HP 5100

Machine Tools
HMC Maintenance
(HP5100)
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. Disassembling and Assembling the Table ..........................................22

2.1 Disassembling the Table -------------------------------------------------------25
2.2 Disassembling the Table Cylinder----------------------------------------------26
2.3 Disassembling the Worm Shaft ------------------------------------------------28
2.4 Disassembling the Worm Wheel -----------------------------------------------30
2.5 Disassembling the Locating Cone----------------------------------------------33
2.6 Assembling the Locating Cone -------------------------------------------------34
2.7 Assembling the Worm Shaft and Worm Wheel --------------------------------35
2.8 Assembling the Table Cylinder -------------------------------------------------42
2.9 Assembling the Table (Pallet Base) --------------------------------------------44
3. Table Accuracy Work .........................................................................45

3.1 Disassembling the Table -------------------------------------------------------45
3.2 Temporary Assembly of theTable (Pallet Base) Body -------------------------48
3.3 Adjusting the Table Alignment -------------------------------------------------48
3.4 Setting the Table Accuracy ----------------------------------------------------49
3.5 Assembling the Table-----------------------------------------------------------49
3.6 Readjusting the Reference point of the B Axis --------------------------------50
4. Servo ATC Recovery ...........................................................................51

4.1 ATC Structure-------------------------------------------------------------------51
4.2 ATC Main Sequence ------------------------------------------------------------53
4.3 Troubleshooting -------------------------------------------------------------- 525
4.4 Centering the ATC --------------------------------------------------------------62
4.5 Important Notes on Troubleshooting the Servo Control ATC -----------------64
4.6 Troubleshooting ----------------------------------------------------------------65
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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. Machine Accuracy work ..................................................................... 98

6.1 Straightness of the Z Axis -----------------------------------------------------98
6.2 Straightness of the X Axis --------------------------------------------------- 101
6.3 Straightness of the Y Axis --------------------------------------------------- 103
6.4 Straightness of the top of the Pallet----------------------------------------- 104
6.5 Perpendicularity between the Coordinate Axes ----------------------------- 105
6.6 Movement towards the X, Z Axes and Parallelism of the top of the Pallet- 108
6.7 Index Table Division Perpendicularity --------------------------------------- 111
6.8 Perpendicularity of the Edge Locator and Movement towards the X Axis-- 112
6.9 Distance between the Edge Locator Standard Side and the Rotation Central Line
-------------------------------------------------------------------------------------- 1167
6.10 Pallet Exchange Repetition Location, Precision and Reciprocal Difference 118
6.11 Z Axis Movement and Parallelism with the Spindle Central Line---------- 119
6.12 Spindle Run-Out ------------------------------------------------------------ 119
6.13 Spindle Movement towards the Z Axis------------------------------------- 119
6.14 Leveling the Machine ------------------------------------------------------- 120
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HP 5100 HP51MTE87
1. Disassembling and Assembling the Spindle Cartridge
1.1 Disassembling the Tool Unclamp Cylinder

▣ Parts List for the Tool Unclamp Cylinder
1200, 1210 1270 1300, 1460

1220, 1230 1250 1280 0420 1490 1320 1350, 1470
410 1240 1260 1290 0430 1500 1330, 1360 1450 1480
1340
1342
900 910 920, 930 990 1010 1050 1070 1080 1380, 1390
940, 950 1000 1060 1090 1400, 1420
1100 1430, 1440
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HP 5100 HP51MTE87
Material /
No. Parts No. Description Q'ty Remarks
Specification
410 C58011324 Spacer, Spring(3) 2 SCM435
420 C58011313B Nut, Spring Clamp 1 SCM440
430 P80300013 O-Ring 1 S13
900 C58012124A Collar, Distance 1 SM435
910 R11247 Bearing, Cyl. Roller 1 N1014KTNHA/SPVR SKF
920 C58011082A Housing, Rear Bearing 1 SM435
930 S8011250 O-Ring 2 G125
940 C58011134A Wall 1 SS41
950 S2201361 Bolt, Hex. Socket Head 1 BB4 ×6
990 C58011093 Support, R-Brg. Housing 1 SM45C
1010 C58012134A Collar, Distance(4) 1 SM435
1050 C58012153A Bracket, Sensor 1 SM435
1060 P64008020 Key 2 KSP8×7 ×20
1070 R02120 Nut, Lock 1 YSR55×2 Duri(Ye-Joon)
1080 C58012173A Stopper, End 1 SM435
1090 S3524376 Screw, Set(Hex. S/Head) 2 BQY6×8
1100 S3520476 Screw, Set(Hex. S/Head) 2 BQY8×10
1200 C58011041A Cap, Motor 1 SM45C
1210 P74060008 Plug, Hex. Socket(S) 1 FPS-S1/4
1220 S2212261 Bolt, Hex. Socket Head 8 BB10×30
1230 R35110 Connector, Male 1 L4N12×9-PT3/8
1240 R32152 Tube, Nylon 1 N5-4-12X9
1250 C51016233A Bracket, Cylinder 1 LMNSC2
1270 C51012463B Cover, Cable 1 SCP1
1280 C51012474 Packing 1 Rubber(T1)
1300 C58011203A Body, Cylinder 1 SM435
1320 C55342214 Bolt, Spring 4 SM45C
1330 184535 Spring 4 PW2
1340 S8001800 O-Ring 1 P180
1342 R53286 O-Ring 1 P115 NOK
1350 C58011213A Piston 1 SM435
1360 R53103 O-Ring 1 P120 NOK
1380 C58011233A Cover, Cylinder 1 SM435
1390 R53076 O-Ring 1 P110 NOK
1400 R53406 O-Ring 1 G125 NOK
1430 S5000501 Washer, Plain 8 ZP8
1440 S5100501 Washer, Spring 8 ZS8
1450 R27053C Rotating, Union 1 1129-018-137 Debulin.W/TSC
1460 C58011223B Cap, Piston 1 SM45C
1470 S8010450 O-Ring 1 G45
1490 C58012254 Pusher, Spring 1 SM435
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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.
1) Remove the various parts (Hyd. Hose,

Coolant Hose, Air Tube, Bracket, Nearby
Switches, etc.) in order to disassemble the
Tool Unclamp Cylinder.
2) Disassemble C58011223B Piston Cap with Piston

Cap
the R27053C Rotating Union.
▪ 4-BB6×20
▪ O-Ring : 1-G45
Rotating
Union
3) Detach the C58011233A Cylinder Cover. Cylinder

▪ 8-BB8×20, 8-ZP8 Cover
▪ O-Ring : 1-P110, 1-G125
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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”
Balancing Bolts (as shown right), and use a
chisel to remove the end stopper.
※ This is to prevent scarring the End
Stopper. Set-screw
▪ 2-BQY-6×8, 2-BQ8×10 chisel
“A”
End Stopper Detail
6) Disassemble the C58011203A Cylinder

Body.
▪ 4-C55342214 Spring Bolts
Cylinder
▪ 4-184535 Spring Body
▪ O-Ring : 1-P180, 1-P115
7) Remove the security bolts on the

C51012463 Cable Cover, put the Cover
aside, and disassemble the C51016233A
Cylinder Bracket. Cable Cover
▪ 8-BB10×100
Cylinder
Bracket
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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 Key

Motor Cap, because it will affect the
concentricity of the position of the Main
Spindle Bearing.
Sensor Bracket
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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.
▣ Spindle Cartridge Parts List
120
130 300
740 140 330
680 750 640 150 340 360
690 760 650 810 160 360 370
700
710
830
840
500 510 520 530 800 540 200 560
Mat. /
Specification
120 C58011031 Housing, Main Bearing SM45C 1
130 P74060006 Plug, Hex. Socket(S) FPS-S1/8 13
140 S8000110 O-Ring P11 7
150 R53388 O-Ring G150 3 NOK
160 S2215361 Bolts, Hex. Socket Head BB12×35 8
200 C5801101B Spindle, Main SCM415 1
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HP 5100 HP51MTE87
Mat. /
Specification
300 C58011303A Rod, Push(1) SCM440 1
330 R56146 Ring, Wear GP65-79L 1 Hansung
340 R55449 Ring, Quad ORAR04216 2 BUSAK(Hansung)
350 R54363 Ring, Backup BP3200280 2 BUSAK(Hansung)
360 C58011334 Base, Spring SCM435 1
370 S8000180 O-Ring P18 1
500 C48042124 Labyrinth(2) SCM435 2
510 C48052114 Labyrinth(1) SCM,435 2
520 R10432 Bearing, ANG. Contact Ball XCM7014.t.P4S 1
530 C58011164 Spacer, Bearing(2) SCM435 2
540 C58011173 Spacer, Long SCM435 2
560 C42018073B Nut, Lock SM45C 1
640 C58011152B Support, Main Bearing 1
650 P80300130 O-Ring S130 1
690 R37260A Nozzle, Coolant SNM10-L20 6
700 C42018324 Ring, Front SCM435 1
710 S8010850 O-Ring G85 1
740 C58011183 Cover, Front SM45C 1
750 P80300120 O-Ring S120 1
800 C35056034A Spacer, Collet SM45C 1
810 R76441B Collet(Din40) Appvd Drow 1
830 C49046664 Key, Drive(BT40) SM45C 2
1) Thoroughly clean the Spindle Head, then

remove the Orientation Air Blow Tube with
Connector
the Connector.
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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
then plug in two M10 Stud Bolts (300mm
or longer) in the Tap position (2-M12).
Slowly and carefully remove the Spindle
Cartridge taking care to maintain Balance.
▪ 8-BB12×36
▪ O-Ring : 7-P11, 3-G150, 1-G115
4) When the Spindle Cartridge is nearly pulled out, use the Rope to completely separate it
and use a Crain to pull it out.
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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 Use the C58012134A Distance
Distance
Collar(4)to hit a section of the inner rim Collar(4)
while making the outer rim touch the Collar
On-site
Roller lightly. The outer rim should be so Dimension
that it moves slightly up and down with
light pressure. At this point, the pressure
on the Bearing can be seen as "0". After
about five minutes' wait (allowing heat
to transfer from your hand to the outer
rim), rotate the outer rim to see if it still
moves up and down with light pressure.
④ If the outer rim seems too loose, hit the
Collar slightly to reduce looseness.
However, if the outer rim is slipping at
about 10 Kg.f pressure, it should be no
problem as a preset pressure in the
Field.
⑤ Measure the gap using the Block Gauge
to verify the "Collar on-site Measure".
⑥ Grind the C58012124A Distance-Collar (3) according to the on-site
measurement. (Measurement tolerance 0/-0.005; Parallelism under 0.005)
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HP 5100 HP51MTE87
2) Measuring the Tightness of the Rear Outer Rear Bearing

Housing
Rim Bearing and on-site grinding Support
Rear
① Measure the difference in height of the Bearing
Outer Rims of the disassembled Bearing Support
and the new Bearing on a plain

measurement table.
② Determine the dimension of the
C58011073A Rear Bearing Support
Rear
▪ Find the figures that add and subtract Bearing
the height difference between the
detached Bearing and the new Bearing
from the measurement of the Rear
Bearing Support.
③ Grind the Rear Bearing Support from on-
site Measure amounts found. (Margin
+0.005/0, Parallelism under 0.005)
Measuring the difference in height
3) Cleaning the Bearing and Applying Bearing

Grease
① Remove all grease from the Bearing
before applying the Grease (Use thinner
or similar material to thoroughly clean
the Bearing, then dry the Bearing for
about an hour.)
▪ The shipped Bearing is stained with
greaseproof material and other
substances. Mixing ordinary lubricant with
Grease will make the Grease useless.
② Apply enough Grease to cover 10~15% of
the spatial area. The chart on the next
page indicates the exact amount to be
applied.
③ The Grease must be inserted evenly Appropriate Grease Applying
throughout the Bearing cylindrically and
must be spread evenly to the bottom of
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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
▪ Release the excessive grease to the
outside
▪ Prevent any air influx
▪ Overheat the Bearing => Noisy/burnt
down
Excessive Grease applying
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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.
I.D Brg.
Nominal Roller Roller
(mm) BA,BT TAC
Brg. NN30 Brg. N10 70 Series 72 Series
Series Series
6 30 0.6 0.4 - - 0.8 0.6
7 35 0.8 0.6 - - 1 0.8
8 40 1 0.7 - - 1.2 1.1
9 45 1.3 1 - - 1.5 1.3
10 50 1.4 1.1 1.2 1.4 1.7 1.5
11 55 2 1.5 2 2 2.3 2
12 60 2.1 1.6 2 2.1 2.4 2
13 65 2.2 1.6 2.1 2.2 2.7 2.3
14 70 3.2 2.4 3 3.2 3.6 3.3
15 75 3.5 2.5 3.2 3.5 3.8 3.6
16 80 4.7 3.5 4.2 4.7 5.1 4.4
17 85 4.9 3.7 4.4 4.7 5.3 4.7
18 90 6.5 4.5 6 6.5 6.9 6.2
19 95 6.6 4.7 6.3 6.6 7.2 6.5
20 100 6.8 4.9 6.5 6.8 7.4 6.8
21 105 9.3 5.9 8.4 9.3 9.3 8.1
22 110 11 7.5 10.1 11 11.9 10.1
24 120 12.5 8.4 10.8 12.5 12.3 10.8
26 130 18 12.9 16.5 18 19.5 16.1
28 140 20 14 17.1 20 20.7 17
30 150 23 - 21.8 23 25.8 21.2
32 160 29 - 26.9 29 31.8 25.5
34 170 38 - 32.4 38 41.6 33.2
36 180 48 - 45.6 - - -
40 200 65 - 60.9 - - -
44 220 88 - - - - -
48 240 97 - 90 - - -
72 360 360 - - - - -
80 400 423 - 395 - - -
※: The amount of grease to be applied should be 12~15% of the spacial capacity for
Angular Contact Bearings, and 10% of spatial capacity for Cylindrical Roller Bearings.
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HP 5100 HP51MTE87
4) Assembling the Spindle Rear bearing Parts

① Thoroughly clean the Rear Bearing R-Bearing
Housing
assembly parts Support
② Insert the Bearing that had been stored
Rear
with NBU16 Grease on it. Bearing
③ Insert the previously on-site grinded Support
C58012124A Distance Collar into the
C58011073A Rear Bearing Support and
assemble it to the C58011082A Rear Rear
Bearing
Bearing Housing.
Distance
▪ 6-BB6×16
Collar(3)
▪ O-Ring : 1-G85
5) Assembling the Spindle Cartridge

Spindle
① Thoroughly clean the C58011021B Motor
Spindle Motor Body. Body
▪ Take special care to remove any
remaining oil from the Motor Coil.
② Apply Grease thinly along the inside of
the Spindle Motor Body.
③ Insert the O-Ring (3-P11, 2-G280) into
the Main Bearing Housing and apply
Grease around the O-Ring.
※ Prevent O-ring separation during Cartridge assembly by inserting the O-Ring

after applying Grease to the 3-P11 O-Ring groove.
④ Lift up the Cartridge using clean linen Rope, then lay it on the interior of the
Body using a crane.
⑤ Insert the Cartridge using 2-M12 Stud Bolts, then use 8-BB12×35 Bolts for
security.
▪ If the Spindle strays into the rear part of the Bearing, insert the C58012134A
Distance Collar(4) into the Spindle and use it to hit the Bearing and continue
assembly.
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HP 5100 HP51MTE87
Spindle Cartridge
⑥ Use the C58012134A Distance Collar(4) to Distance

give shock to the Rear Bearing in order to Collar(3)
Distance
completely attach the Distance Collar(3) Collar(4)
and the Rear Bearing to the Spindle section.
Rear
Bearing
6) Clean the C58011183 Front Cover and Front Cover

assemble.
▪ 8-BB5×20
※ Manually rotate the Spindle to check for
any interference.
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HP 5100 HP51MTE87
7) Insert the parallel Key(2-KSP8×7×20) into the Motor

Spindle, assemble the C58012153A Sensor Cap
Bracket and secure with a Lock-Nut, and then Key
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
BZ-
paper after tightening the BZ-Sensor Sensor
security bolts.
Lock-Nut
17
HP 5100 HP51MTE87
1.4 Assembling the Tool Unclamp Cylinder

1) Assemble the C51016233A Cylinder
Bracket. Cable
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
※ Prevent damage to the O-Ring by applying
Body
Grease around the O-Ring.
▪ 4-C55342214 Spring Bolts
▪ 4-184535 Spring 1-P180
▪ O-Ring : 1-P180, 1-P115/NOK
1-P115
Spring Bolt
3) As shown right, insert the Flat Washer and

Bolts into the Balancing Bolts location (to
prevent scarring the End Stopper) and use
a chisel to give shock to the C58012173A Flat BB8X2
End Stopper until the Set-Screws seem to A W 0
fit the Drill grooves (BQ Bolts grooves)
made at the end of the Spindle. Then
tighten the security Set-screws.
▪ 2-BQY-6×8, 2-BQ8-10 2-BQY 6X8
※ In case no BQ Bolts grooves have been
made chis
① Complete this process before assembling el
the Cylinder Body. End Stopper
“A” Detail
② First,tighten the End Stopper as strongly
as possible.
③ Use the Ø5 Drill to make Drill marks at the
place for Set-Screws (M6 Tap location).
(Centering work)
④ Use the Ø4 Drill to make grooves about
3mm deep.
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HP 5100 HP51MTE87
4) Insert the O-Ring into the C58011231A

Piston which the C58012254 Spring Pusher is 1-G125
assembled, and carefully assemble the
Cylinder Body.
※ Apply grease around the O-Ring to Piston
prevent damaging the O-Ring during
assembly.
▪ O-Ring : 1-P120/NOK Spring
Pusher
5) Insert and assemble the O-Ring into the 1-G125

C58011233A Cylinder Cover and tighten the
1-P110
security bolts.
※ Apply grease around the O-Ring to
prevent damaging the O-Ring during
assembly.
▪ 8-BB8×20, 8-ZP8
▪ O-Ring : 1-P110/NOK, 1-G125/NOK
Cylinder
Cover
6) Use the R27053C Rotating Union to assemble the Piston Cap

C58011223B Piston Cap.
▪ 4-BB6×20
▪ O-Ring : 1-G45
1-G45
Rotating
Union
※ Reference : Assembly of the Deublin-Rotating Union
D1 D2
Cap End Piston
Field
Simultaneo
Piston Cap
Stub. Rotor
Rotating Union
19
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 Grind the attached section of the Piston Cap Rotating Union to make the
difference between the two distances (D1 & D2) 2.3~2.5mm. Make sure that
the attached section of the Rotating Union and the attached section which
Piston Cap is attached to Piston are simultaneously machined. (Refer to the on-
site machining in the picture)
7) Assemble the various Hyd. Hose, Coolant

Hose, Air Tube, Bracket, proximity Switches,
and Wires that had been removed to
disassemble the Tool Unclamp Cylinder.
20
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.
2) Refer to the following program example for specific RPM and running times for
rolling operation
3) Take appropriate measures to deal with miscellaneous strange sounds
(interference noise).
4) The standard maximum temperature is room temperature (atomosphere
temperature) + (40~50 degrees).
※ Example of Milling Spindle Bearing Rolling operation Program

M03 S1000 ; M03 S4000 ; M03 S7000 ; M03 S10000 ;
G04 X300. ; G04 X300. ; G04 X300. ; G04 X180. ;
M04 ; M04 ; M04 ; M04 ;
G04 X300. G04 X300. ; G04 X300. ; G04 X180 ;
M03 S2000 ; M03 S5000 ; M03 S8000 ; M03 S1000 ;
G04 X300. ; G04 X300. ; G04 X180. ; G04 X300. ;
M04 ; M04 ; M04 ; M04 ;
G04 X300. ; G04 X300. ; G04 X180. ; G04 X300.;
M03 S3000 ; M03 S6000 ; M03 S9000 ; M30 ;
G04 X300. ; G04 X300. ; G04 X180. ;
M04 ; M04 ; M04 ;
G04 X300. ; G04 X300. ; G04 X180;
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HP 5100 HP51MTE87
2. Disassembling and Assembling the Table

104 127 117 120 121 122 5 123 111
105 128 118 124 112
96 106 49 129 119 125 113
97 107 126 114 115
98 108
99 109
100
101
102
41 103
42 44
43
146
45 147
148
46 149
47 150
48 151
136 137 50
138
133 139 62-2
51
134 140
52
135 53
131 143 61
132 144
145
54
141
142
55
62
62-3
93 84
85 92
93-6 60
93-2
93-3 57
83 56
59
88
60-3
89 86 82 93-8 60-5
91 87
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HP 5100 HP51MTE87
Material /
Specification
41 C50058283C Piston SM45C 1
42 R53131 X-Ring Q4343-Xseal/Hansung 4
43 R54022 Ring, Back-Up S52015-343/Hansung 8
44 R53129 O-Ring P180/NOK 1
45 R53160 O-Ring P140/NOK 4
46 C50058303 Plate, End SM45C 1
48 S5110701 Washer, Spring Special ZSS12 6
49 P57110032 Pins, Parallel(W/Tap) SPB10×32 1
96 C51051554A Cover SS41 1
97 C51051574A Packing Cork 1
99 P74210008 Elbow, Street HSE1/4 1
100 R55404 Seal, Dust NBR-B2 807 2m
101 C58051153A Gear, Ring SCM440-F 1
103 P51400008 Washer, Conical ZC8 12
104 C40052032 Curvic-Coupling 360320-230XV 1st
106 P57213040 Pins, Taper(W/Tap) TPB13×40 4
107 P57113040 Pins, Parallel(W/Tap) SPB13×40 4
111 C58051143A Cap, Cylinder SM45C 1
114 R53379 O-Ring P135/NOK 1
115 S8011850 O-Ring G185 1
117 C50058253 Cap SS41 1
118 S8011450 O-Ring G145 1
122 S8010900 O-Ring G90 2
123 C50058263A Shaft, Center SM45C 1
125 S8010950 O-Ring G95 1
126 S8011300 O-Ring G130 1
127 R13003 Bearing, Needle NTB100135/IKO 1
128 R13005 Ring, Outer GS100135-IKO 1
129 R13008 Ring, Inner WS100135/IKO 1
146 C58051132A Housing, Piston SM45C 1
149 S8012200 O-Ring G220 4
150 S8000070 O-Ring P7 1
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HP 5100 HP51MTE87
Material /
No. Parts No. Description Specification Q'ty Remarks
151 S8000110 O-Ring P11 2
50 C58051163A Shaft, Gear SM45C 1
51 C58056073 Housing, Bearing SM45C 1
53 C58056083 Liner, Adjust SS400 1st
54 S8010850 O-Ring G85 1
55 R10111 Bearing, Angular Ball 7008ADB/GNP4/NTN 1st
56 R03263 Nut, Lock DZM40×1.5/K-Fukuda 1
57 C58051193A Wheel, Worm ALB2-F 1
59 C58056272 Key SM45C 1
60 C58056284 Collar SM45C 1
60.3 S6003660 Bearing, Radial Ball #6206ZZ 1
60.5 S6500301 Ring, Retaining(Shaft) RS30 1
61 C58056104 Spacer SS400 1st
62 C58056113 Cap, Bearing SS400 1
62.3 S2204661 Bolts, Hex. Socket Head BB6×16 6
62.5 C58056094 Collar SS400 1
82 C51056043 Shaft, Worm SCM440 1
83 R03069 Nut, Lock DZM45×1.5/K-Fukuda 1
84 5000501 Washer, Plain ZP8 1
86 C51056083 Bracket, Motor SM45C 1
88 C51056053 Housing, Bearing SM45C 1
91 S8010850 O-Ring G85 1st
92 R55447 Seal, Oil TC50×72×12/NOK 1
93 R10736 Bearing Angular Ball 7009ADB/CNP4/NTN 8
93.2 C51056063 Cap, Bearing SS41 1
93.4 S2204661 Bolts, Hex. Socket Head BB6×16 1
93.6 C51056074 Collar STKM13A 1
93.8 S6154040 Bearing, Needle RNA4904 1
94 P74151008 Busing HB3/8×1/4 4
131 S8010750 O-Ring G75 1st
132 R53259 O-Ring P38(CO 0037) 1st
133 C51051383A Con, Locating SCM415 24
134 C51051394 Liner SM45C 4
136 C5006802A Cap SM45C 20
137 C50068013A Collar SCM415 4
138 S6250180 Ball, Steel SBB3/8 4
139 R53260 Quad-Ring Quard04335 4
140 R54333 Ring, Back-Up BP4900702 4
141 C50068044A Quad, Spring SM45C 4
142 C50068054 Spring PW2 4
143 C50068034A Shaft, Cap SM45C 4
144 R53070 O-Ring P40/NOK 4
24
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)
(4) L-Wrench Set, Pipe
(5) Copper Hammer or Lead Lump
(6) Appropriate amount of grease
(7) Tools for removing pins
(8) Miscellaneous tools necessary for basic machine maintenance
(9) Spare parts that will need replacing (Example: O-Ring, etc.)
※ Preparations for Table Disassembly

(1) Thoroughly clean the machine interior (take special care to wipe off all grease
from the Sliding cover area in order to prevent slipping.)
(2) Return the X, Y Axes to their reference points, Lift out the APC Pallet with a crane,
and activate Pallet Change to lift out the Pallet to Machine outside.
(3) Move the Z Axis to the around center for convenience, and turn off the power.
1) Disassemble the C50058253 Cap. Cap

▪ 6-BB6×16
▪ O-Ring : 1-G145
25
HP 5100 HP51MTE87
2) Remove the Pallet Base security Bolts security

(12-BB10×65/ZC10) from where the Cap Bolts
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..
※ Be careful to maintain balance when
hanging.
※ It is useful during assembly if the Pallet
Base and Table Base are marked.
4) Slowly and carefully lift up the Pallet Base.

※ Maintain balance, sometimes hitting the
Pallet Base evenly with a hammer or a
wooden plank..
26
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.
1) Remove the security bolts in order to Cylinder

disassemble the C58051143A Cylinder Cap
Cap.
▪ 12-BB10×35
▪ O-Ring : 1-P135/NOK, 1-G185
2) Disassemble the Center Shaft and the eye bolt

Cylinder Ass’y.
① Insert the M12 eye bolt in the Lift Tap
location in the middle of the Center Shaft
and tie the Rope.
② Carefully use the Crane to lift and
disassemble.
3) Remove the C50058303 End Plate, and use Center Shaft

a plastic hammer to disassemble Cylinder Cap
individually the C50058283C Piston, Needle Brg.
C50058263A Center Shaft, R13003 Needle

Bearing, and the C58051154A Cylinder
Cap. Piston
※ Be careful not to damage the O-Ring End Plate
and the X-Ring.
▪ 6-BB12×25, 6-ZSS12
27
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.
3) Separate the B Axis Servo Motor Power Cable and the Feedback Cable from the
Motor and store them inside the Table.
4) Remove the B Axis Servo Motor security Bolts and disassemble the Motor.
Motor Shaft
5) Disassemble the C51056083 Motor Bracket. Motor Bracket

▪ 4-BB8×60
6) Remove the C51056053 Bearing Housing Bearing Bearing

security bolts and turn the Worm Shaft Cap Housing
counterclockwise to disassemble the Worm
Shaft Ass’y.
▪ 6-BB8×25
Worm
Shaft
28
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.
▪ 8-BB6×16
29
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
to lift at least 1 ton)
(4) L-Wrench Set, Pipe
(5) Brass Hammer, or lump of lead
(6) Appropriate amount of Grease
(7) Tools for removing pins
(8) Basic Tools needed for basic machine maintenance
1) Disassembling the Table
※ Preparations for disassembling the Table
(1) Thoroughly clean the interior of the machine and return the X and Y Axes to
their reference points. Remove the Pallet inside the machine or lift it from the
APC and rotate it to a right-angle position.
(2) Move the Z Axis to the around center to make disassembly easier, and
turn off the power.
① Disassemble the C50058253 Cap.

Cap
▪ 6-BB6×16
▪ O-Ring : 1-G145
30
HP 5100 HP51MTE87
② Disassemble the C58051021B Pallet Security

Base. bolt
▪ 12-BB10×65
※ Useful during assembly if kept at the
Pallet Base and TableBase. Eye bolt
③ Remove the Pallet Base security bolts

(12-BB10×65, 12-ZC10) in the place
where the Cap has been disassembled.
④ Remove the Set-Screw (2-BQ12X16)

near the Pallet Base, insert eye bolts,
tie the rope here and hang onto a
Crane.
⑤ Carefully and slowly lift up the Pallet
Base.
※ Be sure to maintain balance,
sometimes hitting evenly with a
hammer or baulk while lifting.
2) Remove the C58056073 Bearing Housing security Bolts and disassemble the Worm
Wheel Ass’y by removing the Pins from the Tap holes in the center of the
C58051163A Gear Shaft.
Bearing
Removing Housing
Pins
31
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
Nut
Pin
4) 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.
Spacer
Worm
Key Wheel
Collar
Lock-Nut
5) Hit and disassemble the C58051163 Gear

Gear Shaft
Shaft.
6) Remove the C58056113 Bearing Cap Collar

Security Bolts (6-BB6×16) and detach (in
order) the C58056113 Bearing Cap,
Bearing
Angular Ball Bearing, C58056104 Spacer, Housing
Bearing, and the C58056094 Collar from Spacer
the C58056073 Bearing Housing. Bearing
Cap
32
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.
※ Preparations for Disassembling the Locating Cone

(1) L-Wrench Set
(3) 8mm Bolts(2EA)
(4) Basic tools necessary for machine maintenance
1) Disassemble the C51051383 Locating Cone.
① Remove the Locating Cone security Bolts(6-BB10×25).
② Disassemble the Locating Cone by alternating inserting and tightening M8 bolts in the
Tap location.
Locating
Cone
Removal Tap
2) Disassemble the C50068014A Collet, Cap Collet

C50068024 Cap, and C50068054 Spring.
Spring
3) Remove the C50068044A Spring Guide

6mm L-Wrench
using a 6mm L-Wrench and disassemble use
the C50068034A Cap Shaft.
Spring Cap
Guide Shaft
33
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 /
Specification
131 S8010750 O-Ring G75 4
132 R53259 O-Ring P38(CO 0037) 4
139 R53260 Quad-Ring Quad04335 4
140 R54333 Ring, Back-Up BP4900702 4
144 R53070 O-Ring P40/NOK 4
145 S8010300 O-Ring G30 4
1) Assemble the C50068044A Spring Guide

and the C50068034A Cap-Shaft. 6mm L-Wrench
use
① Insert the O-Ring into the Cap Shaft and
insert into a groove in the Table Base
body.
※ Apply grease on the lower O-Ring Spring Cap
Guide Shaft
groove in advance to prevent O-Ring
separation during assembly.
▪ O-Ring : 1-P40/NOK, 1-G30
② Assemble the Spring Guide and secure
using a 6mm wrench.
2) Insert the C50068054 Spring into the Inserting Collet

C50068044A Spring Guide, and assemble Steel Ball
Cap
the C50068014A Collet that already has
Spring
C50068024 Cap attached.
※ Apply grease to the O-Ring and Quad
Ring to prevent damage during
assembly. Spring
▪ 1-Quad Ring (QRAR04335) Guide
▪ 1-Back-Up Ring (BP4900702)
3) Apply Grease to the hole in the
C50068014A Collet and insert the SBB 3/8
Steel Ball.
34
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.
※ Apply grease around the O-Ring to prevent
damage during assembly.
▪ 6-BB10×25
▪ O-Ring : 1-G75, 1-P38(CO 0037)
2.7 Assembling the Worm Shaft and Worm Wheel

1) On-site machining of the C58056113
Bearing Cap
① Measure distance "A" from the end of A
the C58056073 Bearing Housing to
the assembling portion of the
Bearing.
② Piling up the Angular Ball Bearing, B
Spacer, and Bearing in order and
measure distance "B".
③ Measure “C”= (“A”-“B”) + 0.05mm Collar
and on-site machine the Bearing
Cap accordingly. Bearing
Housing
C
Space Bearing
r Cap
2) Assembling the Bearing Housing Ass’y

Collar
① Apply Grease to the 7008ADB Angular
Ball Bearing. (Hold the inner rim of the
Bearing and insert Grease while rotating Bearing
Housin
the outer rim so that Grease is applied g
Space
evenly throughout the Bearing Ball.) r Bearing
Cap
② Assemble (in order) the Collar, Bearing,
Spacer, and Bearing to the Bearing
Housing, taking care to match the
correct direction. Assemble the
machined Bearing Cap and secure with
Bolts. ▪ 6-BB6×16
35
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. Key Worm Wheel
※ If assembly is difficult, abrase the
problem area with rope or sandpaper
to aid assembly.
② Try assembling again, this time with the
Key in the Gear Shaft.
※ If assembly is difficult, abrase the
problem area with file or sandpaper
to aid assembly.
③ If temporary assembly goes smoothly,
disassemble again and clean all parts
thoroughly.
4) Assemble the Gear Shaft to the previously
assembled Bearing Housing Ass’y.
Bearing
Housing
Ass’y
Gear Shaft
5) Assemble (in order) the C58056284

Spacer, Key, C58051193A Worm Wheel,
C58056284 Collar, secure the Lock-Nut
strongly, and tighten the security Set- Worm
Wheel
Screws.
Spacer
Collar
Key Lock-
Nut
36
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. Ring
7) Insert the O-Ring (G85) into the Gear Adjust

Shaft Ass’y. Assemble slowly to the Table Liner
Base, and when there is about 10 mm left
insert the C58056083 Adjust Liner, insert
the rest of the body, and tighten the O-Ring
security Bolts. (Simply connect the Bolts
for now, the Adjust Liner will be adjusted
after the Worm Shaft is assembled.)
※ Apply Grease around the O-Ring to
prevent O-Ring damage during
assembly.
▪ O-Ring : 1-G85
8) Assembling the C51056053 Bearing Housing
① On-site machine the Bearing Cap according to Measurement "C" [(Height of the
Adjusted C51056063 Bearing Cap “C”= (Bearing Housing Depth “A”- Bearing
Width “B”)+0.05mm.]
② Apply Grease to the 7009ADB Angular Ball Bearing. (Hold the inner rim of the
Bearing and insert Grease while rotating the outer rim so that Grease is applied
evenly throughout the Bearing Ball.)
③ Assemble the Bearing, matching up the direction with the Bearing Housing, and
then assemble the Bearing Cap.
▪ 8-BB6ⅹ16, 1-Oil Seal(TC50×70×12/NOK)
37
HP 5100 HP51MTE87
C B
9) Attach the C51056043 Worm Shaft to the Collar Worm

previously assembled Bearing Housing, Shaft
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. Nut
10) Assemble the RNA4904 Needle Bearing to

the Table Base and apply Grease.
Needle
Bearing
11) Assemble the Gear Shaft Ass’y to the

Table Base. O-Ring
① Insert the O-Ring (G85) into the
Bearing Housing and apply Grease.
② Slowly insert the Gear Shaft by turning
it clockwise fitting the previously
assembled Worm Wheel Ass’y.
③ Assemble the last Needle Bearing part,
taking care not to damage the Bearing.
④ When the Bearing Housing reaches the
38
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
A
B
① Remove the Bearing Housing security
bolts (6-BB8×35) on the Gear Shaft
Ass’y and pull out the C58056083
Adjust Liner.
② Move the entire Gear Shaft Ass’y to
measure the lowest (ⓐ) and highest(ⓑ)
height. (“A” or “B”) Center
※ “A” : Measured with a Block Gauge Line
“B” : Measured with a Depth Gauge
or Vernier Calipers
③ Calculate the on-site machining
dimension of the Adjust Liner from the
measurements above, and grind the
Adjust Liner.
※ ⓒ = ⓐ + (ⓑ - ⓐ) ÷ 2
④ Grind the Adjust Liner according to the
on-site machining dimension above.
※ On-site grinding tolerance : ± 0.01
⑤ Insert the grinded Adjust Liner under the Bearing Housing and tighten the
security Bolts.
▪ 6-BB8×35
※ After assembly ,manually rotate the Worm Shaft to check or any problems. If
there are none, move forward to the next step.
13) Assemble the C51056083 Motor Bracket. Motor Bracket

▪ 4-BB8×60
39
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.
Key
Motor
Shaft
15) Assembling the Table (Pallet Base) O-Ring

① Apply Grease evenly on the disassembled
O-Ring(2-G90) (part of the Table's inside
diameter) and the Dust Seal (part of the
Table Base's outer diameter) to prevent
damage to the O-Ring during assembly.
② Clean the Curvic Coupling as thoroughly
as possible by blowing all substances Dust
away with air. Seal
③ Lift up the Table (maintaining proper
balance) and lower it onto the marked
line made during disassembly. If the
Table becomes caught in the Base, hit
evenly over the surface with balk or
copper hammer to direct it to the proper
position.
※ Verifying the proper positioning of the

Table
There is a Plug(FPS-S3/4) near the Table
Base. If you remove this Plug and
Plug
provide worklight, you can see the
Coupling assembly position inside the
Table through the Plug holes.
40
HP 5100 HP51MTE87
④ If the Table secured without problems, Cap

connect the Table security Bolts (12-
BB12×65), assemble the C50058253
Cap, and connect the security Bolts(6- Table
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. The last step is executing the Pallet Change and setting the Pallet on the
APC.
41
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 /
Specification
42 R53131 X-Ring Q4343-Xseal/HANSUNG 4
43 R54022 Ring, Back-Up S52015-343/ HANSUNG 8
44 R53129 O-Ring P180/NOK 1
45 R53160 O-Ring P140/NOK 4
114 R53379 O-Ring P135/NOK 1
115 S8011850 O-Ring G185 1
118 S8011450 O-Ring G145 1
122 S8010900 O-Ring G90 2
125 S8010950 O-Ring G95 1
126 S8011300 O-Ring G130 1
149 S8012200 O-Ring G220 4
150 S8000070 O-Ring P7 1
151 S8000110 O-Ring P11 2
1) Insert the various O-Rings, X-Rings, and Cylinder Cap Needle

Bearing
Back-Up Rings into the C50058283C Piston
and C58051143A Cylinder-Cap. Apply
grease to the surrounding area. Assemble
the Inner Ring from among the Piston
Needle Bearings and set on top the Piston
greased Needle.
▪ O-Ring : 4-P140/NOK, 4-X-Ring(Q4343)
▪ 8-Back-Up Ring(S52015-343)
▪ 1-P180/NOK, 1-G185, 1-P135/NOK
2) After assembling the Needle Bearing-Outer Needle

to the C50058263A Center Shaft, assemble Center Bearing
Shaft
to the Piston, and assemble the
C50058303 End Plate. Piston
※ Be sure to apply clean grease around

the O-Rings and X-Rings to prevent End Plate
damage during assembly..
▪ 6-BB12×25, 6-ZCC 12
▪ O-Ring : 1-G95, 1-G130
42
HP 5100 HP51MTE87
3) Assemble the pre-assembled Piston Ass’y Piston Cylinder

Housing Cap
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
43
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
damage to the O-Ring during assembly. Dust
Seal
2) Clean the Curvic Coupling as thoroughly as
possible by blowing all substances away with
air.
3) Lift up the Table (maintaining proper
balance) and lower it onto the marked line
made during disassembly. If the Table
becomes caught in the Base, hit evenly
over the surface with balk or copper
hammer to direct it to the proper position.
※ Verifying the proper positioning of the Table

There is a Plug (FPS-S3/4) near the Table
Base. If you remove this Plug and provide
worklight, you can see the Coupling
Plug
assembly position inside the Table through
the Plug holes.
4) If the Table secured without problems, Cap

fasten the Table security Bolts (12-
BB12×65), assemble the C50058253 Cap,
and tighten the security Bolts (6-BB6×16). Table
security
▪ 12-BB12×65, 6-BB6×16 Bolts
▪ O-Ring : 1-G145
5) Assemble the various Plugs that had been removed, after wrapping them with Tefron.
The last step is executing the Pallet Change and setting the Pallet on the APC.
44
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. The Table should be disassembled and the
Curvic Coupling must be realigned. This process requires the following preparation.
※ preparations
(1) Crane or Chain Block that can lift at least 1 ton (positioned to lift from the center of the
Table)
(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
(6) Copper Hammer or Lead bundle.
(8) Tool for pulling out Pins
(9) Basic tools needed for basic machine maintenance
3.1 Disassembling the Table

※ Preparations for disassembling the Table
(1) Thoroughly clean the interior of the machine. Send X and Y Axes to their
reference points. Lift out the Pallet from inside the machine or lift from the APC
and rotate it 90 degrees.
(2) Move the Z Axis to the center for convenience work, and turn off the power.
45
HP 5100 HP51MTE87
① Disassemble the C50058253 Cap. 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.
① Remove the Pallet Base security Bolts Eye bolt
(12-BB10×65/ZC10) from where the

Cap was disassembled.
② Remove the Set-Screw (2-BQ12×16) near
the Pallet Base, insert eye bolts, tie a rope
around this area and hang the rope on a
crane.
③ Slowly and carefully lift up the Pallet Base.
※ Maintain balance, sometimes hitting the Pallet Base evenly with a hammer or a
wooden baulk.
3) Adjusting the Curving Coupling assembled to the

Curvic
Table Base Body Coupling
① Loosen the Curvic Coupling security Bolts
(12-BB12×30).
② Pull out the Curvic Coupling Positioning
Pins (2-SPB13 ×40) and check for any
problems.
③ If there are no problems with the Pins,
reassemble. If there are problems, replace
with new Pins and assemble after reaming
into the Pin hole again.
④ Fasten the Curvic Coupling security Bolts
(12-BB12×30) as strongly as possible.
4) Preparation for Adjusting the Curvic Coupling
46
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.
47
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
over the surface with baulk or copper
hammer to direct it to the proper position.
3) Fasten the Table security Bolts (12-
BB12×65).
※ Verifying the proper positioning of the

Table
There is a Plug (FPS-S3/4) near the Table
Base. If you remove this Plug and provide Curvic
light, you can see the Coupling assembly Fixed
Curvic ass’y Curvic
Bolt Plug
position inside the Table through the Plug Fixed
State check
holes. Curvic ass’y
Plug hole Bolt Plug
4) Remove the Table's upper Plug (2-FPS-S1/2) and State check
Plug hole
loosen the 2-BB10×65.
※ These Bolts are exclusive bolts necessary for
aligning the Table.
3.3 Table Accuracy Adjustment

1) Put in the power and Set the Indicator on the
Edge Locator by attaching it to the Spindle.
2) Move the X Axis and measure the parallelism
between the X Axis and the grinded face of
the Edge Locator.
3) Turn off the oil pressure by pressing the
emergency stop Switch. Use a hammer or
wooden baulk to hit the end of the Pallet and
move the Table towards the rotation
direction, matching up the parallelism.
4) Reset the Machine Ready and measure the
48
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.
3) Even out the Taper Pins location with 13mm taper reamer, then push in new pins.
▪ 2-TPB13×40
4) Assemble the Plug(FPS-S3/4) in the place where the Taper Pins are attached (the
Plug should not protrude more than the Coupling face).
3.5 Assembling the Table

1) When the Curvic Coupling is secure, blow out all Cap
foreign substances from both the upper and
lower Curvic Coupling with air. Assemble the
Table, referring to the
"2) Table(Pallet Base) Body Temporary
Assembly” above.
2) Referring to the “3) Adjusting the Table
Alignment” above, measure the parallelism
between the X Axis and the adjusted side of
the Edge Locator. If the measurement falls
within the margin, complete final assembly.
① Assemble the C50058253 Cap.
▪ 6-BB6×16, O-Ring : 1-G145
② Wrap the various Plugs with Tefron and
assemble.
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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” is activated.
1) Set the B Axis to 0 degrees and unclamp
the Table.
※ MDI” Mode : G90 B0.; M11;
2) Attach the Test Indicator to the Spindle
Head, and move the X Axis to fit the
parallelism of the Edge Locator.
① Set the Mode to "Handle" and Set the Axis
Selection Switch at B-Axis, 0.01.
② Rotate the Handle incrementally to set the
parallelism between the Edge Locator and
the X Axis as accurately as possible.
3) When the parallelism is set, set Parameter
#1815's Bit (APZ) #4 to "0". Reset it to "1"
and turn off the power.
※ When the Parameter #1815's Bit (APZ) #4
is changed, “P/S Alarm 000 Must Turn Off
Power” and “P/S Alarm 300 nAxis Need
ZRN”will be set off.
Angle Indicator
4) When the power is turned back on, the
alarm will be released and the screen's B
Axis Position will changed to 0.
5) Verify the accurate position of the Table Clamp.
① With B Axis as 0 degrees, activate from 90 degrees to 0 degrees, and from -90
degrees to 0 degrees. When the Table becomes clamped (when the Curvic Coupling
teeth fit together), check the amount that the Table moves through the Angle
Indicator.
② After Unclamping the Table, use the handle to move the B Axis towards the direction
that the B Axis moves when Clamping after executing CW or CCW (ex: ±0.03∼0.05
degrees). Then repeat 3) and 4) above.
6) Continue repeating this process until the amount that the B Axis Moves when
Clamping is the same on the opposite side.
※ The amount of movement here is simply Backlash from the machine itself.
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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
Drive Cam
Ass’y
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HP 5100 HP51MTE87
4.2 ATC Main Sequence
☞ Initial Condition Changer Arm Home

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
☞ Spindle Tool Unclamp

▪ Output: Y4.3(TUCR.R), YV11, Output Module Slot 3 (Pins 5) On
▪ Completion: X6.4(TCL.M), SX11, Input Module Slot 8 (Pins 31) Off
X6.5(TUCL.M), SX12, Input Module Slot 8 (Pins 47) On Spindle Tool Unclamp
Arm Pins Locking
Arm Out
☞ Changer Arm Pin Locking &
▪ Output: Y4.7(ATAL.R), YV55, Output Module Slot 3 (Pins 10) On Rotation
▪ Completion: X15.3(ATAL.M), SD56, Input Module Slot 8 (Pins 43) On
X15.5(ATAR.M), SD53, Input Module Slot 8 (Pins 37) Off
Tool Change
Arm In
☞ Spindle Tool Clamp
▪ Output: Y4.3(TUCR.R), YV11, Output Module Slot 3 (Pins 5) Off
▪ Completion: X6.4(TCL.M), SX11, Input Module Slot 8 (Pins 31) On
Spindle Tool Clamp
X6.5(TUCL.M), SX12, Input Module Slot 8 (Pins 47) Off
Arm Pins Release
☞ Changer Arm Pin Release Arm

▪ Output: Y4.7(ATAL.R), YV55, Output Module Slot 3 (Pins 10) On Forward
▪ Completion: X15.3(ATAL.M), SD56, Input Module Slot 8 (Pins 43) On
X15.5(ATAR.M), SD53, Input Module Slot 8 (Pins 37) On
☞ Changer Arm Home Position

Changer Arm Home
▪ Input Signal: X8.7(CAHP.M), SX53, Input Module Slot 8 (Pins 37) On
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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).

⇒ The ATC, APC Manual screen appears.
④ Press “ATCON”.
⇒ The “ATC MANUAL MODE” is turned on.
※ Selecting a Step: use the cursor keys to

move the cursor up and down and select.
⑤ Manual Control: Select the appropriate

process and press Cycle Start. The
corresponding Process will be activated.
Initial
When "*" appears in the Status line on Condition Status
the right, the process has been
completed.
2) Canceling the AL2065 (Verifying the Arm Home Position)

① Meaning of the Alarm : The alarm becomes activated when there is a change in t
he Main Changer Arm Home Position due to the Servo System or from other causes.
That is, the case where there is a difference between the reference point (X7.6)
memorized in the servo system and the reference point that recognizes
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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.
③ Troubleshooting the Alarm
☞ Checking for Problems with the Changer Arm Home Position Detection Proximity S/W
After checking for problems with switch looseness/ Dog looseness/
contamination/firing range, proceed normally.
☞In case of alarm, when the changer arm home dog is deflected or even if the
position is normal, observe inside the Cam to see if the Turret Can Follower
Bearing is positioned on the Cam's Center area. Since this area is very small, it is
convenient to use a mirror and worklight.
Is the Cam Follower

Bearing in the middle of
the central area?
Central
Mirror Area
A
☞After verifying the Cam Follower Bearing location, use those observations to
release the #2065 Alarm by Origin Initialization from the Servo Drive..
A≒B
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HP 5100 HP51MTE87
Cam
Case S/W & Dog align Solution
Follower
Normal Faulty Reorder the Switch, secure, and Initialize
A Normal Normal Initialize
Faulty Normal Realign the Changer Arm using Inching,
B
Faulty Faulty reorder the Switch, and Initialize
▶Case “A”
① Press the "MODE" Key once on the Servo Drive start

screen [r 0000]
② Press the "DOWN" Key once on the

[rd-oFF] screen
③ Press the "SET" Key for five seconds on the

[Or9.S--] screen. The letters will blink, then complete
Servo Origin Initialization.
④ Power Off → On
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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]. Press the "SET" Key once to
display the [Jr.0000].
② Appropriately use the "UP/DOWN" Key (which

drives the Arm 20rpm every time it is pressed) to
position the Cam Follower Bearing in the center of the
middle section. If necessary, reorder the S/W and press
the "Set" Key once to exit to the [JOG run] screen.
③ Press the "UP" key three times on the [JOG run] screen.
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HP 5100 HP51MTE87
④ Press the "SET" Key for five seconds on the

[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. Verify normal ATC
activity, and close Maintenance Mode.
3) Ordinarily, ATC related trouble shooting that could possibly occur during ordinary
arm driving
Case Status
1 Power interruption before unclamp or after clamp, emergency situation
Power interruption during arm driving after unclamp and before clamp, or
2
emergency situation
Power interruption during unclamp or right after clamp, emergency
3 situation
Arm gets jammed during unclamp or right after clamp (in most cases)
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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. On the PMC G.Data Table, it is the
D450 = D452 status. Case “1”
④ Maintenance Mode Off
⑤ Check for AL2065 activation and take
appropriate steps.
⑥ If there is a record of turning off Power, manually recover the reference point
(unnecessary in the case of emergency).
⑦ M19 / G91 G30 X0 Y0 Z0 in MDI Mode
⑧ Check the tool number (D450 / D452) on the PMC G.Data Table and make any
necessary changes.
⑨ Maintenance Mode On
⑩ Execute 1 Cycle several times to accurately judge the cause of the problem, and to
check for any additional problems.
⑪ Maintenance Mode Off
⑫ Insert the tool that was to be exchanged before the problem arose. Recheck the
program, and continue the original process.
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HP 5100 HP51MTE87
▶ Case “2”
A
① Power On⇒Machine Ready
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.
Removing tools from the "A" location ①
(shown below) is dangerous; be sure to
②
remove tools from the "B" location.
B
④ Maintenance Mode Off
⑤ Check for AL2065 activation and take Case “2”
appropriate steps
⑥ If there is a record of turning off Power, Press the Locking Pin in the
manually recover the reference ① back of the Arm, and remove
point(unnecessary in the case of the tools attached to the Arm
emergency).
Check the CT/DIN
⑦ M19 / G91 G30 X0 Y0 Z0 in MDI Mode rotation
② Shape
⑧ Check the tool number (D450/D452) and
from G.Data Mode and make any abrasion
level of the
necessary changes. Roller and
⑨ Maintenance Mode On take any
⑩ Execute 1 Cycle several times to necessary
actions
accurately judge the cause of the
problem, and to check for any additional
problems.
⑪ Maintenance Mode Off
⑫ Insert the tool that was to be exchanged
before the problem arose. Recheck the
program, and continue the original
process.
▶ Case “3” (Mechanically Jammed) Trouble Shooting Process

Case Tool Data Status
Cannot pull out tools
3-1 D450≠D452
after Unclamping.
Cannot rotate Changer
Arm because it is
3-2 D450=D452
jammed in tools after
Clamping.
Case “3”
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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
switch. C. Arm Home
▶ Reverse Control Position Dog is above
the switch
▶ Forward Control
① Power On ⇒ Machine Ready Control

※ Even if it is not due to a power interruption, due to a machine jam ,An
AL2009 can occur in the Servo System. Since an AL2009 is due to Overload
and is a Power Off Level, it is necessary to toggle Power Off/On in order to
release the alarm.
③ Identify the Cause and Troubleshoot accordingly.
Tool
Case Status
Data
▪ If the Changer Arm falls out easily during Reverse Step
Control, return it to the Cam Home Position and execute the
D450 next step.
3-1 ≠ ▪ If the Arm does not fall out and the Overload Alarm(#2009) is
D452 set off, after Power Off==èOn, and press the Changer Arm
Roller using a screwdriver. Carefully recover using Reverse
control and execute the following step.
▪ If the Changer Arm falls out easily during Forward Step
Control, return it to the Cam Home Position and execute the
D450 next step.
3-2 = ▪ If the Arm does not fall out and the Overload Alarm(#2009) is
D452 set off, after Power Off==èOn and press the Changer Arm
Roller using a screwdriver. Carefully recover using Forward
control and execute the following step.
④ Finding the cause of jamming and Troubleshooting (see below)

⑤ Maintenance Mode Off
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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 Verify the tool number(D450 / D452) on the PMC G.Data Table and make necessary
changes.
⑩ Maintenance Mode On
⑪ Execute 1 Cycle several times to accurately judge the cause of the problem, and to
check for any additional problems.
⑫ Maintenance Mode Off
⑬ Insert the tool that was to be exchanged before the problem arose. Recheck the
program, and continue the original process.
※ Important Notes Concerning Removing Jams

① When Unclamping manually, be careful of tools falling from the Spindle.
② If the tool had not fallen due to weak Kicking amount, send the Arm to its home
position. Carefully hit with a rubber hammer and repeat the manual unclamping
process to pull out the tool. After completion, reset the tool Kicking amount.
③ Loosen the Collet and check for any damage/abrasion/loosening.
④ Recheck the ATC Alignment using Centering tools in order to check the M19,
change in the 2nd reference point, and change or Slip in the Changer Arm.
⑤ Check for any abrasion, dents, or scratchers on the Changer Arm Roller. Also
check the spring strength of the Release Pin.
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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 Remove the tool from the Main Spindle to empty the Spindle, and remove the
two Driving Keys attached on the side of the Spindle.
② Attach the Centering Tool (1) to the Spindle.
③ Send each Axis to the Tool Change Position..
⇒ B Axis : X, Y, Z Axis : 2nd reference point (G91 G30 X0. Y0. Z0.)
④ Activate the Spindle Orientation.
⇒ M19 ;
⑤ Check the empty Pot numbers from the Tool Magazine and recall the appropriate
tools.
⇒ ex) Tool No. 15 : “MDI” Mode T15 ; “Cycle Start”
⑥ Open the ATC Door.
⇒ ex) “MDI” Mode M222 ; “Cycle Start”
2) Insert the ATC Centering Tool(2) into the Changer Arm Gripper.
① Manually operate the ATC from “Maintenance” Mode.
② Select “JOG” Mode.
③ Press the “CUSTOM” Key.
④ Press the “MAN” Key (Function Key).
⑤ Press “ATCON”.
⑥ Manually select the Toggle S/W from the manual ATC menu
⑦ Use the arrow keys to move the cursor to “ATC ARM FORWARD STEP,” then
press the 'Cycle Start‘ button to rotate the Changer Arm towards the Spindle until
just before the Arm Out position.
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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.
▪ Goal : DIN : 3.2mm, BT : 2.0mm
② Insert Tool(3) into the middle hole and Centering Tool (3)
check if the position of Tool(2) and
Area for gap
Tool(1) are correct. measurement
4) Adjusting the gap between Tool(1) and Tool(2) : Set the gap both in front of and
behind the Changer Ass'y.
▪ Goal: DIN : 3.2mm, BT : 2.0mm
5) Adjusting the Center location of Tool(2) and Tool(1)

① If Centering is not correct, remove Centering Tool(3) and change Keep Relay
K7.6 from “1” to “0”. Use MPG to move minutely the X, Y Axis and
check Centering.
▪ Do not use Keep Relay K7.6 “0”→ ATC.
② When Centering is complete, input the coordinates into the X, Y 2nd reference
point.
▪ 2nd Reference Point Parameter : #1241
③ After removing Centering Tool(3), again change the Keep Relay K7.6 from “0” to
“1”.
④ Return the Changer Arm to Home Position using Forward Step, then remove
Centering Tool(1) from the main spindle.
④ Execute tool exchange once in “MDI” Mode, then manually move the Changer
Arm to ‘tool exchange’ position and recheck Centering.
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HP 5100 HP51MTE87
4.5 Important Notes Concerning Troubleshooting the Servo Control ATC

① Cam home position Is the turret cam follower bearing located at the center
check area of the cam center section?
② Second reference Is the alignment of changer arm gripper and spindle
point/orientation drive key normal?
check
③ Tool kicking amount During unclamp, is the shift amount insufficient or
check excessive?
④ C. arm gripper roller Are there any abnormal rotation, over-wear, flaw,
check corrosion and is the release pin tension normal?
⑤ Tool pot spindle side Is the feedrate adequate and is the In/Out positioning
check and clamp confirm accurate?
⑥Tool size/specification Is the shank / pull stud of the tool normal standards and
and state check are there any loosening or damage?
⑦ Arm centering check When checking with step operations, is there any strain
or slip caused by collision during use?
⑧ Tool loading state In the case of CT / DIN tool, is the direction inserted
check correctly in the magazine?
⑨ Remove tool during During maintenance, removing the stuck tool is the
recovery general rule.
⑩ Servo drive check Be sure to understand the alarm release method during
and initialization AL2009 alarm and initialization method during AL2065
alarm
⑪ Tool data check After step operation, must check tool data and prevent
collision and machining error, etc.
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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).

⇒ The ATC, APC Manual screen appears.
④ Press “ATCON”.
⇒ The “ATC MANUAL MODE” is On.
※ Choosing a Step: Use cursor keys from

the Main O.P to move up and down
and select.
⑤ Manual control : Press Cycle Start after
selecting an order. When an "*" appears
in the 'Status' Line on the right, the Initial
process has been completed. Condition Status
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HP 5100 HP51MTE87
5. Disassembling and Assembling the Ball Screw
5.1 Disassembling the X Axis Ball Screw
31 21
36 41
32 22
33 30 23
34
37
29 38
39
35 40
18 27
19
20
6 10 14
7 24
11 15
8 25
26 12 16
9 28 13 17
1
2
3
4
5
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HP 5100 HP51MTE87
No. Parts No. Description Q'ty Material/Specification Remarks

1 C58023013 Ball Screw (X) 1 W4510Z-312PSS-C3Z20 NSK
3 P72130004 Adaptor, Elbow 1 PH4
4 R462945 Connector, Hose 1 C4N8×6-PT1/4 NITTA MOORE
5 R462946 Connector, Elbow 1 L4N×86-PT1/4 NITTA MOORE
6 C58021052A Bracket, Motor 1 GC300
8 P51400016 Washer, Conical Spring 8 ZC16
9 P57208056 Pin, Taper(Tap) 2 TPB8×56
10 C58021062A Bracket. Support 1 GC300
13 P57208056 Pin, Taper(Tap) 2 TPB8×56
14 C58021072A Support, Bearing 1 SM45C
17 C58021084 Liner, Adjusting 4 SS400
18 C58021094A Cover 1 SCP1(t2.0)
20 S5000201 Washer, Plane 4 ZP5
21 C58021103A Damper, Motor 1 Urethane, Rubber
28 C58021124 Liner 1 SM45C
29 R18721 Coupling, Rigid 1 Ø35×Ø30
30 R10712 Ang. Contact Ball Brg. 1 35TAC72BDBDC10PN7A NSK
31 C49021524C Cap. Bearing 1 SM45C
34 C42036094 Collar 1 SM45C
35 R02119 Nut, Lock 1 KSN 7
40 C42036094 Collar 1 SM45C
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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

C58021052A Motor Bracket, and remove Pipe
the lubricant pipe, and the Servo Motor

Power (Power and Feedback Cable)
Connector.
Motor Motor
Connector Bracket
3) Loosen the bolts on the R18721 Rigid Coupling by manually unscrewing the Ball
Screw, then carefully detach and remove the Motor by removing the Servo Motor
Fixing Bolts.
4) Detach the Lock-Nut on the opposite bracket.

▪ Loosen the Security Set-Screws on the Lock-Nut, and remove the Lock-Nut by
using the chisel or hammer.
Lock-
Nut
Lock-
Nut
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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-
(8-BB16×65) and Positioning Pins (2- Security
TPB8×56). Bolts
Motor
Bracket
2-Taper
Pins
7) Lift out the Motor Bracket and the Ball Screw Ass’y from the machine.
8) Loosen the C58021072 Bearing Support

security Bolts (4-BB16×70) and
disassemble the Bearing Support Ass’y.
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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.
Bearing
▪ 6-BB8×30
Cap
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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. ("B")
② Calculate the on-site dimension of the C49021524A Bearing Cap and machine
accordingly.
※ Bearing Cap on-site dimension (Field Adjustment Measure) “A” = “B” - 0.05mm
ⓒ Assemble the on-site machined Bearing Cap to the Bearing Support.
※ Make sure to connect all bolts with the same amount of strength.
▪ 6-BB8×30
“B”
Bearing
Cap
Bearing 35TAC “A”

Support Bearing
2) Insert the C58021084 Adjust Liner into the Adjust Liner

C58021072A Bearing Support, assemble to
the opposite Support from the Motor
Bearing
Bracket, and connect the security Bolts. Cap
▪ 4-BB16×70
※ Replace the four Adjust Liners to their
places as marked number when Bearing
disassembling. Support
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HP 5100 HP51MTE87

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. ("B")
② Calculate the on-site dimension for the C49021524C Bearing Cap and adjust
accordingly.
※ Bearing Cap on-site dimension (Field Adjustment Measurement) “A” = “B” -
0.05mm
③ Assemble the machined Bearing Cap to the Motor Bracket.
※ Try to fasten all security Bolts with the same amount of strength.
▪ 6-BB8×30
“B”
35TAC
Bearing
Bearing “A”
Cap
Motor
Bracket
4) Stand up the Motor Bracket with the Bearing

assembled, assemble the Ball Screw, insert
the C42036094 Collar and fasten the Lock- Collar
Nut.
▪ Simply tighten as much as possible; the
Ball Screw Run-Out will be finally set
later on.
Lock-Nut
5) Carefully push the Ass’y with Ball Screw and Motor Bracket assembled in through
the Column’s X Axis Ball Screw location.
72
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 Liners
assembled to the Support opposite from the Collar
Motor Bracket and pull out the four Adjust
Liners.
▪ Mark the four C58021084 Adjust Liners to Lock-Nut
prevent their locations from being
switched during assembly.
8) Insert the C42036094 Collar and secure the
Lock-Nut.
▪ Simply tighten as much as possible, the
Ball Screw Run-Out will be finally set later
on.
73
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 Gap
Measure
and add Pre-Tension (0.08mm) to the ment
measurements. Do on-site machining of the
Adjusting Liner accordingly.
※ Liner Dimension = Gap Measurement
+ 0.08mm
10) When the on-site machining is complete, Adjust

loosen the Lock-Nut. Widen the gap Liner
between the Bearing Support and the Lock-Nut
Support Bracket, insert according to the
numbers previously marked, and secure
the security Bolts.
▪ 4-BB16×70 Support
Bracket
11) Use a chisel again to secure the Lock-Nut.
Ball Screw Run-Out will be finally set
later on.
12) Fit the Ball Screw Run-Out.

① Set the Indicator at the end of the Ball
Screw.
② Rotating the Ball Screw, read the
Indicator. At the highest point, hit with
a hammer towards the direction of
locking the Lock-Nut
③ When the Ball Screw Run-Out on both
sides fall below 0.01mm, tightly fasten
the Lock-Nut security Set-Screws.
13) Rotate the Ball Screw Nut to move it to its

correct position, then secure the security
Bolts.
▪ Since precise fix is required after turning
the power on, for now loosely secure the
Bolts.
※ Final Securing of the Nut after Power On
74
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. Tighten the security Bolts.
Motor
Bracket
15) Fastening the R10712 Rigid Coupling

① Use a Wrench to lightly fasten the four
bolts in diagonal order.
② Gradually increase tightness.
Rigid
Coupling
③ Set the Indicator on the Rigid Coupling. Manually rotate the Ball Screw to
measure the Run-Out. Repeat until the measurement falls under 0.03mm, then
secure the bolts.
※ The Run-Out must fit all three rings of the Rigid Coupling.
16) When assembly is complete, assemble the Cover Lubricant

C58021094A Cover of the Motor Bracket, Pipe
and assemble the lubricant pipe, and
Servo Motor Wire (Power and Feedback-
Cable) Connector that had been
disassembled.
Motor Motor
Connector Bracket
※ After reassembling the X Axis Ball Screw, you must reset the X Axis reference point.
75
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.
3) Install the Indicator on top of the Table.
Set the Gauge Needle at about 30 mm
away from the end of the Test Bar. Move
the Y Axis up and down along Handle 180˚ Rotation
Mode and set "0" at the highest point.
4) Turn the Spindle to stop it in the middle of
the Run-Out of the Test Bar, and set the
gauge to “0.”
5) Order the setting G91 Y100.; B180. ; Y-
100.; in MDI mode.
▪ Use the Override to decrease the speed of the Test Bar when down in Y-100.;
in order to reduce the shock hitting the gauge.
6) Move the X Axis half of the distance measured by rotating the Table 180˚, then
measure again using 5) above and set it so that it falls below 0.005mm.
7) According to the measurement shown on the CRT screen's Machine Position.
input into the Parameter if it is + 425., enter "+," if it is -, enter "-".
▪ After editing the Parameter, you must power off and restart the machine.
※ X Axis Reference Point Parameter : NO. #1850 X
▪ Add or subtract the above measurement from the original Parameter and enter
“INPUT,” or enter the above measurement with a sign, as “+INPUT”.
8) Reset the machine reference point, and measure 1)∼7) again repeatedly until the
measurement falls below 0.005mm.
76
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.
29 28 6
7
11 17 8
12 18 22
23
13 19 24
25
26
21
20
9
10
27
14
16
16
32
33
30
31
40 34
35
36
37
38
39
1
2
3
4
5
77
HP 5100 HP51MTE87
Material /
Specification
1 C58033013 Ball Screw (Y) 1 W4509Z-450PSS-C3Z20 NSK
4 R462945 Connector, Hose 1 C4N8 ×6-PT1/4 NITTA MOORE
5 R462946 Connector, Elbow 1 L4N8 ×6-PT1/4 NITTA MOORE
6 C58031042A Bracket, Motor(Y) 1 GC300
9 C58021084 Liner Adjusting 8 SS400
10 P57208056 Pin, Taper(Tap) 2 TPB8 ×56
11 C58031094 Cover 1 SCP1(t2.0)
17 C58021094A Cover 1 SCP1(t2.0)
21 C42036094 Collar 1 SM45C
22 C49031123B Cap. Bearing 1 SM45C
23 S8000007 O-Ring 1 P7
26 S3522282 Screw, Set (Hex Socket) 1 BQD5 ×6
29 R18721 Coupling, Rigid 1 Ø35 ×Ø30
30 C57031044 Spacer 1 SM45C
31 S8010350 O-Ring 1 G35
32 C57031053 Spacer 1 SM45C
33 P80300060 O-Ring 1 S60
37 S2209261 Bolt, Hex. Socket Head 6 BB8 ×30 NSK
38 C42036094 Collar 1 SM45C
78
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.
(Make sure to position the baulk so that it will not interfere during Ball Screw
disassembly.)
2) Detach the C58021094 Cover(1) and

C58031094 Cover(2) from the C58031042A
Cover(1)
Motor Bracket(Y), and remove the lubricant Cover(1)
pipe and Servo Motor Cable(Power and
Feedback -Cable) Connector.
Lubrican
t Pipe
3) Manually rotate the Ball Screw of the R18721 Rigid Coupling security Bolts to
loosen them, then remove the Servo Motor security Bolts and carefully detach and
lift out the Motor.
Rigid
Coupling
4) Disassemble the Lock-Nut from the bottom Bracket.

① Disassemble the Z Axis Sliding Cover near the Column.
② Loosen the Lock-Nut security Set-Screw through the bottom of the Cover. Hitting
with a chisel and hammer to remove the Lock-Nut.
Lock-Nut
Lock-Nut
79
HP 5100 HP51MTE87
5) Disassemble the lubricant pipe and cooling Lubricant

pipe near the Ball Screw Nut. Remove the Nut Pipe
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 security

(8-BB16×70) and Positioning Pins (2- Bracket Bolts
TPB8×56).
Taper Pins
7) Lift out the Motor Bracket and Ball Screw Ass’y from the machine.
8) Remove the security bolts from the

Spacer Spacer
C58021072A Bearing Support (4-
BB16×70) and the C49021524C Bearing
Cap security bolts(6-BB8×30) attached to
the Support opposite from the Motor
Bracket, then disassemble the parts.
※ Mark the four C58021084 Adjust Liner
according to location to prevent their Bearing
Collar Cap
positions from switching during assembly.
80
HP 5100 HP51MTE87

※ 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.

Bearing
from the Motor Bracket and separate the Ball Cap
Screw Bearing.
▪ 6-BB8×30
81
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.
② Measure the depth of the end side of the Bearing and the section of the Bracket
(“B)
③ Calculate the on-site dimension of the C49021524C Bearing Cap and do the on-
site machining.
※ Bearing Cap on-site dimension “A” = “B” – 0.05mm
④ Assemble the machined Bearing Cap to the Bracket.
※ Make sure to use all Bolts tightened with the same amount of force.
▪ 6-BB8×30
Spacer(2) Spacer(1)
Bearing
“B”
“A”
Bearing
Cap
2) Assemble the Angular Contact Ball Bearing(35TAC72BDBDC10PN7A) to the

C58031042A Motor Bracket(Y).
① Assemble the 35TAC Angular Contact Bearing to the Motor Bracket, taking care
to match up the directions well, and then measure the depth between the end
of the Bearing and the section of the Motor–Bracket. (“B)
② Calculate the on-site dimension of the C49031123B Bearing Cap and do the on-
site machining.
※ Bearing Cap on-site dimension “A” = “B” – 0.05mm
③ Assemble the machined Bearing Cap to the Motor Bracket, fitting it to the O-Ring
grooves.
※ Make sure to use all Bolts tightened with the same amount of force.
▪ 6-BB8×30, 6-ZP8, 1-P7
Motor
Bracket
“B”
Bearing 35TAC
Cap
“A”
Bearing
82
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.
▪ To adjust the Run-Out, rotate the Ball Screw while reading the Indicator, and at the
highest point hit with a hammer towards the direction of locking the Lock-Nut.
A
300mm
Collar
C
Lock-Nut
5) Hang the Ass'y (with Ball Screw and Motor Bracket assembled) onto a crane with a
rope, and carefully push through the Y Axis Ball Screw position from above the
Column.

opposite Bracket area, be careful not to
hit and scar the lift out screw area near
the end of the ball screw.
83
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
on.
Collar
Lock-Nut
7) Setting the Ball Screw Pre-Tension

① Measure the gap between the Motor
Gapmeasure
Bracket and the upper side of the Column
using a Block Gauge.
② Measure the nine Adjusting Liner assembly
areas with a Block Gauge. Add the Pre-
Tension (0.03mm) to the measurement, and
accordingly grind each Adjusting Liner.
※ Liner Measurement = Gap Measurement +
0.03mm
8) When the Liner on-site grinding is

complete, loosen the Lock-Nut, widen the
gap between the Motor Bracket and
Column a little, insert the liners according
to their locations as previously marked, and
fasten the security bolts and positioning
pins.
▪ 8-BB16×70, 8-ZC16, 2-TPB8×56
9) Use a chisel and hammer again to fasten

the Lock-Nut.
* Simply tighten for now, you must set the
Ball-Screw Run-Out again later.
84
HP 5100 HP51MTE87
10) Fit the Ball Screw Run-Out.

Screw.
② Rotate the Ball Screw while reading the
Indicator. At the highest reading, hit
with a chisel in the direction of locking
the Lock-Nut.
③ When both Ball Screw Run-Outs fall
below 0.01mm, tightly secure the Lock-
Nut security set-screws.
11) Rotate the Ball Screw Nut back to its
original location, fasten the security Bolts, Ball Screw
Nut
and assemble the lubricant pipe and
cooling pipes.
▪ Since accurate fix should be done after
turning on the power, for now loosely
connect the security Bolts.
▪Final Nut Fix after turning on the Power On
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.)
12) Insert the Y-Axis Servo-Motor with the

R10712 Rigid Coupling attached into the
Ball Screw, being careful not to hit the
Rigid Coupling. Assemble to the Motor
Bracket and tighten the security bolts.

① Use the Wrench to lightly secure the four
bolts, in diagonal order.
② Gradually increase the fastening force on
the bolts.
③ Set an Indicator inside the Rigid Coupling.
Manually rotate the Ball Screw to measure Rigid
Run-Out repeatedly until the figure comes Coupling
85
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..
Lubricant
Pipe
※ After reassembling the Y Axis Ball Screw, the Y Axis Reference Point must be reset.
※ Resetting the Y Axis Reference Point
1) Insert the Test Bar into the Spindle.
2) Set the Block Gauge(over 150mm) on top Indicator
of the Pallet and install the Indicator on top Test Bar
of the Pallet to set the Block Gauge's height

Block
at “0” Setting. Gauge
3) Send the Y Axis to the position
corresponding to the measurement found
from the formula below. Pallet
Y Axis position ＝ Block Gauge height － (Test
Bar Radius ＋ 50)
▪ In case of HP-5100, when Y is Y0. the distance from the top of the Table to the
center of the Spindle is 50mm.
Ex): If the Block Gauge height is 150mm: 150 - (30 + 50) = 70. Therefore, Y70.
4) With the Indicator at the highest point of the Test Bar, rotate the Spindle so that it
stops in the center of the Test Bar's Run-Out.
5) Move the Y Axis to set the Indicator needle at "0”.
6) Enter the Parameter according to the measurement shown on the CRT screen's
Machine Position. If it is + the location found in 3), enter "+," if it is -, enter "-".
※ Y Axis Reference Point Parameter : NO. #1850 Y
▪ Add the above measurement from the original Parameter and enter “INPUT,” or
enter the above measurement with a sign, as “+INPUT”.
7) Set the reference points again and measure 1)∼6) repeatedly until the figure
comes under 0.005mm.
86
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.
31 36 41
32
33 30
34
37
29 38
39
35 40
18 27
19
20
10 14
6 24 11 15
7 21 25 12 16
8 22 26 13 17
9 23 28
1
2
3
4
5
87
HP 5100 HP51MTE87
Material /
Specification
1 C58023023 Ball Screw (Z) 1 W4509Z-451PSS-C3Z20 NSK
4 R462945 Connector, Hose 1 C4N8 ×6-PT1/4 NITTA MOORE
5 R462946 Connector, Elbow 1 L4N8 ×6-PT1/4 NITTA MOORE
6 C58021052A Bracket, Support 1 GC300
10 C58021062A Bracket. Support 1 GC300
14 C58021072A Support, Bearing 1 SM45C
17 C58021084 Liner, Adjusting 4 SS400
18 C58021094A Cover 1 SCP1(t2.0)
28 C58021124 Liner 1 SM45C
29 R18721 Coupling, Rigid 1 Ø35 ×Ø30
34 C42036094 Collar 1 SM45C
40 C42036094 Collar 1 SM45C
88
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.
Lubricant
Cover Piping
Motor cable
Motor Cable
Bracket Connector
3) Loosen the R18721 Rigid Coupling bolts by manually rotating the ball screw.
Remove the Servo Motor security Bolts and carefully detach and remove the Motor.
4) Disassemble the opposite C58021072A Bearing Support Lock-Nut.

* Loosen the Lock-Nut security Set-Screws and remove the Lock-Nut using a chisel
and hammer.
Lock-Nut
Lock-Nut
89
HP 5100 HP51MTE87
5) Disassemble the Ball Screw Nut Area's Cooling

lubricant pipe and the cooling pipe and Pipe
remove the Nut security Bolts(10-BB
10×40).
Ball Screw
Nut
6) Remove the Motor Bracket security

Security
Bolts(8-BB16×65) and Positioning Pins(2- Bolts
TPB8×56).
Motor
Bracket
Taper
Pins
7) Remove the Motor Bracket and Ball Screw Ass’y from the machine.
8) Loosen the C58021072A Bearing Support

security Bolts(4-BB16×70) and
disassemble the Bearing Support Ass’y.
90
HP 5100 HP51MTE87

* 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.

from the Motor Bracket and separate the
Ball Screw Bearing.
▪ 6-BB8×30 Bearing
Cap
91
HP 5100 HP51MTE87
5.6 Assembling the Z Axis Ball Screw

C59021072A Bearing Support.
① Assemble the 35TAC Angular Contact Bearing to the Bearing Support, making
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. (“B”)
② Measure the on-site dimension of the C49021524A Bearing Cap and do the on-site
machining accordingly.
※ Bearing Cap on-site dimension “A” = “B” - 0.05mm
③ Assemble the machined Bearing Cap to the Bearing Support.
※ Make sure to apply the same strength to all bolts while securing.
▪ 6-BB8×30
“B”
Bearing
Cap
“A”
Bearing 35TAC
Support Bearing
2) Insert the C58021072A Bearing Support Adjust

and the C58021084 Adjust Liner into the Liner
Support opposite from the Motor Bracket,
Bearing
and secure the security bolts. Cap
▪ 4-BB16×70
※ Insert the four Adjust Liners according to
their positions as marked during Bearing
Support
disassembly.

C58021052A Motor Bracket.
① Assemble the 35TAC Angular Contact Ball Bearing to the Motor Bracket, making
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. (“B")
② Measure the on-site dimension of the C49021524C Bearing Cap and do the on-site
machining accordingly.
※ Bearing Cap on-site dimension “A” = “B” - 0.05mm
③ Assemble the machined Bearing Cap to the Motor Bracket.
※ Make sure to apply the same strength to all bolts while securing.
▪ 6-BB8×30
92
HP 5100 HP51MTE87
“B”
35TAC
Bearing
“A”
Bearing
Cap
Motor
Bracket
4) Stand up the Motor Bracket with Bearing

attached, assemble the Ball Screw, insert
the C42036094 Collar, and fasten the Lock- Collar
Nut.
▪ Simply tighten as much as possible; the Ball
Screw Run-Out will be set later on.
Lock-Nut
5) Carefully push in the Ass'y (with Ball Screw and Motor Bracket attached) through
the X Axis Ball Screw position on the Column.

opposite Bearing Support, be careful not to
hit the screw against something and scar
it.
93
HP 5100 HP51MTE87
6) Fasten the Motor Bracket security Bolts and 8-

Positioning Pins. securit
▪ 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.
▪ Mark the four C58021084 Adjust Liners to Lock-Nut
prevent their locations from being switched
during assembly.
8) Insert the C42036094 Collar and secure
the Lock-Nut.
▪ Simply tighten as much as possible; the Ball
Screw Run-Out will be finally set later on.
9) Setting the Ball Screw Pre-Tension

① Use a Block Gauge to measure the gap
between the Bracket Support and the
Support Bearing.
② Measure six places with the Block Gauge,
Clearance
add the Pre-Tension amount (0.04mm) to Measurement
Motor
the measurements,and grind the
Adjusting Liner accordingly.
▪ Liner Measurement = Gap Measurement +
0.04mm
94
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
the 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.
Ball Screw Run-Out will be finally set later on.
12) Set the Ball Screw Run-Out.
Screw.
② Rotate the Ball Screw while reading the
Indicator. At the highest reading, hit
with a chisel in the direction of locking
the Lock-Nut.
③ When both Ball Screw Run-Outs fall
below 0.01mm, tightly secure the Lock-
Nut security set-screws.
13) Rotate the Ball Screw Nut to move it to its

correct location, then fasten the security
Bolts.
▪ Since accurate fixing should be done after
turning on the power, for now loosely
connect the security Bolts..
※ Finally Securing the Nut after Turning on

the Power
① Send the Z Axis to the “Z0”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) Insert the Z Axis Servo Motor (with R10712 Rigid Coupling attached) into the Ball
Screw and assemble to the Motor Bracket. Fasten the security bolts.
95
HP 5100 HP51MTE87
Motor
Bracket

① Use a Wrench to first lightly fasten the
four Bolts in diagonal order.
② Gradually increase tightening force.
③ Set the Indicator on the Rigid Coupling.
Manually rotate the Ball Screw to measure
the Run-Out, repeating until the Rigid
Coupling
measurement falls below 0.03mm. Secure
the Bolts.
※ The Run-Out must fit all three Rings of the
Rigid Coupling.
16) When assembly is finished, assemble the Motor Bracket C58021094A Cover.
Assemble the lubricant pipe, cooling pipes, and Servo Motor Cable (Power and
Feedback Cable) Connector that were previously disassembled.
Lubricant
Cover
Pipe
Motor Cable
Motor Connector
Bracket
※ When reassembling the Z Axis Ball Screw, you must reset the Z Axis Reference Point.
96
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.
2) Command G91 Z100.; B90.; Z-100.; in “0” Setting
MDI Mode.
▪ When the last Test Bar hits the gauge, use
Override to slow it down and reduce the Measur
ement
shock hitting the gauge. 90˚
Rotation
▪ When the reference
닿지않으면 point
핸들로isX축을
very different,
움직여 위치를 set 맞춘다.
the last Z-100. at about Z-95. and send the Z
Axis over to the gauge using Handle Mode.
▪ If the Test Bar does not reach the gauge because of the difference in Table position,
use the Handle to move the X Axis and position it.
3) Move the Z Axis to set the Indicator needle at “0”.
4) Enter the Parameter according to the measurement shown on the CRT screen's
Machine Position. If it is + Z115., enter "+," if it is -, enter "-".
※ Z115. is for when the Test Bar's length(L) is 310mm, and diameter(D) is 60mm.
Z = L - (200 + D/2), Z = 310 - (165 + 30) = 115
In the case of HP-5100, when Z is Z0. the distance between the center of the
Table to the Spindle Gauge Line is 200mm.
※ X Axis reference point Parameter : NO. #1850 Z
▪ Add the measurement to the original Parameter and enter “INPUT,” or enter the
above measurement with a sign, as “+INPUT”.
5) Set the Z Axis reference points again, send the Z Axis to Z115., and repeatedly
measure with Indicator until the figure comes under 0.005mm.
97
HP 5100 HP51MTE87
6. Machine Accuracy Work
6.1 Straightness of the Z Axis

1) X－Y Plane
X-Axis
① Measurement
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. Z Axis
▪ Measurement position : Z0. Z375. Z750.
transfer
▪ Permitted Range : 0.025mm / Entire Length
② Adjustment
Z-Axis
If the machine transfer level is incorrect, it can
effect the Z Axis X-Y straightness. Make
sure to level the machine first (refer to
"Leveling the Machine").
2) Y－Z Plane
X-Axis
① Measurement
Stand up a Straight Edge on the Pallet in the
Z Axis direction, and install the Indicator on
the Spindle Head to set both ends of the
Straight Edge as "0." Move the Z Axis to
measure the largest difference.
※ If a Straight Edge is not available, a side of a
Z Axis
perpendicular ruler may be used to measure
Transfer
the Y-Z straightness.
▪ Measurement position : Both ends and center Z-Axis
of the Straight Edge.
▪ Permitted Range : 0.005mm / 300mm
② Adjustment
If the machine transfer level or the Z Axis L/M
Guide is incorrect, it can effect the Z Axis Y-
Z straightness. First level the machine first
(refer to "Leveling the Machine"), and if the
problem persists, repair or replace the L/M
Guide.
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3) X－Z Plane
① Measurement
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
※ If a Straight Edge is not available, a side of a perpendicular ruler may be used to
measure the X-Z straightness.
▪ Measurement Location : Both ends and center of the Straight Edge.
X-Axis
② Adjustment
If the machine transfer level or the Z Axis L/M
Guide are incorrect, it can effect the Z Axis
Y-Z straightness. First level the machine
first (refer to "Leveling the Machine"), and
if the problem persists repair or replace the
L/M Guide. Z Axis
Transfer
Z-Axis
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6.2 Straightness of the X Axis

1) X - Y Plane X Axis
① Measurement Transfer
Stand up a Straight Edge on the Pallet in the
X-Axis
X Axis direction, and install the Indicator on
the Spindle Head to set both ends of the
Straight Edge as "0." Move the X Axis to
※ If a Straight Edge is not available, a side of a
perpendicular ruler may be used to measure
X-Z straightness.
▪ Measurement Location : Both ends and center
of the Straight Edge.
Z-Axis
② Adjustment
If the machine transfer level or the X Axis L/M
Guide are incorrect, it can effect the X Axis
X-Y straightness. First level the machine first
(refer to "Leveling the Machine"), and if the
problem persists, repair or replace the L/M
Guide.
2) Y - Z Plane X Axis
①Measurement
Transfer
Install the perpendicular magnetic level on a X-Axis
section of the Spindle in the Z axis direction
so that the level needle can be read, then
divide the X Axis stroke into three equal
parts and transfer, measuring the largest
difference in level.
▪ Measurement Position : X0. X425. X850.
▪ Permitted Range : 0.025mm / Entire Length
② Adjustment
If the machine transfer level is incorrect, it can
Z-Axis
effect the X Axis straightness. Make sure to
level the machine first (refer to "Leveling the
Machine").
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HP 5100 HP51MTE87
3) X - Z Plane
① Measurement
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.
※ If a Straight Edge is not available, a side of a perpendicular ruler may be used to
measure X-Z straightness.
▪ Measurement position : both ends and center of the Straight Edge.
② Adjustment X Axis
If the machine transfer level or the X Axis L/M Transfer
Guide are incorrect, it can effect the X Axis
X-Axis
X-Z straightness. First level the machine
first (refer to "Leveling the Machine"), and
if the problem persists, repair or replace
the L/M Guide.
Z-Axis
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6.3 Straightness of the Y Axis

1) X - Y Plane
① Measurement
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
of the straight edge as "0." Measure the dicular
Indicator Ruler
central area.
Y-Axis
▪ Measurement Position : both ends and
center of the straight edge.
② Adjustment
If the X Axis L/M Guide is incorrect, it can
effect the Y Axis X-Y straightness. Repair
or replace the L/M Guide.
2) Y - Z Plane
① Measurement
Stand up a perpendicular ruler on the Pallet
in the X Axis direction. Install the
indicator on the Spindle Head, and set
both ends of the straight edge as "0."
Y-Axis
Measure the central area.
▪ Measurement Position : both ends and
center of the straight edge.
② Adjustment
If the X Axis L/M Guide is incorrect, it can
effect the Y Axis X-Y straightness. Repair
or replace the L/M Guide.
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6.4 Straightness of the Top of the Pallet

1) X - Y X-
Direction
① Measurement
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. Straight
Edge
※ If a Straight Edge is not available, it is also
possible to attach an indicator to the Block
spindle head and to measure the top of
the pallet by manually moving the Axis. Pallet
▪ Measurement Position: both ends and
center, 9 positions in the X direction
② Adjustment
Since this is the straightness of the top of the
Pallet itself, it is impossible to adjust. If the
problem is serious, the top of the Pallet
should be regrinded.
2) Y - Z Z-
Directi
① Measurement on
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
difference. Straight Spindle
※ If a Straight Edge is not available, it is also Edge
possible to attach an indicator to the
Block
spindle head and to measure the top of
the pallet by manually moving the Axis. Pallet
▪ Measurement Position: both ends and
center, 9 positions in the Z direction
② Adjustment
Since this is the straightness of the top of the
Pallet itself, it is impossible to adjust. If the
problem is serious, the top of the Pallet
must be regrinded.
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6.5 Perpendicularity between the each Coordinate Axes

1) X - Y Perpendicularity
① Measurement
Place a perpendicular ruler on the Pallet in
the X Axis direction. Install an Indicator
on the Spindle Head and measure in the 축
X- and Y-Axis direction to find the greatest
difference.
▪ Measurement : Set ⓑ and ⓒ (shown in the
photo) as "0.”Add +/- signs to the ⓑ－ⓐ
measurement and the ⓒ－ⓓ
measurement. If ⓐ and ⓓ are the same
sign, the measurement is the sum of the
two axes; if they are different signs, the
measurement is the smaller number
subtracted from the larger number. b a
▪ Permitted Range : 0.01mm/300mm
② Adjustment c
X-Y perpendicularity adjustment is possible
by adjusting the thickness of the X Axis
L/M Guide Liner.
ⓐ Refer to“X-Y Perpendicularity”above to d
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 security
Bolts
the grinding amount of the Liner.
ⓒ Remove the L/M Guide Slide security
bolts and loosen the X Axis Ball Screw Nut
Liner
security Bolts.
ⓓ Insert a screw-jack between the Bed and
Column, and lift the column a little until
the Liner can be removed.
ⓔ Pull out the Liner, grind the amount
found in“②,”and reassemble.
ⓕ When reassembling the Ball Screw Nut,
move the X Axis to the outermost
position(X0.) and then secure the bolts one
by one, tightening them equally.
ⓖ Measure the perpendicularity repeatedly
until a satisfactory figure is reached.
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2) Y - Z Perpendicularity
① Measurement
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.
▪ Measurement : Set ⓑ and ⓒ (shown in the photo) as "0.”Add +/- signs to the ⓑ－
ⓐ measurement and the ⓒ－ⓓ measurement. If ⓐ and ⓓ are the same sign, the
measurement is the sum of the two axes; if they are different signs, the
measurement is the smaller number subtracted from the larger number.
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② Adjustment
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.
ⓒ Remove the L/M Guide Slide security
bolts and loosen the X Axis Ball Screw
Nut security Bolts.
ⓓ Insert a screw-jack between the Bed and
Column, and lift the column a little until
b a
the Liner can be removed. c
ⓔ Pull out the Liner, grind the amount
found in“②,”and reassemble.
ⓕ When reassembling the Ball Screw Nut,
move the X Axis to the outermost
d
position(X0.) and then secure the bolts
one by one, tightening them equally.
ⓖ Measure the perpendicularity repeatedly security
until a satisfactory figure is reached. Bolts
Liner
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HP 5100 HP51MTE87
3) X - Z Perpendicularity
① Measurement
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). Measure the parallelism towards the
Z Axis to find the greatest difference.
▪ Measurement : Set ⓐ-ⓑ(shown in the
photo) to“0,”and find the difference ⓒ－
ⓓ.
② Adjustment
It is unlikely that the perpendicularity will be
altered after setting the X-Z
perpendicularity. However, if the X-Z
perpendicularity should be adjusted, the
X- or Z-Axis L/M Guide itself should be
realigned.
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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. Use the measurement Block
to measure the four points on the Pallet,
then rotate the B Axis 90° and repeat the
process to find four new points. Repeat
this process to find a total of 16 points,
then record the measurements into a
chart like the one below.
※ 1,2,3,4 : Table Direction : (Fixed
Position)
A,B,C,D : Pallet Direction (Position changes
with Table Index)
2) Calculation
① Sum : Sum of 4 figures, each horizontally
and vertically
② Average : Sum divided by 4
③ Precision Calculation
ⓐ X Axis direction : The larger difference Pallet
from between Averages 2,3 and Averages

1,4
▪ Permitted Range : 0.012mm / 300mm 3 4
ⓑ Z Axis direction : The larger difference
from between Averages 1,2 and Averages C D
3,4
ⓒ Run-Out : From A, B, C, and D, subtract
the smallest figure from the largest figure
▪ Permitted Range : 0.010mm
B A
Su
1P 1 2 3 4 Avg.
m
2 1
A
B Spindle
C
D
Sum
Avg.
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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.
① A,B,C,D : When the height distribution for Pallet No. 1 and No. 2 are similar, grind
the Liner inside the Table Locating Pin. When they are different, pull out the liner
from the Locating Bush under the Pallet and grind and adjust.
② 1,2,3,4 : The alignment can be corrected by grinding the X Axis L/M Guide Liner.
※ Adjusting the Table Locating Pins Liner, Pallet Locating Bush Liner
① Refer to“Parallelism of the top of the Pallet”and accurately measure the
parallelism.
② Calculate the grinding amount of the Liner according to the measurement.
③ Loosen the Locating Pins or Locating Cup security Bolts.
④ Insert two M8 Bolts into the Tap holes of
Security Lift Bolts
the Locating Pins or the Locating Cup Lift, and Bolts Position
slightly tighten until the Liner can be removed.
⑤ Pull out the Liner, grind the amount found
in “②,”and reassemble.
⑥ Strongly tighten the Locating Pins or
Liner
Locating Cup Security Bolts. Table
⑦ Measure the parallelism again and repeat
until a satisfactory figure is reached. Pallet
Liner Security
Bolts
※ Adjusting the thickness of the Z Axis L/M

Security
Guide Bolts
① Refer to “Parallelism of the top of the
Pallet” to measure the accurate Liner
parallelism.
② Calculate the measured distance of the
Pallet(300mm) and the distance of the
two L/M Guide Sliders(약 450mm) to
find the grinding amount of the Liner.
③ Remove the L/M Guide Slide Security
Bolts and loosen the Z Axis Ball Screw
Nut Security Bolts.
④ Insert a Screw-Jack between the Bed
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HP 5100 HP51MTE87
and Table, and lift up the Table until the

Liner can be removed.
⑤ Pull out the Liner and grind the amount
found in “②.” Reassemble.
⑥ When reassembling the Ball Screw Nut,
send the Z Axis to its reference point,
then tighten the security Bolts
individually with the same strength.
⑦ Measure the parallelism repeatedly until
a satisfactory figure is reached.
6.7 Index Table Division Perpendicularity

1) Measurement
① Lay a perpendicular ruler on the Pallet and
move the X Axis to match the parallelism
between the X Axis and the perpendicular
ruler.
② Clamp so that the perpendicular ruler will
not move during B Axis Index. 90˚ Index
③ Index the B Axis 90˚at a time. Measure the

parallelism of the X Axis and find the
largest figure.
2) Adjustment
The degree division of the machine's Index Table is based on the Curvic Coupling,
which is extremely precise. However, if there is a large margin of error despite
accurate measurement, there is probably a foreign substance stuck in the Curvic
Coupling inside the Table or a faulty part due to damage or wear. The parts must be
replaced with new parts.
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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
difference. Edge Locator
▪ Maximum Amount : 0.010mm
2) Adjustment
This area has been twisted when the B
Axis has collided with something and the
Curvic Coupling inside the Table has
received shock. Refer to "Aligning the
Table" and adjust accordingly.
※ T-Groove and Parallelism of Movement

towards the X Axis (T-Groove Pallet)
1) Measurement
Install the Indicator on the Spindle Head.
Set a gauge on the Pallet T-Groove and
measure while moving it towards the X T-Groove
Axis to find the greatest difference. Pallet
2) Adjustment
This area has been twisted when the B
Axis has collided with something and the
Curvic Coupling inside the Table has
received shock. Refer to "Aligning the
Table" and adjust accordingly.
※ Table Accuracy work
※If a large shock has been applied to the Table in the direction of rotation due to
collision of tools, etc., the parallelism between the Edge Locator and the Removal
Axis could have been twisted. This is due to shock to the Curving Coupling within
the Table and may cause problems when coming into contact with tools. The Table
must be disassembled and the Curvic Coupling must be realigned. This process
requires the following preparation and precise work.
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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)
(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
(6) Copper Hammer or Lead bundle
(8) Tool for pulling out Pins
(9) Basic tools needed for machine maintenance
1) Disassembling the Table

※ Preparation for disassembling the Table
(1) Thoroughly clean the interior of the machine. Move X and Y Axes to their reference
points. Lift out the Pallet from inside the machine or lift from the APC and rotate it
90 degrees.
(2) Move the Z Axis to the center for convenience, and turn off the power.
① Disassemble the C50058253 Cap. Cap

▪ 6-BB6×16, O-Ring : 1-G145
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HP 5100 HP51MTE87
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
ⓐ Remove the Pallet Base security Bolts (12-
BB10×65/ZC10) from where the Cap was
disassembled.
ⓑ Remove the Set-Screw(2-BQ12×16) near
the Pallet Base, insert eye bolts, tie a rope
around this area and hang the rope on a
crane.
ⓒ Slowly and carefully lift up the Pallet Base.
※ Maintain balance, sometimes hitting the
Pallet Base evenly with a hammer or a
wooden baulk.
③ Adjusting the Curving Coupling assembled
to the Table Base Body Curvic
Coupling
ⓐ Loosen the Curvic Coupling security
Bolts(12-BB12×30).
ⓑ Pull out the Curvic Coupling Positioning
Pins(2-SPB13 ×40) to check for any
problems.
ⓒ If there are no problems with the Pins,
reassemble. If there are problems, replace
with new Pins and assemble after reaming
into the Pin hole again.
ⓓ Fasten the Curvic Coupling security
Bolts(12-BB12×30) as strongly as
possible.
④ Preparation for Adjusting the Curvic
Coupling attached to the Table(Pallet Base)
Body
ⓐ Loosen the Curvic Coupling security
Bolts(12-BB12×30).
ⓑ Remove the Plug(2-FPS-S1/2) attached in the Curvic Coupling Positioning Pins(2-
TPB13×40) location, and use the appropriate tool to pull out the Taper Pins.
ⓒ Tighten the Curvic Coupling security bolts about 1/3 force of the way each.
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HP 5100 HP51MTE87
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
over the surface with a piece of lead or
copper hammer to direct it to the proper
position.
③ Fasten the Table security Bolts(12-
BB12×65).
※ Verifying the proper positioning of the Table

There is a Plug(FPS-S3/4) near the Table
Base. If you remove this Plug and
provide light, you can see the Coupling 2-Curvic
assembly position inside the Table Security Bolt
Plug
through the Plug holes.
Curvic
④Remove the Table's upper Plug (2-FPS- Assembly
S1/2) and loosen the 2-BB10×65. Confirmation
※ These Bolts are necessary for adjusting
the Table accuracy.
3) Adjusting the Table accuracy
① Put in the power and Set the Indicator on

the Edge Locator by attaching it to the
Spindle as shown.
② Move the X Axis and measure the
parallelism between the X Axis and the
grinded section of the Edge Locator.
③ Turn off the oil pressure by pressing the
emergency stop Switch. Use a hammer or
wooden baulk to hit the end of the Pallet
and move the Table towards the rotation
direction, matching up the parallelism.
④ Reset the Machine Ready and measure the parallelism. Repeat the above process
until the parallelism is within the optimal measure.
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HP 5100 HP51MTE87
※ Optimal Measure 0.005mm/Entire Area

⑤ When the optimal parallelism is achieved, tighten the loosened 2-BB10×65.
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.
③ Even out the Taper Pins location with 13mm taper reamer, then push in new pins.
▪ 2-TPB13×40
④ Assemble the Plug(FPS-S3/4) in the place where the Taper Pins are attached (the
Plug should not protrude more than the Coupling).
5) Assembling the Table Cap

① When the Curvic Coupling is secure, blow
out all foreign substances with air from
both the upper and lower Curvic Coupling.
Assemble the Table, referring to the "2)
Table(Pallet Base) Body Temporary
Assembly” above.
② Referring to the “3) Adjusting the Table Accuracy” above, measure the parallelism
between the X Axis and the grinded section of the Edge Locator. If the measurement
falls within the margin, complete final assembly.
ⓐ Assemble the C50058253 Cap.
▪ 6-BB6X16, O-Ring : 1-G145
ⓑ Wrap the various unraveled Plugs with Tefron and assemble.
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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
X
customized tools, but since it is difficult to Axis
find such tools ,another method will be
used. This method involves adding up the
machine’s position accuracy with Back-lash
margin, and is not accurate. It should only “0” Setting
be used for reference (the measurement
can also be done using the Z Axis).
① Send to X150. B90. in MDI mode.
② Install an indicator on the spindle head and
mark the center of the edge locator with a pen.
Set the Indicator to “0.” Setting.
③ Command G91 Y100. in MDI mode.

④ Command G90 X650. B180.
⑤ Command G91 Y－100. (Slowly
X
approach the point marked with the Axis
Pen)
180˚ Index
⑥ Half of the The figure being found above
is measurement.
※ Measure separately the long and short
measures of Pallet #1 and Pallet #2.
2) Adjustment
Disassemble the Edge Locator. When the
measurement is “－,” grind the tool
attachment side, and when the
measurement is “＋”grind the Pallet
attachment side according to the
measurement.
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6.10 Repetition Position Precision of Pallet Exchange and Reciprocal
Difference
1) Measurement
① Send the X, Y, Z Axes to the center of
the Axis Stroke (X400. Y350. Z375.).
② Install three indicators on the Spindle
Head. Set the X, Z Axis directions on the
Edge Locator and the Y Axis directions on
top of the Pallet.
③ Create and execute the following
program.
G91 G28 Y0;
G91 G28 X0 Z0;
M60;
G90 G00 X400. Z375.;
Y350.;
M01;
M99;
※ When the Indicator hits the Pallet at Y-

280.; above, adjust the override to slow it
down and reduce the error margin caused Z
by shock.
④ Measure the X, Y, Z Axes simultaneously,
X Y
and measure P#1, p#2 at least four times
each to find the greatest difference.
2) Adjustment
The Table Locator Pins or Cup are most
likely to be faulty. Clean them again
and attempt to measure again. If the
problem is still existing, replace with
new parts.
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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.
Find the greatest figure. Y-Z면
※ Measure the Test-Bar Run-out and stop

the Spindle in the middle of the found
measurement, and find the reading.
▪ Permitted Range :
Y－Z Side 0.012mm/300mm
X－Z Side 0.012mm/300mm
2) Adjustment
Adjust the Y Axis L/M Guide Liner. security
※ Adjusting the Y Axis L/M Guide Liner bolt
Thickness
① Refer to "Z Axis Movement and
Parallelism with the Spindle Central Line"
to accurately measure the parallelism. Liner
② Using the measured distance and
calculating the four L/M Guide Sliders'
distances, calculate the grinding amount
of the Liner.
③ Remove the L/M Guide Slider security Bolts and loosen the Y Axis Ball Screw
Nut security Bolts.
④ Pull out the Liner, grind the amount found in“②,”and readjust.
⑤ When reassembling the Ball Screw Nut, move the Y Axis to "0" and then
individually tighten the security Bolts, using the same amount of strength for
each.
⑥ Measure the parallelism again and repeat until a satisfactory figure is reached.
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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.
▪ Permitted Range :
At the entrance :0.005mm
From 300 mm: 0.012mm
2) Adjustment
It is probable that the side of the Spindle Taper has been dented. Pull out the Pull
Stud using a Test Bar or a new tool, and thinly apply red lead or red seal-ink on
the Taper. Use sandpaper to get rid of the dents caused by Taper sides rubbing
against each other.
※ Do not use a grinder. When the Taper is severely damaged, you must regrind
the Spindle.
6.13 Spindle Movement towards the Z Axis

1) Measurement Steel Ball
Insert the Test Bar into the Spindle.
Attach the Steel Ball to the center of the
end of the Test Bar. Set the Indicator
against the highest point of the X, Y Axes
and rotate the Spindle to find the greatest
amount of shaking.
2) Adjustment
If the Spindle moves towards the Z Axis, it is a problem with the Spindle Main
Bearing. Replace the bearing.
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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 )
▪ Perpendicular Ruler (Rectangular
350×350)
▪ Test-Indicator(0.002mm)
▪ Magnetic Stand
▪ Test-Bar
▪ Tools for Leveling (Spaner : 30mm, 50mm,
58mm)
▪ Pipe(1", 1.5m-long)
Anchor Bolts(BA20)
Washer(ZP20)
Leveling Bolts
Nut
Bed
Leveling Plate
80mm이상
Anchor
(With (Without Foundation)

Foundation)
120
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.
(2) Rotate the Level 180˚ in the same spot and read the measurement of the water
droplets in the same direction.
(3) Turn the Level Adjustment Screw to move halfway between the first and second
water droplet measurements (halfway between the two directions).
(4) Repeat steps (1)∼(3) so that the water droplets come in the same location even
after being rotated to either side.
※ Reading the Level(example)
“-” “+”dirc
(Location of the Right Water drop’s Edge ＋

Left Water drop’s Edge) ÷ 2 ＝ Level
Measurement (-50 + -40) ÷ 2 ＝ -45
※ The above level’s left side is 45μ/m
higher
3) Send the Z Axis to Z0, Z375., Z750., locations while adjusting the Level Bolt to
approximately set the Level. (Set both X,Z-Directions at about 0.04/m.)
▪ It is more convenient to set up a Program before Leveling.
Example) O 001;
G90 G00 Z0.;
M01;
Z375.;
M01;
Z750.;
M01;
Z375.;
121
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.
② Make sure to stop Level Bolts in a locking direction.
▪ If possible, level while pulling up the machine.
4) When the Z Axis Level has been
approximately set, move the Z Axis to the
Z375. location. To begin work on the X
Axis, use a Magnet to flatten the level all
over the Spindle Head, and set the Level
at “0.”
5) Through the same process as the Z Axis,
set the X Axis level by moving the X Axis
through the X0. X400. X800. locations.
※ When working on the X Axis Level, keep in mind that the Z Axis Level may change.
(Keep a Level towards the X Axis on the Table and check periodically.)
▪ It is more convenient to set up a Program before Leveling.
Example) o 002;
G90 G00 X0.;
M01;
X400.;
M01;
X800.;
M01;
X400.;
M01;
M99;
6) As explained above, repeat the Level process for the X and Z Axes and record the
Levels so that the overall levels do not differ by more 0.02/m.
※ Recording the Level Values
① Format of recording the Levels (example)
X-direction :20
X-direction 10 20 30 Z-direction : 15
Z-axis
Z-direction 15 20 30
X-axis Z-direction 10 20 30 (With

Foundation)
※ The method above is the standard way of reading the absolute level. When
122
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. Other areas are measured
and recorded in the same way, and the Level amount is found by subtracting
the smallest number from the largest number.
② When reading the Level scale, make sure that your eye is perpendicular to the
Level.
※ Since there is distance between the Level scale and the waterdrops, reading
from different angles can yield different readings.
7) Lock the Anchor Bolts, beginning with the X Axis Anchor Bolts. (At this point ,the Level
Accuracy should be about what is reached when the above alignment process is
complete.)
※ Locking the Anchor Bolts
① Lock the level bolts which had been locked with the same strength about ¼ turn(90˚)
tighter, then lock all bolts with moderate strength (begin with the X Axis)
② Measure the Level Accuracy again and use the Level Bolts to further adjust the
alignment.
※ If the bolts were locked with similar strength at first, there won't be a large need for
adjustment.
8) Tighten the Z Axis Anchor Bolts in the same manner.
9) Measure the Z and X Axis Levels again. Lock the Anchor Bolts tightly and lock the
Level Bolts' Nut, then measure the Z and X Axis Levels again.
※ Since the machining center(milling machine)'s Anchor Bolts simply hold the
foundation and the Level Bolts, the Level Bolts' backlash creates a slight gap with the
machine's main body. Therefore, the Anchor Bolts cannot completely do it’s anchor
role. When the Level Bolts' Nut is locked, the Level Bolts and the main body are held
together, so it is likely that the anchor bolts hold the machine main body.
123

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Machine Tools

1. Disassembling and Assembling the Spindle Cartridge ........................ 3

2. Disassembling and Assembling the Table ..........................................22

3. Table Accuracy Work .........................................................................45

4. Servo ATC Recovery ...........................................................................51

5. Disassembling and Assembling the Ball Screw .................................. 66

6. Machine Accuracy work ..................................................................... 98

1. Disassembling and Assembling the Spindle Cartridge

1.1 Disassembling the Tool Unclamp Cylinder

1200, 1210 1270 1300, 1460

※ Preparations to Disassemble the Tool Unclamp Cylinder

1) Remove the various parts (Hyd. Hose,

2) Disassemble C58011223B Piston Cap with Piston

3) Detach the C58011233A Cylinder Cover. Cylinder

4) Detach the C58011231A Piston assembled Piston

5) Remove the two security Set-Screws on

6) Disassemble the C58011203A Cylinder

7) Remove the security bolts on the

8) Disassemble the BZ-Sensor, loosen the BZ-Sensor

9) Take out the C58012153A Sensor Bracket

※ You must not disassemble the C58011041 Key

1.2 Disassembling the Spindle Cartridge

▣ Spindle Cartridge Parts List

500 510 520 530 800 540 200 560

1) Thoroughly clean the Spindle Head, then

2) Remove the six R37260A Coolant Nozzles Coolant Nozzle

3) Remove the security bolts (8-BB12X36) on

1.3 Assembling the Spindle Cartridge

2) Measuring the Tightness of the Rear Outer Rear Bearing

and the new Bearing on a plain

Measuring the difference in height

3) Cleaning the Bearing and Applying Bearing

※ In the case of excess applying

Excessive Grease applying

Standard Grease applying Amount for Main spindle Bearing

HS Thrust Angular Ball

4) Assembling the Spindle Rear bearing Parts

5) Assembling the Spindle Cartridge

※ Prevent O-ring separation during Cartridge assembly by inserting the O-Ring

⑥ Use the C58012134A Distance Collar(4) to Distance

and the Rear Bearing to the Spindle section.

6) Clean the C58011183 Front Cover and Front Cover

7) Insert the parallel Key(2-KSP8×7×20) into the Motor

8) Assemble the BZ-Sensor.

1.4 Assembling the Tool Unclamp Cylinder

2) Assemble the C58011203A Cylinder Body.

3) As shown right, insert the Flat Washer and

4) Insert the O-Ring into the C58011231A

5) Insert and assemble the O-Ring into the 1-G125

6) Use the R27053C Rotating Union to assemble the Piston Cap

※ Reference : Assembly of the Deublin-Rotating Union

Cap End Piston

① Separate the Piston Cap while there is no Tool in the Spindle.

7) Assemble the various Hyd. Hose, Coolant

1.5 Main Spindle Rolling Operation

※ Example of Milling Spindle Bearing Rolling operation Program

2. Disassembling and Assembling the Table

2.1 Disassembling the Table

※ Preparations for Table Disassembly

1) Disassemble the C50058253 Cap. Cap

2) Remove the Pallet Base security Bolts security

4) Slowly and carefully lift up the Pallet Base.

2.2 Disassembling the Table Cylinder