Makino F3F5 Install Manual

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o MAKINO
VERTICAL MACHINING CENTER
INSTALLATION MANUAL
V1431I-I1E-XB
/h WARNING
1. Do not maintain, inspect or repair this machine before carefully reading

and understanding this manual.
2. Store this manual in a clearly marked location for easy reference when
maintaining, inspecting or repairing this machine.
This machine, including technical data and software, may be subject to

the Japanese Foreign Exchange and Foreign Trade Law. Prior to any re¬
sell, retransfer or re-export of controlled items, please contact Makino to
obtain any required authorization or approval.
i
Installation Manual Fi/FI>
MACHINE MODEL F3/F5
CONTROLLER TYPE Professional 5
COMPANY NAME
This manual is developed for the use of Makino customers to help and guide in making all
necessary pre-installation arrangements for F-Series machine.
1st Release Date: 26 August 2009

Revision(s) Date: -
Copyright © All Rights Reserved
• No part of this manual may be reproduced or transmitted by any means or in any form
to parties other than which it is intended, without the expressed written permission from
Makino.
• All specifications and designs may change without notice.
• Every attempt was made to ensure that the information in this publication was correct
at the time of printing. As specifications and designs change, Makino is not responsible
for information that becomes incorrect or inaccurate after publication.
V14311-11 E-XB 2
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Installation Manual Fl/FS
Contents
1. Introduction 5
1.1 Machine Characteristics 5
1.2 Components and Machine Function 5
2. Safety Precautions 6
2.1 Introduction 6
2.2 Danger, Warning, Caution Statements and Symbols 6
2.3 Installation Safety 9
3. Specifications 12
3.1 Introduction 12
3.2 Mechanical and Electrical Specification 13
3.3 Makino Professional 5 and Control Specifications 16
3.4 General View and Dimensional Drawings 19
3.5 Tooling Specification 30
4. Pre Installation Process 31
4.1 Introduction 31
4.2 Selecting the Machine Location 31
4.3 Foundation 33
4.4 Floor Plan and Marking 34
4.5 Power Supply and Cables 34
4.6 Transformer (Option) 36
4.7 Earthing/Grounding Preparations 37
4.8 Air Supply 37
4.9 Machine Handling Facilities 38
4.10 Service Facilities 38
4.11 Toolings and Fixtures 38
4.12 Coolant Requirements 55
4.13 Oil and Grease Requirements 55
4.14 Machine and Data server communication 56
4.15 Cables for direct connection to a computer without a network HUB 57
4.16 Installation Tooling Requirements (By FSE) 58
4.17 Pre-Installation Checklist 60
V1431I-I1E-XB 3
Installation Manual F3/FIS
5. Machine Delivery 64
5.1 Introduction 65
5.2 Container Layout 65
5.3 Inspect the Machine 66
5.4 Unloading Lifting and Moving 66
5.4.1 Lifting the Machine 66
5.4.2 Lifting the Front Coolant tank 69
5.4.3 Lifting the Chip Conveyor 70
5.4.4 Lifting the Rear tank 71
5.4.5 Lifting the Transformer 72
5.4.6 Machine Rolling 73
5.5 Initial Cleaning 75
5.6 Machine Packing list . 75
6. Installation Process 76
6.1 Introduction 76
6.2 General Instructions 76
6.3 Installation Process 76
6.3.1 Installation of ATC covers 76
6.3.2 Installation of Spindle Oil Cooler 78
6.3.3 Installation of Transformer 84
6.3.4 Installation of Z axis motor . 85
6.3.5 Installation of Z axis Cable chain 86
6.3.6 Installation of Air Dryer (Option) 87
6.4 Procedure for Machine Leveling 93
6.5 Installation Procedure for S Series Coolant tank 95
6.6 Installation Procedure for Rear coolant tank with chip bucket (option) 97
6.7 Installation Procedure for Rear coolant tank with hinge belt/scrapper Lift up chip
conveyor 99
V14311-11 E-XB 4
Installation Manual Fi/FS
1. Introduction
1.1 Machine Characteristics
F-Series machines are the versatile Vertical Machining Centers with high reliability and
rigidity built on proven design concepts to achieve high productivity and high-speed
machining efficiency especially for the Die and Mold industry.
The main characteristic features of the machine, which contributes to high productivity are
achieved by high speed, GI.3 and SGI Control, high axes rapid traverse rates and high
axes acceleration, sustainable inter-plane geometrical accuracy, reducing cutting time
with high speed and high power machining and also reducing the non cutting time with
faster ATC and special Makino Professional 5 Control functions for simultaneous
operations
1.2 Components and Machine Function
F-Series machines are 3-axis Vertical Machining Centers of fixed column type, the units of
which machine are comprised of bed, column, and the X, Y, Z axes are driven by
servomotors:
• The X-Axis, which is an integrated unit, comprises of the Z-axis and the spindle,
moves left and right.
• The Y-Axis carries the table and is on the bed, moves back and forth.
• The Z-Axis, which is housed on X-axis moves up and down. The spindle housing is
mounted to the Z-axis.
• The spindle is of high speed with a maximum spindle speed of 12000 rpm (optionally
20000 rpm) with power of 22kW.
• Viewed from the machine front, is the NC control panel on the right side and ATC
magazine on the left side and the operator door is at the center.
• The chip disposal is to the chip bucket at the front tank, into the 130t front coolant tank.
• The electrical cabinet, oilmatic, hydraulic and pneumatic systems are located at easily
accessible locations at the rear and side of the machine. The cable and hoses are
neatly routed into the column.
V14311-11 E-XB 5
2. Safety Precautions
2.1 Introduction
This chapter provides general safety guidelines that, if followed, promote a safer working
environment.
Safety precautions and special considerations for all machining operations must be
thoroughly understood by the operator. Careless use of the machine may result in a
personal injury and machine damage. Read this pre-installation Manual thoroughly in
order to install the machine safely. Study all safety precautions and functions before
installing this machine.
Designate specific operators of this machine and provide thorough safety training for all
personnel involved in the operation, maintenance and inspection of this machine. It is
strongly recommended that a copy of this Pre-Installation Manual is easily accessible to
everyone and also kept near the machine at all times.
2.2 Danger, Warning, Caution Statements and Symbols
It is important that all employees recognize each safety symbol on the machine and
understand the meaning of Danger, Warning, and Caution.
These safety labels must never be removed, covered or painted over, and must be
replaced if they are damaged, defaced, or become unreadable. Table 2.1 presents the
meaning of each safety statement. It is important that all employees recognize and
understand the meaning of the safety symbols. The location of safety symbols for specific
hazards on F-Series is shown in Figure 2.1.
V14311-11E-XB 6
Installation Manual Fi/F
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leading to serious
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door to enter, Use care when before cycling ATC.
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Figure 2.1: Locations of Safety symbols
V14311-11E-XB 7
Installation Manual F3/F!
Table 2.1: Definitions of Danger, Warning & Caution statements
Statement Meaning
DANGER DANGER is the most severe safety statement. This statement
means that either severe personal injury or death may result if the
instruction(s) is not followed._
WARNING WARNING is the next level of safety statement. It indicates that if
the instruction(s) is not followed severe personal injury could
result. _
CAUTION CAUTION is the least severe safety statement and indicates that if
the instruction(s) is not followed damage to the equipment may
result. _
2.3 Installation Safety
The following information is related to installation of the machining center:

• Adhere strictly to the installation instructions provided in the Pre-Installation Guide.
•. Make a thorough check of the mechanical and electrical units used for machine moving
and installation to make sure that they are working in good and safe conditions, before
the arrival of the machine.
Lifting Safety
All persons responsible for lifting must follow these lifting safety precautions. This includes,
but is not limited to lifting machinery, machine components, and work pieces:
• All lifting equipment must be properly rated for the weight being lifted.
• All lifting equipment must be inspected on a regularly scheduled basis.
• Any lifting device found to be defective must be repaired in accordance with industry
standards.
Slings
When using slings:
• Never exceed the lifting capacity of any sling.
• Protect slings with heavy padding when lifting objects with sharp edges.
Chains
Lifting chains must be stored properly to prevent damage when not in use. When using
chains:
• Never exceed the lifting capacity of any chain.
• Do not drag chains.
• Do not allow chains to become tangled or kinked.
• Never twist chains in an attempt to shorten their length.
• Use proper devices to shorten a chain's length.
• Use chains equipped with enclosed lifting hooks.
Hooks
When using hooks:
• Never exceed the lifting capacity of any lifting hook.
• Do not repair lifting hooks.
• Destroy and discard bent lifting hooks.
V14311-11E-XB 8
Eye Bolts
To ensure a safe load carrying capacity:
Never exceed the lifting capacity of any eyebolt.
• An eyebolt must be engaged to at least 90 percent of its threaded portion.
• Never weld or heat an eyebolt to a temperature in excess of 480°C (900°F). Heat
exposure can change the physical properties of the stock and create an unsafe
eyebolt.
• Never use an inch eye bolt in a metric thread or vice versa.
• Use inch series thread eyebolts in inch series threads.
• Use metric series thread eyebolts in metric series threads.
• Never use a painted or coated eyebolt as this may cover up defects.
• Discard and destroy any defective eyebolts.
Rings
When using rings:
• When possible use a lifting ring or clevis instead of an eyebolt.
• Secure the lifting ring with the correct inch/metric series bolt.
• Never exceed the lifting capacity on any lifting ring or clevis.
Machine Electrical Devices
When a electrical devices is used:
• Use only industry standard approved electrical testing equipments.
• Always replace defective electrical components, like fuses, shunts, overloads, etc., with
components of the same capacity and rating as the original equipment.
• If you are unsure of the correct electrical component or part, refer to the machine's
electrical drawings or consult Makino.
Machine Grounding
All Makino machining centers must be properly grounded at the time of installation.
• Proper grounding requires an isolated earth ground.
• Ground the machine in accordance with local, state, and federal regulations.
Lifting the Machine or Components
Use only a lifting device and related equipment with rated capacity, to lift the total weight of
the machining center (and shipping skid, if the skid is attached during lifting). Always follow
the lifting instructions provided in this pre-installation guide. In addition:
• Only qualified riggers should perform machine-lifting operations.
• Never place any portion of your body beneath a suspended object.
• Lift the machining center only at the designated lifting points.
• Never lift the machine higher than necessary.
• Always maintain the center of gravity, by properly adjusting the lengths of lifting device.
Before lifting, refer to shipping documents to obtain the weight of the
B machine or component being lifted. If the necessary weights cannot be

determined, consult Makino.
V14311-11E-XB 9
Installation Manual F3/F5
Lifting Work-pieces and Fixtures
Always use a lifting device and related lifting equipment that is of rated capacity, for the
work piece or fixture being lifted.
• Never place hands, arms, feet, or any other portion of your body beneath a suspended
work piece fixture.
• Always maintain the center of gravity by properly adjusting the lengths of the lifting
device.
Always display the emergency contact numbers near the machines. Keep a
certified first Aid Kit available near the machine and easily accessible.
V14311-11E-XB 10
)
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3. Specifications
3.1 Introduction
This chapter contains the specifications for the machine’s main components (units), the
general arrangement of the machine, floor plan dimensional drawings, Makino Pro 5
control, tooling and various optional features. The outline view of F-Series machine is
shown in Figure 3.1.1.
The specifications indicated are subject to change without prior notice as part of
continuous design improvement and market requirements.
Information Subject to Change
Every effort is made to ensure the accuracy of the data presented in this chapter
at the time of its publication. Machine & control specifications are subject to
change without prior notification as part of continuous design improvement and
market requirements. For the exact machine specific details please refer to the
specifications for which your machine has been ordered and supplied.
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Figure 3.1.1 General view of F3
V14311-11E-XB 11
Installation Manual Fl/F
3.2 Mechanical and Electrical Specification
The table below outlines the brief general machine specification.
MACHINE STROKES
Axes Travel 650x500x450 mm 25.59x19.68x17.72 in
X,Y,Z (F3)
Axes Travel 900x500x450 mm 26.77x19.68x17.72 in
X,Y,Z (F5)
Table top
Spindle face
to 150-600 mm 5.9 - 23.63 in
TABLE
Size of Table (F3) 850x500 mm x mm 33.46x19.68 in x in
Size of Table (F5) 1000x500 mm x mm 39.37x19.68 in x in

Table Load Capacity (F3 650 Kg 1433 Lbs
&F5) _
Maximum Work Size on 850x500x450 mm x mm x mm 33.46x19.68 x17.72 in x in x in
Table (F3) _
Maximum Work Size on 1000x500x450 mm x mm x mm 39.37x19.68x17.72 in x in x in
Table (F5) _
T-Slot Size 18H8 mm 0.70866H8 In
T-Slot Pitch 100 mm 3.94 In
Tapped Hole Size M16
SPINDLE HEAD 12,000 RPM

Spindle Speed Range 120-12000 (ASPAC)/130-13000 (US) RPM
Spindle Power 15min/cont 22/18 kw 29.5/24.14 hp
Maximum Torque 15min/cont 117/95 Nm 1035.5/840.8 Lbf-in
Spindle Nose MAS 403-BT40 / DIN 69871-A40 / JIS B6339-40T

Spindle Oil Cooling System Jacket Cooling
Tool Clamp Force 8800 + 5% N 1978 + 5% l Lbf
Spindle Speed Range 200-20000
Spindle Power 30min/cont 15/11 kw 20.4/14.7 HR
Maximum Torque 30min/cont 32/19 Nm 283.2/168.2 Lbf-in
Spindle Nose MAS 403-BT40 / DIN 69871-A40 / JIS B6339-40T / HSK-
A63
Spindle Oil Cooling System Core Cooling and Jacket Cooling
Tool Clamp Force (BT40) 8800 ± 5% N 1978 ±5% Lbf
Tool Clamp Force (HSK) 17600 + 5% N 3957 + 5% Lbf
V14311-11E-XB 12

Spindle Speed Range 300-30000 RPM
Spindle Power 15min/cont 15/11 kw 20.4/14.7 hp
Maximum Torque 15min/cont 20.4/14.6 Nm 180.5/129.2 Lbf-in
Spindle Nose MSK-F63

Spindle Oil Cooling System Core Cooling and Jacket Cooling
Tool Clamp Force 13600 ±5% IN l 3057 + 5% l Lbf
ATC
No. of Tools 20/30 (Option)
Tool Change Time 1.3 (tool to tool) sec
Max. Tool Diameter 114/76.2 (ATC20/ATF5) mm
130 (with alternate pocket
empty) _
Max. Tool Length 300 mm
Max. Tool weight 8 k£L
PNEUMATIC SUPPLY
Min. Pressure 5 Kg/cm3 71 Lbs/in2
Consumption 0.4 M3/min 106 Gal/min
POWER SUPPLY
200/220 V | 3 phase, 50/60 Hz 40 KVA
EQUIPMENT POWER CHART

Spindle (12K) 22/18 Kw 29.5/24 Hp
Spindle (20K) 15/11 KW 20.1/14.7 HP
Spindle (30K) 15/11 KW 20.1/14.7 HP
Axis Feed - X Axis 4.2 Kw 5.6 HR
Axis Feed - Y Axis 4.2 Kw 5.6 HP
Axis Feed - Z Axis 4.2 Kw 5.6 HR
ATC Magazine 0.5 Kw 0.7 HR
Spindle Cooler (12K) 1.6 Kw 2.1 Hp
Spindle Cooler (20K) 3.07 Kw 4.1 Hp
Coolant Pump - Nozzle coolant 0.925 Kw 1.2 Hp
Coolant Pump - Through Spindle Coolant 1.5 Mpa 2.2 KW 3 HP
Coolant Pump - Through Spindle Coolant 3 Mpa 3.7 KW 4.7 HP
Hydraulic Unit 1.5 KW 2 HP
V1431I-I1E-XB 13
CUTTING CHIP DISPOSAL OPTIONS
Reservoir Capacity 130 I 79.2 gal
Nozzle Coolant Pressure 0.2 Mpa 29 psi

Volume 80 l/min 23.8 gal/min
Coolant Flush Pressure 0.2 Mpa 29 psi
Volume 80 l/min 23.8 gal/min
Through Spindle Pressure 1.5 Mpa 217 psi
Coolant Volume 80 l/min 23.8 gal/min
SIZE OF MACHINE
Machine Height 3065 mm 120.6 in
Floor Space 2440x2625 mm x mm 98.6x102.8 in x in

(WxD)
Weight 7300 Kg 16,534 lbs
V14311-11E-XB 14
Installation Manual Fi/FE
3.3 Makino Professional 5 and Control Specifications
Axes control
Number of simultaneous controllable axes
Optional max, no. of simultaneous controllable axes
Input command
Automatic recognition of EIA RS244 / IS00840 tape code
Max. programmable dimension
Absolute/incremental programming G90, G91
Decimal point/calculator type decimal programming
Programming plane selection G17, G18, G19
Least input increment
Inch/metric conversion G20, G21
Interpolation
Positioning GOO
Linear interpolation G01
Circular interpolation G02, G03
Exponential interpolation G02.3, G03.3
Polar coordinate interpolation G12.1, G13.1
Cylindrical interpolation (require rotary table) G07.1
Helical interpolation G02, G03
Involute interpolation G02.2, G03.2
Hypothetical axis interpolation G07
Conical/spiral interpolation G02, G03
NURBS interpolation G06.2
Feed
Cutting feedrate clamp : F direct command
Cutting feedrate override%
F 1-digit code feed (F1 ~ F9)
Jog override
Dwell (per second) G04
Feedrate override cancel M48/M49
Program Memory, Edit

Program number search
Sequence number search
Parity check (horizontal & vertical)
Part program storage memory - 160m/320m/640m/1280m/2560m/5120m
V14311-11E-XB 15
Installation Manual FB/FB
Number of registerable program - 120/250/500/1000/2000/4000
Part program editing
Background editing
Extended part program editing
Operation, Display
Automatic operation (memory)
Machining time stamp
Clock, calendar function
Run-hour and part count display
Dynamic graphic display
PNC operation
MDI unit standard full key
12.4" color LCD
Manual pulse generator on Operator panel
I/O Functions
Data Input/Output interface - Channel 1 (RS-232C)
S,M,T Function
Miscellaneous (auxiliary) function M x-digit
Spindle speed direct S-code, 5 digits
Tool function, 4 digits
Tool Compensation
Tool length compensation G43, G44/G49
Tool offset pairs - 64/99/200/400/499/999/
Tool offset memory A (Geometry Wear)
Tool offset memory B (Geometry/wear)
Tool offset memory C (Geometry/wear, cutter/tool length)
Tool offset
Cutter compensation C G41, G42/G40
Coordinates
Reference position return G28
Reference position return check G27
2nd reference position return G30
3rd/4th reference position return G30
Floating reference position return G30.1
Machine coordinate system selection G53
V14311-11E-XB 16
-
Workpiece coordinate system selection G54 G59
Workpiece coordinate system preset G92.1
Automatic return from reference position G29
Coordinates
Local coordinates setting G52
Work coordinate system setting G92
Machine coordinate selection
Manual reference position return
Operation support
Label skip
Manual absolute ON and OFF
Tool length measurement
Help function
Machine lock
Mirror image for X-axis and Y-axis M21, M22/M23
Block skip
Optional stop M01
Program stop MOO
Z-axis feed neglect
Follow up
Sequence number comparison and stop
Program restart
Dry run
Single block
Manual handle interruption
Skip G31
High-speed skip
Programming support
Normal direction control G41.1, G42.1/G40.1
Chamfering / corner R
Programmable data input (offset, parameter) G10
Sub program call (4 folds nested)
Custom macro
Addition of custom macro common variables 600 numbers
Interruption type custom macro
Canned cycles for drilling
Small-hole peck drilling cycle
V14311-11E-XB 17
Installation Manual Fi/Fl
Circular interpolation by R programming
Scaling G51/G50
Coordinate system rotation G68, G69
Programmable mirror image G51.1/G50.1
Rigid tapping G84.2, G84.3, M135
Programming support
Playback
Tapping mode G63
Cutting mode G64
Exact stop mode G61
Exact stop G09
Automatic corner override
Machine Accuracy Compensation

Backlash compensation
Stored pitch error compensation
Single direction positioning G60
Safety and Maintenance

Interlock
Self-diagnosis function
Alarm history display
Emergency stop
Stored stroke check 1
Professional 5
GI.3 control
Data server
Super GI.4 control
NANO smoothing function for DM application only
Data center A - 160MB
Data center B
Data center (special request high capacity) - 800MB -
The specifications indicated are subject to change without prior notice as

part of continuous design improvement and market requirements. For the
exact machine specific details, please refer to the specifications for which
your machine has been ordered and supplied.
V1431I-I1E-XB 18
3.4 General View and Dimensional Drawings
Different important views and machine dimensional drawings for different options of F-
Series machine are outlined in this chapter. Figure 3.4.1a shows the machine general view
and assemblies for F-Series machine.
PNEUMATIC PANEl
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V14311-11E-XB 19
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V1431I-I1E-XB 23
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V14311-11 E-XB 24
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V14311-11 E-XB 25
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V1431I-I1E-XB 26
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V14311-11E-XB 27
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V1431I-I1E-XB 28
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V14311-11E-XB 29
3.5 Tooling Specification
Preparation of tooling and fixtures typically require long lead times. These two issues
should be addressed before the delivery of the machine. Refer section 4.11 tooling and
fixtures for detailed tooling drawing specifications for different options available on Sseries
machine.
Fixtures
Consider design and manufacturing time, and co-ordinate completion with the delivery of
the machine for a smooth transition into production schedule to avoid unnecessary
underutilization of the machine.
Tooling
The three most important factors to understand and consider when selecting tool holders
and cutting tools for high-speed machining are balance, concentricity, and rigidity. All
highspeed spindles have limitations. Know the spindle design and limitations. Ensuring
machining applications are within the spindle’s allowable radial load and side thrust, will
maximize machine utility, parts production, and machine component and spindle life.
When selecting tooling:

• Tool holders should be designed for the highest rpm available on the spindle. Never
exceed the manufacturer’s design ratings for the tool.
• Tool holders should be designed for high-speed machining. Look for good tool holding
ability, balance, and concentricity.
• Never use Weldon or side lock holders at high rpm.
• Use the shortest possible tool.
• Select the shortest tool holder and cutting tool allowed by the part geometry. Short
tools provide better tool life and surface finish while reducing radial load on the spindle.
V14311-11E-XB 30
4. Pre Installation Process
4.1 Introduction
This chapter describes installation process and contains guidelines to prepare customer
for the delivery and installation of the F-series High-speed Machining Center. It establishes
clear expectations and responsibilities for all concerned.The success and efficiency of
installation rests, in large part on the participation and involvement of customer in the
installation process. Fifteen days before the delivery of your Makino machine take time to:
Review the information and requirements related to pre-installation.
Establish a time-line and detailed schedule for completion of these items.
The Pre-Installation checklist outlines key tasks to prepare for machine delivery and
installation. The items checked in the “required” column must be completed for an efficient
machine installation. Use the resources in this guide to accomplish the pre-installation
tasks:
• Selecting machine location (access, environment, and foundation), refer section 4.2
• Dimensional drawings are provided in section 3.4 to determine required floor space
and clearances.
• Electrical, Service, Air requirements and connection details
• Unloading, moving.
• Preparing tooling and work holding devices.
4.2 Selecting the Machine Location
Key factors in selecting the machine location include:
Required total floor Space
Required Room Space
Easy accessibility
Manufacturing Process
Environment for machine working
Total Floor Space

The machine foot print area plus the total working area required around the machine for
tooling, workpiece storing and movement, utilities and also for future maintenance is
considered. For the machine footprint refer to machine floor plan.
Room Space
The total floor space and the total safe height of the room in which the machine is located
considered.
Easy Accessibility
The machine placement must have sufficient room for safe access around the machine
and for all cabinet doors and panels to swing completely open. Remember to ensure a
path from the truck to the machine site that provides sufficient width, height, and swing
clearance to accommodate the machine rigging and moving equipment like the mobile
crane, forklifts and over-head crane. Failure to ensure sufficient moving room could result
in unnecessary delays in machine installation and additional cost. There should also be
easy accessibility for safe discharge of chips and used coolant. Refer section 3.4 for
machine external dimensions and floor plans, for various machine options.
V14311-11E-XB 31
Manufacturing Process
Ideally the machine should be placed closest to the process it supports. This placement
reduces handling costs and improves communication between process steps.
Environment for Machine Working

Proper environment and foundation are of the utmost importance. These two factors, more
than any others, ensure machine accuracy and dependability. A sub-standard environment
can cause control, machine, and component failures of all types. Do NOT locate the
machine:
• In direct sunlight.
• Near a source of heat.
• In a place subject to large temperature variation.
• Near a source of extreme metallic dust, such as grinding machines, etc.,
• Near a source of severe vibration, this may affect accuracy and alignments. If the
machine must be located in such an environment, we recommend a separate
foundation with an expansion strip to absorb the vibration.
The machine location should meet the following conditions:

• Dust-free, well lighted, and free of temperature changes.
• Ambient Temperature : 10 to 40° C, optimum 24±2° C
• Temperature Fluctuation : 1° C/30 minutes or less
• Relative Humidity : 35 to 70% (no condensation)
• Dust Free: 0.3mg/m3 or less
• Freely flowing air.
• Available floor and bench space for storing raw and finished work pieces, tooling, and
inspection equipment.
• Enough room for maintenance work. Adequate space around machine and clearance
to fully open cabinet doors.
• Adequate and proper sized utilities are available: electrical powers supply, clean and
dry air supply, etc.
• foundation flat and strong enough to support the weight of the machine without
A
appreciable deflection.
V14311-11E-XB 32
Installation Manual FWFB
4.3 Foundation
B
To ensure machine accuracy and performance, customers must comply
with all installation and foundation requirements. Failure to comply may
void the accuracy portion of the warranty. Consistent accuracy can only be
guaranteed on a reinforced concrete foundation that meets the minimum
specifications for the machine.
A reinforced, isolated, concrete floor is the best foundation to minimize vibration and
deflection. Refer Figure 4.3.1 for details on foundation drawings. The concrete pad should
be continuous, flat, and strong enough to support the weight of the machine without
appreciable deflection. Do NOT place machine on separate sections of concrete. As a rule
of thumb, the foundation must meet the following specifications:
• Minimum ground resistance of 5 ton / m2
• (The soil below the concrete medium or large sized crushed stones can be used)
• Minimum thickness of foundation is 300mm.
• Foundation should extend a minimum of 300 mm beyond the machine boundary.
• Minimum anti vibration Isolation around the Foundation is of 100 mm thick and it is also
recommended that a 19-mm (3/4-inch) expansion strip be placed at the perimeter of
the foundation to absorb some vibration
• Floor Level should be within 3.2mm/m.
• If the floor does not meet these specifications, a special foundation is needed to
maintain machine level and alignment. If you are considering a special foundation,
contact Makino.
• The steel reinforcement of the steel inside the concrete should be of D10@230
• Type of Concrete should be of grade FC180 or more.
• When locating the machine on an upper floor of a building, be sure to:
o Consult a structural engineer for load bearing capacity.
o Consult Makino for acceptance or stipulations on this arrangement.
o Locate the machine over a pillar or supporting beams to provide a minimum
vibration environment. If necessary, install one or more pillars under the
machine to provide enough support to keep the machine level and maintain
alignment.
V1431I-I1E-XB 33
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Note:
This foundation is an example of reinforced concrete thickness 300mm.
These data are given, assuming that allowable bearing capacity of soil is 5ft/sq m.
For the rubbles, medium or large sized crushed stones should be used.
The concrete more than FC 180 should be used.
Symbol ‘a’ shows the Machine Support points.
Machine weight, standard 7500 kg.
V1431I-I1E-XB 34
4.4 Floor Plan and Marking
Floor plan for F3 and F5 machine is given in Section 3.4 describes the location of various
machine units and its accessories. After completion of the foundation work, clearly mark
on the floor, location of the basic machine, the transformer, and other optional units as
applicable to the machine ordered, and as per the layout given.
Markings for the gangway, locations for placing the work piece, toolings, and other
intended requirements near the machine are also to be done before locating the machine.
Clear marking of the plan layout helps in machine installation and avoids unnecessary
problems in locating other intended necessary units around the machine and moving
space around the machine.
Clean the floor area completely before marking, and make sure that all factors are
considered before marking. Use a bright paint or marker to mark the location.
4.5 Power Supply and Cables

A 3-phase power source, with stable voltage regulation (±10%), a ground of 25 ohms or
less and a 125A breaker must be provided. The customer must:
• Provide a properly sized electrical service box for the machine. Use local Code
and Table 4.6.1 to assist in sizing the machine electrical service.
• Ensure the electrical service voltages meet all requirements.
• Install an additional automatic voltage regulator/Stabilizer if the required voltage
cannot be maintained within ±10%. (Customer should plan for the location of the
Stabilizer in case used based on the type and dimensions of the unit).
Table 4.5.1gives the total power supply, the cable size and type required for F3 and F5
machine.
S/N Description Data

125A for 230/346 VAC Input
Main Breaker/lsolator
(Customer Plant Side) 100A for 415/440/460 VAC Input
AWG300MCM (UL1505, Flame-retardant
Cable Size and Type
XLPE insulated wire) / SWG _
Wire Type Copper
Wire Size 25 mm2
Connecting Terminal M8
Length of the cable is to be decided by the customer based on main supply point and
machine layout Contact Makino Customer support for any clarifications before installing
the Main circuit breaker and cables for the machine.
V1431I-I1E-XB 35
4.6 Transformer (Option)
F3 and F5 machine requires an input voltage of 200V, 30 AC, 50/60 Hz, for the main
servo control and other units.
If the incoming voltage is other than 200V, 30 AC, an additional external transformer of
rating 40 kVA is required with the secondary output being 200 V.
Table 4.6.1 gives the types of transformers with suitably rated cables from transformer to
the machine are available as an option along with the machine according to the countries
and its power source.
Table 4.6.1 Regional wise main transformer incoming voltage specification.

Region Transformer Voltage
Primary:380/400/420/440V
Asia Pacific
Secondary: 200V
Primary: 400/460/480V
U.S.
Secondary: 200V
Primary: 380/400/420/440V
Europe
Secondary: 200V
Primary: 220/230/240V
Other Than Above
Secondary: 200V
Table 4.6.2 gives the specification of the required transformer and should be ready before
installation of the machine unless ordered with the machine.
Table 4.6.2 Main transformer Specifications

Description Specification
Primary Voltage According to the Local Power supply
Secondary voltage 200 VAC
Phase 03
Frequency 50/60 Hz +/- 1%
Rating 40 kVA
Sec. Voltage tolerance ±5%
Class Class H
Regulation ±3%
Type Isolation
Winding Copper Winding
Out put Tapings 200V and 220V
V1431I-I1E-XB 36
4.7 Earthing/Grounding Preparations
• All Makino Machining Centers must be properly grounded at the time of installation.
• Proper grounding requires an isolated earth ground for the machine.
• Do not use the common earth used in the plant.
• Prepare a separate earth pit in accordance with local regulations near the machine and
properly inspect before connecting to the machine
• Ground of 100 ohms resistance or less, is required
Contact any certified electrician / Makino Customer support for any clarifications regarding
the Grounding preparation before installing the machine
4.8 Air Supply

Table 4.8.1 gives the details of required incoming air supply specification unless an air
dryer is ordered with the machine which is available as an option. The air supply point to
the machine should be near to the machine air inlet. Refer the foundation layout section
3.4 for proper air inlet location. The air supply line should have permanent piping.
A valve for opening and closing the air supply is required at the supply point. A main air
pressure gauge and a filter regulator with 0.005mm of filtration are recommended after the
main supply valve. Air supply piping drop from the top of the main line is recommended
with a connecting port of PT1/2. Keep the Air line and pipes clean and free from dust and
other free particles, as they will damage the line filters of the air drier and the machine or
cause machine component failure.
Table 4.8.1 Air Supply Specification:

Description Specification
• Supply Pressure 0.5 to 0.8 MPa
Inlet Air Temperature 5° to 35° C
Ambient Temperature 5° to 40° C
Relative Humidity Less than 40 %
Machine Pressure 0.5 MPa
Consumption (Volume) 400 L/ min. (1.52 m3/min)
Filtration Water Trap and Oil Mist Filter with 5p and 0.3p filter
Air Dryer Refrigerated Membrane Type (Option)
Connection Port PT1/2 Female or 016mm Hose Nipple (Machine Side)
Inner Dia of Hose Over 15mm
Air Quality Required ISQ8573-1, ISQ1.5.1
Incoming Air Supply

Makino considers it the customer’s responsibility to ensure that the
air supply to the machining center is both clean and dry. Supplied
air must not exceed 40% relative humidity.
Please Note: If the incoming air is not good and cannot meet the minimum standards, it is
recommended to use an Air Drier just before connecting the Main Air supply.
V14311-11E-XB 37
Installation Manual F3/FS
4.9 Machine Handling Facilities
• F3 machine installation requires lifting and moving of some heavy units. Trained and
Professional riggers only should handle the machine for unloading, unpacking, lifting
and moving. Following facilities at the customer place is very much essential for
installing the machine.
• Overhead Crane of minimum capacity 10 T or above.
• Min gap from the Crane Hook to the top of the machine should be about 500mm
• Min gap from the Crane Hook to floor should be about 3000mm
• Shop floor entry door width should be more than 2800mm
• Mobile Crane capacity : 10 T or above
• Forklifts capacity : 10 T or above
• Hydraulic Jacks, : 5 T (Toe type preferable)
• Eyebolts : M6, M8, M12, M16 etc min of 6 nos each
• D shackles : Different sizes
• Crowbars : 2.5 to 3 m in length minimum 2 numbers
• Lifting slings or wire rope of various lengths
4.10 Service Facilities

During the installation of F3 machine following facilities are very much essential for
installing the machine. Customer is requested to arrange for machine installation
• Cotton cloth type waste (Never use thread type cloth waste)
• Soft tissue papers
• Cleaning brushes of different sizes
• Cleaning agents like CTC / Acetone / Heptane / Gasoline, soap oil etc.,
• Big size clean cardboards and Plastic sheets
• Industrial Vacuum cleaner
• Hand lights or Torch lights
• Helmets for FSE
• Safety Hand gloves
• First aid Kit
• Set of Tool Kit
• Dust Bins for waste disposals
• Temporary power facilities
• Aluminum Ladder of height 6 to 8 ft
4.11 Toolings and Fixtures

Consider the specification of the machine spindle which is to be installed. Please refer the
table below to select the correct tooling specification that can be used. For tool maximum
diameter weight and length please refer Figure 4-11-9 Tool Diameter weight and Length
Specifications, Fixtures.
Consider the machine maximum workpiece area that can be accommodated for the machine
that is to be installed. Prepare the fixtures accordingly refer chapter 3 for details.
V1431I-I1E-XB 38
Installation Manual FI/F
TOOL SHANK AND PULL STUD DETAILS FOR 12K/13K SPINDLE
TYPE
PULL-STUD DIMENSIONS TSA/TSC
TOOL SHANK
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MAS403-BT40 Without Hole Figure 4-11-1 NOT APPLICABLE
Without Hole NOT APPLICABLE
JIS B6339-40T Figure 4-11-2
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DIN 69871-A40 Figure 4-11-3
With Hole TSA/TSC
V-CAT - No. 40 Figure 4-11-4
With Hole TSA/TSC
HSK-A63 NOT APPLICABLE
V1431I-I1E-XB 39
TOOL SHANK AND PULL STUD DETAILS
20K SPINDLE
TYPE
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MAS403-BT40
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(JIS B6339-40T)
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DIN 69871-A40 Figure 4-11-6 TSA

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V-CAT - No. 40 Figure 4-11-7 TSA
With Hole
HSK-A63 NOT APPLICABLE Figure 4-11-8 TSA /TSC
V14311-11 E-XB 40
TOOL SHANK AND PULL STUD DETAILS
30K SPINDLE
TYPE
TOOL SHANK
(Retention Knob)
HSK-A63 NOT APPLICABLE Figure 4-11-9 TSA ITSC
V1431I-I1E-XB 41
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V14311-11 E-XB 42
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V1431I-I1E-XB 44
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V14311-11 E-XB 45
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V1431I-I1E-XB 46
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V14311-11E-XB 47
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V14311-11 E-XB 48
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COOLANT DUCT FOR THROUGH-SPINDLE COOLANT/AIR

1. The coolant duct is required for through-spindle coolant/air.
2. 0.8s grind finish is critical to reliability of through-spindle coolant rod o-ring.
Figure 4.11.8 DIN 69893-1HSK A63
V1431I-I1E-XB 49
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V14311-11E-XB 50
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V1431I-I1E-XB 51
Tooling and fixtures typically require long lead times. These two issues should be
addressed before the delivery of the machine tool.
Fixtures
Consider design and manufacturing time, and coordinate completion with the delivery of
the machine for a smooth transition into your production schedule.
Tooling
The three most important factors to understand and consider when selecting tool holders
and cutting tools for high-speed machining are balance, concentricity, and rigidity. All high¬
speed spindles have limitations. Know the spindle design and limitations. Ensuring that
your applications stay below the spindle’s allowable radial load and side thrust will,
maximize machine utility, parts production, spindle life and machine parts. When selecting
tooling:
• Tool holders should be designed for the highest rpm available on the spindle. Never
exceed the manufacturer’s design ratings for the tool.
• Tool holders should be designed for high-speed machining. Look for good tool holding
ability, balance, and concentricity.
• Never use Welded or side lock holders at high rpm.
• Use the shortest possible tool. Select the shortest tool holder and cutting tool allowed
by the part geometry. Short tools provide better tool life and surface finish while
reducing radial load on the spindle.
Balance
Balancing ensures that an object’s center of gravity spins equally around its rotational
center and is essential to effective HSM. At speeds of 10,000 rpm and higher, the forces
from unbalanced tooling become significant, causing machining and machine tool
problems. An out of balance tool:
• Reduces metal cutting capacity, decreases tool life, and degrades surface finish.
• Vibrates, causing chatter and exaggerating eccentricity.
• Transfers excessive load to the spindle bearings, promoting premature wear or
catastrophic failure.
• Can generate over 50% of the recommended spindle side thrust
Out of balance conditions
AX s OF ROTATION
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V14311-11E-XB 52
Balance the Entire Assembly

1. The cutting tool is not usually a problem in balancing. Its small mass
and typical symmetric shape makes balance almost inherent. To
ensure balance, use high quality cutting tools with flutes, pockets, etc.
equidistant from center.
2. Balanced the entire tool assembly to avoid the possibility of “stacking”

tolerances from individual components.
Balance Specification and Calculation
The balance specification establishes a range from which a “target balance’’ for a tool at a
given speed (rpm) is calculated. Tooling is placed on a balancer to measure the out of
balance amount or “unbalance” in grams millimeter (g-mm). Most balancers also indicate
the area of unbalance.
Material is added or removed to meet the required balance specification. All tooling used
on the F3 must meet a balancing specification of G2.5 or lower (the lower the
specification, the better the balance). If sending tools to a balancing service, have tools
balanced to a G2.5 spec, for the maximum spindle rpm, using the following formula.
G : Balance Specification ( G2.5 )

Balance Formula
9.549 : Constant of Acceleration
RPM : Max. Safe Spindle Speed
M x G x 9.549 M : Tool Weight in Grams
g-mm =
RPM g-mm : Amount of Unbalance
To find the maximum safe rpm for a known unbalance amount, use the following formula.
Balance Formula G = Balance Specification (G2.5)

9.549 = Constant of Acceleration
1 g-mm RPM = Max. Safe Spindle Speed

=
M = Tool Weight in Grams
RPM M x G x 9.549
g-mm = Amount of Unbalance
V1431I-I1E-XB 53
Balanced Tooling
Tooling manufacturers can supply balanced or balanceable holders. These holders cost
more, but the benefit in surface quality alone will offset the cost with reduced time on the
finishing bench.
•Order tooling with a G2.5 or lower specification at the machine’s maximum rpm.
•Ensure the holder operates safely and well at the required speed.
Tooling can be sent to a service for balancing. Depending on the cost and delivery for
balancing individual tools and the number of tools balanced per year, purchasing a tool
balancer may be justified.
•Balancing machine operation is not difficult, but requires training and machinery to
properly remove or add material to obtain balance.
Concentricity
Concentricity is important in all machining applications, but it is imperative for effective
HSM, especially using tools with more than one cutting edge. If the tool’s cutting edges do
not swing through the same arc, they are said to be “eccentric” or “run out”.
The outside edge of an eccentric tool wears more quickly, resulting in a wider “wear land”
and shortening the edge’s life. The wider “wear land” on one edge places unequal side
pressure on the tool, adversely affecting balance, deflection, radial load, and surface
finish. Sources of run out are extensions, bushings, and adapters.
• Do not use extensions at high spindle speeds. 1
• Use adapters and bushings only when absolutely necessary
Other sources of run out are dirty tool shanks, unmatched tapers
(holder to spindle taper), and a bell-mouth condition in the holder or
spindle taper. To protect against run out:
* Do not use extensions and adapters.
• Keep tool holder and spindle tapers clean. 1 1
• Purchase high quality tooling.
• Inspect tooling on a comparator.
Rigidity
Tool rigidity significantly impacts performance and results of any machining operation.
Using the shortest, most rigid tool possible helps ensure repeatability, precision, and
reliability. The quality of any milling operation is impacted greatly by the length of the tool.
An extended tool flexes, adversely affecting the final tolerance, finish, and tool life. A tool
holder is essentially a cantilevered beam. Its deflection under load is proportional to the
cube of its length.
(D 13 a), This ratio should underscore the importance of minimizing
overhang or length to diameter (L/D) ratio.
• Reducing tool length by 50% makes the tool 8 times stronger or
more rigid. f
• The greater the tool’s rigidity, the greater is its dampening ‘
OVt-*~A\C
capacity, dynamic stillness, and integrity.
l- -
V14311-11E-XB 54
4.12 Coolant Requirements
Use of a proper coolant is always necessary to achieve the required machining accuracies
and maximum tool life. The coolant should also have better chemical properties such that
the coolant and the chips do not clog the filter. Selection of the coolant, based on the type
of the material to be machined should be decided in consultation with the coolant
manufacturer and kept ready before the arrival of the machine.
The coolant capacity is 160L for the coolant tank or the chip conveyor supplied with the
machine. Sufficient quantity of coolant is to be stocked considering the tank capacity.
Ensure that the coolant preparation procedure suggested by the coolant supplier is clearly
understood and adhered. Also all required instruments kept ready to check the properties
of the coolant such as concentration and the pH value of the coolant.
Note: It is always better to select an environment friendly semi-synthetic water-soluble

coolant.
4.13 Oil and Grease Requirements

Refer Table 4.13.1 for machine Oil and Grease Requirements. The listed are the first use
type in the machine before shipping. It is always recommended to continue to use the
same type for better and trouble free machine performance.
Machine Unit Quantity Type Vendor

Air lubricator 0.2 L 0.05 gal Mobil DTE 24 Mobil oil
Hydraulic system *
(20K Tool CL/UCL)
6.5 L 1.7 gal Hyspin AWS 32 Castrol
Spindle Oilmatic 55 L 14.5 gal Velocite no 3 Mobil oil
Grease for Axis
Linear Guide ways 5cc/ Port 5cc/ Port Alvania EP2 Shell
and
Grease for Ball
5cc/ Port 5cc/ Port MULTEMP LRL3 KYODO YUSHI
Screws
ATC Gear Box 4L 1.1 gal Mobil Gear EP 32 Mobil oil
Daphne Super Gear Idemitsu-
4th Axis Gear Box 0.65 L 0.17 gal oil 100 APPOLO
4,n and 5,n Axis Daphne Super Gear Idemitsu-
1.25 L 0.33 gal
Gear Box oil 100 APPOLO
S33 (20K Spindle) Makino Spindle
40 L 10.6 gal Makino
Spindle Oilmatic Lubricant
* Around VG 32 for cold regions and Around VG68 for Hot regions.
V1431I-I1E-XB 55
4.14 Machine and Data server communication
This section lists the different cables required for machine communication with a computer
for standard RS232C communication and RJ45 cables for direct connection and through a
network HUB for Machines with optional Data Server
Cables for RS232C Communication

Commercially available RS232C communication cable can be used, but we recommend
that sealed and shielded type twisted cable can be used to minimize the influence of
noise, etc.
Figure 4.14.1 shows the cable configuration for 25 pin connectors for both host and
machine side. Figure 4.14.2 shows the cable configuration for 9 pin 25 pin connectors for
host and machine side respectively.
25 PIN - 2 SPIN SERIAL CABLE
25 PINFEMALE (Host Side) 25 PINMALE (Machine Side)
SD 2 SD 2
RD 3 X RD 3
cz RS
CS
4
5
SG 7 SG 7
6 DR
8 CD
Figure 4.14.1 - 20 ER
9 PIN - 25 PIN SERL4L CABLE
9 PINFEMALE (Host Side) 25 PIN MALE (Machine Side)
SD 2 2 SD
RD 3 3 RD
4 RS
5 CS
SG 5 7 SG
6 DR
8 CD
Figure 4.14.2 20 ER
V14311-11E-XB 56
Cables for Data Server Communication
The network interface used with the new data server is 10 Base-T. Shielded twisted pair
cable is used for connections with this type of network. Normally, cable provided with the
machine is used (straight connection type).
Shielded Twisted Pair Cable (STP)

Twisted pair cable is used to make the Ethernet connection between the data server board
and the host computer. Commercially available twisted pair cable can be used, but we
recommend that sealed and shielded type twisted cable be used between the data server
and hub or computer to minimize the influence of noise, etc.
4.15 Cables for direct connection to a computer without a

network HUB
The twisted pair cable is connected to the “CD38M” connector on the CNC unit. Figure
4.14.4 shows the cable configuration for connection to a computer.
©»|l
=.,-r /CD38M
.-mr
Figure 4.15.1
Crossover Cable
Twisted 1 1
Pair #1 2 2
Twisted 3 3
Pair 42
6 6
Figure 4.14.4
V14311-11E-XB 57
4.16 Installation Tooling Requirements (By FSE)

The Makino Field Service Engineer (FSE) is responsible for installing the machine and
training the customer. The FSE installation process should be completed in the stipulated
working schedule.
FSE should be flexible work around unexpected delays or problems and still complete the
installation on time. Always reconfirmation reduces the chance of error or accident. FSE is
required to carry the following Toolings as part of the installation tool kit (Below Table) so
at to ensure proper installation and avoid unnecessary delays
S/N Tooling Quantity

1 Allen key set (2.0mm to 18mm) 01
2 Spanner set (6mm to 41mm) 02
3 Box spanner set 01
4 Hand hacksaw with spare blades 01
5 Smooth files (Flat Round and Half round) 01 each
6 Needle file set 01
7 Cutting player 01
8 Wire Cutter 01
9 Nose player 01
10 Wire Stripper 01
11 Crimping tool 01
12 Soldering gun with lead and flux 01
13 Star Screw driver (min 2 sizes) 02
14 Flat screw driver (min 2 sizes) 02
15 Screwdriver set 01
16 Tester 01
17 Ratchet set 01
18 Steel scale 01
19 Hand torch small and big 01 each
20 Magnifying lens 01
21 Tweezers 01
22 Brass / copper Rod and flat 01
23 Measuring tape (10 m) 01
24 Adjustable Spanner (Screw spanner) 02
25 Center punch 01
26 Chisel 01
27 Gl or steel Pipes 1/2 3A “ (different lengths) 01 each
28 Tap wrench 01
29 Hand Taps 5mm, 6mm, 8mm 01 each
30 Drill bits 4mm, 5.1mm, 6.8mm 01 each
31 Drill Gun 01
32 Small steel hammer 01
33 Nylon or Rubber mallet 01
34 Extension Socket Head keys (5mm, 6mm, 8mm) 01 each
35 Multi meter with probes 01
36 Clamp meter 01
37 Cable ties (different sizes) 100
V1431I-I1E-XB 58
Installation Manual FS/F
38 Permanent marker pens 2-3 colours 01 each
39 Insulation Tapes (red, yellow, blue and black) 02 each
40 Teflon tape roll 04
41 Thread lock (locktite 242) 100ml
42 Silicon sealant (200gm tube or gun type) 02
43 Spirit Level (02mm/m) 02
44Dial indicator lever type (0.002mm LC) 01
45Dial Stand 01
46Dial stand extension rod with mounting plate & screw 01
47HSK test bar 01
48 Standard Test Square 800 X 800 100mm Thick 01
49 Feeler Gauge set 01
50 Slip Gauge set 01
51 ATC setting tool 01
52 Orientation Setting tool 01
53 Oil Stone (rough smooth, and very fine) 01 each
54 Fine emery paper 02
55 Torque wrenches 01 each
56 Hand gloves 2 to 3 pairs
57 Cleaning Brushes small 02
58 Knife 01
59 Grease Gun 01
60 Multi temp LRL 3 / Isoflex NBU15 grease 500gm
61 Fanuc parameter manual 16i series 01
62 Fanuc Maintenance manual 01
63 Makino Pro3 parameter list 01
64 Making Pro3 operation manual 01
65 Machine installation manual 01
66 Machine maintenance manual 01
67 Machine operation manual 01
68 Required Service and Installation reports 01
V14311-11 E-XB 59
4.17 Pre-Installation Checklist
The Pre-Installation Checklist (on the following pages) is a request for the customer
installation services. To help ensure a smooth installation this checklist allows Makino and
your representative to know the status of your preparations and provide additional support
where needed.
It is necessary for you to complete or address the items on the checklist before arrival of
the Field Service Engineer for the installation of the machine. In special cases and with
approval in advance, completion of all checklist items is not mandatory based on the
machine configuration supplied; however, it is essential that Makino be informed of the
status of your preparations before sending the FSE to your facility.
Checklist Questions
For questions or problems with any of the requirements on the Pre-installation checklist or
to inform us of your current status or a delay:
• Contact your distributor or Makino sales/service representative.
• Please provide your contact details to simplify service.
Checklist Instructions
The first page of the checklist serves as the cover sheet. This information is required for us
to serve you in a better way. The Customer contact is the individual from your side
whom our FSE should contact at your facility. This person:
• Should be authorized to sign all installation or service reports
• Should be available to arrange or coordinate any required assistance
• Will become the first customer contact of record in Makino’s customer service
database (Space is provided for additional contacts.)
Completed Checklist Distribution

When the Checklist is complete:
• Retain the original for your records.
• Mail or fax a copy to Makino Sales Representative.
• Mail or fax a copy to Makino Customer Support.
V14311-11E-XB 60
Installation Manual Fl/FES
PRE INSTALLATION CHECKLIST Page 1/3

MACHINE MODEL | Serial # Control Type: PRO 5
Customer: Contact Person
Please indicate the completion of the following items with a “Y” in the space provided. If
there is a question or problem with any item listed below, it should be addressed
immediately by contacting your distributor, sales representative, or Makino, before a Field
Service Engineer is scheduled to supervise installation of the machine. _
Packing list checked. Check that all parts, manuals, keys, tool kit,
schematics, etc., have been received (in addition to immediately contacting
Makino, note any discrepancies on a separate sheet and include with this
document. Take pictures of any shipping damage).
Machine condition checked. The condition of the machine proper and all
system components has been inspected for damage or other unacceptable
conditions (in addition to immediately contacting Makino, note any
discrepancies on a separate sheet, send to the shipper, and include with
this document). _ _
The Machine location is properly selected as per Makino requirements.

(Refer Chapter 4.2)
The Foundation where the machine is to be located is as per Makino

requirements, (Refer Chapter 4.3)
The Floor is clean and marked as per the layout (Refer Chapter 4.4)
Power cables of sufficient length for connecting to the machine mains are
available (Refer Chapter 4.5)
WARNING! Do NOT supply power to the machine at this time (the FSE will
verify proper wiring before power ON).
If the transformer is not ordered with the machine, a transformer with

required specifications is ready for installation (Refer Chapter 4.6)
V14311-11 E-XB 61

MACHINE MODEL | Serial # | Control Type: PRO 5
Customer: | Contact Person
Proper earth ground is prepared and connected to the ground bus bar of
the main isolator supply and another cable be routed via any convenient
path with sufficient length to connect to the machine's ground buss inside
the MTC (Machine Tool Cabinet). (Refer Chapter 4.7)
Air supply to the machine is available. Permanent air lines with proper end
fittings should be run to the machine vicinity (Refer Chapter 4.4 and 4.8)
Over head Crane, Forklifts, mobile crane etc are arranged for moving and
installation of the machine and machine accessories (Refer Chapter 4.9)
Professional Riggers are available for the entire period of installation.
Service facilities are ready for installation (Refer Chapter 4.10)
Proper tools are arranged (confirm that tool holders, tooling, chucks, etc.
are as per the proper specification for the machine supplied) (Refer
Chapter 4.11)
Sufficient Coolant (Cutting Fluid) is available (Refer Chapter 4.12)
V1431I-I1E-XB 62

MACHINE MODEL | Serial # | Control Type: PRO 5~
Customer: | Contact Person
Maintenance personnel selected and scheduled to assist the FSE with the
installation (This is an excellent opportunity for getting the concerned
trained on the machine)
A part has been selected, and a part program is available
Proper fixture and the required cutting tools are available
Operators and Maintenance personnel selected for training.
V1431I-I1E-XB 63
)
)
5. Machine Delivery
5.1 Introduction
The installation process gets started when the pre-installation review and preparations
completed as in chapter 4. The next phase begins with the arrival of the F-Series machine
and the completion of the customer responsibilities described in this chapter.
This chapter describes how to receive, inspect, unload, and move to site, locate, clean,
and prepare for installing the new machining center. Performance of these duties:
69 Ensures the smoothest and shortest installation time.
70 Provides maximum training time for operator and maintenance personnel.
The Installation process

Makino’s installation process includes Pre-Installation duties to be
Q performed by Customer. These duties are described in this chapter 3 and

chapter 4.
Makino customers must perform these duties to provide the maximum
amount of time for proper machine set-up and training. Joint proactive
participation and assistance are critical to ensuring an effective installation.
V14311-11E-XB 64
5.2 Container Layout
This section outlines the brief machine layout when packed inside a container for shipping.
The figures 5.2.1 shows the out line container layout.
2380 1063 ,.780 ,653

Trans¬
former! I I
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s I [jjpc|gj
I F3
I o ATC
1
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U Cover ®l
TOP VIEW
740 1305
12056
1 I
1
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SIDE VIEW
Figure 5.2: Container layout
5.3 Inspect the Machine

Safe shipment of the machine is dependent of the shipper. Before dispatch of the machine
maximum care is taken to avoid damage during transport, all necessary packing is done to
ensure safe handling of the machine. Upon delivery of the machine by the shipper please
ensure the following to minimize the potential effects of shipping:
• Inspect the machine and all packages and containers for damage.
• Check each item against the shipper and packing list for shortages (a copy of the
packing list will be available in advance at the commercial department).
• Acknowledge the shipper for the correct receipt of the items. With a note mentioning,
“Received subject to hidden and concealed damage”.
• Inspect all items, soon after delivery.
• Inspect each item in every box, crate, and carton. And confirm the quantity as per the
packing list.
• If damage or shortage is discovered after releasing the driver, contract the carrier
• immediately:
• File a claim with the carrier or Insurance Company immediately.
• Leave damaged material exactly as found and take photographs of the damage.
• Inform Makino, Makino distributor and Makino Customer support immediately with
company details, contact persons, machine type, and machine serial number. If
possible make a brief report with photos of the type of the damage.
• Send a copy of the photographs to Makino.
V1431I-I1E-XB 65
Installation Manual Fi/FU
Proper Information by the customer regarding any shipment damage or shortages before
arrival of the FSE is very important. This helps in faster arrangement of the damaged
items and avoids delayed installation
Please ensure maximum care while unpacking the boxes. For a simple
reason of improper unpacking the Items inside should not get damaged.
5.4 Unloading Lifting and Moving

This section describes the safes instructions for unloading, lifting and moving the F-Series
machine. Please follow the procedures for safe location of the machine and it accessories
after the machine reaches the factory for installation. The figures in sub chapters of 5.4
shows lifting details of the main machine and its accessories.
5.4.1 Lifting the Machine
Where lifting is required, it is highly recommended to purchase F3/F5

standard lifting fixture, which is included as an option. Any improper lifting
position or equipment may cause damage and injuries.
Confirm there is no physical damage seen on the packing of the Machine. If any damage
observed please inform Makino/lnsurance agent. Safely unpack the unit and move near to
the required location. Carefully lift the unit, follow the hints for lifting and moving:
• The machine is rested flat on a shipping frame and is bolted to it.
• The weight of the machine is about 7.5 tons for standard machine.
• Use the overhead crane for lifting the machine.
• The machine can also be moved to its location using fork lifts, when a fork lift is used
make sure that the machine shipping skid is not removed and the machine is lifted with
the shipping base.
• Lift the complete machine by using wire rope of sufficient length and strength.
• Use the machine standard lifting fixture (provided as an option).
• Make sure enough that the ropes are correctly and properly used as shown in the
machine lifting diagrams Figure 5.4.1.
• Lower the crane hook and lift the machine lifting tackle from the top lifting hole.
• Make sure that all the wire ropes are fixed properly and the D-shackles fixing the rope
to the lifting tackle are properly assembled.
o Move the crane so that the lifting hook is above the machine center, and slightly lower
it so that the other end of the ropes can be fixed to the bottom jigs as shown in Figure
5.4.1.
• Slowly start moving the crane upwards and stop when the ropes are loaded, make sure
that the ropes are in proper position in the grove, and the position of the crane hook is
at the center.
• Ensure all the shipping locks are not disturbed (do not remove the shipping locks of the
unit until placing the machine in it final location).
o Lift the machine only to the minimum required height for safe movement.
° Remove the shipping skid bolted to the machine base and move it aside.
V14311-11E-XB 66
Installation Manual FU/FS
• Do not roll the machine or give vibration or impact - the critical assembled parts of the
unit could get damaged.
• Do not climb up on the unit or put objects on the unit.
• Make sure that machine does not get damaged during moving.
• Only qualified riggers should perform machine-lifting operations.
• Follow all safety rules.
Refer Figure 5.4.1a for lifting standard machine S33 and S56 and Figure 5.4.1b for lifting
machine S33 APC.
Fixture Lifting Point,

Height~3660mm (min from floor)
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Figure 5.4.1.1: F3/F5 Machine Lifting (Front)
V14311-11 E-XB 67
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Figure 5.4.1.2: F3/F5 Machine Lifting (Rear)
V1431I-I1E-XB 68
5.4.2 Lifting the Front Coolant Tank
Confirm there is no physical damage to the coolant tank or the units mounted on it. If any
damage observed please inform Makino/lnsurance agent. Safely unpack the unit and
move near to the required location. Carefully lift the unit, follow the hints for lifting and
moving:
•. The weight of the coolant tank is about 300kg.
•. Use the overhead crane/fork lift or a stacker for lifting the coolant tank.
•. If an overhead crane is used, lift the complete coolant tank by using wire ropes of
• sufficient length and strength. Fix the ropes on the four corner of the coolant tank as
• shown in the Figure 5.4.3.
•. Make sure that the ropes do not damage the units mounted on the coolant tank when
• lifted.
•. Lift the coolant tank only to the minimum required height for safe movement. The
• coolant tank also had castor wheels, after unloading from the container the tank can be
• rolled to the location.
•. Make sure that the bunch of cables from the coolant tank is not damaged during
• moving.
•. Only qualified riggers should perform this machine-lifting operations.
•. Follow all safety rules.
Refer Figure 5.4.2 for lifting details.
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Figure 5.4.2: Lifting the front coolant tank
V14311-11E-XB 69
Installation Manual FI/FI
5.4.3 Lifting the Chip conveyor
Confirm there is no physical damage to the chip conveyor or the units mounted on it. If any
damage observed please inform Makino/lnsuranee agent. Safely unpack the unit and
moving:
• The weight of the chip conveyor is about 150kg.
• Use the overhead crane/fork lift or a stacker for lifting the chip conveyor.
• If an overhead crane is used, lift the complete chip conveyor by using wire ropes of
• sufficient strength and lengths. Fix the ropes on the four corner of the chip conveyor as
• shown in Figure 5.4.3
• Make sure that the ropes do not damage the units mounted on the chip conveyor when
• lifted.
• Lift the chip conveyor only to the minimum required height for safe movement. The chip
• conveyor also had castor wheels, after unloading from the container the conveyor can
• be rolled to the location.
• Make sure that the bunch of cables from the chip conveyor is not damaged during
• moving.
• Only qualified riggers should perform this lifting operations.
Refer Figure 5.4.3 for lifting details.
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Figure 5.4.3: Lifting the chip conveyor
V1431I-I1E-XB 70
5.4.4 Lifting the Rear Tank
Confirm there is no physical damage to the coolant tank or the units mounted on it. If any
damage observed please inform Makino/lnsurance agent. Safely unpack the unit and
moving:
• The weight of the coolant tank is about 300kg.
• Use the overhead crane/fork lift or a stacker for lifting the coolant tank.
• If an overhead crane is used, lift the complete coolant tank by using wire ropes of
• sufficient length and strength. Fix the ropes on the four corner of the coolant tank as
shown in the Figure 5.4.4.
• Make sure that the ropes do not damage the units mounted on the coolant tank when
• lifted.
• Lift the coolant tank only to the minimum required height for safe movement. The
• coolant tank also had castor wheels, after unloading from the container the tank can be
• rolled to the location.
• Make sure that the bunch of cables from the coolant tank is not damaged during
o moving.
• Refer Figure 5.4.4 for lifting details.
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Figure 5.4.4: Lifting the rear coolant tank
V1431I-I1E-XB 71
5.4.5 Lifting the Transformer
Confirm there is no physical damage seen on the packing of the Transformer Unit.
If any damage observed please inform Makino/lnsurance agent. Safely unpack the unit
and move near to the required location. Carefully lift the unit, follow the hints for lifting and
moving
• The Weight of the Transformer is about 250 kg.

• Use the overhead crane/fork lift or a stacker for lifting the Transformer.
• If an over head crane is used, lift the complete Transformer Unit by using wire ropes of
sufficient length and strength, Use a D shackle of size M16 to link the two eyebolts on
top of the Transformer and the wire rope
• Make sure enough that the included angle between the ropes at the point of the main
lifting hook is not more than 50° to 60°
• Lift the Transformer only to the minimum required height for safe movement
• Do not roll the Transformer or give vibration or impact - The electrical hardware
assembled inside could get damaged
• Do not climb up on the unit or put objects on the unit.
• Make sure that the bunch of cables from the Transformer is not damaged during
moving.
• Follow all safety rules
Refer Figure 5.4.5 for lifting details
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Figure 5.4.5 Lifting the Transformer
V14311-11E-XB 72
Installation Manual FS/FS
5.4.6 Machine Rolling
The F-Series machine when shipped in a container has to be rolled out of the container
along with the shipping base. First remove all the wooden strips in front of the machine
shipping base used for locking it to the container so as to prevent from moving during
transportation. Use a forklift or a crow bar to slightly lift the machine and insert machine
moving rollers below the shipping base. Do not lift the machine too much as the machine
can hit the top of the container and get damaged.
Fix wire ropes to the shipping base and tie to the arm of the forklift as shown in the figure
and slowly drag the machine out of the container, make sure that the machine is rolled out
straight without damaging the machine.
The machine can also be rolled without a shipping base, use four roller sets below the
base at the machine rest pad points. Use toe type hydraulic jacks to lift the machine and
place it on the rollers. Make sure to lock the rollers so as to avoid unnecessary movement
while placing other rollers.
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Figure 5.4.6 Machine unloading
V1431I-I1E-XB 73
Pull Out Direction

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Forklift Capacity min tOtons
Figure 5.4.7 Machine unloading
V1431I-I1E-XB 74
5.5 Initial Cleaning
As a standard practice maximum caution is taken so that the machine parts do not get
rusted during the course of transportation.
Anti rust agents like the rust preventive oil, rust preventive grease etc are applied at all the
required areas of the machine, like telescopic covers, table, clamping areas, spindle taper,
splash guards, coolant tank, chip conveyor etc.
To prevent moisture accumulation on the machine, moisture absorbing chemical (silica

gel) packets are placed in various places on the machine and some times tied to machine
parts like the handle etc.
Please remove all these packets and throw it into the dustbin. Confirm that there are no
packets in the moving areas of the machine. Also during transportation sometimes dust
sticks on to the rust preventive oil. Cleaning of this rust preventive can be done using a
mild cleaning solvent with tissue.
Cleaning of the machine guards and the coolant tank is very important, as the oil on these
surfaces get mixed with the coolant and spoil the coolant and filter blocking may occur.
More care is to be exercised during cleaning of spindle taper, ball screws, and linear
guideways, as these are high accuracy parts of the machine.
The outer surface of the machine should be cleaned thoroughly free from stains, such that
the outer appearance of the machine is bright and neat. Be cautious while cleaning higher
areas of the machine.
The transparent covers of the machine are covered with papers to prevent scratches
during assembly neatly peal off these papers.
5.6 Machine Packing list
Please refer to the machine-packing list attached to the machine invoice for the details of
the machine-packing list. In case of any discrepancy, please inform the shipping agent, the
insurance and also your Makino representative immediately.
Should you require additional information please contact Makino.
V14311-11E-XB 75
6. Installation Process
6.1 Introduction
While starting the installation process, it is assumed that machine is placed in the right
location at the customer place as defined in the Chapter 4. The following paragraphs
explain the steps required before power ON and start running the machine.
6.2 General Instructions
Below are some general instructions during installation process:
• F3 Machine is flushed with ILOCUT 603 (Castrol) Oil before shipment.

• Before filling the coolant / cutting oil make sure, it does not react with ILOCUT 603
layer
o Dismantle the X, Y & Z locking fixtures painted with yellow color, before enabling the
axes.
• During shipment, Z-axis servomotor also sent as dismantled condition and the Z-axis is
locked with locking fixture (yellow color). Provide suitable support for Z-axis before
removing the locking fixture and re-install the Z-axis servomotor.
• Confirm all the directions of the Coolant motors rotation as specified in the motor.
• Filter hose sent as spare part to be connected to the chip tray.
6.3 Installation Process
6.3.1 Installation of ATC covers
During shipment ATC cover is removed and sent as separate part.

• Hook the ATC cover by crane using the eyebolt on top.
• Secure the bottom of ATC cover to the main splash guard.
• After fixing all the screws inside the ATC cover, put back the external cover.
The installation of the ATC cover is illustrated in figure 6.3.1 in the following page.
V1431I-I1E-XB 76
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V14311-11E-XB 77
Installation Manual FiIF
6.3.2 Installation of Spindle Oil Cooler
6.3.2.1 12K Spindle Oil Cooler

Instruction Notice
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Packing foam (Polylones) Cooling unit
must be taken off during
installation
Figure 6.3.2.1: 12K Oil Cooler
• Remove polylones before switching the power ON.

• This unit is already installed and wired up and ready for running.
V14311-11E-XB 78
m
6.3.2.2 20K/30K Spindle Oil Cooler
Figure 6.3.2.2: Hose wrapped with Plastic
Plastic wrapper should be removed just before hose plugging to cooler unit. Maintain good
cleanliness during installation of hoses. The equipment houses the trochoid gear pump,
therefore special care must be paid to the following points:
• Pipes to be joined with the equipment must have the same inside diameter or more
than that of suction or discharge port.
• any solid substances are taken inside the pump, these cause malfunction due to their
If
entanglement in gears.
• the pump is operated in reverse with the suction side pipe closed, this makes the
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pump oil seal peel off, thereby causing oil leakage when the pump is at rest.
Warnings:
• Do not place the unit in a dust environment.
• Do not put tools, screws or any other object on top of the unit.
• Once wrapper removed from the hoses, it must be inserted in the unit.
• Plug on the fitting must be removed just before the hose insertion only.
• Always use “Makino Spindle Lubrication Oil” for top up of cooler oil.
V14311-11 E-XB 79
Installation Procedure:
• Use the eyebolt provided in oil cooler to lift the unit which is as shown in the
figure 6.3.2.3.
• Mount oil cooler unit in the rear side of the machine.
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V14311-11 E-XB 80
Installation Manual Fl/Fl
Basic steps on taking out plug from the fitting.
• Ensure that the correct hose is identified and is ready for insertion. There should be no
dust particle inside the Hose/fitting.
• The fitting is connected with identification color ring to ensure that the relevant hose is
kept ready for insertion Refer figure 6.3.9.
• Move the identification ring out of its position so that released ring is visible to release
the plug.
• Press the release ring to remove the plug from its position.
• Now plug is released and it is easily taken out. Retain the identification ring to use in
hose.
Plug Color ring
Release
ring
Figure 6.3.2.5: Plug Removal from Fitting
Basic steps on taking out plug from the hose.
• Ensure the fitting where it is getting inserted is kept ready.

• Once the plug is removed from the hose, the hose should be inserted in the fitting.
Hence identify the fitting and take out the plug from the fitting.
• Press the releasing ring to take out the hose from the fitting.
• Hose comes out with insert ring. Do not remove the insert ring from the hose.
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Figure 6.3.2.6 Plug Removal from Hose
V1431I-I1E-XB 81
Oil Hose connection:
• Connect the identified hoses to oil cooler as given in the figure 6.3.15.
• The hoses are identified with the letters as given in the above figure 6.3.15. Further,
the above schematic identification is given in the cover of cooler for identification.
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V1431I-I1E-XB 82
Electrical connection:
• After power ON the oil cooler, confirm that no alarm is showed.
• The compressor and pump will turn ON only during first few minutes of power ON and
during spindle running.
Power Cables are

inserted in first (Top) of
the inserted point of the
oil cooler
Red | I'.'.mie M black
Note: Color-coding as given,
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Figure 6.3.2.9: Electrical Cable Connection
V1431I-I1E-XB 83
Installation Manual Fl/Fl
6.3.3 Installation of Transformer
The transformer tapping must be selected before power ON of the machine. The
transformer tapping is in highest rated primary voltage of the transformer when it is
supplied. Before power ON, measure the given transformer primary voltage. Choose the
closest tapping in the primary side of the transformer to get 200V at secondary side.
Follow the steps below for tapping the transformer:
• Open the top cover of the transformer to get access to tapping of transformer.
• Change the tapping in primary side and if required change in secondary side of the
transformer.
• The required supply is 200Volts.
• Before power ON, measure the transformer secondary / machine voltage. It must be
200Volts.
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V14311-11E-XB 84
6.3.4 Installation of Z axis motor
Z-axis motor has been removed and sent along with the machine as loose part. Follow the
below procedure to install it.
• Figure 6.3.4.1 shows the Saddle to which the motor is to be fixed.

• All cables and tubes are properly placed on spindle pocket.
• Use M8 screws (x2) and fix them on motor top to lift the motor to the assembly region
• Loosen the screw of coupling at the motor end completely.
• Fix the motor to the saddle and make a mark between the coupling and motor shaft as
shown in the figure 6.3.23.
• Tighten the screw of coupling at the motor end with a torque value of 40Nm.
Nylon Sling
Cable and
hoses j M8 screws (x2)
to lift the motor
Saddle
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Figure 6.3.4.1: Top View of Saddle
Coupling
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motor end
Motor
assembly
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Figure 6.3.4.2: Tightening of Coupling and Motor
V14311-11E-XB 85
6.3.5 Installation of Z axis Cable chain
Z-axis cable chain has been removed and sent along with the machine as loose part.
Follow the below procedure to install them.
• The cable chain (without links) and links are sent along with the machine.
• Insert all the cables and tubes inside the Cable chain.
• Fix all the M8 screws (x8) with spring washers using 6mm Allen key on the spindle and
saddle brackets.
• Fix all the links to the cable chain using a screwdriver.
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V1431I-I1E-XB 86
6.3.6 Installation of Air Dryer (Option)
6.3.6.1 MCB mounting OP. NO: 100

• Power OFF the machine and mount the circuit breaker (L14B022) as shown in the
figure 6.3.29.
• Connect the Internal MTC cable between the mounted circuit breaker and CP5 circuit
breaker as per wiring details given below.
• Turn ON the MCB CP21 (MCB for AIR Dryer) and power ON the machine. Measure
the voltage across CP21 output points CP21-2 and CP21-4. It must be 200 Volts.
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MCB (L14B022)
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CP5- -CP21-2
CP5- -CP21-4
Figure 6.3.6.1: Mounting and Connection of MCB
V1431I-I1E-XB 87
6.3.6.2 Air Dryer inlet supply
• Connect the PLUG 30PM on Air inlet of Air dryer as shown in the figure below.
• Ensure thread portion is applied with white tape.
• Connect the PLUG on inlet connection of air dryer.
• Ensure PLUG should be fully tightened to avoid air leakage.
SB Figure 6.3.6.2: Air Dryer Inlet Supply
6.3.6.3 Air Dryer inlet supply

• Connect the PLUG 30PM on Air inlet of Air dryer as shown in the figure 6.3.33.
• Ensure thread portion is applied with white tape.
• Connect the nipple to outlet connection of Air Dryer.
• Ensure nipple should be fully tightened to avoid leakage.
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Figure 6.3.6.3: Air Dryer Outlet Supply
V14311-11E-XB 88
6.3.6.4 Interfacing to Machine
• Connect the conduit as shown in the figure below. If already connected with the
different type of cable, remove the cable and connect the cable. Remember to select
the Air dryer side where name sleeves are marked as R21 and S21.
• The conduit check nut should be tightened. Connect the cable end R21, S21 and earth
cable. Remove the transparent protective cover before connecting.
• Connect back the transparent protective cover (Acrylic sheet). Close the Air dryer unit
top cover.
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S21 Cable
Connection
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R21 Cable
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Figure 6.3.6.4a: Cable Connection on Air Dryer
V14311-11E-XB 89
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Knock out hole on MCP CP21 connect the
MTC cableCP21-2 and CP21-4
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Figure 6.3.6.4b: Cable Connection on MTC
• Locate the Air dryer supply cable connection on the MTC side and connect the cable.
• Power OFF the machine.
• Route the cable along the available duct path and connect to the MCB terminals CP21-
2 and CP21-4 and connect the earth cable ‘E’.
• OFF the MCB CP21. And power ON the Machine.
• Complete the mechanical interfacing as shown in the figure below.
13
Air inlet to air dryer Air inlet to machine

(from air source) (from air dryer)
Air outlet to machine
(from air dryer)
Figure 6.3.6.4c: Hose Connection to Machine
V14311-11E-XB 90
Installation Manual FB/FE
6.3.6.5 Testing
• After power ON the Dew point meter, all the LEDs in Dew point reading will glow
except the first (First LED is for showing the negative value of Dew point). Also the
Auto LED and Run LED should glow. (Refer figure 6.3.42)
• Run the Air dryer for one hour. During this time Dew point reading will gradually come
down from its highest temperature to 8° C (only three green LEDs will be ON).
• Hence at the end of one hour all the five LEDs should glow (Dew point 8°C position,
Auto and Run LEDs). This is shown in the figure 6.3.42 (Circled). If only single LED
glows, adjust Dew point as shown in the below procedure.
Xeroaqua MONITOR
}
DEW POINT
to ”C
/RUN ALARM
____
_____
Figure 6.3.6.5: Air Dryer Indicator
V14311-11 E-XB 91
Installation Manual Fl/FS)
6.3.6.6 Dew point temperature adjustment
• In case of not getting near 8°C dew point reading, take 5mm Allen key and open the
bottom cover as shown in figure 6.3.43.
• After opening the cover, take out the red color cap (cover) as shown in the figure
6.3.44.
• Adjust the knob as shown in the below picture with the help of Flat screwdriver. To
increase from Zero to 8°C, adjust by rotating the knob in clockwise direction as shown
in the above figure 6.3.45.
• After the adjustment, open some amount of air in machine.
• With in two to three minutes, the reading will obtain the actual value. The reading must
be near to 8°C (i.e. two or three LEDs in Dew point temperature reader)
• Remember that the main idea of this adjustment is to eliminate the condensation at
Machine Air Regulator unit.
• Put back the red color cap (cover) and cover the unit as it was given in original.
• Run the unit for two to three hours. Check and confirm there is no water droplet near
the Regulator unit.
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Air inlet Open the door Air outlet Remove the red color cap
(cover) for adjustment of
dew point temperature
- Flat screwdriver or
test pen
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Figure 6.3.6.6: Dew Point Adjustment
V14311-11 E-XB 92
Installation Manual F WFB
6,4 Procedure for Machine Leveling
F3 / F5 Machine is supported at 6 points. The 6 points are shown in the basic bed figure
6.4.1 and 6.4.2.
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70±2mm
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Figure 6.4.1.1: Leveling height
• Support the machine on the floor initially by leveling bolts 1, 2, 3 & 4 (Figure 6.4.1.2).
• Maintain a gap between the floor and referred machined pad to be 70±2mm (near left
front leveling plate).
V14311-11E-XB 93
Installation Manual F3/FB
2 @
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Spirit level for TWIST
(1 div =0.02mm/m)
;• H
1 ... Spirit level for CROWN
(1 div =0.02mm/m)
4 # 3
Figure 6.4.2.1: Leveling procedure
• Move the table to the center of Y-axis and place two spirit levels (1 div = 0.02mm/m) on
the table as shown in the figure above.
• Adjust the leveling bolts at point 1, 2, 3 & 4 to get proper machine leveling, the bubble
should be located at the center for both spirit levels A & B.
• Adjust the leveling bolts till the twist is within 0.1~0.2 division (reading on spirit level ‘A’)
and the crown is within 0.5-1.0 division (reading on spirit level ‘B”) should be achieved
by moving Y-axis from one end to the other end.
• When the leveling is complete, snug tight the leveling points 5 & 6 and jack the leveling
point 6 to 0.5 division then jack the leveling point 5 to 0.5 division to equalize the twist
reading (approximately 15 degrees tensioning).
V14311-11E-XB 94
6.5 Installation Procedure for F3 and F5 Coolant Tank
r i
Iv m
0
0
o
,KT>.
,,,
nr E L*J ET n
Figure 6.5.1: Front coolant tank
V1431I-I1E-XB 95
Installation Manual FI/FS
Figure 6.5.1 shows the model of front coolant tank coolant tank used in F3 and F5
machines.
The description of the pumps is given below:
A - Nozzle coolant pump
B - Flush coolant pump
C - Coolant chiller pump (option)
V14311-11 E-XB 96
6.6 Installation Procedure for Rear Coolant Tank with Chip
Bucket
i
'-V-
00 l€hPp ;5;
Figure 6.6.1: Rear coolant tank
V14311-11 E-XB 97
Figure 6.6.1 shows the model of coolant tank with chip bucket used in F-Series machines.
The description of the pumps is given below:

C - Secondary bag filter supply pump (option)
D - Coolant chiller pump (option)
V14311-11 E-XB 98
Installation Manual F!/F!S
6.7 Installation Procedure for Rear Coolant Tank with Lift-up
Chip Conveyor (Option)
ft
V
&
I
X
I I
K ji
@
n
i i
0 ©
6.7.1: Rear Coolant Tank with Lift-up Chip Conveyor
V1431I-I1E-XB 99
Installation Manual F1/FS>
Figure 6.7.1 shows the model of coolant tank with hinge-belt/scrapper lift-up chip conveyor
used in F-Series machines. The description of the pumps is given below:

C - Secondary bag filter supply pump (option)
D - Coolant chiller pump (option)
V1431I-I1E-XB 100
)

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{

VERTICAL MACHINING CENTER

1. Do not maintain, inspect or repair this machine before carefully reading

This machine, including technical data and software, may be subject to

MACHINE MODEL F3/F5

CONTROLLER TYPE Professional 5

1st Release Date: 26 August 2009

Copyright © All Rights Reserved

1.1 Machine Characteristics

1.2 Components and Machine Function

2.2 Danger, Warning, Caution Statements and Symbols

2.3 Installation Safety

The following information is related to installation of the machining center:

B machine or component being lifted. If the necessary weights cannot be

Information Subject to Change

Figure 3.1.1 General view of F3

The table below outlines the brief general machine specification.

Size of Table (F5) 1000x500 mm x mm 39.37x19.68 in x in

SPINDLE HEAD 12,000 RPM

Spindle Nose MAS 403-BT40 / DIN 69871-A40 / JIS B6339-40T

SPINDLE HEAD 30,000 RPM

Spindle Nose MSK-F63

EQUIPMENT POWER CHART

Nozzle Coolant Pressure 0.2 Mpa 29 psi

Floor Space 2440x2625 mm x mm 98.6x102.8 in x in

Program Memory, Edit

Machine Accuracy Compensation

Safety and Maintenance

The specifications indicated are subject to change without prior notice as

A T C MAGAZINE ELECTRICAL CABINET

COOLANT TANK o COLUMN

Figure 3.4.1 Internal structure of F3

—350... 1555 1615

.j 300 855 525 385 705 !

g 1 4 'N 325 | 325

Is ' rsf fro

Figure 3.4.2: F3 Floor Layout (Front Tank)

710 500 500 275, nc

Figure 3.4.3: F3 Front and Side View (Front Tank)

Figure 3.4.4: F3 Floor Layout (Rear Tank)

345 525 850 525 195

500 500 |V STROKE)

1110 1090 710 500 500 275 110

Figure 3.4.5: F3 Front and Side View (Rear Tank)

Figure 3.4.6: F5 Floor Layout (Front Tank)

345_ÿ 1075 .1075

500 J_275 JOS

Figure 3.4.7: F5 Front and Side View (Front Tank)

nisi [f* ir— P>

Figure 3.4.8: F5 Floor Layout (Rear Tank)

345 575 1000 575 70

500 500 (Y STROKE)

1110 1090 710 500 500 .275. 110

Figure 3.4.9: F5 Front and Side View (Rear Tank)

348 517 143 239

When selecting tooling:

Total Floor Space

Environment for Machine Working

The machine location should meet the following conditions:

REINFORCING STEEL 010

Figure 4.3.1: Foundation F3 and F5

4.5 Power Supply and Cables

S/N Description Data