INT100,200,300,400mk4

Installation procedure and acuracy sheet

This procedure for when you install INTmk4 machine. And after follow step
by step on this procedure, you will get all accuracy sheet and parameter
sheet in the last 2 pages. Print this sheet and keep it in the machine
cabinet and send another copy to office for record.

This procedure for both Metric and Inch system, However some of
point in this procedure require to use Metric only because of avoid
confusion.
Each sheet give you a for input value and a for output.
Please read carefully each caution.
Rough Level
Original Parameter
inch *Please input "inch" or "mm"

Chuck Width(SP face to Chuck face) Z-axis distance (work center to Home)
BA2 TR1 66535 0.00001inch BA19 TR1 264961 0.00001inch
Correction of center rotation on B-axis (X-direction: from Home) Correction of center rotation on B-axis (Z-direction: from Mill SP face)
BA61 TR1 28 1.0um BA62 TR1 586674 0.00001inch
X-coordinate of the sensor’s reference point Z-coordinate of the sensor’s reference point
BA97 TR1 -1314391 0.00001inch BA99 TR1 -1476157 0.00001inch
BA97 TR2 0 0.00001inch BA99 TR2 0 0.00001inch
Offset amount (X) during automatic tool setting value calculation
BA109 TR2 0 0.00001inch
Height axis rotational center offset of the first rotary axis(Tool tip point control) Z-axis stroke for tip position memory(TEACH function)
K124 1490152 0.1um L5 1704666 0.00001inch
Second zero-point coordinating value
M5 X1 4550 0.1um M5 Y -803900 0.1um
Zero-point shift amount
M16 X1 90600 0.1um M16 Y 14711 0.1um
M16 Z1 28490 0.1um M16 X2 0 0.1um
M16 Z2 39194 0.1um
W-AXIS REVISION (X-AXIS REV.) W-AXIS REVISION (Yt-AXIS REV.)
RS11 0 0.1um RS12 0 0.1um
W-AXIS REVISION (X2-AXIS REV.) Y-AXIS REVISION(B=90°)
RS13 0 0.1um RS15 0 0.1um
Y-AXIS REVISION(B=180° )
RS16 0 0.1um
Final Z-axis Level
 Pitch: When bubble move to HD2 side "-", HD1 side "+".
Twist: When bubble move to Magazine side "-", Operater side "+".
Level HD1 MID HD2
Pitch -0.005 0 0 mm/M
Twist -0.005 -0.005 0 mm/M

Tolerance
Level HD1 MID HD2
Pitch +/- 0.02 +/- 0.01 0 mm/M
Twist +/- 0.01 +/- 0.005 0 mm/M
Final W-axis Level
 Pitch: When bubble move to HD2 side "-", HD1 side "+".
Twist: When bubble move to Magazine side "-", Operater side "+".
Level HD1 MID HD2
Pitch -0.01 -0.005 0 mm/M
Twist +0.005 0 0 mm/M

Tolerance
Level HD1 MID HD2
Pitch +/- 0.02 +/- 0.01 0 mm/M
Twist +/- 0.01 +/- 0.005 0 mm/M
Spindle Taperness Check
This form useable both for inch and metric.
*If you got result with "-" which means B-side is smaller than A-side
Do not use harder material on this test, you will get different result. (aluminium or brass is OK.)
Also do not deep cut, it will get different result.
Headstock Check
inch *Please input "inch" or "mm"
A= 1.7826 inch

B= 1.7826 inch
C
C= 6.1 inch 0.0000 / 10 inch
A B

Tailstock Check

A= 0 inch

B= 0 inch
C

A B C= 1 inch 0.0000 / 10 inch

B A Headstock #2 Check
C
A= 1.9665 inch

B= 1.9665 inch

C= 6 inch 0.0000 / 10 inch

Tolerance
B-side smaller than A-side
-0.0003 / 10 inch
Transfer Position Check
This form useable both for inch and metric.
After SP Taper check, leave cutting material in 2nd SP and grab indicater in 1st SP.
Indicator inch *Please input "inch" or "mm"
Reading Indicator
0.0001 inch

Tolerance
0.0004 inch

You have a procedure in Japanese website as you see in berrow, however useally when you
install new machine you do not need this process to make machine straight. You need
to make this condition with Level adjustment.
Turret Straightness
This form useable both for inch and metric.
inch *Please input "inch" or "mm"
Test Bar Length: 7 inch
Specify to + and - direction.

1,Y -0.0005 inch 0 B=0 B=180 0 6,Y 0.0005 inch

2,X -0.0003 inch 0 0 5,X 0.0007 inch

B=90

0 0 1,Y -0.0003 inch/4inch

2,X -0.0002 inch/4inch
3,Z -0.0004 inch/4inch
4,Y -0.0001 inch/4inch
5,X 0.0004 inch/4inch
6,Y 0.0003 inch/4inch

-0.0007 -0.0001 inch

Indicate from HD1 for B=0 and 90. Indicate from HD2 for B=180.
3,Z 4,Y

Tolerance
+/- 0.0004 / 4 inch
B-axis rotation center BA61,BA62,K124
This form useable both for inch and metric.
inch *Ex: When you want to input "inch" value, please input "inch" if not "mm".

Data
T= Test bar Length 7.874228
D/2= Test bar Diameter 0.984426 D Test Bar Mill SP
X= Distance of X move 9.548198
Z= Distance of X move 9.486078 T
BA61=(Xx25.4)-(Zx254)/2x1000 788.924
BA62=(X+Z)/2x100000 951713.8 T= 7.874228 inch
BA62 Data before change 951766 0.00001inch D= 1.968852 inch
BA61 Data before change 1000 1.0um
K124 Data before change 2417485 0.1um
#1 #2
BA61= Metric Different between OLD and NEW 789 1.0um

BA62=Inch or Metric Different between OLD and NEW -52.2 0.00001inch

New BA61= Metric 1789 1.0um

New BA62=Inch or Metric 951714 0.00001inch

Machine pos. Machine pos.
New K124= Metric 2417353 0.00001inch Z= -10.21627 inch Z= 6.15961 inch
Distance move Z= 9.48608

#1 #2

* When you check this test, you need to find highest point
on the testbar by moving Y-axis. And after found the
position do not move Y-axis until check tip of testbar.

Tolerance
When finished this test, try this test again and if you
Machine pos. Machine pos.
get a result with in 1~2um different(as much X(D)= -37.9883 inch X= -5.1123 inch
smaller), it is OK, because there has no specified X/2(r)= -18.99415 X/2= -2.55615
tolerance. Distance move + L X= 9.5482
These parameters offset the tip coordinates and the tool length on B-axis turn.
The settings differ between BA61 and BA62.
BA61 ： The machine end is offset with actual axes travels according to B-axis turn angle.
BA62 ： The value is automatically calculated on tool length measurement, but without machineend offset.
X1,Yt,Z1-axis Home Posion Adjustment
This form useable both for inch and metric. Integrex 100 *Please input "100","200","300","400"
inch *Please input "inch" or "mm"
Machine Position Target
X -44.1003 inch -44.10000 inch
Y -0.0003 inch 0.00000 inch
-44.09892

Tolerance 100mm = 4" Current Parameter New Parameter

+/- 0.0008 inch M16 X 50040 0.1um 50002 0.1um
M16 Y 24410 0.1um 24334 0.1um
*Find Center of Test Bar by Rotation"

X-axis target
mm inch
Radias Diameter Radias Diameter
INTE 100 -390 -780 -15.35 -30.7
INTE 200 -560 -1120 -22.05 -44.1
INTE 300 -610 -1220 -24.02 -48.04
INTE 400 -610 -1220 -24.02 -48.04

Machine Position Target

Z -11.06797 inch -11.06556 inch
Gage Block Gage Block Length
Length 3 inch
Chuck Width
BA2 40551 0.0001inch
Z-axis distance
BA19 276378 0.0001inch
Different between Turret face to Home position
BA62 951714 0.00001inch
Gage Block
Current Parameter New Parameter
Chuck Width(BA2) M16 Z1 22797 0.1um 22185 0.1um
L5 1406556 0.00001inch

*If machine has not standered KITAGAWA Chuck, You can not use this form unless you find correct Chuck width(BA2).
Y-axis Compansation
This form useable both for inch and metric. Indicator inch *Please input "inch" or "mm"
Find center and set indicater "0" from HD1.
(If it is not make indicator "0" with home position, please check home position adjustment one more time.)

100mm = 4"
Move B-axis 90 degree touch same point which you setted indicater on B-axis 0 degree. And find
highest point.

Indicate from front side and read "+/-" direction also.

Reading Indicater
0 inch
100mm = 4"
Current Parameter New Parameter
RS15 225 -0.0006 225 0.1um
*Max input value on this parameter +/-500.

Select HD2 side on select switch.

Attach indicator on HD2 with no movement on Y,B-axis.

First set indicator "0" on Indicate from front side and read "+/-" direction also.
backside of test bar. Reading Indicater
Y 5E-05 inch
Current Parameter New Parameter
100m
m = 4" RS12 -474 0.1um -468 0.1um
*Max input value on this parameter +/-1000.
This parameter effecteve when you select HD2 side.

Read indicator at
front side.

100mm = 4"

Set again indicator setting "0" with both front and back side, Then move B=180 and check center with HD2. (ex:
X=1120mm(44.1") Y=0mm(0"))
Indicate from front side and read "+/-" direction also.
Reading Indicater
-0.008 inch
Current Parameter New Parameter
RS16 0 0.1um -2032 0.1um
*Max input value on this parameter +/-500.
 Indicate from Top side and read "+/-" direction also.
X Reading Indicater
100mm = 4" X 0.008 inch
Yt Current Parameter New Parameter
RS11 0 0.1um 2032 0.1um
Y *Max input value on this parameter +/-1000.
This parameter effecteve when you select HD2 side.

*Note: After changing "X"(RS11), Please check "Yt"(RS16) again until X and Yt are "0".
X2-axis Home Position
This form useable both for inch and metric. Integrex 200 *Please input "100","200","300","400"
Machine inch *Please input "inch" or "mm"
Call "T1" by MDI mode
Machine Position Target
X2 -10.2397 inch -10.62000 inch

Current Parameter New Parameter

M16 X2 8046 0.1um 56344 0.1um

X2-axis target
mm inch
Radias Diameter Radias Diameter
100 -205 -410 -8.07 -16.14
200 -135 -270 -5.31 -10.62
300 -215 -430 -8.46 -16.92
400 -215 -430 -8.46 -16.92
Select HD2 side on select switch.
Call "T101" by MDI mode
Machine Position Target
X2 -10.236 inch -10.62000 inch

Current Parameter New Parameter

RS13 -100 0.1um -48868 0.1um
*Max input value on this parameter +/-1000.
This parameter effecteve when you select HD2 side.

*Since Lower turret does not has Y-axis, If you see different on Y-direction, you can only adjust by shim.
However, usually new machine does not required to grind shim because already adjustd at Factory.
So if you need to adjust Y-direction on new machine, you need to adjust by Level.
ATC Adjustment
This form useable both for inch and metric. Machine inch *Please input "inch" or "mm"
Set ATC alignment tool

Taper Shaft
Magazine (3piece alignment tool) Mill Spindle

t
ion
Direct
Machine Position
Z-

Ring X1 -0.001177 inch

(3piece alignment tool)
Yt -3.65171 inch
ion
Direct New Parameter
M5 X1 -149 0.1um
own
Up/D
M5 Yt -927534 0.1um

Shaft
ATC Arm (3piece alignment tool)
Tooleye Sensor Adjustment
This form useable both for inch and metric. Machine inch *Please input "inch" or "mm"

All measuurment must be unclamp on Mill coupling

Set BA95,96,97,99 to all "0" before doing this test.

Orient 180
#1 #2 degree
Tool OD

Orient 0
degree

#3 #4

Orient 0 Orient 180

degree degree

Upper Turret
BA95
Tool OD 34.96 inch #1 -479.7816 inch
#2 -548.6806 inch

Original BA95 0.00001inc New BA95 3393900 0.00001inch

BA96
#3 378.5863 inch
#4 447.4895 inch

Original BA96 0.00001inc New BA96 3394320 0.00001inch

Please set BA95,96 with new number before goint to next test.
BA97
#1 -479.9562 inch
#2 -514.7079 inch

Original BA97 -1314391 NEW BA97 -49733205 0.00001inch

BA99
#3 378.6094 inch
#4 413.5769 inch

NEW BA99 -39609315 0.00001inch

Lower Turret

Gage block 3 inch Target 13.38 inch

 #5 -7.37902 inch

New BA97 -49 0.00001inch

Gage block 0.622 inch Target 27.64 inch

#6 14.56057 inch
#7 -12.05669 inch

New BA99 0.00001inch

-19.647975
27.64 20.3597
15.58331
-1558331
 Adjusted Parameter Sheet
Customer: Model: Serial:
Inspected by (Customer): Title:
Machine anchore Yes No Installer: Date:

Factory Setting Current Setting

BA2 66535 0.00001inch BA2 40551 0.00001inch

BA19 264961 0.00001inch BA19 276378 0.00001inch
BA61 28 1.0um BA61 1789 1.0um
BA62 586674 0.00001inch BA62 951714 0.00001inch
BA97 TR1 -1314391 0.00001inch BA97 TR1 ### 0.00001inch
BA99 TR1 -1476157 0.00001inch BA99 TR1 ### 0.00001inch
BA97 TR2 0 0.00001inch BA97 TR2 -49 0.00001inch
BA99 TR2 0 0.00001inch BA99 TR2 0 0.00001inch
BA109 TR2 0 0.00001inch BA109 TR2 0.00001inch

K124 1490152 0.00001inch K124 2417353 0.00001inch

L5 1704666 0.00001inch L5 1406556 0.00001inch

M5 X1 4550 0.1um M5 X1 -149 0.1um

M5 Y -803900 0.1um M5 Y -927534 0.1um
M16 X1 90600 0.1um M16 X1 50002 0.1um
M16 Y 14711 0.1um M16 Y 24334 0.1um
M16 Z1 28490 0.1um M16 Z1 22185 0.1um
M16 X2 0 0.1um M16 X2 56344 0.1um
M16 Z2 39194 0.1um M16 Z2 0.1um

RS11 0 0.1um RS11 2032 0.1um

RS12 0 0.1um RS12 -468 0.1um
RS13 0 0.1um RS13 -48868 0.1um
RS15 0 0.1um RS15 225 0.1um
RS16 0 0.1um RS16 -2032 0.1um

If you have any other parameters were changed, Please write down.
 Integrex mk4 Accuracy Form
Customer: Model: Serial:
Inspected by (Customer): Title:
Machine anchored: Yes No Installer: Date:

Z1-axis Level Check

Level HD1 MID HD2
Pitch -0.005 0 0 mm/M PASS
Twist -0.005 -0.005 0 mm/M PASS

W-axis Level
Level HD1 MID HD2
Pitch -0.01 -0.005 0 mm/M PASS
Twist +0.005 0 0 mm/M PASS

Tolerance
Level HD1 MID HD2
Pitch +/- 0.02 +/- 0.01 0 mm/M
Twist +/- 0.01 +/- 0.005 0 mm/M

Spindle straightness test

Check
Headstock Check
inch PASS
A= 1.7826 inch

B= 1.7826 inch
C

A B C= 6.1 inch
0.0000 / 10 inch

Tailstock Check

A= 0 inch

B= 0 inch
C

A B C= 1 inch
0.0000 / 10 inch
B A
Headstock #2 Check
C

A= 1.9665 inch

B= 1.9665 inch
 C= 6 inch
0.0000 / 10 inch

Tolerance
-0.0003 / 10 inch

Transfer Position

inch
Reading Indicator Check
0.0001 inch
PASS
Tolerance
0.0004 inch

Turret straightness test

Check
1,Y -0.0003 inch/4inch
1,Y 6,Y B=0
2,X -0.0002 inch/4inch PASS
2,X 5,X 3,Z -0.0004 inch/4inch
B=90
4,Y -0.0001 inch/4inch
5,X 0.0004 inch/4inch
B=180
6,Y 0.0003 inch/4inch

Tolerance
3,Z 4,Y +/- 0.0004 / 4 inch
Data Section Description Info from
03/20/2007 release Ver1.0

04/05/2007 Ver1.01 Tooleye Adjustment 1, Drawing of #1,#2(BA97) and #3,#4(BA99) was opposite. Darren Millson(National training)

Adjusted Parameter Sheet 1, correct link to other sheet Tac

04/30/2007 Ver1.02 B-axis Rotation Center(BA61,62) 1, "mm" mode does not works correctly for BA61 Brandon Church(AT Service)

05/29/2007 release Ver1.1 X1,Yt,Z1-axis Home position 1, Z1-axis Home position calculation was not correctly Pierre Gendron(Canada service)
All sheet Adjusted printable setting for all sheet Tac

07/13/2007 Ver1.11 X2,Z2-axis Home Position INT400 X2 storke information(inch only) was wrong Tac

09/11/2007 Ver.1.12 X2,Z2-axis Home Position HD2 side Target number was not link correctlly Tac

Y-axis compensation On RS16 of indicator unit was always "mm", This should be Tac
a changeable when choose a "inch" unit.

Tooleye Adjustment Upper Turret BA97,BA99 calculation was not correct. Tac