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REGULAR INSPECTION AND MAINTENANCE

Maintenance/Inspection Items
List of maintenance/inspection items
The following list explains the check items and intervals. Carry out the routine inspection on the basis of this list. Inspection positions and corresponding numbers are given further down the list in the illustration. Refer to the list and the illustration together.
Table 4-1 List of maintenance/inspection items Period of inspection Reference sections Number of months in this of operation Daily Weekly manual 1 3 6 12 24 ! ! ! ! 5-1, 7-2-1, 7-2-2 ! ! ! ! ! ! 5-5, 7-2-7 ! !! ! ! ! ! 5-4, 7-2-5, 7-2-6 5-3, 7-2-4 4-4, 5-7, 7-2-9 ! 4-4, 5-7, 7-2-10 ! ! ! ! ! ! ! ! ! ! !

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No.

Inspection point

Inspection item

General

Arranging the machine periphery in order, cleaning the machine and its periphery (especially, the floor) Checking the chuck unit and its periphery to scan for chips Checking for secure mounting of the top jaws Checking for smooth chucking/unchucking

Headstock

Greasing the chuck unit (before operation) Disassembling and Cleaning the chuck Removing any chips from the coolant collector Cleaning the draining holes underneath the spindle front-end cover Checking the tailstock spindle to scan for chips Checking the tailstock body for smooth forward/backward movement

Tailstock

Greasing the linear guide blocks Greasing the ball screw Removing chips sticking to the sheet metal sections on the periphery of the tailstock body Checking for secure mounting of the cutting tools and the holder

Turret

Checking the turret and the cutting tools to scan for chips Checking for tension etc. of milling spindle belt

5-2, 5-4, 7-2-3, 7-2-5

X-axis, Z-axis TOOL EYE (Option) Grease lubrication unit Oil lubrication unit

Wiping away the grease stuck to the tip of the linear guide Checking the backlush of X- and Z-axis

Cleaning the sensor section and removing any chips Checking for sounds of reaction during sensor contact Checking the oil levels, and if necessary, refilling Checking for oil leakage and for damaged piping Checking the oil levels, and if necessary, refilling

Cleaning the oil supply fitler Checking for oil leakage and for damaged piping

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REGULAR INSPECTION AND MAINTENANCE

No.

Inspection point

Inspection item

Period of inspection Reference sections Number of months in this of operation Daily Weekly manual 1 3 6 12 24 ! ! 4-4, 5-6, 7-2-8 ! ! ! ! ! 4-4, 5-10, 7-2-13 ! ! ! ! ! ! 5-8, 7-2-11, ! 5-9, 7-2-12 ! ! ! ! ! 5-10-2, 5-16-2, 5-16-4 ! 6-2-4, 6-3 6-2-4 6-1-2, 6-3-2 5-12, 5-16-5, 5-16-6, 7-2-14 ! ! ! ! ! ! ! ! !!

Checking for appropriate pressure Checking the oil levels, and if necessary, refilling 9 Hydraulic unit Cleaning the strainers Replacing the hydraulic oil Checking for oil leakage and for damaged piping Checking the line filter element, and if necessary, replacing Checking the coolant levels, and if necessary, refilling 10 Headstock cooling unit Cleaning the radiator Cleaning the radiator fan Replacing the coolant Checking the coolant levels, and if necessary, refilling Checking the degree of dirtiness of the filters and cleaning 11 Coolant unit Checking the degree of dirtiness of the coolant and if necessary, replacing Cleaning up the chips (Side-pullout chip conveyor specifications) 12 Air unit Checking the element and if necessary, replacing Checking the air pressure Checking if the door is fully closed Electrical control cabinet Checking the electrical components for dirt and discoloration and checking for loose terminal screws Cleaning inside and outside fans of the electrical control cabinet Checking the degree of dirtiness of the filters and cleaning 14 15 16 Connectors Foundation Grounding resistance Slideway and covers Checking for loose connector/terminals between units Checking the electric cables Checking and adjusting the bed level using a level Checking for a grounding resistance of 10 ohms or less (use a 500 V megger) Checking the wipers for abnormalities such as damage 17 Checking the front door safety glass for abnormalities such as damage Checking for the accumulation of chips, and if necessary, cleaning 18 Machine internal covers (Operator door circumference, cover for the lower part of the headstock, cover for the upper part of the turret, cover for the lower part of the turret, Z axis way cover, tail axis rear cover) Cleaning the chips on the steady-rest-roller and connect pins Confirming whether the steady rest arm operates smoothly 19 Steady rest Cleaning the chips accumulated around the steady rest Greasing the linear guide blocks Checking the wipers in the duct for abnormalities such as damage 5-11

13

4-3, 5-5-5, 5-11-4, 5-12

!! !! ! ! ! ! ! !

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REGULAR INSPECTION AND MAINTENANCE

Inspection point

Inspection item

Period of inspection Reference sections Number of months in this of operation Daily Weekly manual 1 3 6 12 24 5-13-1 5-13-2 5-13-3 5-13-4, 5-13-5 5-14-1 5-14-4 !! !! ! ! ! ! !! 5-15-2 ! 5-16-2 ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! !

Checking for secure mounting of cutting tools and milling holders 20 Milling holder Checking the turret, milling holders and the cutting tools to scan for chips Checking for entry of coolant into milling holder Checking for looseness of eccentric pin mounting bolts Automatic operator door opening/closing Coolant temperature control Battery unit Belt tension adjustment Checking the safety switch and if necessary, replacing Checking the degree of dirtiness of the oil pan filter and cleaning Checking and cleaning the chiller unit air filter Replacing the batteries in the battery unit

21

22

23

Note 1: Maintenance check intervals are determined on the basis of eight hours operation a day. Note 2: Actual inspection intervals differ according to the particular operating conditions of the machine and frequency of use. Understand that the listed values are for reference only.

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REGULAR INSPECTION AND MAINTENANCE

4-3-2

Points of inspection items


10 4

19 2 Fig. 4-2 Inspection point of machine (1/3) 6

12

11 8 7 9

13

Fig. 4-3

Inspection point of machine (2/3)

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REGULAR INSPECTION AND MAINTENANCE

21

Fig. 4-4

Inspection point of machine (3/3)

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REGULAR INSPECTION AND MAINTENANCE

Cover to fill the gap

When cleaning this part, remove the cover used to fill the gap (Refer to the figure above) and while the door is closed, shove the chips to the inner side of the machine with a brush.

Fig. 4-5

Cleaning sections of the machine internal covers

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REGULAR INSPECTION AND MAINTENANCE

Supplying Oil and Coolant


1. Lubrication points ! When supplying or exchanging coolant, hydraulic oil and lubricating oil, use only oil brands recommended by MAZAK. Use of another brand of oil will cause machine malfunction and will damage the machine. Use the appropriate amount of the recommended brand of oil when adding or changing oil. A. Hydraulic unit
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CAUTION

1 4 5 3 2

Fig. 4-6

Lubrication points (1/7)

Fig. 4-7

Lubrication points (2/7)

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REGULAR INSPECTION AND MAINTENANCE

B.

Headstock cooling unit/Chuck

10

11

8 Lubrication points (3/7)

Fig. 4-8

C.

Ball screw & Slideway (Tailstock) grease lubrication unit

Fig. 4-9

Lubrication points (4/7)

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REGULAR INSPECTION AND MAINTENANCE

D.

Slideway (Steady Rest: Option)

Fig. 4-10

Lubrication points (5/7)

E.

Grease lubrication unit

Fig. 4-11

Lubrication points (6/7)

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REGULAR INSPECTION AND MAINTENANCE

F.

Oil lubrication unit

12 13

14

Fig. 4-12

Lubrication points (7/7)

2.

List of oil and water supply


Table 4-2 No. 1 2 3 4 5 6 Oil and water supply Lubrication point Qty Recommended oil Remarks Exchange oil every 6 months, then clean the strainer. Refer to

Part name Oil filler port Level gauge Strainer Drain plug Line filter Cartridge

Hydraulic unit

20 L

" "

MOBIL DTE 24

SHELL TELLUS OIL 32 Replace the line filter element every 6 months. Automatic lubrication. Supply occasionally.

5-6

Ball screw & slideway Ball screw & Slideway (Tailstock) Slideway (Steady Rest)

400 mL Cartridge " 28 mL Citrax EP No. 1 (Kyodo Yushi)

Grease supply nipple Grease supply nipple Tank

Manual Lubrication Supply every 6 months.

5-7

12 mL " Distilled water or ion exchanged water: 50% LONG LIFE COOLANT YZ (MOBIL)*: 50% Exchange coolant every 2 years. Follow the procedure outlined MACHINE TOOL LONG in the Maintenance LIFE COOLANT Manual. (MOBIL) Klueberpaste ME 31-52 (KLUEBER Every day LUBRICATION) MOBIL VACTRA OIL No. 2 SHELL TONNA OIL S68 Automatic lubrication. Supply occasionally. Clean the filter every year.

Headstock cooling unit 10 Oil filler port

5.0 L "

5-10

11 12 13 14

Grease supply nipple Oil filler port Level gauge Suction filter

" Chuck C-axis brake (Milling machine) Turret index gear (Oil lubrication unit) 1.8 L 1 to 2 mL

5-1-2

" "

5-7-3, 7-2-10

LONG LIFE COOLANT YZ is a special brand for Yamazaki Mazak. The replacement period is determined on the basis of eight hours operation a day. Delayed replacement or use of any product other than recommended oil may damage the machine.

Note:

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REGULAR INSPECTION AND MAINTENANCE

Processing of the Lubricant Collection Tube


After lubrication of the turret rotation gear and the C-axis brake, the oil accumulates in the oil sump in the center of this machine on its rear side and is discharged through the tube. Waste oil is collected in the attached waste oil can.

Waste oil collection tube Waste oil can (Standard accessories)

Fig. 4-13

Processing of the lubricant collection tube

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