Read meINT100,200,300,400mk4Installation procedure and acuracy sheetThis 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 ofpoint in this procedure require to use Metric only because of avoidconfusion.Each sheet give you afor input value and afor output.Please read carefully each caution.

Rough LevelRough Level

Orignal ParameterOriginal Parameterinch*Please input "inch" or "mm"Chuck Width(SP face to Chuck face)Z-axis distance (work center to Home)BA2TR1665350.00001inchBA19TR12649610.00001inchCorrection of center rotation on B-axis (X-direction: from Home)Correction of center rotation on B-axis (Z-direction: from Mill SP face)BA61TR1281.0umBA62TR15866740.00001inchX-coordinate of the sensors reference pointZ-coordinate of the sensors reference pointBA97TR1-13143910.00001inchBA99TR1-14761570.00001inchBA97TR200.00001inchBA99TR200.00001inchOffset amount (X) during automatic tool setting value calculationBA109TR200.00001inchHeight axis rotational center offset of the first rotary axis(Tool tip point control)Z-axis stroke for tip position memory(TEACH function)K12414901520.1umL517046660.00001inchSecond zero-point coordinating valueM5X145500.1umM5Y-8039000.1umZero-point shift amountM16X1906000.1umM16Y147110.1umM16Z1284900.1umM16X200.1umM16Z2391940.1umW-AXIS REVISION (X-AXIS REV.)W-AXIS REVISION (Yt-AXIS REV.)RS1100.1umRS1200.1umW-AXIS REVISION (X2-AXIS REV.)Y-AXIS REVISION(B=90)RS1300.1umRS1500.1umY-AXIS REVISION(B=180 )RS1600.1um

Final Z-axis LevelFinal Z-axis LevelPitch:When bubble move to HD2 side "-", HD1 side "+".Twist:When bubble move to Magazine side "-", Operater side "+".LevelHD1MIDHD2Pitch-0.00500mm/MTwist-0.005-0.0050mm/MToleranceLevelHD1MIDHD2Pitch+/-0.02+/-0.010mm/MTwist+/-0.01+/-0.0050mm/M

Final W-axis LevelFinal W-axis LevelPitch:When bubble move to HD2 side "-", HD1 side "+".Twist:When bubble move to Magazine side "-", Operater side "+".LevelHD1MIDHD2Pitch-0.01-0.0050mm/MTwist+0.00500mm/MToleranceLevelHD1MIDHD2Pitch+/-0.02+/-0.010mm/MTwist+/-0.01+/-0.0050mm/M

SP Taper CheckSpindle Taperness CheckThis form useable both for inch and metric.*If you got result with "-" which means B-side is smaller than A-sideDo 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 Checkinch*Please input "inch" or "mm"A=1.7826inchB=1.7826inchC=6.1inch0.0000/10inchTailstock CheckA=0inchB=0inchC=1inch0.0000/10inchHeadstock #2 CheckA=1.9665inchB=1.9665inchC=6inch0.0000/10inchToleranceB-side smaller than A-side-0.0003/10inch

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Transfer Position CheckTransfer Position CheckThis form useable both for inch and metric.After SP Taper check, leave cutting material in 2nd SP and grab indicater in 1st SP.Indicatorinch*Please input "inch" or "mm"Reading Indicator0.0001inchTolerance0.0004inchYou 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 StraightnessTurret StraightnessThis form useable both for inch and metric.inch*Please input "inch" or "mm"Test Bar Length:7inchSpecify to + and - direction.1,Y-0.0005inch0B=0B=18006,Y0.0005inch2,X-0.0003inch005,X0.0007inchB=90001,Y-0.0003inch/4inch2,X-0.0002inch/4inch3,Z-0.0004inch/4inch4,Y-0.0001inch/4inch5,X0.0004inch/4inch6,Y0.0003inch/4inch-0.0007-0.0001inchIndicate from HD1 for B=0 and 90.Indicate from HD2 for B=180.3,Z4,YTolerance+/-0.0004/4inch

B-axis Rotation Center(BA61,62)B-axis rotation center BA61,BA62,K124This form useable both for inch and metric.inch*Ex: When you want to input "inch" value, please input "inch" if not "mm".DataT= Test bar Length7.874228D/2= Test bar Diameter0.984426Mill SPX= Distance of X move9.548198Z= Distance of X move9.486078BA61=(Xx25.4)-(Zx254)/2x1000788.9240000001BA62=(X+Z)/2x100000951713.8T=7.874228inchBA62 Data before change9517660.00001inchD=1.968852inchBA61 Data before change10001.0umK124 Data before change24174850.1um#1#2BA61= MetricDifferent between OLD and NEW7891.0umBA62=Inch or MetricDifferent between OLD and NEW-52.20.00001inchNew BA61= Metric17891.0umNew BA62=Inch or Metric9517140.00001inchMachine pos.Machine pos.New K124= Metric24173530.00001inchZ=-10.21627inchZ=6.15961inchDistance move Z=9.486078#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.ToleranceWhen finished this test, try this test again and if you get a result with in 1~2um different(as much smaller), it is OK, because there has no specified tolerance.Machine pos.Machine pos.X(D)=-37.9883inchX=-5.1123inchX/2(r)=-18.99415X/2=-2.55615Distance move + L X=9.548198

TDThese parameters offset the tip coordinates and the tool length on B-axis turn.The settings differ between BA61 and BA62.BA61The machine end is offset with actual axes travels according to B-axis turn angle.BA62The value is automatically calculated on tool length measurement, but without machineend offset.Test Bar

X1,Yt,Z1-axis Home Position X1,Yt,Z1-axis Home Posion AdjustmentThis form useable both for inch and metric.Integrex100*Please input "100","200","300","400"inch*Please input "inch" or "mm"Machine PositionTargetX-44.1003inch-44.10000inchY-0.0003inch0.00000inch-44.09892ToleranceCurrent ParameterNew Parameter+/-0.0008inchM16X500400.1um500020.1umM16Y244100.1um243340.1um*Find Center of Test Bar by Rotation"X-axis targetmminchRadiasDiameterRadiasDiameterINTE100-390-780-15.35-30.7INTE200-560-1120-22.05-44.1INTE300-610-1220-24.02-48.04INTE400-610-1220-24.02-48.04Machine PositionTargetZ-11.06797inch-11.06556inchGage Block Length3inchChuck WidthBA2405510.0001inchZ-axis distanceBA192763780.0001inchDifferent between Turret face to Home positionBA629517140.00001inchCurrent ParameterNew ParameterM16Z1227970.1um221850.1umL514065560.00001inch*If machine has not standered KITAGAWA Chuck, You can not use this form unless you find correct Chuck width(BA2).

Gage BlockChuck Width(BA2)Gage Block Length100mm = 4"

Y-axis compensationY-axis CompansationThis form useable both for inch and metric.Indicatorinch*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.)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 Indicater0inchCurrent ParameterNew ParameterRS15225-0.00062250.1um*Max input value on this parameter +/-500.Select HD2 side on select switch.Attach indicator on HD2 with no movement on Y,B-axis.Indicate from front side and read "+/-" direction also.Reading IndicaterY0.00005inchCurrent ParameterNew ParameterRS12-4740.1um-4680.1um*Max input value on this parameter +/-1000.This parameter effecteve when you select HD2 side.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-0.008inchCurrent ParameterNew ParameterRS1600.1um-20320.1um*Max input value on this parameter +/-500.Indicate from Top side and read "+/-" direction also.Reading IndicaterX0.008inchCurrent ParameterNew ParameterRS1100.1um20320.1um*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".

100mm = 4"100mm = 4"100mm = 4"100mm = 4"100mm = 4"First set indicator "0" on backside of test bar.Read indicator at front side.XYYt

X2,Z2-axis Home PositionX2-axis Home PositionThis form useable both for inch and metric.Integrex200*Please input "100","200","300","400"Machineinch*Please input "inch" or "mm"Call "T1" by MDI modeMachine PositionTargetX2-10.2397inch-10.62000inchCurrent ParameterNew ParameterM16X280460.1um563440.1umX2-axis targetmminchRadiasDiameterRadiasDiameter100-205-410-8.07-16.14200-135-270-5.31-10.62300-215-430-8.46-16.92400-215-430-8.46-16.92Select HD2 side on select switch.Call "T101" by MDI modeMachine PositionTargetX2-10.236inch-10.62000inchCurrent ParameterNew ParameterRS13-1000.1um-488680.1um*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 AdjustmentATC AdjustmentThis form useable both for inch and metric.Machineinch*Please input "inch" or "mm"Set ATC alignment toolMachine PositionX1-0.001177inchYt-3.65171inchNew ParameterM5X1-1490.1umM5Yt-9275340.1um

MagazineMill SpindleShaft(3piece alignment tool)Ring(3piece alignment tool)ATC ArmUp/Down DirectionZ-DirectiontTaper Shaft(3piece alignment tool)

Tooleye AdjustmentTooleye Sensor AdjustmentThis form useable both for inch and metric.Machineinch*Please input "inch" or "mm"All measuurment must be unclamp on Mill couplingSet BA95,96,97,99 to all "0" before doing this test.Upper TurretBA95Tool OD34.96inch#1-479.7816inch#2-548.6806inchOriginal BA950.00001inchNew BA9533939000.00001inchBA96#3378.5863inch#4447.4895inchOriginal BA960.00001inchNew BA9633943200.00001inchPlease set BA95,96 with new number before goint to next test.BA97#1-479.9562inch#2-514.7079inchOriginal BA97-1314391NEW BA97-497332050.00001inchBA99#3378.6094inch#4413.5769inchNEW BA99-396093150.00001inchLower TurretGage block3inchTarget13.38inch#5-7.37902inchNew BA97-490.00001inchGage block0.622inchTarget27.64inch#614.56057inch#7-12.05669inchNew BA990.00001inch-19.64797527.6420.35971515.58331-1558331

Orient 0 degree#3Orient 180 degree#4#2Orient 180 degree#1Orient 0 degreeTool OD

Adjusted Parameter SheetAdjusted Parameter SheetCustomer:Model:Serial:Inspected by (Customer):Title:Machine anchored:YesNoInstaller:Date:Factory SettingCurrent SettingBA2665350.00001inchBA2405510.00001inchBA192649610.00001inchBA192763780.00001inchBA61281.0umBA6117891.0umBA625866740.00001inchBA629517140.00001inchBA97TR1-13143910.00001inchBA97TR1-497332050.00001inchBA99TR1-14761570.00001inchBA99TR1-396093150.00001inchBA97TR200.00001inchBA97TR2-490.00001inchBA99TR200.00001inchBA99TR200.00001inchBA109TR200.00001inchBA109TR20.00001inchK12414901520.00001inchK12424173530.00001inchL517046660.00001inchL514065560.00001inchM5X145500.1umM5X1-1490.1umM5Y-8039000.1umM5Y-9275340.1umM16X1906000.1umM16X1500020.1umM16Y147110.1umM16Y243340.1umM16Z1284900.1umM16Z1221850.1umM16X200.1umM16X2563440.1umM16Z2391940.1umM16Z20.1umRS1100.1umRS1120320.1umRS1200.1umRS12-4680.1umRS1300.1umRS13-488680.1umRS1500.1umRS152250.1umRS1600.1umRS16-20320.1umIf you have any other parameters were changed, Please write down.

Accuracy FormIntegrex mk4 Accuracy FormCustomer:Model:Serial:Inspected by (Customer):Title:Machine anchored:YesNoInstaller:Date:Z1-axis LevelCheckLevelHD1MIDHD2Pitch-0.00500mm/MPASSTwist-0.005-0.0050mm/MPASSW-axis LevelLevelHD1MIDHD2Pitch-0.01-0.0050mm/MPASSTwist+0.00500mm/MPASSToleranceLevelHD1MIDHD2Pitch+/-0.02+/-0.010mm/MTwist+/-0.01+/-0.0050mm/MSpindle straightness testCheckHeadstock CheckinchPASSA=1.7826inchB=1.7826inchC=6.1inch0.0000/10inchTailstock CheckA=0inchB=0inchC=1inch0.0000/10inchHeadstock #2 CheckA=1.9665inchB=1.9665inchC=6inch0.0000/10inchTolerance-0.0003/10inchTransfer PositioninchReading IndicatorCheck0.0001inchPASSTolerance0.0004inchTurret straightness testCheckB=01,Y-0.0003inch/4inch2,X-0.0002inch/4inchPASSB=903,Z-0.0004inch/4inch4,Y-0.0001inch/4inchB=1805,X0.0004inch/4inch6,Y0.0003inch/4inchTolerance+/-0.0004/4inch

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update infoDataSectionDescriptionInfo from03/20/2007release Ver1.004/05/2007Ver1.01Tooleye Adjustment1, Drawing of #1,#2(BA97) and #3,#4(BA99) was opposite.Darren Millson(National training)Adjusted Parameter Sheet1, correct link to other sheetTac04/30/2007Ver1.02B-axis Rotation Center(BA61,62)1, "mm" mode does not works correctly for BA61Brandon Church(AT Service)05/29/2007release Ver1.1X1,Yt,Z1-axis Home position1, Z1-axis Home position calculation was not correctlyPierre Gendron(Canada service)All sheetAdjusted printable setting for all sheetTac07/13/2007Ver1.11X2,Z2-axis Home PositionINT400 X2 storke information(inch only) was wrongTac09/11/2007Ver.1.12X2,Z2-axis Home PositionHD2 side Target number was not link correctllyTacY-axis compensationOn RS16 of indicator unit was always "mm", This should be a changeable when choose a "inch" unit.TacTooleye AdjustmentUpper Turret BA97,BA99 calculation was not correct.Tac