Instruction Manual Specification & Maintenance Data HP 4000 HP 5000 HP 5100 ACE-HP4000 ACE-HP5100 d DHP 4000 DHP 5000 Doosan Infracore Machine Tools HP51INE59Specification and maintenance data Specification and maintenance data This machine instruction manual provides brief and compact information for understanding machine specifications and functions, and also for machine installation and inspection/adjust- ment/maintenance. Please understand fully and keep this manual as a guide to maintain the machine in best condi- tion for a long period. Item Description Remark Page Section 1 | Machine general specification | — Understanding of machine 1-0 Section 2 | Each unit specification specification 2-0 TransportInstallation & Prepara- | ~ Machine installation step and work Section 3 3-0 tion for operation content — Understanding of motion and function ene of each unit Section 5 | Periodic inspection 5-0 — Check point of each unit Section 6 | Check point against trouble 6-0 Section 7 | Data for adjustment/maintenace | — Basic data for adjustmentimaintenance | 7-0 Specification and maintenance data 0-0 HP51INES91. Machine general specification 1. Machine general specification In this section, the brief data for understanding machine totally is provided with illustrations. 1 | Layout drawings Machine dimensions Coordinate system & machine - - 12 4 Understanding machine axis system | 1-5 reference point 1.3 _ | Interference zone = Interference zone in machine 1-6 1.4 | Machine weight and sound level | — Machine weight & sound level 1-7 Machine general specification 1-0 HP51INE59,1. Machine general specification 1.1 Layout drawings 1.1.1 ACE-HP4000(DHP-4000) Layout drawings with side type chip Conveyor Unit : mm(inch) fa] /\e Wa. all} Machine general specification 1-4 HPS51INE591. Machine general specification 1.1.2 ACE-HP4000(DHP-4000) Layout drawings with rear type chip Converyor-Option Unit : mm(inch) ‘veut trite —~"B Machine general specification 1-2 HPS51INE591. Machine general specification 1.1.3 ACE-HP5100(DHP-5000) Layout drawings with side type chip Conveyor Unit : mm{inch) [eae Fi] ee 4 7 i =|] Ec iE Faget 7 ae! f [ on]! Machine general specification 1-3 HP51INE59,1. Machine general specification 1.1.4 ACE-HP5100(DHP-5000) Layout drawings with rear type chip Converyor-Option Unit : mm(inch) "ge ‘ees | f T |oolt eh a &,| = 4 a Sp = a ee F ae a8 a ql bf Machine general specification 1-4 HP51INE59,1. Machine general specification 1.2 Coordinate system & machine reference point Unit : mm(inch) x Column cross 600(28.62) 850(83.46) Y Spindle head vertical 560(22.05) 700(27.56) 2 Pallet table longitudinal 600(28.62) 750(29.53) B Table rotation Coordinate system & machine reference point 1-5 HP51INE591. Machine general specification 1.3 Interference zone 1.3.1 ACE-HP4000(DHP-4000) Unit :mm(inch) PALLET Interference zone 1-6 HP51INE59,1. Machine general specification 1.3.2 ACE-HP5100(DHP-5000) Unit : mm(inch) 7302878) LI oes) +t g 1.4 Machine weight & Sound level 1.4.1 ACE-HP4000(DHP-4000) Machine weight The machine total weight is 12,500kgf(27,558lbf) in standard specification. [NOTICE] 1. Machine total weight can be changed when special specifications or options are included. 1.4.2 ACE-HP5100(DHP-5000) Machine weight The machine total weight is 14,500kgf(31,967Ibf) in standard specification. 1. Machine total weight can be changed when special specifications or options are included. Interference zone 1-7 HP51INE59,1. Machine general specification 1.4.3 Machine sound level / Noise emission The sound level of machine with standard specification is below 80db. Values of aerial noise produced by the machine, according to section 1.7.4 (f) of ANNEX 1 of 98/37 EC DIRECTIVE : Measuring position albfec]da Value of the continuous acoustic pressure level if over 70 dBIA). dBA) | 71 | 72 | 72 | 73 {It should be mentioned if below 70 dB(A). Maximum value of instantaneous acoustic pressure | ypicy | <130 | <130 | <130 | <130 BIC). Value of level of emitted acoustic power, if the con- dB(A tinuous acoustic pressure level is over 85 dB(A). a Data collecting system ‘The measuring position is as shown on drawing and is taken at 1000mm from the floor and at 1000m from the machine. Measuring conditions : * Spindle rotation at maximum speed. (14,000rpm) {not cutting) SE, Machine weight & Sound level 1-8 HP51INES92. Each unit specification 2. Each unit specification In this section, the detailed specification of each unit and available devices are providied with illustrations. [NOTICE] Each unit of this machine is designed as 220Voltage/60Hz. Tem Description =e Remark Page a4 Spindle Head — Main spec. 2-1 2.2 — | Axes system —Main spec. 2-5 23 Table ‘Main spec. and pallet spec. 27 24 ATC(Automatic tool changer) Main spec. and tool spec. 2-12 25 ‘APC(Automatic pallet changer) | — Main spec. and pallet spec. 2-20 26 Air Service Unit — Main spec. 2-24 27 Lubrication Unit — Main spec. ae 28 Hyd. Power Unit — Main spec. ee! 29 Oil Cooler Unit — Main spec. 2-27 2.10 Splash Guard —Main spec. and optional spec. 2-28 2.11 | Name Plates — Function explanation 2-30 212 | Coolant & Chip Devices — Main spec. and optional spec. 2-a1 2.13 Electric Devices ~— Main spec. and optional spec. 2-39 Each unit specification 2-0 HP51INE592. Each unit specification 2.1 Spindle head As the device to generate cutting force with Gripping tool, the spindle is supported with the steel ball bearings and various speed and out- put are also available as optional specifica- tions. Sol. valves for the spindle action control are attached to the rear side of spindle. ‘Smta | Description Function ens Tool gripping and rotation — Generation of power 2 | Driving Unit for rotation ~ Various potional specitication 3g | alUrelanp —|=To execute unclamp Device for tool change ol Master = Control of spindle action = Protection of inner Yeaxis Slide ae 5 Cover devices : = To form outline Xaxis Slide — Protection of inner 6 devices Cover —To form outline Spindle head 2-4 HP51INE592. Each unit specification item Description Remark Page 2.1.1 | Main specifications = Spec. sheet 2-2 2.1.2 | Spindie nose shape — Spindle nose shape and dimensions | 2-3 2.1.3 | Spindle rpm(s) & output diagram Relation of RPM/torque/output 2-4 2.1.1 Main specifications Item Unit Specification NC System FANUC ‘Motor Power(Cont./15min) kWihp) | 22/18.6(29.5/24.81) | 18.5/11(24.81/14.75) Motor Type 1 «:132M/14,000/8 ‘0B1128/20,000/ Spindle Speed rpm 14,000 20,000 Basic Speed rpm 1,000 1,750 lool Clamp Force ‘ot 1,000(2,205) (lbf) Max. Torque(15min.) kat 22.5(1952.91) 6.12(549.55) (ibFinch) Orientation Built.in senor Taper Type 1SO#40, 7/24 Taper Power Transmission Built-in Spindle head 2-2 HPS1INE592. Each unit specification 2.1.2 Spindle nose shape Unit : mm(inch) \s 5 1412.6) 19105), a \ LF g a afl : 3 goa wit F a2 28, ge a Ir Fi I+ ‘ + | soos lise 195 | 5 | se! ao en “| M45 _| ey io.) 472{18.58) Spindle head 2-3 HPS51INE592. Each unit specification 2.1.3 Spindle rpm(s) & output diagram The figures below show the relations between spindle rpm(s), output and torque 1) 12,000rpm (1) FANUC «132M/14,000/B vere el sae sprang | wah 1912) + 20(10816) ° 50 to 2,600 74.00 OTAIONAL SPEED(p) 2) 20,000rpm (Aptinal specification) (1) FANUC 08112S/20,0001 TORQUE POWER eis) vw) sasst19 b= 9 ‘tenner, ester) ‘so24ar) sangre 09 3.07) ‘ola5039) 11041475), asi 78) 1.79185.8) 7511008) WA| essai) lez) é S00 osao72) vu 60 1.000 zoom 2300 FOTATIONAL SPEED (pn 2-4 HP51INES9 Spindle head2. Each unit specification 2.2 Axes system Axes system consists of bodies for axes and ball-screw/servo motor to move those, and X, Y, Z axes is adapted to roller type LM guides for high speed and high productivity. 2.2.1 Main specifications stroke XAxis_ | -mm(incn) 6001 850(33.46) Y Axis. |_mm(inch) '560(22.05) 700(27.58) Z Axis | mm(inch) 600(23.62) 750(29.53) Rapid Traverse | X Axis_| mimin.(pm) 60(2362.2) Y Axis | miminipm) 60(2362.2) Zaxis_| mimin.ipm) 60(2362.2) Cutting Feedrate mminin(ipm) 4 ~ 30,000(0.04-1181.1) Ballscrew(X, Y, Z) mmineh) 2 45 x P20(01.77 x 0.79) Positioning Accuracy “mm(inch) +£0.005(40.0002)/Full storke Repeatabiliy mmtinch) +40.002(+0.00008) Feedback System’? X,Y, Z : Incremental pulse coder, B Axis : Absolute Spd. Nose to table center | mm(inch) | 150 ~ 750(5.91~29.53) | 150 ~ 900(5.91~35.43) Spd. Center to pallet lop inmfineh) | 50 ~610(1.97~24.02) | 50 ~ 750(1.97~29.53) In case of export to the united states of America, absolute pulse coder is stan- dard for all axes. Axes system 2-5 HP51INE59,2. Each unit specification 2.2.2 Servo motor speci Item Unit ‘Specification’ NC System FANUC. X Axis @30/3,000i Y Axis ‘0308/3,000i Z Axis #30/3000i BAxis | 1 Index 12/3000iS 0.001° Rotary 12900078 X Axis kwihp) 7(9.3871) Y Axis kW(hp) 7(9.3871) Z Axis kW(hp) 7(9.3871) BaAxis | 1° Index kWihp) 2.7(8.6207) 0.001° Rotary kWihp) 2.7(8.6207) (NOTICE) The servo motor of axis can be changed by users. Axes system HP51INE592. Each unit specification 2.3 TABLE The table is attached to the inside of machine, carries out moving pallet for machining. Sol. valves for table action control are attached to the rear side of bed. 1 [Pallet = Space to load workpiece Table indexing = Driving by servo motor Location & | Adjusting the step 2. | Driving Unit 3 [clamp position of pallet change Device — Pallet clamp/unclamp Zavie ede |~ Protection of inner 4 devices cover To form out line 2.3.1 | Main specifications ~ Spec. sheet 2-8 2.3.2 | Pallet shape — Pallet spec. 2-9 2.3.3 _| Table index degree = Table indexing 2-11 Table 2-7 HP51INE59,2. Each unit specification 2.3.1 Main specifications 1) Main specifications [AGE-HP4000(DHP-4000)| Index Degree 1° Index 0.001? Rotary Table Positioning Accuracy +3" +6 Repeatability Accuracy 41° +4” Max. Rotating Speed | ‘pm Clamping Force Or Torque 6,383kgf(14.071Ibf) kgf - IbFinch) Index Degree 1° Index. 0.001° Rotary Table Positioning Accuracy 23° 26" Repeatability Accuracy a” 24 Max. Rotating Speed rpm 25 Clamping Force Or Torque 7,775kgi(17143.SIbf) ~ kgfim(- IbFinch) 2) Pallet main specifications [ACE:HP4000(DHP-4000)| Eh Pallet Size mm(inch) 400 x 400 (15.75 x 15.75) Pallet Type Tap Pallet T-slot Pallet Pallet Shape mm 24-M16xP2.0 4-18H8 Remark America standard mi Pallet Size im(inch) 500 x 500 (19.69 x 19.69) Pallet Type Tap Pallet T-slot Pallet Pallet Shape mm 24-M16xP2.0 5-18H8 Remark ‘America standard Table 2-8 HP51INE592. Each unit specification 2.3.2 Pallet shape Unit : mm . {bg TAP a PALLET (sa) vices oF ee Hie psa tL a [pel PALLET tal ‘y ‘a (Opt.) ‘TSLOTSECTION Table 2-9 HP51INE592. Each unit specification TAP PALLET (Std.) TAP SECTION Unit : mm T-SLOT PALLET (Opt) SLOT SECTION Table 2-10 HP51INE59,. Each unit specification 2.3.3 Table Indexing degree [NOTICE] 1. Pallets can be exchanged in 0° position. 2. In case of B command, it should be checked first i there is any interference ‘among the tool, workpiece and machine at the position. [NOTICE] 3. A decimal traction should not be used for B command in 1 degree index table. Table 2-1 HP51INE592. Each unit specification 2.4 ATC(Automatic tool changer) & Tool Magazine 1) ATC(Automatic tool changer) ATC is attached to the left side of machine, and exchanges the both tools in the magazine and spindle head quickly by CAM device. a [symool] Description Function, Execution of tool exchange 1 1 | Changer riven by CAM mechanism — Generation of power 4 2. _| Servo Motor for rotation — Execution of tool 2 Changer | exchange between cS Arm spindle and tool magazine = Reduce rotation speed Reducing | of servo motor 4 gear |-Generation of high torque ATC(Automatic tool changer) 2-12 HP51INES92. Each unit specification 2) Tool Magazine Tool Magazine is attached the left side of machine. Main funtion of tool Magazine is tool storage and Automatic section for exchange. Sol. Valves and Servo Mater for tool Magazine action are attached to the rear side of maga- zine frame. [symbol] Description Function | Tool storage Taal 1 |— Automatic section for Magazine exchange [Waiting Pot | Moving to Magazine! Moving Device Spindle side 3 |Servo. Motor |— To drive magazine — Reduce rotation speed 4 | Reducing | of ero motor gear. _|—Generation of high torque tem Description Remark Page 2.4.1 | Main specifications = Spec. sheet 2-14 24.2 | Tool standard = Tool shank & Pull-stud 2-15 2.4.3 | Available tool = Tool length/diamoteriweight 2-16 24.4 | Changer arm swing area ~ swing area 2-17 2.4.5 | Workpiece limit for tool change = Workpiece limit 2-18 2.4.6 | Tool pot for heavy tools Heavy tool 2-19 ATC(Automatic tool changer) 2-13 HP51INE592. Each unit specification 2.4.1 Main specifications Tool Shank MAS403 BT 40 CAT 40 DIN 69871-A40 Pull Stud(T-S-C Type) NIKKEN PS806 | MODIFIED DIN | DIN69872 #40 Tool Storage Capacity" ool Storage Capaciy” | ex | 40 | 60 | 120 | 170| 40 | 60 | 120 | 170 40 | 60 | 120 | 170 (Include Spindle Tool) Tool Select Type Fixed Adress Max. Tool Diameter way 9757/0140" (62.957/05.51°) Max. Tool Length (inch) 300(11.81) 400 (15.75) Max. Tool Weight glo) 10 (22.05) Max. Tool Moment on 120(104.2) 150 (190.2) Tool Change Position )>=*X¥, Z Axes : Second reference point sec. Less than 7kgf:1.0°9, More than 7kgf : 1.5°9 sec. Less than 7kof :3.5%, More than 7kof : 4°° “1 : Tool storage capacity is included spindle tool *2: Possible to set continuously : Possible to set when adjacent pots empty *4:1 cycle action of Tool changer *5 : tis a measured operating time of motor and each time on the specification has Max. 10% allowance. *6 : Time refering to DOOSAN Infracore standard rr ATC (Automatic too! changer) 2-14 HP51INE592. Each unit specification 2.4.2 Tool standard Unit : mm 66, wrencaceune us / wiosr20. : g nena BT 1} Seep —era! WITH sr 1 © ie oe SJ sladl roy MAS403 BT40 BT WITH DIN SHAPE 111, TAPERGAGEUNE = 3 a CAT ai ] 8 q WITH T i car | 8 2B bos TSC (STD.) CAT 40 DIN SHAPE ~ 4 DIN DIN CH 5 a (STD.) nal 18. DIN69871-A40 DIN 69872 #40 HP51INE59 ATC(Automatic tool changer)2. Each unit specification 2.4.3 Available tool Taper gage line mm ToolLength | | Grup, | 990ctt st) | 400(15.75) 075"(2.95") Possible to set continuously Tool Diameter} D mm Pe i (inch) pee ossible to set when adjacent pots empty kof ToolWeight | Wo] gy 10(22.08) Moment kgtem ws | fotem | s2o(104.2) | 150(190.2) of Too! (iptineny | 12011042) | 150(180.2) ZNCAUION) 1. Non-circlar tool larger than 140mm in diameter may be used depending on the tool conditions. The usage of non-circlar tool should be confirmed by DOOSAN Infracore Engineer. ATC (Automatic too! changer) 2-16 HP51INE592. Each unit specification 2.4.4 Changer arm swing area Unit : mm inch) ATC(Automatic tool changer) 2-17 HP51INES92. Each unit specification 2.4.5 Workpiece limit for tool change ‘ACE-HP4000(DHP-4000) Unit : mm{inch) TAPER GAGE LINE 445(17.52) se0(r28s) TOOL. SPINDLE HEAD) qos) |ACE+HP5100(DHP-5000) Unit : mm(inch) TAPER GAGE LINE 5152028) | -400(15,75) 1751453) — FOOL x |senous — 9003543) ATC(Automatic tool changer) 2-18 HP51INES92. Each unit specification 2.4.6 Tool pot for Heavy Tools(Tool weight > 7.0kgf) The heavy tools must be storaged the assigned pots. The assigaed pots for Heavy tools is attached Number. Tag engraved red color figure. The assigned pots is a multful of 5. That is, The pot number for heavy tools is 5, 10, 15, 20, 25, 30, 35, 40, (45), (50), (55), (60)......- 'synbcl] Description Function 1 |ToolPot — |—Too! storage 2 |PotTag | Experssion pot number Pot Guide & chal — Guide for pot chain (NOTICE) 'f you want to use a unassigned pot for heavy tool, you must be followed as belows. 1, Setting K15.1(0 1) 2.Use “M27” command ex) M27 “T code" Mos; If a unassigned pots continously are used for heavy tools, you must command "M27" code every time before changing of heavy tool. ATC(Automatic tool changer) 2-19 HP51INES92. Each unit specification 2.5 APC(Automatic pallet changer) ‘APC is attached to the front of machine and make it possible to load/unload workpiece and to change pallet fast. Sol. valves for APC action control are attached the rear side of APC left side bracket. [Symtel] Desorption Function — Execution of pallet change 1 |CHANGER |— Changer up/downirota- tion by HYD. cylinder BASE & |—Workpioce eet up 2 |ROTARY |- Pallet 0*/90%180°/270° PLATE rotation i = Confirm the pallet change| position 3. |STOPPER |- Confirm pallet 0°/90°/ 100°/270° rotation | manually Execute Pallet changer x [oumce Serta ne base.(180° rotation) HYD. CYL: |-Execution of changer Arm INDER 180° rotation Item Description Remark Page 25.1 | Main specifications ~ Spec. sheet 2-21 25.2 | Changer arm swing area = Swing area 2-22 253 | Max. workpiece = Workpiewe size 2-23 APC (Automatic pallet changer) HP51INE592. Each unit specification 2.5.1 Main specifications -ACE-HP4000(DHP-4000) a | Number Of Pallet EA 2 more than 7 Type Rotary shuttles Pallet Change Time” sec 60 more than 20 Max. Workpiece Weight kat 500 Max. Workpiece Size ‘mm(inch) eases aaron “X Axis: Any position ‘APC Change Position +Y,Z Axes : Second reference point. “BAxis _ :First reference point Pallet Rotation Index Manually 80° [NOTICE] “1 : APC time on the specification have Max 10% allowance. Number Of Pallet EA more than 7 Type Rotary shuttles Pallet Change Time" sec 69 more than 20 Max. Workpicoc Weight kof 500 Max wonnece ste | men) |g bes (asin) “X Axis: Any position APG Change Position +Y,7 Axes * Second reference point “BAxis First reference point Pallet Rotation Index Manually 90° [NOTICE] “1: APC time on the specification have Max 10% allowance. APC(Automatic pallet changer) 2-21 HP51INE592. Each unit specification 2.5.2 Swing area of changer arm Unit : mm(inch) Workpiece dia. (WD) 600(23.62) 800(31.50) ‘Arm swing dia. (SD) 1,400(56.69) 1,830(72.05) Pallet center from APC center (L) 420(17.72) 515(20.28) APC(Automatic pallet changer) 2-22 HP51INE592. Each unit specification 2.5.3 Max. workpiece Size Unit : mm(inch) ‘Workpiece weight. (h) 800(31.50) 1930(36.61) Workpioce dia. (D) 600(28.62) 800(31.50) Zstroke 600(23.62) 750(29.53) If HYD. Fixture line is installed, Max workpiece size can be changed. APC(Automatic pallet changer) 2-23 HP51INE592. Each unit specification 2.6 Air service unit 2.6.1 Main specifications This device regulates and makes clean the compressed air used as power source or for cleaning of machine. = To regulate and ini 1 | Regulator | tain specified pressure —Toindicate pressure —To remove foreign matter 2 | iter unit | in air = To extract moisture in air | Ping & | - To supply airto operated Block dovioes 4 | Pressure | To detect air pressure Switoh down = To supply air to total 5 | Main Airsol | ~ 7 SuPpIY arto foal machine Inpul Pressure: kglfon(@bin) 5 ~7.5 (73.5 ~ 110.25) Output Pressure kgtfem*(ibfin.2) 5 (73.5) Consuming Volume Nuimin(us gal/min) 330 (87.19) Air service unit 2-24 HP51INE592. Each unit specification 2.7 Lubrication unit The lubrication unit supplies lubrication oil to LM guide and ball-screw bearings. The pres- sure switch and float switch is installed in it for safety. ‘symoo! | Description Function 1 Pump To extract oil 2. | Tank =To store ol 3. | inlet Fiter | —To fiter oil poured in 5 alee - To sippy oil to each 5 | Presue = To detect oil pressure Switch supplied 6 | Float Switch | - To detect oil level 2.7.4 Main specifications Item Unit Specification Tank Capacity US. gal) 4,6(1.2152) Pump Motor Power KW(Hp) 0.02 (0.03) Pressure kgt/em(psi) 16 (235.2) Flowrate. cc/min(gpm) 0.2 (0.00005) Distributor Type Metering Pumping Interval, sec 240 Pumping Time sec 30 Oil Type G68 Oil Lubrication unit 2-25 HP51INE592. Each unit specification 2.8 Hydraulic power unit This device generates hydraulic power used to actuate hyd. cylinder & hyd. devices. It is 10 attached with pressure switch and oil fan for Europe CE regulation. 8 2 ‘Symool | __Desorftion Function 3 1 | Tank To store oil 2 | Pump = To extract oil 7 3 | Motor = Torun pump 4 | Inlet Fiter —To filter oil supplied =To filter suction oil 5 _| Suction Filter of pump 6 | Return Filter | - To fier return oi fl 7 | Pessure —To detect oil pres- Switch sure supplied To display oil pres- 8 | Pessure Gage | Pe 5 20239201 & sure supplies 9 | CoolingFan — | - To cool oil =To connest electric 10. | Terminal Box wire 2.8.1 Main specifications tem Unit ‘Specification Pump Motor Power kwinP) 2.2 (2.94) Tank Capacity 1(US gal) 42 (11.1) Pressure kgticm: (psi) 55 (782.3) Max. Flowrate min{gpm) 25 (6.6) Oil Type HM32 Oil Hydraulic power unit HP51INE592. Each unit specification 2.9 Oil cooler unit The oil cooler chills oil returned after circulat- ing and recirculates for spindle cooler. Symbol | Description Function 1 | Pump = To extract oil 2 | Tank =To store oll 3. | Fitor = To filter air for condenser 4 | Piping = To supply oil chilled 5 | Operation |—To set temperature Panel — Alarm indicate 6 |oiGage | — Display ot amount 7 [Pressure |—Display pressure of ol Gage supplied Item Unit Specification Circulation Pump Motor Power KW (hp) 0.4(0.5364) Tank Capacity 1(U.S gal) -40(10.5669) Oil Type FC10 Oil Cooling Position Spindle Head / Bell Screw Nut Compressor Power KW (hp) 1.4(1.4751) Cooling Capacity Keal/h 3,697 Oil cooler 2-27 HP51INE592. Each unit specification 2.10 Splash guard The splash guard maintains the clean circum- stances as it prevents coolant and chips from splashing away, and protects operator from unoccasional danger, and also, consists of doors and maintenance cover. 1 | Operator's To check cutting Door slatelinspect/clean = To loadiunioad 2 | APC Door workpioce ~To check machine a | pabbtwer state during loading = Protection of opera~ tor DF boo = To load tool into tool magazine 5 | Maiiénanae | ~To ceaninaiitaion Cover machine inside 2.10.1__| Main specifications = Spec. sheet 2-29 2.10.2 _| Safety switches for doors - Opt. = Funetion 2-29 Splash guard 2-28 HP51INE592. Each unit specification 2.10.1 Main specifications DOOSAN Infracore New 3 Tone Color Machine Color ‘APC Door : Gray(Munsell #7.5pb 7/10) Others : Beigo(Munsell # N-8.25) Covering Type Round Shaped Full Enclosure Splash Guard 2.10.2 Safety switches for doors This devices generate alarm and operation prohibition signals for safety according to door openiclose states, and are cortificated with “CE regulation” in Europe. ~ Door locking in auto. operation Switches for + When door poen during manual poeration operator's door 1. ATC, APC, spindle operation impossible 2. Rapid feedrate impossible ‘Alarm When door open state Swilches for ATC door | 4. Tuol change impos 2. Magazine rotation impossible ‘Switches for APC door | « Pallet change impossible when door open le Splash guard 2-29 HP51INE592. Each unit specification 2.11 Name plates They show machine name, safety precautions and hyd./pneumatic diagram, so user are care- fully observed and fully understood before operating machine. = 5 3 4 Machine Name = To indicate machine name DOOSAN Infracore 2 = DOOSAN Infracore symbol mark Logo 3 Safety Precautions ~ Safety precautions 4 Machine Layout = To show position of motor, pressure switch, safety switch 5 Operation precautions | — Operation precautions Name plates 2-30 HP51INE59,2. Each unit specification 2.12 Coolant & chip devices They consist of the device to supply coolant into cutting space for smooth cutting condition and the device to manage chips, and have var- ious selections like T-S-C, shower, etc. as optional specifications. ‘Symbol | Description Function 1 | Pump = To extract coolant 2. | Tank ~To store coolant ; ~To supply coolant Sa aaa into cutting space —To separate and remove chips from coolant Chip Conveyor = To store chips 5 | Chip bucket | extracted from chip conveyor Ttem Description Remark Page 2.12.1. | Main specifications = Spec. sheet 2-32 2.12.2 _| High pressure T-S-C device — Opt. Pump shape and spec. 2-33 2.12.3 _| High pressure T-S-C device — Opt. = Pump shape and spec. 2-33 2.12.4 | Middle pressure T-S-Cdevice— Opt. __| — Pump shape and spec. 2-34 2.12.5 | Shower coolant device — Opt. —Nozzle shape and spec. 2-34 2.12.6 | Chip conveyor — Opt. = Shape and spec. 2-35 2.12.7 | Chip bucket — Opt = Shape 2-36 2.12.8 | Coolant gun — Opt. — Shape and spec. 2-36 2.12.9 | Oil skimmer = Shape 2-37 2.12.10 | Screw conveyor — Shape and spec. 2-38 Coolant & chip devices 2-31 HP51INE592. Each unit specification 2.12.1 Main specifications ltem Unit Specification Flood Goolant | Type FLOOD MACHINE FLUSHING / Pump Immersion Type Machine 1 Fiushing | Tank Capaaiy | 46! gay Sid, tank 650(171.8) Filtration mesh 30(Screen filter) Output KW (hp) 15(2.01) 0.9(1.21) Max. Pressure oD 7(120.87) 4.5164) ‘min Max. FI ax. Flowrate | gy 30(7.9) 30(7.9) T$-C Cool | Type None eae Middle ant System Pressure Pump Piston | Diaphragm | Trochoide Type Rotor: 1 Sid, Coolant | Std, Coolant Tank 400 (106) rank Capacity | (ys, ga) 108 eas oa mesh 5 10 Dual bag fiter)| (ag fe Fiteration Sane | rmansur | (Gag Fiter) | with clossing | with clossing alarm alarm Output kw (hp) 3.7 (4.96) 1512.0) Max. Pressure aon 70 (1029) 20(297) min Max Flowrate | (J 20 (5.4) 20(5.4) ; : 7 : Goolant tank Capacity rasta 690(171.8) Oil Type User define Coolant & chip devices 2-32 HPS1INE592. Each unit specification 2.12.2 High pressure T-S-C(Through spindle coolant) device - Optional specification It consists of extra tank and filter unit, and the followings are the general specifications rec- ommended item Unit | Speciication 1 Tank Capacity (US.gay} 40 (108) Pump Motor Power | kW(hp)| 3.7 (4.96)"1 Pressure(Max.) | 9!°™| 79 (4999) (psi) min Flowrate(Max.) ae ‘Suction Filter Type Strainer Line Filter Type Bag fiter Recovery Pump Immersion Type (Oil Skimmer 25w 220v NOTICE} *1- The recovery pump is installed on coolant tank of machine. 2.12.3 High pressure T-S-C(Through -spindle- coolant) device-Optional specification It consists of filter unit, and the followings are the general specifications recommended. TEM UNIT | SPECIFICATION Pump Motor Power kW. 3.7(4.96) Pressure(Max) kaficm:| 70(1029) Flowrate(Max.) | timin 205.3) Pump Type Diaphragm : 25 (Bag Filter) Line Fitter Type | sa with clogging alarm Recovery pump Immersion type Coolant & chip devices 2-33 HP51INE592. Each unit specification 2.12.4 Middle pressure T-S-C device - Optional specification It consists of std. coolant tank and filter unit the followings are the general specifications reco- mmanded. tem Unit | Specification Pump Motor Power | kW(hp) 1,5(2.0) koticm= Pressure(Max. 20(284) vax) | (284) min Flowrate(M: 20(5.3) lowrate(Max.) (apm) (5.3) Pump Type Immersion Type Fitter Type Bag filter 2.12.5 Shower coolant device - Optional specification As the device for cleaning the finished work- piece with large volumn coolant, the followings are the specifications recommanded. item Unit |” Specification Tank Capacity STD. Coolant tank Pump Motor Power |kW(hp)| _1.5(2) Filteration mesh | 30(Screen fiter) kglione Pressure(Max.) (psi) 1.5(21.33) Umin I () Flowrate(Max.) | (gprq) | 200(52.84) Pump Type Immersion Type Coolant & chip devices 2-34 HP51INE592. Each unit specification 2.12.6 Chip Conveyor - Optional specfication 1) Std. Chip Conveyor 2) Drum Filter Type Chip Conveyor The chip conveyor as optional specification which extracts chips outside of machine pro- vides more convenient management of chip cleaning ‘Symbol Description Function 1 | Outlet — Outlet of chip 2 | Motor = Driver 3 |OperationBox | - Operation device Chip conveyor as optional specification which ‘extracts chips outside of machine provides more convenient management of alumium & fine chip cleaning, ‘Symbol | Description Function 1 | Outlet = Outlet of chip 2 Motor — Driver 3 [Operation Box | - Operation device 4 [Coolant pump | Cleaning drum iter Coolant & chip devices 2-35 HP51INE592. Each unit specification 2.12.7 Chip bucket - Optional specfication To store chips extracted from chip conveyor temporarily and to remove those easily, cast- ers, rotating device and drain plug are installed ‘Symbol Description Funotion 1 [Caster = To move bucket 2 | Locking Device | To lock rotation To di i = To drain oil on 3 Dr Ph cme the bottom 2.12.8 Coolant Gun-Optional specification As the device for removing chips from the fin- ished workpiece and fixture manually without additional pump, the coolant gun is used in ‘common with flood coolant pump. [sw aa Description Function - To control the Coolant Gun extract of coolant — To supply the 2 | Coil Hose Pe coolant 3 | Pocket ~ Insert coolant gun 4 | Pump = To supply coolant Coolant & chip devices 2-36 HP51INE592. Each unit specification 2.12.9 Oil skimmer-Optional specification Belt-type oil skimmer which is basically com- posed of motor, wiper blade assembly, tail pul- ley and skimmer belt is mounted on the coolant tank for removing lubricating oil from the surface of the cool ant liquid. The belt is operated to pick up lubricating oil from the mix- ture in the coolant tank. Lubricating oil is subsequently scraped off the. both side of skimmer belt with wiper blade and discharged into a collection container. Oil skimmer by itself can achieve the desired level of coolant purity. Coolant & chip devices 2-37 HP51INE59,2. Each unit specification 2.12.10 Screw conveyor It consists of geared motors and screw con- veyor on rightleft side of bed and remove chip and dust from machine inside. Symbol] _ Desorption Function Geared motor | Drive Sores 2 mw = Chip removal Conveyor ~To guide screw 3 | Guide plate conveyor = Outlet ofChip & 4 | Screw pan coolant 2-38 HP51INE59 Screw conveyor device2. Each unit specification 2.13 Electric devices canes 5 As the device to supply main power and to operate machine, please refer to operation manual to know how to operate. eo | — Electric Is insic 1 | Bet an power cnecton Cabinel ‘supply. = Operation of machine/ > (Main oP | programming Devices | ~ To consist of monitor and op. devices 3 Ae = Manual operation for ATO OP. Planel_|-To maintain/agjust of ATC 4 APC = Manual operation for OP. Planel APC 5 | Work Light | - To light inside of machine [Operator] To indicate alarm CallLamp | state Electric devices 2-39 HP51INE59,2. Each unit specification 2.13.1 Main specifications Please refer to extra documents for NC specification. Item, Unit Specification Phase PH 3 Electric Power Volt v 220 300 4 440 Supply Frequency Hz 60/50 Power KVA 65 Monitor Size Inch 9.5" Mono LCD /10.4" TFT Color LCD Panel Language EnglishiCE MPG Type’ Portable VO device RS2320 Output Voltage Vv 220 ae a — a lamp Operator Type Signal lower 3-Color Call Lamp Number FA 1 Electric devices 2-40 HP51INE592. Each unit specification 2.13.2 3-color operator call lamp Greenyellow-red lamp indicates accurate machine state easily. Color Condition Green ‘Automatic operation Yellow Program stop Red Alarm state -<3-color operatior call lamp installation example> 2.13.3 Extra transformer - Optional specification itis available as optional specification accord- ing to user's power souroc. The extra transformer is installed the rear of machine. Electric devices 2-41 HP51INE592. Each unit specification 2.13.4 Air conditioner for electric cabinet - Optional specification When the machine is used in warm environ- ment, this device regulates the temperature inside of electric cabinet in order to prevent the des 1s from malfunction because of tempera- ture fluctuation, as optional specification. «Air conditioner for electric cabinet installation example> Electric devices 2-42 HP51INE593, Transport-Installation & Preparation for operation 3. Transport-Installation & Preparation for operation In this chapter, works needed in each process from selection of machine location to final leveling are explained. The following contents are steps of each process, and only maintenance staff(or each mechani- cian and electrician) performs each works. [RCAUTION 1. Please fully understand mechanical and electrical specification before installation. AACAUTION) 2. Please contact our service with points which are not clear. Item Description a Remark Page 21 _ | Selection of machine position ~ Checking environment a-1 Maintenance space 3.2 | Foundation plan = Machine foundation’ 3-2 3.3 _| Transportation Machine transportation 3-6 3.4 | Proparation bofore machine arrival | ~ Conf the preparation a8 —Airfpower line 3.5 | Installation ~ Adjusting leveling block 3-9 = Power connection 3.6 | Connection of ait and 3-11 connection of ait and power a 3.7 _| Disassembling of fixture and cleaning | - Disassembiing of fiture and cleaning | 3-12 = Separated parts for deliver 3.9 _ | Reassembling rest devices aratee P 3-13 ~ Optional accessories chock 39 | Oilsupply — Filling oll each tank 3-14 3.10 | Final leveling ~ Static accuracy check 3-14 Trabsoort Installation & Preparation for operation 3-0 HP51INE593, Transport-Installation & Preparation for operation 3.1 Machine location (CAUTION) 1) To determine the machine location, avoid the place where it is under the direct sun-light, the heat, the severe variation of temperature and dusty. And also, avoid vibration, but if inevitable, take care of the influence on the machine. (ACAUTON] 2) Be careful of maintenance allowance space during installation The space for opening doors of electric cabinet and for chip conveyor is important especially. Machine location 3-1 HP51INE593, Transport Installation & Preparation for operation 3.2 Foundation plan (ACAUTION | is ideal that the foundation is completed 2 months ahead before the machine itself installation, and please check each part according to the drawing below. 3.2.1 ACE-HP4000(DHP-4000) Foundation plan 1) Lay-out MACHINE REAR, mmiinch) || g fl MACHINE FRONT 1. Make necessary piling work and arrange rubbles properly according to the state of soil at the installation cite, [NOTICE | 2. Make adequate steel bar reinforcement to the foundation. [NOTICE] 3. As an anti-shrinkage additive to the concrete we recommend “nonshrink” or “embeco” LNOTICE| 4. Wiring from power source to the machine must be performed by customer. (NOTICE | 5. Air piping to the machine may be done with rubber hose and coupler. ‘The rubber hose(size : @8) must be prepared by customer. Foundation plan 3-2 HP51INE593, Transport Installation & Preparation for operation 2) Detail Unit : mm NECESSARY STRENGTH OF GROUND WMWWAWE | 475TonIne FOUNDATION SURFACE “* FLATNESSILEVEL) OF INSTALATION within One in) TOLER: | PITCH OF FOUNDATION | sci winston ANCE | ROITHOLFS within £200.) SIZE OF FOUNDATION BOLT HOLES +HOmm(.4in) 0072151 | BOLT, HEX HEAD 'S5001101 | WASHER, PLANE (40021 154A] SCREW, ADJUSTING| (040021164 [NUT, ADJUSTING (051031394 [PLATE (C40021183.[ANCHOR, FOUNDATION o]a]slele]— WM: NETWEIGHT OF MACHINE 14.5 TON WW: MAXIMUM WEIGHT OF WOEK PIECE 1.0 TON WF : WEITHT OF FOUNDATION SPECIFIC (GRAVITUY 2.4) 17.8 TON CONCRETE TA2nt NON-SHRINK otg ceEMENT aramorTaR — | 0.184ne ‘94g SAND 254g POWER SOURCE CAPACITY | WAIN MOTOR 2218 5KW(65KVA) Per ero m0s29, (OUTER DA 0005, HERD 0 Foundation plan 3-3 HP51INE59,3, Transport-Installation & Preparation for operation 3.2.2 ACE-HP5100(DHP-5000) Foundation plan 4) Lay-out Unit: {neh MACHINE REAR, MACHINE FRONT . Make necessary piling work and arrange rubbles properly according to the state of soil atthe installation site. {NOTICE| 2. Make adequate steel bar reintorcement to the foundation. [NOTICE] 3. As an ant [NOTICE] 4. Wiring from power source to the machine must be performed by customer. [NOTICE] 5. Air piping to the machine may be done with rubber hose and coupler. The rubber hose(size : @8) must be prepared by customer. A hrinkage additive to the concrete we recommend “nonshrink” or “embeco” Foundation plan 3-4 HP51INE593, Transport Installation & Preparation for operation 2) Detail Unit : mm NECESSARY STRENGTH OF GROUND WM Ws WE 5.25Tonine rd MORTAR s1cONCRETE FOUND ON GUIPACE © FLATNESS(LEVEL) OF INSTALATION iin #10mm(04in) TOLER: | PITCH OF FOUNDATION | sNGLEwitin:tOnn(04i SECTION ADA ANCE | ROITHOLES win £200 4in) ‘SIZE OF FOUNDATION BOLT HOLES 10mm(04in) WM: NET WEIGHT OF MACHINE 14.5 TON WW: MAXIMUM WEIGHT OF WOEK PIECE 1.0 TON. WF : WEITHT OF FOUNDATION SPECIFIC (GRAVITUY 24) 178TON CONCRETE 7.40nt ‘A410 HOLES ‘0072151 | BOLT, HEX HEAD 12 '$5001101_| WASHER, PLANE 12 (400211544) SCREW, ADJUSTING 2 (49021164 | NUT, ADJUSTING 12 (cowsiss4 [PLATE 7 (40021183 | ANCHOR, FOUNDATION 12 ‘2nd MORTAR o2im NON-SHHINK 106kg CEMENT 106k SAND Pag POWER SOURCE CAPACITY [MAIN MOTOR 22/18 SKW65KVA\] FL re, EZ (osnsxasza)| ~~" (OUTER OIA O505,NERON 05206) Foundation plan HP51INE59,3, Transport-Installation & Preparation for operation 3.3 Transportation 3.3.1 ACE-HP4000(DHP-4000) 1. Transportation of this machine is possible with forklift or overcrane, but be sure to use more than 13,500kg{(29,767.5ibf) as nominal load for safety. (AVARHING) 2- When using overcrane, the evacuation height more than 6m is needed. WR ROPE - more than 6,000rm (237 821 He tong 6,000mIm 6.000mm 1.500401 one Transportation 3-6 HP51INE593, Transport-Installation & Preparation for operation 3.3.2 ACE-HP5100(DHP-5000) 1. Transportation of this machine is possible with forklift or overcrane, but be sure to use more than 15,000kgf(33,075ibf) as nominal load for safety. 2. When using overcrane, the evacuation height more than 6m is needed. WIRE ROPE more than 6:000mm (237 52h) Ite ene 6,000rn © 550mm 8:00mm (e3.075t) ae Transportation 3-7 HP51INE593, Transport-Installation & Preparation for operation 3.4 Preparation before machine arrival Refer to machine installation area, plase prepare the air and power source up to machine. 3.4.1 Preparation of 2nd mortar The followings are quantity of 2nd mortar necessary for foundation. (Itis ideal quantity, so it is proper to prepare 20% more) Quantity of foundiation material Model ‘ACE-HP4000(DHP-4000) ‘ACE-HP5100(DHP-5000) ‘Cement ‘94kg 106kg ‘Anti-shrinkage 94kg 106kg Sand 254kg 286kg [ANCHUTION) Anti shrinkage can be selected among Non shrink(grout type), Embeoo and Tascon. 3.4.2 Preparation of parts for temporary leveling When the machine is installed on the foundation, itis necessary to level temporarily with using shim plates and flat plates. Please prepare approximately flat ( []100x80t and’80x80t) each 12sets and shim plate (80x150x100tx601) 6set showed in the following figure. Unit : mm Flat plate 1 100x201 oO] eoxeot 10041 58) Shim plate Preparation before machine arrival 3-8 HP51INE593, Transport-Installation & Preparation for operation 3.4.3 Preparation of air and power source Refering to 3.2 and 3.6, Please prepare the air and power source up to the machine. 3.5 Installation 3.5.1 Temporary leveling 1) Lay down machine on the floor with foundation bolts assembled [NOTICE] 1. Please reter to 3.2 for toundation bolts assembly. 2) Level temporarily the machine with the parts described in 3.3.2. The absolute level should be less than 0.05mm/m when the level gage is laid on pallet. Installation 3-9 HP51INE593, Transport-Installation & Preparation for operation 3.5.2 Filling mortar in anchor bolt holes 1) Face roughly the surfaces of anchor bolt holes, and moisten them more than 12 hours, and finally extract water out just before filing mortar. [ACHUTION, 1. Moisten more than 24 hours if concrete has been set more than one month. NOTICE] 2 This work makes bonding and flowing characteristics of mortar better, and prevents it from being dry too fast. 2) Fill the mortar into anchor bolt holes The weight proporton of (coment : anti shrinkage 27 additive : sand) is 1 : [NCHUTION) 1 Because anti-shrinkage additive expands approximate 3 hours later, this work should be completed within 30 minutes ~ 1 hour. [/NCAUTION 2. Sand should be dry and nice, and should not contain mud, dust and salt. (A\CHUTION) 3. Composite sand, anti-shrinkage and cement properly, and apply water. Al this time, be careful to absorb water into composition. (RCAUTION) 4. The proportion of water : cement is 1:2. 5. 10~21°C is the proper working temperature. 8) After filing mortar, stir it Up with stick or pipe Using pipe is more recommended to extract air absorbed in mortar. 4) Prevent air from permeation by filing from one direction. 5) Be sure to turn off the near machines to avoid the influence of vibration during working. 6) Reinforce the naked surface of mortar for 2~3 days with water. More term makes more strength. Installation 3-10 HP51INE593, Transport-Installation & Preparation for operation 3.6 Power and air source connection 1) Power source connection [ACAITION) Perform the cabling from factory main source to machine electric cabinet. [NOTICE] Power inlet po: 1 Power capacity : 6SKVA ion is at the lower part of electric cabinet as showed in 3.2. ® Allowable fluctuatior 10% [NOTICE] Voltage regulator is necessary when the fluctuation exceeds the above allowance. And be careful to isolate electrical noise sources from same power source, such as electric welders or electric discharge machines. 2) Air source connection Perform the piping from air source to air service unit in the rear of machine. [AVARNNG) 1. Use of inner diameter 29 hose and hose band. \AIRHOSE (AVMRNNG] 2. Be sure that the pressure of air source is 5.5~7.5kgf/em? eee PACAUTION| 3. Use clean ang dry air without mois- ture. Use air dryer, if necessary. Power and air source connection 3-11 HP51INE593, Transport Installation & Preparation for operation 3.7 Disassembling of fixtures & cleaning of machine Q) Each axis is clamped with fixtures for safety in delivery. Therefore, be sure not to operate the machine without disassembling these fixtures. After disassembling fixtures, clean the anti-corrosion oil on the machine with wash oil or gasoline if not designated by factory, and lubricate the cleaned parts. At this time, be careful not to use improper oil which can affect paint on the machine and be careful to avoid fire. The figure below shows the position of each fixture(red color painted parts). Disassembling of fixtures & cleaning of machine 3-12 HP51INE59,3, Transport-Installation & Preparation for operation 3.8 Reassembling of rest devices Alter finishing disassembling fixtures, reassemble the separated devices for transportation. 1) Connectors The electrical connectors are located at the lower part of electric cabinet and in the rear of the machine, and they are showed in left fig- ure. ‘Symbol Description Connection for chip conveyor and coolant devices. 1 2) Coolant tank & chip conveyor (1) Push-in the coolant tank with chip conveyor on, taking care of the coolant outlet position in the bottom of splash guard. Bad positioning results in coolant leakage. (2) Connect the piping connector for coolant pump. Also connect the piping connector for T-S-G recovery pump, shower pump if attached. 3) Reassembling of operator call lamp Check the tap pi n for lamp, and then assemble. 4) Reasmsembling of optional devices Check their position and state, if any devices are attached. Reassembling of rest devices 3-13 HP51INE593, Transport-Installation & Preparation for operation 3.9 Supplying oil Before the operation, fil the tank with proper oil up to the ‘H’ mark on the oil level gage attached to the each tank. Please refer to 5.14 and Section 7 for recommended oil type, supplied position and maintenance of oil tank. 3.10 Final leveling and inspection After machine installation, please check finally the state of each part, refering to Factory control file and Section 5 Atthis time, because it needs machine operation, please fully understand those in Machine oper- ation manual before final inspection. Supplying oil 3-14 HP51INE594. Circuit diagrams and functions 4. Circuit diagrams and functions In this Section, circuit diagrams and functions of machine are illustrated for understanding machine action totally. Please refer to PARTS LIST and ELECTRIC CIRCUIT DIAGRAM, if necessary. The figure below is total circuit diagram. (AIRING) 1. Be sure to adjust each device refering to Section 7. 46 msenvice unir 4PNESEUNESHrTCH oro ‘SOL. VALVE 412 page Sic Gus PUMP MOTOR FRSA Shoo usu sueversuos PALLET LOCKRELEASE — Sniear 414 page Serva | jswrcH CLAMPIUNCLAMP | CHANGER UPDOWN, ) 48 CHANGER AFM FORTIN page noron - nsdn Soren ro ; wouNT 42 8S BEARING MOTOR, LM GUIDE | 4-16 page SMTOK Faxes system 9 PEW _ 'BALLSCREW NUT COOLING. 49 sEpage Lily 4d ms OILCOOLER ¢———} Too. cLAVPUNLANE > MOTOR COLLET AR BLOM, SPD ARMS 18 page SmircH™ | SPWOLEHEAD TrL000 cootanT. 180 ‘Ol JACKET . > 410 +1 page 4 cootanrunrr 4PM MOIO ‘Moro 43. Serva PALLET AR BLOW 419 page Siro 7 taste TABLE CLAMP/UNCLAMP 45 page @ ELECTRIC DEVICES, @ Refer to Electric diagram and Machine operation manual Circuit diagrams and functions 4-0 HP51INE594. Circuit diagrams and functions Circuit diagrams and functions 4-4 HP51INE594. Circuit diagrams and functions 4.1 Spindle head 4) Circuit diagram “OSBAR | @ , Blur uoroR cooune T AIR CURTAIN AIR PURGE (HTATSOP ROE UNS viftas | AR a1ow -— yy — [ BEARWE | {HOUSING COLLET AIR vane FLo00 ves 2) Functions Type | Symbol Description Function Noemal Motor | -MS1_ | Spindle motor To drive spindle OFF Valve | -YVit | Spindle tool unclamp ~To actuate tool unclamp OFF =YVi2 | Spindle air blow =o actuate spindle air blow OFF Yv1a | Collet air blow To actuate collet air blow OFF ‘Switch | -Sx11 | Spindle tool clamp = To detect tool clamp ‘ON =Sx12 | Spindle tool unclamp = To detect tool unclamp OFF Spindle head 4-2 HP51INE594. Circuit diagrams and functions 4.2 Axes system 4) Circuit diagram ‘ Axes system 4-3 HP51INE594. Circuit diagrams and functions 2) Functions Type _| Symbol Description Function Normal] Location’ Motor |-M21 |X-Axis servo motor —_| ~ To drive X-axis OFF | Bed =w22_ | Y-Axis servo motor —To drive Y-axis oFF | Column M23 _| Z-Axis servo motor =To drive Z-axis, OFF | Bed ‘Switch |-SL1.0 | X-Axis emergency! stop |-To detect X-axis emergency stop | ON =SL1.1 | X-Axis emergency2 stop |-To detect X-axis emergency stop | ON | Bed -SL1.2 | X-Axis reference point | - To postion X-axis reference point 812.1 | Y-Axis emergency stop |-To detect Y-axis emergency stop | ON | —Spndle =SL2.2 | Y-Axis reference point —_|-To postion Y-axis reference point | * | Head Body ~SL3.1 [Z-Axis emergency stop _|~To detect Zanis emergency sep | ON | le -SL3.2 | Z-Axis reference point | -To postion Z-axis reference point | * (AVARNING 1. Switch for reference point return On the reference point return of cach axis, the machine is decelerated when this, switch is “OFF” at about forward 65mm from the reference point. and stops at exact position due to stop signal after this switch "ON". The shift of grid signal makes the machine stop at reference point exactly, and its adjustment is in Sec- tion 7. (AURING) 2. Switch for emergency stop The emergency stop position is set at 8mm outside from both ends of the stroke range When the machine goes over stroke range and this switch is actuated, emer- gency stop state occurs. 3. As double safety device, over travel(OT) function is adapted. The OT position is set at 1mm outside from the both ends of the stroke range, and the feedrate stops immediately and alarm message Is displayed when the machine goes over this range. Axes system 4-4 HP51INE594. Circuit diagrams and functions 4.3 Table 4) Circuit diagram a 2) Functions Type _| Symbol Description Function Normal Motor. |-MB | B-Axis servo motor ~To drive B-axis OFF Valve |-Yvet | Table unciamp = To actuate table unclamp OFF =Yve2 | Pallet unclamp = To actuate pallet unclamp OFF ~Yv63 | Pallet air = To actuate pallet air blow OFF =yvo2 | Air Source = Air Source ON/OFF ‘ON Switch | -SL62_| Table clamp confirm = To confirm table clamp ON =SL64 | Table unclamp confirm ~ To confirm table unclamp OFF ~SP61 | Pallet clamp check = To check pallet clamp ON Table HP51INE594. Circuit diagrams and functions 4.4 ATC(Automatic Tool Changer) & Tool Magazine 4.4.1 ATC(Automatic tool changer) 1) Circuit Diagram 2) Functions = mm Type | Symbol Description Funetion Normal Motor | -M81 | Tool changer motor = To drive tool changer OFF ‘Switch | -Sx53 | ATC CAM tool home =To detect tool home: ON =SD55 | Locking pin out —To tool release OFF S056 | Locking pin in = To tool rocking ON ATC(Automatic tool changer) 4-6 HP51INES94. Circuit diagrams and functions 4.4.2 Tool Magazine 1) Circuit Diagram <40/60 Tool Magazine> ATC(Automatic pallet changer) 4-7 HP51INES94. Circuit diagrams and functions Po] aro D0R . j sauew aon | “ESS sonouesie & umcamesoe FOTUNANP j Razed (686 | Sosa ey 1 joss —tH sod ti) + Peo 2 Ue Porcini i S| som Sen 8 : io | ATgagon L | | IXRS LIZ | | ae vist 59 war | vee] ee | o ; | || an | | wa IOSD ATC(Automatic pallet changer) 4-8 HP51INES94. Circuit diagrams and functions 2) Functions Type | Symbol Description Function Normal ~YV54 | Waiting pot magazine side | - To move waiting pot to magazine side | ON =Yv53 | Waiting pot spindle side = To move waiting pot to spindle side | OFF Valve |—Yv51 | ATC door open —To open APC door OFF -Yvs2 | ATC door close —To close APC door ON =YV3/_ | Tool pot clamp/unciamp. = To clamp/unclamp tool pot OFF —SX36 | Tov! pol delect — Te detect lool pol of wailing pol OFF §D33 | Tool pot unclamp confirm To confirm tool pot unclamp: ON =$D32 | Too! pot clamp confirm —To confirm tool pot clamp OFF ‘Switch | -SX5A | Waiting pot spindle side detect | — To detect waiting pot spindle side | OFF -SX5B | Waiting pot magazine side detect | ~ To detect waiting pot magazine side | ON. =SD52 | ATC door close detect ~ To detect ATC door close ON =SD51 | ATC door open detect —To detect ATC door open OFF Motor | -M11_ | Tool Magazine Motor ~Totum magazine OFF ATC(Automatic pallet changer) 4-9 HP51INES94. Circuit diagrams and functions 4.5 APC(Automatic Pallet Changer) 41) Circuit diagram wow sa ia Be i See | 5x05 [ ta): J\e7 ww || 8 Same a | Beer 5 N ABM CONE we Salle alla j a weer) iesbom, ee ya, “Si - sey vee a YVE5: . AAT ES NIE HP51INE59 ATC(Automatic pallet changer) 4-104. Circuit diagrams and functions 2) Functions Type | Symbol Description Function Normal Valve |-YV65 | Setup rotating stopper —To release setup stopper ON = v6 | APC alr blow —To blew APC corn air OFF =YV75 | APC up = To actuate changer up OFF —Yv76 | APC down —To actuate changer down ON - YV73 | APC ARM CW rotation ~To actuate changer arm cw rotation | OFF ~YV74 [APC ARM CCW rotation | ~To actuate changer arm cow rotation | OFF ‘Switch |= SX75 | APC pallet No.1 detect =To detect No. 1st pallet ON = 8X76 | APC pallet No.2 detect = To detect No. 2nd pallet OFF — Sx81 | APC up detect ~To detect changer up OFF — SX82 | APC down detect =To detect changer down ON =SL81 | APC locking detect —To detect APC setup ref. position | ON ATC (Automatic pallet changer) 4-1 HP51INES94. Circuit diagrams and functions 4.6 Air service unit 4) Circuit diagram MAG. HOSE TABLE HOSE AIR (6.5kgH/em; 330NLimin) 2) Functions Switch | -SP12 | Air pressure check ~To detect air pressure down OFF valve | -Yvoz | Air source = Air source ON/OFF ON Air service unit 4-12 HP51INE59,4. Circuit diagrams and functions 3) Air diagram of std. machine sess cow oa = oll L F ates MAIER = “AIERS vies vie : mua Q wes : = lie os-tow 3, Ba? | ots, eee Bot > yi ‘NR CURTANN (6skglem’ ani) | Air service unit co ROT UNON som RRIPUBE SPINOLE AR COWECT AR HP51INE594. Circuit diagrams and functions 4.7 Lubrication unit 4) Circuit diagram 2) Functions ‘Type | Symbol Function Normal Motor |-M51 | Lubrication pump motor —To extract lub. pump OFF ‘Switch SPI LUB. pressure — To detect oil pressure down ON =82 | LUB level To detect oil level down ON Lubrication unit HP51INE59,4. Circuit diagrams and functions 3) Lub. diagram of std. machine [ 3 stands for 0.03 ce/shot(4min. term) 6 stands for 0.06 cc/shot(4min. term) Lubrication unit 4-15 HP51INE594. Circuit diagrams and functions 4.8 HYD. power unit 4) Circuit diagram 2) Functions Type | Symbol Description Function Normal Motor | -M31 | Hydraulic pump motor —To generate hydraulic power | ON Switch |-SP01_| Hydraulic pressure check ~To detect oil pressure down | ON HYD. power unit HP51INE59ions d functi ircuit diagrams an 4.C 3) HYD. diagram of std. machine weld LINN #3MOd ‘OAH <5 a mower ‘arcane Joram Seon oa Sa sagas ans A. 1a XI I) x ee [Ff 1 C ayo 4-17 HP51INE59, HYD. power unit4. Circuit diagrams and functions 4.9 Oil cooler 4) Circuit diagram 2) Functions Type _| Symbol Description Function Normal unit | -w7t | Oilcooting unit =To chill oil for spindle cooling | ON ii cooler 4-18 HP51INE594. Circuit diagrams and functions 4.10 Coolant & chip devices 4) Circuit diagram (1) Flood coolant device (2) Machine Flusning coolant device - ‘COOLANT TANK "APG ARM Coolant & chip devices 4-19 HP51INE594. Circuit diagrams and functions (3-1) High pressure T-S-C device - Optional specification ' 5 eee | BO ik) § WC mnt [ 8 lh High pressure T'S-C tank Coolant & chip devices 4-20 HP51INE594. Circuit diagrams and functions (3-2) High pressure T-S-C device - Optional specification aR nn punce If High Pressure Coolant eo Pre sw Mt S 5 QF =e , i) ° zaie_IS BN ea ic pure sot < APG Switch > < ATC Switch > 2) Functions Switch | -S23__| Door open/Close Check ~To detect Main door open ON -S91 | Door open/Close Check = To detect APC door ON -S85 | Door open/Close Check —To detect ATC door ON Coolant & chip devices 4-25 HP51INE595. Periodic inspection 5. Periodic inspection In this section, brief and compact information just after installation is provided . In addition to the inspection items given here, there can be some other items which should be. checked according to the actual condition of the machine. Please make ad fional check sheet and schedule, if necessary. Re-adjustment and maintenance must be followed carefully by maintenance staff or our service man, if anything is observed by inspection. Be sure not to change setting and adjusting value without intention in any case. Contents tem Description ST S Remark Page 5.1 | Spindle head ~ Peridoc check point of each unit 5-1 5.2 | Axes system 5-2 53 | Table 5-3 5.4 | ATC(Automatic tool changer) 5-4 5.5_| APC(Automatic pallet changer) 5-6 56 | Airservice unit 5-6 5.7 | Lubrication unit 5-6 5.8 | Hydraulic unit 5-7 5.9 | Oilcooler 5-7 5.10 | Splash guard 5-8 5.11 | Name plates 5-8 5.12 | Coolant and chip devices 5-9 5.18 | Electric devices 5-10 5.14 | Peridoc check of oil = Oil supply diagram and comparative ol table | §— 11 Periodic inspection 5-0 HP51INE595. Periodic inspection 5.1 Spindle head ‘State | Tool unclamp device | Check and adjust ° TA Spindle orientation ‘Adjust stop position | O. ° Spindle drive key Check abnormal ° Spindle taper wearing ° Spindle RPM Check and adjust ° Input voltage of motor | #10% oO Bolts and connectors | Check connecting state fe} Funetion | Spindle rotation Manual operation | O | O Operation Spindle orientation | MDI operation o | 0 manual Clamp/unclamp Manual operation | O | O Position detector ‘Compare HPM oO Sol. valves action ‘Check DGN ° Switches action ° “ Oil supply | Moving parts. Apply grease ° Cleaning | Spindle taper Remove foreign ° Inside of cover substance ° Spindle head 5-1 HP51INE595. Periodic inspection 5.2 Axes system State | Check reference point | Check and adjust °o Static accuracy oO FOF Position accuracy ° Feedrate acciracy ° Slide cover ° Input voltage of servo-motors | 10% oO Bolts and connectors | Check connecting state fe} Oo Funetion | Switch action forret.point | Check DGN ° ° 42 Switch action for emergency ° ° Reference point returm | Manual operation | O | O OP manual Axis motion oO oO Cleaning | Moving parts. Remove foreign ° Inside of cover substance ° Axes system 5-2 HP51INE59,5. Periodic inspection 5.3 Table State | Check reference point | Check and adjust oO Position accurancy o FOF Pallet clamp ° Input vollage of servo motor | #10% ° Bolts and connectors | Check connecting state | O ° Function | Pallet clamp action | Manual operation | 0 ° 43 Sol. valve action Check DGN oO fe} Switch ction for emergency 0 ° Reference point retum |Manual operation | O | O B-Axis moving oO oO 43 ‘ll supply | Moving parts. CC320 oil oO oO Cleaning | Inside of cover Remove foreign ° ‘substance Table 5-3 HP51INE595. Periodic inspection 5.4 ATC(Automatic tool changer) and magazine Item Check point Remark ba Daily ale Annual | Ref.to state | ATC centering Check with jig | Oo ° Tool magazine Check position | O ° ‘Waiting pot stopping position ° ° Gripper ‘Check abnor- ° Taper in pot mal Wearing ° Key of pot oO Input voltage for moors | #10% ° Bolts and connectors __| Checkcomecingstae | O ° Function | Tool change action Manual operation | © | O Operation Tool magazine action ° ° manual Waiting pot moving action o | o Sol. valves action ‘Check DGN ° 4A Switches action ° Oil | Cam-follower for magazine ° 44 ‘Apply grease supply | Tool pot chain ° Cleaning | Changer arm gripper Remove ° Inside of pot foreign ° Waiting pot moving quide | Substance ° Tools ° Inside of cover ° ATC (Automatic tool changer) 5-4 HP51INE595. Periodic inspection 5.5 APC(Automatic pallet changer) ‘State. | APC Centering Check with Jig ° ° Up/Down stroke Check cylinder oO stroke Botts and connectors. | Creckeonnect: |g ° ing state Funotion | Change action Manual oporation| O | O OP manual Sol. valves action | Check DGN ° 45 ‘Switches action ° Cleaning | Surtace of changer _| Remove foreigh 0 Surface APC top frame | substance ° Inside of cover ° 41/U APC (Automatic pallet changer) 5-5 HP51INE595. Periodic inspection 5.6 Air service unit state | Pressure gage 5.5kgtiom: o | o 75 Oiler flowrate Sdropsimin. o [0 Pressure switch 3kgH/cm: (ORO) Pipings Air leakage o |] o 46 Bolts and connectors | Check state ° Funotion | Air blow for cleaning | ATC & APC o | o 46 Air regulator Check function ° 75 Oiler ° Pressure switch ° il supply | Oiler Level gage o fo Cleaning | tank tor iter device | Extract water o fo Filter for filter device | Cheok cleaning ° 5.7 Lubrication unit State | Pressure gage 16~20 katiom: o |} 0 76 Input voltage of motor | +10% ° Pipings Check leakage o | 0 76 Bolts and connectors | Check state ° Pump ‘Check action o | Oo Funation |! Sstrbuton Check state o | 0 47 Pressure switch ‘Check DGN ‘Operation Float switch manual Oil supply | Oil level gage Check level o | o 76 Cleaning | Oil fitter Check/cleaning ° Air service unit 5-6 HP51INE595. Periodic inspection 5.8 Hydraulic unit Pressure switch 20kgficm= oO fa} Input voltage of motor | #10% ° Pipings Checkieakage | O | O 77 Bolts and connectors | Check state ° ° Function | Pump action Check action o | o Pressure switch Check DGN oO OP manual Oil supply | Level gage Check state o | 0 77 Oil replacement ° Cleaning | Inside of tank Cleaning ° Inlet tilter Check/cleaning oO ‘Suction filter ° Return fiter ° 41 / US 5.9 Oil cooler Stale | Seling temperature | SV=03 78 Input valtage to device | +10% ° Pipings Check leakage o | 0 49 Bolts and connectors | Check state ° ° Device action Check state o | 0 Function OP panel Check function ° Oil supply | Level gage Check state of o 78 Oil replacement ° Cleaning | Filter Check/cleaning ° 78 [NOTICE] 1. Please refer to extra cil cooler instruction for detail check and maintenance. Hydraulic unit 5-7 HP51INE59,5. Periodic inspection 5.10 Splash guard State | Surface ot cover Check leakage oO oO Bolts and connectors. Check state oO oO Function | Each doors Open and close oO Safety switches for door | Check DGN o | 0 OP manual 5.11 Name plates Each nameplate Check state Splash guard 5-8 HP51INE595. Periodic inspection 5.12 Coolant and chip dvices ‘State | Input voltage to pump | +10% ° Coolant flowrate ‘Adjustment ° 79 Pipings Check leakage o | o 4.410 Bolts and connectors | Check state ° ° Function | Each pump Check action o | 0 Chip conveyor ° ° Coolant | Coolant priming Check stato ° 7.9 supply | Level gage ° ° Coolant replacement ° Chain for chip conveyor | Apply grease ° Cleaning | Inside ot tank ‘Cleaning oO Filter Check/cleaning ° Chip conveyor(Daily) | Manual operation ° Chip conveyor(Annual) | Disassemble ° Coolant and chip devices 5-9 HP51INE595. Periodic inspection 5.13 Electric dvices ‘State | Input voltage 110% ° Bolts and connectors: Check state oO Funotion | Each emergency stop switch | Check DGN o | o Operation OP. devices Check function | O ° manual Operator call lamp Check ONOFF | O | O Work light oO oO Fan of electric cabinet ‘Check action fo} fo} Cleaning | Inside of electric cabinet | Check state 41 /U Electric dvices 5-10 HP51INE595. Periodic inspection 5.14 Periodic check of oil 1) Oil supply diagram (Hy 1000 (1) FUNNNGHOURS 20 Ges Haz OL Fow0 ol 20981) suquagay ‘ssoga.) 1.5(04gat) Periodic check of oil 5-11 HP51INE595. Periodic inspection 2) Comparative oil table OIL TYPE ‘MOBIL OIL ‘SHELL OIL ESSO OIL, TOTAL, a VELOCITE TELLUS SPINESSO AZZOLA ° NO.6 C10 10 10 VELOCITE TELLUS AZZOLA Fo22 NO. 10 2 zs15 a DTE OIL TELLUS TERESSO AZZOLA LIGHT 32 32 32 DTE TELLUS NUTO AZZOLA HMg2 24 82 Hs2 z832 ‘VACUOLINE TONNA FEBIS DROSERA HG32 1405 32 K32 Ms32 DTE TELLUS NUTO AZZOLA HMa6 25 46 Has 7868 DIE TELLUS NUIO HM68 26 68 Hea a VACUOLINE TONNA FEBIS DROSERA 1409 T68 K 68 ses ces VACTRA TONNA FEBIS DROSERA No.2 68 K 68 mses pteo | ‘TELLUS TERESSO cB150 EXTRA HEAVY C150 150 200 VACTRA TONNA FEBIS DROSERA ~ NO.4 7220 kK 220 Ms220 MOBILGEAR OMALA SPARTAN CARTER cc820 632 320 EP 320 P320 x2 MOBILUX | ALVANIAGREASE | BEACON MULTIS EP2 EP2 EP2 EP2 [NOTICE] 1. The Oil types are samed as symbol and viscosity grades specifiod by ISO. (ISO VG No.) (ANCAUTION 2. Do not mix two type of oil. It decreases the machine performance and causes the accident. Periodic check of oil 5-12 HP51INES96. Check point against trouble 6. Check point against trouble In this section, brief and compact information for check point of each unit when its trouble is occured as any form provided. In adGition to the check points given here, there are some other items which should be checked according to the actual condition of the machine. Please make additional check sheet and sched- ule, if necessary. Re-adjustment and maintenance must be followed carefully by maintenance staff or our service man, if anything is observed by inspection. Be sure not to change setting and adjusting value without intention in any case. NOTICE) 1. 1 adjustment and maintenance is needed, please refer to Section 7 and operation manual. [NOTICE] 2. Please reter to operation manual for treating Alarm. Ttem Desoription Remark Page GA Spindle head — Check point of each unit on trouble G-1 62 Axes system 6-3 63 | Table 6-3 6.4 | ATC(Automatic tool changer) 6-4 6.5 | APC(Aulomatic pallet changer) 6-5 66 Air service unit 6-5 6.7 _| Lubrication unit 6-6 68 | Hydraulic unit 6-6 69 _ | Oilcooter 6-6 6.10 | Coolant and chip devices 6-6 6.11 _| Alarm list and solution = Alarm list and solution for alarm number | 6-7 Check point against trouble 6-0 HPS1INE596. Check point against trouble 6.1 Spindle head 1) Too! clampiunciamp trouble Item Check point Remark Reto Unclamp condition State and position of each part OP manual Air stato Supplied stato Hydraulic state Operation state Clampiunclamp device | Switch reaction 44 Position between Dog and switch Kicking distance on tool unclamp 05 7A ‘Storke of unclamp oylinder 4mm (OP manual Tool unolamp dro-bar stroke 5mm Tool clamp state Shake Tool unclamp speed Inside of spindle taper Foregnsibsance | Parts list Breakage of electric parts Conne Elec. diagram Breakage ot sol. valve 2) Spindle orientation trouble Hem "Checkpoint Remark Retito Parameter setting | Orientation stop variation NC paral ale Orientation device | Variation between stop position on CWICCW ‘Supporting bearings Paris list Breakage of electric parts Connection | Elec. diagram Airstate ‘Supplied state 3) Spindle drive trouble Item ‘Check point Remark Ref.to. Rotation condition _| Slate and position of each part OP manual ‘Shake on rotation Check its state FGF. ‘Spindle drive device | Supporting bearings Parts list Preload device state Motor overload OP manual Breakage of electric parts Connection | Elec. diagram Breakage of spindle motor Spindle head 6-1 HP51INE596. Check point against trouble 6.2 Axes system Initial condition Reference point return once ‘OP manual Lubrication’ Suppied state 87 Abnormal sound ‘Check Its position OP manual ‘Axes system ‘Switch reaction Position between Dog and switch Ballscrews state Parts lst Static accuracy FCF. Breakage of electric parts Elec. diagram Breakage of servo-motor 6.3 Table i a 7] Initial condition Reference point return once OP manual Air state Supplied state Hydraulic state Operation state ‘Abnormal state Check its part OP manual ‘Axes system Each switch action Position between dog and switch Table clamp/unclamp state Static accuracy FCF Breakage of electric parts, Gonnection | Elec. diagram Breakage of servo motor Pallet clamp device | Pallet clamp/unclamp state Air blow Renovefoein bse Each switch action Breakage of electric part Axes system/Table 6-2 HP51INE596. Check point against trouble 6.4 ATC(Automatic tool changer) 1) Tool change trouble Item Tool change condition ‘Check point State and position of each part Remark Refer.to OP manual Tool used Air state Diameter/lenghtweight Shank and grip part Pull-stud state | Supplied state Spindle head Spindle tool clamp/unclamp Orientation stop state Alignment with spindle head ‘Abnormal sound heck its part OP manual Tool changer Stop position of cam follower Center of track Breakage of cam follower Breakage/jam Moving parts Each switch action state Position between Dog and switch Changer arm stop position Parallel Tool shake on tool locking ‘Smoothness of tool release Release pin action Breakage of electric parts | Connection Breakage of changer motor Parts list Flee. diagram Motor brake reaction ‘Click’sound OP manual Servo motor action Connection Gear, reducting Servomotor manual ATC(Automatic tool changer) HP51INE596. Check point against trouble 2) Too! magazine rotation trouble Ttem Check point Remark Relto Magazine rotation condition | State and position of each part OP manual Tool used Diameter/enghvweight ‘Shank and grip part Pullstud state Waiting pot position Waiting pot position stop Air state ‘Supplied state ‘Abnormal sound Checkits part OP manual Tool magazine device ‘Servo. motor action connection | Servo. motor ‘manual Breakageljam of moving parts tach part | Breakage and deformation of pot ‘Shake of loaded tool Pars list Breakage of electric parts Connection | Elec. diagram Gear, reducting 3) Waiting pot moving trouble item (Check point Remark Ret.io Moving condition State and position of each part OP manual Air state Supplied state ‘Abnormal sound Check its part ‘OP manual Moving device Breakageljam of moving parts Gylinder action Waiting pot clamp/unclamp state Switch action Position between Dog and switch Breakage of electric parts Conection | Elec. diagram Breakage of sol. valve ATC(Automatic tool changer) 6-4 HP51INES96. Check point against trouble 6.5 APC(Automatic pallet changer) ttem (Check point Remark. Ref.to Pallet change condition State and position of each part OP manual Air state Supplied state Hydraulic state Operation part ‘Abnormal sound Check its part ‘OP manual Changer device Breakageljam of moving parts Each switches action Position between Dog and switch HYD. cylinder speed for changer up/down! ot. HYD. cylinder state for changer upidowr/Rol. Moving parts Stopping position of changer arm Pin and hole for positioning Foreign substance Parts list Breakaye of electric parts Connection Elec. diagram Breakage of sol. valve 6.6 Air service unit Item) Check point Remark Ref.to Air service unit Air leakage ‘Sound Each valve state 46 Supplying setting pressure 5.5kgfiom® Pressure switch setting value ‘Skgtiome Blocking of filter Extraction of water in fitter unit 75 APC (Automatic pallet changer) 6-5 HP51INE596. Check point against trouble 6.7 Lubrication unit Lubrication unit Float switch reaction Oil leakage in pipings ll supplied state Each valve state Check oil level Level gage Pressure switch reaction ‘Supplie pressure Pressure gage 6.8 Hydraulic unit Hydraulic unit Oil leakage in pipings 48 Check oil level Level gage 7 ‘Supplie pressure Pressure gage | (HUD power unit Prossure ewitch reaction i) 6.9 Oil cooler Oil cooler Gil leakage in pipings 49 Setting temperature 8V-03 78 Blocking of fier (Cit cooler Check oil level Level gage | ™aker manual) 6.10 Coolant and chip devices Coolant and chip | Oil leakage in pipings 4.10 devices Check oil level Level gage 79 Adjustment of flowrate Lubrication unit 6-6 HP51INE596. Check point against trouble 6.11 Alarm(ALARM NO.) list and solution 1) Emergency stop No. Contents Recovery 2001 | OP EMERGENCY PUSH BUTTON OR AXIS LIMIT SW OFF | - Release the EMG STOP. — Some EMERGENCY STOP push button switches in PB switch. operation panels are pressed. Release the limit switch by — Some emergency stop limit switches of X, Y, Z axes are EMG RELEASE PB switch. pressed Check the circuit. ~ Circuit short/PB or LS malfunction. 2002 | MAIN SPINDLE SERVO UNIT ALARM + Refer to main spindle unit — Disorder in spindle drive unit manual. 2003 | CIRCUIT PROTECT TRIP ~ Check the control power — Circuit protector(QF 14, QF15, QF21, QF22, QF23, (AC, DC) and circuit. QF27, QF28, QF81) is tripped. - Reset CP. — Circuit short 2002 | HYDRAULIC PUMP MOTOR OVERLOAD «Check the motor and = Motor of hyd. pump or head lub. pump is overloaded. overload relay. — Circuit breaker(QM31, QM32, QM36) is tripped. * Check the circuit. — Circuil short 2005 | HYDRAULIC PRESSUNE DOWN ALARM Check the hydraulic power — Hydraulic pressure is lower than the set value of unit pressure switch pressure switch(SP01(MAIN), SPF1 (Fixture)). 2006 | HYD. PUMP MOTOR NOT RUN + Check the magnetic relay. —Magnetle relay (KM31, KM32, KM36) for hyd. pump. motor malfunction. 2007 | SPINDLE STOP SIGNAL ALARM + Refer to spindle unit manual. 2009 | ATC SERVO UNIT ALARM. + Refer to the servo motor user manual 2010 | SPINDLE TOOL CLAMP COMMAND SWITCH ALARM * Check spindle tool clamp sig- nal(CLMD.M). 2011 | MAIN POWER PHASE FALUT « Check main power phase. 2015 | SPINDLE TOOL UNCLAMP ALARM + Check spindle tool clamp sia- nal(TUCL.M). Alarm(alarm No.) list and solution 6-7 HP51INE596. Check point against trouble 2) Cycle stop MACHINE MODEL SELECTION KEEP RELAY NOT SET _ | - Set the keep relay(K13.0/ K13.1/K13.2) ATC/APC/COOLANT/LUBRICATION MOTOR OVERLOAD. | « Check the pump and relay. — Lub. pump motor coolant pump motor atc or apc motor is | - Check QM10, QM40, overloaded. ama, aMa2, Maa, — Overcurrent detect relay maifunctic M44, QM45, QMS1, ~ Circuit short QM73, M74, QM76, QMs1 ‘AIR PRESSURE DOWN = Check the air supply line. — Air pressure is lower than the set value of pressure: switeh(SP12). SPINDLE ORIENTATION OVERTIME “Check the set values of ~ Spindle orientation is not finished within 15 sec after ‘corresponding parameters. M19 command, + Check the position coorder = Spindle orientation parameter mis-input. and cable, ~ Position coder or feedback cable malfunction, + Readjust orientation. M06 COMMAND OVERTIME | * Check ATG limit switches — Tool change is not finished within 10 sec after MOS according to tool change command. sequence. — Heterence point signal ot X, ¥, axis or AIC limit switches malfunction. T-CODE OVER COMMAND ERROR Reset. -T0 command — Larger too! no. than its tool capacity is commanded. TOOL MAGAZINE SELECT KEEP OR NOT SET + Set the keep relay. — Keep relay for tool capacity selection is not set. 40 lools : D486-b3/K6-b3 60 Tools : D486-b4/K6-b4 120 Tools : D486-b6/K6-b6- 170 Tools : D486-b0/K6-bO SPINDLE SPEED ARRIVAL OVERTIME Check the related parts. — Commanded speed is not detected within 20 sec. + Refer to spindle drive unit — Parameters for spindle rotation are misinput. manual. ~ Arrival signal of drive unit malfunction. Alarm(alarm No.) list and solution 6-8 HP51INE596. Check point against trouble SPINDLE ROTATION MALFUNCTION Input S-code ~ Spindle rotation is commanded without S-code. - Check the present state of = Spindle rotation is commanded in unavailable state spindle hoad. for example, tool unclamp state. MUST BE RETURNED TO REF. POINT + Check Returned to Refipoint = CYCLE START is commanded without reference point | completel, after program return operation after POWER ON or MACHINE LOCK | check by machine lock and be ON-OFF. coordinate and absioute coor- dinate values must be matched EXTERNAL FEED HOLD(OP PUSH BUTTON SW) — CYCLE STOP push button switch on main control panel is pressed. EXTERNAL COOLANT UNIT OR LEVEL SWITCH ~ Check external coolant unit ALARM or level switch EXTERNAL COOLANT UNIT ALARM OR TSC PRES- —_| « Check external coolant unit SURE SWITCH ALARM — External coolant unit alarm is detected. T-COMMAND ILLEGAL POSITION * Check wait pot position(SX5A, — lool search is commanded in an unabailable position. SX5B), ATC arm home(SX53, ~ ATC related switches malfunction 'SX54) mag. Too! pat int Tool — Solenoid valve malfunction tool magazine pocket detect = Circuit short ‘switch(SX36). M06 COMMAND ILLEGAL POSITION * Check the ATC condition — M06 is commanded when waiting pot is not in a spindle Check ATC arm home(SX53, position. ‘SX54), wait. pot spdi side — ATG related switches malfunction (SX5A), pocket detect(SX36), — Solenoid valve malfunction [NTC door opon.close(S051, actu et1at ‘SD52), D450, D452, 2nd ref position(X, , Z), wait. pot clamp(SD32). PALLET SEAT CHECK ALARM «Check pallet seat check ‘switch(SP69) Alarm(alarm No.) list and solution 6-9 HP51INE596. Check point against trouble APC OVERTIME Check table clamp/ — Pallet change is not finished within 30 sec. tunclamp(SL62,SP02,SP04), = limit switches or solenoid valves malfunction pallet clamp/unclamp(SP61, ‘SP63}, pallet lock(SL81), APC change position(X,Y, 2), pallet 2 check(SX/6), pallet 1 ‘check($X75) M61/M62 COMMAND ILLEGAL POSITION ~ Check table cama! ~ Initial condition for M61/M2 command is not ready. unclamp(SL62,SP02,SPO4), pa let clamplunclamp(SP6 I, SP63), pallet lock(SL8t), APC change Position(X,Z), pat 2 check(SX76), pallet 1 chheck($X78), APC DOWNISXB2}, APC UP(SX8!) FIXTURE ALARM IN CUTTING ROOM PART * Check fixture 1 clamp! — Fixture not clamp.(Table side) unclamp solo(F1HC.V —> ees IAL FICH.M) + Check fixture 2 clamp! unclamp sol.(F2HC.V —> F2CH.M) POWER BACK UP MODULE POWER FAILURE ALARM | - Check electruc hardware circuit. ‘ATC DOOR OPEN + Close ATC door. —ATC door close limit switch is of = ATC door is opened. ILLEGALITY COMMAND TO SPINDLE ROTATION ~ Check S-command DATA THE SPINDLE TOOL BROKER ALARM * Check spindle tool. TOOL DETECT SWITCH ALARM = Check spindle tool clamp switeh(SX13) when HSK tool used, B-AXIS COMMAND & POSITION ERROR + Check B-axis coordinate DAILY OUTPUT COUNT COMPLETED ~ Check daily count & reset. ‘SPINDLE MAX. PRM READ FAILURE Alarm(alarm No.) list and solution 6-10 HP51INE596. Check point against trouble 3) Block end stop LUB. LEVEL LOW or PRESSURE DOWN + Replenish lub. oil — Lubrication oil shortage. * Check the switch. — Oil level switch malfunction. ‘OIL COOLING UNIT OR OIL COOLING FLUX DOWN: * Check oil cooling unit. ALARM, COOLANT FILTER CHANGE ALARM * Check switeh(SP16). COOLANT PRESSURE DOWN OR FLOW ALARM ~ Check switch(SP15) TOOL LIFE MANAGEMENT END ALARM ~ Check too! life. RESET COMMAND ALARM ON CYCLE START Re-execute NC reset and = NC cycle start is commanded just after reset in auto mode. | the alarm reset. PANTS COUNT END - Parts count is finished according to the preset value. HYDRAULIC UNIT OIL LEVEL OR TEMPERATURE + Check hydraulic oil level or ALARM : . temperature. Alarm(alarm No.) list and solution 6-11 HP51INE596. Check point against trouble 4) Only alarm state No. Contents Recovery 2060 | SPINDLE TOOL CLAMP/UNCLAMP ALARM. * Check the related parts. = Clamprunclamp operation Is not finished within 10 sec. | (SLI, SL12, YVI1) = Unclamp limit switch/solenoid valve malfunction. 2063 | ATC ARM PIN LOCKING/RELEASE ALARM ~ Check the related parts. (SD55, SD56, YV55) 2064 | WAITING POT SPINDLE/MAGAZINE SIDE ALARM Check limit switches. = Waiting pot movement is not finished within 15 see. (SXBA, SXBR, YVS3, YVA4) — Limit switch.solenoid valve malfunction. 2065 | CHANGER ARM POS. CHECK ALARM + Check home postion ‘switch(SXS4) or ATC servo unit signal (THOMEL.TCLP-TUCLP) 2073 | PALLET OR TABLE CLAMP/UNCLAMP ALARM Check switch & sol. (SP61, SP62, SL62, SP63, SP64, YV61, YV62, YV68) 2074 | ATC OVERTIME + Check wait. pot magazine = T command or M06 command is not finished within 40 sec, |. side(SX5A, SX5B), pocket — Limit switch/solenoid valve malfunction. detcet(SX36) 2075 | ATC MAGAZINE ROTATION OVERTIME — Magazine rotation is not finished within 50 sec. 2076 | ATC MAGAZINE SERVO DRIVE/BATTERY LOW ALARM. | - Gheck servo drivel battery 2077 | WAITING TOOL POT AND SPINDLE TOOL DATA ZERO Input too! data. ALARM — There is no tool data of waiting pot or main spindle. 2078 | ATC OP MANUAL SWITCH ON * Set the switch to auto mode. The mode switch of ATC op panel is set to manual position. 2080 | ATC OR APC INTERLOCKALARM + Initialize ATC and APC. = Check ATC or APC in position status 2081 | ATC MAGAZINE GUARD DOOR OPEN * Close the door Magazine door is opened. Check the switch. (S85) — Limit ewitch malfunction, 2084 | APC SETUP STATION DOOR OPEN * Check the switch. (S91, $92) = Setup door is opened. = Switch malfunction. Alarm(alarm No.) list and solution 6-12 HP51INE596. Check point against trouble ‘APC SET-UP, LOCATION S/W UNPUSH ~ Push the setup button — Setup confirm button is not pushed in pallet change switch. command(M60) ‘APC OP MANUAL SWITCH ON ~ Set the switch to auto mode. ~The mode switch of ATC op panel is set to manual position TOOL WEAR DETECT ALARM = Check spindle tool sta- tus.(WARN.C) B-AXIS(TABLE) OR PALLET CLAMP ALARM = Table or pallet unclamp state is maintaining over 10 sec. MANUAL AXIS MOVING INTERLOCK ALARM Release axis interlock — Axes are interlocked in JOG feed mode. conditions. — Reference point return to + direction is commanded + Execute reference point when the machine is already in its reference position return to ~ direction, CHIP CONVEYOR ALARM OR BASE CLLANT OVERLOAD | Check the conveyor. — Conveyor motor or clliant motor is overloaded. FEEDRATE OVERRIDE 0% — Feodrate override ewitch ie eet to 0%. AUTO POWER OFFIREADY. MACHINE LOCK AND AUXILLARY FUNCTION LOCK. B- AXASINS MOVE, MUST RF POWER OFF LOW BATTERY FOR MEASUREMENT DEVICE. ~ Check measurement device battery MEASUREMENT DEVICE PROBE ALARM ~ Check measurement probe statue. SERVO TOOL MAGAZINE 1 DRIVE BATTERY LOW ALARM FIXTURE CLAMP/UNCLAMP ALARM IN SET-UP ROM | - Check fixture clamp/unclamp. PART TOOL MAGAZINE SERVO UNIT ALARM ~ Check servo unit. — Check tool magazine sorvo unit in control cabinet TOOL MAGAZINE POSITION ABNORMAL — Check wait pot number (waiting pot number=T-command unmber) Alarm(alarm No.) list and solution 6-13 HP51INE596. Check point against trouble OPERATOR'S DOOR OPEN ALARM + Check switch (S13). ~ Check operator's door status or safety swich key posi- tion & condition. — Check symbol(DSD1.M) ‘SAFETY SWITCH IS UNLOCKING STATUS OR OPEN SO _| - Check switch (S13) PLEASE CLOSE THE OPERATOR'S DOOR = Check symbol(DSDO.M) OPERATOR'S DOOR CLOSE STATUS = It you want operator's door open, please push the door request button. MUST BE Z-AXIS REFERENCE POINT RETURN ~ Machine run after Z-axis reference point return ‘SPINDLE STOPPED IN CUTTING MODE ‘Check spindle rota- tion(SFRA,SRVA) ILLEGALITY COMMAND TO SPINDLE ROTATION * Check s-command data(S=NG). THE SPINDLE TOOL IS BROREN ~ Check spindle tool sta- = Replace the tool with new one & make reset in TMT. tus(STOP.C), APC. ALTO DOOR OPFNIGIOSF ALARM * Check ate auto door sta- tus(SLF7, SLF8, SLF9). CAUTION! MACHINE MAINTENANCE MODE = The machine condition for maintenance. MACHINE INTERFERENCE ZONE ALARM — CAUTION! Y-Z-axis. ‘APC CHANGER UP/DOWN ALARM ~ Check switeh(SX81, SX82, — Limit switch or solenoid manfunction Yv75, YV76) APC CHANGER 180CWICCW ALARM * Check switeh(SX75, SX76, — Limit switch or solenoid manfunction Yv73, YV74) TOOL BREAKAGE DETECT ALARM — Check the spindle head too! PMG SYNCHRONOUS MAL FUNCTION PMG ROTATION COMMAND ALARM PMG SET-UP HOOK ADV/RET. ALARM * Check hook adv. switch(X113.4) or hook return switch(X113.5) Alarm(alarm No.) list and solution 6-14 HP51INE596. Check point against trouble No. Contents Recovery 2137 | PMG STOPPER IN/OUT ALARM Check stooper 1 in/out switch(X110.5X1106) or stooper 2 switch(X111.3/X111.4) 2145 | TRANSFER POT MAGAZINE 1,2 SIDE ALARM IN DOUBLE MAGAZINE 2147 | TOOL MAGAZINE 2 ROTATION OVERTIME ALARM 2149 | TOOL MAGAZINE 2 GUARD OPEN + Check magazine 2 guard(MDT2.M) 2152 | TOOL DETECT SWITCH ALARM ~ Check tool detect ‘switch(STCL.M) 2154 | WAITING POT CLAMP ALARM » Check switch(SD32, SD33,) 2155 | TOOL MAGAZINE POT DETECT SWITCH ALARM + Check switch(SX36) 2156 | TOOL LENGTH SENSOR UP/DOWN ALARM “ Check switeh(SD61, SD62, — Limit switch or solenoid manfunetion Yve7) 2157 | DAILY OUTPUT COUNT COMPLETCD: Check daily count(WCL.M) 2188 | WAITING POT MAGAZINE/SPINDLE SIDE COMMAND ~ Check switch(SX5A, SX5B, ALARM YV53, YV54) — Limit switch or solenoid manfunetion 2159 | WAITING POT IS NOT SAME COUNTER: + Check switch(SX75, SX76, = Check waiting pot or T-command unmber Yv73, YV74) 2160 | APC PALLET CHECK SWITCH ARARM + Check switeh(SP69) 2161 | SPINDLE MAX. RPM READ FAILURE + Check spindle max. rpm(SMAXNG) 2162 | THE WARMING-UP IS NOT COMPLETED 2163 | ATC DOOR OPEN/CLOSE ALARM « Check switch(SD51, SD52, = Limit switch or solenoid manfunetion vst, YV52) 2164 | B-AXIS COMMAND & POSITION EHKOK ~ Check B-axis position 2165 | TOOL MAGAZINE SERVO DRIVE 2 FAULT ~ Check tool magazine eervo drive 2.(TAL2.M) 2166 | TOOL MAGAZINE 2 ROTATION FAULT 2167 | TOOL MAGAZINE 2 ABNORMAL POSITION 2168 | TOOL MAGAZINE 2 IS NOT TOOL POT NO.60 Check tool magazine pot no is 60. 2169 | TOOL MAGAZINE HAS A TOOL POT OR NOT * Check tool pot state Alarm(alarm No.) list and solution 6-15 HP51INE596. Check point against trouble ‘THE COMMAND TOOL IS DUMMY POT TOOL NO. = Incorrect T-code was commanded. TOOL MAGAZINE 2 SERVO DRIVE BATTERY LOW ~ Check servo drive 2 bat- ALARM tery(BAL2.M). PALLET MISS MATCH ALARM * Check pattet schedule or pallet code reader. COMMAND PATTER CAM NOT FIND Check the data in schedule soreen, ‘THE COMMAND PALLET IS LOCATED ON TABLE ‘SELECTED SET-UP MODE ON PMG OPERATION PANEL. IN AUTO MODE. ‘APG MACRO START HOLLING STATUS IT'S COMMAND PMG OPERATION. PLEASE SELECT EDIT MODE AND PUSH “ALARM RESET” PUSH BUTTEN ‘SWITCH ON MAIN PANEL, PMG IS NOT INITINAL POSITION FOR INDEXING. + Check X111.6K112.6/ ree X113.3/X113.5 PMG SET-UP STATION IS NOT HOME POSITION * Check set-up stopper locate & stop 2 switch PMG SET-UP DOOR INTERLOCK Check PMG set-up door switch(SUITM).. PMG SUPPLIER ADVANCE/RETURN ALARM ~ Check supplier advance switch(X111.5) oF supplier return switch(X111.6) PMG HOOK REALEASE ADVANCE/RETURN ALARMIN | - Check hook advance ‘SUPPLIER STATION. switch(X112.5) or hook realeast switch(X112.6). PMG SET-UP PUSH ADVANCE/RETURN ALARM. ~ Check set-up push advance swithch(X113.2) or push return switch(X113.3). PMG SET-UP SIDE LOAD/UNLOAD ALARM PMG SUPPLIER SIDE LOAD/UNLOAD ALARM Check PMG pallet detect swilch(X112.4) or pallet deteck in buffer switch(X15.0). Alarm(alarm No.) list and solution 6-16 HP51INE596. Check point against trouble PMG SET-UP SUPPLIER DOOR OPEN/CLOSE ALARM « Check set-up supplier door state(X10.7X11.0).. ‘SPINDLE WARMMING-UP DATA IS CHANGED. IT COULD. MAKE A WRONG WARMMING-UP. AUTO POWER OFF SWITCH IS NOT ON. WHEN THERE IS ‘A“AUTO POWER ON" M65 COMMAND. PATTER UNCLAMP STATUS. FIXTURE SEAT CHECK ALARM IN SET-UP ROOM PART. _ | - Check fixture seat check state. Alarm(alarm No.) list and solution 6-17 HP51INE597. Data for adjustment/maintenance 7. Data for adjustment/maintenance NC machine is a highly efficient production unit having a much higher utilization than manual one. This section deals with the requirements for adjustmentmaintenance which must be met by every user in order to insure excellent, trouble-free performance and prolonged life. Adjustment and maintenance must be followed carefully by maintenance staff or our service man, if anything is observed by inspection. Be sure not to change setting and adjusting value without intention in any case. The followings are the basic concepts for adjustment and maintenance, and please refer to sec- tion 4, Parts list and Electric/Ladder diagram. Number a Description ; ‘Adjustment of proximity switch .8-1.2mm (Switch Dia 12mm) a_i , Adjustment of other switch 2mm (Switch Dia 18mm) aan A 3 Adjustment of other switch ~ Check DGN signal Right thread by Meter system 4 Bolts/screws 7 Searses (Except for rotating union for T-S-C) Ttem Description Remark Page 7.1 | Spindle head = tustration of each unit for 7-1 7.2 | Axes system adjustment/maintenance 7-2 7.3 _ | ATC(Automatic tool changer) 7-10 7.4 _| APC(Automatic pallet changer) 7-13 75 Air service unit ee 7.6 | Lubrication unit 7.7 | Hydraulic unit 7-18 7.8 | Oilcooler 7-21 79 Coolant and chip devices 7-23 Data for adjustmentmaintenance 7-0 HP51INE597. Data for adjustment/maintenance 7.1 Spindle head 41) Adjusting tool unclamp Unit : mm(inch) ‘Symbol Description (ona Trout 194078] 50.1865) 1 | Spindle 2 | Push rod 3 | Collet 93987 | 05(0.09 exaga.7a)_ | KANG) "root LeNeTH~ [NOTICE] 1. This table be distornced spindle surtace to spindle collet. > | —~ a) 44,000 unit : mm(inch) With tool 100.4(3.9527) Without tool 107.914.0778) IAVRING) 1. Apply the thread locker to the bolt against lossening on re-assembling. [ACAUTION] 2. Figure lett shows the tool 2) Adjusting orientation stop position The orientation stop position can be adjusting accurately by parameter change, and be sure to check the relative position among slot in tool, key in spindle and key in changer arm with step operation of ATC to avoid severe collision.(Please refer to Machine operation manual and parameter sheet.) Spindle head 7-1 HP51INE597. Data for adjustment/maintenance 7.2 Axes system 1) Adjusting reference point Machine coordinate is established on the basis of home position. Careful maintenance is nec- essary not only periodically but also on occasion The reference point of this machine is determined accurately by parameter change to shift the grid signal from position detector, and the relation between them is as figure below. As the figures below, machine is decelerated by the signal of reference deceleration point and stopped by the first grid signal after the extinction of deceleration signal and stop point can be adjusted by the shift of grid signal. The shift value of grid is registered at the parameter no. 508~511 and max. value is 32767.(Please refer to operation manual, parameter sheet.) And grid shift value is equivalent to shift of home position. During one revolution of servo motor, the pulsecoder generates one grid signal while the machine moves 20mm. | 1Grid ee = BOmm(X, ¥, Z AXIS) cine ~ Feeonare FL (ePID) RAPID ——— FL ‘STOP POSTION(SHIFT=Po) ‘STOP POSITION(SHIFT=Pn) simon [SWITCH > “ DOG _zony —_@ “) Ae ON a4 , ore aoe on Axes system 7-2 HP51INE597. Data for adjustment/maintenance (1) Adjustment of X-axis home position 1) Mount test bar on the spindle. 2) Position table to correspond spindle center with table center. (ie. X-axis point = 425.0mm) 3) Position spindle (Y) and column (Z) as illustrated below. 4) Set indicator on table and apply to test bar. Rotate test bar by hand to recog- nize angle which indicates mean value of run-out. 5) Obesrving indicator, traverse Y-axis slowly in HANDLE mode to find Y- value which indicates maximum value, and sel indicator lo zero, 6) Avoid Y-axis and rotate table by 180° as shown below. 7) Turn test bar by 180° and return Y- axis. Record indicated value. Half of the value is the error of home position, Axes system 7-3 HP51INE597. Data for adjustment/maintenance (2) Adjustment of Y-axis home position 1) Mount test bar on the spindle. (Measure diameter(D) of test bar accurately and record.) 2) Place gage block(200mm, typically) on table. 3) Calculate Y-value which make the dimension L below equivalent to the height ot gage block, and position there. v=t-(6+2) S : Distance between pallet surface and spindle center(S = 50.0mm) 4) Set indicator on the table and apply to the top of test bar. Turn test bar to oblain the mean value of runout. 5) Apply indicator to gage block and set zero. 6) Apply indicator to the top of test bar as shown below. Record the value, which is home position error of Y-axis. Axes system 7-4 HP51INE597. Data for adjustment/maintenance (3) Adjustment of Z-axis home position Prepare the test bar of which diame- ter(D) and length(L) have been mea- ‘sured accurately. 1) Prepare X-axis home position error data. 2) Position table to correspond spindle center with table center. 3) Traverse Y-axis to appropriate posi- tion(250~ 300mm from top of table). 4) Mount test bar on the spindle and rotate it to obtain angle which indi- cates mean value of runout. 5) Traverse Z-axis as illustrated below. z=(L410)-2-s orci = S : Distance between spindle head end and pallet center when Z axis is zero. (S = 160.0mm) 6) Apply indicator to tect bar and traverse Y-axis to the position which indicates half of runout. 7) Attatch gage block of 10mm to the end, apply indicator to block and set zero. 8) Avoid test bar(Y-axis), rotate table by 90°, return test bar and record indi- cated value. (Refer to next figure.) 9) Z-axis home position error is given by compensating X-axis error against above recorded value. BLOCK GAUGE Axes system HP51INE59