Why Rebuild

Okuma machine tools are built to last, and are among the most reliable in the world. Over time though, any metal cutting product will experience wear and tear, resulting in decreased productivity.

Rebuilding your existing equipment to like-new condition lets you recapture its original productivity for 50-60% of the cost of a new machine.

Additional savings are realized because:

  • No new foundation is needed.
  • No new tooling is needed.
  • Original parts programs are maintained.
  • No new training is necessary for operations and maintenance personnel.
  • Your spare parts inventory for the machine can still be used.

Other new parts installed on a standard rebuild include:

  • Way wipers
  • Hydraulic hoses & gauges
  • Lubrication flow meters
  • Belts on the spindle and axis drives
  • Headstock spacers & collars
  • All limit switches
  • Moving conduit assemblies
  • All braided components
  • Coolant nozzles
  • Door rollers & safety glass
  • Work light
  • Safety labels

Is your machine a candidate for an IRI rebuild?

  • Rebuild candidates are typically 8 to 10 years old and have 20,000 to 25,000 or more hours of production time.
  • When your machine is producing parts that no longer meet tolerance, it’s time for a rebuild.
  • When up-time on the machine is less than what the product schedule allows, it’s time for a rebuild.
  • When maintenance personnel are spending more time on the machine than the operator, it’s time for a rebuild.

When it comes to rebuilding, nobody can do it better than IRI and here's why:

  • Factory Parts: As the exclusive Okuma America Corporation rebuilder, IRI uses Okuma engineered parts and fixtures. Over 350 parts are replaced and are upgraded (where possible) to the latest revision further enhancing machine performance.
  • Factory Specialists: IRI's staff has an average of 10 years of Okuma assembly and service experience.
  • Factory Process and Certification: The processes and certifications used by IRI are the same as those of Okuma.
  • Rebuilt on Factory Equipment: The slide ways, turret slides and spindle are all reworked on the same factory equipment used to manufacture new Okuma machines.
  • Factory Inspections: The equipment used for inspection is certified to Okuma's exacting standards. Headstock geometry alignments are qualified to the bed ways to restore original parallel and perpendicular accuracy.
  • Motor Drive Certification: Only IRI has the capability to recertify the axis motors and drives, and upgrade drives with the latest engineering revisions.
  • Rebuilt to Original Factory Standards: Only IRI has the OEM standards for machine alignments, bearing loads, ballscrew thrust, gear mesh and pressure settings to ensure that your machine is rebuilt to the level you would expect of an exclusive Okuma rebuilder.

IRI's seven phase Rebuild process is the most comprehensive in the industry. The following steps outline our complete rebuild process:

  • ASSESSMENT: When your machine arrives, our team of technicians will apply power and assess the current condition (mechanical accuracy and electrical functionality).
  • TEAR DOWN: Complete disassembly of machine and all units including, but not limited to, the turrets and headstocks.
  • MACHINING: All slide ways are remachined, reground, and recertified on original Okuma factory equipment. The spindle face and nose are reground to original JIS tolerances and specifications. The spindle bearings are replaced with proprietary bearings designed only for Okuma. All bearings and seals are replaced with new components.
  • HAND SCRAPING: The turret saddles are hand-scraped and fitted on all four axes, while the turret is certified for rotation, positioning, and clamping reliability.
  • MATERIAL REPLACEMENT: All axis ballscrews, wipers, seals, bearings, hydraulic lines, limit switches, moving cables/conduit, belts, door rollers, cable carriers, and work lights are replaced. The lubrication system is flushed out and metering units are replaced at all lubrication points. A new double-wiper system is added to the lower saddle (when applicable). Optionally, retrofits are available to upgrade the control. Door cylinders are rebuilt on all applicable models. All painted parts are sand blasted and repainted to the original factory color.
  • ASSEMBLY: The entire machine is reassembled using original Okuma standards and check points. The machine is started up and debugged. The spindle bearings are run in, in order to meet JIS specifications.
  • FINAL INSPECTION: Final machine alignments are checked. The machine must complete a 24hr run-test cycle with zero faults after which the alignments are recertified.

Rebuild Considerations

Warranty: At IRI, we provide our customers with a complete one-year warranty on all parts and labor associated with the rebuild program.

Trade-Out Program: We know how important it is for you to continue making chips, so we are offering you the option of trading your machine for a rebuilt machine, or renting a replacement while your equipment is being rebuilt.

Optional Retrofit to Replace OSP Control:Now available with your rebuild program is an optional OSP control upgrade. The additional cost of the upgrade is based on the machine size and axis configuration. The following items are included in the retrofit:

  • New operator's display console.
  • New Okuma motors and drives on all axes.
  • Okuma MIV spindle drive and motor.
  • New electrical panel, wiring, and hardware.
  • New electrical braided cable and conduit.
  • New limit switches and relays throughout the entire machine.
  • All new electrical components throughout the machine.
As part of our standard rebuild, the existing OSP control system will be thoroughly cleaned, inspected and repaired at Okuma America Corporation's board repair lab.

Working Time: A standard rebuild will typically take 14-16 weeks after receipt of your machine at our Charlotte, North Carolina facility. The optional OSP control retrofit and machine rebuild will generally take 18-20 weeks.

Infinity Rebuild specializes in rebuilding all Okuma products. Here are the additional services we offer:

  • Saddle and Cross Slide Rebuilds
  • Lathe Headstock Rebuilds
  • Turret and Tailstock Rebuilds
  • Vertical and Horizontal Machining Center Head Rebuilds
  • Machining Center Saddle and Table Re-alignments
  • OSP and Fanuc Control Retrofits
  • Way and Bed Grinding, hand Scraping and Fitting All Slides
  • Partial Mechanical and Electrical Rebuilds
  • Installation of More Complex Standard and Field Retrofit Okuma Options, e.g., Coolant Through the Spindle for Machining Centers
  • De-installation and Re-installation assistance For Okuma Distributor and Customer Personnel
  • All the services listed above can be applied to ANY brand of CNC Machinery.