Doosan HM 1000 Maintenance Manual
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Doosan HM 1000 Maintenance Manual

Doosan HM 1000 Maintenance Manual

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HMC Maintenance Manual
(HM 1000/1250)

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Summary of Contents for Doosan HM 1000

  • Page 1 Machine Tools HMC Maintenance Manual (HM 1000/1250)

  • Page 3: Table Of Contents

    HM 1000/1250 HM1000MTE04 Table of Contents 1. Assembling/disassembling the spindle cartridge ..........3 1.1 Disassembling the tool unclamp cylinder ................. 11 1.2 Disassembling the spindle cartridge ................16 1.3 Installing the spindle cartridge ..................19 1.4 Assembling the tool unclamp cylinder ................21 1.5 Running-in the main spindle bearing ................
  • Page 4 HM 1000/1250 HM1000MTE04 5.5 Disassembling the ball screw on the Z axis ..............112 5.6 Installing the ball screw on the Z axis ................117 6. Machine Precision ....................123 6.1 Straightness of Z axis..................... 125 6.2 Straightness of X Axis ....................126 6.3 Straightness of Y Axis ....................

  • Page 5: Assembling/Disassembling The Spindle Cartridge

    HM 1000/1250 HM1000MTE04 1. Assembling/disassembling the spindle cartridge ※ Spindle Cartridge Parts List 125, 126 127, 128 129, 131...
  • Page 6 HM 1000/1250 HM1000MTE04 Parts No. Description Material / Specification Q'ty Remarks P74060006 Hex. Socket Plug(S) FPS-S1/8 C12011112 Sleeve SCM435 S2215561 Hex. Socket Head Bolt BB12×45 S8000160 O-Ring S8000160 O-Ring S8011900 O-Ring G190 C68012064D Hex Socket Plug (NPT1/16) C12011021 Main Spindle...
  • Page 7 HM 1000/1250 HM1000MTE04 ※ Tool Unclamp Cylinder Parts List 191, 190 189, 188 Parts No. Description Material / Specification Q'ty Remarks C81018273C Housing SM45C S3520506 Set Screw(Hex. S/Head) BQ8×16 C81019104 Spacer STKM13A R11324 Cyl. Roller Bearing N1019BMR1CCG18P5 C81019113 Labyrinth SM45C...
  • Page 8 HM 1000/1250 HM1000MTE04 Parts No. Description Material / Specification Q'ty Remarks C81018532C Cylinder SM45C R46093 Elbow Connector PL8-PT1/4 Sang-A P74060006 Hex. Socket Plug (S) FPS-S1/8 S8001350 O-Ring P135 C81018253B Cylinder Cap SM45C S22215061 Hex. Socket Head Bolt BB12×25 S8000140 O-Ring...
  • Page 9 HM 1000/1250 HM1000MTE04 ※ Spindle Head Gear Box Parts List 239, 240 241, 127 250, 251 252, 253 254, 255 256, 257...
  • Page 10 HM 1000/1250 HM1000MTE04 Parts No. Description Material / Specification Q'ty Remarks S8000110 O-Ring S2208861 Hex. Socket Head Bolt BB8×20 C81018524A Spring Supporter SCM435 S8000320 O-Ring C68011683B Disc Spring 70×32×3.5×5.4 Rolex C68011463A Cap(1) SS41 S2208661 Hex. Socket Head Bolt BB8×16 S8010800...
  • Page 11 HM 1000/1250 HM1000MTE04 Parts No. Description Material / Specification Q'ty Remarks C68011813 Gear (76Z) SCM415 S3520486 Set Screw (Hex. S/Head) BQ8×12 S5711062 Parallel Pin SP8X×20 S8010650 O-Ring ※ Spindle Head Gear Shifter Parts List Parts No. Description Material / Specification...
  • Page 12 HM 1000/1250 HM1000MTE04 Parts No. Description Material / Specification Q'ty Remarks S6260050 Lock Nut AN05 S6270050 Lock Washer AW05 C60011142D Shifter SM45C C50018183A Cylinder Cap SM45C S2208861 Hex. Socket Head Bolt BB8×20 S8010400 O-Ring R56162 SKY Packing SKY-32 Sakagami P51400008...

  • Page 13: Disassembling The Tool Unclamp Cylinder

    HM 1000/1250 HM1000MTE04 1.1 Disassembling the tool unclamp cylinder ※ Preparations for disassembling the tool unclamp cylinder (1) Keep the machine clean and away from dust or oil residues. (2) Pull out the tool from the spindle, if any. (3) Move both Z and Y axis to an appropriate position (near the center position) and turn off the power.
  • Page 14 HM 1000/1250 HM1000MTE04 4) Remove C50019133B rotating union cap. ▪ 4-BB6×20 Rotating Union Cap Rotating Union Cap Fixing Bolt 5) Remove C50019123 housing. ▪ 6-BB5×20 Housing Housing Fixing Bolt 6) Remove R27234 rotating union. Rotating Union ※ Note that the bolt on this union is left- handed.
  • Page 15 HM 1000/1250 HM1000MTE04 8) Remove C81018273C housing. ▪ 8-BB6×30 ※ No not lock or loosen the set-screw that is installed on the housing. Set Screw Housing Housing Set Screw Fixing Bolt 9) Remove C81018263A stopper. ※ Use the air tool to loosen the bolts (as they are too tight to loosen with an ordinary wrench).
  • Page 16 HM 1000/1250 HM1000MTE04 11) Remove C60016063C housing. ▪ 4-BB12×70 Housing Fixing Bolt Housing 12) Loosen C68011573B lock-nut. ① Loosen two set-screws (BQ8×16) on two of 16 bolt holes, one for each, which reveal after you removed C81018263A stopper. ※ To help recognize the location of the set-screw, mark the location of the set-screw with the applicable disk when loosening it.
  • Page 17 HM 1000/1250 HM1000MTE04 14) Remove both C81019123B labyrinth and C81019123B labyrinth. Then, pull out the parallel key (KS10×8×37). ▪ 6-BB8×25, 2-KS10×8×37 Labyrinth Labyrinth Labyrinth Labyrinth 15) The spindle tool unclamp cylinder and labyrinth are removed before removing the spindle cartridge.

  • Page 18: Disassembling The Spindle Cartridge

    HM 1000/1250 HM1000MTE04 1.2 Disassembling the spindle cartridge ※ If you have the necessity to disassemble the spindle cartridge for the reason of repairing any damaged parts such as main spindle or spindle bearing, remove the spindle tool unclamp cylinder as instructed above before proceeding.
  • Page 19 HM 1000/1250 HM1000MTE04 3) Mark the location of C12011042 front cover with a marker pen before removing it. ▪ 4-BB12×30 ※ Take caution not to lose the O-ring. Mark the location of the front cover with a marker pen before removing it.
  • Page 20 HM 1000/1250 HM1000MTE04 5) By the time 2/3 of the sleeve has been revealed, Rope use a thin rope to hook the sleeve to the crane. Then use the crane to pull the sleeve out with care. ▪ Care must be taken to avoid damage to G190 O- ring in the outer side of the sleeve.

  • Page 21: Installing The Spindle Cartridge

    HM 1000/1250 HM1000MTE04 1.3 Installing the spindle cartridge 1) Preparations for installing the spindle cartridge ① Clean up the spindle cartridge and other component parts to remove. (Apply new grease to the installation site of the spindle head body after cleaned up) ②...
  • Page 22 HM 1000/1250 HM1000MTE04 ⑥ Insert N1019BMR1CCG18P5 roller bearing from the outer race so that it contact on the spacers. Sleeve Roller Bearing Gear 57Z Gear97Z Space Gear 63Z 4) Closing the front cover ① With grease applied to the O-ring hole of the sleeve, insert every one of the O-rings.

  • Page 23: Assembling The Tool Unclamp Cylinder

    HM 1000/1250 HM1000MTE04 1.4 Assembling the tool unclamp cylinder 1) Installing the labyrinth ① Use C81019113 labyrinth to impact on the roller bearing inner race so that the bearing completely contacts on the front gears and spacers. ② Insert the parallel key into the spindle. Then, insert C81019113 labyrinth.
  • Page 24 HM 1000/1250 HM1000MTE04 Use a Φ6.8 drill bit to drill a Φ5.5, 2mm ~ 3mm long hole into two penetrated ones of 16 bolt holes (prepared for installing the lock nuts). Clean and smooth the surface of the holes. ③ Tighten two of BQ8×16 set-screws.
  • Page 25 HM 1000/1250 HM1000MTE04 6) Adjusting gap between cylinder base and stopper Cylinder Base Temporary Bolt (target: 2mm) ① To keep the cylinder base in contact on the “B” Cylinder housing, use 2-BB8×40 bolts to install the Base cylinder base temporarily. Measure the gap between cylinder section and stopper section.
  • Page 26 HM 1000/1250 HM1000MTE04 Housing Housing Fixing Bolt ▪ Adjusting the runout on the draw bar Indicator With the housing bolts tightened slightly, install the indicator at the distal section of the draw bar. While turning the spindle manually, check the...
  • Page 27 HM 1000/1250 HM1000MTE04 ② Use the air gun (if available) to push in the Cylinder piston of the tool unclamp cylinder to the Ass’y possible end (tool clamping state) and measure the gap from the pusher. (“B”) “B” ③ Remove the pusher (that is installed on the tool unclamp cylinder) and fit it on site so that the gap between "A"...
  • Page 28 HM 1000/1250 HM1000MTE04 11) Installing the rotating union Install R27238 rotating union. ▪ Note that the bolt on this union is left- handed. Turn it left to tighten. Rotating Union 12) Installing the housing Install C50019123 housing at the end of the piston.
  • Page 29 HM 1000/1250 HM1000MTE04 ④ Fit the installation section of the union cap on site so that the gap between A and B is 2mm. Where, you must fit both of two installation sections (one for the rotating union installation section and one for the piston installation section) before installing the union cap into the rotating union.

  • Page 30: Running-In The Main Spindle Bearing

    HM 1000/1250 HM1000MTE04 1.5 Running-in the main spindle bearing ※ When the installation is completed, check for any problem regarding the installation. If no particular problem is found, turn on the machine tool and set the reference point for each axis before running-in the spindle bearing.
  • Page 31 HM 1000/1250 HM1000MTE04 ※ Major Target Sizes of Tool Unclamp Cylinder Ⓐ2mm Ⓑ12.5mm Ⓓ2mm Ⓒ1mm Ⓐ : Gap between End Cap and Cylinder Ⓑ : Tool Unclamp Cylinder Stroke Ⓒ : Cylinder Gap when in Tool Clamping (Cylinder Pusher Gap) Ⓓ...

  • Page 32: Assembling/Disassembling The Table

    HM 1000/1250 HM1000MTE04 2. Assembling/disassembling the table ※ Index Table Assembly 1280 1270 1260 1770 1760 1710 2160, 2150 2090, 2080 1730 1750 1700 1670 2140, 2130 2070, 2060 1720 1740 1690 1680 1660 2120, 2110 2100 2000 2050, 2040...
  • Page 33 HM 1000/1250 HM1000MTE04 NO. ITEM No. Description Q'ty Mat. / Spec. Remarks 0160 C12051171A Clamp Plate SM45C 0170 S2221861 Hex. Socket Head Bolt BB16×60 0190 R18747 Cam-Follower CF-18UU 0200 C68051054 Set-Piece S273002 0210 S3520486 Set Screw (Hex. S/Head) BQ8×12 1260 C12051433A...
  • Page 34 HM 1000/1250 HM1000MTE04 NO. ITEM No. Description Q'ty Mat. / Spec. Remarks 1970 P74060006 Plug Hex. Socket(S) FPS-S1/8 1980 R55501 Quad Ring Q4442-525 Hansung 1990 R54377 Back-Up Ring BU49T1800-GF40 Busak (Hansung) 2000 R53407 O-Ring P340 (CO 0116) 2010 R53472 O-Ring...
  • Page 35 HM 1000/1250 HM1000MTE04 ※ Worm Shaft & Servo Motor Installation Area 1050, 1060, 1070 1040 1030 1080 1020 1090 1010 1000 ※ Worm & Spur Gear Installation Area 1290 1430 1310 1300 1420 1410 1400 1320 1390 1330 1380 1340...
  • Page 36 HM 1000/1250 HM1000MTE04 NO. ITEM No. Description Q'ty Mat. / Spec. Remarks C81056724B Lock Nut SCM435 S6001680 Radial Ball Bearing #6008ZZ 1000 C81058063C Worm Shaft SCM415 1010 S8202422 Oil Seal D50×72 1020 P80300105 O-Ring S105 1030 C12051733A Bearing Housing SM45C 1040 R10234A Ang.

  • Page 37: Disassembling The Table

    HM 1000/1250 HM1000MTE04 ※ Hydraulic Circuit Line in the Table Pallet Air Blow Table Unclamp Pallet Clamp Pallet Unclamp YV61 YV62 YV63 YV65 2.1 Disassembling the table ※ If you need to disassemble the table for repair purposes, meticulous preparations and care must be taken as this is not an easy work.
  • Page 38 HM 1000/1250 HM1000MTE04 1) Preparations for disassembling the table ① Clean up inside of the machine. (In particular, clean up the sliding cover so that it does not slip off while you are working on it) ② In the middle X axis, remove the middle acrylic plate of the splash guard ceiling to facilitate lifting up the table using the crane.
  • Page 39 HM 1000/1250 HM1000MTE04 5) Use the crane to lift up and remove C12051171A clamp plate. If this is not available, alternatively place a wood support in an appropriate site inside the machine and put down the plate on it. 6) Loosen the table bolts.

  • Page 40: Disassembling The Piston Shaft (Designed For Pallet Clamping/Unclamping)

    HM 1000/1250 HM1000MTE04 2.2 Disassembling the piston shaft (designed for pallet clamping/unclamping) ※ Sometimes you may need to disassemble C12051213C piston shaft to handle with problems such as an oil leak from the cylinder that is designed for pallet clamping/unclamping. Make thorough preparations (new component parts and tools) and keep the work place clean including yourself while working on it.

  • Page 41: Disassembling The Piston (Designed For Table Clamping/Unclamping)

    HM 1000/1250 HM1000MTE04 4) Insert two eye bolts into the tap place in the center Eyebolt Hole of C12051213C piston shaft, hook the rope to the Piston Shaft eye bolt and connect it to the crane. Lift up the cylinder assembly with care.

  • Page 42: Removing The Worm Shaft And Worm Wheel

    HM 1000/1250 HM1000MTE04 Cylinder 3) Place the piston assembly on a clean worktable Center Shaft-P and loosen the bolts (6-16×35) on C12051713 Bearing clamping plate. Clamping Piston Push Rod Plate 4) Remove the clamping plate and separate center shaft-P from the piston before removing bearing Center and cylinder cap.
  • Page 43 HM 1000/1250 HM1000MTE04 2) Remove the side oil cover and the cover as shown. Oil Cover ※ If you remove the oil cover, the oil inside will flow out. Cover 3) Loosen the bolts in the worm-shaft side of the coupling between B-axis servo motor and worm shaft.
  • Page 44 HM 1000/1250 HM1000MTE04 6) Loosen the bolts on C81051353B bearing case and use the pin puller to remove the worm wheel assembly through the tap hole in the center of C81051353B spur gear. ▪ 3-BB 8×25 Spur Bearing Adjust Gear...

  • Page 45: Installing The Worm Shaft And Worm Wheel

    HM 1000/1250 HM1000MTE04 2.5 Installing the worm shaft and worm wheel 1) Fitting the bearing cap in the spur gear side on site ① Place two C12051314 spacers on the graplate and measure the length and parallelism using the indicator. If the error of each of the length and parallelism is over 0.002mm, grind or rub the spacer with sandpaper to meet the tolerance.
  • Page 46 HM 1000/1250 HM1000MTE04 “A” “B” Bearing Bearing Case Bearing 3) Fitting the worm wheel into the key hole Spur ① With no key inserted, try installing the worm Gear wheel into the spur gear. ※ If you encounter a problem, use a file or Worm sandpaper to smooth the installation site.
  • Page 47 HM 1000/1250 HM1000MTE04 6) Installing the spur gear assembly Adjust Spur Bearing By the time about 10mm of the spur gear Liner Gear Case assembly is yet to be inserted into the table base, insert C60052144B adjustable liner and the remaining 10mm to the end.
  • Page 48 HM 1000/1250 HM1000MTE04 9) Adjusting the center line of the worm shaft ① Loosen the bearing case bolts (3-BB8×25) of the spur gear assembly and remove C60052144B adjustable liner. ② While moving the whole spur gear assembly, measure the highest (①) and Center lowest (②) points.

  • Page 49: Assembling The Piston (Designed For Table Clamping/Unclamping)

    HM 1000/1250 HM1000MTE04 2.6 Assembling the piston (designed for table clamping/unclamping) ※ Before assembling the table cylinder and piston, clean up each component part and the table base as well as around the work area. 1) Installing the center shaft-P unit ①...
  • Page 50 HM 1000/1250 HM1000MTE04 2) Installing the center shaft-P 1-P420 ① Clean up the inner table base and insert the O- rings before applying grease. ▪ O-Ring: 3-P340, 1-P420 3-P340 ② Insert two eye bolts into the tap place in C12051141B center shaft-P, hook the rope to the eye bolt and connect it to the crane.

  • Page 51: Installing The Piston Shaft (Designed For Pallet Clamping/Unclamping)

    HM 1000/1250 HM1000MTE04 2.7 Installing the piston shaft (designed for pallet clamping/unclamping) 1) Preparations P200 Center O-Ring Shaft-P Clean up the inner center shaft-P into which you insert the O-ring. Then, apply grease to it. ▪ O-Ring: 1-P200 2) Installing the piston shaft...

  • Page 52: Assembling The Table (Pallet Base)

    HM 1000/1250 HM1000MTE04 2.8 Assembling the table (pallet base) 1) Preparations for assembling the table ① Apply grease to the O-rings (1-G390) of the inner table and the dust seal of the outer table base as even as possible to avoid damage to...
  • Page 53 HM 1000/1250 HM1000MTE04 3) Installing the clamp plate Bolt ① Lift up C12051171A clamp plate and put it down on the table in the right direction with care. Then, tighten the bolts. Clamp Plate ▪ 6-BB16×60 ② Turn on the machine, perform the pallet unclamping manually and use a 30mm wrench to tighten NA24 nut (for C10051034A shift).

  • Page 54: Resetting The Reference Point For The B Axis

    HM 1000/1250 HM1000MTE04 2.9 Resetting the reference point for the B axis ※ If there occurs one of the following problems with the B axis, you must reset the home position for the B axis. (1) If you re-install the B-axis servo motor (2) If the B axis is mis-positioned (3) If the "...
  • Page 55 HM 1000/1250 HM1000MTE04 3) If the parallelism is corrected properly, set the fourth item "Bit (APZ)" of the B-axis row in parameter #1815 to "0". Then, change it to "1" and turn off the power. ▪ If you change the "Bit (APZ)" parameter, the “P/S Alarm 000 Must Turn Off Power” and “P/S Alarm 300 nAxis Need ZRN”...

  • Page 56: Adjusting And Repairing Atc

    HM 1000/1250 HM1000MTE04 3. Adjusting and repairing ATC Servo motor for rotating tool magazine Reducing Gear Sub Changer Waiting Pot Main Changer Changer Arm Tool Pot Pot Chain Tension Adjusting Device 3.1 Resetting the reference point for ATC servo magazine ※...
  • Page 57 HM 1000/1250 HM1000MTE04 2) Change the value of "Keep Relay K12.2" to 1. ▪ K12.2(KMATC) : If you adjust the position of ATC changer, set it to 1. (This will control the servo motor regardless of the changer arm position) 3) Press the MODE button in the start screen [ r 0000 ] of the servo drive to display [ rd-off ].
  • Page 58 HM 1000/1250 HM1000MTE04 6) From the [ Jr.0000 ] screen, use the up/down arrow buttons to rotate the magazine in a desired direction. In such a way, adjust the pot position.  Fine-tune the magazine position ▪ If you want to fine-tune the magazine position, set parameter #27 to a lower value.
  • Page 59 HM 1000/1250 HM1000MTE04 8) In the [ Jog.run ] screen, press the MODE button to display [ rd-off ].  [ rd-off ] : Ready to operate the jog run 9) In the [ rd-off ] screen, press the up arrow button to display [ Org.S - - ].

  • Page 60: Adjusting The Position Of Atc Sub Changer

    HM 1000/1250 HM1000MTE04 3.2 Adjusting the position of ATC sub changer 1) Positioning the magazine pot ① Move the magazine tool pot #1 to the change position, and install the centering fixture between tool pot and sub changer. Then, move the sub changer to the magazine pot position.
  • Page 61 HM 1000/1250 HM1000MTE04 ③ Horizontal position of the waiting pot Use the center bar to check the position. Use the screw for adjusting the stroke of the right hydraulic cylinder piston to correct the sub changer position.

  • Page 62: Alignment Between Atc And Spindle

    HM 1000/1250 HM1000MTE04 3.3 Alignment between ATC and spindle 1) Adjusting the spindle orientation In the current spindle orientation (M19), install the indicator on the pallet and present the gauge to the spindle driving key or key place. While moving the X axis manually, measure the parallelism between X axis and two driving key places.
  • Page 63 HM 1000/1250 HM1000MTE04 5) Insert the centering fixture into the changer arm. ① Perform "Pin Unlocking" in manual operation. ② 5) Insert the changer arm fixture into the changer arm. 6) Use the adjustable (up/down, forward/backward) bolts to set the exact center of ATC centering fixture and adjust the distance between two centering fixtures.

  • Page 64: Atc Hydraulic Circuit Line

    HM 1000/1250 HM1000MTE04 3.4 ATC Hydraulic Circuit Line Sub Changer Arm In / Out SX31 Tool Pull Out Waiting Pot Home Mag.Pot Wait.Pot SX32 Forward Backwar Position Position Position Confirm SL39 Tool SX33 SX34 SX35 Detect SX38 S2 S3 YV31...

  • Page 65: Learning About Atc Magazine Touch Panel

    HM 1000/1250 HM1000MTE04 3.5 Learning about ATC magazine touch panel 1) Switching screen ① Manual Operation ② Machine Information ③ Tool Offset ④ Alarm Information ⑤ I/O Information...
  • Page 66 HM 1000/1250 HM1000MTE04 2) Rotating the tool magazine ① Select an operation mode If you press a mode button (Manual or Auto), the selected button will light on. If you select a different mode, the current mode will be cancelled.
  • Page 67 HM 1000/1250 HM1000MTE04 3) Operate the sub changer manually ▪ You can use the [Mode change] button to switch between Rotary Switch screen and Button screen. Select a desired screen. ① Operating the sub changer manually in the Rotary Switch screen (a) Press the MANUAL button both on the main OP and on the manual OP.
  • Page 68 HM 1000/1250 HM1000MTE04 4) Machine Information Press the button to check the state of the machine in the Machine Information screen. ☞ You can check the current state of the machine by the corresponding indicator. Lamp Explanation [Mode in main OP] ☞...
  • Page 69 HM 1000/1250 HM1000MTE04 5) I/O in the Tool Offset screen ▪ In [Tool Offset], you can read and write offset values to and from the NC. ※ No I/O is enabled if the selected tool number is currently in the spline or in the waiting pot.
  • Page 70 HM 1000/1250 HM1000MTE04 ③ Writing data (a) Follow the steps above to select a desired tool number. (b) Enter a numeric in the applicable field(s). ☞ Press any data field to display the keypad where you select a numeric and press [ENT].
  • Page 71 HM 1000/1250 HM1000MTE04 ② To check the alarm history (a) If you press the [Alarm History] button, you can check the history of alarms that have ever occurred in the current machine. The operation of the function button ([Start], up/down arrow button, [Del], [END]) is the same.
  • Page 72 HM 1000/1250 HM1000MTE04 ① Input Screen If you press [INPUT], there appears the start page showing the information including address, symbol and description of the input signal where you can check the operation state of the tool magazine and various switches.
  • Page 73 HM 1000/1250 HM1000MTE04 ◈ Input / Output Address Information Description Address Symbol Magazine Tool Pot Tool Out X9.5 SF31 Magazine Tool Pot Tool Out Interlock X10.0 SL39 Sub Changer Arm In X10.1 SL31 Sub Changer Arm Out X10.2 SL32 Sub Changer Home Position X10.3...
  • Page 74 HM 1000/1250 HM1000MTE04 ◈ Alarm Message Alarm Massage Recovery 1) T code instructed at a position where no tool can be selected. 2) Defective ATC related switch or solenoid 2059 T-COMMAND ILLEGAL POSITION valve 3) Check the ATC state as well as the component parts.
  • Page 75 HM 1000/1250 HM1000MTE04 1) ATC arm not in the reference point. 2252 ATC INITIAL POSTION ALARM 2) Return the ATC arm to the reference point. 3) Check if the switches work properly. 1) Rotating the changer CW/CCW by 180 degrees is not completed within 25 seconds.
  • Page 76 HM 1000/1250 HM1000MTE04 1) The Arm In/Out operation of the auxiliary exchange unit is not completed within 15 seconds. 2273 2) Defective switch or solenoid valve. Or ATC SUB CHG. ARM IN/OUT ALM distance from the dog is set improperly.

  • Page 77: Tool Search Sequence Chart

    HM 1000/1250 HM1000MTE04 3.6 Tool Search Sequence Chart Tool Search Start (T _ _;) ★ AL 2250 “ATC OP Manual Mode” ATC Sub Changer ▪ From manual OP, turn the Auto/Manual selection switch to O.P Auto Mode? Auto. Searched tool No = Spd.
  • Page 78 HM 1000/1250 HM1000MTE04 ▪ Output: Y4.1(SCAO.R) –YV32 Sub Changer Arm Out Sub Changer Arm Out ▪ Completed: X10.2(SCAO.M) –SL32 Sub Changer Arm Out ★ AL 2273 “ATC Sub Tool In/Out Alarm” Sub Changer Arm ▪ Check: X10.1(SCAO.M) –SL31 Sub Changer Arm In Out? X10.2(SCAO.M) –SL32 Sub Changer Arm Out...

  • Page 79: Tool Changing (M06) Sequence Chart

    HM 1000/1250 HM1000MTE04 3.7 Tool Changing (M06) Sequence Chart Tool Change Start (M06) ATC Main O.P ★ AL 2250 “ATC O.P Manual Mode” Auto Mode? ★ AL 2260“M06 Command Illegal Position” Tool Search ▪ Check: Perform the tool search. O.K? Program : T _ _;...
  • Page 80 HM 1000/1250 HM1000MTE04 “1” ▪ Output: Y5.1(MCSS.R) –YV42 Main Changer Spd Side Main Changer Spindle Side ▪ Completed: X11.2(MCSS.M) –SX42 Main Chan. Spd Side ★ AL 2274“Tool Changer Spindle/Mag Side Alarm” Main Changer ▪ Check: X11.1(MCMS.M) –SX41 Main Chan. Mag Side Spindle Side? X11.2(MCSS.M) –SX42 Main Chan.
  • Page 81 HM 1000/1250 HM1000MTE04 “A” ▪ Output: Y5.5(CACW.R) –YV11 M-Chan. Arm 180CW Changer Arm 180CW Rotation ▪ Completed: X11.4(CACW.M) –SX45 M-Chan. Arm 180CW ★ AL 2055“Spindle Tool CL/UC Overtime Alarm” M-Chan. Arm ▪ Check: X11.4(CACW.M) –SX45 M-Chan. Arm 180CW 180CW? X11.5(CACC.M) –SX46 M-Chan. Arm 180CCW “B”...

  • Page 82: Tool Re-Charge Sequence Chart

    HM 1000/1250 HM1000MTE04 3.8 Tool Re-Charge Sequence Chart M06 End ▪ Output: Y4.7(WPFD.R) –YV41 Waiting Pot Forward Waiting Pot Forward ▪ Completed: X10.6(WPFD.M) –SX36 Waiting Pot Forward ★ AL 2256 “Waiting Pot Backward/Forward Alarm” Waiting Pot ▪ Check: X10.6(WPFD.M) –SX36 Waiting Pot Forward Forward? X10.7(WPRC.M) –SX37 Waiting Pot Backward...
  • Page 83 HM 1000/1250 HM1000MTE04 “1” ▪ Output: Y12.2(SCS1.R) –YV33 Sub Changer Pos. 1 Sub Changer Mag. Pot Position Y12.3(SCS2.R) –YV34 Sub Changer Pos. 2 Y12.4(SCS3.R) –YV35 Sub Changer Pos. 3 Y12.5(SCS4.R) –YV36 Sub Changer Pos. 4 ▪ Completed: X10.4(SCMP.M)–SX34 Sub Chan.Mag.Pot Pos.

  • Page 84: Apc Sequence Chart

    HM 1000/1250 HM1000MTE04 4. APC Sequence Chart...
  • Page 85 HM 1000/1250 HM1000MTE04 ※ Pallet Changing (M60) Sequence Chart M60 Command ★ AL 2326 “APC O.P Manual Mode” APC O.P ▪ From APC manual OP, turn the Auto/Manual selection Auto Mode? switch to Auto. ▪ Move to Z-axis ref. point Move to Z-Axis 1 Ref.
  • Page 86 HM 1000/1250 HM1000MTE04 ▪ Output: Y8.5(CRET.R) –KA92 Pallet Changer Arm Ret. APC 1 Arm Return ▪ Completed: X14.1(ARET.M) –SL72 Pallet Chan. Arm 1 Ret. ★ AL 2329 “APC Arm Advance./Return. Alarm” APC 1 Arm ▪ Check: X14.0(AADV.M) –SL71 Pallet Chan. Arm 1 Adv.
  • Page 87 HM 1000/1250 HM1000MTE04 ▪ Output: Y7.7(SG2C.R) –YV74 S/G Door 2 Close APC 2 Door Close ▪ Completed: X16.3(SG2C.M) –SL8D S/G Door 2 Close ★ AL 2331“Splash Guard Door Open /Close Alarm” APC 2 Door ▪ Check: X16.0(SG1O.M) –SL8A S/G Door 1 Open Close O.K?
  • Page 88 HM 1000/1250 HM1000MTE04 “B” Go To “A” Pallet Stay On ▪ “A” Check: X14.5(PSTL.M) –SL76 Pallet Stay ON Right Side For Left Side? X15.5(PSTR.M) –SL86 Pallet Stay ON Left Side ▪ Move to X-axis 3rd ref. point ▪ Move to X-Axis 3rd Ref. Position Output: Y7.6(SG2O.R) –YV73 S/G Door 2 Open...
  • Page 89 HM 1000/1250 HM1000MTE04 ▪ Move to X-axis 2 ref. point ▪ Move to X-Axis 2nd Ref. Position Output: Y5.7(SG1O.R) –YV71 S/G Door 1 Open ▪ & Splash Guard Door 1 Open Output: Y7.7(SG1C.R) –YV74 S/G Door 2 Close & Splash Guard Door 2 Close ▪...

  • Page 90: Assembling & Disassembling The Ball Screw

    HM 1000/1250 HM1000MTE04 5. Assembling & disassembling the ball screw 5.1 Disassembling the ball screw on the X axis ※ Ball screw on the X axis 220, 210 200, 080 160, 170, 180 220, 210 160, 170, 180 200, 080...
  • Page 91 HM 1000/1250 HM1000MTE04 Parts No. Description Mat. / Spec. Q'ty Remarks C12041023 Ball Screw(X) 50TIF012-2634C3 Tsubaki S8000070 O-Ring C68023043D Bearing Supporter SS41 S2215261 Hex. Socket Head Bolt BB12×30 P74060006 Hex. Socket Plug (S) FPS-S1/8 S8000100 O-Ring R12065 Thrust Ang. Ball Bearing...
  • Page 92 HM 1000/1250 HM1000MTE04 1) Remove the sliding covers on both sides on the X axis, move the X axis to an appropriate position for the work, and turn off the machine. 2) Separate C12021053 cover from C12021032 Lubrication Motor Pipe...
  • Page 93 HM 1000/1250 HM1000MTE04 5) Loosen the fixing bolts (6-BB 12×30) of the ball Ball Screw screw nut that is installed on the table base. 6) Loosen C12021032 motor bracket bolts (6- BB12×30) and positioning pins (4-TPB-10×50). 7) Pull out the motor bracket and ball screw assembly from the machine.
  • Page 94 HM 1000/1250 HM1000MTE04 9) Loosen the lock-nut from the ball screw and motor bracket assembly (pulled out from the machine). Motor Lock Nut ▪ Loosen the set-screws (x3) that are designed for Bracket locking the lock-nut. Then, use the tool that is specific to the lock-nut.

  • Page 95: Installing The Ball Screw On The X Axis

    HM 1000/1250 HM1000MTE04 5.2 Installing the ball screw on the X axis 1) Installing the thrust angular ball bearing into the bracket ① Install R1206540TAC thrust angular ball bearing into C12021032 bracket in the correct direction, and measure the sectional depth between bearing and bracket.
  • Page 96 HM 1000/1250 HM1000MTE04 “A” “B” Bearing Motor Support Bracket 3) Tightening the lock nut in the motor bracket side Place the motor bracket (where the bearing is Spacer Lock Nut already installed) vertically into which you install the ball screw, insert C68023034 collar, and tighten the lock nut.
  • Page 97 HM 1000/1250 HM1000MTE04 5) Installing the motor bracket Motor Bracket Insert C50042034A adjustable liners (x6) into C12021032 motor bracket so that they fit into their respective position (marked when removing them). ▪ 6-BB16×45, 2-TPB10×50 Adjustin g Liner 6) Runout on the ball screw in the motor bracket side ①...
  • Page 98 HM 1000/1250 HM1000MTE04 9) Pre-tension on the ball screw If the measurement is off the target after Space following the "Check the pre-tension work on the ball screw" instructions above, you must correct the pre-tension on the ball screw. ① Loosen the lock-nut.
  • Page 99 HM 1000/1250 HM1000MTE04 12) Installing the servo motor on the X axis Lift up the servo motor (with R18717 rigid Coupling Bolt coupling installed) using the crane, where balance must be maintained horizontally, and install it into the motor bracket with care. The...
  • Page 100 HM 1000/1250 HM1000MTE04 ▪ Resetting the reference point for the X axis (1) Insert the test bar into the spindle. (2) Return the X axis to the reference point manually. (3) In MDI mode, move the X axis to the middle stroke position (X1050), Y to Y250, and Z to Z30, respectively.

  • Page 101: Disassembling The Ball Screw On The Y Axis

    HM 1000/1250 HM1000MTE04 5.3 Disassembling the ball screw on the Y axis ※ Ball screw on the Y axis 1000 1000 1020 1030 1040...
  • Page 102 HM 1000/1250 HM1000MTE04 Parts No. Description Mat. / Spec. Q'ty Remarks C12131522A Motor Bracket GC250 S2221861 Hex. Socket Head Bolt BB10×60 P57210080 Taper Pin (W/Tap) TPB10×80 R18717 Rigid Coupling JKW-63-35-35 C68023104A Lock Nut C68023034 Collar SS41 R12065 Thrust Ang. Ball Bearing...
  • Page 103 HM 1000/1250 HM1000MTE04 1) Remove the column cover. 2) To facilitate the disassembling work, move the Y axis to the intermediate position, and insert a wood support at an appropriate area between column and head body in order to prevent the spindle head from falling off when removing the ball screw, and turn off the machine.
  • Page 104 HM 1000/1250 HM1000MTE04 5) Disconnect the lubrication pipe from the C12031532B bracket (see the picture below) and loosen the lock nut. ▪ Loosen the set-screws (x3) that are designed for locking the lock-nut. Then, use the tool that is specific to the lock-nut. If it is not available, use the hammer and chisel to impact on and loosen the lock-nut.
  • Page 105 HM 1000/1250 HM1000MTE04 8) Pull out the motor bracket and ball screw assembly from the machine. Motor ▪ Use the crane to take the ball screw by the center Bracket of gravity and pull it out from the machine. ※ Mark the position of each of 8 C50042034A...
  • Page 106 HM 1000/1250 HM1000MTE04 11) Separate the motor bracket from the ball screw. ※ When separating the ball screw from the bearing housing, take caution not to damage the lock-nut of the ball screw. Motor Bracket Ball Screw Screw Area 12) Separate C68032543B bearing supporter from C12031522A motor bracket before removing R12065 40TAC thrust angular ball bearing and C68023034 collar.

  • Page 107: Installing The Ball Screw On The Y Axis

    HM 1000/1250 HM1000MTE04 5.4 Installing the ball screw on the Y axis 1) Installing the thrust angular ball bearing into the bracket ① Install R1206540TAC thrust angular ball bearing into C12031532B bracket in the correct direction, and measure the sectional depth between bearing and bracket.
  • Page 108 HM 1000/1250 HM1000MTE04 Motor Bearing Bracket Support Bearing 3) Tightening the lock nut in the motor bracket side Motor Bracket Place the motor bracket (where the bearing is already installed) vertically into which you install the ball screw, insert C68023034 collar, and tighten the lock nut.
  • Page 109 HM 1000/1250 HM1000MTE04 5) Installing the motor bracket Motor Bracket Insert C50042034A adjustable liners (x5) into C12031522A motor bracket so that they fit into their respective position (marked when removing them). ▪ 5-BB16×60, 2-TPB10×80 Adjusting Liner 6) Runout on the ball screw in the motor bracket side ①...
  • Page 110 HM 1000/1250 HM1000MTE04 ▪ Pre-tension on the ball screw If the measurement is off the target after Labyrinth following the "Check the pre-tension work on the ball screw" instructions above, you must correct the pre-tension on the ball screw. ① Loosen the lock-nut.
  • Page 111 HM 1000/1250 HM1000MTE04 ▪ Final fixing after power on ① Move the Y axis to the “Y0” coordinates. ※ Ensure that the X axis should move smoothly without interruption by the Z axis. ② Put force as even as possible to each bolt until you tighten them up finally.
  • Page 112 (3) Move the Y axis according to the calculation of the below formula. Y axis coordinates = height of block gauge – (radius of test bar + 75) For HM 1000, if the coordinates is Y0, the distance between table deck and center of the spindle is 75mm.
  • Page 113 HM 1000/1250 HM1000MTE04 (4) Install the indicator on the top of the test bar and rotate the spindle while reading the runout on the test bar. Stop rotating the spindle at an intermediate value of the runout. (5) Move the Y axis to set the indicator to "0".

  • Page 114: Disassembling The Ball Screw On The Z Axis

    HM 1000/1250 HM1000MTE04 5.5 Disassembling the ball screw on the Z axis ※ Ball screw on the Z axis 220, 210 200, 080 160, 170, 180 220, 210 160, 170, 180 200, 080...
  • Page 115 HM 1000/1250 HM1000MTE04 Parts No. Description Mat. / Spec. Q'ty Remarks C12021023 Ball Screw(Z) 50TIF012-1784C3 Tsubaki S8000070 O-Ring C68023043D Bearing Supporter SS41 S2215261 Hex. Socket Head Bolt BB12×30 P74060006 Hex. Socket Plug (S) FPS-S1/8 S8000100 O-Ring R12065 Thrust Ang. Ball Bearing...
  • Page 116 HM 1000/1250 HM1000MTE04 4) Loosen the R18717 rigid coupling fixing bolts closer to the ball screw, loosen the fixing bolts of the servo motor, and separate the motor from C12021032 motor bracket with care. ▪ 4-BB12×40 Coupling Bolt Rigid Coupling...
  • Page 117 HM 1000/1250 HM1000MTE04 7) Loosen C12021032 motor bracket bolts (6- BB12×30) and positioning pins (4-TPB-10×50). 8) Pull out the motor bracket and ball screw assembly from the machine. Ball Screw ▪ Use the crane to take the ball screw by the center of gravity and pull it out from the machine.
  • Page 118 HM 1000/1250 HM1000MTE04 11) Separate the ball screw from the motor bracket. ※ When separating the ball screw from the motor bracket, take caution not to damage the lock-nut installation area of the ball screw. Ball Motor Screw Bracket Screw Area 12) Separate C68023043D bearing supporter from the motor bracket before removing R12065 40TAC thrust angular ball bearing and C68023034 collar.

  • Page 119: Installing The Ball Screw On The Z Axis

    HM 1000/1250 HM1000MTE04 5.6 Installing the ball screw on the Z axis 1) Installing the thrust angular ball bearing into the bracket ① Install R1206540TAC thrust angular ball bearing into C12021032 bracket in the correct direction, and measure the sectional depth between bearing and bracket.
  • Page 120 HM 1000/1250 HM1000MTE04 “A” “B” Bearing Motor Support Bracket 3) Tightening the lock nut in the motor bracket side Place the motor bracket (where the bearing is Spacer Lock Nut already installed) vertically into which you install the ball screw, insert C68023034 collar, and tighten the lock nut.
  • Page 121 HM 1000/1250 HM1000MTE04 5) Installing the motor bracket Motor Bracket Insert C50042034A adjustable liners (x6) into C12021032 motor bracket so that they fit into their respective position (marked when removing them). ▪ 6-BB16×45, 2-TPB10×50 Adjusting Liner 6) Runout on the ball screw in the motor bracket side ①...
  • Page 122 HM 1000/1250 HM1000MTE04 9) Pre-tension on the ball screw If the measurement is off the target after Space following the "Check the pre-tension work on the ball screw" instructions above, you must correct the pre-tension on the ball screw. ① Loosen the lock-nut.
  • Page 123 HM 1000/1250 HM1000MTE04 12) Installing the servo motor on the Z axis Coupling Bolt Lift up the servo motor (with R18717 rigid coupling installed) using the crane, where balance must be maintained horizontally, and install it into the motor bracket with care. The...
  • Page 124 HM 1000/1250 HM1000MTE04 ▪ Reference point for Z axis (Z-axis stroke: 1250mm) (1) Refer to "Reference point for X axis" above to set the reference point of the X axis and set the indicator to "0". ▪ The machine position is X1050. Z30 and around Y250 for the Y axis.

  • Page 125: Machine Precision

    X-Y Plane Y-Z Plane ▶ Straightness of Pallet Deck Pallet #1 0.000 0.015/500 Pallet #2 0.000 ▼ ▼ Pallet #1 0.000 0.015/500 Pallet #2 ▶ Squareness between coordinate axes 0.010/300 0.000 0.010/300 0.000 0.010/300 0.000 M.DMF-Q7200-5(1992.2.10) Doosan Infracore Co., Ltd. A4(210×297mm)
  • Page 126 IN X-Z Plane PLANE 0.000 IN Y-Z Plane PLAN From ▶ Shaking inside the main spindle hole 0.005 0.000 opening 0.012 0.000 away ▶ Displacement of main spindle movement to Z axis 0.003 0.000 M.DMF-Q7200-5(1992.2.10) A4(210×297mm) Doosan Infracore Co., Ltd.

  • Page 127: Straightness Of Z Axis

    HM 1000/1250 HM1000MTE04 6.1 Straightness of Z axis 1) X－Y ⓐ How to measure Install the level on the grinding side of the column in the X-axis direction and set the reference point. Feed the Z axis in 3-divided stroke and check the greatest difference of the level changes.

  • Page 128: Straightness Of X Axis

    HM 1000/1250 HM1000MTE04 3) X－Z ⓐ How to measure Install the straight edge horizontally on the pallet in the Z-axis direction and install the indicator on the spindle head. Set either end of the straight edge to "0" and move the Z axis to check the greatest difference (measurement in the middle of the movement).
  • Page 129 HM 1000/1250 HM1000MTE04 2) Y - Z ⓐ How to measure Install the magnetic square level on the pallet in the Z-axis direction and position it so that you can read the level gradation. Feed the Z axis in 3-divided stroke and check the greatest difference of the level changes.

  • Page 130: Straightness Of Y Axis

    HM 1000/1250 HM1000MTE04 6.3 Straightness of Y Axis 1) X - Y ⓐ How to measure Install the square vertically on the pallet deck in the X-axis direction and install the indicator on the spindle head. Set either end of the square to “0” and check the measurement in the middle of the square.

  • Page 131: Straightness Of Pallet Deck

    HM 1000/1250 HM1000MTE04 ▪ Aligning the ball screw nut (1) Loosen all fixing bolts on the ball screw nut. (2) Move the Y axis to the reference point "0". (3) Slightly tighten the bolts diagonally one by one at first, and then tighten them up by applying force as evenly as possible to each of them.

  • Page 132: Squareness Between Coordinate Axes

    HM 1000/1250 HM1000MTE04 2) Y - Z Z-axis Direction ⓐ How to measure Install the straight edge on the pallet deck in the Z-axis direction and install the indicator on the block. Measure the greatest difference in straightness of the top side of the straight edge.
  • Page 133 HM 1000/1250 HM1000MTE04 ⓑ Correction Squareness between X and Y can be corrected using the level in the column bed (Z axis). (1) Place the square graplate (surface plate) vertically in the X-axis direction and install the indicator on the spindle head. Measure the parallelism between square graplate and X axis.
  • Page 134 HM 1000/1250 HM1000MTE04 ▪ To perform the scraping of the sliding plate ※ Preparations: Scraper, whetstone, minium, screw jack (x2), cloth, other repair tools (1) Unplug the cable that supplies power to the lubricant motor from the electric cabinet to block lubricant inflow.
  • Page 135 HM 1000/1250 HM1000MTE04 3) X – Z squareness ⓐ How to measure Place the square on the pallet deck in the X-axis direction and move the indicator to set either end of the square to "0". Adjust the parallelism of the X axis by impacting on higher points using the handle of a screwdriver.

  • Page 136: Parallelism Between Pallet Deck And X/Z Axis

    HM 1000/1250 HM1000MTE04 6.6 Parallelism between pallet deck and X/Z axis 1) How to measure Install the indicator on the spindle head and use the measuring block to measure 4 points 250mm away from the center of the pallet in either direction (2 points in one direction). Then, rotate the B axis by 90 degrees and measure another 4 points in the same way.
  • Page 137 HM 1000/1250 HM1000MTE04 3) Correction Perform the measuring on pallet 1 and pallet 2 and decide which one you should correct. (1) A, B, C, D: If pallet 1 and pallet 2 show similar results in height distribution, grind the liner of the table locating pin for the correction.

  • Page 138: Squareness In Division Of Index Table

    HM 1000/1250 HM1000MTE04 6.7 Squareness in division of index table 1) How to measure (1) Place the square horizontally on the pallet deck. While moving the X axis, correct the parallelism between square and X axis. (2) While indexing the B axis, perform the clamping so that the square should not move.
  • Page 139 HM 1000/1250 HM1000MTE04 ◈ Table Precision If the table is significantly affected on the rotating side due to a crash with devices, parallelism between edge locator and X axis may go wrong. This is because the curvic coupling inside the table is mis-positioned due to the crash.
  • Page 140 HM 1000/1250 HM1000MTE04 3) Loosen the set-screw on C68051044 cap and use Clamp Plate Bolt the pin puller to remove the cap. Then, loosen the bolts on C12051171A clamp plate. ▪ 6-BB16×60 Clamp Plate 4) Perform the pallet unclamping manually and use the 30mm wrench to loosen NA24 shift nut.
  • Page 141 HM 1000/1250 HM1000MTE04 8) Lift up the table gently. ▪ It is very important to balance the table while lifting it up. Using the wood support or lead piece may help for this purpose. 9) Then, move the table to a safe place and keep it upside down.
  • Page 142 HM 1000/1250 HM1000MTE04 2. Assembling the table (pallet base) temporarily 1) Preparations for assembling the table ① Apply grease to the O-rings (1-G390) of the inner table and the dust seal of the outer table O-Ring Dust Seal base as even as possible to avoid damage to the rings during the installation process.
  • Page 143 HM 1000/1250 HM1000MTE04 3) Loosening the curvic coupling bolts ① Remove the plugs (2-FPS-S1/2) on the table deck. ② Loosen the curvic coupling bolts (2-BB10×35). ▪ The bolt is designed specifically for the table precision work. Plug Plug Bolt 4) Installing the clamp plate Fixing Bolt ①...
  • Page 144 HM 1000/1250 HM1000MTE04 3. Correcting the table precision 1) Measuring the table precision ① Turn on the machine, install the indicator on the spindle and present the gauge to the edge locator. ② While moving the X axis, measure the parallelism between X axis and grinded section of the edge locator.
  • Page 145 HM 1000/1250 HM1000MTE04 4. Setting the table precision 1) Disassembling the table Refer to "1. Disassembling the table" above to disassembly the table in sequence. 2) Fixing the curvic coupling on the table ① Tighten the curvic coupling bolts (12-BB16×40) evenly, one by one diagonally, until they are tightened up.
  • Page 146 HM 1000/1250 HM1000MTE04 5. Assembling the table 1) Installing the table ① When the curvic coupling is fixed completely, use the air tool to blow off all dust and impurities from both upper and lower curvic couplings. Refer to "2. Assembling the table (pallet base) temporarily"...
  • Page 147 HM 1000/1250 HM1000MTE04 ② Perform the pallet unclamping manually and use a 30mm wrench to tighten NA24 nut (for C10051034A shift). Then, use a hexagon wrench to tighten the shift through the cap hole. If the shift head contacts on the seat plate, loosen the shift by half turn and tighten it back with the nut.
  • Page 148 HM 1000/1250 HM1000MTE04 6. Resetting the reference point for the absolute B axis ※ If there occurs one of the following problems with the B axis, you must reset the home position for the B axis. ① If you re-install the B-axis servo motor ②...

  • Page 149: Distance Between Base Section Of Edge Locator And Swiveling Center Of Table

    HM 1000/1250 HM1000MTE04 6.9 Distance between base section of edge locator and swiveling center of table 1) How to measure ※ This should be done using the dedicated jig. However, the jig may not be available in your site. So follow the steps below alternatively. Note that the following method is not correct but is provided just for your information as it involves errors in positioning precision and backlash.

  • Page 150: Difference In Y-Axis Height When In Changing The Pallet

    HM 1000/1250 HM1000MTE04 6.10 Difference in Y-axis height when in changing the pallet 1) How to measure (1) Move the X, Y, Z axes to the middle position (X1050. Y625. Z775.) of the stroke. (2) Install the indicator on the spindle head and present the gage to the Y-axis side of the pallet deck.
  • Page 151 HM 1000/1250 HM1000MTE04 2) Correction ▪ X-Z: This is to turn the column itself so it is recommended to grind the parallel gib of the column and adjust the taper gib gap simultaneously. (1) Grinding the parallel gib ① Remove the sliding cover and rear cover from the Z axis.

  • Page 152: Runout On The Spindle

    HM 1000/1250 HM1000MTE04 6.12 Runout on the spindle 1) How to measure Insert the test bar into the spindle and present the indicator to the mouth of the test bar, and to a point 300mm away from the mouth. While turning the...
  • Page 153 HM 1000/1250 HM1000MTE04 ※ Machine Leveling ▪ As machine leveling has a direct effect on the precision of the machine, it is generally accepted that machine leveling is done along with the machine precision work. However, special care must be taken.
  • Page 154 HM 1000/1250 HM1000MTE04 3) Move the X axis to "X0, X1050., X2100." and adjust the level bolt to set the leveling roughly. (set the leveling for both X and Z axes to approximately 0.04/m) ▪ It is recommended to make coordinate settings for the leveling in advance.
  • Page 155 HM 1000/1250 HM1000MTE04 5) Similarly to the X-axis leveling, move the Z axis to "Z0. Z775. Z1550." and perform the leveling. ▪ However, you must be careful for the change to the X axis leveling while working on the Z axis.
  • Page 156 HM 1000/1250 HM1000MTE04 7) Tighten the anchor bolt, starting from the X axis. Anchor Bolt Anchor Nut Fixing Nut Level Bolt Level Block Anchor ▪ To tighten the anchor bolt ˚) before locking the nu ① Tighten the already tightened level bolts by another 1/4 turn (90 evenly.

  • Page 157: Regular Checkpoints

    HM 1000/1250 HM1000MTE04 7. Regular Checkpoints 7.1 Auto Tool Changer (ATC) Upon Semi- Item Checkpoint Description Daily Annually installation annually ○ ○ ATC centering Check using the fixture ○ ○ Tool magazine ○ ○ Tool port stop position Check with bare eye.

  • Page 158: Apc (Auto Pallet Changer)

    HM 1000/1250 HM1000MTE04 7.2 APC (Auto Pallet Changer) Upon Semi- Item Checkpoint Description Daily Annually installation annually ○ ○ APC alignment Check using the fixture ○ Check for any Changer arm hook State abnormal abrasion Check if properly fixed ○...

  • Page 159: Spindle Head

    HM 1000/1250 HM1000MTE04 7.4 Spindle Head Upon Semi- Item Checkpoint Description Daily Annually installation annually Test and correct it if ○ Tool unclamping device necessary. Adjust the stop angle ○ Main spindle orientation properly ○ Main spindle driver key Check if it’s abraded.

  • Page 160: Air Service Unit

    HM 1000/1250 HM1000MTE04 7.6 Air Service Unit Upon Semi- Item Checkpoint Description Daily Annually installation annually ○ ○ Manometer 5Kgf/cm² ○ ○ Oiler flowrate 5 drops/min. ○ ○ Pressure switch 4Kgf/cm² State ○ ○ Tubes Check for any leakage ○...

  • Page 161: Hydraulic Unit

    HM 1000/1250 HM1000MTE04 7.8 Hydraulic Unit Upon Semi- Item Checkpoint Description Daily Annually installation annually ○ ○ Manometer 50Kgf/cm² ○ ○ Pressure switch 30Kgf/cm² ○ Power supply to pump motor ±10% State ○ ○ Tubes Check for any leakage ○...

  • Page 162: Splash Guard

    HM 1000/1250 HM1000MTE04 7.10 Splash Guard Upon Semi- Item Checkpoint Description Daily Annually installation annually ○ Check with bare eye if operating Check for any leakage ○ properly. State ○ Check if properly fixed or Bolts and connectors ○ connected.

  • Page 163: Electric Devices

    HM 1000/1250 HM1000MTE04 7.13 Electric Devices Upon Semi- Item Checkpoint Description Daily Annually installation annually ○ ○ Power supply ±10% ○ State Check if properly fixed or ○ Bolts and connectors connected. ○ ○ Check DSN and check if Emergency stop buttons working properly ○...

  • Page 164: Check Oil Supply

    HM 1000/1250 HM1000MTE04 7.14 Check Oil Supply ※ Lubrication System...
  • Page 165 HM 1000/1250 HM1000MTE04 ※ Oil Analysis Table (by oil maker) Maker Mobil Oil Shell Oil Esso Oil Caltex Oil BP Oil Sun Oil Symbol Velocite Tellus Spinesso Spindural Energol Solnus (FC10) No.6 HP 10 DTE Oil Tellus Teresso Rando Energol...
  • Page 166 HM 1000/1250 HM1000MTE04 Revision History HMC Maintenance Manual HM 1000 Version Year/Month Revision history Created by Jeong, Sam 2010. 04 Official draft (HM1000MTE04) Young...

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