 Peripherals
These supporting components include:
• Spindle temperature controller unit: regulating the spindle
temperature.
• Machine light: fluorescent light provides, machine lighting.
• Nozzle coolant: coolant system during work piece machining.
• Air blow: air blow coolant system while machining.
• ATC: automatic tool changer.
• Signal light: signaling machine running, machining finished,
operator attention, and machine in alarm state.
• Rotary work head (OPTION): single / dual.
• Through spindle coolant (OPTION): coolant system for tool and
work piece when tool goes through the work piece.

Maintenance Manual
3-12 V1431I-E1E-XC
• Coolant flush: flush the chips on telecover area.
• Lift up chip conveyor (OPTION): efficient chip disposal system.
• Part counter (OPTION): to give count of the number of parts
produced.
• Hydraulic unit (OPTION): provides hydraulic fixture clamping.
• Air seat check (OPTION): for checking the work contact.
• Fixture coolant (OPTION): to clean and take away the chips
from the fixture area.
• Fixture air (OPTION): provides air cleaning for the fixture.
• Light curtain (OPTION): with Auto door this option ensures
safety to the operator.
• Tool broken sensor (OPTION): for checking the tool breakage
condition on machine tool.
• ATLM & AWM (OPTION): for tool length and work piece auto
measurements.
• Linear Scales (OPTION): The machine was equipped with
linear scales for better accuracy.
• Many other options are possible depending on the machining
requirement. Please refer to the circuit diagrams and operation
manual for further operation and trouble shooting assistance.
3.4.4 Limit switches and solenoid valves
Limit switches are sensors use for machine control, for example
axes travel limits, ATC pot horizontal/vertical sensing. Solenoid
valves are use for activating control air valves, e.g. the air valves
actuating the cylinder for ATC pot horizontal/vertical position.
The specifications of motors and peripherals can be found in
Chapter 3.6 of this manual.
Limit switches and solenoid valves are described in more detail in
Chapter 8.1 and 8.2 of this manual.

Maintenance Manual
V1431I-E1E-XC 3-13
3.5 CNC UNIT
The CNC control system used in the machine was the integrated type Fanuc
FS310i and was mounted inside the operator panel. The following
components and printed circuit boards were associated with the CNC
system.
3.5.1 DI/DO Boards
The digital inputs and digital outputs for the machine control were
performed through these boards. The number of digital inputs and
outputs depends on the machine configuration and options
available.
Three I/O modules were mounted on the main PCB inside the MTC,
and handle all the I/O’s from the machine. The operator station I/O
was handled by two separate printed circuit board resided in the
operation station called operator I/O board.
3.5.2 Main CPU Board
The “brain” of the control system is the Main CPU board. It has
multiple modules on the printed circuit board, which perform various
functions including:
• CNC operation command control
• CNC program data and machine parameter storing
• RS-232 serial communication
• Manual Pulse Generator control
• LCD display control (non-graphic)
• Execution of Programmable Machine Controller (PMC) program
• Servo control for axis 1 to 4
• Spindle control with serial interface
The program data and machine parameter were stored in the Main
CPU board's static RAM area, which requires battery backup, under
power off condition.

Maintenance Manual
3-14 V1431I-E1E-XC
3.5.3 LCD Display Unit
A 12.1 inch LCD unit was used for Professional 5 controls as a
standard feature.
3.5.4 Manual Data Input (MDI) Unit
The MDI unit is a full key type keypad for data entry and screen
selection.
3.5.5 Function Keys & Rotary Switches
The function keys and rotary switches were used to control the
machine operation consisting of push buttons with illumination,
keyed switches and rotary switches.
3.5.6 Operator I/O Board
It controls the input & output of the functional keys & rotary
switches.

Maintenance Manual
V1431I-E1E-XC 3-15
3.6 Electrical Specifications
Table 3.1
Control & Control Cabinet Specifications
Nominal power consumption 25 kW
Maximum power consumption 50 kW
Input voltage to the control cabinet 3-phase 200VAC +/-10%
No-fuse-breaker rating at incoming 125A
Main transformer input voltage Country dependent
Main transformer output voltage 3-phase 200VAC 3-phase, 50/60 Hz
Main transformer power rating 40 KVA
X, Y, Z Axis AC Servo Motors Specifications
X, Y-axis motor type Fanuc AC Servo Alpha 22i/3000
X, Y-axis motor rated power 4.2 kW
X, Y-axis motor rated torque 22Nm
X, Y-axis motor Fanuc part number A06B-0247-B100
Z-axis motor type Fanuc Ac servo Alpha 22i/3000
Z-axis motor Fanuc part number A06B-0247-B400
Z-axis motor rated power 4.2 Kw
Z-axis motor rated torque 22Nm
Type of pulse code for all axis motors Fanuc A1000 (serial type)
Resolution of pulse coder 1 million pulse/rev
X, Y, Z Axis AC Servo Amplifiers Specifications
X-axis motor and Y-axis motors share a unit with two amplifiers
Z-axis motor and C-axis motors share a unit with two amplifiers
X, Y-axis motor amplifier type SVM80/80I
X, Y-axis motor amplifier Fanuc part number A06B-6117-H209
Rated output current (rms) 19A
Maximum current for each amplifier (peak) 80A
Z, C-axis motor amplifier type SVM40/80i
Z, C-axis motor amplifier Fanuc part number A06B-6117-H205/H208
Rated output current (rms) 19A
Maximum current of the amplifier (peak) 40A/80A
Spindle Motor Specifications
Type Fanuc B112Li, switching range
Manufacturer part number A06B-1675-B100#Z311
Type of speed range switching Electronic
Switching speed 1650 rpm
Output torque @ continuous rated 95 Nm
Output torque @ 15 min. rated 117 Nm
Built-in thermal overload detection Yes

Maintenance Manual
3-16 V1431I-E1E-XC
A & B Axis AC Servo Motors Specifications
A, B – axis motor type Alpha 4 / 5000is
A, B – axis motor rated power 1.2 kW
A, B – axis motor rated torque 4Nm
A, B axis motor Fanuc part number A06B-0215-B000
A Axis AC Servo Amplifier Specifications
A axis motor amplifier type SVM 20
A axis motor amplifier Fanuc part number A06B-6117-H103
Maximum current of the amplifier 20A
B Axis AC Servo Amplifier Specifications
A axis motor amplifier type SVM 20
A axis motor amplifier Fanuc part number A06B-6117-H103
Maximum current of the amplifier 20A
ATC Motors / Amplifier Specifications
Arm motor type 3-phase one speed induction, gear motor
Arm motor manufacturer Deta machinery Co.Ltd
Arm motor manufacturer's part number -
Arm motor power for low/high speed 0.75 kW
Magazine motor type Fanuc AC Servo β2/3000
Magazine motor Fanuc part number A06B-0032-B075#0008
Magazine motor amplifier Fanuc part number Twin amplifier with Z-axis
Spindle Cooling Oil Temperature Controller Specifications (12K)
Type HBO-V750PTSBM3
Manufacturer Harbor Precision Industry, Taiwan
Input voltage 220V 3-phase, 50/60Hz
Total power rating 1.95 kW
Compressor power rating 1.185 kW
Circulating pump power rating 0.75kW
Cooling capacity 2,600/3000 Kcal/H
Circulating volume 30 l/min.
Spindle Cooling Oil Temperature Controller Specifications (20/30K)
Type MRSD-15A-N-1
Manufacturer Oil Matic
Input voltage AC200V 50/60Hz
Circulating pump power rating 0.75 kW
Circulating volume 30 l/min
Lift Up Chip Conveyor Motor Specifications
Type Fongex
Power ¼ HP, 220V 3-phase, 50/60Hz
Chain Speed 1.2 ~ 1.4 m/min.

Maintenance Manual
V1431I-E1E-XC 3-17
Nozzle Coolant Pump Specifications
Type MTH 4-40/3
Manufacturer GRUNDFOS
Input voltage 200V, 3-phase, 50Hz
Power rating 0.760 kW
Flow Rate 83 l/min.
Pressure 8 bar (maximum)
Coolant Flush Pump Specifications
Type MTH 4-40/3
Power rating 0.760 kW
Flow rate 83 l/min
Spindle Hydraulic Unit Specifications
Manufacturer Rexroth
Power 550W (220V, 3P, 50 Hz)
Oil Pressure for 12K Spindle 68~72 bar
Oil Pressure for 20K Spindle 80~85 bar
Hydro-Pneumatic Booster Specifications
Type CS1LH160-Q6528-80
Manufacturer SMC
Oil Pressure for 30K Spindle 138 bar (maximum)
Through Spindle Coolant Pump (1.5 MPa) Specifications
Type CRK2-220/19
Power rating 3 kW
Flow rate 18 l/min
Through Spindle Coolant Pump (3 MPa) Specifications
Type BFS260/30-G61
Manufacturer Brinkmann Pumpen
Power rating 3.3 kW
Flow rate 40 l/min
The maximum power consumption is based on the standard
machine with all the major components operating at maximum
rated power. If your machine is equipped with options like lift-up
chip conveyor or other peripherals, the power capacity will be
higher.

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3-18 V1431I-E1E-XC
3.7 CNC Control Specifications
The table below shows the NC control specifications of the machine. The
following symbols are use:
Ο Means a standard feature to this machine tool
♦ Means a optional feature to this machine tool
The actual configuration of your machine maybe different from what has
listed since your machine maybe equipped with additional option or the
configuration of the machine for your market was different. Please confirm
with your distributor the functions/features available for your machine.
Table 3.2
Standard Specification
CNC Control Professional 5
CNC type FS310is
Basic Machine functions, Pro 5 Win CE
ATC controls Ladder
12.1 inch LCD Screen, Touch type Ο
Full MDI Ο
Number of Simultaneous Controllable axes 3
3 controlled axes (3 simultaneously controllable axes) Ο
Pen for Touch panel Ο
Programming Method Professional 5
Least increment: 0.0001mm, ISC Ο
Maximum programmable dimension: ±8 digits (±99999.999) (2) Ο
Absolute / incremental programming (G90/G91) Ο
Decimal point programming / calculator type decimal point input Ο
Automatic recognition of EIA / ISO code Ο
Interpolation Functions Professional 5
Positioning (G00) Ο
Linear interpolation Ο
Circular interpolation Ο
Helical interpolation (G02, G03) (Included in Die Mould Package) Ο

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V1431I-E1E-XC 3-19
Plane selection G17, G18, G19 Ο
Feed Functions Professional 5
Rapid traverse, bell shape acc/dec, 20m/min Ο
Cutting feedrate: F direct command Ο
Dwell (G04) Ο
Rapid traverse override (0~100%) Ο
Cutting feedrate override (0~200%) Ο
Feedrate override cancel (M49/M48) Ο
Part Program Storage & Editing Professional 5
Part program storage: 160m Ο
Registered program number: 120 Ο
Part program editing Ο
Background editing, Dual program view screen Ο
Program number search Ο
Sequence number search Ο
Operation & Display Professional 5
Clock, Calendar function Ο
MDI function Ο
Run hour and parts quantity display, Fanuc screen Ο
Machining time stamp function, Fanuc Ο
I/O Devices Professional 5
Data Input / Output Interface – Channel 1 (RS-232C) Ο
DNC Operation Ο
I/O Memory Card Slot Ο
Wincom Communication Interface (Included in Die Mould Package) Ο
Data Center A: 160MB (Included in Die Mould Package) Ο
S, M, T Functions Professional 5
Spindle Speed Direct S-Code, 5 Digits Ο
Tool Function, 4 Digits Ο
Miscellaneous Function Ο
Tool Compensation Professional 5
Tool length compensation (G43, G44/G49) Ο
Cutter compensation C (G41, G42/G40) Ο
Tool offset pairs - 64 Ο

Maintenance Manual
3-20 V1431I-E1E-XC
Tool Offset Memory C (Geometry/Wear/Cutter/Tool Length) Ο
Coordinate Systems Professional 5
Manual return to reference position Ο
Automatic return to reference position (G28) Ο
Reference position return check (G27) Ο
Automatic return from reference position (G29) Ο
Setting for work coordinate system (G92) Ο
Machine coordinate system selection (G53) Ο
Work coordinate system selection (G54~G59) Ο
Local coordinate system setting (G52) Ο
Operation Support Functions Professional 5
Label skip Ο
Single block Ο
Program stop (M00) Ο
Optional stop (M01) Ο
Optional block skip (/) Ο
Dry run Ο
Machine lock Ο
Z-axis feed cancel Ο
Mirror image for X-axis and Y-axis (M21, M22/M23) Ο
Manual absolute Ο
Tool length measurement (manual) Ο
Follow-up Ο
Help function Ο
Run hour and parts quantity display, Pro 5 Ο
Machining time stamp function, Pro 5 Ο
Manual Pulse generator on operator panel Ο
Skip function, G31 Ο
Sequence number comparison and stop Ο
Programming Support Functions Professional 5
Canned cycle Ο
Sub program call (4 folds nested) Ο
Exact stop (G09) Ο
Exact stop mode (G61) Ο

Maintenance Manual
V1431I-E1E-XC 3-21
Tapping mode (G63) Ο
Cutting mode (G64) Ο
Programmable data input (G10) (offset value, parameter) Ο
Custom Macro Ο
Manual absolute ON & OFF Ο
Extended part program editing Ο
Cut, Paste and Replace function Ο
Program Directory Ο
M code insert from M code table Ο
Data input safety check function Ο
Rigid Tapping (G84.2, G84.3, M135) Ο
Machine Accuracy Compensation Professional 5
Stored Pitch error compensation Ο
Backlash compensation Ο
Maintenance & Safety Professional 5
Emergency stop Ο
Stored stroke limit 1 Ο
Self-diagnostics Ο
Interlock Ο
Alarm history display Ο
High Speed High Accuracy Function Professional 5
GI.3 Control Ο
Super GI.4 Control (Included in Die Mould Package) Ο

Maintenance Manual
3-22 V1431I-E1E-XC
Optional Specification
CNC Control Professional 5
4 controlled axes (4 simultaneously controllable axes) ♦
5 controlled axes (5 simultaneously controllable axes) ♦
Programming Method Professional 5
Inch (G20) / metric (G21) ♦
Exponential interpolation (G02.3, G03.3) ♦
Hypothetical axis interpolation (G07) ♦
Conical/Spiral interpolation (G02, G03) ♦
Involute interpolation (G02.2, G03.2) ♦
Cylindrical interpolation (G07.1) (requires NC rotary table) ♦
Feed Functions Professional 5
Automatic corner override (G62) ♦
I/O Devices Professional 5
Data Center B – 400MB ♦
Data Center, High capacity, 800 MB ♦
Part Program Storage & Editing Professional 5
1. Additional Part Program Storage:
• 160 m
• 320 m
• 640 m
• 1280 m
• 2560 m
• 5120 m
• 10240 m
• 20480 m
2. Number of Registered Program (Option 1):
• 120 – Possible with 160 m part program storage
• 1000 – Possible with 1280 m, 2560 m, 5120 m, 10240 m, 20480 m
part program storage
3. Number of Registered Program (Option 2):
• 4000 – Possible with 5120 m, 10240 m, 20480 m part program storage
♦

Maintenance Manual
V1431I-E1E-XC 3-23
High Speed High Accuracy Function Professional 5
Nano smoothing ♦
Tool offset (G45~G48) ♦
Additional tool offsets pairs (total): 99, 200, 400, 499, 999 ♦
Tool offset memory A (Geometry / Wear) ♦
Tool offset memory B (Geometry / Wear) ♦
Coordinate Systems Professional 5
3rd and 4th reference position return (G30) ♦
Floating reference position return (G30.1) ♦
Work coordinate system preset (G92.1) ♦
Additional work coordinate system selection (G54.1 P1~P48) ♦
Additional work coordinate system selection (G54.1 P1~P300) ♦
Operation Support Functions Professional 5
High-speed skip function ♦
Additional optional block skip: 9 blocks total (/1~/9) ♦
Program restart ♦
2
nd
Auxiliary function ♦
Manual Handle interruption ♦
Optional angle chamfering, corner R programming ♦
Programmable mirror image (G51.1/G50.1) ♦
Scaling (G51/G50) ♦
Coordinate system rotation (G68/G69) ♦
Polar coordinate command (G15/G16) ♦
Normal direction control (G41.1, G42.1/G40.1) ♦
Addition of custom macro common variables (total) : 600 ♦
Interruption type custom macro ♦
Small-hole peck drilling cycle ♦
Playback ♦
Machine Accuracy Compensation Professional 5
Single direction positioning (G60) ♦
Maintenance & Safety Professional 5
Stored stroke limit 2 (G22/G23) ♦

Maintenance Manual
3-24 V1431I-E1E-XC
Machine Functions
Spindle Professional 5
20K spindle Ο
Hydraulic tool clamp/unclamp Ο
Additional Axes Professional 5
X,Y,Z axes, CNC control Ο
ATC Magazine. PMC control Ο
4th Axis NC rotary table & control ♦
5th Axis NC rotary table & control ♦
Fixture Control Functions Professional 5
Hydraulic fixture control functions, 2nd PMC Ladder ♦
1st User M-Code ♦
2nd user M-Code ♦
3rd User M-code ♦
Feedback Functions Professional 5
Absolute Encoder Ο
Absolute Linear scale, 0.05 um resolution, X,Y,Z axes ♦
Coolant Functions Professional 5
Nozzle Coolant Ο
Coolant Flush Ο
Air Blow ♦
Through’ Spindle Coolant ♦
Lift Up Chip Conveyor ♦
Centralized Auto Grease ♦
Safety Functions Professional 5
Front door Interlock with safety lock Ο
ATC shutter with interlock Ο
ATC shutter with safety lock ♦
Operation Functions Professional 5
MPG on Operator panel Ο
Measurement Functions Professional 5
Auto Work Measurement – Renishaw, Blum, Marposs ♦
Auto Tool Length Measurement, Laser – Renishaw, Blum, Marposs ♦
Auto Tool Length Measurement, Touch probe – Renishaw, Blum, Marposs ♦

Maintenance Manual
4-0 V1431I-E1E-XC
Chapter 4 Periodic Maintenance

Maintenance Manual
V1431I-E1E-XC 4-1
4.1 Periodic Maintenance of Mechanical Items
4.1.1 Outline/Precautions
Read “Chapter 1 Safety” thoroughly and ensure adequate
precautions are taken before performing inspections and
maintenance.
Before performing inspections and maintenance (Excluding
tasks that must be performed with power ON), stop the
machine, switch OFF the control and main power supplies, and
perform the Lock-Out and Tag-Out procedures.
When the operator door must remain open to perform
maintenance or inspections, open the door then switch OFF the
power supply, and perform the Lock-Out and Tag-Out
procedures, before working. However, note that it maybe
necessary to perform some tasks with power supply switched
ON.
Press the [Emergency] stop button or switch OFF the power,
before entering the machining chamber, column room and/or
Tool Magazine. Take care to avoid slipping while performing
maintenance within the machine.
Main power is automatically switched OFF following specified
time after control power is switched OFF.
Periodic inspection of ambient air quality is recommended to
ensure optimum machine operation environment.
Machine inspections and maintenance must be performed regularly to
maintain optimum machining accuracy and long-term performance.
Periodic maintenance is classified into the following categories:
1. Periodic Maintenance Irrespective of Accumulated Machine Operation
Time.
Daily or Pre-Operation Maintenance
Post-Operation Maintenance
Monthly Maintenance
Bi-Annual Maintenance
Annual Maintenance

Maintenance Manual
4-2 V1431I-E1E-XC
2. Maintenance Based on Accumulated Machine Operation Time.
Maintenance schedule differs when based on accumulated machine
operation time.
Perform Maintenance according to the following time table.
Table 4.1 Maintenance Interval According to Daily Operating Hours
Please note that the respective maintenance intervals are calculated
using 5 days as equaling one week.
Machine Operation Time / Day
16 Hours 24 Hours
160 Hours 2 Weeks 7 Days
500 Hours 1.5 Months 1 Month
2000 Hours 6 Months 4 Months
4000 Hours 1 Year 8 Months
6000 Hours 1.5 Years 1 Year
AccumulatedMachine
OperationTime
12000 Hours 3 Years 2 Years

Maintenance Manual
V1431I-E1E-XC 4-3
4.2 Periodic Maintenance List
4.2.1 Daily/Pre-Operation Inspection/Maintenance
Unit Chapter Maintenance Point
4.3.1 Clean Spindle Taper.
4.3.2 Check Sealing Rod Rubber Seal (12K – BT (TSC)).Spindle
4.3.4 Check O-Rings in Sleeve (20K/30K – HSK).
ATC Tool Magazine 4.6.1 Clean Tool / Pot.
Spindle Cooling Oil
Temperature
Controller
4.7.1 Check Cooling Oil Level and replenish if necessary.
Hydraulic Unit
4.8.1
4.8.3
Check Hydraulic Oil Level and replenish if necessary.
Pneumatic Unit 4.9.3 Check Main Air Supply Pressure.
4.10
Clear the chips inside the Chip Tray (Front Coolant
Tank) / Chip Bucket (Rear Coolant Tank).
Chip Disposal /
Cutting Fluid
Supply Unit
4.10.1 Check Cutting Fluid Level and replenish if necessary.
Axes Telescopic
Cover
4.13 Check Wiper.
Splash Guard Front
Door Glass
4.14 Check Glass and Polycarbonate.
Tool Length Sensor
Unit
4.15.2 Clean Sensor Unit.
Automatic
Workpiece
Measuring Unit
(AWM)
4.15.3 Check and clean the Measuring Probe / Receiver.

Maintenance Manual
4-4 V1431I-E1E-XC
Figure 4-1 Daily/Pre-Operation Inspection/Maintenance
Cutting Fluid
Level Check
Cooling Oil
Level Check
Clearing of chips inside
the Chip Bucket
(Rear Coolant Tank).
Main Air
Pressure Check Hydraulic Oil
Level Check
Tool / Pot Cleaning
Clearing of chips
inside the Chip Tray
(Front Coolant Tank)
a. Spindle Taper Cleaning
b. Rubber Seal Inspection (12K – BT (TSC))
c. O-Ring Inspection (20K/30K – HSK)

Maintenance Manual
V1431I-E1E-XC 4-5
4.2.2 Post-Operation Maintenance
Unit Maintenance Point
Machining Chamber Clean Machining Chamber
ATC Unit Clean ATC Unit
Make sure to switch OFF the power supply before performing
the following procedures. Subsequently, perform the Lock-Out
and Tag-Out procedures, to ensure that other personnel do not
switch ON the machine power inadvertently which could result
in the machine being operated.
Exercise extreme caution as entry into the machine is
necessary in order to perform the following procedures.
Make sure to remove the tool and leave an empty tool holder in
the spindle when cleaning the inside of the machining chamber.
Do not use compressed air.
Cleaning Procedure (Post Operation)
1. Open the ATC shutter completely in maintenance mode.
2. Open the operator door.
3. Switch OFF the power supply.
4. Clean the following locations:
a. Around X, Y & Z Axes Telescopic Cover(s)
b. Around Operator Door
c. Table Top
d. Table, X-Axis, Tool Length Sensor Unit (Optional Item)
e. ATC - Shutter, Shutter Rails, Arm / Gripper
5. Confirm there are not chips or dust in the Machining Chamber.
6. After cleaning, close the Operator Door.
7. Switch ON the power supply.
8. Close the ATC Shutter completely in maintenance mode.
This completes post-operation maintenance procedure.

Maintenance Manual
4-6 V1431I-E1E-XC
Figure 4-2 Post-Operation Maintenance (Cleaning Locations)
e. ATC: Shutter,
Shutter Rails,
Arm / Gripper
b. Around
Operator
Door
a. Around X, Y & Z Axes
Telescopic Cover(s)
c. Table Top
d. Table, X-Axis, Tool Length
Sensor Unit (Optional Item)

Maintenance Manual
V1431I-E1E-XC 4-7
4.2.3 Monthly Maintenance
4.2.4 Biannual Maintenance
4.2.5 Annual Maintenance
4.2.6 160-Hour Maintenance
Chip Disposal / Cutting
Fluid Supply Unit
4.10.3 Clean Coolant Tank Filters.
Automatic Tool Changer
(ATC)
4.5.1
4.5.2
Check Cam Box Lubricant Level
and replenish if necessary.
Automatic Workpiece
Measuring Unit (AWM)
4.15.3
Check and replace Diaphragm
(Renishaw).
4.10.2
Clean Coolant Tank
(Clean Tank and Dirty Tank).Chip Disposal / Cutting
Fluid Supply
4.10.4
Replace Pump Mechanical Seal
Kit.
4.12.1
Replace Absolute Pulse Coder
Battery.
Machine Controller
4.12.2
Replace Battery for Data Memory
Back-up.
Spindle Cooling Oil
Temperature Controller
4.7.2 Clean Air Filter Mesh.

Maintenance Manual
4-8 V1431I-E1E-XC
Spindle 4.3.5
Supply lubricant to Collet
(20K/30K – HSK).
Feed Axis 4.4.1
Supply manual grease to all the
grease point.
4.3.3
Replace Sealing Rod Rubber
Seal (12K – BT (TSC)).
Spindle
4.3.4
Replace O-Ring in Sleeve
(20K/30K – HSK).
Hydraulic Unit
4.8.1
4.8.3
Replace Hydraulic Oil.
Pneumatic Unit 4.9.4 Replace Main Air Unit Filter.
Spindle Cooling Oil
(20K/30K Spindle)
4.7.1 Replace Cooling Oil.
ATC Tool Magazine 4.6.2 Change ATC Arm Finger Spring.
Replace Exhaust Cleaner
Element (20K/30K Spindle).Spindle Cooling Oil
4.7.3
Replace Line Filter Element.

Maintenance Manual
V1431I-E1E-XC 4-9
4.2.12 Alarm-Related Maintenance
Automatic Tool Changer
(ATC)
4.5.3 Replace Cam Box Lubricant.
Spindle Cooling Oil
(12K Spindle)
4.7.1 Replace Cooling Oil.
Alarm Unit Chapter Maintenance Point
Warning No. 130028
Alarm No. 130027
Spindle Cooling
Oil Temperature
Controller
4.7.3
Replace the Line
Filter Element.
Alarm No. 135***
(NC Alarm No.
DS0306/DS0307/DS
0308: absolute pulse
coder (APC))
4.12.1
Replace Absolute
Pulse Coder Battery.
Alarm No. 130042
Machine
Controller
4.12.2
Replace Battery for
Data Memory Back-
up.
Warning No. 130054
Automatic
Grease Supply
4.15.1
Replace Grease
Cartridge.
Warning No. 320001
Automatic
Workpiece
Measuring Unit
(AWM)
4.15.3
Replace the
Measuring Probe
Battery.

Maintenance Manual
4-10 V1431I-E1E-XC
Figure 4-3 Alarm-Related Maintenance
Spindle Cooling Oil
Replace the Line Filter
Element (Inside Bowl).
Automatic
Grease Supply
Replace Grease
Cartridge.
Machine Controller
• Replace Battery
for Data Memory
Back-up.
• Replace Absolute
Pulse Coder
Battery.
Automatic
Workpiece Measuring
Replace Probe Battery.

Maintenance Manual
V1431I-E1E-XC 4-11
4.3 Spindle
4.3.1 Cleaning of Spindle Taper
Press the [EMERGENCY] stop switch prior to performing the
following procedure.
necessary in order to perform the following procedure.
Daily cleaning:
1. Return the tool from spindle to the tool magazine.
2. Move the spindle (Z-Axis) to the operator comfortable down
position.
4. Press the [EMERGENCY] switch to set the machine in the
emergency stop condition.
5. Enter the machining chamber.
6. Clean the spindle taper with white cloth.
• Do not use compressed air inside machining chamber. This
is to prevent cutting chips or fluid entering into the spindle.
The spindle seal gets damaged if cutting chips or fluid
enters the spindle.
7. After cleaning, close the operator door and release the
4.3.2 Sealing Rod (12K – BT (TSC))
Checking Sealing Rod Rubber Seal
• Press the [EMERGENCY] stop switch prior to performing the
• Exercise extreme caution as entry into the machine is

Maintenance Manual
4-12 V1431I-E1E-XC
Daily inspection:
position.
6. Visually check for any damages such as cracks or cutting chips
adhering to the Rubber Seal in the Sealing Rod.
7. Remove any chips adhering to the Sealing Rod. Replace the
Rubber Seal immediately if damaged or worn.
Figure 4-4 Sealing Rod Rubber Seal Inspection
Sealing Rod
Rubber Seal

Maintenance Manual
V1431I-E1E-XC 4-13
4.3.3 Sealing Rod Rubber Seal Replacement (12K – BT (TSC))
Confirm the “Machine Lock” and “Auxiliary Function Lock”
functions are activated prior to entering the machine.
Replacement part:
Name Make Part No. Qty
Rubber Seal Viton 13M11G704 1
Replacement (every 2000 hours):
1. Return the tool from the spindle to tool magazine.
2. Turn ON the [MACHINE LOCK] and [AUX. FUNC LOCK]
switches on the main operation panel.
3. Press the [HANDLE] switch to turn the handle mode ON.
5. Confirm that the [TOOL UNCLAMP] switch is OFF. This put the
spindle in the tool clamped condition (collet closed).
6. Screw the threaded T-wrench into the tapped hole at the end of
the sealing rod.
7. Firmly press the T-wrench in and turn 90° clockwise in (1), (2),
(3), order as diagrammed. This releases the pin catch, and
allows the sealing rod to be pushed out by an internal spring.
8. Put the spindle in the tool unclamped condition (collet opened),
and put out the sealing rod.
9. Replace the rubber seal, and reassemble the unit in reverse
order.
10. After attaching rubber seal to sealing rod, apply small amount
of medium-strength thread adhesive (e.g. Arcloc 2351) to the
inner sleeve threads before inserting into the sealing rod.
11. Adjust seal compression using the inner sleeve so that the
rubber seal projects 0.7 ±0.1 mm from the sealing rod face.

Maintenance Manual
4-14 V1431I-E1E-XC
12. Press the [TOOL UNCLAMP] switch to clamp the spindle. This
completes the replacement procedure.
Sealing Rod
(2VS140A403-01)
Collet
(2VS140A411-01)
Inner Sleeve
(13M11G404=2)
Rubber Seal
(13M11G704)
P9
(Z261A7100901)
T-Wrench
(2VS140A718-01)
(1)
Press(8mm)
Turn the T-Wrench
90° Clockwise
(2)
(3) Sealing Rod is push
out by Internal Spring
PushOut
Press in the
T-Wrench

Maintenance Manual
V1431I-E1E-XC 4-15
4.3.4 O-Ring in Sleeve (20K/30K – HSK)
Checking Sleeve O-Ring(s)
• Press the [EMERGENCY] stop switch prior to performing the
Daily inspection:
position.
6. Visually check for any damages such as cracks or cutting chips
adhering to the O-Ring.
7. Remove any chips adhering to the O-Ring. Replace the O-Ring
immediately if damaged or worn.
Figure 4-5 Sleeve O-Ring Inspection (20K/30K – HSK (A63))
O-Ring
Backup Ring
Sleeve

Maintenance Manual
4-16 V1431I-E1E-XC
Replacing Sleeve O-Rings
• Confirm the “Machine Lock” and “Auxiliary Function Lock”
Replacement part (20K/30K – HSK (A63)):
Name Type Part No. Qty
O-Ring JIS B2401-P12 (Fluorine) Z261A7101201 1
Backup Ring SUN-3BP-12 Z269A1301201 2
Replacement (every 2000 hours or when damage noted):
2. Turn ON the [MACHINE LOCK] and [AUX. FUNC LOCK]
5. Press the [TOOL UNCLAMP] switch to unclamp the spindle.
6. Remove the sleeve with the spanner wrench.
7. Remove the Snap-Ring and the Cap from the sleeve, to access
the O-Ring and 2 Backup Rings.
8. Remove the 2 Backup Rings and O-Ring from the sleeve. Than
install the new O-Ring (B2401-P12) and 2 Backup Rings (SUN-
3BP-12) inside the sleeve.
9. Apply a small amount of medium-strength anaerobic thread
adhesive to the sleeve thread area and install (tightening
torque: 35 Nm).
• Care must be taken to prevent the adhesive from adhering
to the O-Ring.
• Do not switch ON the through-spindle coolant until the
adhesive sets (approximately 10 minutes).

Maintenance Manual
V1431I-E1E-XC 4-17
10. Attach the Cap and the Snap-Ring to the sleeve.
11. Press the [TOOL UNCLAMP] switch to clamp the spindle. This
completes the replacement procedure.
Figure 4-6 Sleeve O-Ring Replacement (20K/30K – HSK (A63))
O-Ring
(B2401-P12)
Sleeve
Backup Ring
(SUN-3BP-12)
CapSnap-Ring
(Ø20)

Maintenance Manual
4-18 V1431I-E1E-XC
Note: Do not leave residual coolant in the spindle
To prevent coolant from remaining in the spindle after using the
through-spindle coolant function, the coolant line is vacuumed for a
certain time period that is set before the unit is shipped. However,
coolant may not be completely vacuumed during this period
depending on the type of tool. In this case, remove the residual
coolant as stated in procedure (a). If the coolant cannot be
completely vacuumed, follow procedure (b).
(a) Adjust the coolant vacuum time for each tool individually at the
Tool Detail Screen.
(b) Discharge air for a fixed time through-spindle air (M77) function.
Condition for coolant duct usage
Make use of the recommended coolant duct (with O-Ring).
Otherwise, coolant may intrude into the spindle-head, and cause
damages to the spindle.
4.3.5 Collet Lubrication (20K/30K – HSK)
• Confirm the "Machine Lock" and "Auxiliary Function Lock"
Lubrication (every 500 hours):
Finished to 0.8S or more
Shank sealed
by O-Ring
Coolant Duct

Maintenance Manual
V1431I-E1E-XC 4-19
2. Switch ON the [MACHINE LOCK] and [AUX. FUNC LOCK]
5. Press the [TOOL UNCLAMP] switch to unclamp the spindle.
6. Spray the front and rear ends of the collet with grease.
• Spray type grease: Kluber L801
• Insufficient lubricant may hinder proper tool clamping.
Figure 4-7 Grease Application for Collet
Spray
Nozzle
Collet
Sleeve
Grease
Spray

Maintenance Manual
4-20 V1431I-E1E-XC
4.4 Feed Axis
4.4.1 Feed Axis Ball-Screw/Linear Guide Grease Supply
Replacement part:
Name Type Part No. Qty
Grease Cartridge
(Manual, 400g)
GKL-2-040 Z192A0200008 1
Manual grease supply (every 500 hours):
The manual grease supply operation is required for machines
without automatic grease supply unit. Move all the axes slowly
(5-10 m/min) and operate the lever for a minimum of 55 times.
Ensure that the cartridge is filled with grease before the start of the
greasing operation.
Figure 4-9 Manual Grease Supply
Grease Pump Lever

Maintenance Manual
V1431I-E1E-XC 4-21
4.5 ATC Unit
4.5.1 Cam Box Lubricant Level Check
• Switch OFF the power supply and perform "Lock-Out and Tag-
Out" prior to performing the following procedures.
Inspection (Bi-Annually):
1. Return all axes to reference position.
2. Open the operator front door as shown in Figure 4-10(a).
Figure 4-10(a) ATC Cam Box Lubricant Level Check
Open
Front
Door
ATC

Maintenance Manual
4-22 V1431I-E1E-XC
3. Remove the ATC Splash Guard, and Check the lubricant level
on the indicator as shown in Figure 4-10(b).
If the lubricant level is above half of the indicator, it is adequate.
If the level is below half of the indicator, replenish the lubricant
by following the procedures as stipulated in Chapter 4.5.2.
Figure 4-10(b) ATC Cam Box Lubricant Level Check
Lubricant at Full Level
Remove
ATC
Splash Guard
Lubricant Level Indicator
Lubricant Level is below half
of the Indicator (Replenish)

Maintenance Manual
V1431I-E1E-XC 4-23
4.5.2 Cam box Lubricant Replenishment
• Switch OFF the power supply and perform Lock-Out and Tag-
Out prior to performing the following procedures.
Replenishment:
2. Remove the ATC Splash Guard as shown in Figure 4-11(a).
Figure 4-11(a) Cam Box Lubricant Replenishment
Replenish the
Lubricant, when
the level is below
half of the
Indicator.
Lubricant
Remove
ATC
Splash Guard
Lubricant Level Indicator

Maintenance Manual
4-24 V1431I-E1E-XC
3. Replenish the specified lubricant from the oil inlet as shown in
Figure 4-11(b).
4. Confirm the lubricant level from the level indicator, as shown in
Figure 4-11(c).
Figure 4-11(c) Cam Box Lubricant Replenishment
Lubricant at Full Level (Adequate)
Figure 4-11(b) Cam Box Lubricant Replenishment
Remove the cap and
replenish the lubricant
until the indicator is at
its full level, as shown
in Figure 4-11(c).
Oil Inlet

Maintenance Manual
V1431I-E1E-XC 4-25
4.5.3 Cam box Lubricant Replacement
2. Remove the ATC Splash Guard, to access the Drain Hole, as
shown in Figure 4-12(a).
Figure 4-12(a) Cam Box Lubricant Replacement
ATC
Splash Guard
Remove

Maintenance Manual
4-26 V1431I-E1E-XC
3. Remove the drain plug to drain the lubricant, as shown in
Figure 4-12(b). Once done install back the drain plug.
4. Fill the lubricant from the oil inlet, until the indicator is at its full
level, as shown in Figure 4-12(c).
Figure 4-12(c) Cam Box Lubricant Replacement
Remove the cap and fill the
lubricant from the oil inlet until
the indicator is at its full level.
Oil Inlet
Lubricant at Full Level
(Adequate)
Figure 4-12(b) Cam Box Lubricant Replacement
Place an oil tray directly
below the Drain Hole.
Than remove the Drain
Plug to drain the lubricant.
Drain Hole
Drain Plug

Maintenance Manual
V1431I-E1E-XC 4-27
4.6 ATC Tool Magazine
4.6.1 Tool Shank Check/Cleaning & Tool Pot Key Check
Daily inspection or cleaning:
1. Check the tool holders and clean the parts specifically indicated
below:
• BT: tool taper, retention knob end surface
• HSK / FHSK: tool taper, tool clamping area clamping face,
lubrication pipe (TSC Only).
2. Confirm the specified o-rings are attached to the tool shanks
properly.
3. Check and clean the outer surface of the pot and Inner surface
of the tapered section to remove chips.
4. Check the pot key visually for damage. If any damage is found,
contact Makino service representatives for assistance.
• Ensure that the lubrication pipes (TSC Only) are attached to
all tool holders.
• Attach the lubrication pipes (TSC Only) to all tool holders.
Spindle is damaged by coolant entering inside if coolant is
discharged without attaching lubrication pipe.

Maintenance Manual
4-28 V1431I-E1E-XC
Figure 4-13(b) HSK Tool Pot
HSK Tool Pot Key
Figure 4-13(a) BT Tool Pot
BT Tool Pot Key

Maintenance Manual
V1431I-E1E-XC 4-29
Figure 4-14 Tool Shank Inspection / Cleaning
Figure 4-13(c) FHSK Tool Pot

Maintenance Manual
4-30 V1431I-E1E-XC
4.6.2 Replacement of ATC Arm Finger Spring
Replacement part:
Name Deta International Part Number Qty
Finger Spring A40C-0007A02 2
2. Remove the Finger Stopper from the ATC Arm, as shown in
Figure 4-15(a).
Figure 4-15(a) Replacement of ATC Arm Finger Spring
Finger Stopper
Unscrew
Unscrew
ATC Arm

Maintenance Manual
V1431I-E1E-XC 4-31
3. Remove the Finger together with the Spring, as shown in
Figure 4-15(b).
4. Replace the spring and apply grease to the spring with a brush,
as shown in Figure 4-15(c).
Figure 4-15(c) Replacement of ATC Arm Finger Spring
Replace Spring Replace Spring
Apply Grease
Apply Grease
Figure 4-15(b) Replacement of ATC Arm Finger Spring
Spring
Finger
Remove
Remove

Maintenance Manual
4-32 V1431I-E1E-XC
4.7 Spindle Cooling Oil Temperature Controller
4.7.1 Checking/Replacing of Cooling Oil
Daily inspection:
1. Check the oil level is between the upper (High) and lower (Low)
limits on the Oil Level Gauge, while the unit is not running. If top
up was done while the unit is running, possibility of over flow
may occur.
2. If the oil is insufficient, replenish following the procedure below:
4. Open the Oil Filler Cap.
5. Add cooling oil up to the upper (HIGH) limit on the Oil Level
Gauge.
Replacement of Cooling Oil for 12K Spindle (every 12000 hrs)
& 20K/30K Spindle (every 4000 hrs)
2. Open Oil Filler Cap.
3. Remove the Drain Port Plug to completely drain the oil.
4. Wrap the threads of the Drain Plug with sealing tape and install.
• When using sealing tape, leave the first two threads free of
tape (varies for different type of sealing tape) to prevent
contaminating the oil reservoir.
5. Add oil up to the upper (HIGH) limit on the Oil Level Gauge.
6. Install the Oil Filler Cap.
• Failure to tighten the Oil Filler Cap will cause the oil to
overflow.
• Tighten the Oil Filler Cap by hand. Do not over-tighten with
a tool.
7. Confirm the oil level with power ON.

Maintenance Manual
V1431I-E1E-XC 4-33
Figure 4-16 Checking/Replacing of Cooling Oil (12K Spindle)
High
Low
Line Filter
Oil Filler
Cap
Drain Port Plug
Oil Level Gauge
Air Filter
Figure 4-17(a) Checking/Replacing of Cooling Oil (20K/30K Spindle)
Line Filter
High
Low
Oil Level Gauge
Air Filter
Oil Filler
Cap

Maintenance Manual
4-34 V1431I-E1E-XC
4.7.2 Cleaning of Air Filter and Condenser Coil
Cleaning (every 160 hours):
2. Pull upward on the handle to remove the air filter.
• The condenser coil is visible after removing the filter.
3. Clean the condenser coil fins with a brush or a vacuum cleaner,
to remove the dust and foreign particles from the gaps between
the fins.
4. Remove dust from the air filter with a vacuum cleaner. Wash
the filter with detergent and rinse with water if necessary. Allow
the filter to dry completely before reinstallation.
• Do not use benzene or thinner.
5. To reinstall, place the air filter into the upper guide from above
and lower into position.
Figure 4-17(b) Checking/Replacing of Cooling Oil (20K/30K Spindle)
Drain Port Plug
Line Filter
Sensor
(LS173)

Maintenance Manual
V1431I-E1E-XC 4-35
Figure 4-18 Cleaning of Air Filter & Condenser Coil (12K Spindle)
The Condenser Coil is
overlapping behind the Air
Filter.
Air Filter
Lift up & remove the Air Filter
Figure 4-19 Cleaning of Air Filter & Condenser Coil (20K/30K Spindle)
Lift up & remove the Air Filter
The Condenser Coil is
overlapping behind the
Air Filter.
Air Filter

Maintenance Manual
4-36 V1431I-E1E-XC
4.7.3 Line Filter & Exhaust Cleaner Element Replacement
• If the filter is changed without reducing the internal pressure, oil
overflow, component damage and serious injury may occur.
Line Filter Element Replacement part:
Line Filter Element Make Type Qty
12K Spindle Hydac 0060D010BN4HC 1
20K/30K Spindle Nihon Pall HC7400SKZ4H 1
Line Filter Element Replacement (every 6000 hours / at alarm):
2. Remove the Bowl to access the Filter Element.
• Prepare a container to collect the dripping oil from the filter.
3. Replace the Filter Element.
4. Reverse the above procedure to reassemble the Filter Element
5. After replacement, switch ON the power supply then allow the
spindle oil flow to check for oil leakage from the filter.
Figure 4-20(a) Line Filter Element Replacement (12K Spindle)
Line Filter
Bowl
Remove the Bowl
to replace the Filter
Element.
Filter Element (Inside)

Maintenance Manual
V1431I-E1E-XC 4-37
Figure 4-20(b) Line Filter Element Replacement (12K Spindle)
Clogging Indicator
If the Line Filter is not clog,
the Indicator will show a
“Green Line”, if it is clogged,
it will show a “Red Line”.
Replace the Filter Element
when the Clogging Indicator
shows a “Red Line”.
Figure 4-21 Line Filter Element Replacement (20K/30K Spindle)
Line Filter
Sensor
(LS173)
Bowl
Remove the Bowl
to replace the
Filter Element.
when an alarm is triggered,
due to clogging of the Line
Filter.

Maintenance Manual
4-38 V1431I-E1E-XC
Element Replacement part (20K/30K Spindle):
Exhaust Cleaner Element Make Model Qty
20K/30K Spindle SMC AMC510-06D 2
Note:
Cleaners are installed to remove the mist accumulated in the
reserve tank. If the cleaners are restricted, the pressure inside the
reserve tank rises and inhibits smooth spindle operation and might
cause spindle oil leakage.
Exhaust Cleaner Element Replacement (every 6000 hours):
1. Remove the side cover to expose the exhaust cleaners (located
on top of the suction pump).
2. Turn the oil case counter-clockwise and remove.
3. Remove the hexagon nut and gasket that hold the element.
4. Pull the element downward.
5. Before replacing the element of the exhaust cleaner, first make
sure that the spindle is not rotating.
6. Turn OFF the NC power and for 1 minute, than turn OFF the
main power supply of the machine.
7. Install the new element, and secure it with the gasket and the
hexagon nut.
8. Screw the oil case into the body and secure it.

Maintenance Manual
V1431I-E1E-XC 4-39
Exhaust Cleaner Element Replacement (20K/30K Spindle)
Exhaust Cleaner
Remove Side Cover

Maintenance Manual
4-40 V1431I-E1E-XC
4.8 Hydraulic Unit
1. Contact Makino service representative immediately should the following
problems occur:
• Oil level decreases excessively: maybe an indication of a machine
malfunction.
• Pressure is out of setting range: extremely dangerous operating
conditions. DO NOT attempt to adjust.
2. Switch OFF the power supply, perform Lock-Out and Tag-Out
procedures and confirm operation has completely ceased prior to
performing the following procedures.
4.8.1 Hydraulic Oil Check/Replacement (12K/20K Spindle)
Daily inspection:
2. Check that the oil level is more than half on the indicator.
3. If the oil level is less than 50%, add the hydraulic oil from the oil
inlet, until the indicator is at its full level, as shown in Figure 4-
22(a). Please note that if top up was done while the unit is
running, possibility of over flow may occur.
4. Confirm the hydraulic oil level with power ON.
2. Open the oil inlet cap.
3. Remove the drain plug to drain the oil completely.
4. Add new hydraulic oil up to the top of the oil level indicator then
close the cap.
• Take care to prevent contamination during hydraulic oil
replacement.
5. Confirm the hydraulic oil level after power ON.

Maintenance Manual
V1431I-E1E-XC 4-41
4.8.2 Line Filter Element Replacement (12K/20K Spindle)
• If the filter is changed without reducing the internal pressure, oil
overflow, component damage and serious injury may occur.
Replacement part:
Make Type Qty
Hydac 0030D010BN4HC 1
Figure 4-22(a) Hydraulic Oil Check/Replacement
12K/20K Spindle
Line Filter
Remove the cap
and replenish the
lubricant until the
indicator is at its
full level.
Oil Inlet Cap
Pressure Gauge
Drain Plug
Remove the
drain plug to
drain the oil
completely.
Oil Level Indicator

Maintenance Manual
4-42 V1431I-E1E-XC
Replacement:
2. Remove the Bowl to access the Filter Element.
• Prepare a container to collect the dripping oil from the filter.
3. Replace the Filter Element.
4. Reverse the above procedure to reassemble the Filter Element
5. After replacement, switch ON the power supply then allow the
spindle oil flow to check for oil leakage from the filter.
Figure 4-22(b) Line Filter Element Replacement (12K/20K Spindle)
Clogging Indicator
If the Line Filter is not clog,
the Indicator will show a
“Green Line”, if it is clogged,
it will show a “Red Line”.
when the Clogging Indicator
shows a “Red Line”.
Bowl
Remove the Bowl
to replace the Filter
Element.
Line Filter

Maintenance Manual
V1431I-E1E-XC 4-43
4.8.3 Hydraulic Oil Check/Replenishment (30K Spindle)
Daily inspection:
2. Check that the oil level is not below 25 mm from the bottom of
the oil reservoir.
3. If the oil reservoir is at low level, add the hydraulic oil until it is
at high level, as shown in Figure 4-22(c).
4. Confirm the hydraulic oil level after the power is switched ON.
Figure 4-22(c) Hydraulic Oil Check/Replenishment
Hydro-Pneumatic Booster for 30K Spindle
Low Oil Level
25 mm
45 mm
High Oil Level
Oil Reservoir

Maintenance Manual
4-44 V1431I-E1E-XC
4.9 Pneumatic Unit
4.9.1 Air Panel Configuration
Figure 4-23 Air Panel Configuration
For CE Only

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