Doosan HP5100 Operating manual

Machine Tools
HMC Maintenance
(HP5100)

1
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

2
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

3
HP 5100 HP51MTE87
1. Disassembling and Assembling the Spindle Cartridge
1.1 Disassembling the Tool Unclamp Cylinder
▣ Parts List for the Tool Unclamp Cylinder
1270
1280
1290
1300
,
1320
1330,
1340
1342
410
1200
,
1210
1220, 1230
1240
0420
0430
1490
1500
1350
,
1360
1450
1460
1470
1480
1250
1260
900
910
920
,
930
940, 950
990
1000
1380
,
1390
1400, 1420
1430, 1440
1080
1090
1100
1070
1050
1060
10
10

4
HP 5100 HP51MTE87
No. Parts No. Description Q'ty Material /
Specification Remarks
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
1000 S2204661 Bolt, Hex. Socket Head 12 BB6 × 16
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
1260 S2213661 Bolt, Hex. Socket Head 8 BB10 × 100
1270 C51012463B Cover, Cable 1 SCP1
1280 C51012474 Packing 1 Rubber(T1)
1290 S22046461 Bolt, Hex. Socket Head 4 BB6 × 12
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
1420 S2208861 Bolt, Hex. Socket Head 8 BB8 × 20
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
1480 S2204861 Bolt, Hex. Socket Head 4 BB6 × 20
1490 C58012254 Pusher, Spring 1 SM435
1500 S2204561 Bolt, Hex. Socket Head 4 BB6 × 14

5
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
the R27053C Rotating Union.
▪ 4-BB6×20
▪ O-Ring : 1-G45
3) Detach the C58011233A Cylinder Cover.
▪ 8-BB8×20, 8-ZP8
▪ O-Ring : 1-P110, 1-G125
Piston
Cap
Rotating
Union
Cylinder
Cover

6
HP 5100 HP51MTE87
4) Detach the C58011231A Piston assembled
with the C58012254 Spring Pusher.
▪ O-Ring : 1-P120
5) Remove the two security Set-Screws on
the C58012173A End Stopper, plug in the
Washer and Bolts in the place of the
Balancing Bolts (as shown right), and use
a
chisel to remove the end stopper.
※ This is to prevent scarring the End
Stopper.
▪ 2-BQY-6×8, 2-BQ8×10
6) Disassemble the C58011203A Cylinder
Body.
▪ 4-C55342214 Spring Bolts
▪ 4-184535 Spring
▪ 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.
▪ 8-BB10×100
Spring
Pusher
Piston
BB8X20
Flat washer
chisel
“A”
Detail
“A”
Set
-
screw
End Stopper
Cylinder
Body
Cylinde
r
Bracket
Cable Cover

7
HP 5100 HP51MTE87
8) Disassemble the BZ-Sensor, loosen the
security bolts on the R02120 Lock-Nut,
and use a chisel to remove the Lock-Nut.
9) Take out the C58012153A Sensor Bracket
and remove the Key (2-KSP8×7×20).
※ You must not disassemble the C58011041
Motor Cap, because it will affect the
concentricity of the position of the Main
Spindle Bearing.
BZ
-
Sensor
Lock
-
Nu
t
Key
Sensor
Bracket
Motor
Cap

8
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
No. Parts No. Description
Mat. /
Specification
Q'ty Remarks
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
680
690
640
650
740
750
760
700
710
830
840
810
120
130
140
150
160
300
330
340
360
360
370
500
510
520
530
800
540
200
560

9
HP 5100 HP51MTE87
No. Parts No. Description
Mat. /
Specification
Q'ty Remarks
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
680 S2208661 Bolts, Hex. Socket Head BB8×16 8
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
840 S2204661 Bolts, Hex. Socket Head BB6×16 2
1)
Thoroughly clean the Spindle Head, then
remove the Orientation Air Blow
Tube with
the Connector.
Connecto
r