USED MAZAK INTEGREX 200-IV ST – 2003

The 2003 Mazak INTEGREX 200-IV ST is a high-performance multi-tasking CNC turn-mill center designed to complete complex parts in a single setup by combining CNC turning, milling, drilling, boring, tapping, and simultaneous 5-axis machining. Manufactured by Yamazaki Mazak, a global leader in advanced CNC machine tools, the INTEGREX Series revolutionized modern manufacturing by eliminating multiple machine setups and significantly reducing production time. The 200-IV ST model features both a main spindle and sub-spindle, a B-axis milling spindle, and a lower turning turret, allowing multiple machining operations to be performed simultaneously for maximum productivity.

Built with a rigid slant-bed cast iron construction, the Mazak INTEGREX 200-IV ST provides exceptional thermal stability, vibration damping, and machining accuracy during long production cycles. The machine offers approximately 22.8 inches (580 mm) of X-axis travel, 6.3 inches (160 mm) of Y-axis travel, 41.1 inches (1,045 mm) of Z-axis travel, and a programmable B-axis milling head with a wide angular range for machining complex features. Equipped with an 8-inch main chuck, 8-inch sub-spindle, and a high-speed milling spindle capable of 12,000 RPM, the machine performs both heavy-duty turning and precision milling without moving the workpiece between machines. The primary spindle delivers up to 5,000 RPM, making it suitable for machining aluminum, alloy steel, stainless steel, titanium, Inconel, and other difficult-to-machine materials.

The 2003 model is typically equipped with the Mazatrol Fusion 640MT Pro CNC Control, providing conversational programming, ISO G-code compatibility, advanced tool management, and simultaneous multi-axis machining capability. A large tool magazine supports numerous live and static tools, while the lower turret enables simultaneous machining operations to further reduce cycle times. Standard features commonly include through-tool coolant, automatic tool measurement, chip conveyor, hydraulic chucking, spindle synchronization, and automatic workpiece transfer between the main and sub-spindles. Optional accessories such as bar feeders, probing systems, high-pressure coolant, and automation interfaces further increase production efficiency.

The Mazak INTEGREX 200-IV ST is widely used throughout the aerospace, medical, automotive, defense, oil and gas, energy, and precision engineering industries. Typical applications include aerospace shafts, hydraulic manifolds, turbine components, orthopedic implants, valve bodies, transmission components, medical instruments, complex housings, and precision production parts. By completing nearly every machining operation in one setup, manufacturers improve dimensional accuracy while reducing lead times and labor costs.

Purchasing a used 2003 Mazak INTEGREX 200-IV ST provides manufacturers with world-class multi-tasking machining capability at a fraction of the cost of a new machine. Mazak machines are recognized worldwide for their exceptional reliability, advanced CNC technology, and long service life. A properly maintained INTEGREX 200-IV ST continues to deliver outstanding precision, productivity, and flexibility, making it one of the most sought-after multi-tasking CNC machines in the used equipment market.

MAZAK INTEGREX 200-IV ST – 2003 SPECIFICATIONS

Axis

Specification	Value
Machine Type	Multi-Tasking CNC Turn-Mill Center
Controlled Axes	7 Axes (X, Y, Z, B, C, X2, Z2)
X-Axis Travel	22.8 in (580 mm)
Y-Axis Travel	6.3 in (160 mm)
Z-Axis Travel	41.1 in (1,045 mm)
B-Axis Rotation	-30° to +210°
C-Axis	0.0001° Positioning

Travels / Work Envelope

Specification	Value
Maximum Turning Diameter	26.0 in (660 mm)
Maximum Machining Length	39.2 in (995 mm)
Maximum Swing Over Bed	30.0 in (760 mm)
Maximum Workpiece Weight	660 lbs (300 kg)

Main / Sub Spindle

Specification	Value
Main Chuck Size	8 in (210 mm)
Sub-Spindle	Standard
Main Spindle Speed	5,000 RPM
Sub-Spindle Speed	5,000 RPM
Spindle Bore	3.0 in (76 mm)
Bar Capacity	2.0 in (51 mm)
Main Spindle Motor	30 HP (22 kW)
Sub-Spindle Motor	25 HP (18.5 kW)

Milling Spindle

Specification	Value
Milling Spindle Speed	12,000 RPM
Tool Interface	Capto C6
Milling Motor	25 HP (18.5 kW)
Maximum Torque	88 ft-lb (119 Nm)

Tool Changer

Specification	Value
Tool Magazine Capacity	40 Tools
Tool Changer Type	Automatic Tool Magazine
Maximum Tool Diameter	3.5 in (90 mm)
Maximum Tool Length	11.8 in (300 mm)
Maximum Tool Weight	22 lbs (10 kg)

CNC Control

Specification	Value
CNC Control	Mazatrol Fusion 640MT Pro
Programming	Mazatrol Conversational & ISO G-Code
Simultaneous 5-Axis Machining	Standard
Tool Management	Standard

Coolant / Chip Management

Specification	Value
Coolant System	Flood Coolant
Through-Tool Coolant	Standard
Chip Conveyor	Standard
Automatic Tool Measurement	Standard

Power Requirements

Specification	Value
Electrical Supply	220V / 440V, 3-Phase
Connected Load	Approx. 55 kVA
Pneumatic Supply	80–100 PSI (5.5–6.9 bar)

Dimensions

Specification	Value
Machine Footprint	Approx. 200 × 129 in (5,080 × 3,280 mm)
Machine Height	Approx. 111 in (2,820 mm)
Machine Weight	Approx. 26,500 lbs (12,020 kg)

General Information

Specification	Value
Manufacturer	Yamazaki Mazak
Model	INTEGREX 200-IV ST
Year	2003
Machine Category	Multi-Tasking CNC Turn-Mill Center
Materials Machined	Aluminum, Steel, Stainless Steel, Titanium, Inconel, Brass, Engineering Plastics
Typical Applications	Aerospace Shafts, Medical Implants, Valve Bodies, Hydraulic Components, Turbine Parts, Precision Production Components

HOW MUCH DOES A USED MAZAK INTEGREX 200-IV ST – 2003 COST?

A used 2003 Mazak INTEGREX 200-IV ST typically sells for $90,000 to $180,000 USD, depending on machine condition, spindle hours, maintenance history, CNC control version, tooling package, and installed options such as bar feeders, probing systems, high-pressure coolant, or automation equipment. Machines with documented service records, low operating hours, and production-ready accessories generally command higher resale values due to their reliability and remaining service life.

Before purchasing a used Mazak INTEGREX 200-IV ST, buyers should inspect spindle condition, B-axis accuracy, sub-spindle synchronization, lower turret operation, guideways, ballscrews, lubrication system, and overall machine geometry. A properly maintained INTEGREX 200-IV ST offers exceptional long-term value by combining turning, milling, drilling, and 5-axis machining into a single platform, making it an outstanding investment for manufacturers producing complex, high-precision components.

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MAZAK INTEGREX 200-IV ST VS MAZAK INTEGREX 200-IV S – WHICH ONE TO BUY?

The Mazak INTEGREX 200-IV ST and Mazak INTEGREX 200-IV S are advanced multi-tasking CNC machines designed to combine turning, milling, drilling, boring, and multi-axis machining into a single setup. Both machines belong to Mazak’s renowned INTEGREX Series and are widely used in aerospace, automotive, medical, oil and gas, defense, and precision engineering industries. The primary difference between these two models is that the INTEGREX 200-IV ST incorporates both a main spindle and a fully functional secondary spindle, allowing complete front-and-back machining in one cycle, while the INTEGREX 200-IV S is primarily configured for single-spindle multi-tasking operations.

The INTEGREX 200-IV S is an excellent choice for manufacturers producing complex precision components that require multiple milling and turning operations. It significantly reduces setups, improves dimensional accuracy, and shortens production times by performing numerous machining processes in one machine.

The INTEGREX 200-IV ST builds upon these capabilities by adding a secondary spindle that allows complete machining of both ends of a component without operator intervention. This feature increases automation, reduces handling time, and improves productivity, making it ideal for medium- to high-volume production environments.

Both machines provide exceptional accuracy, rigidity, and machining flexibility. The INTEGREX 200-IV S is well suited for lower-volume, high-mix manufacturing, while the INTEGREX 200-IV ST is better suited for manufacturers seeking complete part processing and reduced cycle times through dual-spindle operation.

For companies producing complex precision components with minimal manual intervention, the Mazak INTEGREX 200-IV ST offers greater productivity and long-term manufacturing efficiency.

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MAZAK INTEGREX 200-IV ST SPINDLE NOT TURNING – CAUSES AND TROUBLESHOOTING

If the spindle on a Mazak INTEGREX 200-IV ST does not rotate, the issue may be caused by spindle drive faults, electrical failures, CNC control alarms, lubrication problems, hydraulic issues, cooling system faults, or machine safety interlocks. Since this machine incorporates both a main spindle and a secondary spindle, troubleshooting should determine which spindle is affected before repairs begin.

Start by reviewing all alarms displayed on the CNC control. Emergency stop activation, door interlock faults, spindle drive alarms, servo errors, hydraulic pressure alarms, lubrication warnings, tool changer faults, or spindle synchronization errors can prevent spindle operation. Clear all alarms before attempting to restart the machine.

Inspect the spindle drive system for electrical issues. Loose electrical connections, damaged encoder cables, spindle amplifier faults, motor overload conditions, blown fuses, or overheating may stop spindle rotation. Verify that spindle lubrication systems, spindle cooling units, compressed air supply, hydraulic pressure, and machine power are functioning correctly.

Review the CNC program to ensure spindle commands are correct. Missing M03, M04, or M05 commands, incorrect spindle speed settings, spindle synchronization errors, interrupted tool changes, or incorrect workholding sequences can prevent spindle startup.

If the spindle attempts to rotate but immediately stops, inspect spindle bearings, chuck condition, drawbar mechanisms, tooling interfaces, spindle taper cleanliness, and cutting loads. Excessive vibration, overheating, or unusual mechanical noise may indicate bearing damage or mechanical wear.

Routine spindle inspections, lubrication maintenance, hydraulic system servicing, and preventive maintenance help reduce unexpected downtime and extend spindle life.

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MAZAK INTEGREX 200-IV ST MAINTENANCE AND PREVENTIVE CARE GUIDE

The Mazak INTEGREX 200-IV ST is a sophisticated multi-tasking machining center that combines turning and milling operations into one highly productive platform. Because of its dual-spindle configuration, milling spindle, and multiple servo-controlled axes, regular preventive maintenance is essential for maintaining machining accuracy, productivity, and machine reliability.

Daily maintenance should include removing chips from the machining area, spindle noses, milling spindle taper, tool magazine, chuck surfaces, and guideway covers. Operators should inspect coolant levels, coolant concentration, lubrication systems, hydraulic pressure, compressed air supply, spindle cleanliness, and tool holder condition before beginning production.

Weekly maintenance should include inspecting coolant pumps, chip conveyors, lubrication units, hydraulic systems, spindle cooling systems, automatic tool changer operation, chuck clamping mechanisms, and electrical cabinet filters. Chip buildup around spindle areas and tool magazines should be removed to prevent mechanical interference.

Monthly inspections should focus on spindle runout, chuck accuracy, tool retention force, ball screws, linear guideways, encoder cables, spindle bearings, hydraulic lines, electrical connections, coolant filtration systems, lubrication lines, and machine leveling. Machine calibration should also be verified to maintain tight machining tolerances.

Additional preventive maintenance includes monitoring spindle vibration, checking backlash on all controlled axes, inspecting spindle bearings, replacing worn filters, servicing lubrication systems, and verifying machine geometry. Maintaining detailed maintenance records helps identify developing issues before they become major repairs.

A structured preventive maintenance program maximizes spindle life, machining accuracy, automation reliability, and overall production efficiency. Proper care ensures the INTEGREX 200-IV ST continues to deliver reliable multi-tasking performance over many years of operation.

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FAQ

What is the Mazak INTEGREX 200-IV ST?

The Mazak INTEGREX 200-IV ST is a high-performance multi-tasking CNC machining center that combines turning, milling, drilling, boring, and simultaneous multi-axis machining into one machine. It features both a main spindle and a secondary spindle, allowing complete machining of both ends of a workpiece in a single setup.

The machine is widely used in aerospace, automotive, medical, oil and gas, energy, defense, and precision engineering industries. It is capable of producing complex shafts, valves, housings, turbine components, medical implants, hydraulic parts, and precision mechanical components while reducing multiple setups and improving overall manufacturing efficiency.

Its dual-spindle design, advanced milling capability, and multi-axis functionality make it an ideal solution for manufacturers seeking complete part processing with high precision and improved productivity.

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What are the most common problems with the Mazak INTEGREX 200-IV ST?

The most common problems with the Mazak INTEGREX 200-IV ST include spindle alarms, secondary spindle synchronization faults, servo drive errors, hydraulic system problems, automatic tool changer faults, lubrication warnings, encoder failures, coolant contamination, chuck clamping issues, spindle orientation errors, communication faults, and axis positioning errors.

Machines operating in demanding production environments may also experience spindle bearing wear, hydraulic pressure fluctuations, tool magazine issues, thermal expansion effects, and calibration drift over time. Inadequate lubrication, coolant contamination, improper tooling practices, and missed preventive maintenance can increase the likelihood of these problems.

Routine spindle inspections, hydraulic system maintenance, lubrication checks, coolant management, machine calibration, electrical inspections, and scheduled preventive servicing help minimize downtime and maintain the high precision, productivity, and reliability expected from the Mazak INTEGREX 200-IV ST.