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Doosan HM 1000 Installation Manual

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Machine Tools
Installation Manual
(HM 1000/1250)

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Summary of Contents for Doosan HM 1000

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

  • Page 3: Table Of Contents

    HM 1000/1250 HM1000ISE99 Table of Contents 1. Preparations before shipment .................. 3 1.1 Installation Site ..........................3 1.2 Foundation Work .......................... 6 2. Transportation ......................9 3. What's included ....................... 11 3.1 Column & Column Bed Assembly ....................11 3.2 APC Assembly ..........................12 3.3 Table Assembly ..........................14...
  • Page 4 HM 1000/1250 HM1000ISE99 8.2 Leveling on the X-axis bed (table bed) ..................37 8.3 Leveling on the Z-axis bed (column bed) ..................39 8.4 Finishing the leveling ........................40 9. Resetting the reference point for each axis............42 9.1 Resetting the reference point for the X axis (X-axis stroke: 2100mm)........... 42 9.2 Resetting the reference point for the Z axis (Z-axis stroke: 1250mm) ...........

  • Page 5: Preparations Before Shipment

    HM 1000/1250 HM1000ISE99 1. Preparations before shipment 1.1 Installation Site 1) Do not install the machine in a place of a high temperature difference or in areas that are exposed to dust or direct sunlight, and consider the ventilation condition. Besides, it is recommended to select a place of less vibration.
  • Page 6 HM 1000/1250 HM1000ISE99 ※ Ref 1): Front View 2532 2532 ※ Ref 2) : Right View (967) 8766...
  • Page 7 HM 1000/1250 HM1000ISE99 ※ Ref 3) : Top View 4780 3715(4000) 9733(9747)[60 Tool Magazine] 10216[90 Tool Magazine] 10840[120 Tool Magazine]...

  • Page 8: Foundation Work

    HM 1000/1250 HM1000ISE99 1.2 Foundation Work 1) Foundation work timing and post checkpoints ① It is recommended to take a two-month schedule from completion of the foundation work to completion of the installation. ▪ It should take at least one month to cure the concreted surface.
  • Page 9 HM 1000/1250 HM1000ISE99 ※ Detailed Diagram 7, 8 12,13,14 Φ300 Φ240 “A” - 30 Holes “B” – 10 Holes First concrete Second grout Section C-C Item No. Definition Mat. / Spec. Q’ty Remark R00314 Stud Bolt B14491044 C40021154A Level Bolt...
  • Page 10 HM 1000/1250 HM1000ISE99 Important) 1) Reinforce the ground with stake driving, riprap piling and rebar reinforcement. ▪ The minimum bearing power of soil on the foundation surface should be 6 tons/㎡. 2) Make reinforcement on the surface with ferroconcrete as appropriate to maintain the necessary strength.

  • Page 11: Transportation

    HM1000ISE99 2. Transportation For HM 1000/1250, these models can be dismantled into each unit to facilitate the transportation of the machine to the plant. Since each one of the units is heavy weighted and unbalanced, pay attention to keep every unit balanced and take caution not to damage the covers such as scratches or bents if using a forklift or crane for transporting purpose.
  • Page 12 HM 1000/1250 HM1000ISE99 2) Moving the column and column bed using the forklift 3) Moving the table and table bed using the forklift 4) Moving the tool magazine using the forklift 5) Moving the splash guard using the crane...

  • Page 13: What's Included

    HM 1000/1250 HM1000ISE99 3. What's included The following illustration shows a list of component parts that should be delivered on site safe and intact. Check if there is no missing part. This is important because installation should be delayed if there is a component part missing.

  • Page 14: Apc Assembly

    HM 1000/1250 HM1000ISE99 Ass’y No. Dwg. No. Definition Q’ty Weight Check Remark S2240362 Bolt P57113050 13-1 C12021102B Coolant Pan (L) 13-2 120221112B Coolant Pan (R) C12063331 Under Cover (Rear) C12041313 Jack Bolt C12021063 Slide Cover (Z) C12141313 Front Cover (L)
  • Page 15 HM 1000/1250 HM1000ISE99 Ass’y No. Dwg. No. Definition Q’ty Weight Check Remark C12100001A APC Ass’y 1.8on C121611743 Floor Work C121611753 Floor Work C121611763 Floor Work C121611773 Floor Work C121611783 Floor Work C121611463 Pan Cover C121611411A APC Pan (C) C121611421A APC Pan (L)

  • Page 16: Splash Guard Assembly

    HM 1000/1250 HM1000ISE99 3.3 Table Assembly Ass’y No. Dwg. No. Definition Q’ty Weight Check Remark C12111011B Pallet 2.4Ton C12111053A Pallet Cover C12042083 Slide Cover (Mag.) C12042073 Slide Cover (OP.) C12041063 Slide Cover (X) Table Ass’y 7Ton C12041173A Bed Cover C12163273A Bracket 3.4 Splash Guard Assembly...
  • Page 17 HM 1000/1250 HM1000ISE99 Ass’y No. Dwg. No. Definition Q’ty Weight Check Remark C12160111B Main Guard Ass’y C12160141C OP Door Ass’y C12160131A ATC Door Ass’y C12162103 Chip Cover (L) C12162303 Chip Cover (R) C12161653 Connection Cover (C) C12161663 Connection Cover (2)

  • Page 18: Tool Magazine & Atc Assembly

    HM 1000/1250 HM1000ISE99 3.5 Tool Magazine & ATC Assembly Ass’y No. Dwg. No. Definition Q’ty Weight Check Remark Magazine Ass’t Guard Ass’y (1) Guard Ass’y (2) Door C12092753 Mag. Supporter C12092763 Mag. Bracket C12092773A Pan Supporter C12092021B Magazine Base C12092662B Mag.

  • Page 19: Coolant Tank Assembly & Option

    HM 1000/1250 HM1000ISE99 3.6 Coolant Tank Assembly & Option Ass’y No. Dwg. No. Definition Q’ty Weight Check Remark Chip Conveyor Ass’y 중압 TSC Oil Skimmer Coolant Tank Ass’y Transformer Coolant Gun Ass’y Air Gun Ass’y High TSC (Line) 자동계측장치 자동계측장치 부속품 1 자동계측장치...

  • Page 20: Installing The Machine Temporarily

    HM 1000/1250 HM1000ISE99 4. Installing the machine temporarily 4.1 Temporary installation of the column bed (Z-axis bed) assembly 1) Put final touches on the anchor holes that were prepared for installing the machine. ① Clean up the inside of the holes.
  • Page 21 HM 1000/1250 HM1000ISE99 4) Install the foundation components into the bed. ※ If you are using the crane to lift up the bed, prop up the bed with a strong support for your safety. ① Insert the bush in the level bolt that has already been installed on the bed.

  • Page 22: Temporary Installation Of The Table Bed (X-Axis Bed) Assembly

    HM 1000/1250 HM1000ISE99 4.2 Temporary installation of the table bed (X-axis bed) assembly 1) Make preparations for temporary installation by referring to the “Temporary installation of the column bed (X-axis bed) assembly” section above. Lift up the table bed assembly with the crane or forklift and move it to the temporary installation site.

  • Page 23: Temporary Installation Of Atc Base

    HM 1000/1250 HM1000ISE99 4) Put together X-axis bed with Z-axis bed. ① Move the bed slowly until the X axis gets close to the Z-axis bed. ② Align the hole of the clamp bolt with that of the positioning pin using the temporary bolt and the adjusting bracket bolt.

  • Page 24: Temporary Installation Of Apc

    HM 1000/1250 HM1000ISE99 4.4 Temporary Installation of APC 1) Install the foundation components onto APC in the same manner as you did onto the bed. Stud Bolt Plain Bush Washer Level-bolt Level Fixing Nut Bolt Anchor Level Block 2) Install the APC temporary bracket in the X-axis bed and place APC over APC temporary block.

  • Page 25: Second Round Of Mortar Injection (Grouting)

    HM 1000/1250 HM1000ISE99 5. Second Round of Mortar Injection (Grouting) 5.1 Inspecting the foundation holes 1) Is the concrete surface of each foundation hole rough? ▪ If the foundation surface is smooth, then it is necessary to make it rough in order to reinforce the adhesiveness between concrete wall that was constructed in the primary foundation work, and secondary grout.

  • Page 26: Injecting Grout

    HM 1000/1250 HM1000ISE99 Mechanical Mixer Motorized Hand Mixer ※ Changes in compression strength of grout according to water ratio (example) Compression Strength (Kgf/cm²) Water 20˚C Flow Initial Hardening Ratio (30 min)(mm) Time (Min) Day 1 Day 3 Day 7 Day 28 5.4 Injecting grout...

  • Page 27: Curing The Surface Of Mortar

    HM 1000/1250 HM1000ISE99 Injecting grout in APC Injecting grout in ATC 2) Grout Compacting Use a pipe or long thin pole to keep stirring in the grout mixture so that the mixture fills up the whole hole evenly without the buildup of air bubbles.

  • Page 28: Assembling The Main Unit

    HM 1000/1250 HM1000ISE99 6. Assembling the main unit 6.1 Installing the duct 1) Locate the cable duct in the shipping package and put it back to the original position. Position: under the electric cabinet from the X- axis bed. Cable Duct 2) Install the X-axis bed duct on the side of the X- axis bed.
  • Page 29 HM 1000/1250 HM1000ISE99 2) Arranging the coolant tank wires Push in the coolant tank wires, which were tied up in the front duct of the Z axis by factory default, through the wiring hole of the Z-axis bed to the rear duct. Then, arrange them up for later connection.
  • Page 30 HM 1000/1250 HM1000ISE99 6) Arranging ATC wires and hydraulic hoses Keep the ATC wires and hydraulic hoses separately and, connect the ATC main hydraulic hoses, if available. 7) Connecting the wires and connectors inside the electric cabinet ① Plug the connectors in the servo driver unit.
  • Page 31 HM 1000/1250 HM1000ISE99 ④ Plug the glass scale connectors (optional) ⑤ Plug the connectors for the tool length meter (Optional) 8) Installing the Y-axis servo motor and connecting the cables ① Lift up the Y-axis servo motor using the crane. While keeping it balanced, place it down on the motor bracket in the column before installation.

  • Page 32: Removing The Transit Clamps

    HM 1000/1250 HM1000ISE99 6.3 Removing the transit clamps Remove the transit clamps that are designed to prevent the slippery table or column base by factory default. 1) Removing the X-axis (Table) transit clamps Remove the X-axis (table) transit clamps fixed to the edge of the table bed and the table base.

  • Page 33: Connecting The Main Power And Main Air Sources

    HM 1000/1250 HM1000ISE99 6.4 Connecting the main power and main air sources 1) Connecting the main power source Connect the wires from the switch board to the On-site Power terminal block of the main NFB in the electric Source cabinet.
  • Page 34 HM 1000/1250 HM1000ISE99 2) Oil cooling tank ① Position: Piping frame in the rear of the Z- axis bed ② Type of Oil: HM32 Oil ③ Fueling Capacity: 45L 3) Table Oil Inlet ① Position: Rear of the table base ②...

  • Page 35: Power On

    HM 1000/1250 HM1000ISE99 7. Power On 7.1 Main Power Supply 1) Checking the input voltage Turn on the switch board and check if there is an error in the main NFB power supply using the circuit tester. ▪ Allowable voltage variation : 220V±10% (60Hz area)

  • Page 36: Checking The Pressure On Each Unit

    HM 1000/1250 HM1000ISE99 7.2 Checking the pressure on each unit 1) Hyd. Hydraulic pressure of power unit: 55Kg/cm² Pressure Gauge Pressure Control Valve 2) Main air pressure: 0.5∼0.6MPa (5∼6Kg/cm²) Pressure Air Filter Gauge Pressure Control Valve Oiler 3) Oil cooler pressure: 0.7MPa 4) Pressure of the lubrication pump: 15Kg/cm²...

  • Page 37: Installing The Coupling Between Y-Axis Motor And Ball Screw

    HM 1000/1250 HM1000ISE99 7.3 Installing the coupling between Y-axis motor and ball screw Fix the rigid coupling connecting between Y-axis servo motor and Y-axis ball screw. 1) Use the wrench to tighten just one of 4 bolts with about half of the standard torque.

  • Page 38: Machine Leveling

    HM 1000/1250 HM1000ISE99 8. Machine Leveling ※ 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 39: Leveling On The X-Axis Bed (Table Bed)

    HM 1000/1250 HM1000ISE99 8.2 Leveling on the X-axis bed (table bed) ※ Setting the reference point for the X-axis level (1) Place the level in the center of the table and read one-end gradation of the water bubble of the level.
  • Page 40 HM 1000/1250 HM1000ISE99 1) Move the machine to the coordinates of X1050. Y1000. Z800. 2) Clean up the table deck and place the level in the center of the table. Then, perform the "setting the reference point for the level".

  • Page 41: Leveling On The Z-Axis Bed (Column Bed)

    HM 1000/1250 HM1000ISE99 8.3 Leveling on the Z-axis bed (column bed) ※ Setting the reference point for the Z-axis level (1) Place the level in either side of the column and read one-end gradation of the water bubble of the level.

  • Page 42: Finishing The Leveling

    HM 1000/1250 HM1000ISE99 2) Take a note of the leveling values while repeating the leveling on both X and Z axes until the overall difference of the leveling falls below 0.02/m. ① To take a note of the leveling values on paper ※...
  • Page 43 HM 1000/1250 HM1000ISE99 5) When the leveling is completed, use a 58mm wrench to tighten up the level-bolt fixing nuts. ※ Importance of the level-bolt fixing nut The anchor nut can be fixed only using the level bolt. Tightening the level-bolt fixing nut is to fix the level bolt to the bed of the machine, resulting that the machine is fixed by the anchor.

  • Page 44: Resetting The Reference Point For Each Axis

    HM 1000/1250 HM1000ISE99 9. Resetting the reference point for each axis 9.1 Resetting the reference point for the X axis (X-axis stroke: 2100mm) 1) Insert the test bar into the spindle. 2) Return the X axis to the reference point manually.

  • Page 45: Resetting The Reference Point For The Z Axis (Z-Axis Stroke: 1250Mm)

    HM 1000/1250 HM1000ISE99 9.2 Resetting the reference point for the 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 46: Resetting The Reference Point For The Y Axis (Y-Axis Stroke: 1250Mm)

    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 47: Precision Accuracy & Correction

    0.005/300 0.005/300 in X-Y plane in Y - Z plane ▶ Straightness of Pallet Deck Pallet#1 0.015/500 Pallet #2 ▼ ▼ Pallet #1 0.015/500 Pallet #2 ▶ Squareness between coordinate axes 0.010/300 0.010/300 0.010/300 M.DMF-Q7200-5(1992.2.10) A4(210×297mm) Doosan Infracore Co., Ltd.
  • Page 48 Z axis 0.012/300 IN X-Z Plane PLANE IN Y-Z Plane PLAN From ▶ Shaking inside the main spindle hole 0.005 mouth 300mm 0.012 away ▶ Displacement of main spindle movement to Z axis 0.003 M.DMF-Q7200-5(1992.2.10) A4(210×297mm) Doosan Infracore Co., Ltd.

  • Page 49: Straightness Of Z Axis

    HM 1000/1250 HM1000ISE99 10.1 Straightness of Z axis 1) X-Y ⓐ 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 50: Straightness Of X Axis

    HM 1000/1250 HM1000ISE99 3) X-Z ⓐ 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 51 HM 1000/1250 HM1000ISE99 2) Y - Z ⓐ Measure Install the magnetic square level on the spindle section 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 52: Straightness Of Y Axis

    HM 1000/1250 HM1000ISE99 10.3 Straightness of Y Axis 1) X - Y ⓐ 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 Indicator measurement in the middle of the square.
  • Page 53 HM 1000/1250 HM1000ISE99 ▪ Target of the gap for the Y-axis gib: 0.01mm ∼ 0.02mm ※ Aligning the ball screw nut (1) Loosen all fixing bolts on the ball screw nut. (2) Move the Y axis to "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 54: Straightness Of Pallet Deck

    HM 1000/1250 HM1000ISE99 10.4 Straightness of Pallet Deck 1) X - Y X-axis Direction ⓐ 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 55: Squareness Between Coordinate Axes

    HM 1000/1250 HM1000ISE99 10.5 Squareness between coordinate axes 1) X – Y Squareness ⓐ Measure Place the square on the pallet deck in the X-axis direction and install the indicator on the spindle head. Check the squareness between X and Y axes. The greatest difference is the measurement.
  • Page 56 HM 1000/1250 HM1000ISE99 2) Y – Z squareness ⓐ Measure Place the square on the pallet deck in the Z-axis direction and install the indicator on the spindle head. Check the squareness between Y and Z axes. The greatest difference is the measurement.
  • Page 57 HM 1000/1250 HM1000ISE99 (8) Clean up the sliding plate and apply minium. (9) Wrap a thin tool with a clean cloth to wipe up the bottom of the column and the grinding side of the column bed. (Clean them up until no oil residues and impurities are left) (10) Insert the sliding plate back to the original and remove the screw jack.

  • Page 58: Parallelism Between Pallet Deck And X/Z Axis

    HM 1000/1250 HM1000ISE99 ⓑ Correction You can correct the accuracy by grinding Bed Fixing Bolt the adjustable liner between table bed and column bed. (1) Loosen the anchor bolt on the column Adjusting bed. Liner (2) Loosen the fixing bolt between column...
  • Page 59 HM 1000/1250 HM1000ISE99 2) Calculation 4 Total Average (1) Total: Sum for each column and row (2) Average: Sum divided by 4 (3) Accuracy ① X-axis direction: Greater mean value comparing item 2 and item 3 or Total comparing item 1 and item 4 Average ▪...

  • Page 60: Squareness In Division Of Index Table

    HM 1000/1250 HM1000ISE99 Fixing Bolt Pallet Locating Locating Liner Liner 10.7 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.

  • Page 61: Parallelism Between Edge Locator And X Axis

    HM 1000/1250 HM1000ISE99 10.8 Parallelism between edge locator and X axis 1) How to measure Install the indicator on the spindle head and move the grinding side of the edge locator (in the side of the pallet) in the X direction. The greatest difference in parallelism is the measurement.
  • Page 62 HM 1000/1250 HM1000ISE99 1. Disassembling the table ▪ Preparations for disassembling the table ① Keep the machine clean and away from dust or oil residues. (In particular, clean up the sliding cover so that it does not slip off while you are working on it) ②...
  • Page 63 HM 1000/1250 HM1000ISE99 3) Perform the pallet unclamping manually and use the 30mm wrench to loosen NA24 shift nut. Then, loosen the shift through the cap hole. Shift Seat Plate Shift Seat Plate Nut (NA24) Nut (NA24) 4) Use the crane to lift up and remove C12051171A clamp plate.
  • Page 64 HM 1000/1250 HM1000ISE99 7) 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. 8) Then, move the table to a safe place and keep it upside down.
  • Page 65 HM 1000/1250 HM1000ISE99 10) Preparations for correcting the position of the curvic coupling on the table ① Loosen the bolts (12-BB16×40) on the curvic coupling. ② Remove the plugs (2-FPS-S1/2) from the curvic coupling positioning pin (2- Curvic Positioning TPB13×50) places. And use the puller to...
  • Page 66 HM 1000/1250 HM1000ISE99 4) If the table settles down with no problem, check the table bolt places if they are aligned properly. If not, insert two bolts into the cylinder cap as shown and use the pipe to rotate the cylinder so that it fits into the bolt holes. Then, tighten the table bolts.
  • Page 67 HM 1000/1250 HM1000ISE99 7) 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 68 HM 1000/1250 HM1000ISE99 5) If the measurement falls below the target, 2-BB10×35 tighten up the bolts (2-BB10×35). 4. Setting the table precision 1) Refer to "1 Disassembling the table" above to disassemble the table in sequence. 2) Tighten the curvic coupling bolts (12-BB16×40) evenly, one by one diagonally, until they are tightened up.
  • Page 69 HM 1000/1250 HM1000ISE99 5. Assembling 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" above to assemble the table.
  • Page 70 HM 1000/1250 HM1000ISE99 4) 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 71 HM 1000/1250 HM1000ISE99 6. Resetting the reference point for the B axis You must reset the home position for the B axis if you have reinstalled the B-axis servo motor, or the B axis goes wrong, or "2073 Pallet or Table CL/UNCL Switch Alarm” occurs.

  • Page 72: Distance Between Base Section Of Edge Locator And Swiveling Center Of Table

    HM 1000/1250 HM1000ISE99 10.9 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 73: Positioning Precision And Difference In Changing The Pallet

    HM 1000/1250 HM1000ISE99 10.10 Positioning precision and difference 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 3 indicators on the spindle head and present two gauges to the X- and Z-axis edge locators, and the other gauge to the pallet deck in the Y axis side.

  • Page 74: Parallelism Between Center Line Of Spindle And Movement Of Z-Axis

    HM 1000/1250 HM1000ISE99 10.11 Parallelism between center line of spindle and movement of Z-axis 1) How to measure Z Axis Insert the test bar into the spindle and move the Z axis up to 300mm away to measure the parallelism. The greatest difference is the measurement.

  • Page 75: Runout On The Spindle

    HM 1000/1250 HM1000ISE99 squareness first and, if no error is found, the spindle head itself is a problem. If this is the case, you have no option but to scrape the base side of the spindle head for the correction.

  • Page 76: Installing Atc & Alignment

    HM 1000/1250 HM1000ISE99 11. Installing ATC & Alignment 11.1 Installing ATC ※ When the machine leveling, static accuracy inspection and resetting the reference point for each axis are completed, install ATC base alone before installing ATC. This is to facilitate the installation work for you.
  • Page 77 HM 1000/1250 HM1000ISE99 3) Connecting the lubricant hose of the tool Lubricant magazine Hose Plug the lubricant hose coming from the main unit into the pipe connector that is connected to the tool magazine. Connector 4) Connecting ATC inter connection units ①...

  • Page 78: Atc Alignment

    HM 1000/1250 HM1000ISE99 6) Removing the transit clamps from the ATC arm Remove the transit clamps from the ATC arm, which were installed to prevent possible damage to the locking pin in the process of Lubrica nt Pipe rotation of ATC main changer.
  • Page 79 HM 1000/1250 HM1000ISE99 3) Preparing centering fixture ① : Center Bar ② : Fixture for Changer Arm ③ : Fixture for Spindle 4) Remove the spindle driving key and clamp the Fixture for Spindle spindle fixture into the spindle. Perform the spindle orientation.
  • Page 80 HM 1000/1250 HM1000ISE99 7) 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. 2.5mm Right Left Positioning ATC Fixing Height Positioning Bolt Bolt Adjusting Bolt Bolt...
  • Page 81 HM 1000/1250 HM1000ISE99 Ref 1) Adjusting the position of ATC servo magazine If the ATC sub changer and the tool pot of the magazine do not align properly due to mis- position of the ATC servo magazine, you must adjust the position of ATC servo magazine manually.
  • Page 82 HM 1000/1250 HM1000ISE99 4) From the [ rd-off ] screen, press the down arrow button. è [ Jog.run ] : Switch to the jog run mode 5) From the [ Jog.run ] screen, press the SET button. è [ Jr.0000 ] : Jog run mode 6) From the [ Jr.0000 ] screen, use the up/down...
  • Page 83 HM 1000/1250 HM1000ISE99 ※ Centering the tool pot of the tool magazine Use the up/down arrow buttons in the [ Jr.0000 ] screen, or press the rotation button on the manual operation panel. While holding the button, insert the center bar into the centering fixture until it is inserted smoothly.
  • Page 84 HM 1000/1250 HM1000ISE99 9) From the [ Org.S - - ] screen, press and hold the SET button for 7 seconds. è [ r 0000 ] : Return to the start screen 10) From the [ Org.S - - ] screen, press and hold the SET button for 7 seconds.

  • Page 85: Atc Alignment

    HM 1000/1250 HM1000ISE99 12. ATC Alignment 12.1 Adjusting APC 1) Adjusting the height and position of APC ① Refer to "Resetting the reference point for each axis" above to set the reference point for the X axis and move all axes to their respective reference point. (X1250., Y1000, Z1000, B0) ②...
  • Page 86 HM 1000/1250 HM1000ISE99 Right Left Left Right Gap A Gap B 2) Adjusting the distance ① Perform the pallet clamping in manual Distance Bolt operation. ② Perform the "Arm 1 Hook Advance" in manual operation. ③ Then, perform the pallet unclamping manually back again.

  • Page 87: Fixing Apc

    HM 1000/1250 HM1000ISE99 12.2 Fixing APC When the adjustment is completed, tighten up the APC fixing bolts (6 EA per APC) and lock up the bolt fixing nuts. APC Fixing Bolt Adjusting Bolt Fixing Anchor Adjusting Bolt Adjusting Bolt Fixing Nut...

  • Page 88: Installing The Covers

    HM 1000/1250 HM1000ISE99 13. Installing the covers Put together or install the component parts such as covers, brackets, chip pins, chip conveyor, coolant tank oil pan, fence, splash guards and footsteps (all of which were removed for transportation of the machine) back in the original position.
  • Page 89 HM 1000/1250 HM1000ISE99 ④ Installing the rear cover of the Z axis 2) Installing the sliding cover of the X axis Install the X-axis sliding covers one by one with the front side first. Tighten the bolts in the table base side, then the bolts in the bracket side.

  • Page 90: Installing The Splash Guard

    HM 1000/1250 HM1000ISE99 13.2 Installing the splash guard 1) Installing the lower brackets of the splash guard Install the lower brackets of the splash guard respectively to ATC, to the operator and to the X-axis bed as shown. Operator Side...
  • Page 91 HM 1000/1250 HM1000ISE99 2) Installing the splash guard in the operator side Use the upper eye bolts (x2) and hook a rope to the operator-side splash guard. While keeping it balanced, lift it up with the crane and put it down so that it locks into the lower latches.
  • Page 92 HM 1000/1250 HM1000ISE99 4) Installing the main splash guard ① Hook several ropes to the main splash guard and lift it up with the crane. Care must be taken for the balance. ② Loosen the splash guard brackets (x2) that overlap with APC.
  • Page 93 HM 1000/1250 HM1000ISE99 ② Concatenating the splash guards in the ceiling Use the ceiling concatenating covers to concatenate the ceiling sides between main splash guard, operator-side and ATC-side splash guards ③ Concatenating with the lower brackets Concatenating the bottom brackets of the main splash guard with the lower brackets.
  • Page 94 HM 1000/1250 HM1000ISE99 ③ Installing the chip cover on the Z-axis bed ④ Installing the sliding cover of the X axis Wiper ⑤ If you find a gap inside the splash guard, seal up the gap with silicone. 7) Installing the outer cover of the splash guard ①...
  • Page 95 HM 1000/1250 HM1000ISE99 ② Insert the splash-guard wires and hydraulic hose through the duct to the ceiling of the splash guard. ③ Connect the wires to the terminal box that is located on the top of the electronic cabinet and in the side of the splash guard.
  • Page 96 HM 1000/1250 HM1000ISE99 ⑥ Install the top cover on the splash guard. ⑦ Plug in or place the air tube and air solenoid valve designed for ATC door in the right position. ⑧ When the splash guard is installed properly, close the under covers to the sides.

  • Page 97: Installing The Front Cover Of The Y Axis

    HM 1000/1250 HM1000ISE99 13.3 Installing the front cover of the Y axis 1) Install the covers in the left and right sides of the column. Front Front Cover Cover (Right) (Left) 2) Attach the brackets (x3) to the top of the left and right front covers.
  • Page 98 HM 1000/1250 HM1000ISE99 1) Install the oil pan brackets on both inner and outer sides of APC. Oil Pan Bracket Oil Pan Oil Pan Bracket Bracket Oil Pan Bracket 2) Mount the oil pans on both sides of APC and install the pan supports.
  • Page 99 HM 1000/1250 HM1000ISE99 5) Attach the floor work to the installed oil pan. Floor Floor Work Work 6) Place down the APC Set-Up switch box and beam sensor wire on the right oil pan. 7) Install both APC Guards. Guard Guard 8) Install both APC front guards.
  • Page 100 HM 1000/1250 HM1000ISE99 9) Install the APC Set-Up switch box and beam sensor wire in the right position. 10) When the oil pan and guard are installed properly, proceed with the APC skirt. Skirt Skirt 11) Install the connect covers between APC pan and splash guard.

  • Page 101: Installing Atc Chip Pan And Guards

    HM 1000/1250 HM1000ISE99 13) Install the footstep in the front center of APC unit. Foot Step 13.5 Installing ATC chip pan and guards Manifold cover ATC Cover Bracket ATC Door TMG. Pan (1) TMG Guard ATC Pan TMG. Pan (2)
  • Page 102 HM 1000/1250 HM1000ISE99 2) Attach the pan brackets before installing TMG pans (x2). Bracket Bracket (longer) (shorter) Pan(2) Pan Support 3) Install TMG pan(1). Pan(1) Pan Support 4) Use the height adjusting bolts to adjust the overall height of the pan support.
  • Page 103 HM 1000/1250 HM1000ISE99 6) Install TMG guard. Guard 7) Insert TMG support between TMG guard and tool magazine. Support 8) Install ATC door safety switch and ATC manual operation panel (OP) with the wires arranged. Safety Switch ATC Manual Operation Panel(OP) 9) Arrange up the wires and hydraulic hoses in the tool magazine side.

  • Page 104: Installing The Coolant Tank & Chip Conveyor

    HM 1000/1250 HM1000ISE99 10) When TMG pan and guard are installed properly, proceed with TMG skirt. Pan Support TMG Skirt 14. Installing the coolant tank & chip conveyor 14.1 Installing the coolant tank 1) Arrange the wires and hoses through the duct...

  • Page 105: Connecting The Coolant Pump Components

    HM 1000/1250 HM1000ISE99 14.2 Connecting the coolant pump components 1) Connect the flood coolant pump hose. Flood Coolant Hose 2) Connect the shower coolant pump hose. Shower Coolant Hose 3) Connect the flushing coolant pump hose. Flushing Coolant Hose 4) Connect the middle-pressure T.S.C coolant T.S.C...
  • Page 106 HM 1000/1250 HM1000ISE99 5) When all these hoses are connected properly, arrange up the hoses and wires and press down the fixing bolt against the ground to hold the coolant tank. Tank Fixing Bolt...
  • Page 107 HM 1000/1250 HM1000ISE99 Revision History Installation Manual HM 1000/1250 Version Year/Month Revision history Created by 2009. 09 Official draft (HM1000ISE99) Jeong, Sam Young...

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Hm 1250

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