Mazak Live Tooling Repair

Mazak live tool, 5000rpm

We offer Mazak live tool repair services for all Mazak precision tools.  Our repairs will typically cost 1/2, or less than 1/2 the price of a new live tool.  Plus, we can upgrade the original non-sealed bearing design, to a sealed / shielded bearing design at all bearing locations.  We keep bearings in stock for these live tools to allow us to keep pace with our repair volume.  Lead-time can be as short as 2-3 days.

  • Most live tools exceeding 0.001″ runout are due, or almost due, for a repair.  0.0008″ or less is the target runout for a live tool.
  • Live tools like to rest as long as they cycle at full speed or maximum load.  5 minutes is a typical maximum run time followed by a 5 minute rest.
  • 150 to 160F temperatures are common when running at full load.
  1. Disassembled and cleaned.
  2. Inspected dimensionally and visually.
  3. Quoted for repair.
  4. The spindles are assembled with new precision grade sealed / shielded bearings.
  5. If necessary, the spindle is ground to true the taper, and / or the bearing journals are plated and re-ground to proper bearing tolerance and total indicated runout.
  6. As required, the lower, middle and upper bearing housings may be bored, bushed, and reground to proper concentricity and dimensional tolerance.
  7. The spindles are re-assembled.
  8. The spindles are installed in the housing.
  9. The unit is run tested for 5-10 hours with testing of vibration, temperature, and noise levels

Why should you have your multi-spindle boring head, high speed right angle head, or other aggregate head, repaired by Ekstrom-Carlson?

  1. Lead-time: 1-2 Week average for multi-spindle heads, including tear down, inspection, quotation, and repair.  3-5 days for right angle heads and live tooling repairs.
  2. Price: Much lower price than the OEM, or the OEM distributor.
  3. USA repair: We repair the unit in Rockford, Illinois.  It is not shipped overseas, as is often the case for various machines.
  4. Parts repair: Where possible, we will save money by repairing motor spindles and gear spindle shafts.  Some manufacturer’s representatives will always quote a brand new unit if the unit drive shaft is damaged, or if the bearings require replacement.  75% of the time, we can save the original unit at less than 50% the cost of new.
  5. Sealed bearings when available and possible conversion to ceramic bearings.
  6. Free inspections.
  1. The condition of the machine before the rebuild along with accurately diagnosing any and all problems.
  2. Installing proper replacement parts including spindle grade bearings and parts with OEM tolerances that are known only to OEM’s such as Ekstrom-Carlson.
  3. Precision tolerance machinery and tooling including grinding, plating and balancing equipment.
  4. Experience and quality workmanship of the repair technician.

Live Tool Repair • Case Studies

Custom Tool for Worldwide Auto Manufacturer

We are honored to have manufactured a custom carbide parabolic spline form tool for a worldwide luxury car manufacturer to precise tolerances. This is just another example of how we can meet all of your custom tooling needs at a great price without sacrificing quality.

Gros-Ite

5M2-L40-00-R, s/n 70004927-3, 10Hp, 7200rpm, 460v, 240Hz DR7000877 Angular contact bearing DR7002280 Angular contact bearing DR7000087 Dynamic Balance Rotating Part DR7000041 Spindle Repair Labor And Assy Inspection Results: •The spindle journal diameters show no appreciable wear and are acceptable for proper bearing fits. •The upper bearing housing inner diameter meets design specifications and shows no appreciable wear. [...]

Haas, VF-4B, s/n 31560, 10000rpm

VF-4B, s/n 31560, 10000rpm DR7000951 Lower bearing DR7000426 Upper bearing DR7000039 Bearing Cartridge Repair DR7000087 Dynamic Balance Rotating Part DR7000041 Spindle Repair Labor And Assy Inspection Results: •The spindle journal diameters show no appreciable wear and are acceptable for proper bearing fits. •The upper bearing housing inner diameter is larger than design specifications and shows [...]

Gerardi

head, F90-07ATC, s/n 038075, 10000rpm DR7000149 Angular contact bearing DR7001929 Angular contact bearing DR7002209 Angular contact bearing DR7000024 Misc. Seals / Grease / etc... DR7000041 Spindle Repair Labor And Assy Inspection Results: •The spindle journal diameters show no appreciable wear and are acceptable for proper bearing fits. •The bearing housing inner diameter meets design specifications [...]

SKF

4-075-03-0615, 21123K11, 7.5kW, 24000rpm, 380v, 400Hz DR7000041 Spindle Repair Labor And Assy Inspection Results: •The proximity sensor was adjusted to read properly

Haas

VF2 spindle, 18783 DR7000610 Lower bearing DR7001051 Upper bearing DR7000009ATC Dust Grind Taper - ATC spindle DR7000039 Bearing Cartridge Repair - plate & grind upper bore DR7001250 Haas Disc Spring DR7000024 Gripper balls DR7000087 Dynamic Balance Rotating Part DR7000041 Spindle Repair Labor And Assy Inspection Results: •The spindle journal diameters show no appreciable wear and [...]

Mori Seiki

Linear live tool, T32376C02 DR7000003 Angular contact bearing DR7001147 Needle roller bearing DR7001854M Plate & Grind Journal - Manual spindle motor or live tool DR7000024 Misc. Seals / Grease / etc... DR7000041 Spindle Repair Labor And Assy Inspection Results: •The upper journal is worn and rough. We recommend plating and grinding the journal. •The bearing [...]

Coromant

live tool, 410504033-65, K15-02098-3.06, 6000rpm DR7001467 Tapered roller bearing DR7001343 Angular contact bearing DR7001179 Deep groove bearing DR7001764 Needle roller bearing DR7000024 Misc. Seals / Grease / etc... DR7000041 Spindle Repair Labor And Assy Inspection Results: •The spindle journal diameters show no appreciable wear and are acceptable for proper bearing fits. •The bearing housing inner [...]

Coromant

live tool, 410104010-65, K15-06146-5.2, 6000rpm DR7001467 Tapered roller bearing DR7000484 Angular contact bearing DR7000024 Misc. Seals / Grease / etc... DR7000041 Spindle Repair Labor And Assy Inspection Results: •The spindle journal diameters show no appreciable wear and are acceptable for proper bearing fits. •The bearing housing inner diameter meets design specifications and shows no appreciable [...]

WTO

Variable angle live tool, 411010007-40, K97-801 5-1 DR7002203 Angular contact bearing DR7002204 Angular contact bearing DR7002205 Angular contact bearing DR7002206 Angular contact bearing DR7002207 Angular contact bearing DR7001954 Angular contact bearing DR7001533 Needle roller bearing DR7001375 Needle roller bearing DR7001854M Plate & Grind Journal - Manual spindle motor or live tool DR7000039 Bearing Cartridge Repair [...]

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