The Winning Force DURMA

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Contents

1. Durmazlar Installation Guide 1-1

1.1 Pre-Installation 1-1

1.1.1 XAxis Pre-Installation 1-1
1.1.2 Y Axis pre-Installation 1-6
1.1.3 Z Axis Pre-Installation 1-9

1.2 Final Assembly 1-15

1.2.1 BodyAssembly 1-15

1.2.2 Dust Collector Unit and Suction Group Assembly 1-20
1.2.3 Table Assembly 1-22
1.2.4 Gas Panel Assembly Installation 1-24
1.2.5 Pneumatic Group Assembly 1-27
1.2.6 Power supply Installation 1-28
1.2.7 BodyAssembly 1-31
1.2.8 Electric Installation 1-35

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DurmazJar lnstaMatiior` Gulide DUFI MA

1. Durmazlar Installation Guide

1.1 Pre-Installation
1.1.11.1.1 X Axis pre-Installation

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qayAINrm PART NAutE IusTAunTioN ro

1 REDUCEf` MOTOR 13

1 REDUCER 12

1 X AXIS MOTOR MOUNTING PLATE 11

1 luBRICATION VALVE 10

1 X AXIS MOVEMENT GROUP PROTECTION SHEET 2 9

1 X AXIS MOVEMENT GROUP PROTECTION SHEET 1 8

1 LUBRICATED SHAFT PROCESSES 7

2 X-AXIS 0F THE BELLOWS CONNECTION FLANGES 6

1 MOTOR ADJUSTMENT PART 5

2 SHOCK ABSORBER WEDGE 4

1 X-Y AXIS WEDGE 3

3 BALL CAR 35" 1622-314-20 2

1 X AXIS LEFT MOVEMENT GROUP PLATE 1

1.1
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 DurmazJar lnsta+Jerfiion Gulide DU R MA

• Engineplatesxlandx2aretakentothexaxismounting

area (part number 1).

• The marks on the plates are cleaned with cloth.
- Lubrication fittings are assembled on ball cars.
I Thecarisconnectedtotheengineplate byusingl2

MBX15 imbus bolts (item 2).

I The lubrication hoses are connected to the cars.
- The hoses are secured to the plate usingthe lubrication

clamp and 4 M4X10 imbus bolts.

I The lubrication shaft is mounted on the x-axis plate with

the MBX15 bolt (item 7)

I Lubrication pinion is mounted to the lubrication shaft

assembly by using special springs and countersunk head

M5X10
• 1 greaser is connected lubrication shaft and 1 lubrication

fittings is connected on it.

i igure lJ)1

- Lubrication wedge is fixed on motor plate with 2 M5x50

imbus bolts (item 10).

I The hoses from the cars and the lubrication pinion are

inserted to the fittings on the wedge.

2:I ]T6|Or |v .in

Durmazlar Installation Guide
DURMA

Figure 1-02

• X-Yaxiswedge is connected its place on plate by using 2

M6xl5 imbus bolts (part number 3).

I Motorplate side cover sheets are connected with 6 M5xl0
imbus bolts. (part numbers 8-9).
- The bellowsconnection flange is connected to the motor

plate with 6 countersunk head bolts M5xl0 (item 6)

Reducer pusher wedge is connected with 2 M5x20 imbus
bolts and 2 M5x20 imbus bolts are used for reductor thrust
adjustment (part number 5)

F,g,Jre 1-04
Figure 1-03

Reducer connection flange is mounted to the reducer by

using 12 M6x20 imbus bolts and spring washers.

-L`-.-.--/CniJfy) 1.3
 DurmazJar lnst±XJafiron Guide DUF\ MA

24 PNEUMATIC ELBOW FESTO QSML M3-3 5

23 ORING A92.127006 lLC 2
22 BLIND FLANGE A73.087010 lLC 2
21 GftEASER 5
20 PLAIN PIPE FllTING STRAIGHT PIPE 6mm lNTEC 1/8" lLC (04.112.0) 1

19 PLAIN FllTING STRAIGHT PUSH-lN D6 M10xl 2508 ILC (03.256.3) 1

18 CHECK VALVE RING 10xllN DPA RING 4/6 ILC (14.050.6) 1

17 OIL DISTRIBIITOR BLOCK DPA-3 lLC (02.800.3) 1

16 CHEESE HEAD IMBUS BOLT M5x50 8.8 BLACK DIN 912 3
15 CHEESE HEAD IMBUS BOLT M6X10 8.8 BLACK DIN 912 12
14 PLAIN WASHER M6 GALVANIZ DIN 125-A 12
13 COUNTERSUNK IMBUS BOLT M4xl0 8.8 BLACK DIN 7991 12
12 CHEESE HEAD IMBUS BOLT MBX1610.9 BIACK DIN 912 8
11 SPRING WASHER M8 DIN 127-a 8
10 CHEESE HEAD IMBUS BOLT MBX3010.9 BLACK DIN 912 28
9 CHEESE HEAD IMBUS BOLT MBX3510.9 BLACK DIN 912 57
8 CHAIN PROTECTION SHEET METAL LINEEf` (RAL 7035) 4
7 X AXIS WEDGE 1
6 X EXIS BELLOW RACK 2
5 XAXIS COVERING PLATE (RAL 7035) 2
4 X AXIS LEFT MOVEMENT GROUP RACK 1

3 RACK ZST-300-PA5-500 M=3 STAR 7

2 GulDE 35" R160530431 / 4556 1

1 X AXIS LEFT PROCESSING RACK 1

NoTablrg2 Deflnitjol) Quantfty

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 Durmazjar ,nsta+,atjon c,ul,de DU R MA

I X1-X2 axis bodies are moved tothe installation area (item

1)
- Clean the guide mounting surfaces with athinner cloth.
• The machined surfacesofthe x1-X2 axes are leveled and

cleaned.
I The machined surfaces on the axes are lubricated with

protective oil.

Figure 1-06
Figure lJ)5

ln the maEhin€d surfa€e§ on axis, the gaps are taken

boctite (2 mum
I The guides are pressed to the thrust surfaces and

tightened with a gun.

- The bolts are covered with the BLACKguide tap.

=g-I,:a 1J)7 Figure 1-08

- Racksare placedonthemachinedsurfacesonaxis
----,

(number part 3)
+---,
- Clearances are taken by using M8x30 imbus bolts Loctite in
----,
rack holes.
----,

----,

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----,

---,
 DurmazJar lristaINilriron Guide DU R MA

lmbus bolts are tightened their places by pressing rack

apparatus to the gear.

Figure 1-09

I Axis shock wedges are fixed tothe both end ofaxiswith

M6x40 imbus bolts

I Hardware switch sheet bar is mounted totheir places on

X2 axis by using M5xlo imbus bolt and special washer.

1.1.2 Y Axis Pre-Installation

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 DurmazJar lnsta"atiion Gui`de DIJR MA

41 SPRING WASHER M12 DIN 127-a 8

40 CHEESE HEAD IMBUS BOLT MBX1610.9 BLACK DIN 912 4

39 CHEESE HEAD IMBuS BOLT M4X16 8.8 BLACK DIN 912 16

38 COuNTERSUNK IMBUS BOLTMBX30 8.8 DIN 7991 25

37 CHEESE HEAD IMBUS BOLT M5xl6 8.8 BLACK DIN 912 29

36 PLAIN WASHER M5 GALVANIZ DIN 125-A 29

35 CHEESE HEAD IMBUS BOLT MBX3010.9 BLACK DIN 912 4

34 SPECIAL WASHER (BICAK VE KAMA BAGLAMA) ¢22x¢9x4 4

33 CHEESE HEAD IMBUS BOLT M6x30 8.8 BLACK DIN 912 16

32 CHEESE HEAD IMBUS BOLT M5x25 8.8 BLACK DIN 912 68

31 BLIND FLANGE A73.087010 lLC 2

30 CHECK VALVE 10xl OUT RING 4/6 lLC (14.050.8) 4

29 PIAIN PIPE FITTING STRAIGHT PIPE 6mm INTEC 1/8'` lLC (04.112.0) 5

28 PLAIN FllTING STRAIGHT PUSH-lN D6 M10xl 2508 ILC (03.2S6.3) 5

27 CHECK VALVE RING 10xllN DPA RING 4/6 lLC (14.050.6) 1

26 SWITCH OIL DISTRIBUTOR BLOCK DPA-3 WITH MICROSVIC ILC (02.850.3) 1

25 DISTRIBUTOR BOX 8" ME 00027116 1

24 X AXIS BELLOWS PROTECTION SHEET RIGHT RACK i

23 X AXIS BELLOWS PROTECTION SHEET LEFT RACK 1

22 Y AXIS SIDE DOOR 2

21 SHulTLE TABLE SWICTH SHEET BAR 2

20 SWITCH NIHAYET XCK P2118P16 SCHNEIDER 4

19 Y AXIS LOCKING SHEFT BAR 2

18 X AXIS CABLE CARRIER MP62.3 R200 (25 LINK) (CLOSED) 1

17 HEXAGON HEADED NUT M6 GALVANIZ DIN 934 4

16 Y-X CABLE CHANNEL PROTECTION SHEET 1

15 Y AXIS CABLE PROTECTION SHEET 1

14 Y AXIS CABLE FIXING SHEET 1

13 Y AXIS BELLOWS PROTECTION SHEET 1

12 Y-X FIBER RACK BELLOW 2 (RAL 7035) 1

11 y-X FIBER CABLE CHANNEL (RAL 7035) 1

10 Y AXIS CABLE CARRIER MP52.2 f`200 (17 BAKLA) (OPEN IYPE) 1

9 CHEESE HEAD IMBUS BOLT M6x35 8.8 BLACK DIN 912 4

8 RACK BELLOWS Y AXIS La:1700 Lz:100 2

7 X AXIS CABLE CHANNEL SUPPORT TIE PIECE 2

6 X AXIS CABLE CHANNEL TRANSPORT SHEET 1

5 Y AXIS SIDE PLATE 2 1

4 Y AXIS SIDE PLATE 1 1

3 RACK ZST-200-PA5-500 M=2 STAR 4

2 20" GUIDE 2236 MM 8/60x38/8 R987403670 REXROTH 2

1 Y AXIS PROCESSING RACK 1

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DurmazJar lnstana+ion Gulide DU R MA

Clean the guide mounting surfaces with a thinner cloth.

Guides are mounted to the machined surfaces of Y AXIS
with M5x25 imbus bolts and bolts guide plugs are inserted
on them (2nd numbered part)
Racks are placed on Y AXIS machined surfaces (3rd
numbered part)
Place M6x25 imbus bolts on the rack by leaving two gaps
and slightly tightened.
Rack apparatus is inserted rack connection points and bolts
are tightened.
M6x25 imbus bolts are inserted into remaining spaces and
tightened.

Y-Axis bellows are mounted (8 numbered part)

Y-Axis side plates ara mounted Y-AXIS with M8x20
countersunk bolts. (part number 4 and 5)
Y-Axis cable channel mounting is performed by using
M5xl0 imbus bolt and M5 washer.
Hardware switch plates are assembled to V-axis by using
M5xlo imbus bolts and M5 washers.
Y-Axis hardware switches are connected to V-axis switch

plates with M4x30 imbus bolts.

I Switch MURRconnection part is mounted to Y-axis by

using M4xl5 imbus bolts.

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DurmazJar lnstallariion Gulide DUR MA

-Y-axis cable fixingsheet is mounted Y-axis by using M6xl0

imbus bolt and M6 washers.

- Plain tube and straight fittings are mounted to the switch

lubrication wedge.
• Y-axisswitch lubrication wedge and Y-axis lubrication

wedge blocks are mounted by M5x50 imbus bolts.

I Sponges are attached tothe bottom ofYaxiscable carrier.
I Y-axis cable carrier is inserted on axis
- The moving end ofY-axis cable carrier is mounted z-axis

pallet table by using

- Fixed end ofY-axis cable carrier is mounted Y-axis by using

M8x25 imbus bolts and M10 nut.

1.1.3Z-AXIS Pre-Installation

1.9
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DurmazJar lnsta"atiior\ Gulide DUB MA

41 HANGER BOLT M8 2

40 SPRING 2

39 Z AXIS HEIGHT CONTROL BODY REAR COVER 1

38 SWITCH MAGNETIC BALLUFF BES516-3042-02-C-PU 2

37 LINEER BELLOWS Z AXIS La:260 Lz:50 1

36 Z AXIS MOVEMENT GROUP-P4 1

35 Z AXIS MOVEMENT GROUP -P1 1

34 COUNTERSUNK IMBUS BOLTM6xl6 8.8 BIACK DIN 7991 3

33 PLAIN WASHER M4 GALVANIZ DIN 125-A 6

32 COUNTERSUNK IMBUS BOLTM4xl0 8.8 BLACK DIN 7991 12

31 CHEESE HEAD IMBUS BOLT M6X20 8.8 BLACK DIN 912 2

30 CHEESE HEAD IMBUS BOLT M5x25 8.8 BLACK DIN 912 4

29 CHEESE HEAD IMBUS BOLT M4xlo 8.8 BLACK DIN 912 10

28 CHEESE HEAD IMBUS BOLT M5xl6 8.8 BLACK DIN 912 6

27 CHEESE HEAD IMBUS BOLT M6x2512.9 BLACK DIN 912 4

26 CHEESE HEAD IMBUS BOLT M5X10 8.8 BLACK DIN 912 4

25 PLAIN WASHER M5 GALVANIZ DIN 125-A 4

24 CHEESE HEAD IMBUS BOLT MBX2010.9 BLACK DIN 912 4
23 CHEESE HEAD IMBUS BOLT M4X16 8.8 BLACK DIN 912 20

22 PULLING ftETAINING PIN ¢6x30 DIN 7979 2

21 Z AXIS MOVEMENT GROUP BODY -2 1

20 Z AXIS MOVEMENT GROUP BODY -1 1

19 GulDE PUSHING PART 3

18 Z AXIS MOVEMENT GROUP -P9 2

17 BEARING SPECIAL NUT GWR45xl,5 R150724004 1

16 BEARING LGN-B-1242 STAR R341400406 1

15 BEARING SPECIAL NUT NMZ 12xl R344600304 1

14 Z AXIS MOVEMENT GROUP -P6 1

13 Z AXIS MOVEMENT GROUP -P8 1

12 SPINDLE RING ¢12xl DIN 471 1

11 FIXED BALL BEARING ¢12x¢32xl0 62012RSR FAG 1

10 Z AXIS MOVEMENT GROUP -P7 1

9 15 mm GUIDE CAR R166611322 REXROTH 4

8 Z AXIS MOVEMENT GROUP -P5 1

7 NUT R1502 040 85 16XIORX3-3 1

6 SCREW SHAFT ¢16xloRx3-3 R1511047 00 1

5 COUPLING KTR GS14 95-98 Sh A-GS HU82-10 HU82-14 1

4 Z AXIS MOVEMENT GROUP -P3 2

3 SERVO MOTOR IFK70334CK71-1RH0 SIEMENS 1

2 Z AXIS MOVEMENT Gf`OUP -P2 1

1 15 mm GUIDE 1605-163-31 2

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Durmaz)ar lr\sta+la+ion Gutide DUFI MA

- Bearingsare inserted to the shaft and tightened.

- Bearing is inserted tothe adapter part and fixed.
I Fittings are connected and motoradapteris inserted z-axis

plate in order to lubricate bearings.

I Nut isinserted to the shaft and mounted to the ballscrew

block of nut by using M6x25 imbus bolts.

- Motoradapter is mounted to the z-axis plate by using

M5xl0 imbus bolts.

- Fitting connections are done forshaft and nut.
I Automatic lubrication fittings are mounted to the ball cars.
I Ball carsare connected to the head bottom plate by using

M4xl5 imbus bolts.

I Head lower plate is inserted tothe z-axis plate by inserting

to the lubrication hoses.

I Protective oil on z-axis motorshaft is cleaned by using

thinner cloth and coupling is connected.

Z-Axis motor is mounted to the adapter part by using
M6x25 imbus bolts and spring washers.
Z-axis plate is inserted V-Axis guides through ball cars.

1.11
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Durmazjar ,nsta+\e,+,on c,ul,de D,, R MA

61 Z AXIS BODY RACK 1

60 LASER HEADB0DY 1

59 PLAIN WASHER M6 GALVANIZ DIN 125-A 3

58 CHEESE HEAD IMBUS BOLT M6X16 8.8 BLACK DIN 912 5

57 CHEESE HEAD IMBuS BOLT M5X10 8.8 BLACK DIN 912 24

56 PLAIN WASHER M5 GALVANIZ DIN 125-A 24

55 CHEESE HEAD IMBUS BOLT M5x50 8.8 BLACK DIN 912 6

54 COUNTERSUNK IMBUS BOLTM4xl0 8.8 BLACK DIN 7991 12

53 COUNTERSUNK IMBUS B0LTM5X10 8.8 BLACK DIN 7991 8

52 CHEESE HEAD IMBUS BOLT M6x50 8.8 BLACK DIN 912 2

51 CHEESE HEAD IMBUS BOLT M5X2010.9 BLACK DIN 912 8

50 SPRING WASHER M5 BLACK DIN 127-8 8

49 WASHEf` SPECIAL (BLADE AND WEDGE COUPLING) ¢22x¢9x4 4

48 CHEESE HEAD IMBUS BOLT MBX20 10.9 BLACK DIN 912 9

47 CHEESE HEAD IMBUS BOLT M5X3010.9 BLACK DIN 912 16

46 CHEESE HEAD IMBUS BOLT M6x30 8.8 BLACK DIN 912 8

45 CHEESE HEAD IMBUS BOLT MBX1610.9 BLACK DIN 912 21

44 CHEESE HEAD IMBUS BOLT MBX3010.9 BLACK DIN 912 16

43 SPRING WASHER M8 DIN 127-a 12

42 M5-¢3 -QSML (153331) AUTOMATIC LUBf`lcATloN FITTINGS 4

41 ORING A92.127006 lLC 1

40 BLIND FLANGE A73.087010 lLC 1

39 PNEUMATIC ELBOW FEST0 QSML M3-3 14

38 PNEUMATIC STRAIGHT FESTO QSM-B-M3-3-20 8

37 GREASER 13

36 PLAIN HOSE FIITING STRAIGHT PIPE 6mm lNTEC 1/8" lLC (04.112.0) 2

35 PLAIN FITTING STRAIGHT PuSH-lN D6 M10xl 2508 ILC (03.256.3) 2

34 CHECK VALVE RING A 10xllN DPA RING 4/6 lLC (14.050.6) 2

33 OIL DISTRIBUTOR BLOCK DPA-3 lLC (02.800.3) 2

32 HOSE POLYAMIT LEGRIS ¢3x¢1,81025P03-00-18 (20 METRE) 1

31 ELBOW 1/8 -10 HYDRAULIC MALE GEAR ELBOW 1

30 PNEUMATIC ELBOW M5x6 2122006050 REXROTH 2

29 BRIGHT METAL COATED BUTTON 423036-MP05 1

28 Z AXIS CABLE COVERING BODY 1

27 Z AXIS MOTOR COVER SHEET MFTAL 1

26 PULLING RETAINING PIN ¢6x30 DIN 7979 4

25 Z AXIS GREASE DISTRIBUTOR 1

24 GAS HOSE ASSEMBLY NITROGEN -HD-FL 301511 -3/8 (11500MM) 1

23 3015 LASER HEAD GAS HOSE ASSEMBLY 1

«0 Dethttfon Quarry

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Durmaz:)ar lr`stalla+ion Gutide DIJ FI MA

22 Y AXIS BELLOW FIANGE 2 1

21 Y AXIS BELLOW FIANGE 1 1

20 LUBRICATloN PINloN 132-020-017 WMH 1

19 LUBRICATloN PINION 133-024-001 WMH 1

18 PROPORTIONAL VALVE 1/4" E7825AMZ LANNY 1

17 PROP0f`TloNAL VALVE TABLE 1

16 Z AXIS MOTOR ADJUSTMENT PART 1

15 Y-Z FIBER CABLE CHANNEL (RAL 7035) 1

14 Y AXIS CABLE CHANNEL CONNECTION PART (RAL 7035) 1

13 Z AXIS CABLE CHANNEL CONNECTION PART 1

12 Z AXIS CABLE CARRIER MP52.2 R200 (11 LINK) (OPEN TYPE) 1

11 SERVO MOTOR IFK7060-2AF71-1RGO 1

10 REDUKTOR TP 010S-MF1-7-OGO-2S + RTP 010-A02-5e24-37 STAR 1

9 REDUCER CONNECTloN PART 1

8 PIERCING AIR PIPE 1

7 PRECITEC PROCuITER CulTING HEAD LASERMATIC 1

6 HEAD CONNECTION PART 1

S 201 GUIDE CAR R162282320 REXROTH 4

4 Z AXIS MOVEMENT GROUP ASSEMBLY 1

3 Z AXIS PLATE SUPPORT 2

2 Z AXIS PLATE 2 1

1 Z AXIS PROCESSING RACK 1

No tnalrmco Qpantry

I The markson the plates are cleaned withcloth.

• Bearing sleeve is mounted to the plate by using4 M6x20

imbus bolts and spring washer.

- The mountingofz-axis movementgroup pl retaining pin is

done.
• Z-axis movementgroup is mounted to the plate by using

PI M6x20 imbus bolt and spring washer.

• Z-axisguidesare connected with M4xl5 imbus bolt.
• Lubrication fittings are mounted to the ball car.
• Ball cars are mounted on z-axis plate by using M8x25

imbus bolts.
I Lubrication hoses are connected to carand fixed on the

plate

1.13
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 r)urmazJar lr\stalJariion Gulide DU FI MA

Figure 2-13 FIgure 2-14

Lubrication shaft is mounted to the Z-axis plate by using

MBX15 imbus bolts.

Lubrication pinion is mounted to the lubrication shaft by

using special washers and countersunk head M5XIO bolts
1 greaser is connected on lubrication shaft and 1
lubrication fitting is mounted on it.
Before adjustment, reducer mounting is done to the Z-Axis

plate in order to insert on Y-axis body.

Reducer is mounted to the Z-axis plate by using M8x30
imbus bolts and special washers.
Pallet table is connected to the Z-axis plate.
- TwoM6xl0boltsatthetopandfourM6xl5boltsatthe

front are used.

1 short silencer,112-1/4 straight union,11/8-10 bellow
are mounted on proportional valve.
It is mounted on proportional valve by using 3 M5xl0 bolts
and spring washer.
Proportional valve table is mounted to the Y-axis plate by
using 2 M5xlo imbus bolts and washers.

Figure 1-15 Figure 1-16

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Our mazJar lnstallation Guiide DIJR MA

1.2 Final Assembly

1.2.1 Body Assembly

I The body brought to the assembly area is cleaned and

leveled.
- M36x70 six cornerscale bolts are inserted to the feet of

body.
-Scale adjustment bolts (bodysixing plate) are mounted to

the body feet by using M12x60 and M12xl00 imbus bolts

Figure 1-17 Figure 1-18

• Body is leveled by using measurement instrument.

- Measurement instrument must be placed on machined

surface, where X-axis is placed.

• Thesamesectionshould beseenatthefourcornerofthe

body on measurement instrument.

Figure 1-19

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 DurmazJar lnstaylefiron Guide DU F\ MA

TABLE MOVEMENT GROUP

18 TABLE FIXING ASSEMBLY (BODY) 1

17 TABLE MOVEMENT GROUP RAIL 1

16 CHAIN RAIL ASSEMBLY 12 81 4
15 CHAIN RAIL CONNECTION PLATE 1
14 TABLE MOVEMENT GROUP EXTENSION TABLE PROCESSING 1

13 TABLE MOVEMENT GROUP MOTOR TABLE 1

12 COUNTERSUNK IMBUS BOLT M4xl0 8.8 BLACK DIN 7991 40

11 WEDGE CONNECTION WASHER (¢28x¢17x5) 4
10 CHEESE HEAD IMBUS BOLT M16X5010.9 BLACK DIN 912 4
9 CHEESE HEAD IMBUS BOLT M12x50x4810.9 BLACK DIN 912 2

8 WEDGE CONNECTION WASHER ¢28x¢13x5 4

7 CHEESE HEAD IMBUS BOLT M12X4012.9 BLACK DIN 912 2

6 HEXAGON HEADED BOLT M8x20 8.8 BLACK DIN 933 4

5 CHEESE HEAD IMBUS BOLT M6x30 8.8 BLACK DIN 912 16
4 WASHER SPECIAL (BLADE AND WEDGE COUPLING) ¢22x¢9x4 8
3 CHEESE HEAD IMBUS BOLT MBX3010.9 BLACK DIN 912 8
2 3015 CHAIN f`ETAINING INSTALLATION 1
1 3015 f`EDUCER GROUP ASSEMBLY 1
NoTabI-06 Dein"on Quautfty

- Extension table fortable movement group is mounted on

the body with 4 pieces M16x45 imbus bolts, special washer

and spring washer.
I The hexagonal rail is connected with the M6x30 imbus

bolt.

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DurmazJar lnstaMariion Gulide DUB MA

Figiire 1-22

Pre-assembled chain stretching apparatus (1 chain

sprocket and roller are used) is connected to chain
extension part with 4 pieces of M8x30 imbus bolt and
special washer.
Motor table is connected with 4 M12x40 imbus bolts and
special washers.
Chain motor is fixed on table with M6x25 imbus bolt and
spring washer (2 bushing,1 sprocket wheel and special
washer is mounted outside)
Shuttle table body fixing is connected with imbus bolt and
special washer.
1 pneumatic cylinder is connected on fixing with M8x70
imbus bolt and 2 pneumatic sleeve are inserted on
cylinder. 6 M8x20 and 4 M10x30 imbus bolts are used on
it.1 stoper and conical pin are tightened on piston end by
using Loctite.

2:oi6|cri N .co 1.17

DurmazJar lr\stallatiior\ Gujide DU R MA

r=

F=

Pushing-pulling parts are touched into machined

referenced surface on X1-Acis body and gaps are taken by
using M16x45 imbus screws and spring washers.
X1-Axis is located on body and bolts are attached.
Y-axis is connected X-axis group carriage tables by using 4
M12x30 hexagon bolts and spring washers.
Axis is moved forward and back, Y-axis is brought to the
feet and bolts are tightened in this area.
Chain rail is mounted on Xl axis with M4xl0 imbus bolt.
Chain is passed through rails and it is mounted with shuttle

[s=-----
I:`...,'.
table movement knob.

i=-.
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Figure 1-23

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: DurmazlarlnstallationGuide DunMA

Pallet table is fixed on body with 8 M6x30 imbus bolts and

spring washers.
2.2.2 filter and suction group is placed into the body of
mounted suction bucket.
- Suction bucket is mounted on body with twisted two L

pieces with M10x20 imbus bolt, special washer and nut

• X-axis reducer is mounted on x-axis carriage plates. It is

mounted with M8x25 imbus bolt, special washer and

spring washer.
• X1-X2 reducer couplingcovers are removed and it is

ensured that the bolt heads are facing each other.

• Reducers are touched rackswith adjustment bolts and
- the working space isadjusted byturningthe coupling

manually.
• X-Axis motors are mounted on reducerswith M8x20 imbus

bolts and spring washers.

I Motorshafts are tightened by using couplings on reducer

with 6 allen wrench.

I Reducercoupling covers are covered by using 10 allen

wrench.
I X-axis bellow mounting is done by using M4xl5

countersunk head bolt

1.2.2 Dust Collection Unit and Suction Group Assembly

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i
DurmazJar lrista+ldtiion clulide DUR MA

28 CHEESE HEAD IMBUS BOLT M5X10 8.8 BLACK DIN 912 6

27 CHEESE HEAD IMBUS BOLT M6x30 8.8 BLACK DIN 912 4

26 CHEESE HEAD IMBUS BOLT M6X10 8.8 BLACK DIN 912 53

25 CHEESE HEAD IMBUS BOLT M6X16 8.8 BLACK DIN 912 20

24 PLAIN WASHER M6 GALVANIZ DIN 125-A 29

23 HYDRAULIC PIPE ¢8.1,5.6000mm 4

22 HYDRAULIC PIPE ¢12*2'1200mm 1

21 NUT ONE SIDE STICKY BAND 5x20 (10 M) 1

20 SINGLE THROTTLING GR-QS-6 FESTO 1

19 REVERSE ELBOW 8" S IYPE -EWSO8SOMD-EWSO8SOMD 8

18 VALVE SPEED ADJUSTMENT G1/8-¢6 -R412010569 12

17 HYDRAULIC NUT ¢8M 8 A3L-MO8SX 24

16 STRAIGHT UNloN 8-1/8 GESBSR STIpl 10

15 GALVANIZ PIPE 1 1

14 EXHAUST PAN MODULE Pll 3

13 EXHAUST PAN REAR COVER SHEET METAL 2 2

12 EXHAUST PAN REAR COVER SHEET METAL 2

11 EXHAUST PAN V BENDED SHEET METAL 2

2!fli6iorrv.OO
DurmazJar lnsta+latior\ Gulide DU R MA

8 EXHAUST PAN PNEUMATIC CONNECTloN PIATE 1

7 PAN CONNECTION TIE PIECE SHEET 2 2

6 PAN CONNECTION TIE PIECE SHEET 2.

5 CONVEYOR STOPPING PART 3

4 EXHAUST PAN COVER SHEET METAL 1

3 EXHAUST WINDOW ASSEMBLy 6

2 EXHAUST PAN U MODULE WELDING ASSEMBLY 2 1

1 EXHAUST PAN WELDING ASSEMBLY 1

NO No No

- Exhaust windowsfromthe suppliercompanyare brought

to the installation site.

I 8-1/8 S type fittings are connected on pneumatic pistons.
- M6xl0 imbus bolts are mounted to the exhaust windows

suction group.

Figure 1-24 Flgrre 1-25

ln the suction group, the place on the bucket is connected

to 12 one way parts.
Pipe assembly is established.
12 pieces 7.5 meter 6" air hose are cut.
Hoses coming from pistons forming suction group in valve
area are connected respectively.
- Valveconnectionisdonefi.omtwoendsasAand Kfor

piston's forward and back status.

2fii6icnri.in 1.21
Dur mazJar lnstaMatiiori Gu.ide DUR MA

FigiJre 1-27

Galvanized pipe connection is done with M6xl5 imbus bolt

and washer in the suction group outlet.
Galvanized pipe assembly is established between filter and
suction group.
• Galvanized pipesare locked and mounted with smart bolts.
I 210 mm spiral hose is used as anti-vibration.
I 1/2 fingerairconnector isconnected to the filter.

1.2.3 Table Assembly

• The lasershuttle table from the supplier is brought to the

installation area.
• Table guide apparatus part must be used for placement of

table in front of body as parallel and the shuttle table

should be placed in the proper position in front of the
body.

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 DurmazJar lnsttl)ation Guiide DU R MA

=. figr re 1-30

I The lowerand uppertablesareremovedandwaited ina

suitable area.
I Articulated switches are connected to the switch sheet

bars with M4x40 imbus bolts.

I Metalsensorconnection ismade.

2f JJ:f.low |V .cO i.23

DurmazJar lnsta"atiion Gulide DUR MA

RE¥I -i- - REF

4E:-_ __
Figure 1-31
_ __-.`
Figure 1-32

I Afterelectrical connectionsare made, replace the upper

and lower tables.

a
a..
•
I
Zimm protection bodiesare placed totheir places.
Motorprotection sheets are mounted with M6xl0 hat a
head bolt €£
e=
e±
t±

1.2.4 Gas Panel Assembly Mounting

I 1 reed ®6" air connector is inserted lubrication tank.

I Lubrication clock is mounted by using copperwasherand

red Loctite.
• Theprepared unitisinstalled inthe panelwith2 M6x20

imbus bolts and special washers.

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Dur mazJar lnstalJatiion Gulide DUB MA

Figure 1-36

Air conditioner 3/2 hand control with permanent position

direction valve, oil filter and 3/2 solenoid controlled spring
back push-button valves are mounted.
• 1 ®12 and 1 ®10airconnector is connected on air

conditioner.
I An air pressure indicatorclock is installed.
I The conditioner is connected to the panel with an M5xl5

imbus bolt.
I Thegasunitismountedonthe panelwithM6xl5imbus

bolt.
- Valve area is delivered as mounted on panel.
• Communication and 24Vsolenoid control connections are

made.

figure 1-37 Figu re 1-38

Nitrogen and oxygen manifolds are placed in a suitable

area near the laser machine.

2:Oufi|Oviv.cO 1.25
Dur mazJar lnstanatiior` Gulide DIJ R MA

Regulators selected according to outlet pressure values on

the manifold are tightened using 32 switches.
I Gas hosesare connected to the oxygen and nitrogen inlet

with 19 and 22 wrench.

Figure 1-39 Figure 140

Nitrogen is set 28 bar, oxygen is set 10 bar over regulator.

Overpressure relief valves on the gas unit are adjusted.
Check for gas leakage.

T`,8REE---TLi=¥ife

Figure 142

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DurmazJar lnstal)atiion Guiide DU FI MA

1.2.5 Pneumatic Group Assembly

1.27
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DurmazJar lnstaMariior\ Gulide DU R MA

NO PART NAIVIE

1 VALVE BLOCK

2 VALVE BLOCK

3 3/2 OPEN CLOSE VALVE

4 FILTER PRESS REGULATOR

5 DISTRIBUTOR

6 OPEN CLOSE VALVE

7 PNEUMATIC CYLINDER (FIXING)

8 LASER CUTTING HEAD (PIERCING)

9 LASER CUTTING HEAD (NOZZLE COOLER)

10 LUBRICATION UNIT

11 GAS PNEUMATIC VALVE

12 PNEUMATIC CYLINDER (EXHAUST PAN)

13 PNEUMATIC CYLINDER (FIXING-SHUITLE TABLE)

The air from the compressor is connected to the main air

inlet of the conditioner.
The air from the conditioner is connected to the valve
body.
Piercing and nozzle line are connected to cutting head
from valve body.
The fixing cylinder connectior,s in the machine are made
from the valve body.
• Thevalve isconnected to the lubricating pump.
• The fixl and fix2 fixing cylinders are connected on the laser

table on valve body.

1.2.6 Power Supply Assembly

Precitec cutting head ceramic is mounted.

I The o-ring must be fitted before installing the ceramic.

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 DurmazJar lnsta"atiion Gulide Dull MA

• The fiberoptictip is brought to the clean room byopening

the cable and connected to the holder on the microscope.

- The dusts are cleaned with methanol and cleaning rods by

using microscope.
- Whenitmakessurethatitisclean,thefiberend is

connected to the Precitec cutting head.

- There are two positionsfortightening the head. The holder

is first turned to the left, then lifted up and turned left

again.
I Afterthe head is installed, the collected collector is

unpacked and assembled.

Figrre 146

Figure 148

Water hose connections between the reserator and the

cooler are done.
Water hose connections should be made as shown in the

picture below.

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_-,

_--,
 DurmazJar Assemkrty Gulide DUB MA

1 = Fiber cooler, 2 = lpG, 3 = Laser cutting head

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DurmazJar Assemhty Gulide DU FI MA

1.2.7 Body Assembly

2!OT6|cn |v .f ro 1.31
DurmazJar Assembly Gulide DUR MA

32 CEILING PANEL (WITHOUT HOLE) 1

31 LEFT SIDE PANEL-1 1

30 BUTTON CONNECTION SHEET 2

29 CEILING VENTILATION SHEET 10

28 GLASS HOLDING PABTS -2 2

27 GLASS HOLDING PARTS -1 2

26 CEILING PANEL REAR 1

25 CEILING PANEL 5

24 CEILING PANEL ON 1

23 RIGHT LOWER PANEL-2 1

22 RIGHT LOWEf` PANEL-1 1

21 LEFT SIDE PANEL ASSEMBLY-2 1

20 RIGHT SIDE PANEL-3 1

19 LEFT SIDE PANEL-1 2

18 FRONT LOWER SHEET 1

17 RIGHT SIDE PANEL-6 1

16 RIGHT SIDE PANEL-5 1

15 RIGHT SIDE PANEL4 1

14 RIGHT SIDE PANEL-3 1

13 RIGHT SIDE PANEL-2 1

12 RIGHT SIDE PANEL-1 1

11 BODY LEFT UPPER SHEET-1 1

10 BODY LEFT UPPER SHEET-2 1

9 PAN0 USTU SHEET 1

8 BODY RIGHT UPPER SHEET-2 1

7 BODY RIGHT UPPER SHEET-1 1

6 FRONT MEDIUM SHEET 1

5 MEDIUM PROFILE ASSEMBLY 1

4 REAR PILLAR RIGHT ASSEMBLY 1

3 BEAR PILLAR LEFT ASSEMBLY 1

2 RIGHT FRONT PILLAR ASSEMBLY 1

1 LEFT FRONT PILLAR ASSEMBLY 1

ee ttefmit!ofl Quenfty

M4x20 imbus bolt and guides are connected to the U

profiles. (part number 1 and 2)

2 counter wedges are connected to the lower of profiles
(number 7)
Door body connection sheet bars are connected to body
by using 8 M10x25 imbus bolts and special washer (parts
number 10 and 11)
- U profiles are connected tothe door bodyconnection

sheet bar by using 4 M10x25 imbus bolts and special

washer and spring washer.

2:ou6|oriv.in 1.32
Our mazJar AIsserhoty Gulide DUR MA

Lower profile is mounted between U profiles by using 8

M6x25 imbus bolts and special washer (part number 5)
I 6 doorbodyconnection sheet bars are connected with

M8x20 imbus bolt and special washer.

- The front lowerand upperdoorassemblies are made.
- The doors are connected to theguide connection sheet

bars on u profile by using 6 M6xl5 galvanized hat head

bolts.
I Door movement system is installed.
I Medium profile pillars are mounted by using 8 M6xl5

galvanized hat head bolts.

I Left front pillarand right front pillarare fixed tothe door
Figure 1-50

body connection sheet bars connected on U profile. (1

and 2 numbered body)
Body right upper front part and medium profile
connections are mounted by using M6xl5 galvanized hat
head bolt (7 numbered body)
Body left upper sheet is connected to middle pillar with
left front pillar (11 numbered body).
Panel closing bodies are connected to the rear pillars by
using 16 M6 nuts and washer (3 and 4 numbered body)
I Right rearand left rear pillar are touched to the panel

and panel upper sheet are mounted between them by

using 8 M6xl5 galvanized hat head bolt. (9 numbered
body)
• Body rear uppersheetsare mounted to rear pillarsand

middle pillars.
- 12andl5numberedsidepanelsarelockedtotheeach

other and they are connected by using M6xl5 hat head

bolt from bottom.
• 34 numbered reardoorassembly is done.
• The fiber protection glass is installed theirplaces in the

upper door and in the right side panel.

1.33
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 Durmaz:)ar Assembrty Gujide D UR MA

Figure 1-S1

Figure 1-52

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DurmazJar Assembrty Gulide DUR MA

1.2.8 Electric Connections

Siemens ET200eco input module connection on the

shuttle table foot is completed according to the
electric scheme.

Module connections are shown in the following

figure.

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DurmazJar AIssemhty Gulide DU R MA

Laser unit communication and signal connections should

be done as machine wiring diagram. The socket
connector label numbers are designed to be the same as
the laser unit sockets. The connection sockets are located
on the main electrical cabin.
Connections will be made by finding the same named
sockets.
• Also, connection image is shown on the left
I The main powersupply connection of the laser power

supply must be connected in accordance with the single

line diagram shown in the preliminary document.
• The grounding must be provided from the special

grounding line for the machine.

Figure 1-55

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