Form no: Rev.

Page:
:
FM-CUS-016 03 1 of 9
ANNUAL MAINTENANCE CHECK LIST
DUO43/64 Series

INSPECTION CHECKLIST

Customer Name :

M/C Model : Serial No :

Inspected By
:
(Makino)

Verified by
:
(customer)

Date of inspection :

Controller :
Software Version :
Room Temperature : °C
Humidity : %
Compressed Air
Temp : °C
 Form no: Rev. Page:
:
FM-CUS-016 03 2 of 9
ANNUAL MAINTENANCE CHECK LIST
DUO43/64 Series

Inspection List
Require
No Units Job Description/ Inspection items Status Remarks
ment
1 Lower head Lower head condition B/C
Energizing plate & blocks B/C
Wire guides B/C
Wire support & V- guide B/C
Wire guide open / close function B/C
K roller function B/C
Power cable & connections B
Arm bellow condition V
2 Upper head Upper Head condition B/C
Energizing plate B/C
Wire support & V guide B/C
Guide open / close function B/C
Power cable condition & connection B
3 Head protect & Head protect cable and function B
Gap Gap cable & connection B
Edging function B
4 Automatic Wire Wire sensor function B/C
Threading Jet Mesh B/C
Jet Nozzle B/C
Jet filter condition B
M6 function B
M7 function & cutter motion B
5 Wire drive unit C ,I H & D roller B/C
LM roller function & accuracy B/C
Water separator assembly B/C
Water leak from separator assembly V
Dry run the powder clutch using Jig B/A
Calibrate the powder clutch B/A
Wire tension with Tension meter B/A
Back tension B
Felt pads B/C
6 Dielectric unit Water level in the bed tank B
Fluid low level detection Float switch function B/C
Filter pump suction port B/C
Filter pressure B Mpa
Water conductivity & Sensor B/C
Resin cartridge B
Ion valve function B
7 Work tank Water filling and float upper function B
Drain cylinder function B/C
Big door seal & locking lever condition B/A
Small door seal condition B/A
Small door up/dn movement B/A
Seal plate condition and water leak B/V
Float switch LS523 function B/C
Small door float switch LS550 function (EIO3B, B/C
bit1, FLT-SDR)
Big door switch LS57 function, EIO 38, B/A
bit7,FILL-EN

A : Adjustment as required B : Physical Check C : Clean

D : Replenish L : Listening to sound V : Visual check
 Form no: Rev. Page:
:
FM-CUS-016 03 3 of 9
ANNUAL MAINTENANCE CHECK LIST
DUO43/64 Series

Require
No Units Job Description/ Inspection items Status Remarks
ment
7 Work tank Upper head submerged float switch LS521function B/C
( EIO:37, bit1, W-OVERHEAD)
Door interlock function B/A
Flushing mode 7&8 for both heads B/A UF LF
(1.8 ~ 2.0 liter/minute) O=
A=
8 Cooler unit Cooling function & Cooling Temp: B °C
Condenser and mesh condition B/C
9 FRL Air pressure (0.6Mpa) B/A Mpa
Filter condition & Air leak B
10 Greasing Ball screws B/D
XYUV&Z axis Linear guides B/D
Axis Bellow condition V
11 Axis back lash X axis B/A O=
A=
Y axis B/A O=
A=
U axis B/A O=
A=
V axis B/A O=
A=
12 MTC Main circuit breaker connection at Machine and B
customer
Cooling fan function V/C
Work light function B
13 Test cut Do basic test cut with the help of operator to B
confirm the machine functions.

A : Adjustment as required B : Physical Check C : Clean

D : Replenish L : Listening to sound V : Visual check

Static Accuracy Inspection

Unit: mm
Toler Measure
No Inspection Items Measuring method Illustration
ance ment
X-axis
direction Position the table or all
axis to the center of SP43=0.015
(Right
movement, and place a / 120mm
side)
X-axis precision level on the
Flatness on SP64=0.018
direction work mounting plate.
the top / 120mm
(Left Measure at three position
surface
1 side) on the left and right
of work
Y-axis mounting plates
mounting
direction separately. The SP43=0.020
base
(Right maximum difference of / 400mm
side) reading on each plate
Y-axis shall be the measured SP64=0.025
direction value. / 500mm
(Left side)
 Form no: Rev. Page:
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FM-CUS-016 03 4 of 9
ANNUAL MAINTENANCE CHECK LIST
DUO43/64 Series

Unit: mm
Toler Measure
No Inspection Items Measuring method Illustration
ance ment
Position the Y axis to the
X-axis center of movement.
direction Place straight edge on
(in XY leveling jacks on the test
plane) plate.
Straightness
Apply the fixed test
of the SP43=0.012
indicator from the head
2 movement
to the straight edge and
in the X- SP64=0.014
move the X-axis. The
axis X-axis maximum difference of
direction readings shall be the
(in XZ measured value.
plane) Square may be used in
place of straight edge.

Position the X-axis to the

Y-axis center of movement.
direction Place a straight edge on
(in YX leveling jacks on the test
Straightness plane) plate. Apply test
of the indicator from the head SP43=0.012
3 movement to the straight edge and
in the Y- move the Y-axis. SP64=0.014
axis Y-axis The maximum difference
direction of the readings shall be
(in YZ the measured value.
plane) Square may be used in
place of straight edge.

SP43=0.017
X-axis / 120mm
Parallelism Direction SP64=0.020
Apply test indicator from / 120mm
between the
the head to the work
table
X – axis mounting plate via SP43=0.032
movement
direction granite block. Move the / 400mm
4 and top
(cross axis. SP64=0.042
surface of
plate) The maximum difference /600mm
Work
in readings shall be the
mounting SP43=0.022
measured value.
base. Y-axis / 400mm
Direction SP64=0.028
/500mm
Place square on the test
plate. Align one side of
the square parallel to the
Squareness between the
X-axis movement. Apply
movement in the X-axis
test indicator from the SP43=0.012
5 direction and the
head to the square. Move SP64=0.017
movement in the Y-axis
the Y-axis.
direction.
The maximum difference
of the readings shall be
the measured value.
 Form no: Rev. Page:
:
FM-CUS-016 03 5 of 9
ANNUAL MAINTENANCE CHECK LIST
DUO43/64 Series

Unit: mm
Toler Measure
No Inspection Items Measuring method Illustration
ance ment
X-Z squareness: Place
square on leveling jacks
Squareness X-axis on the test plate.
between the direction Y-Z squareness: Place
vertical (ZX square on leveling jacks
movement plane) on right mounting plate.
of Align the base to the X-
SP43=0.017
6 the head axis and Y-axis
SP64=0.022
and respectively. Apply test
X-axis Y-axis indicator from the head
movement direction to the square. Move the
(Y-axis (YZ - Z-axis.
movement) plane) The maximum difference
of readings shall be the
measured value.
Place straight edge on
the test plate. Align
straight edge parallel to
the X-axis. Apply test
indicator from the head
to the straight edge.
Parallelism between the
Move the U-axis. SP43=0.017
7 movement in the X-axis
The maximum difference SP64=0.022
and U-axis direction.
of readings shall be the
measured value.
This check can also be
done during the X-Y
squareness check using
the square.
Place straight edge on
the test plate. Align
straight edge parallel to
the Y-axis. Apply test
indicator from the head
to the straight edge.
Parallelism between the
Move the V-axis. SP43=0.017
8 movement in the Y-axis
The maximum difference SP64=0.022
and V-axis direction.
of readings shall be the
measured value.
This check can also be
done during the X-Y
squareness check using
the square.
Place square on the test
plate. Align one side of
square parallel to the U-
axis movement. Apply
Squareness between the test indicator from the
9 movement in the U-axis head to the square. Move 0.017
and V-axis direction. the V-axis.
The maximum difference
of readings shall be the
measured value. Square
error must be eliminated.
 Form no: Rev. Page:
:
FM-CUS-016 03 6 of 9
ANNUAL MAINTENANCE CHECK LIST
DUO43/64 Series

Unit: mm
Toler Measurem
No Inspection Items Illustration Description
ance ent

Surface A 0.010

Upper Head (V-Guide

10 only) Surface B 0.02
Flatness and Squareness

Surface C 0.05

0.003

0.003

Upper Head (V-Guide

Level difference between
11 only)
both guide
Inclination Accuracy
0.010

0.005 A=

0.005 B=

Distance between guide

0.2 +/- 0.030
and energizing plate

Upper Head (V-Guide

12 only) M/C Coordinate (Z @ 0
Inclination Accuracy Position)
Differences of value
between guide face &
fixture = Input in "M/C +/- 0.02 PA5065 =
parameter No:5065
Level difference between
guide and Plate Work
piece.
 Form no: Rev. Page:
:
FM-CUS-016 03 7 of 9
ANNUAL MAINTENANCE CHECK LIST
DUO43/64 Series

Unit: mm
Toler Measurem
No Inspection Items Illustration Description
ance ent
Surface A 0.010
Lower Head (V-Guide
only)
13 Surface B 0.020
Flatness and
Squareness
Surface C 0.005

0.003

Lower Head (V-Guide 0.003

Level difference between
14 only)
both guide
Inclination Accuracy

0.010

0.005 A=

Level difference between

both guide
0.005 B=

Lower Head (V-Guide

15 only)
0.2 +/
Inclination Accuracy
Distance between guide and +0.30
energizing plate -0.0

Level difference between 13400 PA670 =

guide and Plate work piece. +0.2mm
Difference value + 0.9mm = (Between
PA674 =
Parameter 134000 –
13600)
 Form no: Rev. Page:
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FM-CUS-016 03 8 of 9
ANNUAL MAINTENANCE CHECK LIST
DUO43/64 Series

Unit: mm
Toler Measurem
No Inspection Items Illustration Description
ance ent

M run out 0.020 M=

M Axis
L run out 0.020 L=

16 LM Roller L Axis
M / X-Z Inclination 0.050 MXZ =

L / X-Z Inclination 0.050 LXZ =

WIRE TENSION
wire Tension Parameters Parameter Wire Permissible Tolerance Measured
type tape value tension range (g) (g) tension
(dia) (g) (g)
0.1mm 0 780 250 230~270 ±20
1 781 250 230~270 ±20
2 782 350 330~370 ±20
3 783 400 380~420 ±20
0.2mm 4 784 500 450~550 ±50
5 785 700 650~750 ±50
6 786 1000 950~1050 ±50
7 787 1200 1150~1250 ±50
8 788 1400 1350~1450 ±50
9 789 1600 1550~1650 ±50
0.25mm 10 790 1800 1750~1850 ±50
11 791 2000 1900~2100 ±100
0.3mm 12 792 2500 2400~2600 ±100
13 793 3000 2850~3150 ±150
14 794 3500 3500~36505 ±150
15 795 4000 3800~4200 ±200

BACK TENSION
1) Set wire speed to 10[TAP] and tension to 7[TAP] on LIBRARY screen
2) Measure back tension at the point as shown by the arrow (see figure below)
3) Adjustment done by turning the dial.

Wire Back tension

Wire Wire Dia
No Bobbin (grams) Measured back tension (g)
make (mm)
(kg)
1 5/10 0.1~ 0.25 150~190
2 5/10 0.3 270~330
 Form no: Rev. Page:
:
FM-CUS-016 03 9 of 9
ANNUAL MAINTENANCE CHECK LIST
DUO43/64 Series

Recommendations by service engineer:

Name of Service Engineer Name of Customer

_________________________
Signature of Service Engineer Customer Signature

Company Stamp and Date