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

10
HP 5100 HP51MTE87
2) Remove the six R37260A Coolant Nozzles
located in the Front Cover at the front of
the Spindle, then disassemble the
C58011183 Front Cover.
▪ 8-BB5×20
▪ O-Ring : 1-S120
3) Remove the security bolts (8-BB12X36) on
the C58011031B Main Bearing Housing,
then plug in two M10 Stud Bolts (300mm
or longer) in the Tap position (2-M12).
Slowly and carefully remove the Spindle
Cartridge taking care to maintain Balance.
▪ 8-BB12×36
▪ O-Ring : 7-P11, 3-G150, 1-G115
4) When the Spindle Cartridge is nearly pulled out, use
the Rope to completely separate it
and use a Crain to pull it out.
Front Cover
Coolant Nozzle
Bearing
Housing

11
HP 5100 HP51MTE87
1.3 Assembling the Spindle Cartridge
1) Measuring the Pressure on the Rear Bearing and Collar on-site Grinding
① Wash and clean the Spindle thoroughly.
② Insert the R11247 Cylinder Roller Bearing(N1014) into the Spindle.
Washing only
inner Taper area is allowed.
③ Use the C58012134A Distance
Collar(4)to hit a section of the inner rim
while making the outer rim touch the
Roller lightly. The outer rim should be so
that it moves slightly up and down with
light pressure. At this point, the pressure
on the Bearing can be seen as "0". After
about five minutes' wait (allowing heat
to transfer from your hand to the outer
rim), rotate the outer rim to see if it still
moves up and down with light pressure.
④ If the outer rim seems too loose, hit the
Collar slightly to reduce looseness.
However, if the outer rim is slipping at
about 10 Kg.f pressure, it should be no
problem as a preset pressure in the
Field.
⑤ Measure the gap using the Block Gauge
to verify the "Collar on-site Measure".
⑥ Grind the C58012124A Distance-Collar (3) according to the on-site
measurement. (Measurement tolerance 0/-0.005; Parallelism under 0.005)
Distance
Collar(4)
Collar
On-site
Dimension

12
HP 5100 HP51MTE87
2) Measuring the Tightness of the Rear Outer
Rim Bearing and on-site grinding
① Measure the difference in height of the
Outer Rims of the disassembled Bearing
and the new Bearing on a plain
measurement table.
② Determine the dimension of the
C58011073A Rear Bearing Support
▪ Find the figures that add and subtract
the height difference between the
detached Bearing and the new Bearing
from the measurement of the Rear
Bearing Support.
③ Grind the Rear Bearing Support from on-
site Measure amounts found. (Margin
+0.005/0, Parallelism under 0.005)
3) Cleaning the Bearing and Applying Bearing
Grease
① Remove all grease from the Bearing
before applying the Grease (Use thinner
or similar material to thoroughly clean
the Bearing, then dry the Bearing for
about an hour.)
▪ The shipped Bearing is stained with
greaseproof material and other
substances. Mixing ordinary lubricant with
Grease will make the Grease useless.
② Apply enough Grease to cover 10~15% of
the spatial area. The chart on the next
page indicates the exact amount to be
applied.
③ The Grease must be inserted evenly
throughout the Bearing cylindrically and
must be spread evenly to the bottom of
Measuring the difference in height
Appropriate Grease
Applying
Rear
Bearing
Support
Rear Bearing
Housing
Support
Rear
Bearing

13
HP 5100 HP51MTE87
the Ball.
④ After applying, rotate the Ball so that the
Grease is applied on the entire Ball, and
then put it into storage.
※ In the case of excess applying
▪ Lea
ve only the amount needed for
rotation
▪ Release the excessive
grease to the
outside
▪ Prevent any air influx
▪ Overheat the Bearing => Noisy/
burnt
down
Excess
ive
Grease
applying

14
HP 5100 HP51MTE87
HS Thrust Angular Ball
Brg. Angular Contact Brg.
Nominal
I.D
(mm)
DoubleRow
Roller
Brg. NN30
SingleRow
Roller
Brg. N10 BA,BT
Series
TAC
Series 70 Series
72 Series
6 30 0.6 0.4 - - 0.8 0.6
7 35 0.8 0.6 - - 1 0.8
8 40 1 0.7 - - 1.2 1.1
9 45 1.3 1 - - 1.5 1.3
10 50 1.4 1.1 1.2 1.4 1.7 1.5
11 55 2 1.5 2 2 2.3 2
12 60 2.1 1.6 2 2.1 2.4 2
13 65 2.2 1.6 2.1 2.2 2.7 2.3
14 70 3.2 2.4 3 3.2 3.6 3.3
15 75 3.5 2.5 3.2 3.5 3.8 3.6
16 80 4.7 3.5 4.2 4.7 5.1 4.4
17 85 4.9 3.7 4.4 4.7 5.3 4.7
18 90 6.5 4.5 6 6.5 6.9 6.2
19 95 6.6 4.7 6.3 6.6 7.2 6.5
20 100 6.8 4.9 6.5 6.8 7.4 6.8
21 105 9.3 5.9 8.4 9.3 9.3 8.1
22 110 11 7.5 10.1 11 11.9 10.1
24 120 12.5 8.4 10.8 12.5 12.3 10.8
26 130 18 12.9 16.5 18 19.5 16.1
28 140 20 14 17.1 20 20.7 17
30 150 23 - 21.8 23 25.8 21.2
32 160 29 - 26.9 29 31.8 25.5
34 170 38 - 32.4 38 41.6 33.2
36 180 48 - 45.6 - - -
40 200 65 - 60.9 - - -
44 220 88 - - - - -
48 240 97 - 90 - - -
72 360 360 - - - - -
80 400 423 - 395 - - -
※ : The amount of grease to be applied should be 12~15% of the spacial capacity for
Angular Contact Bearings, and 10% of spatial capacity for Cylindrical Roller Bearings.
Technology Production : 2008.09.04
Reference: NTN Scale : ㎤/EA
Standard Grease applying Amount for Main s
pindle
B
earing

15
HP 5100 HP51MTE87
4) Assembling the Spindle Rear bearing Parts
① Thoroughly clean the Rear Bearing
assembly parts
② Insert the Bearing that had been stored
with NBU16 Grease on it.
③ Insert the previously on-site grinded
C58012124A Distance Collar into the
C58011073A Rear Bearing Support and
assemble it to the C58011082A Rear
Bearing Housing.
▪ 6-BB6×16
▪ O-Ring : 1-G85
5) Assembling the Spindle Cartridge
① Thoroughly clean the C58011021B
Spindle Motor Body.
▪ Take special care to remove any
remaining oil from the Motor Coil.
② Apply Grease thinly along the inside of
the Spindle Motor Body.
③ Insert the O-Ring (3-P11, 2-G280) into
the Main Bearing Housing and apply
Grease around the O-Ring.
※ Prevent O-ring separation during Cartridge assembly by inserting the O-Ring
after applying Grease to the 3-P11 O-Ring groove.
④ Lift up the Cartridge using clean linen Rope, then lay it on the interior of the
Body using a crane.
⑤ Insert the Cartridge using 2-M12 Stud Bolts, then use 8-BB12×35 Bolts for
security.
▪ If the Spindle strays into the rear part of the Bearing, insert the C58012134A
Distance Collar(4) into the Spindle and use it to hit the Bearing and continue
assembly.
Spindl
e
Motor
Body
Rear
Bearing
Support
Distance
Collar(3)
R
-
Bearing
Housing
Support
Rear
Bearing

16
HP 5100 HP51MTE87
⑥ Use the C58012134A Distance Collar(4) to
give shock to the Rear Bearing in order to
completely attach the Distance Collar(3)
and the Rear Bearing to the Spindle section.
6) Clean the C58011183 Front Cover and
assemble.
▪ 8-BB5×20
※ Manually rotate the Spindle to check for
any interference.
Spindle Cartridge
Distance
Collar(4)
Distance
Collar(3)
Rear
Bearing
Front Cover

17
HP 5100 HP51MTE87
7) Insert the parallel Key(2-
KSP8×7×20) into the
Spindle, assemble the C58012153A Sensor
Bracket and secure with a Lock-Nut, and then
tighten the Lock-Nut securing Set-Screws.
8) Assemble the BZ-Sensor.
※ Use a gap gauge to create a 0.1mm gap.
If a gap gauge is not available, use a piece
of paper to create the gap and remove the
paper after tightening the BZ-Sensor
security bolts.
BZ
-
Sensor
Lock
-
Nut
Key
Sensor
Bracket
Motor
Cap
Lock
-
Nut

18
HP 5100 HP51MTE87
1.4 Assembling the Tool Unclamp Cylinder
1) Assemble the C51016233A Cylinder
Bracket.
※ Steadily remove the Motor Cable through
the Cable Cover and store safely.
▪ 8-BB10×100
2) Assemble the C58011203A Cylinder Body.
※ Prevent damage to the O-Ring by applying
Grease around the O-Ring.
▪ 4-C55342214 Spring Bolts
▪ 4-184535 Spring
▪ O-Ring : 1-P180, 1-P115/NOK
3) As shown right, insert the Flat Washer and
Bolts into the Balancing Bolts location (to
prevent scarring the End Stopper) and use
a chisel to give shock to the C58012173A
End Stopper until the Set-Screws seem to
fit the Drill grooves (BQ Bolts grooves)
made at the end of the Spindle. Then
tighten the security Set-screws.
▪ 2-BQY-6×8, 2-BQ8-10
※ In case no BQ Bolts grooves have been
made
①
Complete this process before assembling
the Cylinder Body.
② First,t
ighten the End Stopper as strongly
as possible.
③
Use the Ø5 Drill to make Drill marks at the
place for Set-Screws (M6 Tap location).
(Centering work)
④ Use the Ø4 Drill to make grooves about
3mm deep.
BB8X2
0
Flat
W
chi
s
el
“
A
”
Detail
End Stopper
2
-
BQY 6X8
A
Cylinder
Body
1
-
P180
1
-
P115
Spring Bolt
Cylinder
Bracket
Cable
Cover

19
HP 5100 HP51MTE87
4) Insert the O-Ring into the C58011231A
Piston which the C58012254 Spring Pusher
is
assembled, and carefully assemble the
Cylinder Body.
※ Apply grease around the O-Ring to
prevent damaging the O-Ring during
assembly.
▪ O-Ring : 1-P120/NOK
5) Insert and assemble the O-Ring into the
C58011233A Cylinder Cover and tighten the
security bolts.
※ Apply grease around the O-Ring to
prevent damaging the O-Ring during
assembly .
▪ 8-BB8×20, 8-ZP8
▪ O-Ring : 1-P110/NOK, 1-G125/NOK
6) Use the R27053C Rotating Union to assemble the
C58011223B Piston Cap.
▪ 4-BB6×20
▪ O-Ring : 1-G45
※ Reference : Assembly of the Deublin-Rotating Union
D1
Piston
Cap End
Stub. Rotor
Field
Simultaneo
Piston Cap
Rotating Union
D
2
Piston Cap
Rotating
Union
1
-
G45
Cylinder
Cover
1
-
G125
1
-
P110
Piston
Spring
Pusher
1
-
G125