HC Series

4000 | 5000

1 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 TABLE OF CONTENTS

TABLE OF CONTENTS

Introduction ........................................................................................3
Optimum Plus Service and Support ................................................. 4-5
Top 10 Advantages ..............................................................................6
High Accuracy ....................................................................................7
Machine Design ............................................................................. 8-9
Pallets and Two-Pallet Changers.......................................................10
Spindle Power and Speeds.................................................................11
Fast, Easy and Efficient Programming......................................... 12-13
MAZATROL SmoothG Control......................................................... 14-15
Optional Equipment...........................................................................16
Mazak Automation Systems...............................................................17
Mazak Digital Solutions............................................................... 18-19
External Dimensions.................................................................... 20-21
Machine Specifications................................................................ 22-23
Spindle and Unit Rebuild...................................................................24
Financing and Resources...................................................................25
Mazak Technology + Technical Centers........................................ 26-27

2 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 INTRODUCTION

HC SERIES
HIGH PERFORMANCE, OUTSTANDING VALUE

Mazak builds their HC Series machines with

the same proven designs and technologies
long incorporated into its line up of world-
class horizontal machining centers. Designed
and built in Kentucky, the fully-equipped,
yet extremely cost-effective, HC Horizontal
Machining Centers deliver unsurpassed
reliability, productivity and ease of operation.
Get the capabilities and high performance of
a larger Mazak horizontal machining center
but on a space-saving, smaller-footprint
machine platform for low, medium and
high-volume production environments.

As with all its machines, Mazak backs those

in the HC Series with the industry’s most
acclaimed and comprehensive service and HC-4000
support program.

MACHINE CONFIGURATIONS:
• HC-4000
• HC-5000

HC-5000

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 3
OPTIMUM PLUS SERVICE AND SUPPORT

MAZAK OPTIMUM PLUS

To maximize machine tool investments, the Mazak Optimum Plus
program represents a company-wide commitment to provide the best
possible, most comprehensive support.

The Optimum Plus program encompasses Five Pillars — distinct,

yet interrelated areas:
• Single-source service
• Technical support — machine and CNC
• Parts support
• Progressive Learning
• Spindle and unit rebuild

Single-source service
Mazak is a single point of contact for any Mazak-related service
need, whether it involves a machine, control, accessory or automation
solution. This effective service approach helps customers maintain
the highest possible level of productivity.

Benefits of Mazak’s single-source approach include:

• Free technical phone support and software upgrades for the
life of a Mazak machine
• Software support that provides instantaneous diagnostic
services via remote real-time systems
• Guaranteed phone response to any technical question
within one hour via a 24/7 technical phone support system
• More than 350 factory-trained Mazak service representatives
and certified distributor personnel that can be at a customer’s
site within 24 hours under most circumstances
• Wide variety of services, including laser calibration to ISO,
ANSI and JIS standards; ball bar qualification and analysis;
preventive maintenance plans and programs; and vibration
analysis and benchmarking

Technical support — machine and CNC

Comprehensive warranties on every Mazak machine tool component, THE MAZAK OPTIMUM PLUS PROGRAM ENABLES CUSTOMERS TO
including a two-year part warranty on CNC control components. MAXIMIZE THE VALUE OF THEIR MAZAK PURCHASE.

Technical support for machines and CNCs also includes:

• Additional warranty coverage (available upon request)

4 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 OPTIMUM PLUS SERVICE AND SUPPORT

Parts support
Mazak's spare parts fulfillment ensures the fastest possible reaction
time. The state-of-the-art Mazak North American Parts Center
uses the latest AS/RS fully automated warehouse storage system
technology and maintains a $65 million parts inventory.

Benefits of the North American Parts Center include:

• Average 97% same day parts shipment and after hours shipping
• 60,000 part numbers in stock
• Call center open Monday-Saturday
• Convenient web-based parts ordering
• Experienced part specialists
• Lifetime CNC parts support
FULLY AUTOMATED WAREHOUSE STORAGE SYSTEMS ENSURE
Click here for more information on parts support. THE FASTEST DELIVERY OF MAZAK SPARE PARTS.

Progressive Learning
Mazak’s Progressive Learning represents a unique, phased approach
to education and training for customers, combining hands-on
training, web-based instruction and real-world examples. The
program’s tiers of offerings — Pyramid of Learning — range from
self-paced coursework to highly advanced classes. Every Mazak
machine includes three years of programming training at no charge
to customers.

Mazak’s Pyramid of Learning is a visual representation of its

approach to training. The lower levels at the base of the pyramid
represent basic skills education for new machinists, while the upper User Groups
and On-Site
levels signify advanced training for highly experienced programmers Custom Training
ELITE
and operators.
PALLETECH Optimization
Pyramid of Learning levels include: and Hands-on Training (H.O.T.)
for Multi-Tasking Machines
• Simple online training ADVANCED
• Introductory programming training
• Traditional hands-on training
Instructor Led Traditional Classroom
• Advanced training TRADITIONAL Training on Programming and Maintenance
• Customized training CLASSROOM

BASIC Web-based EIA and MAZATROL Programming

PROGRAMMIN
G

Web-based Courses for Customers on Operations, Safety, etc.

INTRODUCT (over 450 tutorials)
ORY

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 5
 TOP 10 ADVANTAGES

TOP 10 ADVANTAGES OF THE HC SERIES

HC Series machines feature several new and innovative technologies

to help job shops boost speed, performance and precision in a wide
variety of metalworking applications. The series brings advanced
technology, value and productivity to part-processing operations.

1. Full fourth-axis as standard.

2. Extremely rigid bases and columns built for stability and

vibration dampening.

3. Robust high-performance spindles offered in various

maximum speeds.

4. 1G axis acceleration provides high speed machining and

superior accuracy.

5. Automatic tool changer and large 84-tool drum-style magazines

provide twice the storage capacity as standard.

6. Standard two-pallet changer further boosts machine utilization.

7. Mazak MX Hybrid Roller Guide System delivers durability,

reliability and long-term accuracy.

8. Mazak MAZATROL SmoothG CNC offers fast and easy EIA/ISO and
conversational programming.

9. Simple and efficient chip management helps reduce downtime.

10. Space-saving innovative small machine footprint and

easy-to-access maintenance panels.

6 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 HIGH ACCURACY

HIGH ACCURACY

Mazak’s rigid machine base structure, advanced spindle/motor

design and MAZATROL CNC submicron machine movement give
HC Series machines extremely high part accuracy and surface
finish capabilities. And, as with all the machines built at the Mazak
iSMART Factory™ in Florence, Kentucky, Mazak closely monitors the
manufacture and assembly of each and every HC Series machine to
guarantee their consistent precision and performance.

To further ensure the highest precision possible over extended

hours of operation, Active Vibration Control and Thermal Shield
intelligent machine functions minimize detrimental vibration and
heat when machining.

ACTIVE VIBRATION CONTROL

Axis acceleration/deceleration can cause machine vibration. Mazak’s
Active Vibration Control function effectively reduces vibration for high
accuracy positioning in all axes and shorter machining cycle times. It
also curbs the effects such vibration has on the cutting tool for longer
tool life and exceptional part surface finishes.

INTELLIGENT THERMAL SHIELD

Mazak designs its machine units to generate the least amount
of heat possible during operation to minimize displacement.
But when ambient shop temperatures fluctuate, the Thermal
Shield function automatically compensates via exhaust ducts that
channel generated heat out and away from the machine and any
machines adjacent to it.

MAZAK iSMART FACTORY

The Mazak iSMART Factory encompasses the complete digital
integration of the factory with state-of-the-art manufacturing
equipment, automation and advanced manufacturing practices.
It hinges on the free flow and sharing of data in terms of process
control and operation monitoring to ensure the highest quality
standards and the utmost production consistency from one
machine to the next.

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 7
MACHINE DESIGN

The HC Series combines high quality, innovation and extreme cost-

effectiveness without sacrificing machine performance, and because
Mazak engineers and builds the series in Kentucky, the company can
ensure the shortest delivery time possible. The Mazak factory uses a
Production-On-Demand approach for extreme manufacturing agility
to quickly react to current market trends, which means machines
coming off the line all incorporate the latest, most innovative
technology.

MACHINE CONFIGURATIONS
HC Series machines are 4-axis horizontal machining centers with
traveling columns and full fourth-axis NC rotary tables as standard. While
smaller in size, the machines accommodate large and heavy workpieces
as well as offer, as standard, built-in two-pallet changing capability.
HC-5000
BASE AND COLUMN
New reinforced cast-iron bases and columns ensure high-rigidity and
thermal control as well as ample part capacity.

Because smaller-size machines are more likely to be moved around

a shop, Mazak equips the HC Series machine bases with its highly
effective 3-point support systems. The system simplifies foundation
preparation for faster machine installations and easier machine-
leveling adjustments.

FULL FOURTH-AXIS ROTARY TABLES

The HC Series rotary tables deliver speed and precision that help
shorten part cycle times, while high-accuracy encoders ensure
exceptional repeatability.

8 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 MACHINE DESIGN

SERVO DRIVE SYSTEM

HC Series machines use the latest servo drive system with 1G axis
acceleration for high machining speeds and superior accuracy. A
ballscrew core cooling system ensures stable machining accuracy
over extended periods for high-speed operation.

ROLLER GUIDE SYSTEM

The Mazak MX Hybrid Roller Guide System featured on HC Series
machines allows for faster speeds and boosts accuracy, leading
to a comprehensive improvement in overall machine productivity
and profitability. When compared with traditional ball guides and
boxways, the advantages of the Mazak MX Hybrid Roller Guide
System are clear.

• More surface contact for large load capacities and better

dampening
• Better distribution of load points via an X-design that allows
load to be applied to four directions
• Higher positioning accuracy than boxways due to no stick
and slip
• Faster and greener than boxways with nearly twice the rapid
traverse rate and less contamination in machine coolant system

SENSORS
Advanced sensor technology incorporated into HC Series machines
allows for optimum stability and condition control. Sensors monitor
heat and vibration along with other machine functions to ensure
consistent high-precision machining over extended hours of
operation.

EASE OF MAINTENANCE
The single maintenance panel for oil and air units on HC Series
machines is easy to access, and cables are easy to identify by color,
which reduces time required for maintenance.

EFFICIENT CHIP MANAGEMENT

Chip conveyor systems on HC Series machines provide fast, low-
maintenance chip management, while flood coolant evacuates
chips quickly and efficiently from machine work envelopes.
Complete chip systems fit within the footprints of the machines.

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 9
 PALLETS AND TWO-PALLET CHANGERS

PALLETS AND TWO-PALLET CHANGERS

Built-in, standalone rotary-style two-pallet changers on HC Series

machines increase spindle utilization and allow for continuous
uninterrupted production. As a form of simple and efficient
automation, the turntable pallet changing capability enhances
productivity by allowing operators to load, unload and inspect parts
on one pallet while the machine continues to work uninterrupted on
parts fixtured on the other pallet.

Number of pallets: 2
Changing system: rotary
Change time: 7 sec (HC-4000), 8 sec (HC-5000)

TAPER CONE PALLET CLAMPING SYSTEM

Four fixed taper cones on HC Series machine pallets clamp with
more force and strength than do existing center-clamping systems.
With each taper cone clamping with 4,114 ft-lb (18.3 kN) of force, the
system delivers overall pallet holding power of 16,456 ft-lb (73.2 kN).
This stronger holding force allows for a higher Z-axis allowable thrust
height of 19.68" (500 mm) as well as an increased allowable thrust
level of 8,487 ft-lb (11.5 kN) at the maximum height for aggressive
machining of bigger parts.

For efficient and interference-free operation, HC Series machines

accommodate, as optional, overhead hydraulic systems. Up to six
ports can supply either hydraulics or pneumatics from the top of
machine pallet changers to the upper ends of fixtures.

10 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 SPINDLE POWER AND SPEEDS

SPINDLE POWER AND SPEEDS

12,000 RPM TORQUE
70.4 ft-lbf (95.5 Nm)(10 min rating)
48.0 ft-lbf (65.1 Nm)(30 min rating)(40% ED)
Output (kW) 35.2 ft-lbf (47.7 Nm)(Cont. rating) Torque (Nm)
HC Series available machine spindles range from standard to high- 100 100
33.0 ft-lbf (44.7 Nm)(10 min rating)
speed versions, all of which feature hybrid ceramic ball bearings and 24.2 ft-lbf (32.8 Nm)(30 min rating)
cooling jackets for precision performance and long life. With such 16.5 ft-lbf (22.4 Nm)(Cont. rating)

a wide offering, spindle speed and power are matched perfectly to 18.5 kW (5 min rating)
15 kW (10 min rating)
11 kW (10 min rating)
intended part applications, whether machining aluminum, cast iron 7.5 kW (30 min rating)(40% ED) 11 kW (30 min rating)
(40% ED)
10 7.5 kW (Cont. rating) 10
or nickel-based alloys. 5.5 kW (Cont. rating)

• 12,000 rpm/40 taper or BigPlus 40 (standard)

• 15,000 rpm/40 taper or BigPlus 40 (optional)
• 20,000 rpm/40 taper or BigPlus 40 (optional)
1 1
100 1,000 2,347 3,200 8,000 12,000 100,000
Spindle rpm (min-1) 3,950
AUTOMATIC TOOL CHANGING AND STORAGE
(FOR REFERENCE ONLY)
With double the capacity, HC Series machine tool magazines — as
standard — accommodate 84 tools. The rotary drum-type storage
system features Mazak’s innovative space-saving double pocket 15,000 RPM TORQUE
design where each tool position actually has two tool pockets Output (kW)
110
Torque [Nm (ft-Ibf)]
210
situated at 60 degree angles from one another. This allows HC Series 205 Nm (10-min)

machines to store twice the amount of tooling within the same space 131 Nm (cont. rating)
52.5 Nm (10-min)

as 42-tool magazine for extended periods of unmanned operation. 44.2 Nm (cont. rating)

15 kW (10-min) 22 kW (10-min)
30
The high-speed automatic toolchangers (ATCs) work in tandem with 18.5 kW (cont.
rating)
11 kW
the double-pocket tool magazines, and because the changer always (cont. rating)
10 10
takes the quickest route to the next needed tool position, tool changes
are extremely fast and help reduce non-cut times. With cam-driven
technology, the changing system delivers strong, dependable and
consistent performance.

1 1
700 800 2,378 4,000 12,000 15,000
100 1,000 2,727 10,000 10,0000

(FOR REFERENCE ONLY)

20,000 RPM TORQUE

Output 10% ED Output 40% ED Torque 30% ED
Output 30% ED Output Continuous rating
Torque (Nm) Output (kW)
1,000 100

35 kW
123.9 ft-lbf (168 Nm)(10% ED) 22 kW
100 62.0 ft-lbf (84 Nm)(40% ED) 26 kW
15 kW
10
42.0 ft-lbf (57 Nm)(Cont. rating)

10

1
1

0.1 0.1
10 100 3,300 10,000 100,000
Spindle rpm (min-1) (Winding changeover speed)

(FOR REFERENCE ONLY)

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 11
FAST, EASY AND EFFICIENT PROGRAMMING

The continuously innovative Mazak MAZATROL SMOOTH CNC controls

make programming HC Series machines easy, fast and efficient. The
highly versatile controls allow for both EIA/ISO and conversational
programming, while other features and capabilities boost power
and functionality.

EIA/ISO COMPATIBILITY STANDARD

MAZATROL G-codes are the same as those used in conventional EIA
CNC machines. This allows HC Series machine users to run programs
made for other machine brands by simply editing M codes and
confirming axis strokes along with cutting conditions.

CONVERSATIONAL PROGRAMMING
The industry standard MAZATROL conversational programming
makes it possible for inexperienced operators to quickly and easily
develop machining programs for HC Series machines. Operators
answer conversationally displayed questions concerning the intended
workpiece. These queries include type of material, OD/ID dimensions,
part lengths and several others. Then, according to the input
SMOOTHG CONTROL SCREEN
data, the MAZATROL control automatically calculates intersection
coordinates and tool index positioning in addition to optimized
cutting conditions and machining processes.
Number of program lines
89% REDUCTION

EIA / ISO MAZATROL

language language

12 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 FAST, EASY AND EFFICIENT PROGRAMMING

PROCESS HOME SCREENS

Innovative touch operation of the MAZATROL
SmoothG control streamlines data entry and
minimizes the number of displays to reduce
programming times for HC Series machines.
Five different home process screens each
display their appropriate data in an easy to
understand manner. Operators can touch
icons to quickly navigate to additional
screen displays.
SMOOTHG PROGRAMMING SCREEN SMOOTHG TOOL DATA SCREEN

Process home screens include:

• Programming
• Tool data
• Setup
• Machining
• Maintenance

SMOOTHG MACHINING SCREEN SMOOTHG MAINTENANCE SCREEN

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 13
MAZATROL SmoothG CONTROL

The MAZATROL SmoothG CNC optimizes programming and makes

it easy to generate programs for processing complex parts through
off-centerline machining as well as angled drilling, milling and
tapping. The control incorporates a wide variety of advanced
programming functions that allow it to offer complete ease of use
and ensure high-speed, high-accuracy machining performance.

Features and functions of the MAZATROL SmoothG control include:

• Virtual Machining allows operators to perfect part programs

prior to initiating cutting
• High Gain Feed Forward Control boosts machining speed
and accuracy
• Fast Rotary Axis Speeds optimize gear skiving and rotary
axis threading
• Variable Acceleration Control calculates optimal
acceleration for a combination of axes
• Position-Controlled Hobbing provides fast, convenient
hobbing and skiving operations
• Real Time Tuning ensures optimal machining balance as
workpiece weight changes
• Quick MAZATROL makes it possible to directly import 3D
CAD models into the control and automatically extract
coordinates from it to simply machine programming
• Quick EIA plots toolpaths prior to running programs and
checks for any interferences in those paths

14 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 MAZATROL SMOOTHG CONTROL

MAZATROL SmoothG SPECIFICATIONS

MAZATROL EIA
Number of controlled axes Simultaneous 2 ~ 4 axes
Least input increment 0.00001 inch, 0.0001 mm, 0.0001º
Shape error designation, Smooth corner control,
High speed, Shape error designation, Smooth corner control, Rapid traverse overlap, Rotary axis shape compensation,
high-precision control Rapid traverse overlap, Rotary axis shape compensation High-speed machining mode,
High-speed smoothing control function
Positioning (Linear interpolation), Positioning (Independent
Positioning (Linear interpolation), Positioning (Independent interpolation), Linear interpolation, Circular interpolation,
interpolation), Linear interpolation, Circular interpolation, Spiral interpolation, Helical interpolation, Cylindrical
Interpolation Cylindrical coordinate interpolation, Polar coordinate coordinate interpolation*, Fine spline interpolation*,
interpolation, Synchronized milling spindle tapping* NURBS interpolation*, Polar coordinate interpolation*,
Synchronized milling spindle tapping*
Rapid traverse, Cutting feed, Cutting feed (per minute), Rapid traverse, Cutting feed, Cutting feed (per minute),
Cutting feed (per revolution),Dwell (specified time, specified Cutting feed (per revolution), Inverse time feed, Dwell
number of rotation), Rapid traverse override, Cutting feed (specified time, specified number of rotation), Rapid traverse
Feed rate override, G0 speed variable control, Feedrate clamp, override, Cutting feed override, G0 speed variable control,
Variable acceleration/deceleration control, Feedrate clamp,Time constant changing for G1, Variable
Constant control for G0 tilting* acceleration/deceleration control, Constant control for G0 tilting*
Program registration Max. number of programs: 960, Program storage: 2 MB, Program storage expansion: 8 MB*, Program storage expansion: 32 MB*
Control display Display: 19" touch panel, Resolution: SXGA
S code output, Spindle speed clamp, Spindle speed override, Spindle speed reaching detection, Multiple position orient, Constant
Spindle functions surface speed, Spindle speed command with decimal digits, Synchronized spindle control, Max. speed control for spindle
Tool offset pairs: 4000, T code output for tool number, Tool offset pairs : 4000, T code output for tool number, T code
Tool functions Tool life monitoring (time), output for group number, Tool life monitoring (time), Tool life
Tool life monitoring (number of machined workpieces) monitoring (number of machined workpieces)
Miscellaneous functions M code output, Simultaneous output of multiple M codes
Tool offset functions Tool position offset, Tool length offset, Tool diameter/tool nose R offset, Tool wear offset
Coordinate system Machine coordinate system, Work coordinate system, Local coordinate system, Additional work coordinates (300 set)
Machine functions — Hobbing*, Shaping function*, Dynamic compensation II*
Machine compensation G0/G1 independent backlash compensation, Pitch error compensation, Volumetric compensation*
Emergency stop, Interlock, Stroke check before travelling, Retraction function for the vertical axis, INTELLIGENT SAFETY SHIELD
Protection functions (manual mode), INTELLIGENT SAFETY SHIELD (automatic mode)*, MAZAK VOICE ADVISER
Memory operation, Tape operation, MDI operation,
Automatic operation mode Memory operation EtherNet operation*
Optional block skip, Optional stop, Dry run, Automatic handle
Automatic operation Optional stop, Dry run, Automatic handle control, control, MDI control, TPS, Restart, Restart 2, Collation stop,
control MDI control, TPS, Restart, Machine lock Machine lock
Tool length and tip teach, Touch sensor coordinates Tool length and tip teach, Tool offset teach, Touch sensor
Manual measuring measurement, Workpiece offset measurement, WPC coordinates measurement, Workpiece offset measurement, WPC
functions coordinate measurement, Measurement on machine coordinate measurement, Measurement on machine
WPC coordinate measurement, Auto tool length measure-
Automatic measuring Auto tool length measurement, Sensor calibration,
ment, Sensor calibration, Tool eye auto tool measurement,
functions Tool breakage detection, External tool breakage detection*
Tool breakage detection, External tool breakage detection*
MDI measurement Partial auto tool length measurement, Auto tool length measurement, Coordinate measurement
Interface PROFIBUS-DP*, EtherNet I/P*, CC-Link*
Card interface SD card interface, USB
EtherNet 10 M / 100 M / 1 G bps

*
Option

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 15
 OPTIONAL EQUIPMENT

OPTIONAL EQUIPMENT

Mazak offers a wide array of options from which to choose for the HC
Series that further enhance machine performance, increase uptime
and boost overall operational efficiency.

• High-pressure coolant maximizes chip evacuation and contributes

to longer cutting tool life
• SUPERFLOW® coolant allows for increased cutting speeds, extends
tool life and makes for efficient chip evacuation
• Mist collector helps reduce maintenance costs and ensures a
clean, safe work environment
• Automatic tool length measurement and tool breakage detection CHIP CONVEYOR MIST COLLECTOR
allows for fast, non-contact tool setting and tool breakage
detection to significantly reduce overall part set-up time
• Mazak monitoring system B (OMP-60) touch sensor tool mounted
in machine spindle to automatically align workpieces via shifting
coordinate values
• Chip conveyor designs for a wide variety of chip shapes and
material types such as aluminum, steel and cast iron
• Work air blast removes sticking chips from chuck and workpiece

SUPERFLOW T8/1000

16 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 MAZAK AUTOMATION SYSTEMS

MAZAK AUTOMATION SYSTEMS

Mazak automation further increases the productivity, throughput and

part quality of HC Series machines. Standard and customized Mazak
automation solutions paired with extensive and ongoing support
ensure the best fit for individual production needs and that output
goals are achieved.

STANDARD AUTOMATION ENGINEERED SOLUTIONS

TWO-PALLET CHANGER ARTICULATED ROBOT

STANDARD TWO-PALLET CHANGERS ARTICULATED ROBOTS

Standard two-pallet changers enhance productivity by allowing Articulated robots automate part transfers and peripheral operations.
part loading and unloading while the machine continues to work They also eliminate the challenges associated with handling large,
uninterrupted. heavy or cumbersome parts. Robot configurations range from two
jointed to seven jointed to meet the needs of various applications.

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 17
MAZAK DIGITAL SOLUTIONS

For the HC Series and all its machines, Mazak offers digital
solutions for fully integrated, data-driven smart manufacturing.
These progressive solutions include SMOOTH TECHNOLOGY,
MTConnect®, Mazak SMOOTH Link and the Mazak SmartBox.

SMOOTH TECHNOLOGY
Spanning the entire part-production landscape, Mazak’s SMOOTH
TECHNOLOGY platform significantly boosts productivity at every
stage of the metal cutting process — from programming and setup
to actual metal removal operations to automation to monitoring/
data collection and transfer.

Features and benefits of SMOOTH TECHNOLOGY:

• All-encompassing continuously evolving process-performance
technology platform
• Combines advanced capabilities of machine tools and
leading-edge CNC processing and software technologies
• Makes machine tools easy to use
• Boosts machining speed and performance accuracy

MTCONNECT
As an open-source, royalty-free manufacturing protocol,
MTConnect easily connects devices and systems from different
suppliers to capture and share information in a common format
such as XML. It then gives manufacturers the means to gather
valuable data from machines and automated systems for use in
process improvement and increased equipment utilization.

With MTConnect, manufacturers can:

• Gain real-time data sharing throughout a manufacturing facility
• Calculate overall equipment efficiency
• Monitor all equipment from one system ®
• Reduce production losses
• Identify lean manufacturing strategies

Mazak builds all its machines, including those

in the HC Series, to be MTConnect compliant
and offers affordable adapters for existing
Mazak machines in the field.

18 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 MAZAK DIGITAL SOLUTIONS

MAZAK SMOOTH LINK

Perfect for both large and small shops, Mazak SMOOTH Link makes
it possible to sync machine tools with mobile devices to monitor
and manage status at any time from a smartphone, tablet or laptop
computer. This digital tool captures real-time information from the
control and securely transfers the information to a mobile device
via Wi-Fi.

Features and benefits of Mazak SMOOTH Link:

• Machine monitoring gives instant operational status of a machine
and the workpiece in production
• Displays tool layouts and data of each tool changer pocket/
position for effective tool management
• Programming application screen quickly shows all saved EIA
programs and machine’s remaining storage capacity
• Simple to set up and does not require Internet access, a server
PC or server license

MAZAK SMARTBOX
Secure the “big data” that comes from connecting machines to
the Industrial Internet of Things (IIoT). Mazak SmartBox is a launch
platform for easy and highly secure entrance into the IIoT. As a
scalable, end-to-end solution, SmartBox connects manufacturing
equipment, including machines, software and other devices,
to a factory’s network and allows the free flow of information to
management systems via MTConnect.

Features and benefits of Mazak SmartBox:

• Advanced cyber security protection gives IT departments
confidence to digitally integrate manufacturing operations
• Completely open architecture and works with all popular
third-party analytical software platforms
• Monitor any machine regardless of make, model or age

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 19
EXTERNAL DIMENSIONS – HC-4000/HC-5000 (FOR REFERENCE ONLY)

4408.3 (173.56")

564 (22.2") 22.47 (88.46") 987.3 (38.87") 610 (24.02")

650 (25.59")

2015 (79.33")
715 (28.15")
(IMG DOOR)
1100 (43.31")
288 (11.34")

(17.72")
450
15 (0.59")

1730 (68.11") (TANK)

307.5 (12.11") 1883.5 (74.15") 879 (34.61")

2180 (85.83") 582.5 (22.93") 830 (32.68") 471 (18.54")

394.7 (15.54")

630 (24.8") 920 (36.22") 630 (24.8")

373 (14.69")

21.7 (0.85")

(OPEN WIDTH) 130 (5.12")

460 (18.11") 460 (18.11")
(DOOR ST) (DOOR ST) POWER INLET
526.3 (20.72")

95 (3.74")

676.37 (26.6")

850 (33.46")
1595 (62.8")
2991.3 (117.77")
2015 (79.33")

664.26 (26.2")

2859.7 (112.59")
2838 (111.73")
2465 (97.05")

1615 (63.58")
1124.36 (44.3")
1558 (61.3")
(12.8")
325
450 (17.72")

20 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 EXTERNAL DIMENSIONS

7062.9 (278.86")

5657.9 (222.75") (MACHINE LENGTH TO CHIP CONVEYOR/JORGENSEN) 1425 (56.1")

(TANK PULL OUT)
14.4 (0.57") 5185 (204.13") (MACHINE LENGTH TO TANK) 458.5 (SPIRAL PULL OUT)
(18.05")
4408.3 (173.56") (MACHINE LENGTH LEFT SIDE) 1235.2 (48.63")

R5
130 (5.12") 776.7 (30.58")

87.
23
(23
.1"
)
530 (20.87")

682 (26.85")
3250 (127.95")

879 (34.61")
(SPIRAL)
1090 (42.91")

471 (18.54")
3070 (120.87")

1386 (54.57")

1883.5 (74.15")
830 (32.68")
1090 (42.91")

694.5 (27.34")

582.5 (22.93")
(SPIRAL)
3250 (127.95")
67.11 (2.6") 465.89 (18.3")
725 (28.54")

192 (7.6")

R63

)
12"
3.6

26.
(24

5(
.95

63.
")

307.5 (12.11")
50°
360 (14.2")

R6

POWER INLET
AIR INLET 629.2 (24.77") 736 (28.98")
4907.5 (193.21") (MACHINE LENGTH RIGHT SIDE) 2161 (85.08")

4940.1 (194.49")
32.6 (1.28") 610 (24.02") 915 (36.02") 1085 (42.72") 997.5 (39.27") 1300 (51.18")
235 (9.25") 850 (33.46") 1000 (39.37") 300
700 (27.56") (11.81")
(DOOR OPEN WIDTH)
(DOOR ST) TRANCE BOX
12 (0.5") 663 (26.1") 25 (1")
200 (7.87")

523.2 (20.6") 139.8 (5.5") CONTROL BOX

(OPEN WIDTH)
(15.5")
394.7

BRAKER
900 (35.43")
2859.7 (112.59")
2015 (79.33")
2665 (104.92")

1050 (41.34")
1218.2 (47.96")
1176.9 (46.3")

150 (5.9")
450 (17.72")

365 (14.4")
1779.6 (70.06")
(20,000 min-1)
1798 (70.79")

12,000 min-1)
20 (0.79")

AIR INLET

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 21
MACHINE SPECIFICATIONS – HC SERIES
HC-4000 HC-5000
X-axis column right/left X axis in (mm) 22.05 (560) 28.74 (730)
Y-axis spindle up/down Y axis in (mm) 25.20 (640) 28.74 (730)
Travel Z-axis table back/forth Z axis in (mm) 25.20 (640) 31.50 (800)
Distance between table top to spindle nose in (mm) 2.76–27.95 (70–710) 2.76–34.25 (70–870)
Distance between pallet to spindle center in (mm) 3.54–28.74 (90–730) 3.94–32.68 (100–830)
Table size in (mm) 15.75 x 15.75 (400 x 400) 19.69 x 19.69 (500 x 500)
Max. workpiece dimensions in (mm) ø24.8 x 35.43 (ø630 x 900) ø31.5 x 39.37 (ø800 x 1,000)
Pallet load (evenly loaded) lb (kg) 881.85 (400) 1,102.31 (500)
Table 5/8–11 UNC tapped holes 5/8–11 UNC tapped holes
Pallet top surface 25 places 25 places
3.15" (80 mm) pitch 3.94" (100 mm) pitch
Minimum indexing angle increment deg 0.0001° 0.0001°
Indexing time sec 1.0 s/90°, 1.3 s/180° 1.2 s/90°, 1.5 s/180°
Spindle speed min-1 40 to 12,000 40 to 12,000
Spindle speed range 2 speeds (electric) 2 speeds (electric)
Spindle
Spindle taper #40 #40
I.D. of spindle bearing in (mm) 2.76 (70) 2.76 (70)
Rapid traverse rate (X, Y, Z axes) ipm (m/min) 2,362.20 (60,000) 2,362.20 (60,000)
Feed rate Cutting feed rate (X, Y, and Z axes) ipm (m/min) 0.04 ~ 2,362 (1 ~ 60,000) 0.04 ~ 2,362 (1 ~ 60,000)
Axis acceleration/deceleration 1.0 G 1.0 G
Tool shank #40 #40
Tool storage capacity 84 84
Automatic Max. tool diameter/ ø3.74"/16.54"/26 lbs ø3.74"/16.54"/26 lbs
tool length (from gauge line)/weight (ø95 mm/420 mm/12 kg) (ø95 mm/420 mm/12 kg)
changer [max. moment: 4.35 ft-lbs (5.9 Nm)] [max. moment: 4.35 ft-lbs (5.9 Nm)]
Max. tool diameter with adjacent pockets empty in (mm) ø6.69" (ø170 mm) ø6.69" (ø170 mm)
Tool selection method Random selection/shortest path Random selection/shortest path
Number of pallets 2 2
Automatic
pallet Changing system Rotary Rotary
changer
Pallet change time sec 7 8
Spindle motor (40% ED (30 min. rating)/ hp (kW) 14/10 (11/7.5) 14/10 (11/7.5)
Motors cont. rating)
Flood coolant pump motor Hz (W) 50/60 (730/1,210) 50/60 (730/1,210)
Electrical power supply (cont./40% ED) 23.7/28.8 kVA @ 50/60 Hz 23.7/28.8 kVA @ 50/60 Hz
Power
requirement 0.5 ~ 0.9 MPa (70 ~ 130 PSI)/ 0.5 ~ 0.9 MPa (70 ~ 130 PSI)/
Air supply 80 L/min (2.82 ft³/min) 80 L/min (2.82 ft³/min)
Machine height in (mm) 112.56 (2,859) 112.56 (2,859)
Machine size Floor space requirement in (mm) 120.87 x 193.23 (3,070 x 4,908) 120.87 x 193.23 (3,070 x 4,908)
Machine weight lbs (kg) 26,565 (12,050) 26,675 (12,100)

22 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 MACHINE SPECIFICATIONS

STANDARD AND OPTIONAL EQUIPMENT HC-4000 HC-5000

12,000 rpm #40 Standard Standard
12,000 rpm BBT-40 Optional Optional
Spindle
15,000 rpm #40/BBT-40 Optional Optional
20,000 rpm #40/BBT-40 Optional Optional
Pallet changer 2PC Standard Standard
Automatic tool length measurement & tool Optional Optional
breakage detection
Set up Mazak monitoring system B (OMP60) Optional Optional
Manual pulse generator Optional Optional
Flood coolant Standard Standard
Cover coolant Standard Standard
Coolant through spindle with flood 71 psi Optional Optional

Coolant chip High-press coolant thru spindle with flood Optional Optional
disposal 213 psi
Hand held coolant nozzle (for workpiece Optional Optional
washing on pallet changer)
Oil skimmer (RB-200) Optional Optional
Magnetic separator for cast iron Optional Optional
Ball screw core cooling (X, Y, Z axes) Standard Standard
Chiller unit Standard Standard
High accuracy Hydraulic unit temperature control Optional Optional
Coolant temperature control Optional Optional
Scale feedback (X, Y, Z axes) Optional Optional

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 23
 SPINDLE AND UNIT REBUILD

SPINDLE AND UNIT REBUILD

Spindle rebuild
Mazak’s spindle exchange and rebuild program provides the option to
purchase a brand new spindle, have an existing spindle repaired or
acquire a Mazak rebuilt spindle.

Benefits of Mazak’s spindle and unit rebuild service include:

• More than 900 different spindle variations for all types of
turning centers, vertical and horizontal machining centers as
well as Multi-Tasking machines.
• Over 300 available rebuilt spindles for a cost-effective
spindle solution delivered in as little as two or three days.
• Spindle repairs are processed in a clean room environment
and overseen by quality control teams with ISO: 9001:2008
certification.
• Spindle repairs/rebuilds occur within five days of receipt and
include 12 hours of test stand runoff.
• A seven-month parts and labor warranty on rebuilt spindles with
Mazak installation.
• Free technical support regarding replacement options
and processes.

SPINDLE REPAIR

BEFORE AFTER

24 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 FINANCING AND RESOURCES

FINANCING AND RESOURCES

MAZAK CREDIT GROUP

As a wholly owned subsidiary of Mazak Corporation, MCC Credit Group
is the preferred one-stop choice for manufacturers throughout the
United States and Canada who want fast, hassle-free, low-cost
financing on an HC Series machine or any other piece of Mazak
equipment. With a complete knowledge of Mazak’s product portfolio,
MCC Credit Group provides factory terms that can work to customer
advantages. Plus, its direct access to machine specifications, delivery
schedules and installation dates eliminates any additional paperwork
or a delay in the approval or shipment process.

Advantages of working with MCC Credit Group:

• Approval of up to $350,000 with a simple online credit application
(subject to credit approval)
• Quick turnarounds on highly competitive leases and loans with no
blanket liens
• Waive security deposits
• Apply machine deposits directly toward advanced rents, fees or
monthly rental payments
• Offer three to five years financing on all Mazak equipment
• Preserve bank credit lines for working capital and your company’s growth
• Structure true leases for off-balance sheet accounting treatment
and maximum cash flow Click here for more information on financing options.

NORTH AMERICAN SERVICE RESOURCES REGIONAL SERVICE LOCATIONS

North American Customer Service Manager Atlanta Houston
Greg Westrick Steve Carbonneau Jim Jackson
859-342-1892 678-985-4800/800-505-1964 281-931-7770
gwestrick@mazakcorp.com scarbonneau@mazakcorp.com jjackson@mazakcorp.com
Assistant North American Service Manager Chicago Los Angeles
Hiroshi Ito Gary Summers Carlos Santos
859-342-1466 847-885-8311/800-677-8311 310-327-7172/800-511-8927
hito@mazakcorp.com gsummers@mazakcorp.com csantos@mazakcorp.com
North American Parts Manager Florence, Kentucky Canada
Steve Trammel Martin Wilber Michael Cummings
859-342-1790 859-342-1561 519-230-3233/800-668-5449
strammel@mazakcorp.com mwilber@mazakcorp.com mcummings@mazakcorp.com
Parts Order Entry Hartford Mexico
Toni Abdon Kurt Petitti Gustavo Alarcon
888-462-9251 860-292-4400/800-436-8900 011 52 818 221 0910
pparts@mazakcorp.com kpetitti@mazakcorp.com galarcon@mazakcorp.com
Training Supervisor
Roy Gentry AFTER HOURS SERVICE: 800-231-1456
859-342-1854 AFTER HOURS PART SUPPORT:
rgentry@mazakcorp.com Click here to register for after hours parts support.

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 25
MAZAK TECHNOLOGY + TECHNICAL CENTERS

MAZAK TECHNOLOGY AND TECHNICAL CENTERS

As a key component of Mazak’s comprehensive customer support,
its network of eight Technology Centers and a Technical Center
strategically located across North America put component machining
demonstrations, experienced applications engineers and training in
close proximity to customers. These centers also provide a channel for
customer input to Mazak manufacturing for the development of new
machine tool technology.

Technology and Technical Centers offer advanced application support,

education and training, new technology and manufacturing systems
along with on-site training and technology seminars.

Click here for more information on Mazak Technology Centers.

Advanced application support New technology and manufacturing systems

• Expert applications engineers help customers optimize • The latest, most advanced manufacturing systems that
part-production processes and create effective manufacturing can optimize the processing of industry-specific components
solutions • Productivity experts help customers select the best new
• Mazak-certified cutting tool, workholding and automation machine tool technology for their particular businesses
partners collaborate to develop optimized turnkey manufacturing
solutions On-Site Training and Technology Seminars
• Test cuts of customer parts run on the latest, most advanced • Hands-on applications and operator development courses
machine tools • Technical seminars held in conjunction with our Value
• Secure applications development and complete design privacy Inspired Partners (VIPs)
of each customer's individual manufacturing system • Regularly scheduled market-focused events that provide
valuable industry insight
Education and training
• Education, training and seminar events in cooperation with
Mazak technology partners
• Free access to the most advanced machine tools
• Industry-focused education

26 Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice.
 MAZAK TECHNOLOGY + TECHNICAL CENTERS

NATIONAL TECHNOLOGY CENTER MIDWEST TECHNOLOGY CENTER SOUTHWEST TECHNOLOGY CENTER

8025 Production Drive 300 East Commerce Drive 10950 Greenbend Blvd.
Florence, Kentucky 41042 Schaumburg, Illinois 60173 Houston, Texas 77067
(800) 331-9151 (847) 885-8311 (281) 931-7770

SOUTHEAST TECHNOLOGY CENTER WESTERN TECHNOLOGY CENTER NORTHEAST TECHNOLOGY CENTER

1075 Northbrook Parkway 1333 West 190th Street 700 Old County Circle
Suwanee, Georgia 30024 Gardena, California 90248 Windsor Locks, Connecticut 06096
(678) 985-4800 (310) 327-7172 (860) 292-4400

DALLAS TECHNICAL CENTER CANADA TECHNOLOGY CENTRE MEXICO TECHNOLOGY CENTER

935 South Kimball, Suite 151, 50 Commerce Court Spectrum 100 Parque Industrial Finsa
Southlake, Texas 76092 Cambridge, Ontario N3C 4P7 Apodaca Nuevo León 66600
(817) 329-6290 (519) 658-2021 +52-818-221-0910

Click here for more information on Mazak Technology Centers.

Product images are for illustration purposes only and may not be exact representations of the product. Mazak reserves the right to change product images and specifications at any time without notice. 27
 HC Series

www.MazakUSA.com

MAZAK CORPORATION
NORTH AMERICAN MANUFACTURING HEADQUARTERS
8025 Production Drive, Florence, KY 41042
Tel: (859) 342-1700 Fax: (859) 342-1865 08_17_SER_HC_B