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Doosan HP5100 Maintenance Manual

Hmc maintenance
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Summary of Contents for Doosan HP5100

  • Page 1 Machine Tools HMC Maintenance (HP5100)

  • Page 2: Table Of Contents

    HP 5100 HP51MTE87 Contents 1. Disassembling and Assembling the Spindle Cartridge ......3 1.1 Disassembling the Tool Unclamp Cylinder-------------------------------------- 3 1.2 Disassembling the Spindle Cartridge ------------------------------------------- 8 1.3 Assembling the Spindle Cartridge ------------------------------------------- 111 1.4 Assembling the Tool Unclamp Cylinder ----------------------------------------18 1.5 Rolling operation of the Main Spindle -----------------------------------------21 2.
  • Page 3 HP 5100 HP51MTE87 5. Disassembling and Assembling the Ball Screw ........66 5.1 Disassembling the X Axis Ball Screw-------------------------------------------66 5.2 Assembling the X Axis Ball Screw ---------------------------------------------71 5.3 Disassembling the Y Axis Ball Screw ------------------------------------------77 5.4 Assembling the Y Axis Ball Screw ---------------------------------------------82 5.5 Disassembling the Z Axis Ball Screw-------------------------------------------88 5.6 Assembling the Z Axis Ball Screw ---------------------------------------------93 6.

  • Page 4: Disassembling And Assembling The Spindle Cartridge

    HP 5100 HP51MTE87 1. Disassembling and Assembling the Spindle Cartridge 1.1 Disassembling the Tool Unclamp Cylinder ▣ Parts List for the Tool Unclamp Cylinder 1300, 1460 1270 1200, 1210 1320 1470 1250 1280 0420 1490 1350, 1220, 1230 1330, 1450 1480 1260 0430...
  • Page 5 HP 5100 HP51MTE87 Material / Parts No. Description Q'ty Remarks Specification 410 C58011324 Spacer, Spring(3) SCM435 420 C58011313B Nut, Spring Clamp SCM440 430 P80300013 O-Ring 900 C58012124A Collar, Distance SM435 910 R11247 Bearing, Cyl. Roller N1014KTNHA/SPVR 920 C58011082A Housing, Rear Bearing SM435 930 S8011250 O-Ring...
  • Page 6 HP 5100 HP51MTE87 ※ Preparations to Disassemble the Tool Unclamp Cylinder (1) Thoroughly clean the machine. (2) Pull out the Tool from the Spindle. (3) Return the Z Axis to its reference point, move the X and Y Axes to a convenient position (roughly the center) to work and turn off the power.
  • Page 7 HP 5100 HP51MTE87 4) Detach the C58011231A Piston assembled Piston with the C58012254 Spring Pusher. ▪ O-Ring : 1-P120 Spring Pusher 5) Remove the two security Set-Screws on the C58012173A End Stopper, plug in the Flat washer BB8X20 Washer and Bolts in the place of the “A”...
  • Page 8 HP 5100 HP51MTE87 8) Disassemble the BZ-Sensor, loosen the BZ-Sensor security bolts on the R02120 Lock-Nut, and use a chisel to remove the Lock-Nut. Lock-Nut 9) Take out the C58012153A Sensor Bracket Motor Cap and remove the Key (2-KSP8×7×20). ※ You must not disassemble the C58011041 Motor Cap, because it will affect the concentricity of the position of the Main Spindle Bearing.

  • Page 9: Disassembling The Spindle Cartridge

    HP 5100 HP51MTE87 1.2 Disassembling the Spindle Cartridge ※ If the Spindle Cartridge is disassembled due to damage to the Main Spindle or Spindle Bearing, first disassemble the Spindle Tool Unclamp Cylinder as explained before and then disassemble the Spindle Cartridge in the front. ▣...
  • Page 10 HP 5100 HP51MTE87 Mat. / Parts No. Description Q'ty Remarks Specification C58011303A Rod, Push(1) SCM440 R56146 Ring, Wear GP65-79L Hansung R55449 Ring, Quad ORAR04216 BUSAK(Hansung) R54363 Ring, Backup BP3200280 BUSAK(Hansung) C58011334 Base, Spring SCM435 S8000180 O-Ring C48042124 Labyrinth(2) SCM435 C48052114 Labyrinth(1) SCM,435 R10432...
  • Page 11 HP 5100 HP51MTE87 2) Remove the six R37260A Coolant Nozzles Coolant Nozzle located in the Front Cover at the front of the Spindle, then disassemble the C58011183 Front Cover. ▪ 8-BB5×20 ▪ O-Ring : 1-S120 Front Cover 3) Remove the security bolts (8-BB12X36) on Bearing the C58011031B Main Bearing Housing, Housing...

  • Page 12: Assembling The Spindle Cartridge

    HP 5100 HP51MTE87 1.3 Assembling the Spindle Cartridge 1) Measuring the Pressure on the Rear Bearing and Collar on-site Grinding ① Wash and clean the Spindle thoroughly. ② Insert the R11247 Cylinder Roller Bearing(N1014) into the Spindle. Washing only inner Taper area is allowed. ③...
  • Page 13 HP 5100 HP51MTE87 Rear Bearing 2) Measuring the Tightness of the Rear Outer Housing Rim Bearing and on-site grinding Support Rear ① Measure the difference in height of the Bearing Support Outer Rims of the disassembled Bearing and the new Bearing on a plain measurement table.
  • Page 14 HP 5100 HP51MTE87 the Ball. ④ After applying, rotate the Ball so that the Grease is applied on the entire Ball, and then put it into storage. ※ In the case of excess applying ▪ Leave only the amount needed for rotation ▪...
  • Page 15 HP 5100 HP51MTE87 Standard Grease applying Amount for Main spindle Bearing Technology Production : 2008.09.04 Reference: NTN Scale : ㎤/EA HS Thrust Angular Ball DoubleRow SingleRow Angular Contact Brg. Brg. Roller Roller Nominal (mm) BA,BT Brg. NN30 Brg. N10 70 Series 72 Series Series Series...
  • Page 16 HP 5100 HP51MTE87 4) Assembling the Spindle Rear bearing Parts R-Bearing ① Thoroughly clean the Rear Bearing Housing assembly parts Support ② Insert the Bearing that had been stored Rear with NBU16 Grease on it. Bearing Support ③ Insert the previously on-site grinded C58012124A Distance Collar into the C58011073A Rear Bearing Support and Rear...
  • Page 17 HP 5100 HP51MTE87 Spindle Cartridge ⑥ Use the C58012134A Distance Collar(4) to Distance Collar(3) give shock to the Rear Bearing in order to Distance Collar(4) completely attach the Distance Collar(3) and the Rear Bearing to the Spindle section. Rear Bearing 6) Clean the C58011183 Front Cover and Front Cover assemble.
  • Page 18 HP 5100 HP51MTE87 7) Insert the parallel Key(2-KSP8×7×20) into the Motor Spindle, assemble the C58012153A Sensor Bracket and secure with a Lock-Nut, and then tighten the Lock-Nut securing Set-Screws. Lock-Nut Sensor Bracket 8) Assemble the BZ-Sensor. ※ Use a gap gauge to create a 0.1mm gap. If a gap gauge is not available, use a piece of paper to create the gap and remove the Sensor...

  • Page 19: Assembling The Tool Unclamp Cylinder

    HP 5100 HP51MTE87 1.4 Assembling the Tool Unclamp Cylinder 1) Assemble the C51016233A Cylinder Cable Bracket. Cover ※ Steadily remove the Motor Cable through the Cable Cover and store safely. ▪ 8-BB10×100 Cylinder Bracket 2) Assemble the C58011203A Cylinder Body. Cylinder ※...
  • Page 20 HP 5100 HP51MTE87 4) Insert the O-Ring into the C58011231A 1-G125 Piston which the C58012254 Spring Pusher is assembled, and carefully assemble the Cylinder Body. ※ Apply grease around the O-Ring to Piston prevent damaging the O-Ring during assembly. Spring ▪...
  • Page 21 HP 5100 HP51MTE87 ① Separate the Piston Cap while there is no Tool in the Spindle. ② Measure the distance from the Piston section to the ceramic section of the Stub Rotor.(D1 Decision) ③ Measure the distance from the attached section of the Piston Cap to the ceramic section of the Rotating Union(D2) ④...
  • Page 22 HP 5100 HP51MTE87 1.5 Main Spindle Rolling Operation ※ When assembly is complete, check for any problems. If there are no problems, turn on the power and begin the spindle rolling operation after setting the reference point of each Axis. 1) The objective of rolling operation is to spread grease evenly throughout the Bearing and to make sure that the Bearing is securely in place.

  • Page 23: Disassembling And Assembling The Table

    HP 5100 HP51MTE87 2. Disassembling and Assembling the Table 120 121 62-2 62-3 93-6 93-2 93-3 60-3 93-8 60-5...
  • Page 24 HP 5100 HP51MTE87 Material / Parts No. Description Q'ty Remarks Specification C50058283C Piston SM45C R53131 X-Ring Q4343-Xseal/Hansung R54022 Ring, Back-Up S52015-343/Hansung R53129 O-Ring P180/NOK R53160 O-Ring P140/NOK C50058303 Plate, End SM45C S2215061 Bolts, Hex. Socket Head BB12×25 S5110701 Washer, Spring Special ZSS12 P57110032 Pins, Parallel(W/Tap)
  • Page 25 HP 5100 HP51MTE87 Material / Parts No. Description Q'ty Remarks Specification 151 S8000110 O-Ring C58051163A Shaft, Gear SM45C C58056073 Housing, Bearing SM45C S2209361 Bolts, Hex. Socket Head BB8×35 C58056083 Liner, Adjust SS400 S8010850 O-Ring R10111 Bearing, Angular Ball 7008ADB/GNP4/NTN R03263 Nut, Lock DZM40×1.5/K-Fukuda C58051193A...

  • Page 26: Disassembling The Table

    HP 5100 HP51MTE87 2.1 Disassembling the Table ※ If the Table is being disassembled, it is so important job that disassembly is carefully planned and carried out. ※ Preparations (1) A crane or chain block that can lift at least 1 ton (placed so that it can lift from the center of the Table) (2) Two M12mm eye bolts (3) Rope that can securely hold the balance (must be able to hold at least 1 ton)
  • Page 27 HP 5100 HP51MTE87 2) Remove the Pallet Base security Bolts security Bolts (12-BB10×65/ZC10) from where the Cap was disassembled. 3) Remove the Set-Screw (2-BQ12×16) near the Pallet Base, insert eye bolts, tie a rope around eye bolt this area an hang the rope on a crane.. ※...

  • Page 28: Disassembling The Table Cylinder

    HP 5100 HP51MTE87 2.2 Disassembling the Table Cylinder ※ The Table Cylinder may have to be disassembled due to oil leakage around the Cylinder inside the Table. Disassembling the Table Cylinder involves disassembling most of the Table, and thus the process must be carefully prepared and executed. When making preparations or reassembling, be especially careful with cleanliness.

  • Page 29: Disassembling The Worm Shaft

    HP 5100 HP51MTE87 2.3 Disassembling the Worm Shaft 1) Return the X and Y Axes to their reference points , move the Z Axis as much as “-“ direction to a convenient location, and then turn off the power. 2) Remove the Cover security Bolts on the APC side of the Z Axis Sliding Cover, and push the Cover towards the APC.
  • Page 30 HP 5100 HP51MTE87 7) Loosen and remove the fastening set- Lock-Nut Worm Shaft screws on the Lock-Nut side using a chisel, and separate the Worm Shaft from the Ass’y. 8) Disassemble the C51056063 Bearing Cap Bearing Cap Bearing and separate the Bearing and Oil Seal from Housing the C51056053 Bearing Housing.

  • Page 31: Disassembling The Worm Wheel

    HP 5100 HP51MTE87 2.4 Disassembling the Worm Wheel ※ You must disassemble the Table before disassembling the Worm Shaft. Prepare the materials below and follow the instructions in detail. ※ Preparations (1) Crane or chain block that can lift at least 1 ton (placed so that it can lift from the center of the table) (2) 2 each of M12mm, 16mm eye bolts (3) Rope that can securely maintain the balance of the various parts (must be able...
  • Page 32 HP 5100 HP51MTE87 ② Disassemble the C58051021B Pallet Security bolt Base. ▪ 12-BB10×65 ※ Useful during assembly if kept at the Eye bolt Pallet Base and TableBase. ③ Remove the Pallet Base security bolts (12-BB10×65, 12-ZC10) in the place where the Cap has been disassembled. ④...
  • Page 33 HP 5100 HP51MTE87 3) Use the exclusive tool to remove the Retaining-Ring at the bottom of the Worm Wheel Ass’y and disassemble the Bearing. Worm Wheel Collar Lock- Retaining ) Loosen and remove the security set-screws near the Lock-Nut using a chisel, then disassemble (in order) the Collar, Worm Wheel, Key, and Spacer.

  • Page 34: Disassembling The Locating Cone

    HP 5100 HP51MTE87 2.5 Disassembling the Locating Cone ※ The Locating Cone Ass'y may need to be disassembled to handle oil leakage around the O-Ring inside the Table Locating Cone, or to repair internal parts. Since the Locating Cone Ass’y has many O-Rings attached, cleanliness is important. Also take care not to cause damage from the corners of O-Ring parts or Oil grooves.

  • Page 35: Assembling The Locating Cone

    HP 5100 HP51MTE87 2.6 Assembling the Locating Cone ※ Clean all parts needed for assembling the Locating Cone and clean the surrounding areas as well. ※ O-Ring List needed for assembling the Locating Cone Material / Parts No. Description Q'ty Remarks Specification S8010750 O-Ring...

  • Page 36: Assembling The Worm Shaft And Worm Wheel

    HP 5100 HP51MTE87 4) Insert the O-Ring into the C51051383 Locating Cone. Slowly assemble while keeping an eye on the Steel Ball attached to the Collet, insert the C51051393 Liner when there is about 10 mm left, and tighten the security bolts. ※...
  • Page 37 HP 5100 HP51MTE87 3) Fitting the Worm Wheel Key Gear Shaft ① First try to assemble the Worm- Wheel without the Key in the Gear Shaft. Worm Wheel ※ If assembly is difficult, abrase the problem area with rope or sandpaper to aid assembly.
  • Page 38 HP 5100 HP51MTE87 6) After assembling the #6206ZZ Radial Ball Bearing, use snap ring nipper to insert the RS30 Retaining Ring. ※ After inserting the Retaining Ring, apply shock towards the Retaining Ring Axis with a screwdriver, etc. to check if it is Bearing Retaining securely in place in the groove.
  • Page 39 HP 5100 HP51MTE87 9) Attach the C51056043 Worm Shaft to the Collar Worm Shaft previously assembled Bearing Housing, insert the C51056074 Collar, and fasten the Lock-Nut.. ※ Use a chisel and hammer to securely fasten the Lock-Nut, then tighten the Lock- security Set-Screw.
  • Page 40 HP 5100 HP51MTE87 Table Base, tighten the Bearing Housing security Bolts(6-BB8×26). ▪ 6-BB8×26, O-Ring : 1-G85 12) Adjusting the Worm Wheel Center Line ① Remove the Bearing Housing security bolts (6-BB8×35) on the Gear Shaft Ass’y and pull out the C58056083 Adjust Liner.
  • Page 41 HP 5100 HP51MTE87 14) Assembling the B Axis Servo Motor ① Insert the Key into the B Axis Servo Motor Shaft. ② Carefully assemble the Motor to the Motor Bracket and tighten the security Bolts. ③ Assemble the various Servo Motor Cables that were previously disassembled. Motor Shaft 15) Assembling the Table (Pallet Base)
  • Page 42 HP 5100 HP51MTE87 ④ If the Table secured without problems, connect the Table security Bolts (12- BB12×65), assemble the C50058253 Table Cap, and connect the security Bolts(6- security BB6×16). bolt ▪ 12-BB12×65, 6-BB6×16 O-Ring : 1-G145 16) Assemble the various Plugs that had been removed, after wrapping them with Tefron.

  • Page 43: Assembling The Table Cylinder

    HP 5100 HP51MTE87 2.8 Assembling the Table Cylinder ※ To assemble the Table Cylinder, thoroughly clean the Table Base assembly area and the disassembled Table Cylinder parts, and clean the surrounding area. ※ Reference : The types of O-Rings needed for Table Cylinder assembly Material / Parts No.
  • Page 44 HP 5100 HP51MTE87 3) Assemble the pre-assembled Piston Ass’y Cylinder Piston Housing to the Piston Housing and fasten the Cylinder Cap's security Bolts(12- BB10×35). ※ Make sure to apply clean Grease around the O-Ring and X-Ring to prevent damage. ▪ 12-BB10×35...

  • Page 45: Assembling The Table (Pallet Base)

    HP 5100 HP51MTE87 2.9 Assembling the Table (Pallet Base) 1) Apply Grease evenly on the disassembled O- O-Ring Ring (2-G90) (part of the Table's inside diameter) and the Dust Seal (part of the Table Base's outer diameter) to prevent Dust damage to the O-Ring during assembly.

  • Page 46: Disassembling The Table

    HP 5100 HP51MTE87 3. Table Accyracy work ※ If a large shock has been applied to the Table in the direction of rotation due to collision, etc., the parallelism between the Edge Locator and the moving Axis could be deviated. This is because Curving Coupling within the Table was deviated by shock and may cause problems when assembling fixture.
  • Page 47 HP 5100 HP51MTE87 ① Disassemble the C50058253 Cap. ▪ 6-BB6×16, O-Ring : 1-G145 2) Disassemble the C58051021B Pallet Base. Security Bolt ▪ 12-BB10×65 ※ It is useful during assembly if the Pallet Base and Table Base are marked. Eye bolt ①...
  • Page 48 HP 5100 HP51MTE87 attached to the Table(Pallet Base) Body ① Loosen the Curvic Coupling security Bolts(12-BB12×30). ② Remove the Plug(2-FPS-S1/2) attached in the Curvic Coupling Positioning Pins(2- TPB13×40) location, and pull out the Taper Pins. ③ Tighten the Curvic Coupling security bolts with about 1/3 force equally.

  • Page 49: Temporary Assembly Of Thetable (Pallet Base) Body

    HP 5100 HP51MTE87 3.2 Temporary Assembly of the Table (Pallet Base) Body 1) Apply Grease evenly on the Table's inner O- Ring (2-G90) and the Table Base's outer Dust Seal to prevent O-ring damage during assembly. 2) Lift up the Table (maintaining proper balance) and lower it onto the marked line made during disassembly.

  • Page 50: Setting The Table Accuracy

    HP 5100 HP51MTE87 parallelism. Repeat the above process until the parallelism comes below the optimal measure. ※ Optimal Measure: 0.01mm/250mm 5) When the optimal parallelism is achieved, tighten the loosened 2-BB10×65. 3.4 Setting the Table Accuracy 1) Disassemble the Table, referring to the "1) Disassembling the Table” section above. 2) Individually fasten the Curvic Coupling security Bolts(12-BB12×30) diagonally using even strength, and tighten as strongly as possible.

  • Page 51: Readjusting The Reference Point Of The B Axis

    HP 5100 HP51MTE87 3.6 Readjusting the B Axis Reference Point ※ The B Axis Reference Point must be readjusted in the following circumstances: when the B Axis Servo Motor has been disassembled and reassembled, when the B Axis location changes after executing CW or CCW, and when the “2073 Pallet Or Table CL/UNCL Switch Alarm”...

  • Page 52: Servo Atc Recovery

    HP 5100 HP51MTE87 4. Servo ATC Recovery 4.1 ATC Structure Magazine Servo Motor With Brake - Reduction Gear - Tool Pot Guide & Clamp Device Changer Arm Home Position Detection Proximity S/W Unique Tool Locking Device Spline Shaft Air Cylinder Reduction Gear ATC Servo Motor...

  • Page 53: Atc Main Sequence

    HP 5100 HP51MTE87 4.2 ATC Main Sequence Changer Arm Home ☞ Initial Condition ① Arm & Servo Home Position X8.7(SX53) CAHP.M ② 2nd Reference Point & M19 ③ Pot Spindle Side & Clamp X7.0(SX5A) WPSS.M X7.2(SD32) WPCL.M ④ Arm Pins Release X15.5(SD56) ATAR.M Gripping Tool ☞...

  • Page 54: Troubleshooting

    HP 5100 HP51MTE87 4.3 Trouble Shooting 1) Operating the Maintenance Screen (Manual Operation of the ATC) ① Select the "JOG” Mode from the Main O.P. ② Press the” CUSTOM” Key. ⇒ The” CUSTOM WINDOW” appears on the screen. ③ Press "MANUAL" (Function Key). ⇒...
  • Page 55 HP 5100 HP51MTE87 proximity switches (X8.7) by the present arm position. ② Objective of the Alarm: The alarm aims to increase the stability of the Servo Mechanisms (e.g. Clamping/Unclamping), which must work based on the Arm's actual location, by maintaining the same Arm position setting regardless of continuous tool exchanges.
  • Page 56 HP 5100 HP51MTE87 Case S/W & Dog align Solution Follower Normal Faulty Reorder the Switch, secure, and Initialize Normal Normal Initialize Faulty Normal Realign the Changer Arm using Inching, reorder the Switch, and Initialize Faulty Faulty ▶Case “A” ① Press the "MODE" Key once on the Servo Drive start screen [r 0000] ②...
  • Page 57 HP 5100 HP51MTE87 ⑤ Move back to Maintenance Mode. Execute the remaining Recovery processes. Verify normal ATC activity, and close Maintenance Mode. ▶Case “B” ① Press the MODE Key once and the "DOWN" Key four times on the Servo Drive start screen[r 0000] to display the [JOG run].
  • Page 58 HP 5100 HP51MTE87 Press the "SET" Key for five seconds on the ④ [Or9.S--] screen. The letters on the screen will blink, and then complete the Servo Origin Initialization. ⑤ Power Off → On ⑥ Move back to Maintenance Mode. Execute the remaining Recovery processes.
  • Page 59 HP 5100 HP51MTE87 ▶ Case “1” ① Power On⇒Machine Ready Control ② Maintenance Mode On ③ Use the Reverse Step Control to recover the Arm Home Position ※ If the problem occurred after Clamping, use the available Forward Step control. The point at which the problem occurred can be judged based on the Forward Step control's availability.
  • Page 60 HP 5100 HP51MTE87 ▶ Case “2” ① Power On⇒Machine Ready ② Maintenance Mode On ③ Use the Reverse Step Control to recover the Arm Home Position ※ Detach all tools attached to the Changer Arm, and use the Reverse control. ①...
  • Page 61 HP 5100 HP51MTE87 ※ It is recommended to judge based on the location of the Changer Arm Home Position Dog in these two situations. Case 3-1 Case 3-2 C. Arm Home Position Dog is under the C. Arm Home switch. Position Dog is above ▶...
  • Page 62 HP 5100 HP51MTE87 ⑥ Finding the reason for AL2065 activation and appropriate measures ⑦ If there is a record of turning off Power, manually recover the reference point(unnecessary in the case of emergency). ⑧ M19 / G91 G30 X0 Y0 Z0 in MDI Mode ⑨...
  • Page 63 HP 5100 HP51MTE87 4.4 ATC Centering work ※ If the Tool Change is not smooth directly after installation or during use, the ATC and Main Spindle must be aligned (centered). ※ Centering Tools for ATC Centering work Tool 3 Tool 2 Tool 1 1) Preparations for ATC Centering ①...
  • Page 64 HP 5100 HP51MTE87 ⑧ Insert the Centering Tool(2), matching it up with the Arm Gripper Key 3) Check the Alignment between the Changer Centering Tool (2) Arm and the Spindle. ① Measure the gap between Tool (1) and Tool(2) by using a gap gauge. ▪...

  • Page 65: Important Notes On Troubleshooting The Servo Control Atc

    HP 5100 HP51MTE87 4.5 Important Notes Concerning Troubleshooting the Servo Control ATC Cam home position Is the turret cam follower bearing located at the center ① check area of the cam center section? Second reference Is the alignment of changer arm gripper and spindle ②...

  • Page 66: Troubleshooting

    HP 5100 HP51MTE87 4.6 Trouble Shooting 1)Operating the Maintenance Screen (Manual Operation of the ATC) ① Select the "JOG” Mode from the Main O.P. ② Press the “CUSTOM” Key. ⇒ The “CUSTOM WINDOW” appears on the screen. ③ Press "MANUAL" (Function Key). ⇒...

  • Page 67: Disassembling And Assembling The Ball Screw

    HP 5100 HP51MTE87 5. Disassembling and Assembling the Ball Screw 5.1 Disassembling the X Axis Ball Screw...
  • Page 68 HP 5100 HP51MTE87 Parts No. Description Q'ty Material/Specification Remarks C58023013 Ball Screw (X) W4510Z-312PSS-C3Z20 × S2212461 Bolt, Hex. Socket Head BB10 P72130004 Adaptor, Elbow × R462945 Connector, Hose C4N8 6-PT1/4 NITTA MOORE × R462946 Connector, Elbow 86-PT1/4 NITTA MOORE C58021052A Bracket, Motor GC300 ×...
  • Page 69 HP 5100 HP51MTE87 1) Move the X Axis to the center in order to easily detach the X Axis Ball Screw, and turn off the power. 2) Detach the C58021094A Cover from the Cover Lubricant Pipe C58021052A Motor Bracket, and remove the lubricant pipe, and the Servo Motor Power (Power and Feedback Cable) Connector.
  • Page 70 HP 5100 HP51MTE87 5) Move the Ball Screw Nut area lubricant pipe Cooling and cooling pipe to the side. Remove the Pipe Nut security Bolts (10-BB 10×40). Ball Screw Nut 6) Remove the Motor Bracket security Bolts (8-BB16×65) and Positioning Pins (2- Security Bolts TPB8×56).
  • Page 71 HP 5100 HP51MTE87 9) Disassemble the Motor Bracket Lock-Nut. ▪ Loosen the Lock-Nut security Set-Screws and remove the Lock-Nut by applying shock with Lock-Nut a chisel or hammer. 10) Separate the Motor Bracket and Ball Screw. 11) Disassemble the C49021524C Bearing Cap from the Motor Bracket and detach the Ball Screw Bearing.

  • Page 72: Assembling The X Axis Ball Screw

    HP 5100 HP51MTE87 5.2 Assembling the X Axis Ball Screw 1) Assemble the Angular Contact Ball Bearing (35TAC72BDBDC10PN7A) to the C59021072A Bearing Support. ① Assemble the 35TAC Angular Contact Bearing to the Bearing Support, making sure to maintain the right direction. Measure the depth between the end of the Bearing and the section of the Bearing Support.
  • Page 73 HP 5100 HP51MTE87 3) Assemble the Angular Contact Ball Bearing (35TAC72BDBDC10PN7A) to the C58021052A Motor Bracket. ① Assemble the 35TAC Angular Contact Bearing to the Motor Bracket, making sure to maintain the right direction. Measure the depth between the end of the Bearing and the section of the Bearing Support.
  • Page 74 HP 5100 HP51MTE87 ※ When assembling the Ball Screw to the opposite Bearing Support, be careful not to hit the screw against something and scar it. 6) Fasten the Motor Bracket security Bolts and Positioning Pins. ▪ 8-BB16×65, 8-ZC16, 2-TPB16×65 7) Release the security bolts (4-BB16 x 70) Pull out the from the C58021072A Bearing Support...
  • Page 75 HP 5100 HP51MTE87 9) Ball Screw Pre-Tension ① Measure the gap between the Bracket Support and Support Bearing with a Block Gauge. ② Measure six places with the Block Gauge Measure and add Pre-Tension (0.08mm) to the ment measurements. Do on-site machining of the Adjusting Liner accordingly.
  • Page 76 HP 5100 HP51MTE87 ① Send the X Axis to the“X0”position. ② Fasten the Nut security Bolts with increasing tightness, taking care to apply equal strength to all bolts, and finally tightly secure all Bolts. (It is also possible to tightly secure to diagonal Bolts, loosen them, then tighten all bolts.) 14) Assemble the X Axis Servo Motor (with R10712 Rigid Coupling assembled) to the Motor Bracket by inserting it into the Ball Screw, being careful of the Rigid Coupling.
  • Page 77 HP 5100 HP51MTE87 ※ Resetting the X Axis Reference Point 1) Insert the Test Bar into the Spindle. 2) Send the X Axis to the center (X425.) of the Stroke, the Z Axis to the Z115. position, and the Y Axis to the Y250. position.

  • Page 78: Disassembling The Y Axis Ball Screw

    HP 5100 HP51MTE87 5.3 Disassembling the Y Axis Ball Screw ※ To disassemble the Y Axis Ball Screw, it is best to disassemble the X Axis Sliding Cover. However, since it is too difficult to disassemble the Sliding Cover, disassemble the Z Axis sliding cover and detach the Ball Screw Lock-Nut from the bottom.
  • Page 79 HP 5100 HP51MTE87 Material / Parts No. Description Q'ty Remarks Specification C58033013 Ball Screw (Y) W4509Z-450PSS-C3Z20 NSK × S2212461 Bolt, Hex. Socket Head BB10 P72130004 Adaptor, Elbow × R462945 Connector, Hose C4N8 6-PT1/4 NITTA MOORE × R462946 Connector, Elbow L4N8 6-PT1/4 NITTA MOORE C58031042A...
  • Page 80 HP 5100 HP51MTE87 1) Move the X and Y Axes to the center, the Z Axis to its reference point (for convenience of disassembling Y axis ball screw) and turn off the power. ※ To prevent the Spindle Head from falling when disassembling the Y Axis Servo Motor, support between the Column and Spindle Head with a baulk and turn off the power.
  • Page 81 HP 5100 HP51MTE87 5) Disassemble the lubricant pipe and cooling Lubricant Pipe pipe near the Ball Screw Nut. Remove the Nut security Bolts. Hold the Nut and rotate the Ball Screw to slightly pull the Nut out from the main body. Ball Screw Nut 6) Remove the Motor Bracket security Bolts Motor...
  • Page 82 HP 5100 HP51MTE87 9) Disassemble the Motor Bracket Lock-Nut. ※ Loosen the Lock-Nut security Set-Screws Lock-Nut and use a hammer to hit and remove the Lock-Nut. 10) Separate the Motor Bracket and the Ball Screw. 11) Disassemble the C49021524C Bearing Cap Bearing from the Motor Bracket and separate the Ball Screw Bearing.

  • Page 83: Assembling The Y Axis Ball Screw

    HP 5100 HP51MTE87 5.4 Assembling the Y Axis Ball Screw 1) Assemble the Angular Contact Ball Bearing (35TAC72BDBDC10PN7A) to the bottom of the Ball Screw Bracket. ① Apply Grease and insert the O-Ring (G35) and Spacer (1) into the Bracket, and assemble the 35TAC Angular Contact-Bearing taking care to keep the correct direction.
  • Page 84 HP 5100 HP51MTE87 3) Stand up the Motor Bracket with the Bearing attached, assemble the Ball Screw, insert the C42036094 Collar and secure the Lock-Nut. ▪ First,secure as tightly as possible. 4) As shown below, use an Indicator to measure the end of the Ball Screw (Coupling assembly area), the area near the Bearing, and the Ball Screw Nut area, and fit the Run-Out.
  • Page 85 HP 5100 HP51MTE87 6) Lightly plug in the Motor Bracket Positioning Pins(2-TPB8×56) to position them, then insert the collar into the Bracket below and fasten the Lock-Nut. ▪ Simply tighten as much as possible; the Ball Screw Run-Out will be finally set later Collar Lock-Nut 7) Setting the Ball Screw Pre-Tension...
  • Page 86 HP 5100 HP51MTE87 10) Fit the Ball Screw Run-Out. Set the Indicator at the end of the Ball ① Screw. Rotate the Ball Screw while reading the ② Indicator. At the highest reading, hit with a chisel in the direction of locking the Lock-Nut.
  • Page 87 HP 5100 HP51MTE87 under 0.03mm, then firmly secure the bolts. The Run -out must match all three rings of ※ the Rigid Coupling. 14) When assembly is complete, assemble the Motor Bracket's Cover(1) and Cover(2), Cover(1) and assemble the lubricant pipe and Cover(2) Servo Motor Wire Connector previously disassembled..

  • Page 88: Disassembling The Z Axis Ball Screw

    HP 5100 HP51MTE87 5.5 Disassembling the Z Axis Ball Screw To disassemble the Z Axis Ball Screw, disassemble the Z Axis Sliding Cover and ※ place it in the center for convenience, and turn off the power.
  • Page 89 HP 5100 HP51MTE87 Material / Parts No. Description Q'ty Remarks Specification C58023023 Ball Screw (Z) W4509Z-451PSS-C3Z20 NSK × S2212461 Bolt, Hex. Socket Head BB10 P72130004 Adaptor, Elbow × R462945 Connector, Hose C4N8 6-PT1/4 NITTA MOORE × R462946 Connector, Elbow L4N8 6-PT1/4 NITTA MOORE C58021052A...
  • Page 90 HP 5100 HP51MTE87 1) To disassemble the Z Axis Ball Screw, disassemble the Z Axis Sliding Cover and place it in the center for convenience, and turn off the power. 2) Disassemble the C58021094A Cover from the C58021052A Motor Bracket. Remove the lubricant pipe and Servo Motor Wire (Power and Feedback Cables) Connector.
  • Page 91 HP 5100 HP51MTE87 5) Disassemble the Ball Screw Nut Area's Cooling Pipe lubricant pipe and the cooling pipe and remove the Nut security Bolts(10-BB 10×40). Ball Screw 6) Remove the Motor Bracket security Security Bolts(8-BB16×65) and Positioning Pins(2- Bolts TPB8×56). Motor Bracket Taper...
  • Page 92 HP 5100 HP51MTE87 9) Disassemble the Motor Bracket Lock-Nut. * Loosen the Lock-Nut security Set-Screws and remove the Lock-Nut by hitting with a Lock-Nut chisel and hammer. 10) Separate the Motor Bracket and Ball Screw. 11) Disassemble the C49021524C Bearing Cap from the Motor Bracket and separate the Ball Screw Bearing.

  • Page 93: Assembling The Z Axis Ball Screw

    HP 5100 HP51MTE87 5.6 Assembling the Z Axis Ball Screw 1) Assemble the Angular Contact Ball Bearing (35TAC72BDBDC10PN7A) to the C59021072A Bearing Support. Assemble the 35TAC Angular Contact Bearing to the Bearing Support, making ① sure to put it in the correct direction, then measure the depth of the end of the Bearing and the section of the Bearing Support.
  • Page 94 HP 5100 HP51MTE87 “B” 35TAC Bearing “A” Bearing Motor Bracket 4) Stand up the Motor Bracket with Bearing attached, assemble the Ball Screw, insert Collar the C42036094 Collar, and fasten the Lock- Nut. ▪ Simply tighten as much as possible; the Ball Screw Run-Out will be set later on.
  • Page 95 HP 5100 HP51MTE87 6) Fasten the Motor Bracket security Bolts and securit Positioning Pins. ▪ 8-BB16×65, 8-ZC16, 2-TPB16×65 Motor Bracket 2-Taper Pins 7) Remove the security bolts (4-BB16 x 70) Pull out the from the C58021072A Bearing Support Liner attached to the Support opposite from the Collar Motor Bracket and pull out the four Adjust Liners.
  • Page 96 HP 5100 HP51MTE87 10) When grinding is complete, loosen Adjust the Lock-Nut and widen the gap Liner between the Bearing Support and Lock-Nut Support Bracket. Insert according to the numbering and tighten the security Bolts. ▪ 4-BB16×70 Support 11) Use a chisel and hammer to fasten the Bracket Lock-Nut again.
  • Page 97 HP 5100 HP51MTE87 Motor Bracket 15) Fastening the R10712 Rigid Coupling Use a Wrench to first lightly fasten the ① four Bolts in diagonal order. Gradually increase tight ening force. ② ③ Set the Indicator on the Rigid Coupling. Manually rotate the Ball Screw to measure Rigid the Run-Out, repeating until the Coupling...
  • Page 98 HP 5100 HP51MTE87 Resetting the Z Axis Reference Point ※ 1) Set the X Axis Reference Point (refer to "Resetting the X Axis Reference Point") and set the Indicator at "0" setting. ▪ Machine coordinates: X425. Z115., Y Axis is near Y250.

  • Page 99: Machine Accuracy Work

    HP 5100 HP51MTE87 6. Machine Accuracy Work 6.1 Straightness of the Z Axis 1) X－Y Plane Measurement ① Install the Level in the center of the top of the Pallet in the X Axis direction to set the reference point. Divide the Z Axis Stroke into three equal parts and transfer them, measuring the greatest difference in level change.
  • Page 100 HP 5100 HP51MTE87 3) X－Z Plane Measurement ① Lay the Straight Edge on the Pallet in the Z Axis direction, and install the Indicator to Spindle Head to set both ends of the Straight Edge as "0." Move the Z Axis to measure the largest difference.

  • Page 101: Straightness Of The X Axis

    HP 5100 HP51MTE87 6.2 Straightness of the X Axis 1) X - Y Plane X Axis Transfer Measurement ① Stand up a Straight Edge on the Pallet in the X Axis direction, and install the Indicator on the Spindle Head to set both ends of the Straight Edge as "0."...
  • Page 102 HP 5100 HP51MTE87 3) X - Z Plane Measurement ① Lay the Straight Edge on the Pallet, in the direction of the X Axis. Install the indicator on the Spindle Head and set both ends of the straight edge to "0". Move the X Axis and measure the greatest difference.

  • Page 103: Straightness Of The Y Axis

    HP 5100 HP51MTE87 6.3 Straightness of the Y Axis 1) X - Y Plane Measurement ① Set up a perpendicular ruler on the Pallet in the X Axis direction. Install the indicator on the Spindle Head, and set both ends Perpen dicular of the straight edge as "0."...

  • Page 104: Straightness Of The Top Of The Pallet

    HP 5100 HP51MTE87 6.4 Straightness of the Top of the Pallet 1) X - Y Direction Measurement ① Place a Straight Edge on top of the Pallet and attach the indicator to the block. Measure the straightness of the top of the straight edge to find the greatest Spindle difference.

  • Page 105: Perpendicularity Between The Coordinate Axes

    HP 5100 HP51MTE87 6.5 Perpendicularity between the each Coordinate Axes 1) X - Y Perpendicularity Measurement ① Place a perpendicular ruler on the Pallet in the X Axis direction. Install an Indicator 축 on the Spindle Head and measure in the X- and Y-Axis direction to find the greatest difference.
  • Page 106 HP 5100 HP51MTE87 2) Y - Z Perpendicularity Measurement ① Place a perpendicular ruler on the Pallet in the Z Axis direction. Install an Indicator on the Spindle Head and measure in the Z- and Y-Axis direction to find the greatest difference.
  • Page 107 HP 5100 HP51MTE87 Adjustment ② Y-Z perpendicularity adjustment is possible by adjusting the thickness of the X Axis L/M Guide Liner. Refer to“X -Y Perpendicularity”above to ⓐ accurately measure the perpendicularity. When measuring, calculate the length of ⓑ the perpendicular ruler and the distance between the two L/M Guide Sliders to find the grinding amount of the Liner.
  • Page 108 HP 5100 HP51MTE87 3) X - Z Perpendicularity Measurement ① Lay a perpendicular ruler on the Pallet, and move the indicator in the X Axis direction to set both ends of the ruler to "0" (hit high points with the handle of a screwdriver to set the parallelism of the X Axis).

  • Page 109: Movement Towards The X, Z Axes And Parallelism Of The Top Of The Pallet

    HP 5100 HP51MTE87 6.6 MovementTowards the X, Z-Axes and Parallelism of top of the Pallet 1) Measurement Install the Indicator onto the Spindle Head, then find the two points on either side of the Pallet, 150 mm away from the Pallet’s center.
  • Page 110 HP 5100 HP51MTE87 3) Adjustment Measure Pallet No. 1 and No. 2 at the same time. Compare and calculate to see which area should be adjusted. A,B,C,D : When the height distribution for Pallet No. 1 and No. 2 are similar, grind ①...

  • Page 111: Index Table Division Perpendicularity

    HP 5100 HP51MTE87 and Table, and lift up the Table until the Liner can be removed. Pull out the Liner and grind the amount ⑤ found in “ .” Reassemble. ② When reassembling the Ball Screw Nut, ⑥ send the Z Axis to its reference point, then tighten the security Bolts individually with the same strength.
  • Page 112 HP 5100 HP51MTE87 6.8 Parallelism of the Edge Locator and Movement towards the X Axis 1) Measurement Install the Indicator onto the Spindle Head. Move the grinding side of the Edge Locator attached on the side of the Pallet in the X Axis direction and measure the greatest Edge Locator difference.
  • Page 113 HP 5100 HP51MTE87 ※ Preparations (1) Crane or Chain Block that can lift at least 1 ton (positioned to lift from the center of the Table) (2) 2 each of M12mm, 16mm eye bolts (3) Rope (able to lift over 1 ton) that can hold the balance of machine parts (4) Gauge (Test Indicator, Magnetic Stand etc) that can measure the parallelism of the Edge Locator (5) L-Wrench Set and Pipe...
  • Page 114 HP 5100 HP51MTE87 Disassemble the C58051021B Pallet Base ② Security Bolt ▪ 12-BB10×65 is useful during assembly if the Pallet Base ※ and Table Base are marked. Eye bolt move the Pallet Base security Bolts (12- ⓐ BB10×65/ZC10) from where the Cap was disassembled.
  • Page 115 HP 5100 HP51MTE87 2) Temporary Assembly of the Table (Pallet Base) Body Apply Grease evenly on the Table's inner ① O-Ring(2-G90) and the Table Base's outer Dust Seal to prevent O-ring damage during assembly. Lift up the Table (maintaining proper ②...
  • Page 116 HP 5100 HP51MTE87 Optimal Measure 0.0 05mm/Entire Area ※ When the optimal parallelism is achieved, ti ghten the loosened 2-BB10×65. ⑤ 4) Setting the Table Accuracy Disassemble the Table, referring to the "1) Disassembling the Table” section ① above. Individually fasten the Curvic Coupling security Bolts(12-BB12×30) diagonally ②...
  • Page 117 HP 5100 HP51MTE87 6.9 Distance Between the Edge Locator Reference plane and the Rotation Central Line 1) Measurement ※ This area should be measured using customized tools, but since it is difficult to Axis find such tools ,another method will be used.
  • Page 118 HP 5100 HP51MTE87 6.10 Repetition Position Precision of Pallet Exchange and Reciprocal Difference 1) Measurement Send the X, Y, Z Axes to the center of ① the Axis Stroke (X400. Y350. Z375.). Install three indicators on the Spindle ② Head. Set the X, Z Axis directions on the Edge Locator and the Y Axis directions on top of the Pallet.

  • Page 119: Z Axis Movement And Parallelism With The Spindle Central Line

    HP 5100 HP51MTE87 6.11 Z Axis Movement and Parallelism with the Spindle Central Line 1) Measurement Insert the Test Bar into the Spindle and move the Z Axis from the entrance to X-Z면 300 mm away to measure parallelism. Y-Z면 Find the greatest figure.

  • Page 120: Spindle Run-Out

    HP 5100 HP51MTE87 6.12 Spindle Run-Out 1) Measure Insert the Test Bar into the Spindle. Set the indicator at the entrance and at 300 mm from the entrance, and rotate the Spindle at low speed to measure shaking. Find the greatest amount of shaking. ▪...

  • Page 121: Leveling The Machine

    HP 5100 HP51MTE87 6.14 Leveling the Machine Leveling the machine has a direct influence on the machine’s accuracy and is very important. It is recommended to accompany this process with the machine accuracy work. ※ Preparations. ▪ two Perpendicular Levels(150×150 ) ▪...
  • Page 122 HP 5100 HP51MTE87 1) Move to the X400. Y700. Z375. position. 2) Clean the top of the Pallet and set the center of the Pallet with the center of the Level to "Set the Original Level". ※ Setting the Level Reference point (1) Place the Level at the center of the Pallet and read the accurate measurement on the side of the Level water droplets.
  • Page 123 HP 5100 HP51MTE87 M01; M99; ※ Cautions during Leveling work ① Make sure that the pressure with which the Level Bolt hits the Level Plate is the same overall. ▪ If any one Level Bolt touches the level Plate with lower or higher pressure, the entire Level will be thrown off balance.
  • Page 124 HP 5100 HP51MTE87 installing the machine center, straightness must be read. Therefore, it is easier to read only one side and then to calculate by comparing the three measurement areas. ▪ In the case of the chart above, the right side is 30μ higher. Therefore, there is an arrow pointing to the right with the number 30.

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