• ● The machine just died — what do we do now?
• ● Can we fix it ourselves?
• ● How long until a technician shows up?
• ● If we’re down for a few days, what happens to those orders?
• ● Do we outsource the work and pray the quality holds?

If those questions are racing through your head, breathe. This playbook breaks down EDM machine repair vs. EDM maintenance in plain, practical terms: how to judge the situation, what to check first, and how to stop being a full-time firefighter. At the end you’ll find our LINE service workflow so you can route requests the fastest way possible.

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On-Site Troubleshooting & Quick Decision Flow

Step 1｜3 Key Questions

• Can it safely run until the end of the shift? → Burning smell, overheating, sparks → Immediate shutdown & repair

• Is quality drifting continuously? → Dimensional errors, rising short-circuit rate → Stop and inspect

• Do you have backup capacity? → No → Prioritize repair; Yes → Schedule preventive maintenance

Step 2｜Typical Triggers

• Dirty linear scale → Positioning drift

• Overheated FET board → Intermittent short circuits

• Blocked dielectric / clogged filter → Unstable discharges

• Environmental temperature drift → Dimensional variation day vs. night

• Loose/contaminated terminals → Unstable signals

Step 3｜Immediate Actions

1. Record evidence: Error codes, abnormal sounds/smells, waveforms, site environment → Photos & videos

2. Prevent secondary damage: Ensure dielectric circulation & cooling, follow proper shutdown

3. Contact LINE Service

   • Emergency → Quick repair form (dispatch scheduled immediately)

   • Non-urgent → Inspection support form (Company/Machine/Serial no./Issue + photo/video, engineer pre-check)

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Most failures have warning signs: the technical deep-dive

1) Linear scale / optical encoder

Symptoms: rising repeatability error, unstable positioning profile, size “wandering.”
Risk: oil mist, coolant and dust distort the read head → long-term systemic dimensional bias.
Do this:

1. Clean per model procedure (scale, reflector, read head); inspect cables & mounts.

2. Measure signal SNR/stability; replace seals/boots if degraded.

Cadence: quarterly inspection; for machines 5+ years, schedule deep clean + re-cal.

 

2) FET power board (spark/power switching core)

Symptoms: intermittent short circuits, abnormal discharge, one-sided temperature spike; in worst cases, hard stop.
Risk: thermal/voltage/current overstress & solder fatigue; when a power device fails short, it can cascade.
Do this:

1. Thermal camera or temp probes to find hotspots; clean PCB and airflow path; check ESR of key caps/resistors; tighten terminals.

2. On heavy-duty lines, consider preventive board refresh at defined hours.

Cadence: semi-annual inspection; shorten interval for 24/7 high-load lines.

 

3) Dielectric fluid & filtration

Symptoms: unstable sparking (higher short-circuit ratio), rougher Ra, slower cutting/removal rate.
Risk: high ionic content or particle load → poor discharge, power stress, even premature PSU wear.
Do this:

1. Monthly conductivity checks; monitor ΔP; replace filters by load, not just by calendar; verify filter grade (micron & flow).

2. Keep two filter sets rotating to avoid “run to total clog.”

Cadence: monthly checks; replace by load.

 

4) Geometry & power calibration + environment

Symptoms: whole-part dimensional bias (not random); big difference across temperature changes.
Risk: thermal drift, geometric misalignment, voltage/current output drift.
Do this:

1. Check squareness/parallelism/positioning; calibrate power with traceable instruments; always test-cut for validation.

2. Manage HVAC, humidity and dust so the machine lives in a controlled envelope.

Cadence: annual calibration; for tight-tolerance customers, add a half-year tune-up.

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Why preventive beats reactive: the money table

Dimension	Reactive EDM machine repair	Preventive EDM maintenance
Downtime	Wait for parts & people — often days	Short, scheduled stops
Cost	Spiky: rush fees, night calls, rework	Predictable & spread: contract/subscription
Quality	Unstable; higher rework risk	Stable dimensions & finish; better yield
Delivery	High risk → customer escalations	Low risk → steadier OEE
Management	Firefighting	Condition monitoring / predictive mindset
Typical case	FET board burnout → 3 days down	Semi-annual check + preventive swap → zero downtime

The goal isn’t “never fail.” It’s see it early, plan the time, control the cost.

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Recommended inspection items

1. Power calibration — every 2 years

2. Leveling — every 1–2 years

3. Linear scale deep clean — for machines 5+ years

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LINE service workflow 

Goal: funnel every request into LINE, centralize info, make dispatch visible to the whole team.

 

Quick Repair (for sudden incidents)

1. Join our official LINE

2. Tap “Quick Repair”

3. Fill the form → Online Repair Form

4. OSCARCARE receives instantly → dispatch arranged

 

Diagnostic Assist (regular repair / maintenance request)

1. Join our official LINE

2. Tap “Diagnostic”

3. Reply with (✅ we’ll respond ASAP):
    Company name
    Machine model
    Serial/Unit No.
    Issue description (photos/videos welcome)

4. Specialist replies → confirms → schedules service

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Make repairs simple; make maintenance comprehensive

• EDM machine repair will happen — but you can see it early, fix it faster, and keep downtime short.

• EDM maintenance isn’t overhead; it’s how you defuse disasters in advance and lock in yield and delivery.

• Build the firewall with OSCARCARE; keep requests transparent and fast with LINE.

Join our official LINE today and move from “fix it when it breaks” to “it barely breaks.”

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